CN106431450A - 一种改性硫酸钙晶须增强的陶瓷砖 - Google Patents

一种改性硫酸钙晶须增强的陶瓷砖 Download PDF

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CN106431450A
CN106431450A CN201610927398.2A CN201610927398A CN106431450A CN 106431450 A CN106431450 A CN 106431450A CN 201610927398 A CN201610927398 A CN 201610927398A CN 106431450 A CN106431450 A CN 106431450A
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郑辉
邹张乐
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ANHUI YA'OU CERAMIC Co Ltd
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Abstract

发明公开了一种改性硫酸钙晶须增强的陶瓷砖，由以下成分制成：麦饭石、钾长石、沸石、石英砂、废旧陶瓷、硅微粉、改性硫酸钙晶须、高岭土、刚玉粉、硼化锆、玻璃纤维。本发明陶瓷砖机械性能好，强度高，耐热性好，抗腐蚀能力强，经久耐用，且原料来源广泛，工艺简单易操作，成本低廉，适合产业化生产，应用前景广阔。

Description

一种改性硫酸钙晶须增强的陶瓷砖
技术领域
本发明涉及陶瓷材料领域，特别是涉及一种改性硫酸钙晶须增强的陶瓷砖。
背景技术
陶瓷砖是由粘土、石英砂以及其他无机非金属原料，经配料、球磨、制粉、成型、烧结等工艺生产的板状或块状陶瓷制品，广泛应用于装饰与保护建筑物、构筑物的墙面和地面。随着房地产业的迅速发展，使得瓷砖的生产和消费都获得了较大的发展，同时对瓷砖的综合性能要求越来越高。
发明内容
本发明的目的是提供一种改性硫酸钙晶须增强的陶瓷砖，通过以下技术方案实现：
一种改性硫酸钙晶须增强的陶瓷砖，由以下重量份的原料制成：麦饭石10-14、钾长石12-16、沸石6-8、石英砂4-7、废旧陶瓷42-47、硅微粉8-10、改性硫酸钙晶须6-10、高岭土34-36、刚玉粉12-14、硼化锆0.2-0.4、玻璃纤维1-3；
所述改性硫酸钙晶须的制备方法如下：
a.按质量比35:2:1称取硫酸钙晶须、富勒烯、纳米碳酸钙，混合均匀，放入硫酸钙晶须质量5倍的丙三醇中，在6-8℃下，保温2-3h，过滤，用蒸馏水洗涤，烘干，在120-125℃下，保温2-3天，然后以10℃/min速度加热至620-625℃，保温1-2h，再以5℃/min速度冷却至120-125℃，然后进行粉碎，过220-260目筛，得到混合固体粉末，待用；
b.按重量份将以下成分：双水杨酸酯3、水杨醇8、十二烷基苯磺酸钠4、琥珀酰亚胺0.8、水100均匀混合到一起，加热至55-58℃，保温3-5h，得到改性溶液，待用；
c.将步骤a制得的混合固体粉末与步骤b制得的改性溶液按重量比1:20的比例混合后，加热至55-58℃，保温1-2h，然后添加硫酸钙晶须质量8.5%的钛酸酯偶联剂，搅拌均匀后，加热至72-75℃，保温5-8h，然后自然冷却至室温，进行固液分离，所得固体进一步粉碎，过280-320目筛，即得所需改性硫酸钙晶须。
进一步的，所述废旧陶瓷经过预处理：将废旧陶瓷粉碎至120-150目，然后添加其质量3-5倍的质量分数为2.8%的水杨醇溶液，浸泡3-5天后，过滤，表面清洗烘干后，在458-465℃下煅烧30min，然后冷却至室温。
