CN107698238A - 基于石墨烯与非金属尾矿发泡轻质装饰一体板及制备方法 - Google Patents
基于石墨烯与非金属尾矿发泡轻质装饰一体板及制备方法 Download PDFInfo
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- CN107698238A CN107698238A CN201711043820.9A CN201711043820A CN107698238A CN 107698238 A CN107698238 A CN 107698238A CN 201711043820 A CN201711043820 A CN 201711043820A CN 107698238 A CN107698238 A CN 107698238A
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- Y02P40/60—Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes
Abstract
本发明公开了基于石墨烯与非金属尾矿发泡轻质装饰一体板,包括基体石墨烯与非金属尾矿发泡轻质材料层和表面装饰面层;所述基体石墨烯与非金属尾矿发泡轻质材料层和所述表面装饰面层之间通过压模后,一次烧结成型粘结在一起;石墨烯与非金属尾矿发泡轻质材料层包括以下原料:非金属尾矿、石墨烯、氧化锆、高温助熔剂、粘土、稳定剂和解胶剂。本发明还公开了基于石墨烯与非金属尾矿发泡轻质装饰一体板的制备方法。本发明制备的基于石墨烯与非金属尾矿发泡轻质装饰一体板具有轻质高强、隔音隔热保温、防水抗渗、阻燃、抗腐蚀、安装轻便、低碳节能和绿色环保等性能的优点。
Description
【技术领域】
本发明涉及建筑装饰材料领域,特别涉及基于石墨烯与非金属尾矿发泡轻质装饰一体板及制备方法。
【背景技术】
目前市场上现有的建筑内外墙体表面装饰层材料主要为:瓷砖、花岗岩、大理石和聚乙烯类挤塑保温装饰板,其中瓷砖、花岗岩和大理石在生产过程中,大量燃烧煤矿资源,对环境污染破坏严重,瓷砖本身自重大,没有自保温功能,在施工安装过程中采用大量水泥砂浆湿法粘贴,工序复杂使用寿命短、易开裂易脱落,造成的安全隐患较大;花岗岩和大理石本身属于不可再生的矿产资源,在城市日益开发建设需求,大量开采过程中严重破坏生态环境,成品率利用率极低,造成尾矿垃圾难以得到有效利用处理,容易造成地质灾害。聚乙烯类挤塑保温装饰板因材料本身限制易老化使用寿命短、耐候性差、防火性能差,且一但发生火灾产生大量有毒烟气,导致对环境污染破坏极大。因此,研究一种质轻、耐阻燃、不易老化和力学性能优良的建筑内外墙体表面装饰材料迫在眉睫。
非金属尾矿是矿业固体废物的主要类型,其综合回收利用率仅为6.95%,它对土地的侵占、堆积过程带来的环境问题日益加剧,使得很多矿山不堪重负,非金属尾矿质轻、含有丰富的金属氧化物的特点,成为对其进行有效地开发是节约利用矿产资源的重要途径。罗学维等(电解锰渣制备轻质发泡陶瓷保温板工艺及性能研究,中国锰业,2016,34(6):125-129)以电解锰渣为原料、长石为助熔剂、金刚砂为脱氧剂,采用改进的乙醇旋转蒸发粉料分散技术,经高温发泡工艺制备了轻质发泡陶瓷保温板。缺点:所制备的材料只具有保温性能,未能提高保温板的阻燃性能。
石墨烯是一种由单层碳原子组成的平面二维结构,具有极高的强度和稳定性。闫姝(博士论文,氧化石墨烯增强铝硅酸盐聚合物的聚合与陶瓷化机制,2016)以偏高岭土、碱激发溶液、氧化石墨烯等为原材料,采用原位合成方法制备了部分还原石墨烯/铝硅酸盐聚合物基复合材料,通过石墨烯激发陶瓷在高温条件下的磁化过程。缺点:必须在碱性溶液、高温条件下才能发生反应,反应条件苛刻,容易造成环境污染,且在高温反应过程中石墨烯和其他物料容易发生团聚现象,无法充分发挥物料的功能。
