CN101700984A - Method for preventing glaze layer from jumping glaze in the productive process of sanitary ceramic - Google Patents
Method for preventing glaze layer from jumping glaze in the productive process of sanitary ceramic Download PDFInfo
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- CN101700984A CN101700984A CN200910198419A CN200910198419A CN101700984A CN 101700984 A CN101700984 A CN 101700984A CN 200910198419 A CN200910198419 A CN 200910198419A CN 200910198419 A CN200910198419 A CN 200910198419A CN 101700984 A CN101700984 A CN 101700984A
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Abstract
The invention provides a method for preventing a glaze layer from jumping glaze in the productive process of a sanitary ceramic. The method draws a six sigma system analysis theory and tool into the analysis and improvement process of glaze jumping of the glaze layer of the sanitary ceramic, analyzes the main factors of glaze jumping generation of the glaze layers from working procedures of formulation design, the glaze preparation, glaze spraying, sintering and inspection, and controls the factors, thus forming a systematization solving method for preventing the glaze layer from jumping glaze in the productive process of the sanitary ceramic. The method can stably prevent and control the generation of the glaze jumping of the glaze layer, reduces defective percentage, and increases product quality and economic effectiveness.
Description
Technical field
The present invention relates to a kind of prevention method of glaze plane defect, specifically, relate to the prevention method of the glaze jumping glaze defective in a kind of snitaryware production process.
Background technology
Snitaryware is good because of its modern design, of a great variety, the bright exquisiteness of glaze, lovely luster, dirt eliminating function, be convenient to clean and be subjected to liking of user deeply, from it is born very strong vitality arranged always and is subjected to user's favor deeply.Recent two decades comes, and China's snitaryware industry is rapidly developed, and manufacturing enterprise occurs like the mushrooms after rain, the output cumulative year after year, and the assortment of product are on the increase, and export volume also improves constantly.According to statistics, output has reached more than 8,000 ten thousand now, occupies to beat the world, and export volume is 4,000 ten thousand, accounts for 50% of output.Though quality product has also had considerable raising, first and last, quality product and market user require to also have no small gap, show that mainly glaze quality is poor.
In the practice, the defective of snitaryware product is except cracking and distortion, and all the other nearly all occur in glaze, and the glaze common deficiency has: jump glaze, pin hole, color spot, pit, salient point, unglazed etc.See that from process aspect to form main all processes operations such as (raw material, modulation, glazing) rebuilding and burn till with glaze formation of glaze plane defect relevant; From the physics aspect, the glaze plane defect is relevant with fineness, admixture, fusing, decomposition, chemical reaction, viscosity, surface tension etc.
The production process of snitaryware product is more, and the production cycle is longer, is systems engineering, and it is a lot of to influence the factor of glaze quality, and a lot of uncontrollable and variable factors is arranged.The report of some glaze related defects is also arranged in the recent period, develop ceramic under glazed binding agent novel material, can solve ceramic product lead and exceed standard and under glazed glaze pin hole and jumping glaze defective as the prosperous vitrification in Zichuan, Shandong factory; " Chinese building material " magazine 2002 3 interim " reason of glaze major defect and terms of settlement thereof " has been introduced the genetic analysis and the corresponding terms of settlement of defectives such as glaze splits, glaze bubble, as: the coefficient of expansion of adjusting glaze adapts to the coefficient of expansion of base, adjust the melt viscosity that glaze formula reduces glaze, control glaze fineness or the like.These solutions all just rest on the partial aspect, do not have the systematized solution at whole technological process, let alone other subject method are introduced the system of ceramic Defect prevention.
Summary of the invention
The prevention method that the purpose of this invention is to provide the glaze jumping glaze defective in a kind of snitaryware production process is to overcome the deficiencies in the prior art.
The present invention introduces Six Sigma systems analysis theory and instrument in snitaryware product glaze jumping glaze Analysis on defects and the improvement process, the deep analysis from raw material detected whole production flow process to final inspection, from people, equipment, material, method, environment, measure system shortsightedness and improvement method that the relevant glaze of each aspect multianalysis is jumped the glaze defective.
