CN112876226A - 一种抗切割裂陶瓷岩板、制备方法 - Google Patents
一种抗切割裂陶瓷岩板、制备方法 Download PDFInfo
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- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 claims abstract description 13
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- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
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- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical group O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
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Abstract
本发明提供一种抗切割裂陶瓷岩板,岩板本体自下至上依次包括坯体层、底釉层、装饰层、抛釉层,坯体层原料包括以下成分:α‑氧化铝粉35~47重量份;煅烧滑石7~17重量份;超白水洗球土12~22重量份;超白水洗钠长石粉38~45重量份;无机粘结剂3~7重量份。本发明还提供一种制备方法。α‑氧化铝粉和超白水洗钠长石分为坯体层提供的氧化铝占上述五种成分总重量的重量比可达40%以上,提高烧成过程中形成的莫来石含量,降低玻璃相的比例以降低脆性;过量的氧化铝形成高模弹性模量的刚玉晶相,提高坯体层的强度、韧性、表观密度,控制好烧成温度和时间,可降低冷却后大气泡的量,使小气泡分散开,一定程度降低岩板本体后期冷加工中的切割裂概率。
Description
技术领域
本发明涉及岩板技术领域,尤其涉及一种抗切割裂陶瓷岩板、制备方法。
背景技术
陶瓷岩板是由天然原料经过浆料球磨机碾磨、干燥喷雾塔造粒工艺,借助大压力的液压机压制,经过辊道高温烧制而成,能够经得起切割、钻孔、打磨等加工过程的超大规格新型瓷质材料。陶瓷岩板主要用于家居、厨房板材领域。作为家居领域的新物种,岩板家居相比其他家居产品,具有规格大、可塑造性强、花色多样、耐高温、耐磨刮、防渗透、耐酸碱、零甲醛、环保健康等特性。目前行业内陶瓷岩板遇到的公认的难题之一为切割裂问题,即后期进行切割、开槽、钻眼等深加工时出现不可控的裂纹延展问题。
发明内容
为了克服现有技术的不足,本发明提供一种抗切割裂陶瓷岩板,对坯体层原料进行改进,以提高制得的岩板本体的抗切割裂性能。
为了实现以上目的,本发明通过以下技术方案实现。
本发明提供一种抗切割裂陶瓷岩板,包括岩板本体,所述岩板本体自下至上依次包括坯体层、底釉层、装饰层、抛釉层,其中,所述坯体层原料包括以下成分:
优选地,所述无机粘结剂选自高模数水玻璃、复配磷酸铝中的至少一种。
优选地,所述复配磷酸铝包括摩尔比为1:5~1:3的铬盐和磷酸铝;
和/或所述复配磷酸铝包括摩尔比为1:5~1:3的氢氧化铝和磷酸铝。
优选地,所述高模数水玻璃的模数为3~3.4。
优选地,所述坯体层原料还包括3~10重量份的红柱石。
优选地,所述坯体层原料还包括2~3重量份的碳化硅。
优选地,所述坯体层原料还包括3~10重量份的莫来石纤维。
