CN108975892B - 制备喷墨渗花玉质抛光砖的方法及喷墨渗花玉质抛光砖 - Google Patents

制备喷墨渗花玉质抛光砖的方法及喷墨渗花玉质抛光砖 Download PDF

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CN108975892B
CN108975892B CN201810979649.0A CN201810979649A CN108975892B CN 108975892 B CN108975892 B CN 108975892B CN 201810979649 A CN201810979649 A CN 201810979649A CN 108975892 B CN108975892 B CN 108975892B
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ink
brick
finished green
finished
jet
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CN108975892A (zh
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林伟
范新晖
廖花妹
刘畅
潘婷
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Foshan Shiwan Eagle Brand Ceramics Co Ltd
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Foshan Shiwan Eagle Brand Ceramics Co Ltd
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Abstract

本申请提供一种制备喷墨渗花玉质抛光砖的方法及喷墨渗花玉质抛光砖。所述方法包括以下步骤：砖坯原料加适量的水经球磨成为浆料，然后喷雾干燥得到粉料，再液压成型得到半成品砖坯，将半成品砖坯干燥得到成品砖坯；在成品砖坯的表面喷一层水雾，控制成品砖坯的表面温度为40－50℃，然后在成品砖坯的表面喷施酸化剂，控制作用时间10‑30min，再用适量去离子水清洗表面；在清洗后的成品砖坯的表面喷施助渗剂，间隔5‑10min后进行喷墨打印渗花，然后进行烧制，最高烧成温度为1250‑1280℃，得到半成品；经过磨边、抛光、打蜡，得到产品。本申请提供的方法及喷墨渗花玉质抛光砖，光透性能好、图案纹理清晰、质感贴近玉石。

Description

制备喷墨渗花玉质抛光砖的方法及喷墨渗花玉质抛光砖
技术领域
本发明涉及陶瓷领域，具体而言，涉及一种制备喷墨渗花玉质抛光砖的方法及喷墨渗花玉质抛光砖。
背景技术
喷墨渗花技术制造得到的玉质砖，具有天然石材质地细腻、柔润、通透、色彩丰富的特点，经常被一些高档场所用作背景墙、点缀景观墙等高档装饰，显得富丽堂皇、高档典雅，集装饰性、欣赏性与一体，具有非常可观的经济效益。
现有技术中，有使用喷墨渗花技术进行玉质砖制造的，但是存在以下缺陷：第一，由于砖坯成分的原因，导致成品的光透性能不够好，性能距天然玉石还很远，装饰性、观赏性不够；第二，由于现有技术中的坯体、酸化剂、助渗剂以及墨水之间的相互作用与兼容问题，使得得到产品的花色和纹理渗透不可控，横向渗透和纵向渗透深度不容易控制，使得整体质量难以均衡控制，导致产品难以大规模批量生产。
有鉴于此，特提出本发明。
发明内容
本发明的第一目的在于提供的一种制备喷墨渗花玉质抛光砖的方法，能够获得光透性能好，仿天然石材度高、质感贴近玉石，图案纹理清晰、观赏性好，质量稳定的砖。
本发明的第二目的在于提供上述喷墨渗花玉质抛光砖。
为了实现本发明的上述目的，特采用以下技术方案：
一种制备喷墨渗花玉质抛光砖的方法，包括以下步骤：
A.砖坯原料加适量的水经球磨成为浆料，然后喷雾干燥得到粉料，再液压成型得到半成品砖坯，将所述半成品砖坯干燥得到成品砖坯；
