CN109437869B - Permeable ceramic powder and preparation method and application thereof - Google Patents
Permeable ceramic powder and preparation method and application thereof Download PDFInfo
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Abstract
The invention relates to a penetrating ceramic powder and a preparation method and application thereof, wherein the penetrating ceramic powder comprises the following raw materials: by mass, 12-18% of clay, 40-60% of sodium-potassium sand, 10-30% of high-temperature sand, 6-20% of pyrophyllite, 1.5-3.5% of toughening agent, 2.0-4.0% of reddening agent and 0.3-0.6% of yellowing aid.
Description
Technical Field
The invention belongs to the field of ceramic building materials, and particularly relates to a permeable ceramic powder and a preparation method and application thereof.
Background
At present, ceramic permeable powder is added with more special materials for color development assistance, so that on one hand, the slurry performance, the strength, the fluidity and the forming performance of the powder are extremely poor; secondly, the special working material can greatly reduce the size of the brick made of the ceramic permeable powder, increase the shrinkage and influence the brick shape, and particularly has great influence on the exhaust and distribution uniformity and the brick shape after firing in the forming process for producing large-size products.
Disclosure of Invention
In view of the above problems, the present invention aims to provide a permeable ceramic powder, a preparation method and an application thereof, wherein the permeable ceramic powder has characteristics of good color development, high wet strength of the powder, low dry strength of the powder, good fluidity and good forming performance, can reduce shrinkage, changes the difference of direct shrinkage of the facing material and the backing material, and improves brick shape.
In a first aspect, the present invention provides an infiltrated ceramic powder, the infiltrated ceramic powder comprising: by mass, 12-18% of clay, 40-60% of sodium-potassium sand, 10-30% of high-temperature sand, 6-20% of pyrophyllite, 1.5-3.5% of toughening agent, 2.0-4.0% of reddening agent and 0.3-0.6% of yellowing aid.
Compared with the existing formula, the penetrating ceramic powder has the advantages of good color development, higher powder wet strength (for example, more than 0.55 MPa), lower powder dry strength (for example, 0.80-0.95MPa), better fluidity and forming performance (no layering), capability of reducing shrinkage, change of difference of direct shrinkage of the surface material and the backing material and improvement of brick shape (the brick shape is controlled within a standard range). The permeable ceramic powder is particularly beneficial to secondary distribution of oversized ceramic plates and development of products with various colors.
Preferably, the chemical composition of the infiltrated ceramic powder comprises: by mass, IL (loss on ignition): 2.5-4.5%; SiO 22:67~71%;Al2O3:17.5~19.5%;Fe2O3:0.1~0.5%;TiO2:0.05~0.5%;CaO:0.1~0.8%;MgO:0.3~0.8%;K2O:3.5~5.5%;Na2O:2.5~4.0%。
Preferably, the toughening agent is selected from at least one of bentonite and montmorillonite.
Preferably, the reddening agent is active silicon dioxide, and the yellowing agent is ultrafine titanium dioxide.
In a second aspect, the present invention provides a method for preparing the above-mentioned infiltrated ceramic powder, comprising: preparing the raw materials into slurry, and then performing spray granulation to obtain the permeable ceramic powder.
Preferably, the water content of the slurry is 33-37 wt%, the flow rate is 30-50 seconds, and the specific gravity is 1.62-1.67 g/mL.
Preferably, the water content of the ceramic powder is 6-8.5%.
Preferably, the grain composition of the penetrating ceramic powder is as follows: 3-10% of 30 meshes; over 75 percent of 30-60 meshes; within 12% of 60-80 meshes; within 10% of 80 meshes.
Preferably, the flow rate of the infiltrated ceramic powder is less than 60 seconds.
In a third aspect, the present invention provides a ceramic tile made using any of the above infiltrated ceramic powders.
The breaking strength of the ceramic tile can be more than 41.66MPa, and the shrinkage rate can be 9.0-10.0%.
