CN111704450B - 一种陶瓷岩板的制备方法及陶瓷岩板 - Google Patents
一种陶瓷岩板的制备方法及陶瓷岩板 Download PDFInfo
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Abstract
本发明公开了一种陶瓷岩板的制备方法,其包括制备浆料、喷雾干燥得到粉料,并将部分粉料筛分后与剩余粉料混合,得到用于压成的粉料,压成,施釉装饰,然后烧成。本发明还公开了采用上述制备方法制备而得的陶瓷岩板。本发明的陶瓷岩板可良好地适应后期深加工工艺,可广泛应用在地板、幕墙、饰面领域,且其具有高强度、高硬度、耐酸碱、耐高温等优点。
Description
技术领域
本发明涉及陶瓷砖领域,具体涉及一种陶瓷岩板的制备方法及陶瓷岩板。
背景技术
随着人们的生活水平日渐提高,在装饰、装修材料的选择上,审美观也越来越个性化,更重视风格品味,对墙地面、幕墙、家具、橱柜、台面板等饰面材料在现代装修中的应用需求也越来越多。现有的饰面材料主要有天然石材和人造石英石。其中,人造石英石是指将树脂、石英、色料振压、在100~200℃固化后形成的板材,其由于含有树脂材料,硬度低,耐酸碱性差、不耐高温。天然石材虽然硬度相对较高,耐高温性能较良好,且色泽丰富,但是天然石材资源极为有限。
近年来,陶瓷大板逐渐被应用到装饰领域,其具有优良的耐酸碱性,硬度高(表面莫氏硬度可达到6级以上),耐高温等优点,因此,具有极其广阔的应用前景。根据国家标准(GB/T 23266-2009)的规定,陶瓷板的表面积不小于1.62m2,厚度不大于6mm;目前行业内生产的陶瓷大板厚度也多在10mm以内,这种陶瓷大板可加工性差,可适用于大规格幕墙或地面的铺贴,但是难以利用到饰面领域。因此,需要对陶瓷大板进行进一步开发。
近一年来,行业推出了陶瓷岩板,其厚度可达到12~20mm,适应深加工工艺,可应用在地面、幕墙、家居装饰领域。然而,现有的岩板,其尺寸多为1200×1600mm2、2400×1800mm2、2400×1200mm2等规格,仍然无法满足大型家居装饰(灶台、橱柜、浴室柜等)的要求。另一方面,现有的岩板生产系统不成熟,导致干燥裂砖、运输裂砖多,干燥合格率低于95%;同样的,烧成合格率也较低,在90%左右。此外,现有的陶瓷岩板,在加工的过程中,极易破裂,根据统计,现有岩板的加工破裂率达到65%以上,成为了困扰行业的极大难题。一般认为,岩板加工破裂是残余应力造成的。因此,如何降低残余应力,是亟需解决的问题。
此外,在从普通陶瓷砖到陶瓷大板的研发过渡中,本领域技术人员形成了一些固化的经验:如对配方而言,在陶瓷大板的配方中,主体是考虑厚度较薄的板在烧成过程中变形严重,因此,很少采用钙镁类矿物熔剂。又如,厚度较薄的陶瓷大板,布料难度低,因此普通的陶瓷粉料的级配即可满足生产。
发明内容
本发明所要解决的技术问题在于,本发明提供一种陶瓷岩板的制备方法,其可提升干燥、烧成合格率,制备得到的陶瓷岩板深加工性能优良,加工破裂率低,应用范围广。
本发明还要解决的技术问题在于,提供一种陶瓷岩板。
为了解决上述技术问题,本发明提供了一种陶瓷岩板的制备方法,其包括:
(1)将各种原料按照配方混合均匀,并球磨得到浆料;
其中,所述配方按照重量份计的原料包括:
钾长石15~20份,钠长石8~15份,煅烧高岭土15~20份,黑泥12~20份,白泥8~15份,叶腊石15~20份,增韧剂1~10份;以上各原料的重量份之和为100份。
(2)将所述浆料喷雾干燥,得到第一粉料;
(3)将40~60%的第一粉料过40~100目筛网,得到筛上物和筛下物;将筛上物与剩余的第一粉料混合,得到第二粉料;将筛下物化浆,并与步骤(1)中的浆料合并;