蒋浩龙等(声共振混合技术及其在火炸药中的应用,化工新型材料,2017,45(2):236-238)公开了以声共振混合技术处理火药粉末,以提高物料混合的均匀性。缺点:声共振混合过程中容易产生静电,导致部分带电物质团聚。因此,研究一种能够充分分散物料、质轻、阻燃性高的基于石墨烯与非金属尾矿发泡轻质装饰一体板,对于拓展建筑内外墙体表面装饰层材料的使用范围具有深远的研究意义。
【发明内容】
为解决上述问题,本发明目的在于提供一种基于石墨烯与非金属尾矿发泡轻质装饰一体板及制备方法。本发明制备的基于石墨烯与非金属尾矿发泡轻质装饰一体板具有质轻高强、阻燃、防火耐火、隔音隔热保温、防水防渗、抗老化、抗腐蚀、力学性能优良、低碳节能和绿色环保的优点。
为达到上述目的,本发明所采用的技术方案是:基于石墨烯与非金属尾矿发泡轻质装饰一体板,包括基体石墨烯与非金属尾矿发泡轻质材料层和表面装饰面层;
所述基体石墨烯与非金属尾矿发泡轻质材料层和所述表面装饰面层之间通过压模后,一次烧结成型粘结在一起;
所述的石墨烯与非金属尾矿发泡轻质材料层按重量百分比计包括以下原料:非金属尾矿55-90%、石墨烯0.05-10%、氧化锆1-10%、高温助熔剂0.05-10%、粘土1-10%、稳定剂0.05-5%和解胶剂0.05-5%;
所述的装饰面层按重量百分比计包括以下原料:非金属尾矿25-80%、石英5-15%、氧化镁0.05-10%、方解石0.05-4%、云母0.05-15%、氧化铝0.05-10%、硅灰石5-15%、锂长石0.05-10%、碳酸钙0.05-11%、石墨烯3-10%和釉面色料0.05-5%。
在本发明中,作为进一步说明,所述的非金属尾矿为花岗岩、长石、石英、砂岩、玄武岩、辉绿岩、页岩、石灰岩和大理岩中的任意一种或多种。
在本发明中,作为进一步说明,所述的高温助熔剂为煅烧滑石、生滑石和萤石中的任意一种或多种。
在本发明中,作为进一步说明,所述的稳定剂为钇的氧化物或铈的氧化物。
在本发明中,作为进一步说明,所述的解胶剂为多元羧酸水溶性有机类。
在本发明中,作为进一步说明,基于石墨烯与非金属尾矿发泡轻质装饰一体板的制备方法,包括以下步骤:
(1)研磨:将所有配方原料分别单独用研磨机研磨10h,细度达到250目全通过,备用;
(2)石墨烯与非金属尾矿发泡轻质材料的制备:按石墨烯与非金属尾矿发泡轻质材料层的配方准确称取非金属尾矿和石墨烯,放入共振混合系统中的混合筒中,使混合筒内的湿度达75%,密封后升温至50℃,在激振器输出的振动频率为50-75Hz的条件下处理15-20s,加入配方中的其它原料,然后进入高速旋转混合机混合均化10-300min,经过喷雾造粒处理,烘干,进入储蓄仓备用,得到石墨烯与非金属尾矿发泡轻质材料;
(3)装饰面材料的制备:按装饰面层的配方准确称取非金属尾矿和石墨烯,放入共振混合系统中的混合筒中,使混合筒内的湿度达75%,密封后升温至50℃,在激振器输出的振动频率为50-75Hz的条件下处理15-20s,加入配方中的其它原料,然后进入高速旋转混合机混合均化10-150min,经过喷雾造粒处理,烘干,进入储蓄仓备用,得到装饰面材料;
(4)二次压模:将石墨烯与非金属尾矿发泡轻质材料放进压模成型机中,在压力为3-5MPa的条件下进行第一次压模,得到石墨烯与非金属尾矿发泡轻质材料层,然后以石墨烯与非金属尾矿发泡轻质材料层为基体的基础上二次压制装饰面材料层,得到二次压模成品;
(5)烘干烧成:将二次压模成品放入辊道窑或者隧道窑内,经900-1300℃高温烧制30-300min,冷却后取出,经打磨、抛光、切割成形,得到基于石墨烯与非金属尾矿发泡轻质装饰一体板成品。
在本发明中,作为进一步说明,所述的基于石墨烯与非金属尾矿发泡轻质装饰一体板成品的规格为:长:400-1200mm、宽:400-1200mm、厚:30-200mm。
部分原料的功能介绍如下:
非金属尾矿,具有质轻和富含金属氧化物的特点,在本发明中用作制备石墨烯与非金属尾矿发泡轻质装饰一体板的主要材料。
氧化锆,在本发明中用于提高材料的耐高温性和耐阻燃性。
粘土,在本发明中用作轻质材料,降低材料的密度。
氧化镁,在本发明中用作提高材料的耐高温性。
石英、方解石、云母、氧化铝、硅灰石、锂长石和碳酸钙,在本发明中用作轻质材料的原料。
解胶剂,在本发明中用于改善轻质材料的流动性。
本发明具有以下有益效果:
1.本发明基于石墨烯与非金属尾矿发泡轻质装饰一体板组成的两部分不同面层中均含有石墨烯和非金属尾矿,通过石墨烯高比表面积、高吸附力的作用,使石墨烯均匀分散在非金属尾矿表面,使物料的物理性质趋于稳定,与配方中各个原料相互辅助起到了抗老化、抗腐蚀、隔热保温、隔音、防水抗渗、防火耐火、轻质高强的效果。而在石墨烯与非金属尾矿发泡轻质材料中加入氧化锆、黏土、稳定剂和解胶剂,是通过石墨烯的二维片层结构,加强石墨烯和解胶剂之间的相互作用,吸附了大量的氧化锆、黏土和稳定剂,形成致密的物理层,提高材料的阻燃性、防水性、保温性和力学性能。在装饰面材料中除石墨烯和非金属尾矿外还添加了石英、氧化镁、方解石、云母、氧化铝、硅灰石、锂长石和碳酸钙,通过石墨烯的二维片层结构,均匀穿插在石英、方解石、碳酸钙、硅灰石和锂长石结构中,提高装饰面材料的力学性能和防水性。
2.本发明所采用的基于石墨烯与非金属尾矿发泡轻质装饰一体板的制备方法能够科学设计、使不同的结构物质分散均匀,进而提高成品的力学性能、阻燃性和保温性能。首先,本发明先通过对物料进行超细化,提高物料表面的比表面积,为物料后续的分散均匀打下基础。其次,本发明采用将石墨烯和非金属尾矿在高湿度条件下进行共振混合处理,使物料分散均匀的同时,降低静电压,减少静电的发生,为后续的烘干烧成步骤的进行埋下伏笔。本发明通过将物料处于50℃中温和高湿度环境中,使石墨烯和非金属尾矿在激振器声波的共振作用下的摩擦变小,进而减少了静电的发生,降低了静电压,使物料容易容易分散,避免了石墨烯团聚现象的发生。最后,本发明将二次压模成品进行一次烧成的技术手段,能够使所有分散均匀的物料能够在高温条件下烧制成型,烧制工艺简单,且全程零污染排放,提高制备效率。本发明所采用的各个技术手段能够做到相互配合、相互促进,大大提高材料综合性能。
3.本发明通过一次烧结成形,制得具有轻质高强、力学性能优良、隔音隔热保温、阻燃、防水抗渗、抗老化、抗腐蚀、安装轻便、低碳节能和绿色环保的基于石墨烯与非金属尾矿发泡轻质装饰一体板,采用自动化高效节能窑炉,实现生产过程零排放、无污染,产品颜色品种多样化,满足安全绿色节能建筑装饰的个性化设计需求。
4.本发明采用非金属尾矿为主要原料,利用非金属尾矿质轻、富含金属氧化物和抗腐蚀的特点,容易和耐腐蚀构件进行点挂施工安装,与建筑墙体同寿命紧密结合,降低原料成本,施工工序简单便捷,大大减少建筑施工造价成本的提前条件下,可达到建筑保温隔热装饰一体化安装效果,提高了建设效率,缩短了工期,在建筑及建筑装饰市场具有极大的发展前景。
【具体实施方式】
实施例1:
1.前期准备:
石墨烯与非金属尾矿发泡轻质材料层按重量百分比计包括以下原料:花岗岩55-90%、石墨烯10%、氧化锆10%、煅烧滑石10%、粘土8.9%、钇的氧化物4%和多元羧酸水溶性有机类解胶剂2.1%。
装饰面层按重量百分比计包括以下原料:花岗岩80%、石英5%、氧化镁0.05%、方解石0.05%、云母0.05%、氧化铝0.05%、硅灰石5%、锂长石0.05%、碳酸钙1%、石墨烯3.75%和釉面色料5%。
将上述所准备的物质用于下述的基于石墨烯与非金属尾矿发泡轻质装饰一体板的制备方法中。
2.基于石墨烯与非金属尾矿发泡轻质装饰一体板的制备方法,包括以下步骤:
(1)研磨:将所有配方原料分别单独用研磨机研磨10h,细度达到250目全通过,备用;