Detailed Description
The present invention is further illustrated by the following examples, which are to be understood as merely illustrative and not restrictive. The following percentages are by mass unless otherwise specified.
A infiltrated ceramic powder is disclosed. "penetrating ceramic powder" refers to a fabric used to prepare ceramic green bricks, which powder contributes to the color development of the penetrating ink.
According to the permeable ceramic powder disclosed by the invention, the raw material formula is adjusted, and the toughening agent and the pyrophyllite with good binding property are introduced, so that the wet strength of the powder can be improved, and the shrinkage can be reduced. In particular, the general characteristics of the permeable facing material are that the shrinkage is much larger than usual, and that the particles are required to be finer, and if the control is not good, various defects are generated in the production. The physical and chemical properties of the block copolymer are improved by introducing pyrophyllite and a toughening agent. In addition, the feedstock for the infiltrated ceramic powder of the present disclosure preferably has a relatively high degree of whiteness. For example whiteness above 68 deg..
The raw materials of the infiltrated ceramic powder according to an embodiment of the present invention include: by mass, 12-18% of clay, 40-60% of sodium-potassium sand, 10-30% of high-temperature sand, 6-20% of pyrophyllite, 1.5-3.5% of toughening agent, 2.0-4.0% of reddening agent and 0.3-0.6% of yellowing aid. The permeable ceramic powder has good whiteness and wet strength, and small shrinkage.
The clay is preferably a higher whiteness clay such as water-washed clay or the like. The whiteness can be improved by washing with water. The clay can play a role in improving the drying strength and the wet strength of the ceramic powder. If the clay content is too small, the powder properties are poor, and if the clay content is too large, the powder is colored. In a more preferred embodiment, the clay content is 14 to 16%.
The clay may be at least one selected from water-washed ball clay, Longyan ball clay, and the like.
The K/Na sand refers to sand having a high K/Na content ratio, for example, the K/Na content ratio may be 12% or more. The potassium sodium sand is preferably water-washed potassium sodium sand, so that the whiteness is better. The potassium sodium sand can reduce the sintering temperature of the formula and is beneficial to color development. If the content of the potassium-sodium sand is too small, the sintering temperature is higher, so that the modulus color development is not facilitated, and if the content of the potassium-sodium sand is too large, the sintering temperature is too low, the whiteness is not enough, and the grains of the base blank cloth are easy to leak out. In a more preferred embodiment, the content of the sodium potassium sand is 40 to 50%.
The potassium-sodium sand can be at least one selected from sodium feldspar powder, potassium feldspar powder and the like.
The high-temperature sand refers to sand with higher sintering temperature. The content of potassium and sodium in the high-temperature sand is less. The high-temperature sand can play a role in providing powder whiteness and is beneficial to the formation of a mullite crystal phase. If the high-temperature sand content is too low, the sintering temperature is too low, the whiteness is not enough, and if the high-temperature sand content is too high, the sintering temperature is too high, and the sintering is not favorable. In a more preferred embodiment, the content of the high-temperature sand is 10 to 15%.
The high-temperature sand can be at least one selected from super-white high-temperature sand, high-white potassium sand, super-white high-alumina sand and the like.
The pyrophyllite can improve whiteness and reduce size shrinkage. If the pyrophyllite content is too small, the whiteness is not enough, the size is smaller, and if the pyrophyllite content is too large, the sintering temperature is high, the potassium and sodium content in the formula is low, and the color development is not facilitated. In a more preferred embodiment, the pyrophyllite content is 10-15%.
The toughening agent can increase the strength of the powder. If the content of the toughening agent is too small, the wet strength of the powder is insufficient, and if the content of the toughening agent is too large, the strength of the powder is too large, and pores are easy to form.
The toughening agent can be at least one of high-whiteness bentonite and montmorillonite with better toughening performance.
The red-assisting agent can assist the red color development. The reddening aid can be, for example, active silica, which can play a reddening role when added in a small amount.