进一步的，所述的保温隔音陶瓷砖的制备方法，包括以下步骤：
（1）取麦饭石、钾长石、沸石、石英砂、硅微粉混合均匀，粉碎，过280-320目筛，然后加入粉末重量6-7.5%的竹醋液，搅拌均匀，然后制成粒径为2-3mm的颗粒，烘干，在1000-1100℃焙烧下10-12min，自然冷却至常温，待用；
（2）将经过处理的废旧陶瓷与高岭土、刚玉粉、硼化锆、玻璃纤维，进行粉碎后，过280-320目筛后，待用；
（3）将步骤（1）和步骤（2）制得的材料与改性硫酸钙晶须均匀混合到一起，加热至120-135℃，保温8-10h，然后自然冷却至室温，得到混合料；
（4）将步骤（3）制得的混合料送到成型机在78-80MPa下压制成砖坯；
（5）将步骤（4）中制得的砖坯以3-4℃/min的速率升温至1350-1390℃，保温3-4h，再以2-4℃/min的速率降温至-6--4℃，保温1-2h，自然恢复至常温，经磨边、包装即得成品。
本发明配制的改性硫酸钙晶须通过与一定质量的富勒烯、纳米碳酸钙混合后，再经过本发明配制的改性溶液的处理，能够极大的改变硫酸钙晶须的表面性质，提高其表面相容性，通过改性硫酸钙晶须与本发明其它成分的协同作用，可以极大的提高机械性能，耐火隔热、健康环保、降低导热系数，尤其是，可以使得陶瓷砖内部结构摆列更加紧密，显著的提高了陶瓷砖的硬度，同时还能再一定程度上降低陶瓷砖的易脆性，通过对废旧陶瓷的处理，能够改善其物理结构，从而增强陶瓷砖的机械强度。
本发明有益效果：本发明陶瓷砖机械性能好，强度高，耐热性好，抗腐蚀能力强，经久耐用，且原料来源广泛，工艺简单易操作，成本低廉，适合产业化生产，应用前景广阔，同时本发明制得的陶瓷砖硬度高，寿命长，相较于普通陶瓷砖的使用寿命提高了2-3倍，本发明通过各成分之间的协同作用，不仅提高了陶瓷砖的硬度，还在一定程度上降低了陶瓷砖的脆性，从而提高了本发明陶瓷砖的应用范围，本发明陶瓷砖销售较普通陶瓷砖的平均销量提高13.5%，经济收入提高16.6%。
具体实施方式
实施例1
一种改性硫酸钙晶须增强的陶瓷砖，由以下重量份的原料制成：麦饭石10、钾长石12、沸石6、石英砂4、废旧陶瓷42、硅微粉8、改性硫酸钙晶须6、高岭土34、刚玉粉12、硼化锆0.2、玻璃纤维1；
所述改性硫酸钙晶须的制备方法如下：
a.按质量比35:2:1称取硫酸钙晶须、富勒烯、纳米碳酸钙，混合均匀，放入硫酸钙晶须质量5倍的丙三醇中，在6℃下，保温2-3h，过滤，用蒸馏水洗涤，烘干，在120℃下，保温2天，然后以10℃/min速度加热至620℃，保温1h，再以5℃/min速度冷却至120℃，然后进行粉碎，过220目筛，得到混合固体粉末，待用；
b.按重量份将以下成分：双水杨酸酯3、水杨醇8、十二烷基苯磺酸钠4、琥珀酰亚胺0.8、水100均匀混合到一起，加热至55℃，保温3h，得到改性溶液，待用；
c.将步骤a制得的混合固体粉末与步骤b制得的改性溶液按重量比1:20的比例混合后，加热至55℃，保温1-2h，然后添加硫酸钙晶须质量8.5%的钛酸酯偶联剂，搅拌均匀后，加热至72℃，保温5h，然后自然冷却至室温，进行固液分离，所得固体进一步粉碎，过280目筛，即得所需改性硫酸钙晶须。
实施例2
一种改性硫酸钙晶须增强的陶瓷砖，由以下重量份的原料制成：麦饭石14、钾长石16、沸石8、石英砂7、废旧陶瓷47、硅微粉10、改性硫酸钙晶须10、高岭土36、刚玉粉14、硼化锆0.4、玻璃纤维3；
所述改性硫酸钙晶须的制备方法如下：
a.按质量比35:2:1称取硫酸钙晶须、富勒烯、纳米碳酸钙，混合均匀，放入硫酸钙晶须质量5倍的丙三醇中，在8℃下，保温3h，过滤，用蒸馏水洗涤，烘干，在125℃下，保温3天，然后以10℃/min速度加热至625℃，保温2h，再以5℃/min速度冷却至125℃，然后进行粉碎，过260目筛，得到混合固体粉末，待用；
