CN103332958B - Foamed ceramic with gradient pore structure and preparation method thereof - Google Patents
Foamed ceramic with gradient pore structure and preparation method thereof Download PDFInfo
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Abstract
The invention relates to a foamed ceramic with a gradient pore structure and a preparation method thereof. The invention comprises following steps: taking polished tile waste residues produced in a polishing section of a polished tile production line; removing impurities, and dehydrating so as to obtain a slurry of the polished tile waste residues; mixing and ball-milling the raw material of an upper layer and a lower layer, and drying the formulated slurry of the upper layer and the low layer so as to obtain a powder material of the upper layer and a powder material of the lower layer; adding the powder material of the lower layer and the powder material of the upper layer into a heat-resistant mould frame successively, and placing the heat-resistant mould frame on roller bars of a roller kin for firing, wherein temperature schedules of the upper layer of the roller bars and the lower layer of the roller bars are controlled; naturally cooling to room temperature, and demoulding so as to obtain burnt products. The obtained foamed ceramic possesses the gradient pore structure, wherein the gradient pore structure comprises three layers; the first layer are provided with a plurality of open pores which are communicated with each other; the second layer is provided with a plurality of closed pores which are not communicated with each other; and the third layer is a transition layer arranged between the other two layers. The foamed ceramic can be used in the fields of heat insulation, noise reduction, corrosion prevention of electricity, desulphurization, and the like.
Description
Technical field
The present invention relates to a kind of foamed ceramics and preparation method thereof, a kind of foamed ceramics with graded pore structure that the waste residues of polished tiles of take is specifically prepared as raw material and preparation method thereof, belongs to novel material development field.
Background technology
In recent years, China's polished tile industry development is rapid, for huge contribution has been made in socio-economic development.Yet for various reasons, the not yet effective recycling of a large amount of polishing slags that polished tile produces in producing, is seriously restricting the Sustainable development of Building Ceramics Industry.
It is reported, the annual polished brick waste quantity of slag producing of Guangdong Province polished tile manufacturing enterprise is 10 million ton, because waste residues of polished tiles contains emery cake composition, (is mainly magnesia oxychloride cement (MgO, MgCl
2), epoxy resin, filler and silicon-carbide particle), under high temperature, easily produce a large amount of gas and foam, cause more than 90% polishing slag of whole industry all cannot cycling and reutilization.The landfill that waste residues of polished tiles taked in the past and the processing mode of stacking not only take a large amount of stacking places, cause environmental pollution, and farmland is destroyed, and have also wasted the ceramic resources of a large amount of preciousnesses simultaneously.If the polishing slag of take is incubated as main material production goes out to have and the foamed ceramics of sound absorption function, not only broken through the awkward situation that waste residue is difficult to recycling, realize the Green Development pattern of ceramic industry, can produce good economic benefit simultaneously.
The foamed ceramics of different air hole structures has different functions (as acoustic foams pottery requires to have the open pore structure interpenetrating, and heat-insulation and heat-preservation foamed ceramics requires the closed pore structure that has independently, do not connect mutually), adding the distinctive excellent specific property such as high temperature resistant, corrosion-resistant of stupalith, is used widely in many fields such as foamed ceramics is anticorrosion at heat-insulation and heat-preservation, sound absorption noise reduction, electric power, desulfurization.
Chinese patent CN1010560112B, discloses a kind of high-performance light vitreous foam ceramic tile and preparation technology thereof.It is raw material that this foam ceramic tile be take porcelain stone, hypothermia grait, rhombspar, lithium porcelain stone, calcite, waste ceramic rejected material, silicon carbide, nano kaoline, dispersion agent, has prepared the light vitreous ceramic tile that a kind of entire body is comprised of numerous small bubbles that independently, do not connect mutually.This invention high-performance light vitreous foam ceramic tile, because air hole structure is closed pore, is mainly used in heat preservation and insulation field.
Chinese patent CN1404459, discloses a kind of porous, sound absorbing ceramic moldings and manufacture method thereof.The porous, sound absorbing ceramic moldings that ceramic molding is comprised of connection perforate, loose density is 0.5～1.0, with low cost, provides from showing the porous, sound absorbing ceramic moldings of the sound absorbing brick of good acoustical absorbance properties and sound absorbing watt etc. in the wide range of bass area to treble.But this formed body air hole structure, for being communicated with perforate, does not possess good heat preservation and insulation.