(2)石墨烯与非金属尾矿发泡轻质材料的制备:按石墨烯与非金属尾矿发泡轻质材料层的配方准确称取非金属尾矿和石墨烯,放入共振混合系统中的混合筒中,使混合筒内的湿度达75%,密封后升温至50℃,在激振器输出的振动频率为50Hz的条件下处理15s,加入配方中的其它原料,然后进入高速旋转混合机混合均化10min,经过喷雾造粒处理,烘干,进入储蓄仓备用,得到石墨烯与非金属尾矿发泡轻质材料;
(3)装饰面材料的制备:按装饰面层的配方准确称取非金属尾矿和石墨烯,放入共振混合系统中的混合筒中,使混合筒内的湿度达75%,密封后升温至50℃,在激振器输出的振动频率为50Hz的条件下处理15s,加入配方中的其它原料,然后进入高速旋转混合机混合均化10min,经过喷雾造粒处理,烘干,进入储蓄仓备用,得到装饰面材料;
(4)二次压模:将石墨烯与非金属尾矿发泡轻质材料放进压模成型机中,在压力为3MPa的条件下进行第一次压模,得到石墨烯与非金属尾矿发泡轻质材料层,然后以石墨烯与非金属尾矿发泡轻质材料层为基体的基础上二次压制装饰面材料层,得到二次压模成品;
(5)烘干烧成:将二次压模成品放入辊道窑或者隧道窑内,经900℃高温烧制30min,冷却后取出,经打磨、抛光、切割成形,得到基于石墨烯与非金属尾矿发泡轻质装饰一体板成品,规格为:长:400mm、宽:400mm、厚:30mm。
经实验检测,基于石墨烯与非金属尾矿发泡轻质装饰一体板的体积密度为400kg/m3。
实施例2:
1.前期准备:
石墨烯与非金属尾矿发泡轻质材料层按重量百分比计包括以下原料:长石25%、石英10%、砂岩33%、石墨烯3%、氧化锆6%、生滑石5%\萤石3%、粘土10%、铈的氧化物0.05%和多元羧酸水溶性有机类解胶剂4.95%;
装饰面层按重量百分比计包括以下原料:长石23%、石英22%、氧化镁2%、方解石3%、云母11%、氧化铝1%、硅灰石15%、锂长石9%、碳酸钙2%、石墨烯10%和釉面色料2%。
将上述所准备的物质用于下述的基于石墨烯与非金属尾矿发泡轻质装饰一体板的制备方法中。
2.基于石墨烯与非金属尾矿发泡轻质装饰一体板的制备方法,包括以下步骤:
(1)研磨:将所有配方原料分别单独用研磨机研磨10h,细度达到250目全通过,备用;
(2)石墨烯与非金属尾矿发泡轻质材料的制备:按石墨烯与非金属尾矿发泡轻质材料层的配方准确称取非金属尾矿和石墨烯,放入共振混合系统中的混合筒中,使混合筒内的湿度达75%,密封后升温至50℃,在激振器输出的振动频率为55Hz的条件下处理16s,加入配方中的其它原料,然后进入高速旋转混合机混合均化100min,经过喷雾造粒处理,烘干,进入储蓄仓备用,得到石墨烯与非金属尾矿发泡轻质材料;
(3)装饰面材料的制备:按装饰面层的配方准确称取非金属尾矿和石墨烯,放入共振混合系统中的混合筒中,使混合筒内的湿度达75%,密封后升温至50℃,在激振器输出的振动频率为60Hz的条件下处理17s,加入配方中的其它原料,然后进入高速旋转混合机混合均化50min,经过喷雾造粒处理,烘干,进入储蓄仓备用,得到装饰面材料;
(4)二次压模:将石墨烯与非金属尾矿发泡轻质材料放进压模成型机中,在压力为3.5MPa的条件下进行第一次压模,得到石墨烯与非金属尾矿发泡轻质材料层,然后以石墨烯与非金属尾矿发泡轻质材料层为基体的基础上二次压制装饰面材料层,得到二次压模成品;
(5)烘干烧成:将二次压模成品放入辊道窑或者隧道窑内,经1000℃高温烧制50min,冷却后取出,经打磨、抛光、切割成形,得到基于石墨烯与非金属尾矿发泡轻质装饰一体板成品,规格为:长:800mm、宽:800mm、厚:80mm。
经实验检测,基于石墨烯与非金属尾矿发泡轻质装饰一体板的体积密度为580kg/m3。
实施例3:
1.前期准备:
石墨烯与非金属尾矿发泡轻质材料层按重量百分比计包括以下原料:砂岩23%、玄武岩18%、辉绿岩26%、石墨烯8%、氧化锆7%、生滑石3%、萤石2%、粘土3%、铈的氧化物5%和多元羧酸水溶性有机类解胶剂5%;
