CN106396637A - 一种轻质低膨胀瓷质建筑陶瓷砖的制备方法及其制得的产品 - Google Patents

一种轻质低膨胀瓷质建筑陶瓷砖的制备方法及其制得的产品 Download PDF

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CN106396637A
CN106396637A CN201610803231.5A CN201610803231A CN106396637A CN 106396637 A CN106396637 A CN 106396637A CN 201610803231 A CN201610803231 A CN 201610803231A CN 106396637 A CN106396637 A CN 106396637A
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CN106396637B (zh
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罗婷
顾幸勇
李萍
吴军明
董伟霞
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Jingdezhen Ceramic Institute
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Abstract

发明公开了一种轻质低膨胀瓷质建筑陶瓷砖的制备方法及其制得的产品。采用复合结构“内+外” 的方式，即外层为基础坯体致密层，中间为基础坯体+莫来石晶须轻质层，即降低了材料的比重，同时可以解决单一孔状结构形成后表面致密度较差的问题，由于外层为致密层，因此可以实现材料的瓷质化（即吸水率＜0.5%），有助于材料强度的提高，以及改善现有多孔轻质材料可加工性和防污性能不佳的现状，同时本方法工艺简单、成本低廉，因此具有广阔的市场空间。

Description

一种轻质低膨胀瓷质建筑陶瓷砖的制备方法及其制得的产品
技术领域
本发明涉及建筑陶瓷砖技术领域，尤其涉及一种轻质低膨胀瓷质建筑陶瓷砖的制备方法及其制得的产品。
背景技术
传统建筑陶瓷砖还存在着热膨胀系数较大（使用寿命短）、产品比重大（运输、铺贴困难）、产品致密度高（导热性大、保温差）等现状。针对上述问题，本专利对传统建筑瓷质砖进行结构创新，研究一种低膨胀、内层多孔外层致密的轻质建筑陶瓷砖以提高传统建筑陶瓷砖的热稳定性、延长其使用寿命，减轻建筑陶瓷砖，提高产品的保温隔热性能以达到绿色节能建材的使用要求。
热膨胀性是陶瓷材料的一项主要性能，当材料承受较大的温度变化时，热膨胀系数的大小直接影响了材料的使用性能和使用寿命，材料的抗热震性、复合材料的力学性能与热膨胀性密切相关，因此开发低膨胀陶瓷材料具有重要意义。
本专利引入可形成网状孔隙的莫来石晶须增强体对现有建筑陶瓷砖的结构上进行减轻，采用复合结构“内+外” 的方式，即外层为基础坯体致密层，中间为基础坯体+莫来石晶须轻质层，即降低了材料的比重，同时可以解决单一孔状结构形成后表面致密度较差的问题，由于外层为致密层，因此可以实现材料的瓷质化（即吸水率＜0.5%），有助于材料强度的提高，以及改善现有多孔轻质材料可加工性和防污性能不佳的现状。该结构的形成可以依靠现代建筑陶瓷工业中较为成熟的压机多层布料系统帮助实现。
同时，由于莫来石材料的热膨胀系数在 4.5～5.6×10-6℃-1范围内，因此在材料配方上，本专利以量大价廉的沙漠沙作为制备低膨胀基础坯体和莫来石晶须前驱体主要原料，通过配方调节两者的热膨胀系数，以提高内外层的匹配性及复合材料的稳定性。其中，利用沙漠沙低温合成莫来石晶须和低膨胀镁质基础坯体的相关技术在本人申请的发明专利“一种利用沙漠砂低温合成莫来石晶须的制备方法”（申请号：201510449490.8）、“一种利用沙漠黄沙及废料制备的低膨胀建筑陶瓷材料及其制造方法”（申请号：201510082698.0）中已有涉及。
发明内容
本发明的目的在于克服现有技术的不足，提供一种成本低廉、工艺简单、性能优异的轻质低膨胀瓷质建筑陶瓷砖的制备方法及其制得的产品。
为解决以上技术问题，本发明的技术方案是：一种轻质低膨胀瓷质建筑陶瓷砖的制备方法，其特征在于包括以下步骤：
步骤一：按重量百分比将沙漠沙20wt%、花岗岩废料20wt%、西矿陶土20wt%、菱镁矿10wt%、黑滑石10wt%、铝矾土20wt%混合后，经湿法球磨、烘干、过筛得到镁质基础粉料；
步骤二：按重量百分比将沙漠沙30wt%、铝矾土40wt%、氢氧化铝30%，外加2%AlF3和2%V2O5混合后，经干法球磨、过筛、造粒、再过筛得到莫来石晶须前驱体颗粒；
步骤三：将步骤二得到的莫来石晶须前驱体颗粒与步骤一得到镁质基础粉料按照3～5∶7～5的重量百分比混合制成轻质内层坯料；
步骤四：在建筑陶瓷砖生产的压机钢模内先布一层镁质基础粉料作为底料层，在底料层上再布一层轻质内层坯料作为中间层，最后在中间层上再布一层镁质基础粉料作为面料层，然后通过压机压制成型获得样品；
步骤五：在第四步制得样品的四个端面，分别用少量镁质基础粉料刮平封口，然后在1180～1230℃下烧制，最高温度下的保温时间为1h，获得轻质低膨胀瓷质建筑陶瓷砖。
所述步骤一中湿法球磨的时间为60min，所述步骤二中干法球磨的时间为60min。
所述步骤二中莫来石晶须前驱体颗粒的粒径范围为80～250目。
所述步骤四中底料层与中间层与面料层的厚度比为1:5～8:1。
所述步骤四中压机压制成型的压强为25-40Mpa。
上述产品的体积密度为1.9～2.3g/cm3、热膨胀系数为4.0～5.2×10-6℃-1、抗折强度为40～65Mpa、吸水率＜0.5%。