Summary of the invention
For overcoming the deficiencies in the prior art, the object of the present invention is to provide a kind of foamed ceramics of the closed pore structure of take open pore structure that waste residues of polished tiles interpenetrates as having concurrently of preparing of main raw material and having independently, not connecting mutually.
It is a kind of simple to operate and be easy to a kind of preparation method with the foamed ceramics of graded pore structure of technology controlling and process that another object of the present invention is to provide.
The present invention utilizes waste residues of polished tiles to develop one deck to have the open pore structure interpenetrating, the foamed ceramics of the graded pore structure that the closed pore structure that another layer has independently, do not connect mutually and two interlayer transition layers form, this foamed ceramics has heat-insulation and heat-preservation and sound-absorbing dual-use function, and can be widely used in auditorium, KTV room, meeting room, cinema etc. needs sound-absorbing, heat insulation field.The present invention has not only utilized the polishing slag of building ceramic enterprises, has greatly expanded again the range of application of foamed ceramics.
The object of the invention is to be achieved through the following technical solutions:
A preparation method with the foamed ceramics of graded pore structure, comprises the following steps:
(1) waste residues of polished tiles slip is collected: extract the waste residues of polished tiles slurry that polished tile production line polishing section produces, carry out impurity elimination, processed, obtain water ratio and be 50～60% waste residues of polished tiles slip;
(2) mixing and ball milling: respectively levels raw material is carried out to mixing and ball milling, ball milling fineness to 250 mesh screen residue is 0.1～0.3%, obtains the upper and lower formula slip; In the mass percent of raw material dry weight, the consisting of of upper strata or lower floor's raw material: waste residues of polished tiles 80～100%, fusing assistant 0～15%, high-alumina clay 0～10%, whipping agent 0～3%; Described fusing assistant is cullet powder or albite; Described high-alumina clay is that clay be who knows middle Al
2o
3mass content is greater than 46%, the clay that alumina silica ratio is 0.85～2.5; Described whipping agent is discarded emery cake, waste gypsum, CaCO
3in one or more mixtures, the particle diameter of whipping agent is more than 325 orders;
(3) dry: by the upper and lower formula slurry drying in step (2) to the upper and lower powder that water ratio is 6～8%;
(4) filling: the lower floor's powder obtaining in step (3) and upper strata powder are packed in heat-resisting die frame successively, and upper and lower layer filling Thickness Ratio is 0.8～1.2, and powder total filling amount is 1/3～1/2 of mould capacity;
(5) burn till: the mould that powder is housed is placed in roller kiln and on roller rod, enters klining, on control roller rod, sheaf space firing temperature system is: 1.5～3h evenly rises to 950 ℃ by room temperature, at 3～5h, by 950 ℃, evenly rise to 1170～1220 ℃ again, insulation 0.5～1h; Roller rod lower layer space firing temperature system is: 1.5～3h evenly rises to 950 ℃ by room temperature, then by 950 ℃, evenly rises to 1150～1200 ℃ at 3～5h, insulation 0.5～1h; Naturally cool to room temperature, then the demoulding obtains burnt product;
(6) cutting: burnt product is cut on request to the product of different specification size, obtains having the foamed ceramics of graded pore structure.
Preferably, the waste residue of described waste residues of polished tiles for adopting emery cake polishing porcelain brick surface to produce, described emery cake main component is magnesia oxychloride cement (MgO, MgCl2), epoxy resin, filler and silicon carbide (SiC).The material of described heat-resisting die frame is high temperature steel, recrystallized silicon carbide or corundum.It is long * wide * thick that the specification of heat-resisting die frame is preferably 610mm * 610mm * 65mm(), also can control according to demand grinding tool frame specification.In the mass percent of raw material dry weight, the formula of the upper and lower raw material forms identical; Or the formula proportion of composing of the upper and lower raw material is different.。
A foamed ceramics with graded pore structure, is made by above-mentioned preparation method.
The present invention is in order to realize graded pore structure characteristic, in the identical or different layer powder formulation of the upper and lower, add fusing assistant, high-alumina clay (improving high-temperature liquid-phase viscosity) and whipping agent, and control goods and burn till up and down the temperature difference to reach goods levels differing temps system burning till stage roller rod, the final one deck that forms has the open pore structure interpenetrating, the graded pore structure that the closed pore structure that another layer has independently, do not connect mutually and two interlayer transition layers form.