The yellowing promoter can promote yellow color development. If the content of the yellowing assistant is too small, the red and yellow color development is not facilitated, and if the content of the yellowing assistant is too large, the green brick turns yellow and is not facilitated to be fired. The yellowing promoter may be, for example, ultrafine titanium dioxide (e.g., having a particle size of 0.1mm), and may be added in a small amount to exert a yellowing promoting effect.
In one embodiment, the chemical composition of the infiltrated ceramic powder comprises IL (loss on ignition): 2.5-4.5%; SiO 22:67~71%;Al2O3:17.5~19.5%;Fe2O3:0.1~0.5%;TiO2:0.05~0.5%;CaO:0.1~0.8%;MgO:0.3~0.8%;K2O:3.5~5.5%;Na2O:2.5~4.0%。
In one embodiment, the water content penetrating through the ceramic powder is 6-8.5%, so that the performance of the powder can be effectively ensured, and when the water content is too low, the fluidity is good, but the surface cracks and delaminates, and particles are easy to break; too high moisture content, poor flowability, and also easy delamination and agglomeration.
In one embodiment, the grain composition of the infiltrated ceramic powder is: 3-10% of 30 meshes; over 75 percent of 30-60 meshes; within 12% of 60-80 meshes; within 10% of 80 meshes. The particle size distribution is small, so that the powder has good fluidity. The particle grading ensures the strength of powder, the uniformity of distribution, and is not easy to agglomerate, and can also ensure that the layering is not problematic.
In one embodiment, the flow rate of the infiltrated ceramic powder is less than 60 seconds. The flow rate here means that a flow cup with a diameter of 8mm is filled with the object to be measured, a small hole below the flow cup is opened, and the time from the beginning to the end of the flow of the object to be measured is recorded as the flow rate of the object to be measured.
The permeable ceramic powder disclosed by the invention has the advantages of better whiteness, small grain composition, good fluidity and higher wet strength, for example, the strength is doubled compared with that of the existing permeable fabric, the permeable ceramic powder is not easy to be crushed in the conveying process, and the permeable ceramic powder is particularly beneficial to secondary distribution of ceramic plates with ultra-large specifications. In addition, the shrinkage of the permeable ceramic powder is small, and is about 1% smaller than that of a common permeable fabric, so that the brick shape can be controlled better. In addition, the penetrating ceramic powder disclosed by the invention has good color development, and is beneficial to development of products with various colors.
In one embodiment of the present invention, the raw materials penetrating the ceramic powder are made into slurry and then granulated by spraying to obtain the penetrating ceramic powder.
In one example, each raw material is wet ball milled to obtain a slurry. The slurry may have a water content of 34 to 37wt%, a flow rate of 35 to 50 seconds, and a specific gravity of 1.64 to 1.67 g/mL.
Spraying the slurry by using a spray tower. The powder can be sieved and aged after powder spraying.
The moisture of the powder after powder spraying can be 6-8.5%. The particle size distribution of the powder material can be as follows: 3-10% of 30 meshes; over 75 percent of 30-60 meshes; within 12% of 60-80 meshes; within 10% of 80 meshes. The powder flowability may be less than 60 seconds (8mm caliber flow cup).
The penetrating ceramic powder of the invention can be used for preparing ceramic tiles. The method for producing the ceramic tile is described below as an example.
First, the cloth is carried out. Specifically, the ceramic powder may be impregnated with a cloth primer and cloth. The primer may be one commonly used in the art.
And then dry pressing and forming to obtain a green brick. The molding pressure can be 25-30 MPa.
Printing patterns on the green bricks. The printing method may be, for example, inkjet printing. The ink can penetrate into the tile blank.
