CN112624746A - 一种轻质高强泡沫陶瓷保温饰面板及其制备方法和应用 - Google Patents

一种轻质高强泡沫陶瓷保温饰面板及其制备方法和应用 Download PDF

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CN112624746A
CN112624746A CN202011473226.5A CN202011473226A CN112624746A CN 112624746 A CN112624746 A CN 112624746A CN 202011473226 A CN202011473226 A CN 202011473226A CN 112624746 A CN112624746 A CN 112624746A
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陈影
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Abstract

本发明属于建筑用发泡陶瓷保温材料技术领域，公开了一种轻质高强泡沫陶瓷保温饰面板及其制备方法和应用，泡沫陶瓷保温饰面板包括坯体层和装饰釉层，坯体层由保温层或者保温层和过渡层组成，本发明以青砂替代珍珠岩作为主原料，该原料烧成塑性好且储量大，容易获得，在配方中大量添加可以极大的降低原材料成本，配以钠长石和钾长石来提高坯体白度，配以滑石来降低坯体的脆性，提高韧性，以使产品的质量符合标准，滑石还可以降低坯体的热膨胀系数，减少坯体的烧成收缩。

Description

一种轻质高强泡沫陶瓷保温饰面板及其制备方法和应用
技术领域
本发明涉及建筑用发泡陶瓷保温材料技术领域，特别是涉及一种轻质高强泡沫陶瓷保温饰面板及其制备方法和应用。
背景技术
现有的泡沫陶瓷保温饰面板是以珍珠岩为主原料的，它抗压、抗折、抗震强度低，产品在运输、安装环节破损严重，加大了使用成本，不便普及，使得适用范围受到限制，更不适用于装配整体式墙体在工厂重压强震状态下一体生产。
基于此，有必要研发一种轻质高强的泡沫陶瓷保温饰面板。
发明内容
本发明的目的在于提供一种轻质高强泡沫陶瓷保温饰面板及其制备方法和应用，以青砂作为主原料，制备的泡沫陶瓷保温饰面板具有质轻、高强、抗震、保温、防火、防水、防潮、抗冷融、不老化、同混凝土同寿命等优点，同时具有瓷砖或仿石材的装饰效果。
为实现上述目的，本发明采用以下技术方案：
一种轻质高强泡沫陶瓷保温饰面板，所述泡沫陶瓷保温饰面板包括坯体层和装饰釉层，所述坯体层由保温层或者保温层和过渡层组成；
所述保温层主要由以下组分制得：青砂、钠长石、钾长石、黑泥、膨润土、滑石、碳化硅、减水剂和分散剂，所述青砂和碳化硅的质量比为(1-3):(0.005-0.05)；
所述装饰釉层主要由以下组分制得：青砂、钠长石、钾长石、黑泥、膨润土、滑石、碳化硅、减水剂、分散剂和颜料；
所述过渡层主要由以下组分制得：青砂、钠长石、钾长石、黑泥、膨润土、滑石、碳化硅、减水剂和分散剂，所述青砂和碳化硅质量比为(1-2):(0.0005-0.025)。
过渡层可以为后续3D喷墨打印饰面及强化产品提供条件。
优选地，所述保温层主要由以下质量份的组分制得：青砂20-60份，钠长石4-20份，钾长石12-40份，黑泥5-20份，膨润土3-10份，滑石2-10份，碳化硅0.1-1.0份，减水剂0.1-1.0份和分散剂0.1-1.0份。