所述砖坯原料以质量百分比计，包括：Al2O320-25％、SiO265-75％、 Fe2O30.1-0.2％、TiO20.1-0.2％、CaO0.1-0.2％、K2O1-3％、Na2O2-6％、 MgO0.1-0.2％、Li2O0.2-0.5％、P2O50.1-0.2％、RuO20.1-0.2％、V2O50.1-0.2％、 Bi2O30.1-0.2％、Ce2O30.1-0.2％、LiNbO30.1-0.2％、SrZrO30.1-0.2％、十水合硫酸钠0.05-0.1％、六硝基合钴酸铵钠0.05-0.1％、三聚磷酸钠0.05-0.1％和铋酸钠0.05-0.1％；
所述粉料以质量百分比计，粒度分布为：100-200目40％，200-250目 35％，300-350目25％；
B.在所述成品砖坯的表面喷一层水雾，控制所述成品砖坯的表面温度为40-50℃，然后在所述成品砖坯的表面喷施酸化剂，控制作用时间 10-30min，再用适量去离子水清洗表面；
C.在清洗后的所述成品砖坯的表面喷施助渗剂，间隔5-10min后进行喷墨打印渗花，然后进行烧制，最高烧成温度的范围为1250-1280℃，得到半成品；
D.经过磨边、抛光、打蜡，得到产品。
除了砖坯的常见成分之外，RuO2、V2O5、Bi2O3、Ce2O3、LiNbO3、SrZrO3这些成分在高温状态下，能够形成改善渗透性能的微观结构，能够有效的控制横向渗透和纵向渗透的程度，此外，这些成分提供部分颜色构成，与渗花墨水配合，形成更加贴近天然玉石的纹理和颜色，同时改善整体的通透性。十水合硫酸钠和三聚磷酸钠的作用是提高砖坯各成分之间的均匀性，保证产品整体的质量，避免产生局部瑕疵；同时，六硝基合钴酸铵钠和铋酸钠的使用可以进一步改善产品的光透性能。粒度控制，一方面是改善渗透性能，提高渗透的可控性，避免出现残次品；另一方面是为了调整产品的硬度，使其更加靠近天然玉石。酸化剂的使用是为了破坏砖坯的表面的结构，使得渗花墨水更容易渗透。助渗剂的使用，是为了帮助渗花墨水的渗透。助渗剂与酸化剂的配合，使得渗透处于一种平衡的可控的状态。酸化剂作用完毕之后用去离子水清洗，是为了避免残留的酸化剂对助渗剂的作用产生负面影响，该负面影响会导致喷墨时表面渗透不均衡、不可控。最高烧成温度的控制，是与砖坯成分相适应的，尤其是RuO2、V2O5、Bi2O3、 Ce2O3、LiNbO3、SrZrO3这些成分；在这一温度条件下，各组分形成恰当的熔融和半熔融状态，为渗透墨水在砖坯内的分布，创造合适的条件，获得品质贴近天然玉石的渗花玉质抛光砖。
优选地，所述烧制的过程为：先用1h升温至500℃，再用1h升温至 900℃，再用1h升温至1200℃，最后用30-40min升至所述最高烧成温度，并保持0.5-1h；然后用2-3h降至常温。
烧制时，为了获得更好的烧制效果，保证产品各部分的质量均匀，升温速度要逐渐放慢，尤其是在最高烧成温度附近，为了保证RuO2、V2O5、 Bi2O3、Ce2O3、LiNbO3、SrZrO3这些成分发挥最佳的作用，获得最佳的色彩、光透性能，升温速度尤其要慢，而且要精准，才能得到更加贴近玉石的高端抛光砖产品。
进一步优选地，所述抛光的过程为：依次使用300目尼龙纤维抛光模块1组、400目尼龙纤维抛光模块2组、500目麻纤维抛光模块2组和600 目羊毛纤维抛光模块3组进行抛光。
抛光方法有很多，上述方法可以最大程度的获得最佳产品表面，保证整体质量效果。
优选地，所述成品砖坯的含水量为总质量的3-5％。
砖坯中含水量的控制，是为了在保证烧制后产品强度的基础上，避免烧制时产生微气孔影响产品质量，避免产生瑕疵。
更加优选地，所述水雾的量为40-60g/m2。
喷水雾的目的，主要是为了给干燥后的砖坯降温，控制酸化剂的作用时间，避免温度高影响酸化剂效果。
优选地，所述酸化剂为弱酸的水溶液，pH值为4.2-5.8；所述弱酸为醋酸、碳酸、次氯酸、氢氟酸中的一种或多种；
所述助渗剂，按重量份数计，包括硅溶胶50-80份、醋酸乙烯乳液20-40 份、脂肪醇聚氧乙烯醚5-10份。
弱酸的选择、pH值的控制是为了控制酸化剂对砖坯表面的破坏行为，使渗花墨水的渗透处于可控范围。需要说明的是，酸化剂的pH值是随着喷雾量的调整进行调整的。