(4)将第二粉料压制,得到生坯;
(5)将所述生坯干燥,然后依次施底釉、印刷装饰、施面釉后得到坯体;
(6)将所述坯体烧成,得到陶瓷岩板成品。
作为上述技术方案的改进,所述第二粉料的颗粒级配为:>20目占比1~4wt%;20~40目占比30~40wt%;40~60目占比25~35wt%,60-120目占比10~17wt%,120~200目占比5~10wt%,200目以下占比1~5wt%。
作为上述技术方案的改进,步骤(4)中,压制压力为400~550kg/cm2。
作为上述技术方案的改进,步骤(6)中,烧成制度为:
从室温到600℃,升温速率为35~45℃/min;
从600℃到900℃,升温速率为20~40℃/min;
从900℃到烧成温度,升温速率为10~25℃/min;
在烧成温度保温8~15min;
从烧成温度到800℃,冷却速率为50~80℃/min;
从800℃到500℃,冷却速率为10~20℃/min;
从500℃到室温,冷却速度为80~100℃/min。
作为上述技术方案的改进,烧成温度为1200~1300℃,烧成周期为60~180min。
作为上述技术方案的改进,所述增韧剂包括低温增韧剂和高温增韧剂;所述低温增韧剂可降低烧成过程中1000℃以下坯体内的残余应力;所述高温增韧剂可降低烧成过程中1000℃以上坯体内的残余应力;
所述低温增韧剂选用纤维素醚、聚丙烯酸钠、木质素、改性多糖或托贝莫来石;所述高温增韧剂选用块滑石、镁橄榄石、莫来石、氧化镁、氧化锆或氧化铝。
作为上述技术方案的改进,所述低温增韧剂选用托贝莫来石;所述高温增韧剂选用镁橄榄石。
作为上述技术方案的改进,所述低温增韧剂和高温增韧剂的用量比例为1:(2~5)
作为上述技术方案的改进,所述陶瓷岩板的表面积为3~12m2,厚度为12~30mm。
相应的,本发明还公开了一种陶瓷岩板,其由上述的制备方法制备而得。
实施本发明,具有以下有益效果:
(1)本发明的陶瓷岩板制备方法,将喷雾干燥得到的第一粉料部分进行筛分,并将筛上料与剩余的第一粉料合并,得到第二粉料;再用第二粉料进行压制成型;这种制备方法可有效提升粉料的流动性,使得成型后的生坯不同位置的密实程度、厚度更加均匀;这种生坯在后期烧成过程中,应力积累少,可提升后期陶瓷岩板的可加工性能。
(2)本发明通过对粉料进行处理,得到了颗粒级配为>20目占比1~4wt%;20~40目占比30~40wt%;40~60目占比25~35wt%,60-120目占比10~17wt%,120~200目占比5~10wt%,200目以下占比1~5wt%;其流动性较高,容易布料;且通过不小于400kg/cm2的成型压力,使得生坯内部均匀性高,密度均匀,后期应力积累少。
(3)本发明中的烧成温度制度,可有效消除烧成过程中的应力,提高烧成合格率,提升陶瓷岩板的平整度,提升陶瓷岩板的可加工性能。
(4)本发明中的陶瓷岩板规格较大,其表面积为3~12m2,厚度为12~30mm,其可良好地适应后期深加工工艺,可广泛应用在地板、幕墙、饰面领域,如洗手台、茶具、灶台等。可大幅度取代天然石材、人造石英石板材;且其具有高强度、高硬度、耐酸碱、耐高温等优点。
(5)本发明的配方之中含有钾长石15~20份,钠长石8~15份,煅烧高岭土15~20份,黑泥12~20份,白泥8~15份,叶腊石15~20份,增韧剂1~10份;这种配方生产得到的陶瓷岩板成品,应力聚集少,可良好适应后期深加工工艺,将后期加工破裂率降低至5%以下。
(6)本发明的配方之中引入了增韧剂,其能在岩板基体中建立弱界面结构,吸收裂纹扩展能量,同时,其自身也能够吸收外来能量,进而消除残余应力。