Technical scheme of the present invention is as follows:
The prevention glaze is jumped the method for glaze defective in a kind of snitaryware production process, the technological process of production of described snitaryware product comprises blank preparation, moulding, glaze preparation, glazing, burns till and inspection process, wherein the glaze preparation process comprise feed intake, ball milling, preparation, old operation, it is characterized in that: in the described glaze preparation process, glaze is no more than 3% with raw material medium clay soil content, and the glaze temperature flowing is 5～6cm; In the described mechanical milling process, the ball milling time is 6～8 hours, and adds sanitas in 20～30 minutes before the ball milling discharging, and the add-on of described sanitas is 0.05～0.1% of a raw material gross weight, and the discharging fineness is 325 mesh screen residues 0.8～1%, and drop temperature is less than 50 ℃; Described preparation process comprises, adds binding agent after the ball milling discharging, stirs 10～20 minutes earlier, leaves standstill the back restir 10～20 minutes, adds weight ratio in the described binding agent and be 5.25% sanitas and 6.7～10 times of weight in the water of binding agent; In the described glazing process, the temperature of base substrate is less than 35 ℃ before the glazing, and ground-coat enamel glazing thickness is no more than 12mil, and cover-coat enamel is no more than 37mil; In the described sintering process, go into the preceding base substrate water ratio of kiln less than 1%.
The present invention segments each distance in the snitaryware product process flow, from formulating of recipe, glaze preparation, glaze spraying, burn till and inspection process, analyze and produce the principal element that glaze is jumped glaze, these factors comprise:
1) glaze temperature flowing: high-temperature stream is long too short, and then the mobile spreadability of glaze is poor, causes jumping easily glaze; Control glaze temperature flowing is preferably and is controlled at 5cm at 5～6cm among the present invention.
2) clay content: glaze then causes the glaze dry shrinkage excessive with raw material medium clay soil too high levels, causes jumping glaze; Control clay weight content is preferably the control clay content 1%～3% less than 3% among the present invention
3) the ball milling time: the ball milling overlong time, then cause glaze meticulous, cause jumping glaze; The present invention was controlled at 6～8 hours.
4) the sanitas joining day: sanitas adds too early, then causes sanitas to lose efficacy; The present invention is adding in 20～30 minutes before the ball mill discharging.
5) sanitas add-on: sanitas adds very few, then causes binding agent to lose efficacy in the subsequent production process, causes jumping glaze;
The add-on of sanitas of the present invention is controlled to be 0.05～0.1% of raw material gross weight, is preferably 0.15%.
6) ball mill discharging fineness and temperature: raw material discharging fineness is meticulous, causes jumping glaze; It is 0.8～1% that discharging fineness of the present invention is controlled at 325 mesh screen residue quantity, and drop temperature is controlled at below 50 ℃, is preferably 20～50 ℃.
7) churning time behind the interpolation binding agent: glaze continuously stirring overlong time behind the adding binding agent, make the glaze temperature too high, the binding agent sex change was lost efficacy, and caused jumping glaze; Stirred 10～20 minutes earlier among the present invention, after leaving standstill, restir 10～20 minutes.For example: can stir earlier 15 minutes for porcelain product glaze, leave standstill after 10 minutes restir 15 minutes; Can stir earlier 10 minutes for fine pottery product glaze, leave standstill after 10 minutes restir 10 minutes.
8) configuration of binding agent: it is very few to add water during the configuration binding agent, and too much binding agent is removed when causing follow-up glaze to sieve, and reduces the glaze bonding strength, causes jumping glaze; Among the present invention during binder making, need to add simultaneously 4.75%～5.75% the sanitas that accounts for described weight of binder, proportioning for described binding agent of porcelain product glaze and water was controlled at 1: 6.7, was controlled at 1: 8～10 for the weight ratio of described binding agent of fine pottery system product glaze and water.