优选地,所述底釉层原料包括35~60重量份的SiO2、17~21重量份的Al2O3、4~8重量份K2O和Na2O混合物、5~8重量份的CaO、0~2重量份的MgO、0~0.2重量份的Fe2O3、0~0.1重量份的TiO2;所述抛釉层原料包括35~60重量份的SiO2、17~21重量份的Al2O3、4~8重量份K2O和Na2O混合物、8~14重量份的CaO、0~2重量份的MgO、0~0.2重量份的Fe2O3、0~0.1重量份的TiO2。
本发明的第二个目的是提供如上所述的一种抗切割裂陶瓷岩板的制备方法,包括以下步骤:
S1、坯体层配料;
S2、将坯体层各原料和适量水加入球磨机中球磨得泥浆料,过筛,除铁、陈腐;
S3、喷雾干燥制得粉料;
S4、将粉料压制成型,干燥得坯体层;
S5、施底釉料,得底釉层;
S6、图案装饰并干燥,得装饰层;
S7、施抛釉料,得抛釉层;
S8、烧成,得岩板本体。
优选地,所述烧成温度为1180~1270℃,烧成时间为50~90min。
相比现有技术,本发明的有益效果在于:
本发明提供的一种抗切割裂陶瓷岩板,对坯体层原料进行了改进,α-氧化铝粉和超白水洗钠长石分为坯体层提供氧化铝,氧化铝占α-氧化铝粉、煅烧滑石、超白水洗球土、超白水洗钠长石粉、无机粘结剂总重量的重量比可达40%以上,进而提高烧成过程中形成的莫来石含量,降低玻璃相的比例以降低坯体层的脆性;此外,过量的氧化铝形成高模弹性模量的刚玉晶相,以提高坯体层的强度、韧性、表观密度,控制好烧成温度和时间,可降低冷却后大气泡的量,且能够使小气泡分散开,一定程度降低岩板本体在后期冷加工过程因应力集中导致的切割裂概率。
本上述说明仅是本发明技术方案的概述,为了能够更清楚了解本发明的技术手段,并可依照说明书的内容予以实施,以下以本发明的较佳实施例并配合附图详细说明如后。本发明的具体实施方式由以下实施例及其附图详细给出。
附图说明
此处所说明的附图用来提供对本发明的进一步理解,构成本申请的一部分,本发明的示意性实施例及其说明用于解释本发明,并不构成对本发明的不当限定。在附图中:
图1为本发明的岩板本体的结构剖视图;
图2为本发明的制备方法的步骤流程图。
图中:100、岩板本体;10、坯体层;20、底釉层;30、装饰层;40、抛釉层。
具体实施方式
下面结合附图对本发明做进一步的详细说明,本发明的前述和其它目的、特征、方面和优点将变得更加明显,以令本领域技术人员参照说明书文字能够据以实施。在附图中,为清晰起见,可对形状和尺寸进行放大,并将在所有图中使用相同的附图标记来指示相同或相似的部件。在下列描述中,诸如中心、厚度、高度、长度、前部、背部、后部、左边、右边、顶部、底部、上部、下部等用词为基于附图所示的方位或位置关系。特别地,“高度”相当于从顶部到底部的尺寸,“宽度”相当于从左边到右边的尺寸,“深度”相当于从前到后的尺寸。这些相对术语是为了说明方便起见并且通常并不旨在需要具体取向。涉及附接、联接等的术语(例如,“连接”和“附接”)是指这些结构通过中间结构彼此直接或间接固定或附接的关系、以及可动或刚性附接或关系,除非以其他方式明确地说明。
下面,结合附图以及具体实施方式,对本发明做进一步描述,需要说明的是,在不相冲突的前提下,以下描述的各实施例之间或各技术特征之间可以任意组合形成新的实施例。
本发明提供一种抗切割裂陶瓷岩板,如图1所示,包括岩板本体100,所述岩板本体100自下至上依次包括坯体层10、底釉层20、装饰层30、抛釉层40,其中,所述坯体层10原料包括以下成分:
具体地,坯体层10原料成分组合简单,在烧成过程中,氧化铝和氧化硅形成硅铝复合物莫来石,以作为烧成后的骨架结构,为岩板本体100提供强度。煅烧滑石为经煅烧的滑石,主要成分为3MgO·4SiO2,具有良好的耐酸性、耐腐蚀性、抗粘性,且熔点高、白度成分高、低热导率性能好,进而使得坯体层10白度增强、密度均匀、光泽好、表面平滑。球土为混有石英、云母、有机质的高岭土Al2O3·2SiO2·2H2O,为可塑性黏土,以便于坯体层10的成型,同时为莫来石的形成提供硅成分,超白水洗球土白度不低于80度;超白水洗钠长石粉主要成分是钠长石Na2O·Al2O3·6SiO2(NaAlSi3O8),能够提高形成的坯体层10的白度,白度为50度左右,有利于坯体层后续色料的发色及图案装饰用的墨水的发色,在配方中主要起到降低始熔温度、提供系统初始液相的作用。无机粘结剂用以提高坯体层10各原料之间的粘接力,起到增强作用,即提高坯体层10的强度。α-氧化铝粉和超白水洗钠长石分为坯体层10提供氧化铝,通过合理设计α-氧化铝粉和超白水洗钠长石粉的含量,使得氧化铝占α-氧化铝粉、煅烧滑石、超白水洗球土、超白水洗钠长石粉、无机粘结剂(上述五种成分)总重量的重量比可达40%以上,进而提高烧成过程中形成的莫来石含量,降低玻璃相的比例以降低坯体层10的脆性;此外,过量的氧化铝形成高模弹性模量的刚玉晶相,以提高坯体层10的强度、韧性、表观密度,控制好烧成温度和时间,可降低冷却后大气泡的量,且能够使小气泡分散开,一定程度降低岩板本体100在后期冷加工过程因应力集中导致的切割裂概率。
在一实施例中,所述无机粘结剂选自高模数水玻璃、复配磷酸铝中的至少一种。
进一步地,所述复配磷酸铝包括摩尔比为1:5~1:3的铬盐和磷酸铝;和/或所述复配磷酸铝包括摩尔比为1:5~1:3的氢氧化铝和磷酸铝。具体地,当无机粘结剂包括复配磷酸铝时,复配磷酸铝采用掺有铬盐和/或氢氧化铝的磷酸铝,得到的复配混合物,以提高无机粘结剂的粘结性能,加快无机粘结剂的固化速度。
进一步地,所述高模数水玻璃的模数为3~3.4,水玻璃模数越大,氧化硅含量越多,进而提高水玻璃的粘度,易于分解硬化,提高粘结性能。
在一实施例中,所述坯体层10原料还包括3~10重量份的红柱石。红柱石是硅线石矿物组的矿物,制备岩板本体100时,在高温烧成过程中,红柱石分解生成二氧化硅相和莫来石网络,以改善形成的岩板本体100的高温烧成过程中出现裂纹的现象,进而提高制得的岩板本体100的整体强度。
在一实施例中,所述坯体层10原料还包括2~3重量份的碳化硅。碳化硅具有低的热膨胀系数和高导热系数,在高温烧成或冷却过程中受到的热应力小,以改善形成的岩板本体100的高温烧成过程中出现裂纹的现象,进而提高制得的岩板本体100的整体强度。此外,碳化硅的添加,还提高了制得的岩板本体100的抗热震性,当岩板本体100后期加工,如切割、开槽、钻眼等深加工时,加工工具与岩板本体100产生的摩擦瞬时高温时,降低岩板本体100的切割断裂概率。
在一实施例中,所述坯体层10原料还包括3~10重量份的莫来石纤维。莫来石纤维为一维结构,莫来石纤维穿插于各晶相原料之间,在形成的莫来石骨架中起到增韧作用,提高岩板本体100的抗冲击性能,防止岩板本体100后期加工出现断裂。
在一实施例中,所述底釉层20原料包括35~60重量份的SiO2、17~21重量份的Al2O3、4~8重量份K2O和Na2O混合物、5~8重量份的CaO、0~2重量份的MgO、0~0.2重量份的Fe2O3、0~0.1重量份的TiO2。
在一实施例中,所述抛釉层40原料包括35~60重量份的SiO2、17~21重量份的Al2O3、4~8重量份K2O和Na2O混合物、8~14重量份的CaO、0~2重量份的MgO、0~0.2重量份的Fe2O3、0~0.1重量份的TiO2。形成的抛釉层40光滑亮洁,视觉效果好。
