CN109400110A - 一种硅藻土烧结板及其制备工艺 - Google Patents
一种硅藻土烧结板及其制备工艺 Download PDFInfo
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Abstract
本发明公开了一种硅藻土烧结板及其制备工艺,所述硅藻土烧结板,包括坯料和釉料,所述坯料由以下质量百分比的原料组成:硅藻土原矿40~67%、吉林土10~30%、碳酸钠0.5~1.5%、硅灰石3~5%、滑石4~10%,废瓷颗粒5~15%、玄武岩纤维0.5~1.5%;所述釉料由以下质量百分比的原料组成:硅藻土助滤剂44~56%,水洗高岭土5~15%,熔块20~30%,碳酸钠1~3%,碳酸钙3~7%,滑石4~10%,电气石1~3%。本发明利用挤出成型的方法制备大尺寸硅藻烧结板材的工艺,所述烧结板除了具有传统板材的装饰效果,更具有祛除室内有害气体、自动调节空气湿度、释放负氧离子等功能。
Description
技术领域
本发明涉及一种装饰板材及制备工艺,具体涉及一种硅藻土烧结板及其制备工艺。
背景技术
随着人们生活水平的逐渐提高,人们对生活、工作的环境要求也越来越高,装饰装修材料也逐渐向绿色化、多功能化、一体化方向发展。
硅藻土是远古微生物经过亿万年沉积形成的,原料内部具有大量的纳米级孔隙,这些孔隙赋予了硅藻土极强的吸附能力,可以自动调节空气湿度以及祛除室内有害气体。随着人们对硅藻土认知的加深,硅藻土的功能性也不断被人们所了解,硅藻土也越来越多的被应用在装饰装修材料领域,如涂料领域出现了硅藻涂料、硅藻泥,内墙砖领域出现了硅藻砖等,但是在板材领域一直未出现硅藻板材相关产品,因为受到硅藻土原料特性以及成型方法的制约,硅藻板材类产品的生产工艺一直没有得到有效的解决,产品尺寸无法向大规格发展。
发明内容
本发明的技术任务是针对以上现有技术的不足,公开了一种硅藻土烧结板及其制备工艺,利用挤出成型的方法制备大尺寸硅藻烧结板材的工艺,所述烧结板除了具有传统板材的装饰效果,更具有祛除室内有害气体、自动调节空气湿度、释放负氧离子等功能,所述工艺有效解决了硅藻板材在生产过程中出现的各种问题。
本发明解决上述技术问题所采用的技术方案是:一种硅藻土烧结板,包括坯料和釉料,所述坯料由以下质量百分比的原料组成:硅藻土原矿40~67%、吉林土10~30%、碳酸钠0.5~1.5%、硅灰石3~5%、滑石4~10%,废瓷颗粒5~15%、玄武岩纤维0.5~1.5%;所述釉料由以下质量百分比的原料组成:硅藻土助滤剂44~56%,水洗高岭土5~15%,熔块20~30%,碳酸钠1~3%,碳酸钙3~7%,滑石4~10%,电气石1~3%。
采用上述组成的原料制备硅藻土烧结板的工艺,包括如下步骤:
(1)坯料混合:按照质量百分比,称取各组分原料混合均匀后待用;
(2)坯料造粒:将混合好的原料送入搅拌造粒机中,同时在原料中加水混合搅拌,造粒后待用;
(3)坯料陈腐:将混合好的原料送入料仓中,密封陈腐,使原料水分分散均匀;
(4)挤出成型:将陈腐好的原料送入挤出成型机中,通过挤出成型方法制备出硅藻土板坯;
(5)板坯烘干:将挤出成型的硅藻土板坯送入烘干窑中,利用低温烘干将板坯内多余的水分排出后待用;
(6)釉料混合:按照质量百分比,称取各组分原料混合均匀后待用;
(7)釉料球磨:将混合好的釉料送入球磨机中,加水使釉料得到充分球磨;
(8)板坯施釉:通过施釉线将球磨好的釉料均匀喷淋在硅藻土板坯上;
(9)板坯烧结:将施釉后的硅藻土板坯送入辊道窑中,经过烧结后得到硅藻烧结板材产品。
进一步地,所述步骤(1)中原料的粒度应满足通过标准筛60~150目之间。
进一步地,所述步骤(2)中坯料的含水率应控制在25~30%。
