CN109987959A - 一种新型瓷砂及其制备方法 - Google Patents

一种新型瓷砂及其制备方法 Download PDF

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CN109987959A
CN109987959A CN201910147692.5A CN201910147692A CN109987959A CN 109987959 A CN109987959 A CN 109987959A CN 201910147692 A CN201910147692 A CN 201910147692A CN 109987959 A CN109987959 A CN 109987959A
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杨道辉
周波
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HUNAN LILING PUKOU HUAGAO ELECTRIC CERAMIC AND ELECTRICAL APPLIANCE CO Ltd
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Abstract

本发明涉及一种瓷砂,公开了一种新型瓷砂及其制备方法,包括如下质量份数的原料:MgCO3 4~6份、石英0.4~0.8份、莫来石0.4~0.8份、Al2O3 0.2~0.6份、Fe2O3 0.2~0.6份、CaO 0.8~1.2份、Na2O 0.8~1.2份、K2O 0.8~1.2份,制备方法:按照质量份数的比例将MgCO3、石英、莫来石、Al2O3、Fe2O3、CaO、Na2O、K2O放入球磨机后球磨混合;经过榨泥,并用真空练泥机挤制成泥段;在大窑中以弱还原焰烧结,烧结温度为1225℃,然后粉碎成0.5~1.0mm的颗粒而制成。本发明制备的瓷砂坯料中石英、莫来石的含量相应减少,焙烧时出现短柱堇青石晶体,降低了瓷的膨胀系数,同时由于特制瓷砂和棕釉构成的胶砂层的膨胀系数小于瓷主体,在产品的外表面上形成了一层具有预压应力的胶砂层,其机械强度要强于普通瓷砂产品,保证产品质量的可靠性。