And then sintering can be carried out to obtain the ceramic tile. Because the permeable ceramic powder is adopted, the shrinkage difference of the bottom fabric is small in the sintering process, the brick shape is better controlled, and the color development is good. For example, the shrinkage (i.e., the ratio of the size of the fired green brick to the size of the mold) of the ceramic tile may be 9.0 to 10.0%, such as 9.5 to 9.88%.
The invention has the following beneficial effects:
1. the grain grading is small, the fluidity is good, the wet strength is doubled compared with the strength of the normal permeable fabric, the fabric is not easy to be crushed in the conveying process, and the secondary distribution of the ceramic plate with the ultra-large specification is particularly facilitated;
2. the brick shape is good: compared with a common permeable fabric, the shrinkage is 1% less; the shrinkage difference of the bottom fabric is small in the firing process, so that the brick shape can be controlled well;
3. the color development is good: the permeable fabric has good color development, is beneficial to the development of products with various colors, and can develop some layouts with very red and black colors, for example.
The present invention will be described in detail by way of examples. It is also to be understood that the following examples are illustrative of the present invention and are not to be construed as limiting the scope of the invention, and that certain insubstantial modifications and adaptations of the invention by those skilled in the art may be made in light of the above teachings. The specific process parameters and the like of the following examples are also only one example of suitable ranges, i.e., those skilled in the art can select the appropriate ranges through the description herein, and are not limited to the specific values exemplified below.
Example 1
1. The formula is as follows: water washed ball clay (from southern motto company, majesty) 18%; albite powder (from ceramic raw materials corporation) 15%; 39% potassium feldspar powder (available from filling ceramics raw materials corporation); 13% of ultra-white high-temperature sand (purchased from gathering and ceramics materials Co., Ltd., Fushan city); pyrophyllite (ex bouillon huichi ltd): 10 percent; toughening agent (specifically, a mixture of montmorillonite and bentonite, available from pul corporation): 2.15 percent; red promoter (active silica, available from bayful corporation): 2.5 percent; 0.35% of yellow-assisting agent (superfine titanium dioxide, purchased from Ontai pigment Co., Ltd.).
2. And ball-milling the raw materials by a wet method to obtain slurry. The moisture content of the slurry is 37 percent; flow rate 35 seconds; the specific gravity is 1.64.
3. Spraying powder on the slurry by using a spray tower, wherein the water content of the powder after powder spraying is 7.5 percent, and the particle grading is 30 meshes to 8 percent; 76% of 30-60 meshes; 60-80 mesh 8%; 80 meshes below 8 percent. Powder flowability was 55 seconds (8mm caliber flow cup). The chemical components of the powder are as follows: 3.20 percent; SiO 22:68.95%;Al2O3:18.61%;Fe2O3:0.28%;TiO2:0.08%;CaO:0.50%;MgO:0.17%;K2O:4.88%;Na2O: 3.20 percent. The wet strength of the powder was tested by the following method: 150 g of powder is taken, and is subjected to pressure maintaining for 15 seconds by a small press (a mold is 8cm by 12cm, the pressure is 15MPa), and then the mold is released. The strength was measured with a flexural strength tester. The dry strength of the powder was tested by the following method: 150 g of powder is taken, pressure is maintained for 15 seconds by a small press (a mold is 8cm by 12cm, the pressure is 15MPa), then the mold is released, and the strength is measured by an anti-bending instrument after the powder is dried for 2 hours at the temperature of 130 ℃. Tests show that the wet strength of the powder is 0.55MPa and is higher than that of the common permeable powder (0.30 MPa); the dry strength is 0.9MPa and is lower than the dry strength (1.0MPa) of common infiltration powder.
4. The method for preparing the ceramic tile by using the obtained powder comprises the following specific steps: the powder is used as a plus material and is distributed with the backing material in a thin method, namely, in the distribution process, the powder is distributed on the backing material, and the thickness of the powder accounts for about 10 to 15 percent of the total thickness; pressing and molding by a press, drying, grinding, ink jetting, sintering and polishing to obtain the ceramic tile.