具体的,低温增韧剂在1000℃以下坯体内保持良好的晶须状态,可充分吸收烧成前段的应力;高温增韧剂则在1000℃以上可有效促进莫来石晶须的析出、成长,达到降低残余应力的作用。两者综合可减少应力聚集,提升陶瓷岩板深加工性能。
(7)本发明中的低温增韧剂,还可在压成、烘干过程中起到提升生坯强度的作用,提升成品率。本发明中的陶瓷岩板生坯的生坯强度可达到1.2~1.8MPa。
附图说明
图1是本发明一种陶瓷岩板的制备方法流程图;
图2是本发明一种陶瓷岩板的结构示意图。
具体实施方式
为使本发明的目的、技术方案和优点更加清楚,下面将结合附图对本发明作进一步地详细描述。
参见图1,本发明提供了一种陶瓷岩板的制备方法,其包括以下步骤:
S1:将各种原料按配方混合均匀,并球磨得到浆料;
具体的,配方为:
钾长石15~20份,钠长石8~15份,煅烧高岭土15~20份,黑泥12~20份,白泥8~15份,叶腊石15~20份,增韧剂1~10份;以上各原料的重量份之和为100份。
其中,钾长石和钠长石为主要的助熔剂,其可促进烧成,得到吸水率<0.1%的陶瓷岩板成品,提升陶瓷岩板抗折强度,减小微气孔,提升耐污能力。其中,钾长石的用量为15~20份,钠长石的用量为8~15份;优选的,钾长石用量为17~20份,钠长石的用量为10~13份。
黑泥和白泥是主要的塑性原料,其可提升生坯阶段的强度,避免生坯在运输,烘干过程中破裂;同时,在高温状态可提供莫来石来源,提升强度和优化后期深加工性能。其中,黑泥的用量为12~20份,白泥的用量为8~15份;优选的,黑泥用量为15~20份,白泥用量为8~12份。
叶腊石可取代传统陶瓷配方中的部分石英,减少应石英相变带来的大量应力积累;叶腊石也可在高温下分解产生莫来石相,提升陶瓷岩板的强度,提升可加工性。具体的,叶腊石的用量为15~20份;当叶腊石的用量>20份时,会降低生坯强度。
煅烧高岭土中的Al含量可达到40wt%以上,在后续烧成过程中会形成大量针状的莫来石晶须,从而在陶瓷岩板基体中建立弱界面结构,减少残余应力。优选的,为了充分发挥煅烧高岭土的作用,还需要控制其粒径,具体的,煅烧高岭土中1μm以下的颗粒占比70~90wt%。煅烧高岭土的用量为15~20份。
增韧剂包括低温增韧剂和高温增韧剂;其主要作用是在烧成阶段和陶瓷岩板成品中建立弱界面结构,减少残余应力,提升深加工性能,降低加工破裂率;同时也起到确保生产顺利进行的作用。
其中,低温增韧剂是指在1000℃以下起到增韧作用的物质;具体的,其可为纤维素醚、聚丙烯酸钠、木质素、改性多糖或托贝莫来石;优选的为托贝莫来石;托贝莫来石呈晶须状,在成型阶段,其可以起到提升生坯强度的作用;在烧成温度低于1000℃时,其主要是相变过程,晶须结构得以维持;从而使得烧成过程中的热应力得以较好的消除。
其中,高温增韧剂是指在1000℃以上起到增韧作用的物质;具体的,其可为块滑石、镁橄榄石、莫来石、氧化镁、氧化锆或氧化铝;其中,莫来石、氧化铝、氧化锆虽然能够达到良好的增韧作用,但是其会大幅提升烧成温度,且其原料价格高。优选的,可选用块滑石或镁橄榄石;更优选的,选用镁橄榄石。块滑石和镁橄榄石可促进莫来石晶体针状化,提升其增韧作用。
低温增韧剂和高温增韧剂的用量比例为1:(2~5),优选的为1:(2.5~4)。
需要说明的是,在常规的陶瓷大板(厚度<10mm)配方中,会尽量降低含钙镁原料的使用量,以防止波浪纹、微翘曲等变形缺陷。在本发明中,陶瓷岩板厚度较大,成型压力较高(后续论述),使得本发明可引入少量的钙镁原料,起到良好增韧作用,有效提升陶瓷岩板的深加工性能,降低加工破裂率。
优选的为:钾长石18份,钠长石11份,煅烧高岭土18份,黑泥16份,白泥10份,叶腊石17份,托贝莫来石2.5份,镁橄榄石6.5份。