更加优选地，所述酸化剂的喷剂量为30-50g/m2，所述助渗剂的喷剂量为40-60g/m2。
喷剂量的控制是为了进一步对渗透行为进行控制，保证产品质量的稳定性。
优选地，所述步骤B中，用去离子水清洗表面至表面pH值为6.7-7.0。
控制清洗后的砖坯表面的pH值，是为了保证渗透剂在表面的作用效果均匀可控。
本申请提供一种喷墨渗花玉质抛光砖，使用所述的方法制得。
与现有技术相比，本发明的有益效果为：
1.通过选择砖坯的成分，尤其是RuO2、V2O5、Bi2O3、Ce2O3、LiNbO3、 SrZrO3这些成分在高温状态下，能够形成改善渗透性能的微观结构，能够有效的控制横向渗透和纵向渗透的程度，形成更加贴近天然玉石的纹理和颜色，同时改善整体的通透性；
2.助渗剂与酸化剂的配合，使得渗透处于一种平衡的可控的状态，可以获得性能优异的产品；
3.粒度控制，可以改善渗透性能，提高渗透的可控性，避免出现残次品；同时调整了产品的硬度，使其更加靠近天然玉石；
4.喷水雾可以给干燥后的砖坯降温，控制酸化剂的作用时间，避免温度高影响酸化剂效果；用去离子水清洗表面是为了保证渗透剂在表面的作用效果均匀可控。
具体实施方式
下面将结合实施例对本发明的实施方案进行详细描述，但是本领域技术人员将会理解，下列实施例仅用于说明本发明，而不应视为限制本发明的范围。实施例中未注明具体条件者，按照常规条件或制造商建议的条件进行。所用试剂或仪器未注明生产厂商者，均为可以通过市售购买获得的常规产品。
实施例1
按照下述步骤制备喷墨渗花玉质抛光砖：
1、选取相应的材料，如钾长石、钠长石、石英、粘土等原材料，控制成分为Al2O322％、SiO268.6％、Fe2O30.15％、TiO20.15％、CaO0.15％、K2O3％、 Na2O4％、MgO0.15％、Li2O0.5％、P2O50.15％、RuO20.15％、V2O50.15％、 Bi2O30.15％、Ce2O30.1％、LiNbO30.1％、SrZrO30.1％、十水合硫酸钠0.1％、六硝基合钴(Ⅲ)酸铵钠0.1％、三聚磷酸钠0.1％和铋酸钠0.1％；砖坯原料加适量的水经球磨成为浆料，然后喷雾干燥得到粉料，粉料的粒度分布为： 100-200目40％，200-250目35％，300-350目25％；再液压成型得到半成品砖坯，将半成品砖坯干燥得到成品砖坯，成品砖坯的含水量为总质量的 3％；
2、在成品砖坯的表面喷一层水雾，水雾的量为60g/m2，控制成品砖坯的表面温度为40℃，然后在成品砖坯的表面喷施酸化剂，控制喷剂量为 50g/m2，控制作用时间10min，再用适量去离子水清洗表面，至表面pH值为6.7；
酸化剂制备方法为：取适量碳酸和次氯酸，调节pH值至5.8，得到弱酸水溶液；
3、在清洗后的成品砖坯的表面喷施助渗剂，助渗剂的喷剂量为40g/m2，间隔10min后进行喷墨打印渗花，然后进行烧制，烧制的过程为：先用1h 升温至500℃，再用1h升温至900℃，再用1h升温至1200℃，最后用30min 升至所述最高烧成温度1250℃，并保持1h；然后用3h降至常温，得到半成品；
助渗剂制备方法为：取硅溶胶80份、醋酸乙烯乳液20份、脂肪醇聚氧乙烯醚5份，混合均匀得到助渗剂；
4、经过磨边、抛光、打蜡，得到产品。抛光的过程为：依次使用300 目尼龙纤维抛光模块1组、400目尼龙纤维抛光模块2组、500目麻纤维抛光模块2组和600目羊毛纤维抛光模块3组进行抛光。
实施例2
按照下述步骤制备喷墨渗花玉质抛光砖：
1、选取相应的材料，如钾长石、钠长石、石英、粘土等原材料，控制成分为Al2O325％、SiO265％、Fe2O30.2％、TiO20.2％、CaO0.2％、K2O2％、Na2O6％、 MgO0.2％、Li2O0.24％、P2O50.1％、RuO20.1％、V2O50.1％、Bi2O30.1％、 Ce2O30.12％、LiNbO30.12％、SrZrO30.12％、十水合硫酸钠0.05％、六硝基合钴(Ⅲ)酸铵钠0.05％、三聚磷酸钠0.05％和铋酸钠0.05％；砖坯原料加适量的水经球磨成为浆料，然后喷雾干燥得到粉料，粉料的粒度分布为： 100-200目40％，200-250目35％，300-350目25％；再液压成型得到半成品砖坯，将半成品砖坯干燥得到成品砖坯，成品砖坯的含水量为总质量的 5％；
