CN110342948A - 一种闭孔型隔音保温耐火板材及其制备方法 - Google Patents
一种闭孔型隔音保温耐火板材及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种闭孔型隔音保温耐火板材及其制备方法，包括基料层、中间层、面料层、面釉层、装饰层和保护釉层，基料层的上方设置中间层，中间层的内部设置有均匀排布的孔洞，孔洞为其特有的闭孔结构，兼具传统陶瓷产品的耐火、阻燃、耐酸碱等性能，同时具有重量轻、隔音、隔热等特点，通过采用陶瓷行业的施釉废泥和难以处理的抛光回收料为主要原料，制成绿色节能产品，在废物利用的同时，满足装修装饰需求，降低建筑物载荷，减少建筑陶瓷对资源、能源、社会资源的综合消耗，基料、中间料和面料的热膨胀系数和收缩率接近，可以减少层间应力，保障产品的平整度，避免后期出现形变，增强本闭孔型隔音保温耐火板材的生产质量。
Description
技术领域
本发明涉及建筑陶瓷废料利用技术领域，具体为一种闭孔型隔音保温耐火板材及其制备方法。
背景技术
陶瓷行业在研磨、抛光的过程中会产生大量的抛光废料，这种抛光废料粒度很细，风干后呈分散状态，极易随风飘落到各处，会严重威胁周围人群的身体健康，并造成周边土地的板结，导致严重的环境污染，而抛光废料的填埋，不但耗费人力、物力，还会污染地下水质，据统计：平均每生产1平方米抛光砖将形成1.5公斤左右的砖屑，同时，磨具的损耗约0.6公斤左右，总之，制造1平方米的抛光砖大致形成2.1公斤左右的抛光废料，抛光废料的处理是一直困扰抛光砖生产的行业难题，抛光废料的有效利用已成为陶瓷行业生产所面临的最紧迫的课题，目前抛光废料的处理多为填埋方式，这样既需要堆场，从经济和环境上讲又都不合理，既占用土地，又影响周边环境。
发明内容
本发明的目的在于提供一种闭孔型隔音保温耐火板材及其制备方法，通过采用陶瓷行业的施釉废泥和难以处理的抛光回收料为主要原料，制成绿色节能产品，相对正常工艺本次成型的压力适度降低，便于烧成时坯体排气，减少因排气不良造成的鼓包变形，基料、中间料和面料的热膨胀系数和收缩率接近，可以减少层间应力，保障产品的平整度，避免后期出现形变，将窑炉预热带适当延长，使坯体在到达烧成温度前充分排气，减少因排气不良造成的鼓包、针孔、凹陷等表面缺陷，增强本闭孔型隔音保温耐火板材的生产质量，在废物利用的同时，满足装修装饰需求，降低建筑物载荷，减少建筑陶瓷对资源、能源、社会资源的综合消耗，以解决上述背景技术中提出的问题。
为实现上述目的，本发明提供如下技术方案：一种闭孔型隔音保温耐火板材，包括基料层、中间层、面料层、面釉层、装饰层和保护釉层，基料层的上方设置中间层，中间层的内部设置有均匀排布的孔洞，中间层的上方依次设置面料层、面釉层、装饰层和保护釉层，保护釉层设置为最外层。
优选的，所述孔洞设置为相互独立的封闭式微孔结构。
优选的，所述中间层的表观密度为0.5～1.0g/cm3或1.0～1.5g/cm3。
优选的，所述中间层的孔隙率为30％～60％。
优选的，所述基料层的厚度设置为1～3mm。
优选的，所述面料层的的厚度设置为1～3mm。
一种如权利要求所述的闭孔型隔音保温耐火板材的制备方法，包括以下步骤：
S1：先将抛光回收料均化处理后备用，按开立的中间料配方进行配料，再将配好的原料加入球磨机，加水球磨5～8h后得到料浆；
S2：将得到的料浆经过筛除铁后采用喷雾干燥方式制粉，得到中间料；
S3：将得到的中间料陈腐24小时后与颗粒基料、微粉面料采用三次布料的方式压制成型，得到坯体，
