CN113354404A - 一种仿砂岩抛光砖及其生产方法 - Google Patents
一种仿砂岩抛光砖及其生产方法 Download PDFInfo
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Abstract
本发明属于抛光砖技术领域,具体涉及一种仿砂岩抛光砖及其生产方法。本发明提供的仿砂岩抛光砖,包括以下原料及其质量份数:钠石粉8‑13份、湖南低温砂7‑10份、水洗球土5‑9份、ABC球土10‑13份、低温钠石粒12‑16份、石英砂17‑22份、101#水磨砂3‑8份、黑滑石1‑2份、高桥钾石粒9‑13份、水洗钾砂6‑10份。本发明制得的仿砂岩抛光砖具有色彩多样、色层间过渡自然、砂粒感清晰明显、纹路流线性突出、图案纹理曲线节奏灵活多变的仿天然砂岩效果。本发明产品的各项性能均高于国家标准要求,本发明产品可以满足所有建筑装修所需抛光砖的要求。
Description
技术领域
本发明属于抛光砖技术领域,具体涉及一种仿砂岩抛光砖及其生产方法。
背景技术
天然砂岩作为建筑常用的石材材料之一,其典雅大方的气质,自然流畅的美感让消费者在选择装饰材料的时候总是爱不释手。产品一经开采面世,便长久未衰。然而自然界天然矿石的形成总是漫长的,随着建筑业对砂岩需求量的不断增加,人类对砂岩石材的开采总会有停止不前的一天。人们正是看到了这种情况,又不舍离开自己钟爱的建筑装饰材料—砂岩,最终在常用建筑装饰材料的陶瓷制品上找到了答案。于是,各类仿天然砂岩瓷质砖应运而生。目前,市场上仿砂岩抛光砖花色相对单一,对不同形状的砖面纹理刻画缺乏自然变化,图案效果不够逼真。究其原理,是因为自然界地质变化形成砂岩是一个极其复杂的过程,采用一般的技术工艺显然难以使产品外观达到天然砂岩应有的效果。
本发明在对天然砂岩形成过程的研究基础之上,结合陶瓷制品的生产工艺及对艺术元素的融合,不断试验,希望能够在工厂现有设备及生产能力的基础上生产出一种不失天然砂岩的装饰效果又具有较好的性能的仿砂岩抛光砖。这样的陶瓷产品,便能满足现代人对建筑装饰材料自然化的高要求。而在工艺上能够实现生产连续稳定、性能优越、装饰性好、操作简单、价格合理的仿砂岩抛光砖,是使研发成果走向市场实现其经济价值的必然之路。本发明正是为满足人们对高仿真砂岩的不断需求,推动陶瓷行业仿石效果更加逼真化及实现企业自身经济增长的要求下提出而来。
发明内容
针对现有技术的不足,本发明的目的在于提供一种仿砂岩抛光砖及其生产方法。本发明制得的仿砂岩抛光砖具有色彩多样、色层间过渡自然、砂粒感清晰明显、纹路流线性突出、图案纹理曲线节奏灵活多变的仿天然砂岩效果。本发明制得的仿砂岩抛光砖具有色彩多样性图案纹理,清晰逼真的砂粒效果,因此动态感强烈,更能体现天然砂岩的自然流动美感。而且本发明产品的各项性能均高于国家标准要求,本发明产品可以满足所有建筑装修所需抛光砖的要求。
本发明的技术方案是:
一种仿砂岩抛光砖,包括以下原料及其质量份数:
钠石粉8-13份、湖南低温砂7-10份、水洗球土5-9份、ABC球土10-13份、低温钠石粒12-16份、石英砂17-22份、101#水磨砂3-8份、黑滑石1-2份、高桥钾石粒9-13份、水洗钾砂6-10份。
进一步地的,所述的仿砂岩抛光砖,包括以下原料及其质量份数:
钠石粉12份、湖南低温砂9份、水洗球土8份、ABC球土12份、低温钠石粒15份、石英砂20份、101#水磨砂5份、黑滑石1份、高桥钾石粒10份、水洗钾砂9份。
另外,本发明还提供了仿砂岩抛光砖的生产方法,步骤如下:
S1按照配方要求,所需原料由铲车送往电子秤,称量后,经皮带输送机运输到指定球磨机进行球磨,得球磨后浆料;
S2将步骤S1所得球磨后浆料进行除铁、过筛处理,将所得泥浆送入泥浆池中均化,浆料配色,将配色后的浆料喷雾进入干燥塔内,得粉料;
S3对步骤S2所得粉料进行陈腐处理,陈腐时间为70-78h,得陈腐后粉料;
S4对步骤S3所得陈腐后粉料进行多次布料,压制成型,得坯料;
S5对步骤S4所得坯料进行干燥处理,得干坯;
S6在步骤S5所得干坯表面进行施釉,得施釉后的坯料;
S7将步骤S6施釉后的坯料进行烧成处理,将烧成后的瓷砖依次进行磨边、抛光打蜡、分级检选、包装、入库。
进一步地,所述步骤S1球磨的具体操作为:球磨时间为11-14h,转速为20r/min,所用球石为中铝球石,球石:料:水为1:1:0.5。
进一步地,所述步骤S2进入泥浆池的泥浆的主要工艺参数控制如下:含水率33%,细度(250目筛余)0.9-1.1%,泥浆比重≥1.69g/mL,流动性40±5s,过筛目数60~80目。
进一步地,所述步骤S3陈腐后粉料的控制工艺参数如下:含水率5.6~6.1%,容重0.91g/mL,颗粒级配(筛上)为:30目<20%,40目50~60%,60目>90%,100目筛下<2.5%。
进一步地,所述步骤S4所述多次布料具体为:采用多管(24条)布料技术,通过微电脑高精度数字化控制每条料管的下料时间、位置及下料量等工艺参数,采用梯形玻璃盒内粉料自由下落的布料方法。
进一步地,所述步骤S7所述烧成处理具体为:采用一次烧成工艺,烧成周期55~65分钟,最高烧成温度1175℃。
本发明对坯料加以改进。坯料性能的改进使其具有较好的流动性,确保在布料管道内流畅运行而不致塞管、在玻璃盒内运动自如而顺利再现砂流效果;坯料配方的改进以确保最终产品图案中砂粒效果逼真,颗粒感强。
本发明通过改进生产工艺,采用多管(24条)布料技术,通过微电脑高精度数字化控制每条料管的下料时间、位置及下料量等工艺参数,确保产品色调的丰富多样性及花样的随机性。本发明采用梯形玻璃盒内粉料自由下落的布料方法。粉料的自由流动模拟了天然砂岩的形成过程,形成动态感更加强烈的流砂效果纹理,根本上克服了目前仿砂岩陶瓷砖纹路变化少、变化不够自然等缺陷。使天然砂岩的仿真度得到了大大的提高。另外,采用玻璃盒有利于随时观察盒内布料情况,达到布料可在线监控的目的,确保布料系统的稳定性。每块砖坯料都是由五个循环布料系统组成,每个循环有多种二次重组的色料参与,色料间相互对冲下料,保证了不同颜色的自然混合效果,最终产品表面色层间过渡自然协调,给人柔和舒适的感觉,克服了同类产品色调过渡呆板的缺陷。
本发明仿砂岩抛光砖的开发采用了改进性能、配方的坯料及改进的生产工艺,以天然砂岩图案为设计参考,严格控制各工艺过程,使之为能够获得高仿真的天然砂岩效果提供保障。为了得到天然砂岩自然清晰的纹路,再现砂粒的流动效果,本发明采用多管输送及混合不同色料、可视玻璃盒内粉料自由下落布料的方式,不断改进配方、烧成制度等工艺。经后续打磨、切削及抛光工序,最终该系列产品性能优异,无论产品的表面装饰效果还是内在品质都超越了当前市面上的同类产品。
