CN105819826B - 保温装饰陶瓷砖制作方法 - Google Patents
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Abstract
本发明涉及建材材料技术领域，公开了一种保温装饰陶瓷砖制作方法，包括：在耐热板上喷涂脱模涂料或放置耐热纸；在所述脱模涂料或耐热纸上形成装饰层；在所述装饰层上覆盖结合层；在所述结合层上均匀地覆盖发泡陶瓷粉料；烧结成型。本发明的保温装饰陶瓷砖制作方法中将发泡陶瓷粉料和装饰层一起高温烧结，一体成型，减少了制作工序，节省了制作成本。
Description
技术领域
本发明涉及建材材料技术领域，特别涉及一种保温装饰陶瓷砖制作方法。
背景技术
现有的轻质发泡陶瓷保温板以陶土尾矿、陶瓷碎片、掺加料等作为主要原料，经1100～1150℃高温焙烧而成的高气孔率的闭孔陶瓷材料，再在闭孔陶瓷材料的一侧面涂抹粘接剂将另一装饰层粘贴到闭孔陶瓷材料的侧面，从而形成保温装饰陶瓷砖。显然这种保温装饰陶瓷砖的制作工序包括：烧制、粘贴及烘干等，制作工序复杂，而且还有额外消耗粘接剂，增加了制作成本，并且粘结层易老化，寿命一般不超过20年。
发明内容
本发明提出一种保温装饰陶瓷砖制作方法，解决了现有技术中制作工序复杂，制作成本高的问题。
本发明的保温装饰陶瓷板制作方法包括：
在耐热板上喷涂脱模涂料或放置耐热纸；
在所述脱模涂料或耐热纸上形成装饰层；
在所述装饰层上依次形成结合层和发泡陶瓷粉料；
烧结成型并脱模。
其中，所述装饰层和发泡陶瓷粉料的耐火度一致，结合层的耐火度比两者低5℃～20℃。
其中，所述装饰层为陶瓷板，所述陶瓷板、结合层及发泡陶瓷粉料各自的组分按质量份数均包括：粘土或河道淤泥10～30份、锂电池尾矿石粉20～60份、玻纤废料10～40份、钾长石矿10～50份、页岩10～50份、石英尾矿10～50份，所述发泡陶瓷粉料在上述组分基础上还包括发泡剂，所述发泡剂包括：石墨、碳素、碳酸钙、碳化硅各0.5～20份；且使得陶瓷板和发泡陶瓷粉料的耐火度一致，结合层的耐火度比两者低5℃～20℃。
其中，所述结合层的组分中钾和钠元素的总含量大于所述陶瓷板及发泡陶瓷粉料两者各自的组分中钾和钠元素的总含量。
其中，所述陶瓷板的组分按质量份数包括：粘土或河道淤泥15份、锂电池尾矿石粉30份、玻纤废料20份、钾长石矿20份、页岩20份、石英尾矿25份；
所述发泡陶瓷粉料的组分按质量份数包括：粘土或河道淤泥15份、锂电池尾矿石粉30份、玻纤废料20份、钾长石矿20份、页岩20份、石英尾矿25份、石墨5份、碳素5份、碳酸钙5份、碳化硅5份；
所述结合层的组分按质量份数包括：粘土或河道淤泥25份、锂电池尾矿石粉45份、玻纤废料30份、钾长石矿40份、页岩30份、石英尾矿35份。
其中，所述装饰层的厚度为3mm～15mm。
其中，所述装饰层为陶瓷板，所述陶瓷板是对其组分各成分的粉料进行压制或挤压成型形成的。
其中，所述发泡陶瓷粉料的厚度为10mm～200mm。
其中，所述烧结成型具体包括：在0～300℃区间预热时间为1～2小时；300～1100℃区间氧化时间为1～3小时；1100～1400℃区间烧结时间为1～5小时；1400～600℃急冷时间为1～3小时；600～0℃缓冷时间为3～8小时。
本发明的保温装饰陶瓷砖制作方法中将发泡陶瓷粉料和装饰层的陶瓷板一起高温烧结，一体成型，减少了制作工序，节省了制作成本，克服了粘结层寿命短的缺点。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动性的前提下，还可以根据这些附图获得其他的附图。
