CN112279633A - 一种三层双密度的发泡陶瓷再生材料及其制备方法 - Google Patents

一种三层双密度的发泡陶瓷再生材料及其制备方法 Download PDF

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CN112279633A
CN112279633A CN202010925557.1A CN202010925557A CN112279633A CN 112279633 A CN112279633 A CN 112279633A CN 202010925557 A CN202010925557 A CN 202010925557A CN 112279633 A CN112279633 A CN 112279633A
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赖坤生
熊国华
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Zhumeng Xiamen Technology Co ltd
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Abstract

本发明公开了一种三层双密度的发泡陶瓷再生材料及其制备方法，包括依次层叠设置且同时烧成的第一发泡陶瓷层、瓷石界面层和第二发泡陶瓷层，第一发泡陶瓷层的密度小于第二发泡陶瓷层的密度，第一发泡陶瓷层和第二发泡陶瓷层的密度均小于瓷石界面层。本发明克服了现有技术生产的单密度材料的单一功能优异，其它功能相对欠缺，不能同时满足建筑墙体材料外围护要求的缺陷，整体性能提高明显，各项指标均优于目前的发泡陶瓷材料，能同时满足保温节能，防水防潮，防火耐烧，安全不脱落，隔音降噪，耐久坚固。

Description

一种三层双密度的发泡陶瓷再生材料及其制备方法
技术领域
本发明属于建筑材料技术领域，具体涉及一种三层双密度的发泡陶瓷再生材料及其 制备方法。
背景技术
所生产的轻质发泡陶瓷隔墙板及保温板具有轻质、保温、抗压、抗折、防火、防水、隔音等功能，且具有环保和节能的效果，可作为建筑墙体的材料或用于外墙装饰，达到建筑减重和节能的目标。但在实际应用过程中，产品的特质和应用场景要求不相匹配的状况时有发生。
由于发泡陶瓷的脆性和密度与保温性能的密切相关性，使得单一密度和结构的产品 无法直接应用到建筑构造中，比如：1)保温板产品：现有产品的导热系数低于0.055w/m·k 的发泡陶瓷，其密度低于200Kg/立方，其抗压强度低于1Mpa，10公分厚的耐火抗洞穿低于1小时，隔音30db，其无法满足建筑墙体材料强度和隔音等方面的要求；2)隔墙板 产品：现有产品的密度为400Kg/立方，抗压强度大于6Mpa，其导热系数高于0.12w/m·k， 10cm厚的耐火抗洞穿低于2小时，无法满足国家建筑外墙保温和耐火极限行业标准要求。 3)发泡陶瓷的脆性使得产品的握钉力不足，易松动。产品的表面耐磨强度低，易划痕， 易掉灰。作为建筑材料使用时有较大安装困难，存在安全隐患。
综上，单一密度和结构的发泡陶瓷的在实际应用时优点不突出，弱点被放大，强点被掩盖，导致整个行业的发展在进入应用领域时遇到瓶颈，因此需要开发出具有多功能多结构的发泡陶瓷产品克服上述缺陷根除安全隐患来满足市场需要。
发明内容
本发明的目的在于克服现有技术缺陷，提供应一种三层双密度的发泡陶瓷再生材料。
本发明的另一目的在于提供上述三层双密度的发泡陶瓷再生材料的制备方法。
本发明的技术方案如下：
一种三层双密度的发泡陶瓷再生材料，包括依次层叠设置且同时烧成的第一发泡陶瓷 层、瓷石界面层和第二发泡陶瓷层，第一发泡陶瓷层的密度小于第二发泡陶瓷层的密度， 第一发泡陶瓷层和第二发泡陶瓷层的密度均小于瓷石界面层；