与现有技术相比,本发明具有以下优势:
(1)天然砂岩作为地质变化过程中形成的变质岩,其强度较低,使用时必须精心养护,不可直接用水冲洗,不可接触非中性物品,不可随意上蜡,不可乱用非中性清洁剂等。随着砂岩不断的开采,其价格会越来越高。与天然砂岩石材相比,本发明仿砂岩抛光砖作为瓷质砖,其强度较高,使用时不必专门养护,化学性能优良,使用性能好。随着仿砂岩抛光砖生产技术的不断完善,其价格只会越来越低。
(2)本发明仿砂岩抛光砖采用了改进性能和配方的坯料,以及多管道下料、粉料在玻璃盒内以自由落体运动的布料技术。产品的流砂纹理曲线是坯料在玻璃盒内自由运动形成而来,图案颜色由料管内色料的多次混合重组而加以控制。最终产品的纹理变化自然,变幅较大,完美的突显了流砂效果。在颜色方面,色层间过渡自然柔和,色调多样。砂粒的颗粒感与整体图案纹理及色调相结合,完美再现了天然砂岩的图案效果。而行业同类产品多采用普通层状布料或控制机械手布料,均没有模拟天然砂岩在自然界地质变化中的形成过程。相比之下,本发明形成的条纹更加自然流畅、曲线多变,而行业同类产品多僵硬呆板;本发明形成的图案色调多样,过渡自然协调,给人以柔和舒适感,而行业同类产品色调变化迅速直接,色层间过渡幅度较大,视觉上缺乏整体美感。另外,本发明采用多管及玻璃盒内自由运动的布料工艺来控制条纹图案及颜色的过渡,使得色调与纹理能够很好的融合,视觉上更能体现出动态美,协调美。
(3)本发明制得的仿砂岩抛光砖的各项性能均高于国家标准要求,可以满足所有建筑装修所需抛光砖的要求。
附图说明
图1为本发明实施例中仿砂岩抛光砖的烧成曲线图。
图2为本发明实施例3制得的仿砂岩抛光砖。
图3为对比例1的砂岩砖。
图4为对比例2的砂岩砖。
具体实施方式
以下通过具体实施方式的描述对本发明作进一步说明,但这并非是对本发明的限制,本领域技术人员根据本发明的基本思想,可以做出各种修改或改进,但是只要不脱离本发明的基本思想,均在本发明的范围之内。
本发明以下实施例中所用原料的化学组成如表1所示。
表1:原料的化学组成
本发明以下实施例中烧成参数控制如表2所示,烧成曲线图如图1所示。
表2:烧成参数控制
实施例1、一种仿砂岩抛光砖
所述仿砂岩抛光砖,包括以下原料及其质量份数:
钠石粉8份、湖南低温砂7份、水洗球土5份、ABC球土10份、低温钠石粒12份、石英砂17份、101#水磨砂3份、黑滑石1份、高桥钾石粒9份、水洗钾砂6份。
所述仿砂岩抛光砖的生产方法,步骤如下:
S1按照配方要求,所需原料由铲车送往电子秤,称量后,经皮带输送机运输到指定球磨机进行球磨,球磨时间为11h,转速为20r/min,所用球石为中铝球石,球石:料:水为1:1:0.5,得球磨后浆料;
S2将步骤S1所得球磨后浆料进行除铁、过筛处理,将所得泥浆送入泥浆池中均化,进入泥浆池的泥浆的主要工艺参数控制如下:含水率33%,细度(250目筛余)1.1%,泥浆比重1.73g/mL,流动性35s,过筛目数60目,浆料配色,将配色后的浆料喷雾进入干燥塔内,得粉料;
S3对步骤S2所得粉料进行陈腐处理,陈腐时间为70h,得陈腐后粉料;
