Background technology
Porous ceramics is the stupalith that has than high porosity, and the pore in the pottery is divided into open pore and closed pore, and according to the requirement of ceramic applications, this two classes pore proportion is different.For chemical catalyst carrier, filtration and separate, infiltration, moisture absorption, air-breathing, sound-absorbing and inhale ripple stealth etc. and use, the pore in the pottery is take open pore as main.Use for heat-insulation and heat-preservation, sound insulation, light building material etc., the pore in the pottery is take closed pore as main.
At present, the fabricating technology of porous ceramics mainly contains: foam process, interpolation pore former technique, foam impregnation technique, sol-gel technology, extrusion moulding porous honeycomb ceramic, solid-phase sintering process, gel injection technique, freeze drying process, synthetic (SHS) technique of self propagating high temperature, hydro-thermal-Re static pressure technique, Structure Inheritance preparation technology, ion exchange method etc.
In building ceramic tiles was produced, the production technology of porous ceramics brick generally adopted foam process (Chinese patent: prepare the method for porous ceramic composite with the protein foaming, the patent No.: 201010288589.1), adds pore former technique (Chinese patent: a kind of Lightweight heat insulating ceramic material and preparation method, the patent No.: 201010150474.6; Chinese patent: a kind of method of preparing SiC porous ceramic by splicing clay, the patent No.: 200910193875.7), extrusion moulding porous honeycomb ceramic technique (Chinese patent: ceramic honeycomb structure and manufacture method thereof, the patent No.: 01814404.7), solid-phase sintering process (Chinese patent: ecological water penetration brick and manufacture method thereof, the patent No.: 02128924.7; Chinese patent: a kind of method of utilizing industrial slag to prepare seepage brick, the patent No.: 201110441509.6)。
The functions such as that the porous ceramics brick has is heat insulation, warming, sound insulation, sound-absorbing, permeable, moistureproof, damping, Application Areas is very wide, and main products has: infiltration road/square brick, lightweight external brick, light internal wall brick, warm floor tile, insulating brick, acoustical tile, acoustic brick, breathing damping brick etc.At present, these products all are to make (monoblock type) by the porous ceramic film material of integral body, and because there is water absorbability in porous ceramic film material, frost resistance is poor, physical strength is low, not wear-resisting, the shortcoming such as resistant not, limited the further popularization of monolithic porous ceramic product Application Areas.
If with porous ceramics and non-porous ceramic phase compound (combined type), then can make product overcome the separately shortcoming of material, bring into play all kinds of stupaliths advantage separately, maximize favourable factors and minimize unfavourable ones.But because there are many differences in porous ceramics and non-porous pottery in production technology, the difference of pucker ﹠ bloat when product burns till particularly, two class stupaliths are difficult to common disposable burning till behind the combined shaping, generally be that two burned class potteries are complex as a whole by tackiness agent at present, do like this, exist energy consumption large, complex process, equipment is many, the problem that production cost is high.
Summary of the invention
The object of the present invention is to provide a kind of preparation method of porous ceramics composite brick, solved the difficult problem that porous ceramics and non-porous ceramic one are burnt altogether, at shaping stage that porous ceramic layer is mutually compound with non-porous ceramic layer by the ceramics forming technology, reenter the kiln once-firing, both can reduce production process and the energy consumption of burning once more, can obtain again the required porous composite ceramics product with unique premium properties.
A kind of manufacture method of porous ceramics composite brick, step comprises:
A. prepare conventional ceramic adobe material for subsequent use;
B. prepare porous ceramics adobe material, the components by weight percent of described porous ceramics adobe material comprises:
100 parts in described conventional ceramic adobe material;
Base substrate burns till 20~150 parts of shrinking agents;
0.03~20 part of whipping agent;
Described base substrate burn till shrinking agent for can be all or part of in the ceramic tile sintering procedure material that loses of burning, described whipping agent be the material of generation gas under the ceramic tile firing temperature;
C. adopt distributing technique described conventional ceramic adobe material and porous ceramics adobe material cloth to be become the multilayer of space, once burn altogether the porous ceramics composite brick that forms porous layer and non-porous layer coexistence through high temperature again.