2、在成品砖坯的表面喷一层水雾，水雾的量为40g/m2，控制成品砖坯的表面温度为50℃，然后在成品砖坯的表面喷施酸化剂，控制喷剂量为 30g/m2，控制作用时间30min，再用适量去离子水清洗表面，至表面pH值为7.0；
酸化剂制备方法为：取适量醋酸和氢氟酸，调节pH值至4.6，得到弱酸水溶液；
3、在清洗后的成品砖坯的表面喷施助渗剂，助渗剂的喷剂量为60g/m2，间隔5min后进行喷墨打印渗花，然后进行烧制，烧制的过程为：先用1h 升温至500℃，再用1h升温至900℃，再用1h升温至1200℃，最后用40min 升至最高烧成温度1280℃，并保持0.5h；然后用2h降至常温，得到半成品；
助渗剂制备方法为：取硅溶胶65份、醋酸乙烯乳液30份、脂肪醇聚氧乙烯醚7份，混合均匀得到助渗剂；
4、经过磨边、抛光、打蜡，得到产品。抛光的过程为：依次使用300 目尼龙纤维抛光模块1组、400目尼龙纤维抛光模块2组、500目麻纤维抛光模块2组和600目羊毛纤维抛光模块3组进行抛光。
实施例3
按照下述步骤制备喷墨渗花玉质抛光砖：
1、选取相应的材料，如钾长石、钠长石、石英、粘土等原材料，控制成分为Al2O323％、SiO267％、Fe2O30.2％、TiO20.2％、CaO0.2％、K2O3％、Na2O5％、 MgO0.18％、Li2O0.2％、P2O50.1％、RuO20.1％、V2O50.1％、Bi2O30.1％、 Ce2O30.1％、LiNbO30.1％、SrZrO30.1％、十水合硫酸钠0.08％、六硝基合钴 (Ⅲ)酸铵钠0.08％、三聚磷酸钠0.08％和铋酸钠0.08％；砖坯原料加适量的水经球磨成为浆料，然后喷雾干燥得到粉料，粉料的粒度分布为：100-200 目40％，200-250目35％，300-350目25％；再液压成型得到半成品砖坯，将半成品砖坯干燥得到成品砖坯，成品砖坯的含水量为总质量的4％；
2、在成品砖坯的表面喷一层水雾，水雾的量为50g/m2，控制成品砖坯的表面温度为45℃，然后在成品砖坯的表面喷施酸化剂，控制喷剂量为 40g/m2，控制作用时间20min，再用适量去离子水清洗表面，至表面pH值为6.8；
酸化剂制备方法为：取适量醋酸，调节pH值至4.2，得到弱酸水溶液；
3、在清洗后的成品砖坯的表面喷施助渗剂，助渗剂的喷剂量为50g/m2，间隔8min后进行喷墨打印渗花，然后进行烧制，烧制的过程为：先用1h 升温至500℃，再用1h升温至900℃，再用1h升温至1200℃，最后用35min 升至最高烧成温度1265℃，并保持0.8h；然后用2.5h降至常温，得到半成品；
助渗剂制备方法为：取硅溶胶50份、醋酸乙烯乳液40份、脂肪醇聚氧乙烯醚10份，混合均匀得到助渗剂；
4、经过磨边、抛光、打蜡，得到产品。抛光的过程为：依次使用300 目尼龙纤维抛光模块1组、400目尼龙纤维抛光模块2组、500目麻纤维抛光模块2组和600目羊毛纤维抛光模块3组进行抛光。
比较例1
与实施例1相比，不同之处在于，砖坯中不含有RuO2、V2O5、Bi2O3、 Ce2O3、LiNbO3、SrZrO3、十水合硫酸钠、六硝基合钴(Ⅲ)酸铵钠、三聚磷酸钠和铋酸钠；
比较例2
与实施例2相比，不同之处在于，用适量去离子水清洗表面至表面pH 值为6.5；
比较例3
与实施例3相比，不同之处在于，助渗剂不含脂肪醇聚氧乙烯醚；
比较例4
与实施例1相比，不同之处在于，烧制过程为：总的烧制时间为2h，最高烧成温度为1220℃。
比较例5
与实施例2相比，不同之处在于，使用研磨刷进行抛光。
测试实施例1－3和比较例1-5 所得的500组产品的参数得到平均值，结果如下表1所示：
表1测试结果
Figure BDA0001778198770000101
需要说明的是，上表1中良品率的检测标准是：表面无裂纹、表面平整度小于2mm、渗花深度和广度可控且误差不超过5％；光直线透过率是指在光照强度为1000w/m2的平行光源照射下，在光源背侧使用光照度计测得的光强占光源光强的比率。其中，翡翠的最大光直线透过率为12.67％。