进一步地,所述步骤(3)中造粒原料陈腐时间应控制在24~48小时内。
进一步地,所述步骤(4)中挤出成型机的真空压力范围为-0.6~-0.8Mpa之间。
进一步地,所述步骤(5)中板坯烘干温度应控制在105~130℃,烘干过程中的空气湿度应保持在70~90%之间。
进一步地,所述步骤(6)中原料的粒度应满足通过标准筛60~150目之间。
进一步地,所述步骤(7)釉料球磨过程中,釉料含水率应控制在40~50%之间,浆料的粒度应满足全部通过325目标准筛。
进一步地,所述步骤(8)中板坯的施釉量应控制在40~80克/平方米。
进一步地,所述步骤(9)中板坯的烧结温度应控制在800-1100℃。
与现有技术相比,本发明的有益效果为:
1.本发明利用挤出成型的方法可以随意调节产品长度、宽度以及厚度,实现产品尺寸的可定制化;
2.本发明所述的烧结板除了具有传统板材质地坚、强度高、重量轻、装饰性强等特点外,由于原料硅藻土内部具有大量的纳米级孔隙,这些孔隙赋予了硅藻土极强的吸附能力,使烧结板还具有祛除室内有害气体、自动调节空气湿度、释放负氧离子等功能,实现了产品功能性的一体化。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白,以下结合实施例,对本发明进行进一步详细说明。应当理解,此处所描述的具体实施例仅用以解释本发明,并不用于限定本发明。
实施例1
本实施例中,制备硅藻土烧结板,包括坯料和釉料,以质量百分比计,所述坯料的所用原料及配比为:硅藻土原矿67%、吉林土20%、碳酸钠0.5%、硅灰石3%、滑石4%,废瓷颗粒5%、玄武岩纤维0.5%;所述釉料的所用原料及配比为:硅藻土助滤剂55%,水洗高岭土5%,熔块30%,碳酸钠2%,碳酸钙3%,滑石4%,电气石1%。
采用上述原料制备硅藻土烧结板的工艺,包括如下步骤:
(1)坯料混合:称取各组分原料,原料的粒度应满足通过标准筛60~150目之间,将原料混合均匀后待用;
(2)坯料造粒:将混合好的原料送入搅拌造粒机中,同时在原料中加入适量的水,控制含水率在30%,混合搅拌,造粒后待用;
(3)坯料陈腐:将混合好的原料送入料仓中,密封陈腐,使原料水分分散均匀,陈腐时间控制在48小时;
(4)挤出成型:将陈腐好的原料送入挤出成型机中,通过挤出成型方法制备出硅藻土板坯,挤出真空压力控制在-0.7Mpa;
(5)板坯烘干:将挤出成型的硅藻土板坯送入烘干窑中,利用低温烘干板坯,烘干温度控制在130℃,湿度控制在90%,将板坯内多余的水分排出后待用;
(6)釉料混合:按照质量百分比,称取各组分原料混合均匀后待用;原料的粒度应满足通过标准筛60~150目之间,将原料混合均匀后待用;
(7)釉料球磨:将混合好的釉料送入球磨机中,引入适量的水,控制釉料的含水率为50%,釉料得到充分球磨,釉料的粒度应满足全部通过325目标准筛;
(8)板坯施釉:通过施釉线将球磨好的釉料均匀喷淋在硅藻土板坯上,施釉量控制在40克/平方米;
(9)板坯烧结:将施釉后的硅藻土板坯送入辊道窑中,经过烧结后得到硅藻烧结板材产品,烧结温度控制在1000℃。
实施例2
本实施例中,制备硅藻土烧结板,包括坯料和釉料,以质量百分比计,所述坯料的所用原料及配比为:硅藻土原矿57%、吉林土20%、碳酸钠1.5%、硅灰石5%、滑石6%,废瓷颗粒10%、玄武岩纤维0.5%;所述釉料的所用原料及配比为:硅藻土助滤剂56%,水洗高岭土10%,熔块20%,碳酸钠1%,碳酸钙5%,滑石6%,电气石2%。
采用上述原料制备硅藻土烧结板的工艺,包括如下步骤:
(1)坯料混合:称取各组分原料,原料的粒度应满足通过标准筛60~150目之间,将原料混合均匀后待用;
(2)坯料造粒:将混合好的原料送入搅拌造粒机中,同时在原料中加入适量的水,控制含水率在28%,混合搅拌,造粒后待用;