With respect to prior art, the invention has the beneficial effects as follows:
(1) foam ceramic material of the present invention has the open pore structure that one deck interpenetrates, closed pore structure and two interlayer transition layer structures that another layer do not connect independently, mutually, can realize and have the multifunctional foam pottery that heat-insulation and heat-preservation and sound absorption function are integrated, its superior performance, Application Areas are extensive.
(2) to adopt waste residues of polished tiles be that main raw material is prepared multifunctional foam pottery in the present invention, can effectively solve in a short time the pollution of waste residues of polished tiles, and the recyclable recycling of waste material that the follow-up cutting of burnt product produces, the present invention has realized turns waste into wealth, and the Green Development of architectural pottery industry is had to very big meaning.
(3) polished brick waste solid impurity particle tiny (median size approximately 10 μ m), raw material ball milling only need reach the object of mixing with other raw materials, and mechanical milling process power consumption is low, the raw materials used industrial waste that is mainly in addition, foamed ceramics overall manufacturing is with low cost.
(4) by controlling roller kiln roller rod levels temperature schedule to realize goods levels differing temps system, to have widened the purposes of the roller kiln that are mainly used in burning till wall floor tile in the past.
Accompanying drawing explanation
Fig. 1 is the sectional structure schematic diagram of patent of the present invention:
Shown in figure: closed pore structural sheet 1, open pore structural sheet 2 and transition layer 3.
Embodiment
For a better understanding of the present invention, below in conjunction with embodiment, the present invention is further set forth, but the scope of protection of present invention is not limited to the scope that embodiment describes.
Embodiment 1:
Raw material: upper and lower layer: waste residues of polished tiles 100%
Preparation method:
(1) waste residues of polished tiles slip is collected: extract the waste residues of polished tiles slurry that polished tile production line polishing section produces, carry out impurity elimination, processed, obtaining water ratio is the waste residues of polished tiles slip of 50wt%;
(2) ball milling: by waste residues of polished tiles slurry ball-milling, ball milling fineness to 250 mesh screen residue 0.1%;
(3) dry: the powder that is 6～8% to water ratio by slurry drying in step (2);
(4) filling: the powder obtaining in step (3) is loaded in the high temperature steel mould frame of 610mm * 610mm * 65mm specification, powder loadings is 1/2 of mould capacity;
(5) burn till: the mould that powder is housed is placed in roller kiln and on roller rod, enters klining, on control roller rod, in upper strata temperature schedule: 1.5h, from room temperature, be at the uniform velocity warming up to 950 ℃, at the uniform velocity be warming up to 1170 ℃ from 950 ℃ in 4h, top temperature soaking time is 1h, amounts to 6.5h; From room temperature, is at the uniform velocity warming up to 950 ℃ in Gun Bang lower floor temperature schedule: 1.5h, in 4.5h, is at the uniform velocity warming up to 1150 ℃ from 950 ℃, top temperature soaking time is 0.5h, amounts to 6.5h, then naturally cools to room temperature, and the demoulding obtains burnt product;
(6) cutting: burnt product is cut into 300mm * 300mm * 60mm specification, also can be cut into by construction requirement the product of different specification size, be described a kind of foamed ceramics with graded pore structure, this foamed ceramics can be used for heat-insulation and heat-preservation, sound absorption noise reduction field, has heat insulation, sound absorption dual-use function.
Adopt microscopic examination goods air hole structure, press GB/T1966-1996 test article unit weight, by GB/T1964-1996 test article ultimate compression strength, by GB/T5990-2006 test article thermal conductivity, adopt standing wave tube test article sound absorbing capabilities, test frequency is 150-4000Hz.As shown in Figure 1, products obtained therefrom upper strata is mainly has the open pore structural sheet 2 interpenetrating, and lower floor is mainly the closed pore structural sheet 1 that has independently, do not connect mutually, and upper and lower two interlayers are transition layer 3.
By controlling temperature schedule and then controlling high-temperature gas, produce speed and gas generated; By adjusting, fill a prescription, can control goods high-temperature viscosity.Finally by gas production rate, gas generated and goods high-temperature viscosity, jointly determined the final air hole structure of foamed ceramics.