本发明在本人前期专利研究的基础上，选择匹配性高的莫来石晶须前驱体配方和低膨胀镁质基础坯体配方，通过工艺创新，制备出了一种低膨胀、内层多孔外层致密的轻质低膨胀瓷质（吸水率＜0.5%）建筑陶瓷砖新材料，并且工艺简单、成本低廉，因此具有广阔的市场前景。
附图说明
图1是本发明实施例1制得轻质低膨胀瓷质建筑陶瓷砖的截面结构示意图。
具体实施方式
下面结合附图和具体实施方式对本发明作进一步详细的说明。
镁质基础坯料和莫来石前驱体制备：
按重量百分比将沙漠沙20wt%、花岗岩废料20wt%、西矿陶土20wt%、菱镁矿10wt%、黑滑石10wt%、铝矾土20wt%混合后，经湿法球磨60min、烘干、过筛得到镁质基础粉料；
按重量百分比将沙漠沙30wt%、铝矾土40wt%、氢氧化铝30%，外加2%AlF3和2%V2O5混合后，经干法球磨60min、过筛、造粒、再过筛得到莫来石晶须前驱体颗粒。
沙漠沙的化学组成为：SiO275.95wt%、Al2O312.68 wt %、Fe2O32.08 wt %、TiO20.29wt %、CaO2.09 wt %、MgO0.72 wt %、Na2O1.54 wt %、K2O2.02 wt %、烧失2.63%。
其余原料的化学组成与“一种利用沙漠砂低温合成莫来石晶须的制备方法”（申请号：201510449490.8）和“一种利用沙漠黄沙及废料制备的低膨胀建筑陶瓷材料及其制造方法”（申请号：201510082698.0）中的一致。
实施例1
将粒径范围为120～160目的莫来石晶须前驱体颗粒与镁质基础粉料按照3∶7的重量百分比混合制成轻质内层坯料；在建筑陶瓷砖生产的压机钢模内按照1:5:1的厚度比，先布一层镁质基础粉料作为底料层，在底料层上再布一层轻质内层坯料作为中间层，最后在中间层上再布一层镁质基础粉料作为面料层，然后通过压机在33Mpa的压强下压制成型获得样品；在样品的四个端面用基础坯料粉料刮平封口后，在1200℃下烧制，保温1h，自然冷却后得到体积密度为2.13 g/cm3，热膨胀系数（室温-800℃）为4.68×10-6℃-1，抗折强度为52.5Mpa，吸水率为0.38%的轻质低膨胀瓷质建筑陶瓷砖。
实施例2
将粒径范围为160～200目的莫来石晶须前驱体颗粒与镁质基础粉料按照4∶6的重量百分比混合制成轻质内层坯料；在建筑陶瓷砖生产的压机钢模内按照1:6:1的厚度比，先布一层镁质基础粉料作为底料层，在底料层上再布一层轻质内层坯料作为中间层，最后在中间层上再布一层镁质基础粉料作为面料层，然后通过压机在36Mpa的压强下压制成型获得样品；在样品的四个端面用基础坯料粉料刮平封口后，在1180℃下烧制，保温1h，自然冷却后得到体积密度为2.08 g/cm3，热膨胀系数（室温-800℃）为4.83×10-6℃-1，抗折强度为57.8Mpa，吸水率为0.40%的轻质低膨胀瓷质建筑陶瓷砖。
实施例3
将粒径范围为200～250目的莫来石晶须前驱体颗粒与镁质基础粉料按照5∶5的重量百分比混合制成轻质内层坯料；在建筑陶瓷砖生产的压机钢模内按照1:7:1的厚度比，先布一层镁质基础粉料作为底料层，在底料层上再布一层轻质内层坯料作为中间层，最后在中间层上再布一层镁质基础粉料作为面料层，然后通过压机在25Mpa的压强下压制成型获得样品；在样品的四个端面用基础坯料粉料刮平封口后，在1200℃下烧制，保温1h，自然冷却后得到体积密度为2.08 g/cm3，热膨胀系数（室温-800℃）为4.22×10-6℃-1，抗折强度为48.2Mpa，吸水率为0.38%的轻质低膨胀瓷质建筑陶瓷砖。
实施例4
将粒径范围为80～120目的莫来石晶须前驱体颗粒与镁质基础粉料按照4∶6的重量百分比混合制成轻质内层坯料；在建筑陶瓷砖生产的压机钢模内按照1:8:1的厚度比，先布一层镁质基础粉料作为底料层，在底料层上再布一层轻质内层坯料作为中间层，最后在中间层上再布一层镁质基础粉料作为面料层，然后通过压机在28Mpa的压强下压制成型获得样品；在样品的四个端面用基础坯料粉料刮平封口后，在1210℃下烧制，保温1h，自然冷却后得到体积密度为1.92 g/cm3，热膨胀系数（室温-800℃）为4.09×10-6℃-1，抗折强度为40.5Mpa，吸水率为0.45%的轻质低膨胀瓷质建筑陶瓷砖。
实施例5
将粒径范围为200～250目的莫来石晶须前驱体颗粒与镁质基础粉料按照3∶7的重量百分比混合制成轻质内层坯料；在建筑陶瓷砖生产的压机钢模内按照1:5:1的厚度比，先布一层镁质基础粉料作为底料层，在底料层上再布一层轻质内层坯料作为中间层，最后在中间层上再布一层镁质基础粉料作为面料层，然后通过压机在40Mpa的压强下压制成型获得样品；在样品的四个端面用基础坯料粉料刮平封口后，在1230℃下烧制，保温1h，自然冷却后得到体积密度为2.28 g/cm3，热膨胀系数（室温-800℃）为4.91×10-6℃-1，抗折强度为64.6Mpa，吸水率为0.15%的轻质低膨胀瓷质建筑陶瓷砖。
实施例6
将粒径范围为120～200目的莫来石晶须前驱体颗粒与镁质基础粉料按照4∶6的重量百分比混合制成轻质内层坯料；在建筑陶瓷砖生产的压机钢模内按照1:6:1的厚度比，先布一层镁质基础粉料作为底料层，在底料层上再布一层轻质内层坯料作为中间层，最后在中间层上再布一层镁质基础粉料作为面料层，然后通过压机在30Mpa的压强下压制成型获得样品；在样品的四个端面用基础坯料粉料刮平封口后，在1210℃下烧制，保温1h，自然冷却后得到体积密度为2.02 g/cm3，热膨胀系数（室温-800℃）为4.35×10-6℃-1，抗折强度为63.6Mpa，吸水率为0.28%的轻质低膨胀瓷质建筑陶瓷砖。