优选地，所述装饰釉层主要由以下质量份的组分制得：青砂10-30份，钠长石18-42份，钾长石20-51份，黑泥2-15份，膨润土1-5份，滑石1-5份，碳化硅0.05-0.2份，减水剂0.1-0.5份、分散剂0.01-0.1份和颜料1-10份。
优选地，所述过渡层主要由以下质量份的组分制得：青砂20-40份，钠长石5-30份，钾长石15-40份，黑泥5-15份，膨润土2-10份，滑石2-10份，碳化硅0.01-0.5份，减水剂0.1-0.5份和分散剂0.1-0.5份。
更优选地，所述保温层主要由以下质量份的组分制得：青砂30-60份，钠长石4-20份，钾长石20-40份，黑泥10-20份，膨润土5-10份，滑石4-10份，碳化硅0.1-1.0份，减水剂0.1-1.0份和分散剂0.1-1.0份；所述装饰釉层主要由以下质量份的组分制得：青砂11-22份，钠长石18-42份，钾长石23-51份，黑泥3.5-8份，膨润土2-4份，滑石1.6-3.3份，碳化硅0.08-0.16份，减水剂0.1-0.2份、分散剂0.04-0.08份和颜料1-5份；所述过渡层主要由以下质量份的组分制得：青砂20-40份，钠长石5-30份，钾长石20-40份，黑泥5-13份，膨润土3-7份，滑石2-6份，碳化硅0.01-0.5份，减水剂0.2-0.4份和分散剂0.1-0.2份。
优选地，所述减水剂为纯碱、水玻璃、六偏磷酸钠或焦磷酸钠中的一种或几种。
优选地，所述分散剂为三聚磷酸钠、焦磷酸钠、水玻璃、腐植酸钠、CMC、柠檬酸钠中的一种或几种。
优选地，所述颜料为釉中彩或釉上彩矿物颜料。
一种轻质高强泡沫陶瓷保温饰面板的制备方法，包括以下步骤：
保温层材料的制备：将保温层的各组分混合，再破碎、湿法球磨、喷雾干燥造粒、陈腐，得到保温层材料；
过渡层材料的制备：将过渡层的各组分混合，再破碎、湿法球磨、喷雾干燥造粒、陈腐，得到过渡层材料；
制釉：将装饰釉层的各组分混合，用釉磨湿法球磨，得到釉浆；
压坯：将保温层材料经一次布料压坯得到素坯Ⅰ，或将保温层材料与过渡层材料经二次布料一次压坯得到素坯Ⅱ；
装饰与烧制：将素坯Ⅰ或素坯Ⅱ干燥，淋釉浆或在釉上3D喷墨打印花纹，烧结，即得泡沫陶瓷保温饰面板。
优选地，所述烧结的温度为1150℃-1185℃。
优选地，保温层的各组分混合后所得浆料经过高梯度磁选机进行除铁；过渡层的各组分混合后所得浆料经过高梯度磁选机进行除铁；装饰釉层的各组分混合后所得浆料经过高梯度磁选机进行除铁。
本发明还提供所述的轻质高强泡沫陶瓷保温饰面板在装饰墙体中的应用。
本发明的优点：
1、本发明的泡沫陶瓷保温饰面板的抗压、抗折、抗震强度大，可以减少运输、安装破损，适应装配整体式墙体在重压、强震状态下的一体化生产，改变了现有产品只能在建筑上安装的模式，实现了建筑工厂化、装配化。
2、本发明的泡沫陶瓷保温饰面板具有质轻、高强、保温、防火、防水、防潮、抗冷融、不老化等优点。
3、本发明以青砂替代珍珠岩作为主原料，该原料烧成塑性好且储量大，容易获得，在配方中大量添加可以极大的降低原材料成本，配以钠长石和钾长石来提高坯体白度，配以滑石来降低坯体的脆性，提高韧性，以使产品的质量符合标准，滑石还可以降低坯体的热膨胀系数，减少坯体的烧成收缩。
具体实施方式
为了对本发明进行深入的理解，下面结合实例对本发明优选实验方案进行描述，以进一步的说明本发明的特点和优点，任何不偏离本发明主旨的变化或者改变能够为本领域的技术人员理解，本发明的保护范围由所属权利要求范围确定。
实施例1：
本实施例的泡沫陶瓷保温饰面板，由以下步骤制得：
步骤(1)保温层材料的制备：按重量份数计，称量青砂54份，钠长石16份，钾长石39份，黑泥18份，膨润土9.5份，滑石8份，碳化硅0.4份，减水剂0.5份，分散剂0.2份，混合，经破碎、湿法球磨，所得浆料经过高梯度磁选机进行除铁，再干燥造粒，陈腐，得到保温层材料；
