CN112047721A - 一种钢化建筑陶瓷制品的制备方法及其陶瓷制品 - Google Patents

一种钢化建筑陶瓷制品的制备方法及其陶瓷制品 Download PDF

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CN112047721A
CN112047721A CN202010940467.XA CN202010940467A CN112047721A CN 112047721 A CN112047721 A CN 112047721A CN 202010940467 A CN202010940467 A CN 202010940467A CN 112047721 A CN112047721 A CN 112047721A
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孙熠
包亦望
万德田
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China Building Materials Academy CBMA
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Abstract

本发明公开了一种钢化建筑陶瓷制品的制备方法，通过在建筑陶瓷坯体表面铺设低收缩材料粉体，经干压成型、烧结而成。此外，还公开了利用上述钢化建筑陶瓷制品的制备方法制得的陶瓷制品。本发明通过低收缩材料来抵消陶瓷坯体的收缩，使得陶瓷在收缩过程中表层收缩少于基体的收缩，从而被基体的收缩牵扯而形成表层压应力，进而达到显著提高陶瓷制品抗折强度的目的；同时，也有助于建筑陶瓷薄板的制备，从而能够减少生产坯体原料的使用量、节约优质陶瓷原料资源，降低生产成本，有利于节能减排，从而为建筑陶瓷行业的可持续发展，以及加快生态文明建设、实现绿色发展发挥重要作用。