装饰面层按重量百分比计包括以下原料:砂岩13%、玄武岩15%、辉绿岩20%、石英6%、氧化镁5%、方解石2%、云母5%、氧化铝3%、硅灰石6%、锂长石10%、碳酸钙11%、石墨烯3%和釉面色料1%。
将上述所准备的物质用于下述的基于石墨烯与非金属尾矿发泡轻质装饰一体板的制备方法中。
2.基于石墨烯与非金属尾矿发泡轻质装饰一体板的制备方法,包括以下步骤:
(1)研磨:将所有配方原料分别单独用研磨机研磨10h,细度达到250目全通过,备用;
(2)石墨烯与非金属尾矿发泡轻质材料的制备:按石墨烯与非金属尾矿发泡轻质材料层的配方准确称取非金属尾矿和石墨烯,放入共振混合系统中的混合筒中,使混合筒内的湿度达75%,密封后升温至50℃,在激振器输出的振动频率为63Hz的条件下处理18s,加入配方中的其它原料,然后进入高速旋转混合机混合均化200min,经过喷雾造粒处理,烘干,进入储蓄仓备用,得到石墨烯与非金属尾矿发泡轻质材料;
(3)装饰面材料的制备:按装饰面层的配方准确称取非金属尾矿和石墨烯,放入共振混合系统中的混合筒中,使混合筒内的湿度达75%,密封后升温至50℃,在激振器输出的振动频率为60Hz的条件下处理17s,加入配方中的其它原料,然后进入高速旋转混合机混合均化40min,经过喷雾造粒处理,烘干,进入储蓄仓备用,得到装饰面材料;
(4)二次压模:将石墨烯与非金属尾矿发泡轻质材料放进压模成型机中,在压力为4MPa的条件下进行第一次压模,得到石墨烯与非金属尾矿发泡轻质材料层,然后以石墨烯与非金属尾矿发泡轻质材料层为基体的基础上二次压制装饰面材料层,得到二次压模成品;
(5)烘干烧成:将二次压模成品放入辊道窑或者隧道窑内,经1100℃高温烧制80min,冷却后取出,经打磨、抛光、切割成形,得到基于石墨烯与非金属尾矿发泡轻质装饰一体板成品,规格为:长:1000mm、宽:1000mm、厚:100mm。
经实验检测,基于石墨烯与非金属尾矿发泡轻质装饰一体板的体积密度为703kg/m3。
实施例4:
1.前期准备:
石墨烯与非金属尾矿发泡轻质材料层按重量百分比计包括以下原料:辉绿岩22%、页岩40%、石灰岩17%、石墨烯2%、氧化锆3%、生滑石1%、萤石6%、粘土3%、铈的氧化物4%和多元羧酸水溶性有机类解胶剂2%;
装饰面层按重量百分比计包括以下原料:石英16%、玄武岩21%、辉绿岩14%、页岩10%、石灰岩10%、大理岩10%、氧化镁4%、方解石1%、云母1%、氧化铝2%、硅灰石5%、锂长石1.9%、碳酸钙0.05%、石墨烯4%和釉面色料0.05%。
将上述所准备的物质用于下述的基于石墨烯与非金属尾矿发泡轻质装饰一体板的制备方法中。
2.基于石墨烯与非金属尾矿发泡轻质装饰一体板的制备方法,包括以下步骤:
(1)研磨:将所有配方原料分别单独用研磨机研磨10h,细度达到250目全通过,备用;
(2)石墨烯与非金属尾矿发泡轻质材料的制备:按石墨烯与非金属尾矿发泡轻质材料层的配方准确称取非金属尾矿和石墨烯,放入共振混合系统中的混合筒中,使混合筒内的湿度达75%,密封后升温至50℃,在激振器输出的振动频率为59Hz的条件下处理17s,加入配方中的其它原料,然后进入高速旋转混合机混合均化200min,经过喷雾造粒处理,烘干,进入储蓄仓备用,得到石墨烯与非金属尾矿发泡轻质材料;
(3)装饰面材料的制备:按装饰面层的配方准确称取非金属尾矿和石墨烯,放入共振混合系统中的混合筒中,使混合筒内的湿度达75%,密封后升温至50℃,在激振器输出的振动频率为60Hz的条件下处理19s,加入配方中的其它原料,然后进入高速旋转混合机混合均化130min,经过喷雾造粒处理,烘干,进入储蓄仓备用,得到装饰面材料;
(4)二次压模:将石墨烯与非金属尾矿发泡轻质材料放进压模成型机中,在压力为4.5MPa的条件下进行第一次压模,得到石墨烯与非金属尾矿发泡轻质材料层,然后以石墨烯与非金属尾矿发泡轻质材料层为基体的基础上二次压制装饰面材料层,得到二次压模成品;
