CN106083170A - 发泡彩石保温装饰板的制备方法及其产品 - Google Patents

发泡彩石保温装饰板的制备方法及其产品 Download PDF

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CN106083170A
CN106083170A CN201610406222.2A CN201610406222A CN106083170A CN 106083170 A CN106083170 A CN 106083170A CN 201610406222 A CN201610406222 A CN 201610406222A CN 106083170 A CN106083170 A CN 106083170A
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base substrate
glaze
glazing
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周国华
邵敏
江毅
李永兴
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Zhejiang Ou Fu Technology Co Ltd
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Abstract

本发明涉及一种发泡彩石保温装饰板的制备方法，步骤一、制坯：将珍珠岩、膨润土、沸石、高岭土、凝灰石、黑泥、绿陶瓷硅粉、莹石尾矿、可燃性碳粉、煤矸石、短切玄武岩纤维、聚丙烯短切纤维的原料进行混合后，然后破碎、湿法球磨、陈腐均匀，再进行喷雾干燥、造粒、制粉，而后压制成型得到素坯，再对素坯进行烘干得到坯体；步骤二、制釉、施釉：将坯体原料、钠长石、钾长石的原料进行球磨得到釉料，用釉料对所述坯体进行上釉；步骤三、将上釉后的坯体经高温烧制，形成坯体闭口气孔均匀密布带釉面的发泡彩石保温装饰板。本发明技术方案，具有轻质、保温、防火、防水、高强度、耐老化带装饰面的技术效果。