Described base substrate burns till shrinking agent and is selected from one or more mixture in carbon dust, flour, Semen Maydis powder, sweet potato powder, starch, yeast powder, paraffin, asphalt powder, wood chip, vegetable fibre, gelatin, the gel.
Described whipping agent is selected from one or more the mixture in silicon carbide, silicon nitride, boron nitride, the calcium carbonate.
Described base substrate burns till the burning of shrinking agent and loses the γ-ray emission temperature that temperature is less than or equal to whipping agent.
Described base substrate burns till shrinking agent and whipping agent is evenly dispersed in the described porous ceramics adobe material, and the particle diameter of described whipping agent is less than 50 microns.
The weight percentage of each component is in the described conventional ceramic adobe material:
SiO2 67.38~72.00
Al2O3 14.66~18.56
CaO 0.59~3.73
MgO 1.18~2.30
K2O 3.15~5.20
Na2O 3.68~3.93
Fe2O30.39~1.19
TiO20.44~1.30。
The described conventional ceramic adobe material of step a preparation is shaped for subsequent use through adding water for ball milling, drying, granulation; Step c adopts the secondary material distributing technology and equipment, distinguishes porous ceramics adobe material and conventional ceramic adobe material on the cloth in mould, and dry-pressing obtains the double-layer ceramic adobe body of one deck porous ceramics adobe material and one deck conventional ceramic adobe material.
The described conventional ceramic adobe material of step a preparation is put into suction pit and is stored for future use through adding water for ball milling, sieving; Step c adopts first dry-pressing technique described porous ceramics blank to be pressed into the base substrate of porous ceramics brick, this base substrate after drying, adopt and drench sizing process, the material-mud of described conventional ceramic adobe material is applied to equably the surface of the base substrate of described porous ceramics brick, then drying is waited to burn.
Preferably, the step that flower, cloth decoration, silk screen printing, roller printing, spray ink Printing or glazing are decorated is polished, oozed to the one side that also is included in conventional ceramic adobe material.
The present invention is because porous ceramics burns till with non-porous pottery, and bonding force between the two is stronger, has reduced the process for processing operation, has reduced energy consumption and production cost, has realized maximizing favourable factors and minimizing unfavourable ones of individual material properties in the product use properties.
Embodiment
Stupalith forms in the similar situation after identical firing temperature, burning, the contraction of burning till of porous ceramics does not generally have burning till of non-porous densified sintering product pottery to shrink greatly, some porous ceramics in addition burn till after volumetric expansion can occur, under this sight, porous ceramics to be become whole and once-firing with the Ceramic Composite of densification, the defectives such as being out of shape, ftracture, peel off can appear in product cause product to use and scrap.Therefore, the control porous ceramics burn till contraction and thermal expansivity is consistent with non-porous stupalith, be the gordian technique of production porous ceramics composite brick.
The present invention is a kind of manufacture method of porous ceramics composite brick, comprises feed proportioning, ball milling processing, spraying drying, the dry pressing of existing ceramic tile or extrudes the operations such as shaping, drying, decoration, high temperature sintering, edging processing.
Compare with non-porous ceramic formula, contain base substrate in the porous ceramics composition of raw materials and burn till shrinking agent and whipping agent.In the porous ceramics blank, conventional ceramic adobe material accounts for 100 parts of gross weight, and base substrate burns till shrinking agent and accounts for 20 ~ 150 parts of gross weight, and whipping agent accounts for 0.03~20 part.
Base substrate burn till shrinking agent be can be all or part of in the base substrate sintering process material that loses of burning, include but not limited to carbon dust, flour, Semen Maydis powder, sweet potato powder, starch, yeast powder, paraffin, asphalt powder, wood chip, all kinds of vegetable fibre, gelatin, all kinds of gelatinous mass and mixture thereof etc., consider from the manufacturing cost angle, under the front topic that guarantees quality product, base substrate burns till shrinking agent to be worth cheap article as first-selected.Base substrate burns till shrinking agent should begin to burn mistake after ceramic body has some strength, and basic burning is lost complete before liquid phase appears in ceramic body inside.Because base substrate burns till shrinking agent and burnt, and stays a large amount of spaces in ceramic body, when liquid phase occurring in the ceramic body under the high temperature, it is occupied by liquid phase that base substrate burns till the space that shrinking agent stays, thereby the high temperature that has increased ceramic body burns till contraction.Utilize this part to burn till contraction and offset the volumetric expansion that whipping agent produces, the percent of firing shrinkage of porous ceramics and the percent of firing shrinkage of non-porous pottery are complementary, be conducive to both compound and burn till.