具体的,球磨后,应控制浆料细度为250目筛筛余<0.5%。
S2:将浆料喷雾干燥,得到第一粉料;
具体的,将浆料喷雾干燥,干燥后过10目筛,得到第一粉料。
S3:将40~60%的第一粉料过40~100目筛网,得到筛上物和筛下物;将筛上物与剩余的第一粉料混合,得到第二粉料;将筛下物化浆,并与步骤S1中的浆料合并;
通过以上方法,可控制第二粉料的颗粒级配为:>20目占比1~4wt%;20~40目占比30~40wt%;40~60目占比25~35wt%,60-120目占比10~17wt%,120~200目占比5~10wt%,200目以下占比1~5wt%。
需要说明的是:传统的陶瓷砖粉料或陶瓷大板粉料较细,其在60目以上的占比为30~50%。而本发明则可占比达到50~80%;大幅度提升了流动性,便于布料。使得成型后的生坯不同位置的密实程度、厚度更加均匀;这种生坯在后期烧成过程中,应力积累少,可提升后期陶瓷岩板的可加工性能。
S4:将第二粉料压制,得到生坯;
需要说明的是,目前大规格陶瓷板材(陶瓷大板、陶瓷岩板)的压制一般有三种方法,连续辊压成型、皮带干压成型和模腔干压成型三种。其中,连续辊压采用对辊连续压制,然后切割成目标尺寸,对粉料的要求很高;皮带干压成型主要是采用两条钢带进行挤压,然后对边角进行切割,对粉料的要求也相对较高,模腔干压成型采用模框,冲压成型,对粉料要求较低,本发明的粉料可良好满足其要求。本发明选用模腔干压成型,其内应力低,压制得到的生坯平整性良好,尺寸精度高,。
进一步的,控制压制过程中压制压力为400~500kg/cm2;由于本发明中的粉料颗粒较大,空气含量高,因此,可采用较大的压力排气,提升坯体压实程度,提升干燥合格率、烧成合格率。
S5:将生坯干燥,然后依次施底釉、印刷装饰、施面釉后得到坯体;
具体的,干燥最高温度为120~180℃。
具体的,底釉、墨水、面釉可采用现有技术。
S6:将坯体烧成,得到陶瓷岩板成品;
具体的,烧成制度为:
从室温到600℃,升温速率为35~45℃/min;本发明中陶瓷岩板中粘土类原料较多,在600℃以前会排出结构水;采用35~45℃/min的升温速率可防止排水过快,应力积累,进而造成收缩不均。
从600℃到900℃,升温速率为20~40℃/min;在此阶段,主要发生氧化反应,板材中的一些有机物被氧化,且粘土类矿物进一步相变。由于本发明中的陶瓷岩板厚度较大,且成型压力较高,其密实程度较高。因此,采用较慢的升温速率,以保证氧化反应充分进行。优选的,在此温度区间的升温速率为25~35℃/min;
从900℃到烧成温度,升温速率为10~25℃/min;此阶段,熔剂类原料开始熔化,开始析出莫来石晶体。具体的,烧成温度为1200~1300℃,优选的为1220~1290℃。
在烧成温度保温8~15min
相应的,还要对冷却阶段的温度制度进行控制,以减少应力积累:
从烧成温度到800℃,冷却速率为50~80℃/min;
从800℃到500℃,冷却速率为10~20℃/min;优选的,在此阶段的冷却速率为10~15℃/min。
从500℃到室温,冷却速度为80~100℃/min。
控制整体的烧成时间(烧成周期)为60~180分钟。需要说明的是,现有的陶瓷岩板,为了降低应力聚集,一般20mm厚的板材,烧成周期在180~200分钟左右,而本发明通过配方、粉料、压制、烧成相互配合,缩短了烧成周期,提升了烧成效率。
具体的,S6包括:
S61:将坯体烧成;
S62:将烧成的坯体进行抛光,即得到陶瓷岩板成品。
需要说明的是,本发明中的配方、制备工艺使得陶瓷岩板在烧成过程中收缩均匀,烧成后尺寸均匀性高;因此在烧成后的加工工艺中,不包括磨边工序,简化了生产流程。