Description

一种钢化建筑陶瓷制品的制备方法及其陶瓷制品
技术领域
本发明涉及陶瓷材料技术领域，尤其涉及一种钢化建筑陶瓷制品的制备方法及其陶瓷制品。
背景技术
钢化玻璃(也称预应力玻璃)是指普通玻璃经过一定的处理方法使得玻璃表面形成压缩应力来有效阻止表面的微裂纹扩展，并部分或全部抵消外加荷载引起的表层拉应力，从而提高玻璃的机械强度、稳定性及安全性。目前，玻璃钢化表面压应力的形成方式包括物理钢化和化学钢化两种。物理钢化玻璃最早由法国人De la Basti于1874年首次提出，具体是将普通玻璃加热至软化温度(650～800℃)，使其在冷却介质下(气体、液体等)快速冷却。由于熔融玻璃表面立即冷却变成刚性，收缩速率小，而内部仍处于熔融状态，继续冷却过程中的收缩使得硬化的玻璃表面产生压缩残余应力。这种物理钢化玻璃直到首次发明后30多年才得以广泛应用。化学钢化法(也称离子交换法)是通过化学的方法改变玻璃表面的组成，具体可利用熔盐中大半径碱金属离子(如K+半径大小为1.33埃)置换玻璃表面小半径离子(如Na+半径大小为0.98埃)，冷却后，大离子受到挤压对表层形成钉扎效应，给玻璃表面提供压应力，从而提高玻璃的强度、热稳定性和安全性能。
钢化玻璃被世人广泛认知，但同为传统硅酸盐材料的预应力陶瓷却不及钢化玻璃。实际上，陶瓷表层的压缩应力可以大幅提高强度的概念由来已久，但如何实现这种表面压应力一直是业界的研究关键和难题。近年来，现有技术也研究开发了利用涂层法来形成表面压应力以制备预应力陶瓷，如形成一种低膨胀系数、高弹性模量的涂层，通过在建筑陶瓷和日用陶瓷表面形成压应力以提高强度。但是，这种方法的烧成技术还要进一步优化提高。
发明内容
本发明的目的在于克服现有技术的不足，提供一种钢化建筑陶瓷制品的制备方法，通过在陶瓷表面添加低收缩材料来抵消陶瓷坯体的收缩，表层收缩会少于基体的收缩而被基体的收缩牵扯形成表层压应力，从而提高陶瓷的抗折强度。本发明的另一目的在于提供利用上述钢化建筑陶瓷制品的制备方法制得的陶瓷制品。
本发明的目的通过以下技术方案予以实现：
本发明提供的一种钢化建筑陶瓷制品的制备方法，由建筑陶瓷坯体粉料和低收缩材料粉体制得，包括以下步骤：
(1)低收缩材料粉体的制备
所述低收缩材料为以下材料中的一种或其组合、或者与瓷粉的组合：以SiO2为主的矿物或岩石、硅灰石、透辉石、堇青石、透闪石、叶蜡石、红柱石、夕线石；所述瓷粉为所述建筑陶瓷坯体烧结成瓷后的粉料；所述低收缩材料经球磨、过筛、干燥造粒后，即得到低收缩材料粉体；
(2)钢化建筑陶瓷坯体的制备
在模具中由下至上依次均匀铺设下层低收缩材料粉体、中层建筑陶瓷坯体粉料、上层低收缩材料粉体；所述上层低收缩材料粉体与下层低收缩材料粉体的用量相同，低收缩材料粉体的总量为建筑陶瓷坯体粉料的5～20wt％；经干压成型，即制得钢化建筑陶瓷坯体；
(3)钢化建筑陶瓷制品的制备
将所述钢化建筑陶瓷坯体在1180～1230℃温度下进行烧结，烧成周期为40～60min，即制得钢化建筑陶瓷制品。
进一步地，本发明按照重量份数所述低收缩材料的组成为硅灰石70～90和瓷粉10～20，或者透辉石85～97和红柱石3～10，或者透闪石80～95和红柱石5～15，或者石英75～85和堇青石15～25。
进一步地，本发明所述步骤(1)制得的低收缩材料粉体的粒度为150～500目。
进一步地，本发明所述建筑陶瓷坯体按重量份数其原料组成为：粘土类原料10～40、瘠性原料10～30、助熔性原料10～40、矿化剂0～30。具体地，所述粘土类原料、瘠性原料、助熔性原料、矿化剂分别为高岭土、石英、长石、滑石，并可添加兼具瘠性原料和粘土类原料的中温砂。
利用上述钢化建筑陶瓷制品的制备方法制得的制品。
本发明具有以下有益效果：
(1)本发明在陶瓷表面添加低收缩材料来抵消陶瓷坯体的收缩，使得陶瓷在收缩过程中表层收缩少于基体的收缩，从而被基体的收缩牵扯而形成表层压应力，类似物理钢化玻璃，从而达到显著提高陶瓷制品抗折强度的目的(抗折强度＞60MPa，提高率为50％以上)。
(2)本发明有助于建筑陶瓷薄板(小于6mm)的制备，不仅能够减少生产坯体原料的使用量、节约优质陶瓷原料资源，降低生产成本，而且有利于节能减排，从而为建筑陶瓷行业的可持续发展，以及加快生态文明建设、实现绿色发展发挥重要作用。
(3)本发明的制备及应用生产简单易控、成本低，沿用现有的工艺成熟的陶瓷生产设备和工艺技术即可，有助于推广应用，具有很高的实用价值和应用前景。
下面将结合实施例对本发明作进一步的详细描述。
具体实施方式
本发明实施例一种钢化建筑陶瓷制品的制备方法，由建筑陶瓷坯体粉料和低收缩材料粉体制得。所用的建筑陶瓷坯体，采用建筑陶瓷瓷质坯体配方，按重量份数其原料组成为：高岭土30份、石英20份、长石35份、滑石5份、中温砂10份。上述制备方法的步骤如下：
(1)低收缩材料粉体的制备
低收缩材料为以下材料中的一种或其组合、或者与瓷粉的组合：以SiO2为主的矿物或岩石、硅灰石、透辉石、堇青石、透闪石、叶蜡石、红柱石、夕线石；瓷粉为上述建筑陶瓷坯体烧结成瓷后的粉料；上述低收缩材料经球磨、过筛、干燥造粒后，得到粒度为150～500目的低收缩材料粉体；
各实施例低收缩材料粉体的原料组成及粉体粒度如表1所示；
(2)钢化建筑陶瓷坯体的制备
在模具中由下至上依次均匀铺设下层低收缩材料粉体、中层建筑陶瓷坯体粉料、上层低收缩材料粉体；其中，上层低收缩材料粉体与下层低收缩材料粉体的用量相同，低收缩材料粉体的总量为建筑陶瓷坯体粉料的5～20wt％；经干压成型(成型压力35MPa，保压时间30s)，即制得钢化建筑陶瓷坯体；
(3)钢化建筑陶瓷制品的制备
将上述钢化建筑陶瓷坯体在辊道窑中进行烧结处理，烧结温度为1180～1230℃，烧成周期为40～60min，即制得厚度为5.2mm的钢化建筑陶瓷制品。
各实施例钢化建筑陶瓷制品的制备方法其工艺参数如表2所示。
表1本发明各实施例低收缩材料粉体的原料组成及粉体粒度
Figure BDA0002673467820000031
表2本发明各实施例钢化建筑陶瓷制品的制备方法工艺参数
Figure BDA0002673467820000041
*为建筑陶瓷坯体粉料的重量百分比。
以本发明各实施例未使用低收缩材料的建筑陶瓷制品作为对应的对比例。本发明各实施例所制得的钢化建筑陶瓷制品、以及相应各对比例所得制品的抗折强度如表3所示。
表3本发明各实施例以及对比例所制得建筑陶瓷制品的抗折强度
Figure BDA0002673467820000042