本发明还提供如上所述的一种抗切割裂陶瓷岩板的制备方法,如图2所示,包括以下步骤:
S1、坯体层配料,即按配方配好各原料以备用;
S2、将坯体层各原料和适量水加入球磨机中球磨得泥浆料,过筛,除铁、陈腐;具体地,各原料和水的重量比为1:0.5~0.8,加工得的泥浆料325目筛余不超过3%,除铁后陈腐24h以上,获得混合均匀的泥浆料;
S3、喷雾干燥制得粉料,粉料含水率为5.5~7.0%,陈腐24h以上以平衡粉料含水率;
S4、将粉料压制成型,干燥得坯体层;可采用压机进行压制成型,压力为380~400Kg/cm2;压制成型的坯体在干燥窑里干燥,制得坯体层10;
S5、施底釉料,得底釉层;进一步地,施底釉料前先采用坯磨抛设备去除坯体层10表面杂质,并在坯体层10朝向底釉层20的一面喷施一定量的水分,喷水量为35~40g/m2,以便于底釉料的施加;可采用喷洒或喷淋进行底釉料的施加;
S6、图案装饰并干燥,得装饰层;具体地,可采用喷墨设备,将图案所需的墨水按照设计图案喷施于底釉层20外表面,采用干燥设备将油墨干燥固化,以形成所需的清晰的图案装饰;
S7、施抛釉料,具体地,采用辊筒印刷抛釉料,经烧成后形成具有亮丽镜面效果的抛釉层;
S8、烧成,得岩板本体。
进一步地,在步骤S8中,所述烧成温度为1180~1270℃,烧成时间为50~90min。
进一步地,还包括步骤抛光,对烧成所得的岩板本体进行抛光磨边处理,使得岩板本体10表面光洁亮丽。
进一步地,还包括步骤检选、包装,以便出货。
为了阐述本文的发明,以下以具体实施例进行阐述。应当理解这些实施例仅用于说明性目的并且不应被理解为以任何方式限制本发明。
实施例1
如上所述的一种抗切割裂陶瓷岩板的制备方法,包括以下步骤:
(1)称取35重量份的α-氧化铝粉、7重量份的煅烧滑石、12重量份的超白水洗球土、38重量份的超白水洗钠长石粉、3重量份的无机粘结剂;无机粘结剂为模数为3的水玻璃;
(2)将步骤(1)称取的各原料和47.5重量份的水加入球磨机中球磨得泥浆料,325目筛余3%,除铁后陈腐24h以上,获得混合均匀的泥浆;
(3)喷雾干燥制得粉料,粉料含水率为5.5%,陈腐24h以上;
(4)将粉料压制成型,压力为380Kg/cm2,干燥得坯体层,坯体层长3.4m、宽1.5m、厚6mm;
(5)施底釉料,底釉料包括60重量份的SiO2、21重量份的Al2O3、5重量份K2O和Na2O混合物、5重量份的CaO、2重量份的MgO、0.2重量份的Fe2O3、0.1重量份的TiO2;得底釉层;
(6)采用喷墨设备,将图案所需的墨水按照设计图案喷施于底釉层20外表面,采用干燥设备将油墨干燥固化,以形成所需的清晰的图案装饰,形成装饰层30;
(7)采用辊筒印刷抛釉料,抛釉料包括60重量份的SiO2、21重量份的Al2O3、4重量份K2O和Na2O混合物、12重量份的CaO、2重量份的MgO、0.2重量份的Fe2O3、0.1重量份的TiO2;形成抛釉层40;
(8)烧成,烧成温度为1180℃,烧成时间为90min,得岩板本体。
实施例2
本实施例中坯体层10原料包括47重量份的α-氧化铝粉、17重量份的煅烧滑石、22重量份的超白水洗球土、45重量份的超白水洗钠长石粉、7重量份的无机粘结剂,球磨时加69重量份的水。其他成分及工艺步骤与实施例1相同。
实施例3
本实施例中坯体层10原料还包括8重量份的红柱石,球磨时51.5重量份的水,烧成温度为1270℃。其他成分及工艺步骤与实施例1相同。
实施例4
本实施例中坯体层10原料还包括2重量份的碳化硅,球磨时加52.5重量份的水。其他成分及工艺步骤与实施例3相同。
实施例5