Whipping agent is the material that produces gas in ceramic sintering process, includes but not limited to silicon carbide, silicon nitride, boron nitride, calcium carbonate and mixture thereof etc.Base substrate burns till the burning of shrinking agent and loses the γ-ray emission temperature that temperature should be less than or equal to whipping agent.Base substrate burns till shrinking agent and whipping agent is evenly dispersed in the ceramic batch, and the particle diameter of whipping agent is less than 50 microns.By kind, quantity and the granularity of control whipping agent, can control size, the shape of pore in the porous ceramics and the ratio with open pore of remaining silent.
Burn till the chemical constitution (wt%) of rear porous ceramics: SiO232~72, Al2O310~28, CaO0~15, MgO 0~12, K2O 2~8, Na2O1~6.Form close after chemical constitution and the burning with its mutually compound non-porous pottery after the burning of this porous ceramics and be complementary.
This porous ceramics can be mutually compound when being shaped with non-porous pottery, adopt repeatedly cloth compacting, extrude or mud waters the forming technologies such as pouring, obtain on brick, having simultaneously the ceramic tile base substrate of porous ceramic layer and non-porous ceramic layer, after high temperature once burns altogether, obtain the MULTILAYER COMPOSITE ceramic tile of porous layer and non-porous layer coexistence, non-porous ceramic layer surface can be polished, and also can ooze flower, cloth decoration, silk screen printing, roller printing, spray ink Printing or glazing and decorate.
The present invention compared with prior art has following characteristics: 1, because porous ceramics burns till with non-porous pottery, bonding force between the two is stronger; 2, reduce the process for processing operation, reduced energy consumption and production cost; 3, realized maximizing favourable factors and minimizing unfavourable ones of individual material properties in the product use properties.
Embodiment 1
A kind of preparation method of porous ceramics composite brick, this ceramic composite brick is suitable for exterior wall, and step comprises:
A. the preparation of conventional ceramic adobe material: adopt the raw mineral materials preparation conventional ceramic adobe material such as clay, quartz, hypothermia grait, the chemical constitution of described conventional ceramic adobe material following (wt%):
SiO2 69.02
Al2O3 17.89
CaO 1.66
MgO 1.18
K2O 5.20
Na2O 3.93
Fe2O3 0.59
TiO2 0.53。
Batching has to be formed for subsequent use through adding water for ball milling, drying, granulation.
B. the preparation of porous ceramics adobe material: on the basis of above-mentioned conventional ceramic adobe material, by 100 parts of conventional ceramic adobe material, add 35 parts of flour, the part by weight of 0.2 part of silicon carbide mixes, and through adding water for ball milling, drying, granulation, has to be formed for subsequent use.
C. adopt the secondary material distributing technology and equipment, in mould, distinguish porous ceramics adobe material and conventional ceramic adobe material on the cloth, dry-pressing obtains the double-layer brick base substrate of one deck porous ceramics adobe material and one deck conventional ceramic adobe material, after appearance decoration, drying, advancing kiln burns till at 1200 ℃, obtain the porous ceramics composite brick, the common exterior wall tile light 1/3rd or 1/2nd of the weight ratio same size of this brick, heat-insulating capability doubles or twice than common exterior wall tile.
Embodiment 2
A kind of preparation method of porous ceramics composite brick, this composite brick also can polish the formation polished tile after burning till, and step comprises:
A. the preparation of conventional ceramic adobe material: adopt the raw mineral materials preparation conventional ceramic adobe material such as clay, quartz, hypothermia grait, the chemical constitution of described conventional ceramic adobe material following (wt%):
SiO2 71.62
Al2O3 18.56
CaO 0.59
MgO 1.39
K2O 3.15
Na2O 3.86
Fe2O3 0.39
TiO2 0.44。
Batching has to be formed for subsequent use through adding water for ball milling, drying, granulation.