图1为本发明的一种保温装饰陶瓷砖制作方法流程图。
具体实施方式
下面将对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
本实施例的保温装饰陶瓷砖制作方法流程如图1所示，包括：
步骤S110，在耐热板上喷涂脱模涂料或放置耐热纸，耐热板、脱模涂料和耐热纸均具有耐800～1700℃高温的特性。放置耐热纸或喷涂脱模涂料的作用是在最后烧结成型后便于脱模，陶瓷砖不会与耐热板发生粘连。
步骤S120，在所述脱模涂料或耐热纸上形成装饰层。装饰层可以是烧制或未烧制陶瓷板，采用烧制的陶瓷板可以达到陶瓷板二次利用的效果。当然装饰层也可以是耐热涂料层或釉，可以通过印花、打点或喷涂的方式在结合层表面形成耐热涂料层或釉。
步骤S130，在所述装饰层上依次形成结合层和发泡陶瓷粉料，可以通过在耐热板周围放置模具以保持结合层和发泡陶瓷粉料各自的层均匀覆盖、保持形状且达到一定的厚度。结合层材料优选为粉料，与发泡陶瓷粉料都是未烧制的粉料，两者结合的表面彼此的粉料相互渗透，烧结后会结合的更紧密。
步骤S140，烧结成型并脱模。
本实施例的保温装饰陶瓷砖制作方法中将发泡陶瓷粉料、结合层和装饰层一起高温烧结，由于高温作用，三者的成分在接触面相互渗透，冷却后紧密结合在一起，使得保温装饰陶瓷砖的砖体和装饰层一体成型，减少了制作工序，节省了制作成本，克服了粘结层寿命短的缺点。而且装饰层位于发泡陶瓷粉料下方，与高温耐热板接触，由于耐热板表面平整硬度高，因此即使在烧制时装饰的装饰层发生膨胀(装饰层只能向结合层和发泡陶瓷粉料的一侧膨胀，使三者结合更紧密)，也能保证最终装饰层表面的平整度。
为了使三者更好地结合，装饰层和发泡陶瓷粉料的耐火度一致，结合层的耐火度比两者低5℃～20℃。烧结时，结合层的成分渗透至装饰层和发泡陶瓷粉料，并且先硬化，使发泡陶瓷粉料层与装饰层更好的结合成一体
本实施例中，装饰层以陶瓷板为例，陶瓷板、结合层及发泡陶瓷粉料各自的组分按质量份数均包括：粘土或河道淤泥10～30份、锂电池尾矿石粉20～60份、玻纤废料10～40份、钾长石矿10～50份、页岩10～50份、石英尾矿10～50份，所述发泡陶瓷粉料在上述组分基础上还包括发泡剂，所述发泡剂包括：石墨、碳素、碳酸钙、碳化硅各0.5～20份。且使得陶瓷板和发泡陶瓷粉料的耐火度一致，使得烧结后两者的硬度和物理特性一致，结合层的耐火度比两者低5℃～20℃。烧结时，结合层的成分渗透至陶瓷板和发泡陶瓷粉料，并且先硬化，使发泡陶瓷粉料层与陶瓷板更好的结合成一体，而且增加了陶瓷板的强度或使陶瓷板与发泡层结合更紧密。
可以采用以下两种方式使结合层的耐火度比陶瓷板和发泡陶瓷粉料低5℃～20℃。
方式一，结合层的组分中钾和钠元素的总含量大于所述陶瓷板及发泡陶瓷粉料两者各自的组分中钾和钠元素的总含量。可以预先选择含钾和钠元素较高的原材料。
方式二，所述陶瓷板的组分按质量份数包括：粘土或河道淤泥15份、锂电池尾矿石粉30份、玻纤废料20份、钾长石矿20份、页岩20份、石英尾矿25份；所述发泡陶瓷粉料的组分按质量份数包括：粘土或河道淤泥15份、锂电池尾矿石粉30份、玻纤废料20份、钾长石矿20份、页岩20份、石英尾矿25份、石墨5份、碳素5份、碳酸钙5份、碳化硅各5份；所述结合层的组分按质量份数包括：粘土或河道淤泥25份、锂电池尾矿石粉45份、玻纤废料30份、钾长石矿40份、页岩30份、石英尾矿35份。及增加结合层的组分含量，从而提高钾和钠元素的总含量。