And testing the breaking strength of the ceramic tile by a ceramic breaking resistance instrument. The test shows that the flexural strength of the ceramic tile is 42.53MPa, the shrinkage rate is 9.53 percent and is lower than that of the common infiltration powder (10.5 percent).
Example 2
1. The formula is as follows: water washed ball clay (from southern motto company, majesty) 16%; 13% of albite powder (from ceramics raw materials company, pottery); potassium feldspar powder (available from general ceramics raw materials corporation) 42%; 10% of ultra-white high-temperature sand (purchased from gathering and ceramics materials Co., Ltd., Fushan city); pyrophyllite (ex bouillon huichi ltd): 13 percent; toughening agent (specifically, a mixture of montmorillonite and bentonite, available from pul corporation): 2 percent; red promoter (active silica, available from bayful corporation): 3.5 percent; 0.5% of yellowing assistant (superfine titanium dioxide, available from Ontai pigment Co., Ltd.).
2. And ball-milling the raw materials by a wet method to obtain slurry. The water content of the slurry is 35.5 percent; the flow rate was 40 seconds; the specific gravity was 1.68.
3. Spraying powder on the slurry by using a spray tower, wherein the moisture content of the powder after powder spraying is 7.0 percent, and the particle size distribution is 5.0 percent of 30 meshes; 78% of 30-60 meshes; 60-80 mesh 8.5%; 8.5 percent under 80 meshes. The powder was flowable for 50 seconds (8mm bore flow cup). The chemical components of the powder are as follows: 3.40 percent; SiO 22:70.19%;Al2O3:17.60%;Fe2O3:0.30%;TiO2:0.10%;CaO:0.40%;MgO:0.16%;K2O:4.80%;Na2O: 3.10 percent. Tests show that the wet strength of the powder is 0.60MPa, and the dry strength is 0.95 MPa.
4. The procedure of preparing ceramic tiles from the powder thus obtained was the same as in example 1.
The test shows that the breaking strength of the ceramic tile is 44.36MPa, and the shrinkage rate is 9.88%.
Example 3
1. The formula is as follows: water washed ball clay (from southern motto company, majesty) 18%; 13% of albite powder (from ceramics raw materials company, pottery); potassium feldspar powder (from filling ceramics raw materials corporation) 40%; 11.5 percent of ultra-white high-temperature sand (purchased from gathering and ceramics materials Co., Ltd., Fushan city); pyrophyllite (ex bouillon huichi ltd): 10 percent; toughening agent (specifically, a mixture of montmorillonite and bentonite, available from pul corporation): 1.5 percent; red promoter (active silica, available from bayful corporation): 3.0 percent; 0.4% of yellowing assistant (superfine titanium dioxide, available from Ontai pigment Co., Ltd.).
2. And ball-milling the raw materials by a wet method to obtain slurry. The water content of the slurry is 34 percent; flow rate 50 seconds; the specific gravity is 1.65.
3. Spraying powder on the slurry by using a spray tower, wherein the moisture of the powder after powder spraying is 6.5 percent, and the particle grading is 30 meshes to 10 percent; 77% of 30-60 meshes; 60-80 meshes 6%; 5.5 percent under 80 meshes. Powder flowability 57 seconds (8mm caliber flow cup). The chemical components of the powder are as follows: 3.80 percent; SiO 22:69.55%;Al2O3:18.2%;Fe2O3:0.0.26%;TiO2:0.11%;CaO:0.35%;MgO:0.12%;K2O:4.70%;Na2O: 3.15 percent. Tests show that the wet strength of the powder is 0.62MPa, and the dry strength is 0.92 MPa.
4. The procedure of preparing ceramic tiles from the powder thus obtained was the same as in example 1.
The test shows that the breaking strength of the ceramic tile is 41.66MPa, and the shrinkage rate is 9.77%.