Claims (6)

1.一种轻质低膨胀瓷质建筑陶瓷砖的制备方法，其特征在于包括以下步骤：
步骤一：按重量百分比将沙漠沙20wt%、花岗岩废料20wt%、西矿陶土20wt%、菱镁矿10wt%、黑滑石10wt%、铝矾土20wt%混合后，经湿法球磨、烘干、过筛得到镁质基础粉料；
步骤二：按重量百分比将沙漠沙30wt%、铝矾土40wt%、氢氧化铝30%，外加2%AlF3和2%V2O5混合后，经干法球磨、过筛、造粒、再过筛得到莫来石晶须前驱体颗粒；
步骤三：将步骤二得到的莫来石晶须前驱体颗粒与步骤一得到镁质基础粉料按照3～5∶7～5的重量百分比混合制成轻质内层坯料；
步骤四：在建筑陶瓷砖生产的压机钢模内先布一层镁质基础粉料作为底料层，在底料层上再布一层轻质内层坯料作为中间层，最后在中间层上再布一层镁质基础粉料作为面料层，然后通过压机压制成型获得样品；
步骤五：在第四步制得样品的四个端面，分别用少量镁质基础粉料刮平封口，然后在1180～1230℃下烧制，最高温度下的保温时间为1h，获得轻质低膨胀瓷质建筑陶瓷砖。
2.根据权利要求1所述的制备方法，其特征在于：所述步骤一中湿法球磨的时间为60min，所述步骤二中干法球磨的时间为60min。
3.根据权利要求1所述的制备方法，其特征在于：所述步骤二中莫来石晶须前驱体颗粒的粒径范围为80～250目。
4.根据权利要求1所述的制备方法，其特征在于：所述步骤四中底料层与中间层与面料层的厚度比为1:5～8:1 。
5.根据权利要求1所述的制备方法，其特征在于：所述步骤四中压机压制成型的压强为25-40Mpa。
6.根据权利要求1-5任一所述方法制得的产品，其特征在于：所述产品的体积密度为1.9～2.3g/cm3、热膨胀系数为4.0～5.2×10-6℃-1、抗折强度为40～65Mpa、吸水率＜0.5%。
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