CN113636828B - 一种单面施釉还青勾瓦烧成工艺 - Google Patents
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Abstract
本发明公开了一种单面施釉还青勾瓦烧成工艺,属于建筑材料技术领域,包括制粉、发酵、压制成型、烘干、施釉、烧成六个步骤,该工艺采用还青烧成法对勾瓦进行单面施釉,制得的产品具有防水作用,防止水分浸入木架,造成房梁腐朽霉烂,延长房梁使用寿命,且烧成后的勾瓦为仿古青色,美丽大气,强度也增强,减少破损率,也防止在运送过程中瓦片跳动损坏。
Description
技术领域
本发明属于建筑材料技术领域,具体涉及一种单面施釉还青勾瓦烧成工艺。
背景技术
仿古勾瓦面积大,重量轻,具有超强自洁功能,易于安装和广泛应用,随着钉的使用,使瓦片以平行排列的方式,使它们重叠以便雨水流下来,仿古屋面系统可以持续50年,仿古勾瓦正在逐步被公认为现有的瓦中最好的屋顶材料。
在勾瓦上施釉,能使瓦面具备防水作用,防止水分浸入木架,造成房梁腐朽霉烂,延长使用寿命,且颜色呈青色,更具仿古韵味,美丽大气,增加强度,但因是单面施釉,正面瓦面在下雨是还是会透水,使得勾瓦的使用期限得不到较大提高。
发明内容
针对现有技术中存在的问题,本发明的目的在于提供一种单面施釉还青勾瓦烧成工艺,该工艺采用还青烧成法对勾瓦进行单面施釉,制得的产品具有防水作用,防止水分浸入木架,造成房梁腐朽霉烂,延长房梁使用寿命,且烧成后的勾瓦为仿古青色,美丽大气,强度也增强,减少破损率,也防止在运送过程中瓦片跳动损坏。
为实现以上目的,本发明采取的技术方案是:
一种单面施釉还青勾瓦烧成工艺,具体工艺步骤如下:
步骤1、制粉:将红页岩和红黏土采用磨粉机进行粉碎,过150-200目筛,得到坯体粉料;
步骤2、发酵:将步骤1得到的坯体粉料加水进行发酵,发酵放置时间为48-54h,得到发酵物料;
步骤3、压制成型:将步骤2得到的发酵物料注入模具中,压制成坯,脱模,得到坯体;
步骤4、烘干:将步骤3得到的坯体烘干至含水率至1.5-2%,得到瓦坯;
步骤5、施釉:采用釉料涂布于瓦坯反面,再经干燥,得到施釉瓦坯;
步骤6、烧成:将步骤5得到的施釉瓦坯转入辊道窑中进行烧成,烧成气氛为强还原气氛,烧成温度控制在1000-1100℃,烧成时间为45-60min,最后进入蒸汽隔氧冷却阶段,温度冷却至室温,得到单面施釉勾瓦。
进一步地,所述红页岩和红黏土之间的质量比为1:2-3。
进一步地,所述步骤3中压制条件为:压力为62-65MPa,温度为100-110℃,保温保压时间为35-40min。
进一步地,所述步骤5采用釉料的原料组成以质量份数计:石灰石10-15份、钾长石25-30份、高岭土2-5份、石英7-9份、色料5-10份、纳米二氧化硅60-80份、异丙醇铝溶液10-15份、水50-55份。
进一步地,所述色料包括梅子青、孔雀绿、钴蓝、镨黄、大红色料中的一种。
进一步地,所述釉料的制备方法是:将上述各组分按质量份数称重,直接放入球磨机中进行球磨,球磨时间为25-30h,得到釉料。
进一步地,所述步骤5中釉料涂布厚度为0.1-0.2mm。
进一步地,所述步骤5中干燥温度为350-400℃,时间为20-30min。
本发明的有益效果是:(1)本发明工艺采用还青烧成法对勾瓦进行单面施釉,制得的产品具有防水作用,防止水分浸入木架,造成房梁腐朽霉烂,延长房梁使用寿命,且烧成后的勾瓦为仿古青色,美丽大气,强度也增强,减少破损率,也防止在运送过程中瓦片跳动损坏;
(2)本发明采用的红黏土在高温烧成时膨胀效率甚微,但失水收缩强烈,故表面收缩,就会造成裂隙发育,但同时在高温烧成过程中,釉料中的纳米二氧化硅层发生熔融后填充于瓦坯孔隙中,提高了产品致密度,不仅如此,在釉料混合制备中,起到了润滑的作用,有利于体系中各组分均匀混合,使得各组分联系紧密,进一步增强釉料强度;釉料中的异丙醇铝溶液在高温烧成时也会形成蒸汽进入瓦坯孔隙结构中,再经过蒸汽隔氧冷却降温,使异丙醇铝水解生成的氧化铝沉积于瓦坯残留孔隙中,将剩余孔隙填满,有利于进一步提高勾瓦的致密度,从微观结构上提高产品致密度和强度,进而降低瓦面的透水度,较大延长勾瓦的使用期限;