本实施例中坯体层10原料还包括7重量份的莫来石纤维,球磨时加56重量份的水。其他成分及工艺步骤与实施例4相同。
对比例1
本实施例中坯体层10原料中α-氧化铝粉含量为17.5重量份,其他成分及工艺步骤与实施例1相同。
对比例2
本实施例中坯体层10原料中α-氧化铝粉含量为25重量份,其他成分及工艺步骤与实施例1相同。
实施例6
将实施例1至实施例5及对比例1、对比例2的岩板板材切割成500mm×300mm规格的板材,按GB/T3810.4方法进行检测,检测结果见表一。
表一
由表一可知,实施例1与实施例3相比、实施例3与实施例4相比、实施例4与实施例5相比,红柱石、碳化硅、莫来石纤维的添加提高了岩板本体的断裂模数,进而提高相应的岩板本体的抗切割裂性,在岩板本体后期进行切割、开槽、钻眼等深加工时能够降低裂纹延展问题的出现概率。实施例1分别与对比例1、对比例2对比可知,α-氧化铝粉添加量的限定,对岩板本体的断裂模数的影响比较明显。
以上,仅为本发明的较佳实施例而已,并非对本发明作任何形式上的限制;凡本行业的普通技术人员均可按说明书附图所示和以上而顺畅地实施本发明;但是,凡熟悉本专业的技术人员在不脱离本发明技术方案范围内,利用以上所揭示的技术内容而做出的些许更动、修饰与演变的等同变化,均为本发明的等效实施例;同时,凡依据本发明的实质技术对以上实施例所作的任何等同变化的更动、修饰与演变等,均仍属于本发明的技术方案的保护范围之内。
Claims (10)
2.根据权利要求1所述的一种抗切割裂陶瓷岩板,其特征在于,所述无机粘结剂选自高模数水玻璃、复配磷酸铝中的至少一种。
3.根据权利要求3所述的一种抗切割裂陶瓷岩板,其特征在于,所述复配磷酸铝包括摩尔比为1:5~1:3的铬盐和磷酸铝;
和/或所述复配磷酸铝包括摩尔比为1:5~1:3的氢氧化铝和磷酸铝。
4.根据权利要求3所述的一种抗切割裂陶瓷岩板,其特征在于,所述高模数水玻璃的模数为3~3.4。
5.根据权利要求1所述的一种抗切割裂陶瓷岩板,其特征在于,所述坯体层(10)原料还包括3~10重量份的红柱石。
6.根据权利要求1所述的一种抗切割裂陶瓷岩板,其特征在于,所述坯体层(10)原料还包括2~3重量份的碳化硅。
7.根据权利要求1所述的一种抗切割裂陶瓷岩板,其特征在于,所述坯体层(10)原料还包括3~10重量份的莫来石纤维。
8.根据权利要求1所述的一种抗切割裂陶瓷岩板,其特征在于,所述底釉层(20)原料包括35~60重量份的SiO2、17~21重量份的Al2O3、4~8重量份K2O和Na2O混合物、5~8重量份的CaO、0~2重量份的MgO、0~0.2重量份的Fe2O3、0~0.1重量份的TiO2;所述抛釉层(40)原料包括35~60重量份的SiO2、17~21重量份的Al2O3、4~8重量份K2O和Na2O混合物、8~14重量份的CaO、0~2重量份的MgO、0~0.2重量份的Fe2O3、0~0.1重量份的TiO2。
9.如权利要求1-8任意一项所述的一种抗切割裂陶瓷岩板的制备方法,其特征在于,包括以下步骤:
S1、坯体层配料;
S2、将坯体层各原料和适量水加入球磨机中球磨得泥浆料,过筛,除铁、陈腐;
S3、喷雾干燥制得粉料;
S4、将粉料压制成型,干燥得坯体层;
S5、施底釉料,得底釉层;
S6、图案装饰并干燥,得装饰层;
S7、施抛釉料,得抛釉层;
S8、烧成,得岩板本体。
10.根据权利要求9所述的制备方法,其特征在于,所述烧成温度为1180~1270℃,烧成时间为50~90min。
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