Description

一种新型瓷砂及其制备方法
技术领域
本发明涉及一种瓷砂,具体为一种新型瓷砂及其制备方法。
背景技术
由于目前采用的瓷砂胶装的产品在进行弯曲破坏试验时,出现瓷套断裂位置不在危险端面(下端法兰胶装砂位置),而是在法兰与瓷套胶装水泥中间部位。这种比例也较大,根据目前弯曲破坏试验统计的数量,约占25%左右,因为它没有充分发挥瓷质具有的机械强度,稳定产品的机械性能,保证产品质量的可靠性。
随着国外客户市场的开拓,对于强度要求越来越高,目前现有的工艺不能充分发挥瓷质具有的机械强度。
发明内容
本发明的目的在于提供一种新型瓷砂及其制备方法,本发明制备的瓷砂降低了瓷的膨胀系数,同时由于特制瓷砂和棕釉构成的胶砂层的膨胀系数小于瓷主体,在产品的外表面上形成了一层具有预压应力的胶砂层,其机械强度要强于普通瓷砂产品,保证产品质量的可靠性,以解决上述背景技术中提出的瓷砂机械强度不能满足要求的问题。
为实现上述目的,本发明提供如下技术方案:一种新型瓷砂,包括如下质量份数的原料:MgCO3 4~6份、石英0.4~0.8份、莫来石0.4~0.8份、Al2O3 0.2~0.6份、Fe2O3 0.2~0.6份、CaO 0.8~1.2份、Na2O 0.8~1.2份、K2O 0.8~1.2份。
进一步地,包括如下质量份数的原料:MgCO3 4份、石英0.8份、莫来石0.4份、Al2O30.6份、Fe2O3 0.6份、CaO 1.2份、Na2O 1.2份、K2O 1.2份。
进一步地,包括如下质量份数的原料:MgCO3 5份、石英0.6份、莫来石0.6份、Al2O30.4份、Fe2O3 0.4份、CaO 1份、Na2O 1份、K2O 1份。
进一步地,包括如下质量份数的原料:MgCO3 6份、石英0.4份、莫来石0.8份、Al2O30.2份、Fe2O3 0.2份、CaO 0.8份、Na2O 0.8份、K2O 0.8份。
本发明提供另一种技术方案:一种新型瓷砂的制备方法,包括如下步骤:
步骤1:按照质量份数的比例将MgCO3、石英、莫来石、Al2O3、Fe2O3、CaO、Na2O、K2O放入球磨机后球磨混合;
步骤2:经过榨泥,并用真空练泥机挤制成泥段;
步骤3:在大窑中以弱还原焰烧结,烧结温度为1225℃,然后粉碎成0.5~1.0mm的颗粒而制成。
进一步地,MgCO3在焙烧过程中发生如下反应:
与现有技术相比,本发明的有益效果是:
1.本发明提出的新型瓷砂及其制备方法,由于在坯料中加入MgCO3,在焙烧过程中,MgCO3在350℃左右就开始分解,分解时所产生的CO2排出坯外,使坯体内部的空位增多所致,同时这也降低了瓷坯的烧结温度,玻璃相也相应增多,气孔膨胀,显示出过烧的特征,气孔多呈圆形,孔径较大,分布也较均匀。
2.本发明提出的新型瓷砂及其制备方法,坯料中石英、莫来石的含量相应减少,焙烧时出现约1~2μm的短柱堇青石晶体,降低了瓷的膨胀系数,同时由于特制瓷砂和棕釉构成的胶砂层的膨胀系数小于瓷主体,在产品的外表面上形成了一层具有预压应力的胶砂层,其机械强度要强于普通瓷砂产品,保证产品质量的可靠性。
附图说明
图1为本发明的工艺流程图。
具体实施方式
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
本发明实施例中:一种新型瓷砂,包括如下质量份数的原料:MgCO3 4~6份、石英0.4~0.8份、莫来石0.4~0.8份、Al2O3 0.2~0.6份、Fe2O3 0.2~0.6份、CaO 0.8~1.2份、Na2O 0.8~1.2份、K2O 0.8~1.2份。
实施例1
取如下质量份数的原料:MgCO3 4份、石英0.8份、莫来石0.4份、Al2O30.6份、Fe2O30.6份、CaO 1.2份、Na2O 1.2份、K2O 1.2份。
基于上述原料配比,提供一种新型瓷砂的制备方法,工艺流程如图1,包括以下步骤:
步骤1:按照上述质量份数的比例将MgCO3、石英、莫来石、Al2O3、Fe2O3、CaO、Na2O、K2O放入球磨机后球磨混合;
步骤2:经过榨泥,并用真空练泥机挤制成泥段;
步骤3:在大窑中以弱还原焰烧结,烧结温度为1225℃,MgCO3在350℃左右开始分解,分解时所产生的CO2排出坯外,使坯体内部的空位增多所致,同时这也降低了瓷坯的烧结温度,玻璃相也相应增多,气孔膨胀,气孔多呈圆形,孔径较大,分布也较均匀,显示出过烧的特征,然后粉碎成0.5~1.0mm的颗粒而制成。
实施例2
取如下质量份数的原料:MgCO3 5份、石英0.6份、莫来石0.6份、Al2O30.4份、Fe2O30.4份、CaO 1份、Na2O 1份、K2O 1份。
基于上述原料配比,提供一种新型瓷砂的制备方法,工艺流程如图1,包括以下步骤:
步骤1:按照上述质量份数的比例将MgCO3、石英、莫来石、Al2O3、Fe2O3、CaO、Na2O、K2O放入球磨机后球磨混合;
步骤2:经过榨泥,并用真空练泥机挤制成泥段;
步骤3:在大窑中以弱还原焰烧结,烧结温度为1225℃,MgCO3在350℃左右开始分解,分解时所产生的CO2排出坯外,使坯体内部的空位增多所致,同时这也降低了瓷坯的烧结温度,玻璃相也相应增多,气孔膨胀,气孔多呈圆形,孔径较大,分布也较均匀,显示出过烧的特征,然后粉碎成0.5~1.0mm的颗粒而制成。
实施例3
取如下质量份数的原料:MgCO3 6份、石英0.4份、莫来石0.8份、Al2O30.2份、Fe2O30.2份、CaO 0.8份、Na2O 0.8份、K2O 0.8份。
基于上述原料配比,提供一种新型瓷砂的制备方法,工艺流程如图1,包括以下步骤:
步骤1:按照上述质量份数的比例将MgCO3、石英、莫来石、Al2O3、Fe2O3、CaO、Na2O、K2O放入球磨机后球磨混合;
步骤2:经过榨泥,并用真空练泥机挤制成泥段;
步骤3:在大窑中以弱还原焰烧结,烧结温度为1225℃,MgCO3在350℃左右开始分解,分解时所产生的CO2排出坯外,使坯体内部的空位增多所致,同时这也降低了瓷坯的烧结温度,玻璃相也相应增多,气孔膨胀,气孔多呈圆形,孔径较大,分布也较均匀,显示出过烧的特征,然后粉碎成0.5~1.0mm的颗粒而制成。
本发明的瓷砂中石英、莫来石的含量相应减少,石英的熔融边变宽,而在玻璃基质中,出现约1~2μm的短柱堇青石晶体,该晶体在薄片中无色透明,折射率介于石英和树脂之间,颗粒均匀。在二次气孔边缘的玻璃相中,有时可观察到10~20μm的短柱状堇青石晶体。这是由于坯料中加入MgCO3后,在焙烧过程中出现下列反应的结果:
对特殊瓷砂进行X射线衍射分析,也证明了堇青石的存在,由于特殊瓷砂中存在堇青石晶体,因此,降低了瓷的膨胀系数(堇青石晶体的膨胀系数为2.60x10-6)。另外一方面,MgO不可能都消耗到堇青石的结晶反应中去,有一部分作为熔挤熔解于玻璃相中,使玻璃相的成分改变,降低了瓷坯的烧结温度。玻璃相的含量增多,也使膨胀系数降低。实际测得的特殊瓷砂的膨胀系数为3.91x10-6(20℃~600℃)。
本发明对瓷砂进行显微结构与上砂强度分析可知,瓷砂种类及粒度均对试样及产品的弯曲强度有很大的影响。经过试验对比,上特殊瓷砂的试棒的强度与目前生产的瓷砂提高8~10%。提高瓷体外部胶砂层的强度及使之产生预压应力,有利于提高瓷套的弯曲强度,并且通过对比试验,发现之后断裂位置都正常。
本发明对制备的特殊瓷砂进行物理性能分析,与现有的瓷砂进行比较,比较结果如下表:
通过上表可知,本发明制备的特殊瓷砂的膨胀系数为3.91x10-6,小于目前瓷砂的5.03x10-6膨胀系数,而本发明制备的特殊瓷砂未上釉的试棒弯曲强度为139kgf/cm2,现有的瓷砂未上釉的试棒弯曲强度为125kgf/cm2,由此可知,特殊瓷砂的未上釉试棒弯曲强度大于现有瓷砂的未上釉试棒弯曲强度,本发明制备的特殊瓷砂上生产棕釉的试棒弯曲强度为162kgf/cm2,现有的瓷砂上生产棕釉的试棒弯曲强度为146kgf/cm2,由此可知,特殊瓷砂的上釉试棒弯曲强度大于现有瓷砂上釉试棒弯曲强度,这是由于特制瓷砂和棕釉构成的胶砂层的膨胀系数小于瓷主体,在产品的外表面上形成了一层具有预压应力的胶砂层,所以,其机械强度要强于普通瓷砂产品的机械强度,保证了产品质量的可靠性。
综上所述:本发明提出的新型瓷砂及其制备方法,由于在坯料中加入MgCO3,在焙烧过程中,MgCO3在350℃左右就开始分解,分解时所产生的CO2排出坯外,使坯体内部的空位增多所致,同时这也降低了瓷坯的烧结温度,玻璃相也相应增多,气孔膨胀,显示出过烧的特征,气孔多呈圆形,孔径较大,分布也较均匀。坯料中石英、莫来石的含量相应减少,焙烧时出现约1~2μm的短柱堇青石晶体,降低了瓷的膨胀系数,同时由于特制瓷砂和棕釉构成的胶砂层的膨胀系数小于瓷主体,在产品的外表面上形成了一层具有预压应力的胶砂层,其机械强度要强于普通瓷砂产品的机械强度,保证了产品质量的可靠性。
以上所述,仅为本发明较佳的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明披露的技术范围内,根据本发明的技术方案及其发明构思加以等同替换或改变,都应涵盖在本发明的保护范围之内。