9) sieve: glaze is crossed the glaze quantity that tails over behind 230 mesh sieves in the old Cheng Qian of crossing after preparation process: too much as impurity in the glaze, impurity explosion when burning till causes jumping glaze; The present invention controls glaze and crosses 230 mesh screen residue quantity below 0.05%.
10) base substrate temperature before the glaze spraying: the base substrate temperature is too high before the glaze spraying, causes glaze spraying glaze drying too fast, causes jumping glaze; The preceding base substrate temperature of control glaze spraying is preferably room temperature to 35 ℃ less than 35 ℃ among the present invention; Described room temperature is 20～25 ℃.
11) glazing thickness: the blocked up easy generation glaze of glaze spraying splits and causes jumping glaze; Ground-coat enamel glazing thickness must not surpass 12mil among the present invention, is preferably 8～12mil; Cover-coat enamel must not surpass 37mil, is preferably 28～37mil.
12) go into base substrate water ratio before the kiln: the base substrate water ratio of going into before the kiln is too high, causes sintering process glaze layer sharply to shrink the glaze layer is broken producing jumping glaze; The present invention controls into the base substrate water ratio before the kiln less than 1%.
Preferably, the prevention glaze is jumped the method for glaze defective in a kind of snitaryware production process of the present invention, also comprises the following factors in the control Production Flow Chart:
1) raw material is gone into ball milling in proper order: disposable feeding in raw material causes indivedual easily mill raw materials overground, and then the glaze contraction is bigger than normal, causes jumping glaze; In the mechanical milling process of the present invention, raw material adds ball mill at twice, adds wear-resistant material earlier, and ball milling to 325 mesh screen residue adds easy abrasive material again after 3%.For example: add quartz sand earlier, wear-resistant materials such as aluminum oxide, ball milling adds zirconium silicate again to tailing over quantity＜3%, and lime carbonate etc. are abrasive material easily.
2) ballstone vacancy height: ballstone vacancy height is excessive, and during the raw material ball milling, the ballstone slabbing action is excessive, and indivedual materials are overground, cause jumping glaze; Ballstone vacancy height is controlled at 1157～1163cm among the present invention.As: it is that per 15 mills of 40# and half and half, 1 ton of ball mill of 50# ballstone add the 25kg40# ballstone that 5 tons of ball mills add ballstone.
3) the old time: the old phase of glaze is long, and adhesive failure in the glaze causes jumping glaze; The present invention controlled the old time at 1～3 day; As exceed old fate return glaze and pure glaze, needed to add in addition the sanitas of 0.01% (wt%) every 3 days.
4) performance of binding agent and sanitas: if binding agent cohesiveness or less stable, sanitas sterilizing ability are lower, then the glaze bonding strength is on the low side, causes jumping glaze; Among the present invention, the performance index of binding agent are: binding agent was placed 7 days after allocating glaze into continuously, and the variation of glaze viscosity is no more than 30 degree; The performance index of sanitas are: sanitas is allocated in the airtight environment that is placed on below 30 ℃ of glaze did not have rotten odor after 21 days.
5) sieve before glaze is sent: after glaze prepared, some can accumulate in glaze without abundant dissolved binding agent agglomerate, causes jumping glaze after burning till; Among the present invention, glaze is sent preceding through the processing of sieving, for example: the porcelain glaze is crossed 100 mesh sieves, and fine pottery matter glaze is crossed double-deck 60 mesh sieves.
6) temperature after glaze is sent: after glaze was sent, if the too high meeting of envrionment temperature causes the glaze thixotropy excessive, spray was thick easily easily to cause glaze, produces to jump glaze; Among the present invention, the glaze after sending is controlled at below 35 ℃.