(5)烘干烧成:将二次压模成品放入辊道窑或者隧道窑内,经1100℃高温烧制150min,冷却后取出,经打磨、抛光、切割成形,得到基于石墨烯与非金属尾矿发泡轻质装饰一体板成品,规格为:长:900mm、宽:900mm、厚:150mm。
经实验检测,基于石墨烯与非金属尾矿发泡轻质装饰一体板的体积密度为625kg/m3。
实施例5:
1.前期准备:
石墨烯与非金属尾矿发泡轻质材料层按重量百分比计包括以下原料:页岩2%、石灰岩27%、大理岩31%、石墨烯0.05%、氧化锆1%、萤石0.05%、粘土1%、钇的氧化物4%和多元羧酸水溶性有机类解胶剂3.9%;
装饰面层按重量百分比计包括以下原料:长石25%、石英15%、氧化镁10%、方解石4%、云母15%、氧化铝10%、硅灰石8%、锂长石4%、碳酸钙2%、石墨烯4%和釉面色料3%。
将上述所准备的物质用于下述的基于石墨烯与非金属尾矿发泡轻质装饰一体板的制备方法中。
2.基于石墨烯与非金属尾矿发泡轻质装饰一体板的制备方法,包括以下步骤:
(1)研磨:将所有配方原料分别单独用研磨机研磨10h,细度达到250目全通过,备用;
(2)石墨烯与非金属尾矿发泡轻质材料的制备:按石墨烯与非金属尾矿发泡轻质材料层的配方准确称取非金属尾矿和石墨烯,放入共振混合系统中的混合筒中,使混合筒内的湿度达75%,密封后升温至50℃,在激振器输出的振动频率为75Hz的条件下处理20s,加入配方中的其它原料,然后进入高速旋转混合机混合均化300min,经过喷雾造粒处理,烘干,进入储蓄仓备用,得到石墨烯与非金属尾矿发泡轻质材料;
(3)装饰面材料的制备:按装饰面层的配方准确称取非金属尾矿和石墨烯,放入共振混合系统中的混合筒中,使混合筒内的湿度达75%,密封后升温至50℃,在激振器输出的振动频率为75Hz的条件下处理20s,加入配方中的其它原料,然后进入高速旋转混合机混合均化150min,经过喷雾造粒处理,烘干,进入储蓄仓备用,得到装饰面材料;
(4)二次压模:将石墨烯与非金属尾矿发泡轻质材料放进压模成型机中,在压力为5MPa的条件下进行第一次压模,得到石墨烯与非金属尾矿发泡轻质材料层,然后以石墨烯与非金属尾矿发泡轻质材料层为基体的基础上二次压制装饰面材料层,得到二次压模成品;
(5)烘干烧成:将二次压模成品放入辊道窑或者隧道窑内,经1300℃高温烧制300min,冷却后取出,经打磨、抛光、切割成形,得到基于石墨烯与非金属尾矿发泡轻质装饰一体板成品,规格为:长:1200mm、宽:1200mm、厚:200mm。
经实验检测,基于石墨烯与非金属尾矿发泡轻质装饰一体板的体积密度为800kg/m3。
试验1:
静电检测:按实施例1-5的制备方法各制备10000g石墨烯与非金属尾矿发泡轻质材料和装饰面材料,以配方中不含有石墨烯的发泡轻质装饰一体板为对照例1,以石墨烯和非金属尾矿没经过共振混合处理为对照例2,用静电压检测仪检测石墨烯与非金属尾矿发泡轻质材料和装饰面材料的最大静电压,检测结果见表1。
表1:
由表1可知:静电压的数值越高,说明样品表面的静电聚集得越多。实施例1-5样品的石墨烯与非金属尾矿发泡轻质材料静电压最大值和装饰面材料静电压最大值均远远低于对照例1和对照例2的数值,说明本发明所采用的方法能显著降低材料表面的静电的聚集程度。
试验2:
力学性能测试:按实施例1-5的制备方法各制备10000g基于石墨烯与非金属尾矿发泡轻质装饰一体板样品,以配方中不含有石墨烯的发泡轻质装饰一体板为对照例1,以石墨烯和非金属尾矿没经过共振混合处理为对照例2,制成30mm×20mm×20mm的式样,用万能力学试验机检测式样的抗压强度和抗折强度,具体步骤参照GB/T17657-1999,全部结果见表2。
表2:
抗压强度 | 抗折强度 | |
对照例1 | 2.13MPa | 1.03MPa |
对照例2 | 3.25MPa | 1.11MPa |
实施例1 | 6.49MPa | 2.68MPa |