Foamed ceramics correlated performance test result is: unit weight 0.55g/cm
3, ultimate compression strength 3.5MPa, thermal conductivity 0.15W/mK, sound absorbing coefficient is 0.36.This foamed ceramics is heat insulation, sound absorption and other are functional, and can be used for meeting room, cinema, auditorium etc. needs heat insulation, sound absorption field.
Embodiment 2:
Raw material:
Upper strata: waste residues of polished tiles 80%, cullet 10%, albite 5%, high-alumina clay 3%, discarded emery cake 2%
Lower floor: waste residues of polished tiles 90%, cullet 3%, high-alumina clay 5%, discarded emery cake 1%, waste gypsum 1%
Preparation method:
(1) waste residues of polished tiles slip is collected: extract the waste residues of polished tiles slurry that polished tile production line polishing section produces, carry out impurity elimination, processed, obtain water ratio and be 60% waste residues of polished tiles slip;
(2) ball milling: levels is prepared burden and is milled to respectively fineness 250 mesh screen residues 0.1% by above-mentioned raw materials weight percent respectively, obtains the upper and lower formula slip;
(3) dry: by step (2) at the middle and upper levels with lower layer formula slurry drying to the upper and lower powder that water ratio is 7%;
(4) filling: the lower floor's powder obtaining in step (3) and upper strata powder are packed in the heat-resisting die frame of 610mm * 610mm * 65mm specification successively, and upper and lower layer filling Thickness Ratio is 0.8, and powder total filling amount is 5/12 of mould capacity;
(5) burn till: the mould that powder is housed is placed in roller kiln and on roller rod, enters klining, on control roller rod, in upper strata temperature schedule: 2h, from room temperature, be at the uniform velocity warming up to 950 ℃, at the uniform velocity be warming up to 1200 ℃ from 950 ℃ in 4.5h, top temperature soaking time is 0.5h, amounts to 7h; From room temperature, is at the uniform velocity warming up to 950 ℃ in Gun Bang lower floor temperature schedule: 2h, in 4h, is at the uniform velocity warming up to 1190 ℃ from 950 ℃, top temperature soaking time is 1h, amounts to 7h, then naturally cools to room temperature, and the demoulding obtains burnt product;
(6) cutting: burnt product is cut into 300mm * 300mm * 60mm specification, also can be cut into by construction requirement the product of different specification size, be described a kind of foamed ceramics with graded pore structure, this foamed ceramics can be used for heat-insulation and heat-preservation, sound absorption noise reduction field, has heat insulation, sound absorption dual-use function.
Product testing method is with embodiment 1.Products obtained therefrom upper strata is mainly the open pore structure interpenetrating, the closed pore structure that lower floor is mainly independently, does not connect mutually, and foamed ceramics correlated performance test result is: unit weight 0.46g/cm
3, ultimate compression strength 2.1MPa, thermal conductivity 0.14W/mK.Adopt standing wave tube, when test frequency is 150-4000Hz, average sound absorbing coefficient is 0.47.This foamed ceramics is heat insulation, sound absorption and other are functional, and can be used for meeting room, cinema, auditorium etc. needs heat insulation, sound absorption field.
Embodiment 3:
Raw material:
Upper strata: waste residues of polished tiles 85%, cullet 12%, discarded emery cake 2.5%, CaCO
30.5%
Lower floor: waste residues of polished tiles 90%, cullet 3%, high-alumina clay 5%, discarded emery cake 1.5%, CaCO
30.5%
Preparation method:
(1) waste residues of polished tiles slip is collected: extract the waste residues of polished tiles slurry that polished tile production line polishing section produces, carry out impurity elimination, processed, obtain water ratio and be 55% waste residues of polished tiles slip;
(2) ball milling: levels is prepared burden by above-mentioned raw materials weight percent respectively and is milled to fineness 250 mesh screen residues 0.1%, obtains the upper and lower formula slip;
(3) dry: by step (2) at the middle and upper levels with lower layer formula slurry drying to the upper and lower powder that water ratio is 6%;
(4) filling: the lower floor's powder obtaining in step (3) and upper strata powder are packed in the recrystallized silicon carbide mould frame of 610mm * 610mm * 65mm specification successively, and upper and lower layer filling Thickness Ratio is 1.0, and powder total filling amount is 1/3 of mould capacity;
(5) burn till: the mould that powder is housed is placed in roller kiln and on roller rod, enters klining, on control roller rod, in upper strata temperature schedule: 3h, from room temperature, be at the uniform velocity warming up to 950 ℃, at the uniform velocity be warming up to 1180 ℃ from 950 ℃ in 4h, top temperature soaking time is 1h, amounts to 8h; From room temperature, is at the uniform velocity warming up to 950 ℃ in Gun Bang lower floor temperature schedule: 3h, in 4.5h, is at the uniform velocity warming up to 1170 ℃ from 950 ℃, top temperature soaking time is 0.5h, amounts to 8h, then naturally cools to room temperature, and the demoulding obtains burnt product;
(6) cutting: burnt product is cut into 300mm * 300mm * 60mm specification, also can be cut into by construction requirement the product of different specification size, be described a kind of foamed ceramics with graded pore structure, this foamed ceramics can be used for heat-insulation and heat-preservation, sound absorption noise reduction field, has heat insulation, sound absorption dual-use function.