Claims (6)

1.一种新型瓷砂,其特征在于,包括如下质量份数的原料:MgCO3 4~6份、石英0.4~0.8份、莫来石0.4~0.8份、Al2O3 0.2~0.6份、Fe2O3 0.2~0.6份、CaO 0.8~1.2份、Na2O 0.8~1.2份、K2O 0.8~1.2份。
2.根据权利要求1所述的一种新型瓷砂,其特征在于,包括如下质量份数的原料:MgCO34份、石英0.8份、莫来石0.4份、Al2O3 0.6份、Fe2O3 0.6份、CaO 1.2份、Na2O 1.2份、K2O 1.2份。
3.根据权利要求1所述的一种新型瓷砂,其特征在于,包括如下质量份数的原料:MgCO35份、石英0.6份、莫来石0.6份、Al2O3 0.4份、Fe2O3 0.4份、CaO 1份、Na2O 1份、K2O 1份。
4.根据权利要求1所述的一种新型瓷砂,其特征在于,包括如下质量份数的原料:MgCO36份、石英0.4份、莫来石0.8份、Al2O3 0.2份、Fe2O3 0.2份、CaO 0.8份、Na2O 0.8份、K2O 0.8份。
5.一种根据权利要求1-4任一项所述的新型瓷砂的制备方法,其特征在于,包括如下步骤:
S1:按照质量份数的比例将MgCO3、石英、莫来石、Al2O3、Fe2O3、CaO、Na2O、K2O放入球磨机后球磨混合;
S2:经过榨泥,并用真空练泥机挤制成泥段;
S3:在大窑中以弱还原焰烧结,烧结温度为1225℃,然后粉碎成0.5~1.0mm的颗粒而制成。
6.根据权利要求5所述的一种新型瓷砂的制备方法,其特征在于,MgCO3在焙烧过程中发生如下反应:
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