(3)本发明采用蒸汽隔氧冷却,因強还原气氛段青黑色通体无红芯氧化层,为了确保高温还原的青色坯体不在降温过程中遇氧气而再次被氧化成弱红色,使得到的施釉瓦表面光润、平滑,坯釉结合性好。
附图说明
图1为本发明制备得到的单面施釉勾瓦产品。
具体实施方式
为了更好地理解本发明,下面结合实施例对本发明的实施方案进行详细描述,但是本领域技术人员将会理解,下列实施例仅用于说明本发明,而不应视为限制本发明的范围。
实施例1:
一种单面施釉还青勾瓦烧成工艺,具体工艺步骤如下:
步骤1、制粉:将红页岩和红黏土采用磨粉机进行粉碎,述红页岩和红黏土之间的质量比为1:2,过150目筛,得到坯体粉料;
步骤2、发酵:将步骤1得到的坯体粉料加水进行发酵,发酵放置时间为48h,得到发酵物料;
步骤3、压制成型:将步骤2得到的发酵物料注入模具中,压制成坯,压力为62MPa,温度为100℃,保温保压时间为40min,脱模,得到坯体;
步骤4、烘干:将步骤3得到的坯体烘干至含水率至1.5%,得到瓦坯;
步骤5、施釉:采用釉料涂布于瓦坯反面,釉料涂布厚度为0.2mm,再经干燥,干燥温度为350℃,时间为20min,得到施釉瓦坯,所述釉料的原料组成以质量份数计:石灰石15份、钾长石25份、高岭土2份、石英9份、色料7份、纳米二氧化硅60份、异丙醇铝溶液10份、水55份,将上述各组分按质量份数称重,直接放入球磨机中进行球磨,球磨时间为25h,得到釉料;
步骤6、烧成:将步骤5得到的施釉瓦坯转入辊道窑中进行烧成,烧成气氛为强还原气氛,烧成温度控制在1000℃,烧成时间为60min,最后进入蒸汽隔氧冷却阶段,温度冷却至室温,得到单面施釉勾瓦。
实施例2:
一种单面施釉还青勾瓦烧成工艺,具体工艺步骤如下:
步骤1、制粉:将红页岩和红黏土采用磨粉机进行粉碎,述红页岩和红黏土之间的质量比为1:3,过200目筛,得到坯体粉料;
步骤2、发酵:将步骤1得到的坯体粉料加水进行发酵,发酵放置时间为54h,得到发酵物料;
步骤3、压制成型:将步骤2得到的发酵物料注入模具中,压制成坯,压力为65MPa,温度为110℃,保温保压时间为35min,脱模,得到坯体;
步骤4、烘干:将步骤3得到的坯体烘干至含水率至2%,得到瓦坯;
步骤5、施釉:采用釉料涂布于瓦坯反面,釉料涂布厚度为0.1mm,再经干燥,干燥温度为400℃,时间为30min,得到施釉瓦坯,所述釉料的原料组成以质量份数计:石灰石10份、钾长石30份、高岭土5份、石英7份、色料5份、纳米二氧化硅80份、异丙醇铝溶液15份、水50份,将上述各组分按质量份数称重,直接放入球磨机中进行球磨,球磨时间为30h,得到釉料;
步骤6、烧成:将步骤5得到的施釉瓦坯转入辊道窑中进行烧成,烧成气氛为强还原气氛,烧成温度控制在1100℃,烧成时间为45min,最后进入蒸汽隔氧冷却阶段,温度冷却至室温,得到单面施釉勾瓦。
实施例3:
一种单面施釉还青勾瓦烧成工艺,具体工艺步骤如下:
步骤1、制粉:将红页岩和红黏土采用磨粉机进行粉碎,述红页岩和红黏土之间的质量比为1:2.5,过160目筛,得到坯体粉料;
步骤2、发酵:将步骤1得到的坯体粉料加水进行发酵,发酵放置时间为50h,得到发酵物料;
步骤3、压制成型:将步骤2得到的发酵物料注入模具中,压制成坯,压力为64MPa,温度为105℃,保温保压时间为38min,脱模,得到坯体;
步骤4、烘干:将步骤3得到的坯体烘干至含水率至1.7%,得到瓦坯;
步骤5、施釉:采用釉料涂布于瓦坯反面,釉料涂布厚度为0.1mm,再经干燥,干燥温度为380℃,时间为25min,得到施釉瓦坯,所述釉料的原料组成以质量份数计:石灰石12份、钾长石27份、高岭土4份、石英8份、色料10份、纳米二氧化硅75份、异丙醇铝溶液12份、水53份,将上述各组分按质量份数称重,直接放入球磨机中进行球磨,球磨时间为26h,得到釉料;