第一发泡陶瓷层由53-57wt％的花岗岩粉料、35-37wt％的溶剂和8-10wt％的发泡剂制 成；
瓷石界面层由质量比为2.8-3.2∶1.8-2.2∶0.8-1.2的低温瓷石、长石和滑石粉制成，其 中，低温瓷石的熔点为1000-1100℃；
第二发泡陶瓷层由60-65wt％的花岗岩粉料、32-35wt％的溶剂和2-5wt％的发泡剂制 成；
上述助溶剂由质量比为1.8-2.2∶0.8-1.2∶1.1-1.3的锂长石粉、钾长石粉和黏土粉制成；
上述发泡剂由质量比为3.8-4.2∶2.7-3.3∶0.8-1.2∶0.3-0.5的膨润土、滑石粉、白云石粉 和碳化硅粉制成。
在本发明的一个优选实施方案中，所述第一发泡陶瓷层的密度为0.2-0.3t/m3。
在本发明的一个优选实施方案中，所述瓷石界面层的密度为2.0t/m3。
在本发明的一个优选实施方案中，所述第二发泡陶瓷层的密度为0.7-1.0t/m3。
在本发明的一个优选实施方案中，所述第一发泡陶瓷层的厚度为8-15cm，所述瓷石 界面层的厚度为2-5mm，所述第二发泡陶瓷层的厚度为4-6cm。
上述三层双密度的发泡陶瓷再生材料的制备方法，包括如下步骤：
(1)分别制备第一发泡陶瓷层、瓷石界面层和第二发泡陶瓷层所用的物料：
(2)在模具内，先在底层均匀的铺上第二发泡陶瓷层所用的物料至所需的厚度，再铺上瓷石界面层所用的物料至所需的厚度，最后铺上第一发泡陶瓷层所用的物料至所需的厚度，进而置于窑炉内烧结，得到所述发泡陶瓷再生材料，窑炉余热用于上述各物料的干燥，其中，烧结过程为：于3.0-3.5h匀速升温至840-880℃后保温0.4-0.6h，接着于3.0-3.5h匀速升温至1150-1165℃后保温1.8-2.2h，最后随炉冷却即成。
在本发明的一个优选实施方案中，所述第一发泡陶瓷层的物料的制备方法包括：
a、按重量百分比和质量比称取第一发泡陶瓷层所涉及的各组分；
b、将花岗岩粉料经干燥后球磨至220-300目；
c、将锂长石粉、钾长石粉和黏土粉混合后经干燥再球磨均匀至220-300目，配制成助溶剂；
d、将膨润土、滑石粉、白云石粉和碳化硅粉充分混合后经干燥再球磨均匀至220-300 目，配制成发泡剂；
e、将步骤b至d所得的物料混合均匀后，通过造粒系统制成粒度为40-80目的原料粉；
f、将步骤e制得的原料粉经陈腐，以达到湿度均匀，即得第一发泡陶瓷层的物料。
在本发明的一个优选实施方案中，所述瓷石界面层的物料的制备方法包括：按质量比 称取瓷石界面层所涉及的各组分，混合球磨成200-260目的粉末，再通过造粒系统制粒度 为30-60目的原料粉，即成。
在本发明的一个优选实施方案中，所述第二发泡陶瓷层的物料的制备方法包括：
a、按重量百分比和质量比称取第二发泡陶瓷层所涉及的各组分；
b、将花岗岩粉料经干燥后球磨至220-300目；
c、将锂长石粉、钾长石粉和黏土粉混合后经干燥再球磨均匀至220-300目，配制成助溶剂；
d、将膨润土、滑石粉、白云石粉和碳化硅粉充分混合后经干燥再球磨均匀至220-300 目，配制成发泡剂；
e、将步骤b至d所得的物料混合均匀后，通过造粒系统制成粒度为40-80目的原料粉；
f、将步骤e制得的原料粉经陈腐，以达到湿度均匀，即得第二发泡陶瓷层的物料。。
在本发明的一个优选实施方案中，所述烧结过程为：于3.2h匀速升温至860℃后保温 0.5h，接着于3.2h匀速升温至1155-1160℃后保温2h，最后随炉冷却即成。
本发明的有益效果是：
1、本发明的第一发泡陶瓷层具有优良的保温效果，第二发泡陶瓷层除具有良好的的 保温效果，还具有良好的抗压枪强度，隔音，防水，防火耐洞穿，中间的瓷石界面层作为上下两层不同密度发泡陶瓷的中间层既有紧密过渡作用又具有增强作用。
2、本发明的发泡陶瓷再生材料一次烧成合成一体，因此层间不存在剥落老化可能。