S4：在坯体表面添加面釉，得到面釉层，然后在面釉层上喷墨打印装饰图案，得到装饰层，最后在装饰层上添加保护釉，施釉重量为120～200g/m2，得到保护釉层；
S5：将按以上步骤得到的生坯入窑炉烧成，得到半成品后进行后期加工，拣选和包装，得到成品。
优选的，所述S1中提及的中间料配方为抛光回收料30～75份，施釉回收料0～15份，长石0～25份，粘土20～55份，石英为2～15份，添加剂为0.5～2份。
优选的，所述S1中提及的抛光回收料的化学组成为：65～75％SiO2、15～20％Al2O3、3～6％K2O+Na2O、0.1～1％CaO、2～6％MgO、0.1～0.6％Fe2O3、0.1～0.5％TiO2、烧失2～4％。
优选的，所述S3中提及的颗粒基料的含水率为6％～9％，且30目筛上的颗粒级配不超过5％，30～40目之间的颗粒级配为5％～10％，40～60目之间的颗粒级配为35％～45％，60～80目之间的颗粒级配为20％～30％，80～120目之间的颗粒级配为10％～20％，120～170目之间的颗粒级配为5～10％，170目筛下的颗粒级配不超过5％。
优选的，所述S5中所提及的窑炉预热带节数为30节，烧成带节数为4节，烧成温度为1120～1230℃，烧成周期60～90min。
优选的，所述S3中的成型压力设置为20～25MPa。
与现有技术相比，本发明的有益效果是：
1、本发明提供的一种闭孔型隔音保温耐火板材及其制备方法，采用陶瓷行业的施釉废泥和难以处理的抛光回收料为主要原料，制成绿色节能产品，夹心式结构更便于对表面和地面进行其他装饰和加工，防污性能更好，在废物利用的同时，满足装修装饰需求，降低建筑物载荷，减少建筑陶瓷对资源、能源、社会资源的综合消耗。
2、本发明提供的一种闭孔型隔音保温耐火板材及其制备方法，孔洞为其特有的闭孔结构，兼具传统陶瓷产品的耐火、阻燃、耐酸碱等性能，同时具有重量轻、隔音、隔热等特点，是节能环保型的绿色产品。
3、本发明提供的一种闭孔型隔音保温耐火板材及其制备方法，在成型过程中的成型压力设置为20～25MPa，相对正常工艺本次成型的压力适度降低，便于烧成时坯体排气，减少因排气不良造成的鼓包变形，基料、中间料和面料的热膨胀系数和收缩率接近，可以减少层间应力，保障产品的平整度，避免后期出现形变，将窑炉预热带适当延长，使坯体在到达烧成温度前充分排气，减少因排气不良造成的鼓包、针孔、凹陷等表面缺陷，增强本闭孔型隔音保温耐火板材的生产质量。
附图说明
图1为本发明的闭孔型隔音保温耐火板材结构示意图；
图2为本发明的附图1中A部分结构放大示意图；
图3为本发明的闭孔型隔音保温耐火板材制造方法的工艺流程示意图。
图中：1、基料层；2、中间层；21、孔洞；3、中间层；4、面釉层；5、装饰层；6、保护釉层。
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。
请参阅图1-3，一种闭孔型隔音保温耐火板材，包括基料层1、中间层2、中间层3、面釉层4、装饰层5和保护釉层6，基料层1的上方设置中间层2，中间层2的内部设置有均匀排布的孔洞21，中间层2的上方依次设置中间层3、面釉层4、装饰层5和保护釉层6，保护釉层6设置为最外层，夹心式结构更便于对表面和地面进行其他装饰和加工，防污性能更好，孔洞21设置为相互独立的封闭式微孔结构，孔洞21的孔径可通过配方及烧成制度来调节，孔径的大小会影响材料的隔热、隔音性能，可以通过抛光回收料的用量及烧成温度加以调节，抛光回收料中存在发泡成分SiC、MgO、MgCl2以及少量的有机树脂等，有机树脂的分解温度大于1000℃，随着温度的升高，有机树脂燃尽，留下大量相互独立的闭口气孔，随着抛光回收料的用量增大、烧成温度的升高，气孔体积随之增大，冷却后最终形成存在大量封闭孔洞21的独特结构，此种闭孔结构的隔热、隔音性能要明显优于开孔结构，中间层2的表观密度为0.5～1.0g/cm3或1.0～1.5g/cm3，中间层2的孔隙率为30％～60％，基料层1的厚度设置为1～3mm，中间层3的的厚度设置为1～3mm。