Product testing method is with embodiment 1.Products obtained therefrom upper strata is mainly the open pore structure interpenetrating, the closed pore structure that lower floor is mainly independently, does not connect mutually, and foamed ceramics correlated performance test result is: unit weight 0.40g/cm
3, ultimate compression strength 1.3Mpa, thermal conductivity 0.15W/mK.Adopt standing wave tube, when test frequency is 150-4000Hz, sound absorbing coefficient is 0.41.This foamed ceramics is heat insulation, sound absorption and other are functional, and can be used for meeting room, cinema, auditorium etc. needs heat insulation, sound absorption field.
Embodiment 4:
Raw material:
Upper strata: waste residues of polished tiles 80%, cullet 15%, high-alumina clay 4%, discarded emery cake 1%
Lower floor: waste residues of polished tiles 80%, cullet 5%, albite 4%, high-alumina clay 10%, discarded emery cake 1%
Preparation method:
(1) waste residues of polished tiles slip is collected: extract the waste residues of polished tiles slurry that polished tile production line polishing section produces, carry out impurity elimination, processed, obtain water ratio and be 55% waste residues of polished tiles slip;
(2) ball milling: levels is prepared burden by above-mentioned raw materials weight percent respectively and is milled to fineness 250 mesh screen residues 0.3%, obtains the upper and lower formula slip;
(3) dry: by step (2) at the middle and upper levels with lower layer formula slurry drying to the upper and lower powder that water ratio is 7%;
(4) filling: the lower floor's powder obtaining in step (3) and upper strata powder are packed in the corundum mould frame of 610mm * 610mm * 65mm specification successively, and upper and lower layer filling Thickness Ratio is 1.2, and powder total filling amount is 1/2 of mould capacity;
(5) burn till: the mould that powder is housed is placed in roller kiln and on roller rod, enters klining, on control roller rod, in upper strata temperature schedule: 1.5h, from room temperature, be at the uniform velocity warming up to 950 ℃, at the uniform velocity be warming up to 1220 ℃ from 950 ℃ in 4.5h, top temperature soaking time is 0.5h, amounts to 6.5h; From room temperature, is at the uniform velocity warming up to 950 ℃ in Gun Bang lower floor temperature schedule: 1.5h, in 4.5h, is at the uniform velocity warming up to 1200 ℃ from 950 ℃, top temperature soaking time is 0.5h, amounts to 6.5h, then naturally cools to room temperature, and the demoulding obtains burnt product;
(6) cutting: burnt product is cut into 300mm * 300mm * 60mm specification, also can be cut into by construction requirement the product of different specification size, be described a kind of foamed ceramics with graded pore structure, this foamed ceramics can be used for heat-insulation and heat-preservation, sound absorption noise reduction field, has heat insulation, sound absorption dual-use function.
Product testing method is with embodiment 1.Products obtained therefrom upper strata is mainly the open pore structure interpenetrating, the closed pore structure that lower floor is mainly independently, does not connect mutually, and foamed ceramics correlated performance test result is: unit weight 0.36g/cm
3, ultimate compression strength 0.8MPa, thermal conductivity 0.09W/mK.Adopt standing wave tube, when test frequency is 150-4000Hz, sound absorbing coefficient is 0.45.This foamed ceramics is heat insulation, sound absorption and other are functional, and can be used for meeting room, cinema, auditorium etc. needs heat insulation, sound absorption field.