3、本发明克服了现有技术生产的单密度材料的单一功能优异，其它功能相对欠缺， 不能同时满足建筑墙体材料外围护要求的缺陷，整体性能提高明显，各项指标均优于目前 的发泡陶瓷材料，能同时满足保温节能，防水防潮，防火耐烧，安全不脱落，隔音降噪，耐久坚固。
具体实施方式
以下通过具体实施方式对本发明的技术方案进行进一步的说明和描述。
实施例1
一种三层双密度的发泡陶瓷再生材料，包括依次层叠设置且同时烧成的第一发泡陶瓷 层、瓷石界面层和第二发泡陶瓷层，第一发泡陶瓷层的密度小于第二发泡陶瓷层的密度， 第一发泡陶瓷层和第二发泡陶瓷层的密度均小于瓷石界面层；
第一发泡陶瓷层的密度为300kg/m3，由55wt％的花岗岩粉料、37wt％的助溶剂和8wt％ 的发泡剂制成；
瓷石界面层的密度为2.0t/m3，由质量比为3∶2∶1的低温瓷石、长石粉和滑石粉制成， 其中，低温瓷石的熔点为1000-1100℃；
第二发泡陶瓷层的密度为850kg/m3，由65wt％的花岗岩粉料、32wt％的助溶剂和3wt％的发泡剂制成；
上述助溶剂由质量比为2∶1∶1.2的锂长石粉、钾长石粉和黏土粉制成；
上述发泡剂由质量比为4∶3∶1∶0.4的膨润土、滑石粉、白云石粉和碳化硅粉制成。
上述三层双密度的发泡陶瓷再生材料的制备方法，包括如下步骤：
(1)分别制备第一发泡陶瓷层、瓷石界面层和第二发泡陶瓷层所用的物料，具体如下：
所述第一发泡陶瓷层的物料的制备方法包括：
a、按重量百分比和质量比称取第一发泡陶瓷层所涉及的各组分；
b、将花岗岩粉料经干燥后球磨至220-300目；
c、将锂长石粉、钾长石粉和黏土粉混合后经干燥再球磨均匀至220-300目，配制成助溶剂；
d、将膨润土、滑石粉、白云石粉和碳化硅粉充分混合后经干燥再球磨均匀至220-300 目，配制成发泡剂；
e、将步骤b至d所得的物料混合均匀后，通过造粒系统制成粒度为40-80目的原料粉；
f、将步骤e制得的原料粉经陈腐，以达到湿度均匀，即得第一发泡陶瓷层的物料；
所述瓷石界面层的物料的制备方法包括：按质量比称取瓷石界面层所涉及的各组分， 混合球磨成200-260目的粉末，再通过造粒系统制粒度为30-60目的原料粉，即成。
所述第二发泡陶瓷层的物料的制备方法包括：
a、按重量百分比和质量比称取第二发泡陶瓷层所涉及的各组分；
b、将花岗岩粉料经干燥后球磨至220-300目；
c、将锂长石粉、钾长石粉和黏土粉混合后经干燥再球磨均匀至220-300目，配制成助溶剂；
d、将膨润土、滑石粉、白云石粉和碳化硅粉充分混合后经干燥再球磨均匀至220-300 目，配制成发泡剂；
e、将步骤b至d所得的物料混合均匀后，通过造粒系统制成粒度为40-80目的原料粉；
f、将步骤e制得的原料粉经陈腐，以达到湿度均匀，即得第二发泡陶瓷层的物料；
(2)在模具内，先在底层均匀的铺上第二发泡陶瓷层所用的物料至所需的厚度，再铺上瓷石界面层所用的物料至所需的厚度，最后铺上第一发泡陶瓷层所用的物料至所需的厚度，进而置于窑炉内烧结，得到所述发泡陶瓷再生材料，窑炉余热用于上述各物料的干燥，其中，烧结过程为：于3.2h匀速升温至860℃后保温0.5h，接着于3.2h匀速升温至 1160℃后保温2h，最后随炉冷却即成。
本实施例制成的发泡陶瓷再生材料中，第一发泡陶瓷层的厚度为100mm，抗压强度为3MPa，瓷石界面层的厚度为5mm，抗压强度为50MPa，抗折强度为21MPa，第二发 泡陶瓷层的厚度为45mm，抗压强度为25MPa，具有保温防水耐火功能，抗压抗折强度提 高，常温导热系数0.10W/(m*k)，耐洞穿极限≥3小时，体积吸水率1.2％，耐酸性0.96， 耐热性≥0.96，耐水性≥0.96，且第一发泡陶瓷层的导热系数为0.065w/m·k，第二发泡 陶瓷层的导热系数为0.18w/m·k。
实施例2