B. the preparation of porous ceramics adobe material: on the basis of above-mentioned conventional ceramic adobe material, by 100 parts of conventional ceramic adobe material, add 20 parts of flour, 20 portions of Semen Maydis powder, 0.1 part of silicon carbide, the part by weight of 0.2 part of boron nitride mixes, through adding water for ball milling, drying, granulation, have to be formed for subsequent use.
C. adopt the secondary material distributing technology and equipment, in mould, distinguish porous ceramics adobe material and conventional ceramic adobe material on the cloth, dry-pressing obtains the double-layer brick base substrate of one deck porous ceramics adobe material and one deck conventional ceramic adobe material, through appearance decorate, dry, advance kiln 1200 ℃ burn till after, again the one side of conventional ceramic adobe material is carried out polished finish, through edging, obtain porous ceramics composite polishing brick, the common polished tile of the comparable same size of weight of this polished tile is light by 1/3rd.
Embodiment 3
A kind of preparation method of porous ceramics composite brick, this composite brick can be used for preparing wood grain tile, and step comprises:
A. the preparation of conventional ceramic adobe material: adopt the raw mineral materials preparation conventional ceramic adobe material such as clay, quartz, hypothermia grait, the chemical constitution of described conventional ceramic adobe material following (wt%):
SiO2 67.38
Al2O3 16.19
CaO 3.73
MgO 2.30
K2O 4.05
Na2O 3.86
Fe2O3 1.19
TiO2 1.30。
Batching has to be formed for subsequent use through adding water for ball milling, drying, granulation.
B. the preparation of porous ceramics adobe material: on the basis of above-mentioned conventional ceramic adobe material, by 100 parts of conventional ceramic adobe material, add 30 parts of sweet potato powder, 15 parts of carbon dusts, 10 parts of starch, 3 parts of yeast parts, 0.3 part silicon carbide, the ratio of 3 parts of silicon nitrides is mixed, and through adding water for ball milling, drying, granulation, has to be formed for subsequent use.
C. adopt the secondary material distributing technology and equipment, in mould, distinguish porous ceramics adobe material and conventional ceramic adobe material on the cloth, dry-pressing obtains the double-layer brick base substrate of one deck porous ceramics adobe material and one deck conventional ceramic adobe material, after the drying, spoon the special slurry of skim wood grain tile blank in the one side of porous ceramics adobe material, carry out grain pattern decorates on this surface again, after the drying, advancing kiln burns till at 1200 ℃, kiln discharge obtains the compound wood grain tile of porous ceramics by edging, and the common wood grain tile of the weight ratio same size of this exterior wall tile is light by 1/4th, because thermal conductivity and the timber of porous ceramics are close, so the tactility of this wood grain tile is more true to nature than common wood grain tile.
Embodiment 4
A kind of preparation method of porous ceramics composite brick, it has preferably thermal insulation of roof effect, and step comprises:
A. the preparation of conventional ceramic adobe material: adopt the raw mineral materials preparation conventional ceramic adobe material such as clay, quartz, hypothermia grait, the chemical constitution of described conventional ceramic adobe material following (wt%):
SiO2 72.00
Al2O3 14.66
CaO 1.09
MgO 2.21
K2O 4.92
Na2O 3.68
Fe2O3 0.89
TiO2 0.55。
Batching is put into suction pit and is stored for future use through adding water for ball milling, sieving.
B. the preparation of porous ceramics adobe material: on the basis of above-mentioned conventional ceramic adobe material, by 100 parts of conventional ceramic adobe material, add 45 parts of wood chips, 15 parts of gelatin, 20 parts of asphalt powders, the ratio of 20 parts of calcium carbonate is mixed, through adding water for ball milling, drying, granulation, have to be formed for subsequent use.