一种闭孔型隔音保温耐火板材的制备方法，包括以下步骤：
步骤一：先将抛光回收料均化处理后备用，按开立的中间料配方进行配料，抛光回收料的化学组成为：65～75％SiO2、15～20％Al2O3、3～6％K2O+Na2O、0.1～1％CaO、2～6％MgO、0.1～0.6％Fe2O3、0.1～0.5％TiO2、烧失2～4％，中间料配方为抛光回收料30～75份，施釉回收料0～15份，长石0～25份，粘土20～55份，石英为2～15份，添加剂为0.5～2份，再将配好的原料加入球磨机，加水球磨5～8h后得到料浆；
步骤二：将得到的料浆经过筛除铁后采用喷雾干燥方式制粉，得到中间料；
步骤三：将得到的中间料陈腐24小时后与颗粒基料、微粉面料采用三次布料的方式压制成型，颗粒基料的含水率为6％～9％，且30目筛上的颗粒级配不超过5％，30～40目之间的颗粒级配为5％～10％，40～60目之间的颗粒级配为35％～45％，60～80目之间的颗粒级配为20％～30％，80～120目之间的颗粒级配为10％～20％，120～170目之间的颗粒级配为5～10％，170目筛下的颗粒级配不超过5％，成型压力设置为20～25MPa，相对正常工艺本次成型的压力适度降低，便于烧成时坯体排气，减少因排气不良造成的鼓包变形，得到坯体，基料、中间料和面料的热膨胀系数和收缩率接近，可以减少层间应力，保障产品的平整度，避免后期出现形变；
步骤四：在坯体表面添加面釉，得到面釉层4，然后在面釉层4上喷墨打印装饰图案，得到装饰层5，最后在装饰层5上添加保护釉，施釉重量为120～200g/m2，得到保护釉层6；
步骤五：将按以上步骤得到的生坯入窑炉烧成，窑炉预热带节数为30节，窑炉预热带适当延长，使坯体在到达烧成温度前充分排气，减少因排气不良造成的鼓包、针孔、凹陷等表面缺陷，烧成带节数为4节，烧成温度为1120～1230℃，烧成周期60～90min，得到半成品后进行后期加工，后加工工序包含磨边、刷抛中的一种或两种，拣选和包装，得到成品。
综上所述：本发明提供的一种闭孔型隔音保温耐火板材及其制备方法，采用陶瓷行业的施釉废泥和难以处理的抛光回收料为主要原料，制成绿色节能产品，夹心式结构更便于对表面和地面进行其他装饰和加工，防污性能更好，孔洞21为其特有的闭孔结构，兼具传统陶瓷产品的耐火、阻燃、耐酸碱等性能，同时具有重量轻、隔音、隔热等特点，是节能环保型的绿色产品，在成型过程中的成型压力设置为20～25MPa，相对正常工艺本次成型的压力适度降低，便于烧成时坯体排气，减少因排气不良造成的鼓包变形，基料、中间料和面料的热膨胀系数和收缩率接近，可以减少层间应力，保障产品的平整度，避免后期出现形变，将窑炉预热带适当延长，使坯体在到达烧成温度前充分排气，减少因排气不良造成的鼓包、针孔、凹陷等表面缺陷，增强本闭孔型隔音保温耐火板材的生产质量，在废物利用的同时，满足装修装饰需求，降低建筑物载荷，减少建筑陶瓷对资源、能源、社会资源的综合消耗。