由上表1可知，RuO2、V2O5、Bi2O3、Ce2O3、LiNbO3、SrZrO3十水合硫酸钠、六硝基合钴(Ⅲ)酸铵钠、三聚磷酸钠和铋酸钠的添加，能够有效的改善成品的光透性能，使其获得更加近似于玉石的效果，同时能够对渗花的横向和纵向进行控制，保证良品率，也能提高强度；对于清洗后pH值的控制，是为了控制渗花效果，进而影响良品率；助渗剂成分的选择，尤其是脂肪醇聚氧乙烯醚的使用，是为了控制助渗剂的效果，保证渗花工艺可控，提高良品率；烧制过程的控制，是与砖坯成分相匹配的，有利于优化内部及表面结构，提高光透性能和强度；抛光方式的选择，是为了最终保证产品的整体的效果。
本申请提供的喷墨渗花玉质抛光砖，光透性能好、图案纹理清晰、质感贴近玉石，强度高。
对于本领域的技术人员来说，本申请可以有各种更改和变化。凡在本申请的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本申请的保护范围之内。尽管已用具体实施例来说明和描述了本发明，然而应意识到，在不背离本发明的精神和范围的情况下可以作出许多其它的更改和修改。因此，这意味着在所附权利要求中包括属于本发明范围内的所有这些变化和修改。

Claims (9)

1.一种制备喷墨渗花玉质抛光砖的方法，其特征在于，包括以下步骤：
A.砖坯原料加适量的水经球磨成为浆料，然后喷雾干燥得到粉料，再液压成型得到半成品砖坯，将所述半成品砖坯干燥得到成品砖坯；
所述砖坯原料以质量百分比计，包括：Al2O320-25％、SiO265-75％、Fe2O30.1-0.2％、TiO2 0.1-0.2％、CaO 0.1-0.2％、K2O 1-3％、Na2O 2-6％、MgO 0.1-0.2％、Li2O 0.2-0.5％、P2O5 0.1-0.2％、RuO2 0.1-0.2％、V2O5 0.1-0.2％、Bi2O3 0.1-0.2％、Ce2O3 0.1-0.2％、LiNbO3 0.1-0.2％、SrZrO3 0.1-0.2％、十水合硫酸钠0.05-0.1％、六硝基合钴酸铵钠0.05-0.1％、三聚磷酸钠0.05-0.1％和铋酸钠0.05-0.1％；
所述粉料以质量百分比计，粒度分布为：100-200目40％，200-250目35％，300-350目25％；
B.在所述成品砖坯的表面喷一层水雾，控制所述成品砖坯的表面温度为40-50℃，然后在所述成品砖坯的表面喷施酸化剂，控制作用时间10-30min，再用适量去离子水清洗表面；
C.在清洗后的所述成品砖坯的表面喷施助渗剂，间隔5-10min后进行喷墨打印渗花，然后进行烧制，最高烧成温度的范围为1250-1280℃，得到半成品；
D.经过磨边、抛光、打蜡，得到产品。
2.根据权利要求1所述的方法，其特征在于，所述烧制的过程为：先用1h升温至500℃，再用1h升温至900℃，再用1h升温至1200℃，最后用30-40min升至所述最高烧成温度，并保持0.5-1h；然后用2-3h降至常温。
3.根据权利要求1所述的方法，其特征在于，所述抛光的过程为：依次使用300目尼龙纤维抛光模块1组、400目尼龙纤维抛光模块2组、500目麻纤维抛光模块2组和600目羊毛纤维抛光模块3组进行抛光。
4.根据权利要求1所述的方法，其特征在于，所述成品砖坯的含水量为总质量的3-5％。
5.根据权利要求1所述的方法，其特征在于，所述水雾的量为40-60g/m2。
6.根据权利要求1所述的方法，其特征在于，所述酸化剂为弱酸的水溶液，pH值为4.2-5.8；所述弱酸为醋酸、碳酸、次氯酸、氢氟酸中的一种或多种；
所述助渗剂，按重量份数计，包括硅溶胶50-80份、醋酸乙烯乳液20-40份、脂肪醇聚氧乙烯醚5-10份。
7.根据权利要求6所述的方法，其特征在于，所述酸化剂的喷剂量为30-50g/m2，所述助渗剂的喷剂量为40-60g/m2。
8.根据权利要求1所述的方法，其特征在于，所述步骤B中，用去离子水清洗表面至表面pH值为6.7-7.0。
9.一种喷墨渗花玉质抛光砖，其特征在于，使用权利要求1-8任一项所述的方法制得。
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