实施例2 | 6.68MPa | 2.74MPa |
实施例3 | 6.58MPa | 2.79MPa |
实施例4 | 6.88MPa | 2.66MPa |
实施例5 | 6.69MPa | 2.75MPa |
由表2可知:抗压强度的数值越高,说明样品的抗压能力越强,力学性能越好。实施例1-5样品的抗压强度远远高于对照例1和对照例2的数值,说明本发明所制备的基于石墨烯与非金属尾矿发泡轻质装饰一体板能够显著提高材料的抗压强度;
抗折强度的数值越高,说明样品的抗折能力越强,力学性能越好。实施例1-5样品的抗折强度远远高于对照例1和对照例2的数值,说明本发明所制备的基于石墨烯与非金属尾矿发泡轻质装饰一体板能够显著提高材料的抗折强度。
试验3:
燃烧等级测试:按实施例1-5的制备方法各制备10000g基于石墨烯与非金属尾矿发泡轻质装饰一体板样品,以配方中不含有石墨烯的发泡轻质装饰一体板为对照例1,以石墨烯和非金属尾矿没经过共振混合处理为对照例2,具体操作参考GB8624-2006、GB50016-2006和GB50005-2003,进行燃烧等级测试和耐火极限测试,全部结果见表3。
表3:
燃烧等级中,A级为不燃物等级,其中A1级为绝对不燃且无任何烟气毒气产生的材料,A2级为不燃但有一定烟气毒气的材料,A1级别的阻燃性能高于A2级燃烧等级。
由表3可知:对比例1-5的燃烧等级均为A1级,且均高于对照例1和对照例2的A2级,说明本发明所制备的基于石墨烯与非金属尾矿发泡轻质装饰一体板能够显著提高材料的阻燃性。
耐火极限的数值越高,说明样品的阻燃性、防火和耐火性越强。对比例1-5的耐火极限的数值均高于对比例1和对照例2的耐火极限,说明本发明所制备的基于石墨烯与非金属尾矿发泡轻质装饰一体板能够显著提高材料的阻燃性、防火和耐火性。
试验4:
吸水性测试:按实施例1-5的制备方法各制备10000g基于石墨烯与非金属尾矿发泡轻质装饰一体板样品,以配方中不含有石墨烯的发泡轻质装饰一体板为对照例1,以石墨烯和非金属尾矿没经过共振混合处理为对照例2,按照GB/T 1934.1-2009进行测试,测试结果见表4。
表4:
对照例1 | 对照例2 | 实施例1 | 实施例2 | 实施例3 | 实施例4 | 实施例5 | |
吸水率 | 2.51% | 1.07% | 0.08% | 0.07% | 0.07% | 0.08% | 0.08% |
由表4可知:吸水后的材料会导致材料变形、力学性能和防腐抗菌性能的下降,最终材料的使用寿命缩短,因此吸水率越低,材料的防水性越高。实施例1-5的吸水率远远低于对照例1和对照例2的吸水率,说明本发明所制备的基于石墨烯与非金属尾矿发泡轻质装饰一体板能够显著提高材料的防水性、防潮性、不吸水性。
试验5:
热传导试验:按实施例1-5的制备方法各制备10000g基于石墨烯与非金属尾矿发泡轻质装饰一体板样品,以配方中不含有石墨烯的发泡轻质装饰一体板为对照例1,以石墨烯和非金属尾矿没经过共振混合处理为对照例2,使用热特性分析仪检测样品的热传导系数,测试结果见表5。
表5:
由表5可知:导热系数越低,说明材料的保温能力越好。实施例1-5的导热系数远远低于对照例1和对照例2的导热系数,说明本发明所制备的基于石墨烯与非金属尾矿发泡轻质装饰一体板能够显著提高材料的保温隔热性能。
试验6:
放射性核素限量测试:按实施例1-5的制备方法各制备10000g基于石墨烯与非金属尾矿发泡轻质装饰一体板样品,以配方中不含有石墨烯的发泡轻质装饰一体板为对照例1,以石墨烯和非金属尾矿没经过共振混合处理为对照例2,用γ谱仪系统测量检测样品的内照射指数和外照射指数,检测结果见表6。
表6:
对照例1 | 对照例2 | 实施例1 | 实施例2 | 实施例3 | 实施例4 | 实施例5 | |
内照射指数 | 1.12 | 1.00 | 0.01 | 0.02 | 0.02 | 0.02 | 0.01 |