7) glaze spraying air pressure, glaze press, rifle flow and glaze atomizing shape: glaze pressure during glaze spraying, air pressure, flow are too high excessive, and the undesired local long-pending glaze of product that easily causes that then atomizes produces and jumps glaze; Each parameter is controlled to be among the present invention: glaze spraying air pressure 0.5～0.6mpa, glaze is pressed 0.4～0.5mpa, 20～25 seconds/500ml of gun traffic glaze, the glaze atomizing is shaped as the minor axis 20～30cm of the major diameter 30～40cm of ellipse, described ellipse, described ellipse, and gun slot glaze temperature is less than 30 ℃.
8) glaze spraying speed: glaze spraying is too fast easily to make the too fast accumulation of glaze, produces local (especially position, turning) long-pending glaze and causes the jumping glaze; The present invention controls glaze spraying speed 3～5cm/s.
9) the glazed body spacing after streamline and the entrucking: between the product glazed body of glaze spraying on the streamline and the spacing between the glazed body after the entrucking too small, transportation product knock against each other destroys the glaze layer, produces to jump glaze; Control glazed body product spacing＞10cm among the present invention is in order to avoid the product knock against each other destroys the glaze layer.
Further, in the snitaryware production process, easily produce a large amount of glaze (i.e. the glaze of Hui Shouing) that return.The present invention adds back the amount of glaze at total below 80% of glaze weight before glaze sieves, be preferably below 50%.If it is excessive to add back the glaze amount, it is insufficient that glaze is stirred, and the glaze piece can not fully be stirred and open in time glaze, and the local easily glaze that collects produces and jumps glaze during glaze spraying.The maximum that can add back glaze in the porcelain product glaze need be controlled at below 80% of total glaze weight, can not add back glaze in the fine pottery matter product glaze.
Further, the present invention increases ball-milling processing to returning glaze, and the deironing of sieving is then controlled back glaze and crossed 230 mesh screen residue quantity below 0.5%, to control back the content of impurity in the glaze.If impurity is too much in time glaze, impurity explosion when then burning till can cause jumping glaze.
The glaze of glaze described in the present invention for forming with feedstock production by glaze.
Defect control method of the present invention is applicable to the technology controlling and process of sanitarywares such as porcelain, fine pottery matter.
The glaze preparation technology flow process of porcelain sanitaryware comprises: (sieve, the add binding agent) → old → glaze spraying that feeds intake → ball milling → preparation → burn till → check.
The glaze preparation technology flow process of fine pottery matter sanitaryware comprises: (sieve, the add binding agent) → old → glaze spraying that feeds intake → ball milling → preparation → burn till → check.
The invention has the beneficial effects as follows: adopt systematic analytic method of the present invention to control each stage from flow process, from all respects of process organization, at all levels process defect is carried out comprehensive and systematic analysis and control, effectively filter out major influence factors, and controlled, prevention that can be comparatively stable and the generation of controlling glaze jumping glaze defective, reduction in the numbers of seconds is improved the quality of products and economic benefit.
Description of drawings
Fig. 1: glaze is jumped the performance of glaze in 2008 the 12nd thoughtful 2009 the 12 all fine pottery matter product once-firings.
Embodiment
Embodiment 1:
Utilization Six Sigma systems analysis theory and instrument carry out snitaryware product glaze and jump the glaze Analysis on defects:
At first, the method for utilization flow chart analysis, each distance in the segmentation snitaryware product process flow analyzes the factor that glaze is jumped the glaze defective that produces, result such as table 1:
Table 1 flow chart analysis result
Then, utilize causality matrix figure to screen out the uncorrelated factor of part, analytical results is as shown in table 2:
Table 2 matrix diagram analytical results
The uncorrelated factor of part that screens out according to the causality matrix map analysis result of table 2 has: formulating of recipe people, formulating of recipe program, test method, mill speed, vibratory screening apparatus, glaze are sent back stirring, rifle mouth, rifle pin, streamline, firing temperature, sintering curve, furnace pressure, kiln atmosphere, kiln car, inspection man, the method for inspection.