b.按重量份将以下成分：双水杨酸酯3、水杨醇8、十二烷基苯磺酸钠4、琥珀酰亚胺0.8、水100均匀混合到一起，加热至58℃，保温5h，得到改性溶液，待用；
c.将步骤a制得的混合固体粉末与步骤b制得的改性溶液按重量比1:20的比例混合后，加热至58℃，保温1-2h，然后添加硫酸钙晶须质量8.5%的钛酸酯偶联剂，搅拌均匀后，加热至75℃，保温8h，然后自然冷却至室温，进行固液分离，所得固体进一步粉碎，过320目筛，即得所需改性硫酸钙晶须。
实施例3
一种改性硫酸钙晶须增强的陶瓷砖，由以下重量份的原料制成：麦饭石12、钾长石14、沸石6-8、石英砂6、废旧陶瓷44、硅微粉9、改性硫酸钙晶须8、高岭土35、刚玉粉13、硼化锆0.3、玻璃纤维2；
所述改性硫酸钙晶须的制备方法如下：
a.按质量比35:2:1称取硫酸钙晶须、富勒烯、纳米碳酸钙，混合均匀，放入硫酸钙晶须质量5倍的丙三醇中，在7℃下，保温2h，过滤，用蒸馏水洗涤，烘干，在125℃下，保温2天，然后以10℃/min速度加热至625℃，保温2h，再以5℃/min速度冷却至125℃，然后进行粉碎，过250目筛，得到混合固体粉末，待用；
b.按重量份将以下成分：双水杨酸酯3、水杨醇8、十二烷基苯磺酸钠4、琥珀酰亚胺0.8、水100均匀混合到一起，加热至56℃，保温3-5h，得到改性溶液，待用；
c.将步骤a制得的混合固体粉末与步骤b制得的改性溶液按重量比1:20的比例混合后，加热至56℃，保温1-2h，然后添加硫酸钙晶须质量8.5%的钛酸酯偶联剂，搅拌均匀后，加热至74℃，保温5-8h，然后自然冷却至室温，进行固液分离，所得固体进一步粉碎，过310目筛，即得所需改性硫酸钙晶须。
上述实施例中：
进一步的，所述废旧陶瓷经过预处理：将废旧陶瓷粉碎至130目，然后添加其质量4倍的质量分数为2.8%的水杨醇溶液，浸泡4天后，过滤，表面清洗烘干后，在460℃下煅烧30min，然后冷却至室温。
进一步的，所述的保温隔音陶瓷砖的制备方法，包括以下步骤：
（1）取麦饭石、钾长石、沸石、石英砂、硅微粉混合均匀，粉碎，过310目筛，然后加入粉末重量7.5%的竹醋液，搅拌均匀，然后制成粒径为2mm的颗粒，烘干，在1050℃焙烧下11min，自然冷却至常温，待用；
（2）将经过处理的废旧陶瓷与高岭土、刚玉粉、硼化锆、玻璃纤维，进行粉碎后，过310目筛后，待用；
（3）将步骤（1）和步骤（2）制得的材料与改性硫酸钙晶须均匀混合到一起，加热至130℃，保温9h，然后自然冷却至室温，得到混合料；
（4）将步骤（3）制得的混合料送到成型机在79MPa下压制成砖坯；
（5）将步骤（4）中制得的砖坯以3℃/min的速率升温至1360℃，保温3h，再以2℃/min的速率降温至-6℃，保温2h，自然恢复至常温，经磨边、包装即得成品。
对比例1：与实施例1区别仅为将改性硫酸钙晶须替换成普通未改性硫酸钙晶须。
对比例2：与实施例1区别仅为不对废旧陶瓷处理。
性能比较
表1
抗折强度MPa 导热系数W/m·k 莫氏硬度/级
实施例1 19.8 5.9 7
实施例2 19.7 5.9 7
实施例3 19.8 5.8 7
对比例1 15.4 9.2 5
对比例2 18.1 6.3 7
由表1可以看出，本发明制备的陶瓷砖性能优越。
经测试，本发明陶瓷砖的机械性能和力学性能相较于采用未改性硫酸钙晶须制备的陶瓷砖提高幅度达到了28%左右，这对于改性硫酸钙晶须增强的陶瓷砖来说是一个很大的进步，本发明陶瓷砖相较于普通陶瓷砖隔音效果更好，可增加隔声量8分贝左右，当将本发明中改性硫酸钙晶须替换成普通硫酸钙晶须制备的陶瓷砖相较于普通陶瓷砖只能增加隔声量3分贝左右。