C. adopt first dry-pressing technique the porous ceramics blank to be pressed into the base substrate of porous ceramics brick, this base substrate after drying, adopt and drench sizing process, the material-mud of described conventional ceramic adobe material is applied to equably the surface of the base substrate of described porous ceramics adobe, if need certain thickness, can drench several times more, surface decoration, after the drying, advance kiln and burn till at 1180 ℃, behind the kiln discharge, through edging, obtain the porous ceramics combined floor, the common floor tile of the weight ratio same size of this floor tile is light more than 1/2nd, and the comparable common floor tile of heat-insulating capability improves three to five times, and surface abrasion resistance uses foam heat insulating material high than now.
Embodiment 5
A kind of preparation method of porous ceramics composite brick, step comprises:
A. the preparation of conventional ceramic floor tile blank: adopt the raw mineral materials preparation conventional ceramic adobe material such as clay, quartz, hypothermia grait, the chemical constitution of described conventional ceramic adobe material following (wt%):
SiO2 68.39
Al2O3 17.24
CaO 2.98
MgO 1.39
K2O 3.84
Na2O 3.69
Fe2O3 1.18
TiO2 1.29。
Batching has to be formed for subsequent use through adding water for ball milling, drying, granulation.
B. the preparation of porous ceramics adobe material: on the basis of above-mentioned conventional ceramic adobe material, by 100 parts of conventional ceramic adobe material, the ratio that adds 40 parts of paraffin, 40 parts of vegetable fibres, 70 parts of gels and 0.3 part of silicon carbide is mixed, and through adding water for ball milling, drying, granulation, has to be formed for subsequent use.
C. adopt the secondary material distributing technology and equipment, in mould, distinguish porous ceramics adobe material and conventional ceramic adobe material on the cloth, dry-pressing obtains the double-layer brick base substrate of one deck porous ceramics adobe material and one deck conventional ceramic adobe material, after the drying, advancing kiln burns till at 1200 ℃, kiln discharge obtains the porous ceramics composite brick by edging, and the conventional ceramic brick of the weight ratio same size of this brick is light by 1/4th.
Embodiment 6
A kind of preparation method of porous ceramics composite brick, it has preferably effect of heat insulation and folding strength, and step comprises:
A. the preparation of conventional ceramic adobe material: adopt the raw mineral materials preparation conventional ceramic adobe material such as clay, quartz, hypothermia grait, the chemical constitution of described conventional ceramic adobe material following (wt%):
SiO2 72.00
Al2O3 14.66
CaO 1.09
MgO 2.21
K2O 4.92
Na2O 3.68
Fe2O3 0.89
TiO2 0.55。
Batching is put into suction pit and is stored for future use through adding water for ball milling, sieving.
B. the preparation of porous ceramics adobe material: on the basis of above-mentioned conventional ceramic adobe material, by 100 parts of conventional ceramic adobe material, 80 parts of burned wood chips, 110 parts of ratios that contain the waste ceramic tile polishing material of 0.5%~3% silicon carbide are mixed, through adding water for ball milling, drying, granulation, have to be formed for subsequent use.The present invention utilizes this ceramic industry waste material of silicon carbide that contains of waste ceramic tile polishing material as the whipping agent of preparation porous ceramics composite brick, both can be salvaged, and saves cost, and environmental protection.
C. adopt repeatedly distributing technique and equipment, in mould, press respectively the common blank of one deck, one deck porous blank, the common blank of one deck, one deck porous blank, the common blank of one deck, be separated by five layers, five layers blank is pressed into the base substrate of five layers of ceramic tile through dry-pressing technique, this base substrate after drying, advancing kiln burns till at 1200 ℃, behind the kiln discharge, through edging, obtain multi-layer porous ceramic composite brick, the common brick of the weight ratio same size of this floor tile is light more than 1/3rd, and the comparable conventional ceramic brick of heat-insulating capability improves one to three times, and folding strength is higher one to two times than entire body porous ceramics brick.
Above-described only is preferred implementation of the present invention, should be pointed out that for the person of ordinary skill of the art, under the prerequisite that does not break away from the invention design, can also make some distortion and improvement, and these all belong to protection scope of the present invention.