Claims (5)
1. a preparation method with the foamed ceramics of graded pore structure, is characterized in that comprising the following steps:
(1) waste residues of polished tiles slip is collected: extract the waste residues of polished tiles slurry that polished tile production line polishing section produces, carry out impurity elimination, processed, obtaining water ratio is the waste residues of polished tiles slip of 50wt%;
(2) ball milling: by waste residues of polished tiles slurry ball-milling, ball milling fineness to 250 mesh screen residue 0.1%;
(3) dry: the powder that is 6～8% to water ratio by slurry drying in step (2);
(4) filling: the powder obtaining in step (3) is loaded in the high temperature steel mould frame of 610mm * 610mm * 65mm specification, powder loadings is 1/2 of mould capacity;
(5) burn till: the mould that powder is housed is placed in roller kiln and on roller rod, enters klining, on control roller rod, in upper strata temperature schedule: 1.5h, from room temperature, be at the uniform velocity warming up to 950 ℃, at the uniform velocity be warming up to 1170 ℃ from 950 ℃ in 4h, top temperature soaking time is 1h, amounts to 6.5h; From room temperature, is at the uniform velocity warming up to 950 ℃ in Gun Bang lower floor temperature schedule: 1.5h, in 4.5h, is at the uniform velocity warming up to 1150 ℃ from 950 ℃, top temperature soaking time is 0.5h, amounts to 6.5h, then naturally cools to room temperature, and the demoulding obtains burnt product;
(6) cutting: burnt product is cut into the product of different specification size by construction requirement, must there is the foamed ceramics of graded pore structure.
2. a preparation method with the foamed ceramics of graded pore structure, is characterized in that comprising the following steps:
(1) waste residues of polished tiles slip is collected: extract the waste residues of polished tiles slurry that polished tile production line polishing section produces, carry out impurity elimination, processed, obtaining water ratio is the waste residues of polished tiles slip of 60wt%;
(2) ball milling: levels is prepared burden and is milled to respectively fineness 250 mesh screen residues 0.1% by raw material weight per-cent respectively, obtains the upper and lower formula slip; Upper strata raw material consists of: waste residues of polished tiles 80%, cullet 10%, albite 5%, high-alumina clay 3%, discarded emery cake 2%; Lower floor's raw material consists of: waste residues of polished tiles 90%, cullet 3%, high-alumina clay 5%, discarded emery cake 1%, waste gypsum 1%;
(3) dry: by step (2) at the middle and upper levels with lower layer formula slurry drying to the upper and lower powder that water ratio is 7%;
(4) filling: the lower floor's powder obtaining in step (3) and upper strata powder are packed in the heat-resisting die frame of 610mm * 610mm * 65mm specification successively, and upper and lower layer filling Thickness Ratio is 0.8, and powder total filling amount is 5/12 of mould capacity;
(5) burn till: the mould that powder is housed is placed in roller kiln and on roller rod, enters klining, on control roller rod, in upper strata temperature schedule: 2h, from room temperature, be at the uniform velocity warming up to 950 ℃, at the uniform velocity be warming up to 1200 ℃ from 950 ℃ in 4.5h, top temperature soaking time is 0.5h, amounts to 7h; From room temperature, is at the uniform velocity warming up to 950 ℃ in Gun Bang lower floor temperature schedule: 2h, in 4h, is at the uniform velocity warming up to 1190 ℃ from 950 ℃, top temperature soaking time is 1h, amounts to 7h, then naturally cools to room temperature, and the demoulding obtains burnt product;
(6) cutting: burnt product is cut into the product of different specification size by construction requirement, must there is the foamed ceramics of graded pore structure.