Claims (4)

1.一种改性硫酸钙晶须增强的陶瓷砖，其特征在于，由以下重量份的原料制成：麦饭石10-14、钾长石12-16、沸石6-8、石英砂4-7、废旧陶瓷42-47、硅微粉8-10、改性硫酸钙晶须6-10、高岭土34-36、刚玉粉12-14、硼化锆0.2-0.4、玻璃纤维1-3。
2.根据权利要求1所述的一种改性硫酸钙晶须增强的陶瓷砖，其特征在于，所述改性硫酸钙晶须的制备方法如下：
a.按质量比35:2:1称取硫酸钙晶须、富勒烯、纳米碳酸钙，混合均匀，放入硫酸钙晶须质量5倍的丙三醇中，在6-8℃下，保温2-3h，过滤，用蒸馏水洗涤，烘干，在120-125℃下，保温2-3天，然后以10℃/min速度加热至620-625℃，保温1-2h，再以5℃/min速度冷却至120-125℃，然后进行粉碎，过220-260目筛，得到混合固体粉末，待用；
b.按重量份将以下成分：双水杨酸酯3、水杨醇8、十二烷基苯磺酸钠4、琥珀酰亚胺0.8、水100均匀混合到一起，加热至55-58℃，保温3-5h，得到改性溶液，待用；
c.将步骤a制得的混合固体粉末与步骤b制得的改性溶液按重量比1:20的比例混合后，加热至55-58℃，保温1-2h，然后添加硫酸钙晶须质量8.5%的钛酸酯偶联剂，搅拌均匀后，加热至72-75℃，保温5-8h，然后自然冷却至室温，进行固液分离，所得固体进一步粉碎，过280-320目筛，即得所需改性硫酸钙晶须。
3.根据权利要求1所述的一种改性硫酸钙晶须增强的陶瓷砖，其特征在于，所述废旧陶瓷经过预处理：将废旧陶瓷粉碎至120-150目，然后添加其质量3-5倍的质量分数为2.8%的水杨醇溶液，浸泡3-5天后，过滤，表面清洗烘干后，在458-465℃下煅烧30min，然后冷却至室温。
4.根据权利要求1所述的一种改性硫酸钙晶须增强的陶瓷砖，其特征在于，所述的保温隔音陶瓷砖的制备方法，包括以下步骤：
（1）取麦饭石、钾长石、沸石、石英砂、硅微粉混合均匀，粉碎，过280-320目筛，然后加入粉末重量6-7.5%的竹醋液，搅拌均匀，然后制成粒径为2-3mm的颗粒，烘干，在1000-1100℃焙烧下10-12min，自然冷却至常温，待用；
（2）将经过处理的废旧陶瓷与高岭土、刚玉粉、硼化锆、玻璃纤维，进行粉碎后，过280-320目筛后，待用；
（3）将步骤（1）和步骤（2）制得的材料与改性硫酸钙晶须均匀混合到一起，加热至120-135℃，保温8-10h，然后自然冷却至室温，得到混合料；
（4）将步骤（3）制得的混合料送到成型机在78-80MPa下压制成砖坯；
（5）将步骤（4）中制得的砖坯以3-4℃/min的速率升温至1350-1390℃，保温3-4h，再以2-4℃/min的速率降温至-6--4℃，保温1-2h，自然恢复至常温，经磨边、包装即得成品。
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