Description

发泡彩石保温装饰板的制备方法及其产品
技术领域
本发明涉及一种发泡彩石保温装饰板的制备方法及其产品。
背景技术
建筑物外墙保温系统是节能建筑中很重要的部分，在国内外建筑工程中广泛应用，现有的保温板主要有 EPS板，XPS板，PU板，酚醛板，泡沫混泥土板，岩棉板等。饰面层为带各类涂层的无机板，金属板，石材板和陶瓷板等。饰面采用聚氨酯胶或环氧胶直接粘结在保温层材料上。这类材料主要存在以下的缺点：
1.饰面板不是轻质材料，容重大，无法做到轻量化。
2.保温层采用有机材料，存在耐久性差和防火性能差的问题。采用的无机保温材料存在吸水率高，收缩率大，强度低，使用寿命短等问题。
3.饰面板与保温层材料之间的容重相差十来倍，强度相差几十倍，形成外重内轻，外强内弱的外墙保温系统。虽然通常采用粘锚结合，但锚固件必须锚固于饰面板上，所以其支承结构体系和施工工艺非常复杂。
另外目前普遍采用的保温砂浆外墙保温系统存在4个方面的问题：
1.系统耐久性短，外墙外保温工程设计使用年限为25年，常用的有机类保温材料能否用到25年还有待考验，而无机类保温存在吸水率高，收缩率大，影响实际使用寿命。
2.安全性能让人担忧，目前最常用的外墙保温材料仍然是有机材料，其防火性能差，施工和使用过程中存在防火安全隐患。
3.施工工序复杂，质量隐患多，外墙外保温技术对施工水平要求非常严格，若对其施工方法，技术要求不熟悉，或者工人技术操作水平较低，施工管理不够严格，极易产生严重的质量问题。
4.系统造价高，外墙外保温系统施工工序较多，当采用保温砂浆作为保温层时，一般分三道（甚至更多）抹灰，每道抹灰需在前一道抹灰层硬化后再进行，保温层外需增设置抗裂层，还要设置网格布或钢丝网保护层，最后再做装饰面涂层。
发明内容
针对现有技术存在的不足，本发明的目的在于提供一种轻质、保温、防火、防水、高强度、耐老化带装饰面的发泡彩石保温装饰板的制备方法及其产品。
为实现上述目的，本发明提供了如下技术方案：包括以下步骤：步骤一、制坯：将以重量份计的珍珠岩35~55份、膨润土5~10份、沸石10~20份、高岭土5~10份、凝灰石5~15份、黑泥10~20份、绿陶瓷硅粉0.4~1.0份、莹石尾矿10~20份、粒径小于0.02mm的可燃性碳粉10~20份、煤矸石3~8份、短切玄武岩纤维2~6份、聚丙烯短切纤维3~8份的原料进行混合后，然后破碎、湿法球磨、陈腐均匀，再进行喷雾干燥、造粒、制粉，而后压制成型得到素坯，再对素坯进行烘干得到坯体；步骤二、制釉、施釉：将以重量份计的坯体原料40~60份、钠长石20~30份、钾长石20~30份的原料进行球磨得到釉料，用釉料对所述坯体进行上釉；步骤三、将上釉后的坯体经1100℃~1300℃高温烧制，形成坯体闭口气孔均匀密布带釉面的发泡彩石保温装饰板。
本发明进一步设置：所述步骤一、制坯中：将以重量份计的珍珠岩45~50份、膨润土6~8份、沸石12~18份、高岭土6~8份、凝灰石8~12份、黑泥13~16份、绿陶瓷硅粉0.5~0.8份、莹石尾矿12~18份、粒径小于0.02mm的可燃性碳粉13~18份、煤矸石4~6份、短切玄武岩纤维3~5份、聚丙烯短切纤维5~7份的原料进行混合。
本发明进一步设置：所述步骤二、制釉、施釉中：将以重量份计的坯体原料45~55份、钠长石22~26份、钾长石22~26份的原料进行球磨得到釉料。
本发明进一步设置：所述步骤三中，将上釉后的坯体经1180℃~1200℃高温烧制。
本发明进一步设置：所述步骤二、制釉、施釉中：用釉料对所述坯体进行上釉后，在釉面上进行印花。
本发明进一步设置：所述印花采用网板印花或喷墨印花方式。
一种发泡彩石保温装饰板，包括坯体与釉面，所述坯体具有均匀密布的闭口气孔，所述坯体与釉面呈一体设置。
本发明与现有技术相比，其有益效果是：本发明发泡彩石保温装饰板充分利用尾矿等废弃物，制成具有轻质，热传导率低，防火，防水，耐老化，与水泥制品相容性好，耐气候，坯体与釉面采用上述材料烧结时装饰面（釉面）与坯体直接复合，装饰面丰富等优越性能可应用于建筑，装饰，环保等领域，其具体优点在于：
1.装饰面与坯体一体烧结成型，而无需粘结剂粘结。
2.轻量化。轻量化主要体现在产品与石材幕墙、大规格陶板相比，在重量上大幅度减轻，适合高层建筑，将简化面板与支承结构体系和施工工艺，大大降低工程成本，也为后期维护提供方便。
3．抗拉强度高。《建筑工程饰面砖粘结强度检验标准》（JGJ110-2008）中要求瓷砖的粘结强度不小于0.4Mpa。发泡彩石保温装饰板的抗拉强度≥1.0Mpa。采用专业外墙陶瓷粘结剂，完全能够确保拉伸粘结强度，满足规范要求。
4.导热系数≤0.07w/(m*k)。与无机轻集料保温砂浆相当，可充当外墙外保温系统的隔热保温材料。
5.防火性能好。产品经1200℃高温煅烧而成，燃烧性能为A1级。
6.吸水率低。产品体积吸水率≤0.8%，对照膨胀珍珠岩保温板等其它的保温体积吸水率≤10%，不会因外墙渗漏而降低隔热保温性能。
7.耐老化。陶瓷材料性能稳定，耐久性好，不老化，可实现与建筑物同寿命，是常规的有机保温材料无可比拟的。
8.相容性好。与水泥砂浆、混凝土等线膨胀系数相近，相容性好，粘结可靠，与高温烧制的传统的陶瓷建材一样，热胀冷缩下不开裂，不变形，不收缩。