Whether afterwards, set up the failure mode that glaze is jumped the glaze defective, the principle of setting up of failure mode is: produce and jump the glaze defective; Above-mentioned analytical results is imported failure mode and effect analysis, further screen out the uncorrelated factor of part, the factor that screens out has: ball mill, charging process, water, ballstone material, glaze testing method, glaze spraying worker, spray gun type, glaze spraying distance, glazed body car, glaze drying room, go-cart speed, unload the firer, unload the kiln mode.
At last, the residue factor is utilized the mathematical statistic method of Six Sigma, study the association between each factor, interaction and set up the main factor mathematical model, thereby effective defect analysis of the system that sets up and solution, the result is as shown in table 3.
Table 3 produces the analytical results that glaze is jumped the glaze defect factors
Embodiment 2:
As shown in Figure 1, adopt glaze of the present invention to jump control of glaze defective and solution before, glaze is jumped the glaze defective, and to be in 1.8% level and fluctuation violent, extremely unstable; After adopting glaze of the present invention to jump control of glaze defective and solution, glaze jumping glaze defective is in the level about 0.9%, and glaze is jumped the glaze defective and descended 50%, and performance is stable.
Claims (10)
1. prevent glaze to jump the method for glaze defective in a snitaryware production process, the technological process of production of described snitaryware product comprises blank preparation, moulding, glaze preparation, glazing, burns till and inspection process, wherein the glaze preparation process comprise feed intake, ball milling, preparation, old operation, it is characterized in that: the glaze temperature flowing is 5～6cm, and glaze is no more than 3% with raw material medium clay soil content; In the described mechanical milling process, the ball milling time is 6～8 hours, and adds sanitas in 20～30 minutes before the ball milling discharging, and the add-on of described sanitas is 0.05～0.1% of a raw material gross weight, and the discharging fineness is 325 mesh screen residues 0.8～1%, and drop temperature is less than 50 ℃; In the described preparation process, binding agent adds the back and stirred 10～20 minutes earlier, leaves standstill the back restir 10～20 minutes, adds weight ratio in the described binding agent and be 5.25% sanitas and 6.7～10 times of weight in the water of binding agent; In the described glaze spraying process, the temperature of base substrate is less than 35 ℃ before the glaze spraying, and ground-coat enamel glazing thickness is no more than 12mil, and cover-coat enamel is no more than 37mil; In the described sintering process, go into the preceding base substrate water ratio of kiln less than 1%.
2. the prevention glaze is jumped the method for glaze defective in a kind of snitaryware production process as claimed in claim 1, it is characterized in that: in the described mechanical milling process, raw material adds ball mill at twice, adds wear-resistant material earlier, and ball milling to 325 mesh screen residue adds easy abrasive material again after 3%.
3. the prevention glaze is jumped the method for glaze defective in a kind of snitaryware production process as claimed in claim 1, and it is characterized in that: ballstone vacancy height is 1157～1163cm in the described mechanical milling process.
4. the prevention glaze is jumped the method for glaze defective in a kind of snitaryware production process as claimed in claim 1, and it is characterized in that: the described old time is 1～3 day.
5. the prevention glaze is jumped the method for glaze defective in a kind of snitaryware production process as claimed in claim 1, it is characterized in that: the performance of described binding agent and sanitas should satisfy following index: binding agent was placed 7 days after allocating glaze into continuously, changed in glaze year to be no more than 30 degree; Sanitas is allocated in the airtight environment that is placed on below 30 ℃ of glaze did not have rotten odor after 21 days.
6. the prevention glaze is jumped the method for glaze defective in a kind of snitaryware production process as claimed in claim 1, it is characterized in that: through the processing of sieving, the porcelain glaze was crossed 100 mesh sieves before glaze was sent, and fine pottery matter glaze is crossed double-deck 60 mesh sieves; Glaze after sending is controlled at below 35 ℃.