3. a preparation method with the foamed ceramics of graded pore structure, is characterized in that comprising the following steps:
(1) waste residues of polished tiles slip is collected: extract the waste residues of polished tiles slurry that polished tile production line polishing section produces, carry out impurity elimination, processed, obtaining water ratio is the waste residues of polished tiles slip of 55wt%;
(2) ball milling: levels is prepared burden by raw material weight per-cent respectively and is milled to fineness 250 mesh screen residues 0.1%, obtains the upper and lower formula slip; Upper strata raw material consists of: waste residues of polished tiles 85%, cullet 12%, discarded emery cake 2.5%, CaCO
30.5%; Lower floor's raw material consists of: waste residues of polished tiles 90%, cullet 3%, high-alumina clay 5%, discarded emery cake 1.5%, CaCO
30.5%;
(3) dry: by step (2) at the middle and upper levels with lower layer formula slurry drying to the upper and lower powder that water ratio is 6%;
(4) filling: the lower floor's powder obtaining in step (3) and upper strata powder are packed in the recrystallized silicon carbide mould frame of 610mm * 610mm * 65mm specification successively, and upper and lower layer filling Thickness Ratio is 1.0, and powder total filling amount is 1/3 of mould capacity;
(5) burn till: the mould that powder is housed is placed in roller kiln and on roller rod, enters klining, on control roller rod, in upper strata temperature schedule: 3h, from room temperature, be at the uniform velocity warming up to 950 ℃, at the uniform velocity be warming up to 1180 ℃ from 950 ℃ in 4h, top temperature soaking time is 1h, amounts to 8h; From room temperature, is at the uniform velocity warming up to 950 ℃ in Gun Bang lower floor temperature schedule: 3h, in 4.5h, is at the uniform velocity warming up to 1170 ℃ from 950 ℃, top temperature soaking time is 0.5h, amounts to 8h, then naturally cools to room temperature, and the demoulding obtains burnt product;
(6) cutting: burnt product is cut into the product of different specification size by construction requirement, must there is the foamed ceramics of graded pore structure.
4. a preparation method with the foamed ceramics of graded pore structure, is characterized in that comprising the following steps:
(1) waste residues of polished tiles slip is collected: extract the waste residues of polished tiles slurry that polished tile production line polishing section produces, carry out impurity elimination, processed, obtaining water ratio is the waste residues of polished tiles slip of 55wt%;
(2) ball milling: levels is prepared burden by raw material weight per-cent respectively and is milled to fineness 250 mesh screen residues 0.3%, obtains the upper and lower formula slip; Upper strata raw material consists of: waste residues of polished tiles 80%, cullet 15%, high-alumina clay 4%, discarded emery cake 1%; Lower floor's raw material consists of: waste residues of polished tiles 80%, cullet 5%, albite 4%, high-alumina clay 10%, discarded emery cake 1%;
(3) dry: by step (2) at the middle and upper levels with lower layer formula slurry drying to the upper and lower powder that water ratio is 7%;
(4) filling: the lower floor's powder obtaining in step (3) and upper strata powder are packed in the corundum mould frame of 610mm * 610mm * 65mm specification successively, and upper and lower layer filling Thickness Ratio is 1.2, and powder total filling amount is 1/2 of mould capacity;
(5) burn till: the mould that powder is housed is placed in roller kiln and on roller rod, enters klining, on control roller rod, in upper strata temperature schedule: 1.5h, from room temperature, be at the uniform velocity warming up to 950 ℃, at the uniform velocity be warming up to 1220 ℃ from 950 ℃ in 4.5h, top temperature soaking time is 0.5h, amounts to 6.5h; From room temperature, is at the uniform velocity warming up to 950 ℃ in Gun Bang lower floor temperature schedule: 1.5h, in 4.5h, is at the uniform velocity warming up to 1200 ℃ from 950 ℃, top temperature soaking time is 0.5h, amounts to 6.5h, then naturally cools to room temperature, and the demoulding obtains burnt product;
(6) cutting: burnt product is cut into the product of different specification size by construction requirement, must there is the foamed ceramics of graded pore structure.
5. a foamed ceramics with graded pore structure, is characterized in that it is made by preparation method described in claim 1-4 any one; Gained foamed ceramics upper strata is to have the open pore structural sheet interpenetrating, and lower floor is the closed pore structural sheet that has independently, do not connect mutually, and upper and lower two interlayers are transition layer.
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| CN112759268A (en) * | 2019-11-06 | 2021-05-07 | 南京航空航天大学 | Heat-insulating sound-absorbing gradient porous foam glass |
| CN110981413B (en) * | 2019-12-23 | 2022-03-22 | 佛山欧神诺陶瓷有限公司 | High-performance foamed ceramic and preparation method and application thereof |
| CN111875258A (en) * | 2020-08-12 | 2020-11-03 | 洛南县恒丰非金属矿业有限公司 | Preparation method of foamed ceramic material with density gradient |
| CN113135770A (en) * | 2021-04-22 | 2021-07-20 | 熊伟 | Ceramic sound-absorbing material with straight-through gradient pore structure and preparation method thereof |
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