Claims (6)

1.一种钢化建筑陶瓷制品的制备方法，其特征在于：由建筑陶瓷坯体粉料和低收缩材料粉体制得，包括以下步骤：
(1)低收缩材料粉体的制备
所述低收缩材料为以下材料中的一种或其组合、或者与瓷粉的组合：以SiO2为主的矿物或岩石、硅灰石、透辉石、堇青石、透闪石、叶蜡石、红柱石、夕线石；所述瓷粉为所述建筑陶瓷坯体烧结成瓷后的粉料；所述低收缩材料经球磨、过筛、干燥造粒后，即得到低收缩材料粉体；
(2)钢化建筑陶瓷坯体的制备
在模具中由下至上依次均匀铺设下层低收缩材料粉体、中层建筑陶瓷坯体粉料、上层低收缩材料粉体；所述上层低收缩材料粉体与下层低收缩材料粉体的用量相同，低收缩材料粉体的总量为建筑陶瓷坯体粉料的5～20wt％；经干压成型，即制得钢化建筑陶瓷坯体；
(3)钢化建筑陶瓷制品的制备
将所述钢化建筑陶瓷坯体在1180～1230℃温度下进行烧结，烧成周期为40～60min，即制得钢化建筑陶瓷制品。
2.根据权利要求1所述的钢化建筑陶瓷制品的制备方法，其特征在于：按照重量份数所述低收缩材料的组成为硅灰石70～90和瓷粉10～20，或者透辉石85～97和红柱石3～10，或者透闪石80～95和红柱石5～15，或者石英75～85和堇青石15～25。
3.根据权利要求1所述的钢化建筑陶瓷制品的制备方法，其特征在于：所述步骤(1)制得的低收缩材料粉体的粒度为150～500目。
4.根据权利要求1或2所述的钢化建筑陶瓷制品的制备方法，其特征在于：所述建筑陶瓷坯体按重量份数其原料组成为：粘土类原料10～40、瘠性原料10～30、助熔性原料10～40、矿化剂0～30。
5.根据权利要求4所述的钢化建筑陶瓷制品的制备方法，其特征在于：所述粘土类原料、瘠性原料、助熔性原料、矿化剂分别为高岭土、石英、长石、滑石，并可添加兼具瘠性原料和粘土类原料的中温砂。
6.利用权利要求1-5之一所述钢化建筑陶瓷制品的制备方法制得的制品。
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