步骤(2)制釉：按重量份数计，称量青砂18.22份，钠长石29.9份，钾长石37.16份，黑泥6.07份，膨润土3.21份，滑石2.7份，碳化硅0.13份，减水剂0.17份、分散剂0.07份和颜料3.5份，混合，用釉磨湿法球磨，所得浆料经过高梯度磁选机进行除铁，得到釉浆；
步骤(3)压坯：将保温层材料经一次布料压坯得到素坯Ⅰ；
步骤(4)装饰与烧制：素坯Ⅰ干燥后用釉浆进行上釉或在釉上印制图案，于1170℃辊道窑中烧制得到气均匀、带有釉面的泡沫陶瓷保温饰面板。
实施例2：
本实施例的泡沫陶瓷保温饰面板，由以下步骤制得：
步骤(1)保温层材料的制备：按重量份数计，称量青砂54份，钠长石16份，钾长石39份，黑泥18份，膨润土9.5份，滑石8份，碳化硅0.4份，减水剂0.5份，分散剂0.2份，混合，经破碎、湿法球磨，所得浆料经过高梯度磁选机进行除铁，再干燥造粒，陈腐，得到保温层材料；
步骤(2)过渡层材料的制备：按重量份数计，称量青砂33.47份，钠长石13.92份，钾长石28.6份，黑泥11.16份，膨润土5.89份，滑石4.96份，碳化硅0.1份，减水剂0.31份和分散剂0.12份，混合，经破碎、湿法球磨，所得浆料经过高梯度磁选机进行除铁，干燥造粒、陈腐，得到过渡层材料；
步骤(3)制釉：按重量份数计，称量青砂18.22份，钠长石29.9份，钾长石37.16份，黑泥6.07份，膨润土3.21份，滑石2.7份，碳化硅0.13份，减水剂0.17份、分散剂0.07份和颜料3.5份，混合，用釉磨湿法球磨，所得浆料经过高梯度磁选机进行除铁，得到釉浆；
步骤(4)压坯：将保温层材料与过渡层材料经二次布料一次压坯得到素坯Ⅱ；
步骤(5)装饰与烧制：素坯Ⅱ干燥后用釉浆进行上釉或在釉上印制图案，于1175℃辊道窑中烧制得到气均匀、带有瓷砖饰面的泡沫陶瓷保温饰面板。
实施例1和实施例2得到的产品经检测的性能指标如表1所示。
表1
Figure BDA0002836650530000041
Figure BDA0002836650530000051
由表1可知，运用本发明的配方和方法生产的轻质高强泡沫陶瓷保温饰面板的容重、导热系数、吸水率都比对比例的小，说明本发明产品的质量更轻，保温效果更好，防水防潮性能更佳，而抗压强度和抗拉强度都比对比例高，说明本发明产品具有更好的抗压和抗折性能，上述性能能够适应装配整体式墙体在重压、强震状态下的一体化生产。另外，由实施例1和实施例2的对比可以看出，增加了过渡层的实施例2具有更高的抗压强度和抗拉强度，可以根据实际应用场景或性能需求灵活选择实施例1或实施例2的产品。
以上对本发明提供的一种轻质高强泡沫陶瓷保温饰面板及其制备方法和应用进行了详细的介绍，本文中应用了具体实施例对本发明的原理及实施方式进行了阐述，以上实施例的说明只是用于帮助理解本发明的方法及其核心思想，包括最佳方式，并且也使得本领域的任何技术人员都能够实践本发明，包括制造和使用任何装置或系统，和实施任何结合的方法。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，还可以对本发明进行若干改进和修饰，这些改进和修饰也落入本发明权利要求的保护范围内。本发明专利保护的范围通过权利要求来限定，并可包括本领域技术人员能够想到的其他实施例。如果这些其他实施例具有不是不同于权利要求文字表述的结构要素，或者如果它们包括与权利要求的文字表述无实质差异的等同结构要素，那么这些其他实施例也应包含在权利要求的范围内。