一种三层双密度的发泡陶瓷再生材料，包括依次层叠设置且同时烧成的第一发泡陶瓷 层、瓷石界面层和第二发泡陶瓷层，第一发泡陶瓷层的密度小于第二发泡陶瓷层的密度， 第一发泡陶瓷层和第二发泡陶瓷层的密度均小于瓷石界面层；
第一发泡陶瓷层的密度为240kg/m3，由55wt％的花岗岩粉料、35wt％的助溶剂和10wt％的发泡剂制成；
瓷石界面层的密度为2.0t/m3，由质量比为3∶2∶1的低温瓷石、长石粉和滑石粉制成， 其中，低温瓷石的熔点为1000-1100℃；
第二发泡陶瓷层的密度为750kg/m3，由62wt％的花岗岩粉料、34wt％的助溶剂和4wt％的发泡剂制成；
上述助溶剂由质量比为2∶1∶1.2的锂长石粉、钾长石粉和黏土粉制成；
上述发泡剂由质量比为4∶3∶1∶0.4的膨润土、滑石粉、白云石粉和碳化硅粉制成。
上述三层双密度的发泡陶瓷再生材料的制备方法，包括如下步骤：
(1)分别制备第一发泡陶瓷层、瓷石界面层和第二发泡陶瓷层所用的物料，具体如下：
所述第一发泡陶瓷层的物料的制备方法包括：
a、按重量百分比和质量比称取第一发泡陶瓷层所涉及的各组分；
b、将花岗岩粉料经干燥后球磨至220-300目；
c、将锂长石粉、钾长石粉和黏土粉混合后经干燥再球磨均匀至220-300目，配制成助溶剂；
d、将膨润土、滑石粉、白云石粉和碳化硅粉充分混合后经干燥再球磨均匀至220-300 目，配制成发泡剂；
e、将步骤b至d所得的物料混合均匀后，通过造粒系统制成粒度为40-80目的原料粉；
f、将步骤e制得的原料粉经陈腐，以达到湿度均匀，即得第一发泡陶瓷层的物料；
所述瓷石界面层的物料的制备方法包括：按质量比称取瓷石界面层所涉及的各组分， 混合球磨成200-260目的粉末，再通过造粒系统制粒度为30-60目的原料粉，即成。
所述第二发泡陶瓷层的物料的制备方法包括：
a、按重量百分比和质量比称取第二发泡陶瓷层所涉及的各组分；
b、将花岗岩粉料经干燥后球磨至220-300目；
c、将锂长石粉、钾长石粉和黏土粉混合后经干燥再球磨均匀至220-300目，配制成助溶剂；
d、将膨润土、滑石粉、白云石粉和碳化硅粉充分混合后经干燥再球磨均匀至220-300 目，配制成发泡剂；
e、将步骤b至d所得的物料混合均匀后，通过造粒系统制成粒度为40-80目的原料粉；
f、将步骤e制得的原料粉经陈腐，以达到湿度均匀，即得第二发泡陶瓷层的物料；
(2)在模具内，先在底层均匀的铺上第二发泡陶瓷层所用的物料至所需的厚度，再铺上瓷石界面层所用的物料至所需的厚度，最后铺上第一发泡陶瓷层所用的物料至所需的厚度，进而置于窑炉内烧结，得到所述发泡陶瓷再生材料，窑炉余热用于上述各物料的干燥，其中，烧结过程为：于3.2h匀速升温至860℃后保温0.5h，接着于3.2h匀速升温至 1155℃后保温2h，最后随炉冷却即成。
本实施例制成的发泡陶瓷再生材料中，第一发泡陶瓷层的厚度为100mm，抗压强度为2MPa，瓷石界面层的厚度为5mm，抗压强度为50MPa，抗折强度为21MPa，第二发 泡陶瓷层的厚度为45mm，抗压强度为18MPa，具有保温防水耐火功能，抗压抗折强度提 高，常温导热系数0.09W/(m*k)，耐洞穿极限≥3小时，体积吸水率1.25％，耐酸性0.96， 耐热性≥0.96，耐水性≥0.96，且第一发泡陶瓷层的导热系数为0.060w/m·k，第二发泡 陶瓷层的导热系数为0.16w/m·k。
以上所述，仅为本发明的较佳实施例而已，故不能依此限定本发明实施的范围，即依 本发明专利范围及说明书内容所作的等效变化与修饰，皆应仍属本发明涵盖的范围内。

Claims (10)

1.一种三层双密度的发泡陶瓷再生材料，其特征在于：包括依次层叠设置且同时烧成的第一发泡陶瓷层、瓷石界面层和第二发泡陶瓷层，第一发泡陶瓷层的密度小于第二发泡陶瓷层的密度，第一发泡陶瓷层和第二发泡陶瓷层的密度均小于瓷石界面层；