步骤6、烧成:将步骤5得到的施釉瓦坯转入辊道窑中进行烧成,烧成气氛为强还原气氛,烧成温度控制在1080℃,烧成时间为50min,最后进入蒸汽隔氧冷却阶段,温度冷却至室温,得到单面施釉勾瓦。
对比例1:
对比例1与实施例1的不同之处在于,采用的釉料原料组成是石灰石、钾长石、高岭土、石英、梅子青、豆青、异丙醇铝溶液、水,其余工艺步骤内容与实施例1相同。
对比例2:
对比例2与实施例1的不同之处在于,采用的釉料原料组成是石灰石、钾长石、高岭土、石英、梅子青、豆青、纳米二氧化硅、水,其余工艺步骤内容与实施例1相同。
将上述实施例和对比例得到的单面施釉勾瓦进行物理检测,检测结果如表1所示。
表1
从上述表1中可以看出,本发明通过优化釉料配方,以及采用单面施釉及还青烧成工艺,得到的产品具有防水作用,防止水分浸入木架,造成房梁腐朽霉烂,延长房梁使用寿命,且烧成后的勾瓦为仿古青色,美丽大气,强度也增强,减少破损率,瓦面质感细腻平滑,瓦面正面吸水率很低,说明不仅反面施釉防水,正面也因同时加入异丙醇铝溶液和纳米二氧化硅和坯体原料产生协同作用而使勾瓦内部微观结构更加致密,从而透水率大幅度减少,致使吸水率降低,解决瓦面透水问题。
上述对实施例的描述是为了便于该技术领域的普通技术人员理解和使用本发明。熟悉本领域的技术人员可以容易地对这些实施例做出各种修改,并把在此说明的一般原理应用到其他实施例中,而不必经过创造性的劳动。因此,本发明不限于上述实施例。本领域技术人员根据本发明的原理,不脱离本发明的范畴所做出的改进和修改都应该在本发明的保护范围之内。
Claims (7)
1.一种单面施釉还青勾瓦烧成工艺,其特征在于,具体工艺步骤如下:
步骤1、制粉:将红页岩和红黏土采用磨粉机进行粉碎,过150-200目筛,得到坯体粉料;
步骤2、发酵:将步骤1得到的坯体粉料加水进行发酵,发酵放置时间为48-54h,得到发酵物料;
步骤3、压制成型:将步骤2得到的发酵物料注入模具中,压制成坯,脱模,得到坯体;
步骤4、烘干:将步骤3得到的坯体烘干至含水率至1.5-2%,得到瓦坯;
步骤5、施釉:采用釉料涂布于瓦坯反面,再经干燥,得到施釉瓦坯,所述采用釉料的原料组成以质量份数计:石灰石10-15份、钾长石25-30份、高岭土2-5份、石英7-9份、色料5-10份、纳米二氧化硅60-80份、异丙醇铝溶液10-15份、水50-55份;
步骤6、烧成:将步骤5得到的施釉瓦坯转入辊道窑中进行烧成,烧成气氛为强还原气氛,烧成温度控制在1000-1100℃,烧成时间为45-60min,最后进入蒸汽隔氧冷却阶段,温度冷却至室温,得到单面施釉勾瓦。
2.根据权利要求1所述的一种单面施釉还青勾瓦烧成工艺,其特征在于,所述红页岩和红黏土之间的质量比为1:2-3。
3.根据权利要求1所述的一种单面施釉还青勾瓦烧成工艺,其特征在于,所述步骤3中压制条件为:压力为62-65MPa,温度为100-110℃,保温保压时间为35-40min。
4.根据权利要求1所述的一种单面施釉还青勾瓦烧成工艺,其特征在于,所述色料包括梅子青、孔雀绿、钴蓝、镨黄、大红色料中的一种。
5.根据权利要求1所述的一种单面施釉还青勾瓦烧成工艺,其特征在于,所述釉料的制备方法是:将上述各组分按质量份数称重,直接放入球磨机中进行球磨,球磨时间为25-30h,得到釉料。
6.根据权利要求1所述的一种单面施釉还青勾瓦烧成工艺,其特征在于,所述步骤5中釉料涂布厚度为0.1-0.2mm。
7.根据权利要求1所述的一种单面施釉还青勾瓦烧成工艺,其特征在于,所述步骤5中干燥温度为350-400℃,时间为20-30min。
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