(3)坯料陈腐:将混合好的原料送入料仓中,密封陈腐,使原料水分分散均匀,陈腐时间控制在36小时;
(4)挤出成型:将陈腐好的原料送入挤出成型机中,通过挤出成型方法制备出硅藻土板坯,挤出真空压力控制在-0.8Mpa;
(5)板坯烘干:将挤出成型的硅藻土板坯送入烘干窑中,利用低温烘干板坯,烘干温度控制在105℃,湿度控制在70%,将板坯内多余的水分排出后待用;
(6)釉料混合:按照质量百分比,称取各组分原料混合均匀后待用;原料的粒度应满足通过标准筛60~150目之间,将原料混合均匀后待用;
(7)釉料球磨:将混合好的釉料送入球磨机中,引入适量的水,控制釉料的含水率为40%,釉料得到充分球磨,釉料的粒度应满足全部通过325目标准筛;
(8)板坯施釉:通过施釉线将球磨好的釉料均匀喷淋在硅藻土板坯上,施釉量控制在80克/平方米;
(9)板坯烧结:将施釉后的硅藻土板坯送入辊道窑中,经过烧结后得到硅藻烧结板材产品,烧结温度控制在1100℃。
实施例3
本实施例中,制备硅藻土烧结板,包括坯料和釉料,以质量百分比计,所述坯料的所用原料及配比为:所用原料及配比为:硅藻土原矿65%、吉林土10%、碳酸钠1%、硅灰石5%、滑石8%,废瓷颗粒10%、玄武岩纤维1%;所述釉料的所用原料及配比为:硅藻土助滤剂44%,水洗高岭土15%,熔块20%,碳酸钠3%,碳酸钙7%,滑石8%,电气石3%。
采用上述原料制备硅藻土烧结板的工艺,包括如下步骤:
(1)坯料混合:称取各组分原料,原料的粒度应满足通过标准筛60~150目之间,将原料混合均匀后待用;
(2)坯料造粒:将混合好的原料送入搅拌造粒机中,同时在原料中加入适量的水,控制含水率在30%,混合搅拌,造粒后待用;
(3)坯料陈腐:将混合好的原料送入料仓中,密封陈腐,使原料水分分散均匀,陈腐时间控制在24小时;
(4)挤出成型:将陈腐好的原料送入挤出成型机中,通过挤出成型方法制备出硅藻土板坯,挤出真空压力控制在-0.8Mpa;
(5)板坯烘干:将挤出成型的硅藻土板坯送入烘干窑中,利用低温烘干板坯,烘干温度控制在120℃,湿度控制在80%,将板坯内多余的水分排出后待用;
(6)釉料混合:按照质量百分比,称取各组分原料,混合均匀后待用;原料的粒度应满足通过标准筛60~150目之间,将原料混合均匀后待用;
(7)釉料球磨:将混合好的釉料送入球磨机中,引入适量的水,控制釉料的含水率为45%,釉料得到充分球磨,釉料的粒度应满足全部通过325目标准筛;
(8)板坯施釉:通过施釉线将球磨好的釉料均匀喷淋在硅藻土板坯上,施釉量控制在60克/平方米;
(9)板坯烧结:将施釉后的硅藻土板坯送入辊道窑中,经过烧结后得到硅藻烧结板材产品,烧结温度控制在800℃。
实施例4
本实施例中,制备硅藻土烧结板,包括坯料和釉料,以质量百分比计,所述坯料的所用原料及配比为:硅藻土原矿40%、吉林土30%、碳酸钠0.5%、硅灰石3%、滑石10%,废瓷颗粒15%、玄武岩纤维1.5%;所述釉料的所用原料及配比为:硅藻土助滤剂51%,水洗高岭土5%,熔块25%,碳酸钠1%,碳酸钙5%,滑石10%,电气石3%。
采用上述原料制备硅藻土烧结板的工艺,包括如下步骤:
(1)坯料混合:称取各组分原料,原料的粒度应满足通过标准筛60~150目之间,将原料混合均匀后待用;
(2)坯料造粒:将混合好的原料送入搅拌造粒机中,同时在原料中加入适量的水,控制含水率在25%,混合搅拌,造粒后待用;
(3)坯料陈腐:将混合好的原料送入料仓中,密封陈腐,使原料水分分散均匀,陈腐时间控制在24小时;
(4)挤出成型:将陈腐好的原料送入挤出成型机中,通过挤出成型方法制备出硅藻土板坯,挤出真空压力控制在-0.6Mpa;