S4对步骤S3所得陈腐后粉料进行多次布料,所述多次布料具体为:采用多管(24条)布料技术,通过微电脑高精度数字化控制每条料管的下料时间、位置及下料量等工艺参数,采用梯形玻璃盒内粉料自由下落的布料方法,压制成型,得坯料;
S5对步骤S4所得坯料进行干燥处理,得干坯;
S6在步骤S5所得干坯表面进行施釉,得施釉后的坯料;
S7将步骤S6施釉后的坯料进行烧成处理,采用一次烧成工艺,烧成周期55分钟,最高烧成温度1175℃,烧成参数控制如表2所示,烧成曲线图如图1所示,将烧成后的瓷砖依次进行磨边、抛光打蜡、分级检选、包装、入库。
实施例2、一种仿砂岩抛光砖
所述仿砂岩抛光砖,包括以下原料及其质量份数:
钠石粉13份、湖南低温砂10份、水洗球土9份、ABC球土13份、低温钠石粒16份、石英砂22份、101#水磨砂8份、黑滑石2份、高桥钾石粒13份、水洗钾砂10份。
所述仿砂岩抛光砖的生产方法,步骤如下:
S1按照配方要求,所需原料由铲车送往电子秤,称量后,经皮带输送机运输到指定球磨机进行球磨,球磨时间为12h,转速为20r/min,所用球石为中铝球石,球石:料:水为1:1:0.5,得球磨后浆料;
S2将步骤S1所得球磨后浆料进行除铁、过筛处理,将所得泥浆送入泥浆池中均化,进入泥浆池的泥浆的主要工艺参数控制如下:含水率33%,细度(250目筛余)1%,泥浆比重1.70g/mL,流动性45s,过筛目数70目,浆料配色,将配色后的浆料喷雾进入干燥塔内,得粉料;
S3对步骤S2所得粉料进行陈腐处理,陈腐时间为78h,得陈腐后粉料;
S4对步骤S3所得陈腐后粉料进行多次布料,所述多次布料具体为:采用多管(24条)布料技术,通过微电脑高精度数字化控制每条料管的下料时间、位置及下料量等工艺参数,采用梯形玻璃盒内粉料自由下落的布料方法,压制成型,得坯料;
S5对步骤S4所得坯料进行干燥处理,得干坯;
S6在步骤S5所得干坯表面进行施釉,得施釉后的坯料;
S7将步骤S6施釉后的坯料进行烧成处理,采用一次烧成工艺,烧成周期65分钟,最高烧成温度1175℃,烧成参数控制如表2所示,烧成曲线图如图1所示,将烧成后的瓷砖依次进行磨边、抛光打蜡、分级检选、包装、入库。实施例3、一种仿砂岩抛光砖,包括以下原料及其质量份数:
钠石粉12份、湖南低温砂9份、水洗球土8份、ABC球土12份、低温钠石粒15份、石英砂20份、101#水磨砂5份、黑滑石1份、高桥钾石粒10份、水洗钾砂9份。
所述仿砂岩抛光砖的生产方法,步骤如下:
S1按照配方要求,所需原料由铲车送往电子秤,称量后,经皮带输送机运输到指定球磨机进行球磨,球磨时间为14h,转速为20r/min,所用球石为中铝球石,球石:料:水为1:1:0.5,得球磨后浆料;
S2将步骤S1所得球磨后浆料进行除铁、过筛处理,将所得泥浆送入泥浆池中均化,进入泥浆池的泥浆的主要工艺参数控制如下:含水率33%,细度(250目筛余)0.9%,泥浆比重1.69g/mL,流动性40s,过筛目数80目,浆料配色,将配色后的浆料喷雾进入干燥塔内,得粉料;
S3对步骤S2所得粉料进行陈腐处理,陈腐时间为74h,得陈腐后粉料;
S4对步骤S3所得陈腐后粉料进行多次布料,所述多次布料具体为:采用多管(24条)布料技术,通过微电脑高精度数字化控制每条料管的下料时间、位置及下料量等工艺参数,采用梯形玻璃盒内粉料自由下落的布料方法,压制成型,得坯料;
S5对步骤S4所得坯料进行干燥处理,得干坯;