相应的,本发明还公开了一种陶瓷岩板,其采用上述制备方法制得。具体的,参考图2,其包括坯体层1、底釉层2、图案层3和面釉层4;其表面积为3~12m2,整体厚度为12~30mm;其中,坯体层1的厚度为11.5~29.5mm,坯体层1的厚度占比达到95%以上。优选的,本发明中的陶瓷岩板为矩形,其对角线长度为2500~6000mm,厚度为18~30mm。这种陶瓷岩板可良好的适应后期深度加工,适应于幕墙、地板。
下面采用具体实施例对本发明进行说明:
实施例1
本实施例提供一种陶瓷岩板,其尺寸为3600×2000×20mm3;其中,坯体层的厚度为19mm;
坯体层的配方为:
钾长石19份,钠长石12份,煅烧高岭土16份,黑泥18份,白泥10份,叶腊石18份,低温增韧剂1份,高温增韧剂6份;
其中,煅烧高岭土中80%的颗粒粒径<1μm;低温增韧剂选用甲基纤维素,高温增韧剂选用莫来石晶须;
陶瓷岩板的制备方法:
(1)将各种原料按照配方混合均匀,并球磨得到浆料;
其中,浆料的250目筛余为0.2%;
(2)将浆料喷雾干燥,筛分后得到第一粉料;
(3)将45%的第一粉料过40目筛网,得到筛上物,将筛上物与剩余的第一粉料混合,得到第二粉料;将筛下物化浆,并与步骤(1)的浆料合并;
具体的,第二粉料的颗粒级配为:
>20目占比2wt%;20~40目占比38wt%;40~60目占比32wt%,60-120目占比16wt%,120~200目占比8wt%,200目以下占比4wt%。
(4)将第二粉料压制,得到生坯;
具体的,采用HT36000型压机进行压成,成型压力为450kg/cm2。
(5)将生坯干燥,并依次施底釉、喷墨印刷、施面釉,得到坯体;
(6)将坯体烧成,得到陶瓷岩板成品;
其中,烧成温度曲线为:
从室温到600℃,升温速率为35℃/min;
从600℃到900℃,升温速率为20℃/min;
从900℃到1300℃,升温速率为12℃/min;
在1300℃保温15min;
从1300℃到800℃,降温速率为60℃/min;
从800℃到500℃,降温速率为11℃/min;
从500℃到室温,降温速率为85℃/min;
烧成周期为120min。
实施例2
本实施例提供一种大规格陶瓷岩板,其尺寸为3600×1800×25mm3;其中,坯体层的厚度为24.5mm;
坯体层的配方为:
钾长石19份,钠长石12份,煅烧高岭土16份,黑泥18份,白泥10份,叶腊石18份,低温增韧剂1份,高温增韧剂6份;
其中,煅烧高岭土中90%的颗粒粒径<1μm;低温增韧剂选用托贝莫来石,高温增韧剂选用块滑石;
陶瓷岩板的制备方法:
(1)将各种原料按照配方混合均匀,并球磨得到浆料;
其中,浆料的250目筛余为0.4%;
(2)将浆料喷雾干燥,筛分后得到第一粉料;
(3)将50%的第一粉料过60目筛网,得到筛上物,将筛上物与剩余的第一粉料混合,得到第二粉料;将筛下物化浆,并与步骤(1)的浆料合并;
具体的,第二粉料的颗粒级配为:
>20目占比2wt%;20~40目占比37wt%;40~60目占比33wt%,60-120目占比16wt%,120~200目占比9wt%,200目以下占比3wt%。
(4)将第二粉料压制,得到生坯;
具体的,采用HT36000型压机进行压成,成型压力为480kg/cm2。
(5)将生坯干燥,并依次施底釉、喷墨印刷、施面釉,得到坯体;
(6)将坯体烧成,得到陶瓷岩板成品;
其中,烧成温度曲线为:
从室温到600℃,升温速率为40℃/min;
从600℃到900℃,升温速率为24℃/min;
从900℃到1280℃,升温速率为15℃/min;
在1280℃保温10min;
从1280℃到800℃,降温速率为75℃/min;
从800℃到500℃,降温速率为12℃/min;