7. the prevention glaze is jumped the method for glaze defective in a kind of snitaryware production process as claimed in claim 1, it is characterized in that: each processing parameter is in the described glaze spraying operation: glaze spraying air pressure 0.5～0.6mpa, glaze is pressed 0.4～0.5mpa, 20～25 seconds/500ml of gun traffic glaze, the glaze atomizing is shaped as ellipse, major diameter 30～40cm, minor axis 20～30cm, gun slot glaze temperature is less than 30 ℃, and glaze spraying speed is 3～5cm/s.
8. the prevention glaze is jumped the method for glaze defective in a kind of snitaryware production process as claimed in claim 1, it is characterized in that: the glazed body product spacing＞10cm after streamline and the entrucking.
9. jump the method for glaze defective as prevention glaze in the described a kind of snitaryware production process of arbitrary claim in the claim 1～8, it is characterized in that: the amount of adding back glaze in described glaze preparation section is at total below 80% of glaze weight.
10. the prevention glaze is jumped the method for glaze defective in a kind of snitaryware production process as claimed in claim 9, it is characterized in that: carry out ball-milling processing to returning glaze, the deironing of sieving is then controlled back glaze and is crossed 230 mesh screen residue quantity below 0.5%.
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| CN200910198419A CN101700984A (en) | 2009-11-06 | 2009-11-06 | Method for preventing glaze layer from jumping glaze in the productive process of sanitary ceramic |
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| CN200910198419A CN101700984A (en) | 2009-11-06 | 2009-11-06 | Method for preventing glaze layer from jumping glaze in the productive process of sanitary ceramic |
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Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104529393A (en) * | 2014-12-04 | 2015-04-22 | 宋展泓 | Method fro producing low-cost high-whiteness sanitary ceramic with clay tailings |
| CN107892478A (en) * | 2017-10-23 | 2018-04-10 | 鹰牌陶瓷实业（河源）有限公司 | A kind of method of quality control of glaze production and processing |
| CN110041103A (en) * | 2019-04-28 | 2019-07-23 | 东莞市唯美陶瓷工业园有限公司 | A kind of process improving Ceramic Tiles glaze surface evenness |
| CN110615664A (en) * | 2018-06-20 | 2019-12-27 | 骊住株式会社 | Sanitary ware and method for producing sanitary ware |
| CN113537751A (en) * | 2021-07-09 | 2021-10-22 | 联通(浙江)产业互联网有限公司 | Method and device for determining quality factors affecting milled products |
-
2009
- 2009-11-06 CN CN200910198419A patent/CN101700984A/en active Pending
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104529393A (en) * | 2014-12-04 | 2015-04-22 | 宋展泓 | Method fro producing low-cost high-whiteness sanitary ceramic with clay tailings |
| CN104529393B (en) * | 2014-12-04 | 2016-05-11 | 宋展泓 | A kind of method that adopts the high whiteness sanitary ceramics of clay tailing production low cost |
| CN107892478A (en) * | 2017-10-23 | 2018-04-10 | 鹰牌陶瓷实业（河源）有限公司 | A kind of method of quality control of glaze production and processing |
| CN107892478B (en) * | 2017-10-23 | 2020-07-21 | 河源市东源鹰牌陶瓷有限公司 | Quality control method for glaze production and processing |
| CN110615664A (en) * | 2018-06-20 | 2019-12-27 | 骊住株式会社 | Sanitary ware and method for producing sanitary ware |
| CN110041103A (en) * | 2019-04-28 | 2019-07-23 | 东莞市唯美陶瓷工业园有限公司 | A kind of process improving Ceramic Tiles glaze surface evenness |
| CN113537751A (en) * | 2021-07-09 | 2021-10-22 | 联通(浙江)产业互联网有限公司 | Method and device for determining quality factors affecting milled products |
| CN113537751B (en) * | 2021-07-09 | 2024-05-17 | 联通(浙江)产业互联网有限公司 | Method and device for determining quality factors affecting ground products |
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Application publication date: 20100505 |