CN107244891A - 一种能够自动修复表面划痕外墙砖的生产方法 - Google Patents
一种能够自动修复表面划痕外墙砖的生产方法 Download PDFInfo
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Abstract
本发明公开了一种能够自动修复表面划痕外墙砖的生产方法,包括以下步骤:(1制备干坯粉料:以废玻璃为主要原料,将其处理后,磨成粉末,过筛网,再加入增速成型剂和添加剂,将其搅拌均匀即得;2)制备干釉粉料;3)坯釉成型;4)烧制;5)后期加工;(6)贴膜:待成品砖胚冷却后,在其釉面贴合自动修复树脂层,并在自动修复树脂层稳固后,在自动修复树脂层表面均匀涂抹憎水剂。本发明通过在瓷砖的釉面增设自动修复树脂层,使得瓷砖表面在被刮擦后,在阳光照射下具有自我修复的功能,对瓷砖提供了保护的同同时,也大大降低了搬运过程中,瓷砖的报废率,降低了瓷砖的生产成本。
Description
技术领域
本发明涉及瓷砖生产技术领域,具体是指一种能够自动修复表面划痕外墙砖的生产方法。
背景技术
如今,建筑陶瓷装饰材料随着人们审美观的不同,以多变的款式、考究的质地以及流行的色彩来不断满足消费者的需求,美化人们的生活环境。
现有的瓷砖,被生产出来,便直接被使用,在瓷砖的搬运过程中,难免发生擦碰,这样的瓷砖,要么用户忍痛丢弃,要么勉为其难的继续使用,极大的降低了用户的体验。一些安装墙面外部的瓷砖,还长时间经受风吹日晒,时间久了,瓷砖褪色或划伤严重,需要更换,这极大的提高了瓷砖的使用成本。
发明内容
本发明的目的在于提供能够自动修复表面划痕外墙砖的生产方法。
本发明通过下述技术方案实现:一种能够自动修复表面划痕外墙砖的生产方法,包括以下步骤:
(1)制备干坯粉料:以废玻璃为主要原料,将其处理后,磨成粉末,过筛网,得到粒度分布为80~150目,30%;150~200目,30%;200目以下,40%的废玻璃粉末,再加入增速成型剂和添加剂,将其搅拌均匀即得;
(2)制备干釉粉料:按质量分数计,将70~85%的低温无铅熔块、5~10%的磷酸二氢铝溶液、2~8%的硅酸锆、2~8%的煅烧氧化锌、以及过渡金属氧化物1~2%混合,搅拌均匀后,磨成粒度分布与干坯粉料相同的干釉粉料;
(3)坯釉成型:先将干坯粉料填入砖坯模具内,然后把砖坯磨具内的干坯粉料刮平,然后填加干釉粉料,压制得带釉胚体;
(4)烧制:将制得的带釉胚体在烧制窑内进行烧制,烧成温蒂1230~1260℃,烧成周期为80~120分钟;
(5)后期加工:烧制后的砖坯体用机械设备对砖的表面进行刮平磨削,得到成品砖胚;
(6)贴膜:待成品砖胚冷却后,在其釉面贴合自动修复树脂层,并在自动修复树脂层稳固后,在自动修复树脂层表面均匀涂抹憎水剂。
自动修复树脂层内包含壳聚糖和环状分子环氧丙烷。当自动修复树脂层表面被划,就会使环氧丙烷的环状结构断裂,暴露出易产生化学反应的两个末端。当阳光照射自动修复树脂层时,紫外线会让涂料中的壳聚糖活跃,与环氧丙烷断裂的末端互相吸引,结合在一起,从而修复断裂的环状结构,实现自动修复功能。自动修复树脂层内还含有树脂,使其具备抗紫外线、抗黄、防污、防腐蚀等功能。配合表面涂布的憎水剂,能够避免瓷砖表面的自动修复树脂层被水分破坏。
为更好的实现本发明的方法,进一步地,所述步骤(1)中,处理废玻璃的主要过程包括分选、清洗以及烘干,之后选择球磨机将其磨成细分,并过80目的筛网。
为更好的实现本发明的方法,进一步地,所述步骤(1)中加入的增塑成型剂为聚氯乙烯,添加剂为石膏。
为更好的实现本发明的方法,进一步地,所述步骤(2)中,所述过渡金属氧化物为Fe2O3、CuO、MnO2、TiO2、NiO中的至少一种。