从500℃到室温,降温速率为85℃/min;
烧成周期为100min。
实施例3
本实施例提供一种大规格陶瓷岩板,其尺寸为3600×1800×20mm3;其中,坯体层的厚度为19mm;
坯体层的配方为:
钾长石18份,钠长石11份,煅烧高岭土18份,黑泥16份,白泥11份,叶腊石17份,低温增韧剂2.5份,高温增韧剂6.5份;
其中,煅烧高岭土中90%的颗粒粒径<1μm;低温增韧剂选用托贝莫来石,高温增韧剂选用镁橄榄石;
陶瓷岩板的制备方法:
(1)将各种原料按照配方混合均匀,并球磨得到浆料;
其中,浆料的250目筛余为0.4%;
(2)将浆料喷雾干燥,筛分后得到第一粉料;
(3)将50%的第一粉料过60目筛网,得到筛上物,将筛上物与剩余的第一粉料混合,得到第二粉料;将筛下物化浆,并与步骤(1)的浆料合并;
具体的,第二粉料的颗粒级配为:
>20目占比2wt%;20~40目占比36wt%;40~60目占比34wt%,60-120目占比17wt%,120~200目占比8wt%,200目以下占比3wt%。
(4)将第二粉料压制,得到生坯;
具体的,采用HT36000型压机进行压成,成型压力为460kg/cm2。
(5)将生坯干燥,并依次施底釉、喷墨印刷、施面釉,得到坯体;
(6)将坯体烧成,得到陶瓷岩板成品;
(6)在图案层上施面釉,形成面釉层,得到坯体;
(7)将坯体烧成,得到大规格岩板成品;
其中,烧成温度曲线为:
从室温到600℃,升温速率为40℃/min;
从600℃到900℃,升温速率为25℃/min;
从900℃到1260℃,升温速率为16℃/min;
在1260℃保温8min;
从1260℃到800℃,降温速率为74℃/min;
从800℃到500℃,降温速率为15℃/min;
从500℃到室温,降温速率为90℃/min;
烧成周期为88min。
对比例1
某江西厂家生产的规格为2400×1200×15mm3的陶瓷岩板,对各项性能进行测定。
对比例2
某企业生产的规格为800×800×11mm3的普通抛光砖50片,对各项性能进行测定。
对实施例1~3、对比例1~2中的材料进行性能测定,具体结果如下(参考方法参见GB/T 3810-2016):
实施例1 | 实施例2 | 实施例3 | 对比例1 | 对比例2 | |
吸水率(%) | 0.09% | 0.06% | 0.05% | 0.1% | 0.2% |
断裂模数(MPa) | 45.6 | 45.1 | 48.2 | 37.5 | 45.1 |
实施例4干燥、烧成合格率的测定
1,干燥合格率的测定
压制500片陶瓷岩板生坯,进行干燥。
干燥后,若生坯断裂或边角有小开裂纹路,计为不合格,否则计为合格;
此外,干燥后,选取20片合格的生坯,测定边弯曲度和中心弯曲度(GB3810.2-2016)。
2,烧成合格率的测定
对干燥后的合格的陶瓷岩板生坯进行烧成。
烧成后,若发生断裂或边角有开裂纹路,或肉眼可见明显翘曲,则计为不合格;否则计为合格;
烧成后,选取20片合格的陶瓷岩板,测定变弯曲度和中心弯曲度。
测定结果如下表(其中对比例2的数据为经验数据):
实施例5加工破裂率的测定
加工破裂率分为切割加工破裂率和雕刻加工破裂率两部分;其具体测试方法如下:
1,切割加工破裂率:采用电锯切割机对岩板边部(1/3边长以内)、中心(中心线)分别进行贯穿切割。
若切割后,产生除切割纹以外的破裂或断裂纹路,则计为破裂。若切割后,未产生肉眼可见裂纹,则测定切割后陶瓷岩板的断裂模数(GB/T 3810.4-2016);若断裂模数变化为原断裂模数的90%以下,则计算为破裂;否则,计为不破裂。
2,雕刻加工破裂率:采用数控水刀对陶瓷岩板中心区域进行雕刻,雕刻出深度为5~10mm,内径为495mm,外径为500mm的环形孔。