Claims (10)

1.一种轻质高强泡沫陶瓷保温饰面板，其特征在于，所述泡沫陶瓷保温饰面板包括坯体层和装饰釉层，所述坯体层由保温层或者保温层和过渡层组成；
所述保温层主要由以下组分制得：青砂、钠长石、钾长石、黑泥、膨润土、滑石、碳化硅、减水剂和分散剂，所述青砂和碳化硅的质量比为(1-3):(0.005-0.05)；
所述装饰釉层主要由以下组分制得：青砂、钠长石、钾长石、黑泥、膨润土、滑石、碳化硅、减水剂、分散剂和颜料；
所述过渡层主要由以下组分制得：青砂、钠长石、钾长石、黑泥、膨润土、滑石、碳化硅、减水剂和分散剂，所述青砂和碳化硅质量比为(1-2):(0.0005-0.025)。
2.根据权利要求1所述的轻质高强泡沫陶瓷保温饰面板，其特征在于，所述保温层主要由以下质量份的组分制得：青砂20-60份，钠长石4-20份，钾长石12-40份，黑泥5-20份，膨润土3-10份，滑石2-10份，碳化硅0.1-1.0份，减水剂0.1-1.0份和分散剂0.1-1.0份。
3.根据权利要求1所述的轻质高强泡沫陶瓷保温饰面板，其特征在于，所述装饰釉层主要由以下质量份的组分制得：青砂10-30份，钠长石18-42份，钾长石20-51份，黑泥2-15份，膨润土1-5份，滑石1-5份，碳化硅0.05-0.2份，减水剂0.1-0.5份、分散剂0.01-0.1份和颜料1-10份。
4.根据权利要求1所述的轻质高强泡沫陶瓷保温饰面板，其特征在于，所述过渡层主要由以下质量份的组分制得：青砂20-40份，钠长石5-30份，钾长石15-40份，黑泥5-15份，膨润土2-10份，滑石2-10份，碳化硅0.01-0.5份，减水剂0.1-0.5份和分散剂0.1-0.5份。
5.根据权利要求1所述的轻质高强泡沫陶瓷保温饰面板，其特征在于，所述减水剂为纯碱、水玻璃、六偏磷酸钠或焦磷酸钠中的一种或几种。
6.根据权利要求1所述的泡沫陶瓷保温饰面板，其特征在于，所述分散剂为三聚磷酸钠、焦磷酸钠、水玻璃、腐植酸钠、CMC、柠檬酸钠中的一种或几种。
7.根据权利要求1所述的轻质高强泡沫陶瓷保温饰面板，其特征在于，所述颜料为釉中彩或釉上彩矿物颜料。
8.权利要求1-7任一项所述的轻质高强泡沫陶瓷保温饰面板的制备方法，其特征在于，包括以下步骤：
保温层材料的制备：将保温层的各组分混合，再破碎、湿法球磨、喷雾干燥造粒、陈腐，得到保温层材料；
过渡层材料的制备：将过渡层的各组分混合，再破碎、湿法球磨、喷雾干燥造粒、陈腐，得到过渡层材料；
制釉：将装饰釉层的各组分混合，用釉磨湿法球磨，得到釉浆；
压坯：将保温层材料经一次布料压坯得到素坯Ⅰ，或将保温层材料与过渡层材料经二次布料一次压坯得到素坯Ⅱ；
装饰与烧制：将素坯Ⅰ或素坯Ⅱ干燥，淋釉浆或在釉上3D喷墨打印花纹，烧结，即得泡沫陶瓷保温饰面板。
9.根据权利要求8所述的制备方法，其特征在于，所述烧结的温度为1150℃—1185℃。
10.权利要求1-7任一项所述的轻质高强泡沫陶瓷保温饰面板在装饰墙体中的应用。
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