(5)板坯烘干:将挤出成型的硅藻土板坯送入烘干窑中,利用低温烘干板坯,烘干温度控制在105℃,湿度控制在80%,将板坯内多余的水分排出后待用;
(6)釉料混合:按照质量百分比,称取各组分原料混合均匀后待用;原料的粒度应满足通过标准筛60~150目之间,将原料混合均匀后待用;
(7)釉料球磨:将混合好的釉料送入球磨机中,引入适量的水,控制釉料的含水率为45%,釉料得到充分球磨,釉料的粒度应满足全部通过325目标准筛;
(8)板坯施釉:通过施釉线将球磨好的釉料均匀喷淋在硅藻土板坯上,施釉量控制在40克/平方米;
(9)板坯烧结:将施釉后的硅藻土板坯送入辊道窑中,经过烧结后得到硅藻烧结板材产品,烧结温度控制在900℃。
按照上述各实施例的工艺方法制备的板材,其性能测试数据见表1:
表1性能测试数据表
以上所述仅为本发明的实施例,并非因此限制本发明的专利范围,凡是利用本发明说明书内容所作的等效结构或等效流程变换,或直接或间接运用在其他相关的技术领域,均同理包括在本发明的专利保护范围内。
Claims (10)
1.一种硅藻土烧结板,其特征在于:包括坯料和釉料,所述坯料由以下质量百分比的原料组成:硅藻土原矿40~67%、吉林土10~30%、碳酸钠0.5~1.5%、硅灰石3~5%、滑石4~10%,废瓷颗粒5~15%、玄武岩纤维0.5~1.5%;所述釉料由以下质量百分比的原料组成:硅藻土助滤剂44~56%,水洗高岭土5~15%,熔块20~30%,碳酸钠1~3%,碳酸钙3~7%,滑石4~10%,电气石1~3%。
2.一种权利要求1所述的硅藻土烧结板的制备工艺,其特征在于:包括如下步骤:
(1)坯料混合:按照质量百分比,称取各组分原料混合均匀后待用;
(2)坯料造粒:将混合好的原料送入搅拌造粒机中,同时在原料中加水混合搅拌,造粒后待用;
(3)坯料陈腐:将混合好的原料送入料仓中,密封陈腐,使原料水分分散均匀;
(4)挤出成型:将陈腐好的原料送入挤出成型机中,通过挤出成型方法制备出硅藻土板坯;
(5)板坯烘干:将挤出成型的硅藻土板坯送入烘干窑中,利用低温烘干将板坯内多余的水分排出后待用;
(6)釉料混合:按照质量百分比,称取各组分原料混合均匀后待用;
(7)釉料球磨:将混合好的釉料送入球磨机中,加水使釉料得到充分球磨;
(8)板坯施釉:通过施釉线将球磨好的釉料均匀喷淋在硅藻土板坯上;
(9)板坯烧结:将施釉后的硅藻土板坯送入辊道窑中,经过烧结后得到硅藻烧结板材产品。
3.根据权利要求2所述的硅藻土烧结板的制备工艺,其特征在于:所述步骤(2)中坯料的含水率应控制在25~30%。
4.根据权利要求2所述的硅藻土烧结板的制备工艺,其特征在于:所述步骤(3)中造粒原料陈腐时间应控制在24~48小时内。
5.根据权利要求2所述的硅藻土烧结板的制备工艺,其特征在于:所述步骤(4)中挤出成型机的真空压力范围为-0.6~-0.8Mpa之间。
6.根据权利要求2所述的硅藻土烧结板的制备工艺,其特征在于:所述步骤(5)中板坯烘干温度应控制在105~130℃,烘干过程中的空气湿度应保持在70~90%之间。
7.根据权利要求2所述的硅藻土烧结板的制备工艺,其特征在于:所述步骤(1)、(6)中原料的粒度应满足通过标准筛60~150目之间。
8.根据权利要求2所述的硅藻土烧结板的制备工艺,其特征在于:所述步骤(7)釉料球磨过程中,釉料含水率应控制在40~50%之间,浆料的粒度应满足全部通过325目标准筛。
9.根据权利要求2所述的硅藻土烧结板的制备工艺,其特征在于:所述步骤(8)中板坯的施釉量应控制在40~80克/平方米。
10.根据权利要求2所述的硅藻土烧结板的制备工艺,其特征在于:所述步骤(9)中板坯的烧结温度应控制在800~1100℃。
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