9. 利用粒径小于0.020mm 的可燃性碳粉，使其在烧结过程中氧化，而留下大量的微米级阵列孔。煤矸石是在成煤过程中与煤共同沉积的有机化合物和无机化合物混合在一起的岩石。煤矸石是碳质、泥质和砂质页岩的混合物，具有低发热值。煤矸石成分主要是硅、铝、钙、镁、铁的氧化物和某些稀有金属，其化学组成为SiO2、Al2O3、Fe2O3、CaO、MgO、TiO2、P2O5、(K2O+Na2O)、V2O5等。煤矸石弃置不用，占用大片土地。煤矸石中的硫化物逸出或浸出会污染大气、农田和水体。矸石山还会自燃发生火灾，或在雨季崩塌，淤塞河流造成灾害。因此，煤矸石的处理和综合利用越来越受到世界各国的重视。在本发明中采用煤矸石作为制备发泡彩石保温装饰板的原料，既减少了环境污染，又提高了煤矸石的有效利用率。传统的发泡彩石保温装饰板常会因保温板内的各部位干缩比不一致而导致出现破裂（干缩破裂），而本发明将由连续纤维材料经表面处理后切成的段状短切纤维掺入，并通过短切纤维在发泡彩石保温装饰板内部发挥均匀干缩应力的功能，使干缩应力趋于均匀的施加在整个保温板内部，大大降低了发泡彩石保温装饰板的干缩破坏率。短切玄武岩纤维发挥了增强作用，聚丙烯短切纤维在起到增韧的作用。
具体实施方式
实施例一、
步骤一、制坯：将以重量份计的珍珠岩35份、膨润土5份、沸石10份、高岭土5份、凝灰石5份、黑泥10份、绿陶瓷硅粉0.4份、莹石尾矿10份、粒径小于0.02mm的可燃性碳粉10份、煤矸石3份、短切玄武岩纤维2份、聚丙烯短切纤维3份的原料进行混合后，然后破碎、湿法球磨、陈腐均匀，再进行喷雾干燥、造粒、制粉，而后压制成型得到素坯，再对素坯进行烘干得到坯体；步骤二、制釉、施釉：将以重量份计的坯体原料40份、钠长石20份、钾长石20份的原料进行球磨至350目釉料，过筛出球到釉桶储存，用釉料对所述坯体进行上釉；步骤三、将上釉后的坯体经1100℃高温连续式辊道窑烧制，形成坯体闭口气孔均匀密布带釉面的发泡彩石保温装饰板。
实施例二、
步骤一、制坯：将以重量份计的珍珠岩55份、膨润土10份、沸石20份、高岭土10份、凝灰石15份、黑泥20份、绿陶瓷硅粉1.0份、莹石尾矿20份、粒径小于0.02mm的可燃性碳粉20份、煤矸石8份、短切玄武岩纤维6份、聚丙烯短切纤维8份的原料进行混合后，然后破碎、湿法球磨、陈腐均匀，再进行喷雾干燥、造粒、制粉，而后压制成型得到素坯，再对素坯在烘干窑进行烘干得到坯体；步骤二、制釉、施釉：将以重量份计的坯体原料60份、钠长石30份、钾长石230份的原料进行球磨至350目釉料，过筛出球到釉桶储存，用釉料对所述坯体进行以淋釉方式上釉；步骤三、将上釉后的坯体经1300℃高温连续式辊道窑烧制，形成坯体闭口气孔均匀密布带釉面的发泡彩石保温装饰板。
实施例三、步骤一、制坯：将以重量份计的珍珠岩45份、膨润土6份、沸石12份、高岭土6份、凝灰石8份、黑泥13份、绿陶瓷硅粉0.5份、莹石尾矿12份、粒径小于0.02mm的可燃性碳粉13份、煤矸石4份、短切玄武岩纤维3份、聚丙烯短切纤维5份的原料进行混合后，然后破碎、湿法球磨、陈腐均匀，再进行喷雾干燥、造粒、制粉，而后压制成型得到素坯，再对素坯在烘干窑进行烘干得到坯体；步骤二、制釉、施釉：将以重量份计的坯体原料45份、钠长石22份、钾长石22份的原料进行球磨至350目釉料，过筛出球到釉桶储存，用釉料对所述坯体以淋釉方式进行上釉；步骤三、将上釉后的坯体经1180℃高温连续式辊道窑烧制，形成坯体闭口气孔均匀密布带釉面的发泡彩石保温装饰板。
实施例四、步骤一、制坯：将以重量份计的珍珠岩50份、膨润土8份、沸石18份、高岭土8份、凝灰石12份、黑泥16份、绿陶瓷硅粉0.8份、莹石尾矿18份、粒径小于0.02mm的可燃性碳粉18份、煤矸石6份、短切玄武岩纤维5份、聚丙烯短切纤维7份的原料进行混合后，然后破碎、湿法球磨、陈腐均匀，再进行喷雾干燥、造粒、制粉，而后压制成型得到素坯，再对素坯在烘干窑进行烘干得到坯体；步骤二、制釉、施釉：将以重量份计的坯体原料55份、钠长石26份、钾长石26份的原料进行球磨至350目釉料，过筛出球到釉桶储存，用釉料对所述坯体以淋釉方式进行上釉；步骤三、将上釉后的坯体经1200℃高温连续式辊道窑烧制，形成坯体闭口气孔均匀密布带釉面的发泡彩石保温装饰板。
实施例五、步骤一、制坯：将以重量份计的珍珠岩48份、膨润土7份、沸石15份、高岭土7份、凝灰石10份、黑泥14份、绿陶瓷硅粉0.7份、莹石尾矿15份、粒径小于0.02mm的可燃性碳粉14份、煤矸石5份、短切玄武岩纤维4份、聚丙烯短切纤维6份的原料进行混合后，然后破碎、湿法球磨、陈腐均匀，再进行喷雾干燥、造粒、制粉，而后压制成型得到素坯，再对素坯在烘干窑进行烘干得到坯体；步骤二、制釉、施釉：将以重量份计的坯体原料50份、钠长石23份、钾长石24份的原料进行球磨至350目釉料，过筛出球到釉桶储存，用釉料对所述坯体以淋釉方式进行上釉；步骤三、将上釉后的坯体经1190℃高温连续式辊道窑烧制，形成坯体闭口气孔均匀密布带釉面的发泡彩石保温装饰板。
本实施例1-5发泡彩石保温装饰板，经检测，其性能指标如下参照表格：
实施例1 实施例2 实施例4 实施例5 实施例5
容重 ≤160kg/m2 ≤160kg/m2 ≤350kg/m2 ≤320kg/m2 ≤300kg/m2
抗拉强度 ≥2.3MPA ≥2.3MPA ≥2.3MPA ≥1.2MPA ≥1.2MPA
导热系数 ≤0.085w/(m*k) ≤0.085w/(m*k) ≤0.08W/(m*k) ≤0.07w/(m*k) ≤0.07w/(m*k)
防火性能 A1级 A1级 A1级 A1级 A1级
吸水率 ≤0.8% ≤0.8% ≤0.8% ≤0.8% ≤0.8%
耐老化 耐老化 耐老化 耐老化 耐老化 耐老化
相容性 相容 相容 相容 相容 相容
抗压强度 ≥6.5MPa ≥6.2MPa ≥5.4MPa ≥4.3MPa ≥3.8MPa