若雕刻过程中或雕刻后,陶瓷岩板断裂,则记为破裂;若雕刻后,陶瓷岩板未产生肉眼可见裂纹,则对雕刻后陶瓷岩板的断裂模数进行测定,若断裂模数变化为原断裂模数的80%以下,则计为破裂。否则,计为不破裂。
选用实施例1~3中陶瓷岩板50片,对比例1的陶瓷岩板50片(对比例1);对比例2的抛光砖50片(对比例2);进行加工破裂率实验,其实验数据如下表:
实施例1 | 实施例2 | 实施例3 | 对比例1 | 对比例2 | |
切割破裂率 | 0% | 4% | 0% | 48% | 0% |
雕刻破裂率 | 4% | 4% | 4% | 64% | 8% |
以上所述是发明的优选实施方式,应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明原理的前提下,还可以做出若干改进和润饰,这些改进和润饰也视为本发明的保护范围。
Claims (6)
1.一种陶瓷岩板的制备方法,其特征在于,包括:
(1)将各种原料按照配方混合均匀,并球磨得到浆料;
其中,所述配方由以下重量份的原料组成:
钾长石 15~20份,钠长石8~15份,煅烧高岭土15~20份,黑泥12~20份,白泥8~15份,叶腊石 15~20份,增韧剂1~10份;以上各原料的重量份之和为100份;所述增韧剂包括低温增韧剂和高温增韧剂;所述低温增韧剂可降低烧成过程中1000℃以下坯体内的残余应力;所述高温增韧剂可降低烧成过程中1000℃以上坯体内的残余应力;所述低温增韧剂和高温增韧剂的用量比例为1:(2~5);
所述低温增韧剂选用纤维素醚、聚丙烯酸钠、木质素或托贝莫来石;所述高温增韧剂选用镁橄榄石;
(2)将所述浆料喷雾干燥,得到第一粉料;
(3)将40~60%的第一粉料过40~100目筛网,得到筛上物和筛下物;将筛上物与剩余的第一粉料混合,得到第二粉料;将筛下物化浆,并与步骤(1)中的浆料合并;
(4)将第二粉料压制,得到生坯;
(5)将所述生坯干燥,然后依次施底釉、印刷装饰、施面釉后得到坯体;
(6)将所述坯体烧成,得到陶瓷岩板成品;其中,烧成制度为:
从室温到600℃,升温速率为35~45 ℃/min;
从600℃到900℃,升温速率为20~40 ℃/min;
从900℃到烧成温度,升温速率为10~25 ℃/min;
在烧成温度保温8~15 min;
从烧成温度到800℃,冷却速率为50~80 ℃/min;
从800℃到500℃,冷却速率为10~20 ℃/min;
从500℃到室温,冷却速度为80~100 ℃/min;
其中,所述陶瓷岩板包括坯体层、底釉层、图案层和面釉层,所述陶瓷岩板的表面积为3~12 m2,总厚度为12~30 mm,坯体层的厚度为11.5~29.5mm。
2.如权利要求1所述的陶瓷岩板的制备方法,其特征在于,所述第二粉料的颗粒级配为:>20目占比 1~4 wt%;20~40目占比30~40 wt%;40~60目占比25~35 wt%,60-120目占比10~17 wt%,120~200目占比5~10 wt%,200目以下占比1~5 wt%。
3.如权利要求2所述的陶瓷岩板的制备方法,其特征在于,步骤(4)中,压制压力为400~550 kg/cm2。
4.如权利要求1所述的陶瓷岩板的制备方法,其特征在于,烧成温度为1200~1300 ℃,烧成周期为60~180 min。
5.如权利要求1所述的陶瓷岩板的制备方法,其特征在于,所述低温增韧剂选用托贝莫来石。
6.一种陶瓷岩板,其特征在于,其由如权利要求1-5任一项所述的制备方法制备而得。
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