S6在步骤S5所得干坯表面进行施釉,得施釉后的坯料;
S7将步骤S6施釉后的坯料进行烧成处理,采用一次烧成工艺,烧成周期60分钟,最高烧成温度1175℃,烧成参数控制如表2所示,烧成曲线图如图1所示,将烧成后的瓷砖依次进行磨边、抛光打蜡、分级检选、包装、入库。
对比例1、现有市面上某厂家砂岩砖。
对比例2、现有市面上某厂家砂岩砖。
本发明仿砂岩抛光砖与现有市面上的同类产品的比较如表3所示。本发明仿砂岩抛光砖与现有市面上的同类产品(对比例1、对比例2)对比图如图2-4所示。
表3:本发明仿砂岩抛光砖与现有市面上的同类产品的比较
Claims (8)
1.一种仿砂岩抛光砖,其特征在于,包括以下原料及其质量份数:
钠石粉8-13份、湖南低温砂7-10份、水洗球土5-9份、ABC球土10-13份、低温钠石粒12-16份、石英砂17-22份、101#水磨砂3-8份、黑滑石1-2份、高桥钾石粒9-13份、水洗钾砂6-10份。
2.如权利要求1所述的仿砂岩抛光砖,其特征在于,包括以下原料及其质量份数:钠石粉12份、湖南低温砂9份、水洗球土8份、ABC球土12份、低温钠石粒15份、石英砂20份、101#水磨砂5份、黑滑石1份、高桥钾石粒10份、水洗钾砂9份。
3.如权利要求1或2所述的仿砂岩抛光砖的生产方法,其特征在于,步骤如下:S1按照配方要求,所需原料由铲车送往电子秤,称量后,经皮带输送机运输到指定球磨机进行球磨,得球磨后浆料;
S2将步骤S1所得球磨后浆料进行除铁、过筛处理,将所得泥浆送入泥浆池中均化,浆料配色,将配色后的浆料喷雾进入干燥塔内,得粉料;
S3对步骤S2所得粉料进行陈腐处理,陈腐时间为70-78h,得陈腐后粉料;
S4对步骤S3所得陈腐后粉料进行多次布料,压制成型,得坯料;
S5对步骤S4所得坯料进行干燥处理,得干坯;
S6在步骤S5所得干坯表面进行施釉,得施釉后的坯料;
S7将步骤S6施釉后的坯料进行烧成处理,将烧成后的瓷砖依次进行磨边、抛光打蜡、分级检选、包装、入库。
4.如权利要求3所述的仿砂岩抛光砖的生产方法,其特征在于,所述步骤S1球磨的具体操作为:球磨时间为11-14h,转速为20r/min,所用球石为中铝球石,球石:料:水为1:1:0.5。
5.如权利要求3所述的仿砂岩抛光砖的生产方法,其特征在于,所述步骤S2进入泥浆池的泥浆的主要工艺参数控制如下:含水率33%,细度(250目筛余)0.9-1.1%,泥浆比重≥1.69g/mL,流动性40±5s,过筛目数60~80目。
6.如权利要求3所述的仿砂岩抛光砖的生产方法,其特征在于,所述步骤S3陈腐后粉料的控制工艺参数如下:含水率5.6~6.1%,容重0.91g/mL,颗粒级配(筛上)为:30目<20%,40目50~60%,60目>90%,100目筛下<2.5%。
7.如权利要求3所述的仿砂岩抛光砖的生产方法,其特征在于,所述步骤S4所述多次布料具体为:采用多管(24条)布料技术,采用梯形玻璃盒内粉料自由下落的布料方法。
8.如权利要求3所述的仿砂岩抛光砖的生产方法,其特征在于,所述步骤S7所述烧成处理具体为:采用一次烧成工艺,烧成周期55~65分钟,最高烧成温度1175℃。
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