为更好的实现本发明的方法,进一步地,所述步骤(2)中的干釉粉料的具体配方为:按重量份计,85%的低温无铅熔块、8%的磷酸二氢铝溶液、3%的硅酸锆、3%的煅烧氧化锌、以及过渡金属氧化物1%,其中磷酸二氢铝溶液的质量分数为50%。
为更好的实现本发明的方法,进一步地,所述步骤(2)中,低温无铅熔块的化学成分为,按质量分数计,7~9%的Al2O3,55~60%的SiO2,5~10%的K2O,5~8%的Na2O,2~8%Li2O,10~20%B2O3。
本发明与现有技术相比,具有以下优点及有益效果:
(1)本发明通过在瓷砖的釉面增设自动修复树脂层,使得瓷砖表面在被刮擦后,在阳光照射下具有自我修复的功能,对瓷砖提供了保护的同同时,也大大降低了搬运过程中,瓷砖的报废率,降低了瓷砖的生产成本;
(2)本发明采用坯釉一次压成工艺,使制得的砖坯具有较高的抗折强度、较低的气孔率,并能够提高坯釉的结合度,使其无明显交界面,制得的仿古砖各项性能均超过同类产品;
(3)本发明采用特殊配方的釉原料,制备出的金属釉,能够使釉面表面光洁,质地细腻,具有耐磨、使用寿命长的特点,并适合于快速烧成;
(4)本发明提供的仿古砖生产工艺相对简单,实现较为方便,是适宜大批量生产,相较于传统仿古砖的生产,节约了很多工艺,提高了仿古砖的生产效率。
(5)本发明使用的釉原料来源广泛,方便生产控制,生产出的金属釉仿古砖不含重金属铅,具有环保、发色稳定的特点,适宜广泛推广应用。
具体实施方式
为使本发明的目的、工艺条件及优点作用更加清楚明白,结合以下实施实例,对本发明作进一步详细说明,但本发明的实施方式不限于此,在不脱离本发明上述技术思想情况下,根据本领域普通技术知识和惯用手段,做出各种替换和变更,均应包括在本发明的范围内,此处所描述的具体实施实例仅用以解释本发明,并不用于限定本发明。
实施例1:
本实施例的一种能够自动修复表面划痕外墙砖的生产方法,其特征在于,包括以下步骤:
(1)制备干坯粉料:以废玻璃为主要原料,将其处理后,磨成粉末,过筛网,得到粒度分布为80~150目,30%;150~200目,30%;200目以下,40%的废玻璃粉末,再加入增塑成型剂和添加剂,将其搅拌均匀即得;
(2)制备干釉粉料:按质量分数计,将70~85%的低温无铅熔块、5~10%的磷酸二氢铝溶液、2~8%的硅酸锆、2~8%的煅烧氧化锌、以及过渡金属氧化物1~2%混合,搅拌均匀后,磨成粒度分布与干坯粉料相同的干釉粉料;
(3)坯釉成型:先将干坯粉料填入砖坯模具内,然后把砖坯磨具内的干坯粉料刮平,然后填加干釉粉料,压制得带釉胚体;
(4)烧制:将制得的带釉胚体在烧制窑内进行烧制,烧成温度为1230~1260℃,烧成周期为80~120分钟;
(5)后期加工:烧制后的砖坯体用机械设备对砖的表面进行刮平磨削,得到成品砖胚;
(6)贴膜:待成品砖胚冷却后,在其釉面贴合自动修复树脂层,并在自动修复树脂层稳固后,在自动修复树脂层表面均匀涂抹憎水剂。
生产得到的不含铅金属釉仿古砖的产品性能跟同类产品性能比较,如下表所示:
由上表可知,本实施使用方法生产出的不含铅金属釉仿古砖各项性能与同类产品相比,性能良好。
当瓷砖表面遇到擦碰时,自动修复树脂层2在阳光的照射下会慢慢进行自动修复,使车身表面的划痕消失。
实施例2:
本实施例在上述实施例的基础上,进一步地限定所述步骤(1)中,处理废玻璃的主要过程包括分选、清洗以及烘干,之后选择球磨机将其磨成细分,并过80目的筛网。本实施例的其他部分与上述实施例相同,不再赘述。
实施例3:
本实施例在上述实施例的基础上,进一步地限定所述步骤(1)中加入的增塑成型剂为聚氯乙烯,添加剂为石膏。本实施例的其他部分与上述实施例相同,不再赘述。
实施例4:
本实施例在上述实施例的基础上,进一步地限定步骤(2)中,所述过渡金属氧化物为Fe2O3、CuO、MnO2、TiO2、NiO中的至少一种。本实施例的其他部分与上述实施例相同,不再赘述。
实施例5:
本实施例在上述实施例的基础上,进一步地限定所述步骤(2)中的干釉粉料的具体配方为:按重量份计,85%的低温无铅熔块、8%的磷酸二氢铝溶液、3%的硅酸锆、3%的煅烧氧化锌、以及过渡金属氧化物1%,其中磷酸二氢铝溶液的质量分数为50%。本实施例的其他部分与上述实施例相同,不再赘述。
实施例6:
本实施例在上述实施例的基础上,进一步地限定所述步骤(2)中,低温无铅熔块的化学成分为,按质量分数计,7~9%的Al2O3,55~60%的SiO2,5~10%的K2O,5~8%的Na2O,2~8%Li2O,10~20%B2O3。本实施例的其他部分与上述实施例相同,不再赘述。
实施例7:
本实施例在上述实施例的基础上,进一步地限定所述步骤(6)中,使用的憎水剂为氟系憎水剂。氟系憎水剂含有大量极性强的氟院子,当氟原子核其他元素结合时,几乎是夺取其电子,成为最外层8电子的稳定结构,因此很难使其它基团语气发生范德华力作用,导致其表面能极地。使用氟系憎水剂可自由调节其流动性,拨釉效果好。本实施例的其他部分与上述实施例相同,不再赘述。
尽管已经示出和描述了本发明的实施例,本领域的普通技术人员可以理解:在不脱离本发明的原理和宗旨下可以对这些实施例进行多种变化、修改、替换和变型,本发明的范围由权利要求及其等同物限定。
Claims (7)
1.一种能够自动修复表面划痕外墙砖的生产方法,其特征在于,包括以下步骤:
(1)制备干坯粉料:以废玻璃为主要原料,将其处理后,磨成粉末,过筛网,得到粒度分布为80~150目,30%;150~200目,30%;200目以下,40%的废玻璃粉末,再加入增塑成型剂和添加剂,将其搅拌均匀即得;
(2)制备干釉粉料:按质量分数计,将70~85%的低温无铅熔块、5~10%的磷酸二氢铝溶液、2~8%的硅酸锆、2~8%的煅烧氧化锌、以及过渡金属氧化物1~2%混合,搅拌均匀后,磨成粒度分布与干坯粉料相同的干釉粉料;
(3)坯釉成型:先将干坯粉料填入砖坯模具内,然后把砖坯磨具内的干坯粉料刮平,然后填加干釉粉料,压制得带釉胚体;
(4)烧制:将制得的带釉胚体在烧制窑内进行烧制,烧成温度为1230~1260℃,烧成周期为80~120分钟;
(5)后期加工:烧制后的砖坯体用机械设备对砖的表面进行刮平磨削,得到成品砖胚;
(6)贴膜:待成品砖胚冷却后,在其釉面贴合自动修复树脂层,并在自动修复树脂层稳固后,在自动修复树脂层表面均匀涂抹憎水剂。
2.根据权利要求1所述的一种能够自动修复表面划痕外墙砖的生产方法,其特征在于,所述步骤(1)中,处理废玻璃的主要过程包括分选、清洗以及烘干,之后选择球磨机将其磨成细分,并过80目的筛网。
3.根据权利要求1所述的一种能够自动修复表面划痕外墙砖的生产方法,其特征在于,所述步骤(1)中加入的增塑成型剂为聚氯乙烯,添加剂为石膏。
4.根据权利要求1所述的一种能够自动修复表面划痕外墙砖的生产方法,其特征在于,步骤(2)中,所述过渡金属氧化物为Fe2O3、CuO、MnO2、TiO2、NiO中的至少一种。
5.根据权利要求1所述的一种能够自动修复表面划痕外墙砖的生产方法,其特征在于,所述步骤(2)中的干釉粉料的具体配方为:按重量份计, 85%的低温无铅熔块、8%的磷酸二氢铝溶液、3%的硅酸锆、3%的煅烧氧化锌、以及过渡金属氧化物1%,其中磷酸二氢铝溶液的质量分数为50%。
6.根据权利要求1所述的一种能够自动修复表面划痕外墙砖的生产方法,其特征在于,所述步骤(2)中,低温无铅熔块的化学成分为,按质量分数计, 7~9%的Al2O3,55~60%的SiO2,5~10%的K2O,5~8%的Na2O,2~8%Li2O,10~20%B2O3。
7.根据权利要求1所述的一种能够自动修复表面划痕外墙砖的生产方法,其特征在于,所述步骤(6)中,使用的憎水剂为氟系憎水剂。
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