外照射指数 | 1.24 | 1.03 | 0.03 | 0.02 | 0.03 | 0.03 | 0.02 |
表6可知:内照射指数和外照射指数越低,说明样品的辐射量小,对人体产生的辐射作用也越小。实施例1-5的内照射指数和外照射指数均远低于对照例1和对照例2,说明本发明所制备的基于石墨烯与非金属尾矿发泡轻质装饰一体板能够显著降低材料的辐射量。
上述说明是针对本发明较佳可行实施例的详细说明,但实施例并非用以限定本发明的专利申请范围,凡本发明所提示的技术精神下所完成的同等变化或修饰变更,均应属于本发明所涵盖专利范围。
Claims (6)
1.基于石墨烯与非金属尾矿发泡轻质装饰一体板,其特征在于:包括基体石墨烯与非金属尾矿发泡轻质材料层和表面装饰面层;
所述基体石墨烯与非金属尾矿发泡轻质材料层和所述表面装饰面层之间通过压模后,一次烧结成型粘结在一起;
所述的石墨烯与非金属尾矿发泡轻质材料层按重量百分比计包括以下原料:非金属尾矿55-90%、石墨烯0.05-10%、氧化锆1-10%、高温助熔剂0.05-10%、粘土1-10%、稳定剂0.05-5%和解胶剂0.05-5%;
所述的装饰面层按重量百分比计包括以下原料:非金属尾矿25-80%、石英5-15%、氧化镁0.05-10%、方解石0.05-4%、云母0.05-15%、氧化铝0.05-10%、硅灰石5-15%、锂长石0.05-10%、碳酸钙0.05-11%、石墨烯3-10%和釉面色料0.05-5%。
2.根据权利要求1所述的基于石墨烯与非金属尾矿发泡轻质装饰一体板,其特征在于:所述的非金属尾矿为花岗岩、长石、石英、砂岩、玄武岩、辉绿岩、页岩、石灰岩和大理岩中的任意一种或多种。
3.根据权利要求1所述的基于石墨烯与非金属尾矿发泡轻质装饰一体板,其特征在于:所述的高温助熔剂为煅烧滑石、生滑石和萤石中的任意一种或多种。
4.根据权利要求1所述的基于石墨烯与非金属尾矿发泡轻质装饰一体板,其特征在于:所述的稳定剂为钇的氧化物或铈的氧化物。
5.根据权利要求1所述的基于石墨烯与非金属尾矿发泡轻质装饰一体板,其特征在于:所述的解胶剂为多元羧酸水溶性有机类。
6.根据权利要求1-5任意一项所述的基于石墨烯与非金属尾矿发泡轻质装饰一体板的制备方法,其特征在于:包括以下步骤:
(1)研磨:将所有配方原料分别单独用研磨机研磨10h,细度达到250目全通过,备用;
(2)石墨烯与非金属尾矿发泡轻质材料的制备:按石墨烯与非金属尾矿发泡轻质材料层的配方准确称取非金属尾矿和石墨烯,放入共振混合系统中的混合筒中,使混合筒内的湿度达75%,密封后升温至50℃,在激振器输出的振动频率为50-75Hz的条件下处理15-20s,加入配方中的其它原料,然后进入高速旋转混合机混合均化10-300min,经过喷雾造粒处理,烘干,进入储蓄仓备用,得到石墨烯与非金属尾矿发泡轻质材料;
(3)装饰面材料的制备:按装饰面层的配方准确称取非金属尾矿和石墨烯,放入共振混合系统中的混合筒中,使混合筒内的湿度达75%,密封后升温至50℃,在激振器输出的振动频率为50-75Hz的条件下处理15-20s,加入配方中的其它原料,然后进入高速旋转混合机混合均化10-150min,经过喷雾造粒处理,烘干,进入储蓄仓备用,得到装饰面材料;
(4)二次压模:将石墨烯与非金属尾矿发泡轻质材料放进压模成型机中,在压力为3-5MPa的条件下进行第一次压模,得到石墨烯与非金属尾矿发泡轻质材料层,然后以石墨烯与非金属尾矿发泡轻质材料层为基体的基础上二次压制装饰面材料层,得到二次压模成品;
(5)烘干烧成:将二次压模成品放入辊道窑或者隧道窑内,经900-1300℃高温烧制30-300min,冷却后取出,经打磨、抛光、切割成形,得到基于石墨烯与非金属尾矿发泡轻质装饰一体板成品。
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