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揭露的技术范围内，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 (12)
1.一种闭孔型隔音保温耐火板材，包括基料层(1)、中间层(2)、面料层(3)、面釉层(4)、装饰层(5)和保护釉层(6)，其特征在于：所述基料层(1)的上方设置中间层(2)，中间层(2)的内部设置有均匀排布的孔洞(21)，中间层(2)的上方依次设置面料层(3)、面釉层(4)、装饰层(5)和保护釉层(6)，保护釉层(6)设置为最外层。
2.如权利要求1所述的一种闭孔型隔音保温耐火板材，其特征在于：所述孔洞(21)设置为相互独立的封闭式微孔结构。
3.如权利要求1所述的一种闭孔型隔音保温耐火板材，其特征在于：所述中间层(2)的表观密度为0.5～1.0g/cm3或1.0～1.5g/cm3。
4.如权利要求1所述的一种闭孔型隔音保温耐火板材，其特征在于：所述中间层(2)的孔隙率为30％～60％。
5.如权利要求1所述的一种闭孔型隔音保温耐火板材，其特征在于：所述基料层(1)的厚度设置为1～3mm。
6.如权利要求1所述的一种闭孔型隔音保温耐火板材，其特征在于：所述面料层(3)的的厚度设置为1～3mm。
7.一种如权利要求1所述的闭孔型隔音保温耐火板材的制备方法，其特征在于，包括以下步骤：
S1：先将抛光回收料均化处理后备用，按开立的中间料配方进行配料，再将配好的原料加入球磨机，加水球磨5～8h后得到料浆；
S2：将得到的料浆经过筛除铁后采用喷雾干燥方式制粉，得到中间料；
S3：将得到的中间料陈腐24小时后与颗粒基料、微粉面料采用三次布料的方式压制成型，得到坯体；
S4：在坯体表面添加面釉，得到面釉层，然后在面釉层上喷墨打印装饰图案，得到装饰层，最后在装饰层上添加保护釉，施釉重量为120～200g/m2，得到保护釉层；
S5：将按以上步骤得到的生坯入窑炉烧成，得到半成品后进行后期加工，拣选和包装，得到成品。
8.如权利要求7所述的一种闭孔型隔音保温耐火板材的制备方法，其特征在于，所述S1中提及的中间料配方为抛光回收料30～75份，施釉回收料0～15份，长石0～25份，粘土20～55份，石英为2～15份，添加剂为0.5～2份。
9.如权利要求7所述的一种闭孔型隔音保温耐火板材的制备方法，其特征在于，所述S1中提及的抛光回收料的化学组成为：65～75％SiO2、15～20％Al2O3、3～6％K2O+Na2O、0.1～1％CaO、2～6％MgO、0.1～0.6％Fe2O3、0.1～0.5％TiO2、烧失2～4％。
10.如权利要求7所述的一种闭孔型隔音保温耐火板材的制备方法，其特征在于，所述S3中提及的颗粒基料的含水率为6％～9％，且30目筛上的颗粒级配不超过5％，30～40目之间的颗粒级配为5％～10％，40～60目之间的颗粒级配为35％～45％，60～80目之间的颗粒级配为20％～30％，80～120目之间的颗粒级配为10％～20％，120～170目之间的颗粒级配为5～10％，170目筛下的颗粒级配不超过5％。
11.如权利要求7所述的一种闭孔型隔音保温耐火板材的制备方法，其特征在于，所述S5中所提及的窑炉预热带节数为30节，烧成带节数为4节，烧成温度为1120～1230℃，烧成周期60～90min。
12.如权利要求7所述的一种闭孔型隔音保温耐火板材的制备方法，其特征在于，所述S3中的成型压力设置为20～25MPa。
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