上述组分材料中某些材料选自其他产品的废料，如：玻纤废料和锂电池尾矿石粉，不但降低陶瓷砖的成本，而且环保。
本实施例中，装饰层的厚度为3mm～15mm，发泡陶瓷粉料的厚度为10mm～200mm，两者的厚度可根据实际需要确定。其中，装饰层为陶瓷板时，陶瓷板是对其组分各成分的粉料进行压制或挤压成型形成的，若是烧制的陶瓷板，在成型的基础上再烧制。
本实施例中，所述烧结成型具体包括：在0～300℃区间预热时间为1～2小时；300～1100℃区间氧化时间为1～3小时；1100～1400℃区间烧结时间为1～5小时；1400～600℃急冷时间为1～3小时；600～0℃缓冷时间为3～8小时。采用这种分温度区间烧结的方式使得陶瓷砖的材料在适应一个温度后再逐步升温，不至于温度骤然升高或降低导致陶瓷砖在烧制过程中开裂或变形。
以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。
Claims (7)
1.一种保温装饰陶瓷砖制作方法，其特征在于，包括：
在耐热板上喷涂脱模涂料或放置耐热纸；
在所述脱模涂料或耐热纸上形成装饰层；
在所述装饰层上依次形成结合层和发泡陶瓷粉料；
烧结成型并脱模；
所述装饰层为陶瓷板，所述陶瓷板、结合层及发泡陶瓷粉料各自的组分按质量份数均包括：粘土或河道淤泥10～30份、锂电池尾矿石粉20～60份、玻纤废料10～40份、钾长石矿10～50份、页岩10～50份、石英尾矿10～50份，所述发泡陶瓷粉料在上述组分基础上还包括发泡剂，所述发泡剂包括：石墨、碳素、碳酸钙、碳化硅各0.5～20份；且使得陶瓷板和发泡陶瓷粉料的耐火度一致，结合层的耐火度比两者低5℃～20℃。
2.如权利要求1所述的保温装饰陶瓷砖制作方法，其特征在于，所述结合层的组分中钾和钠元素的总含量大于所述陶瓷板及发泡陶瓷粉料两者各自的组分中钾和钠元素的总含量。
3.如权利要求1所述的保温装饰陶瓷砖制作方法，其特征在于，所述陶瓷板的组分按质量份数包括：粘土或河道淤泥15份、锂电池尾矿石粉30份、玻纤废料20份、钾长石矿20份、页岩20份、石英尾矿25份；
所述发泡陶瓷粉料的组分按质量份数包括：粘土或河道淤泥15份、锂电池尾矿石粉30份、玻纤废料20份、钾长石矿20份、页岩20份、石英尾矿25份、石墨5份、碳素5份、碳酸钙5份、碳化硅5份；
所述结合层的组分按质量份数包括：粘土或河道淤泥25份、锂电池尾矿石粉45份、玻纤废料30份、钾长石矿40份、页岩30份、石英尾矿35份。
4.如权利要求1～3中任一项所述的保温装饰陶瓷砖制作方法，其特征在于，所述装饰层的厚度为3mm～15mm。
5.如权利要求1～3中任一项所述的保温装饰陶瓷砖制作方法，其特征在于，所述装饰层为陶瓷板，所述陶瓷板是对其组分各成分的粉料进行压制或挤压成型形成的。
6.如权利要求1～3中任一项所述的保温装饰陶瓷砖制作方法，其特征在于，所述发泡陶瓷粉料的厚度为10mm～200mm。
7.如权利要求1～3中任一项所述的保温装饰陶瓷砖制作方法，其特征在于，所述烧结成型具体包括：在0～300℃区间预热时间为1～2小时；300～1100℃区间氧化时间为1～3小时；1100～1400℃区间烧结时间为1～5小时；1400～600℃急冷时间为1～3小时；600～0℃缓冷时间为3～8小时。
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