Claims (9)
1. The permeable ceramic powder is characterized in that the permeable ceramic powder is a fabric which is conductive to ink permeation and is used for preparing ceramic adobes; the raw materials of the penetrating ceramic powder comprise: 12-18% of clay, 40-60% of sodium-potassium sand, 10-15% of high-temperature sand, 6-20% of pyrophyllite, 1.5-3.5% of toughening agent, 2.0-4.0% of reddening agent and 0.3-0.6% of yellowing aid by mass; the chemical composition of the infiltrated ceramic powder comprises: loss on ignition by mass: 2.5-4.5%; SiO 22:67~71%;Al2O3:17.5~19.5%;Fe2O3:0.1~0.5%;TiO2:0.05 ~0.5%;CaO:0.1~0.8%;MgO:0.3~0.8%;K2O:3.5~5.5%;Na2O:2.5~4.0%;
The permeable ceramic powder is used as a plus material and is distributed with a backing material by a thin method, in the distribution process, the powder is distributed on the backing material, the thickness of the powder accounts for 10-15% of the total thickness, and a green brick is obtained by pressing and forming through a press; the ratio of the size of the ceramic green brick prepared by the ceramic powder penetration after being fired to the size reduction of the die is 9.0-10.0%.
2. The infiltrated ceramic powder of claim 1, wherein said toughening agent is selected from at least one of bentonite and montmorillonite.
3. The infiltrating ceramic powder of claim 1, wherein the reddening aid is activated silica and the yellowing aid is ultrafine titanium dioxide.
4. A method for preparing an infiltrated ceramic powder according to any one of claims 1 to 3, comprising: preparing the raw materials into slurry, and then performing spray granulation to obtain the permeable ceramic powder.
5. The method according to claim 4, wherein the slurry has a water content of 33 to 37wt%, a flow rate of 30 to 50 seconds, and a specific gravity of 1.62 to 1.67 g/mL.
6. The method according to claim 4, wherein the infiltrated ceramic powder has a moisture content of 6 to 8.5%.
7. The method according to claim 4, characterized in that the grain composition of the infiltrated ceramic powder is: 3-10% of 30 meshes; over 75 percent of 30-60 meshes; within 12% of 60-80 meshes; within 10% of 80 meshes.
8. The method of claim 4, wherein the flow rate of the infiltrated ceramic powder is less than 60 seconds.
9. A ceramic tile made using the infiltrated ceramic powder of any one of claims 1-3.
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WO2007126178A1 (en) * | 2006-05-01 | 2007-11-08 | Shin Jong Jin | Bubble ceremic material with low weight and method for preparing thereof |
CN105367131A (en) * | 2015-12-07 | 2016-03-02 | 蒙娜丽莎集团股份有限公司 | Ink-jet penetrated polished semitransparent ceramic sheet, and preparation method thereof |
CN105777089A (en) * | 2016-04-01 | 2016-07-20 | 蒙娜丽莎集团股份有限公司 | Light-permeable tile and preparation method thereof |
CN108484144A (en) * | 2018-05-07 | 2018-09-04 | 蒙娜丽莎集团股份有限公司 | A kind of light penetrate after be in blue light ultrawhite light-transmittance ceramics thin plate and preparation method thereof |
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WO2007126178A1 (en) * | 2006-05-01 | 2007-11-08 | Shin Jong Jin | Bubble ceremic material with low weight and method for preparing thereof |
CN105367131A (en) * | 2015-12-07 | 2016-03-02 | 蒙娜丽莎集团股份有限公司 | Ink-jet penetrated polished semitransparent ceramic sheet, and preparation method thereof |
CN105777089A (en) * | 2016-04-01 | 2016-07-20 | 蒙娜丽莎集团股份有限公司 | Light-permeable tile and preparation method thereof |
CN108484144A (en) * | 2018-05-07 | 2018-09-04 | 蒙娜丽莎集团股份有限公司 | A kind of light penetrate after be in blue light ultrawhite light-transmittance ceramics thin plate and preparation method thereof |
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