第一发泡陶瓷层由53-57wt％的花岗岩粉料、35-37wt％的溶剂和8-10wt％的发泡剂制成；瓷石界面层由质量比为2.8-3.2∶1.8-2.2∶0.8-1.2的低温瓷石、长石和滑石粉制成，其中，低温瓷石的熔点为1000-1100℃；
第二发泡陶瓷层由60-65wt％的花岗岩粉料、32-35wt％的溶剂和2-5wt％的发泡剂制成；上述助溶剂由质量比为1.8-2.2∶0.8-1.2∶1.1-1.3的锂长石粉、钾长石粉和黏土粉制成；
上述发泡剂由质量比为3.8-4.2∶2.7-3.3∶0.8-1.2∶0.3-0.5的膨润土、滑石粉、白云石粉和碳化硅粉制成。
2.如权利要求1所述的一种三层双密度的发泡陶瓷再生材料，其特征在于：所述第一发泡陶瓷层的密度为0.2-0.3t/m3。
3.如权利要求1所述的一种三层双密度的发泡陶瓷再生材料，其特征在于：所述瓷石界面层的密度为2.0t/m3。
4.如权利要求1所述的一种三层双密度的发泡陶瓷再生材料，其特征在于：所述第二发泡陶瓷层的密度为0.7-1.0t/m3。
5.如权利要求1至4中任一权利要求所述的一种三层双密度的发泡陶瓷再生材料，其特征在于：所述第一发泡陶瓷层的厚度为8-15cm，所述瓷石界面层的厚度为2-5mm，所述第二发泡陶瓷层的厚度为4-6cm。
6.权利要求1至5中任一权利要求所述的一种三层双密度的发泡陶瓷再生材料的制备方法，其特征在于：包括如下步骤：
(1)分别制备第一发泡陶瓷层、瓷石界面层和第二发泡陶瓷层所用的物料：
(2)在模具内，先在底层均匀的铺上第二发泡陶瓷层所用的物料至所需的厚度，再铺上瓷石界面层所用的物料至所需的厚度，最后铺上第一发泡陶瓷层所用的物料至所需的厚度，进而置于窑炉内烧结，得到所述发泡陶瓷再生材料，窑炉余热用于上述各物料的干燥，其中，烧结过程为：于3.0-3.5h匀速升温至840-880℃后保温0.4-0.6h，接着于3.0-3.5h匀速升温至1150-1165℃后保温1.8-2.2h，最后随炉冷却即成。
7.如权利要求6所述的制备方法，其特征在于：所述第一发泡陶瓷层的物料的制备方法包括：
a、按重量百分比和质量比称取第一发泡陶瓷层所涉及的各组分；
b、将花岗岩粉料经干燥后球磨至220-300目；
c、将锂长石粉、钾长石粉和黏土粉混合后经干燥再球磨均匀至220-300目，配制成助溶剂；
d、将膨润土、滑石粉、白云石粉和碳化硅粉充分混合后经干燥再球磨均匀至220-300目，配制成发泡剂；
e、将步骤b至d所得的物料混合均匀后，通过造粒系统制成粒度为40-80目的原料粉；
f、将步骤e制得的原料粉经陈腐，以达到湿度均匀，即得第一发泡陶瓷层的物料。
8.如权利要求6所述的制备方法，其特征在于：所述瓷石界面层的物料的制备方法包括：按质量比称取瓷石界面层所涉及的各组分，混合球磨成200-260目的粉末，再通过造粒系统制粒度为30-60目的原料粉，即成。
9.如权利要求6所述的制备方法，其特征在于：所述第二发泡陶瓷层的物料的制备方法包括：
a、按重量百分比和质量比称取第二发泡陶瓷层所涉及的各组分；
b、将花岗岩粉料经干燥后球磨至220-300目；
c、将锂长石粉、钾长石粉和黏土粉混合后经干燥再球磨均匀至220-300目，配制成助溶剂；
d、将膨润土、滑石粉、白云石粉和碳化硅粉充分混合后经干燥再球磨均匀至220-300目，配制成发泡剂；
e、将步骤b至d所得的物料混合均匀后，通过造粒系统制成粒度为40-80目的原料粉；
f、将步骤e制得的原料粉经陈腐，以达到湿度均匀，即得第二发泡陶瓷层的物料。
10.如权利要求6至9中任一权利要求所述的制备方法，其特征在于：所述烧结过程为：于3.2h匀速升温至860℃后保温0.5h，接着于3.2h匀速升温至1155-1160℃后保温2h，最后随炉冷却即成。
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