Claims (7)

1.一种发泡彩石保温装饰板的制备方法，其特征在于：包括以下步骤：步骤一、制坯：将以重量份计的珍珠岩35~55份、膨润土5~10份、沸石10~20份、高岭土5~10份、凝灰石5~15份、黑泥10~20份、绿陶瓷硅粉0.4~1.0份、莹石尾矿10~20份、粒径小于0.02mm的可燃性碳粉10~20份、煤矸石3~8份、短切玄武岩纤维2~6份、聚丙烯短切纤维3~8份的原料进行混合后，然后破碎、湿法球磨、陈腐均匀，再进行喷雾干燥、造粒、制粉，而后压制成型得到素坯，再对素坯进行烘干得到坯体；步骤二、制釉、施釉：将以重量份计的坯体原料40~60份、钠长石20~30份、钾长石20~30份的原料进行球磨得到釉料，用釉料对所述坯体进行上釉；步骤三、将上釉后的坯体经1100℃~1300℃高温烧制，形成坯体闭口气孔均匀密布带釉面的发泡彩石保温装饰板。
2.根据权利要求1所述的发泡彩石保温装饰板的制备方法，其特征在于：所述步骤一、制坯中：将以重量份计的珍珠岩45~50份、膨润土6~8份、沸石12~18份、高岭土6~8份、凝灰石8~12份、黑泥13~16份、绿陶瓷硅粉0.5~0.8份、莹石尾矿12~18份、粒径小于0.02mm的可燃性碳粉13~18份、煤矸石4~6份、短切玄武岩纤维3~5份、聚丙烯短切纤维5~7份的原料进行混合。
3.根据权利要求1所述的发泡彩石保温装饰板的制备方法，其特征在于：所述步骤二、制釉、施釉中：将以重量份计的坯体原料45~55份、钠长石22~26份、钾长石22~26份的原料进行球磨得到釉料。
4.根据权利要求1所述的发泡彩石保温装饰板的制备方法，其特征在于：所述步骤三中，将上釉后的坯体经1180℃~1200℃高温烧制。
5.根据权利要求1或2或3或4所述的发泡彩石保温装饰板的制备方法，其特征在于：所述步骤二、制釉、施釉中：用釉料对所述坯体进行上釉后，在釉面上进行印花。
6.根据权利要求5所述的发泡彩石保温装饰板的制备方法，其特征在于：所述印花采用网板印花或喷墨印花方式。
7.根据权利要求1-5任一项所述的发泡彩石保温装饰板的制备方法制得的发泡彩石保温装饰板，其特征在于：包括坯体与釉面，所述坯体具有均匀密布的闭口气孔，所述坯体与釉面呈一体设置。
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