CN113636870A - 一种抗菌耐磨防滑抛釉瓷砖的生产工艺 - Google Patents
一种抗菌耐磨防滑抛釉瓷砖的生产工艺 Download PDFInfo
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Abstract
本发明公开了一种抗菌耐磨防滑抛釉瓷砖的生产工艺，包括坯体成型、喷底釉、氧化锌离子抗菌釉施釉、印花、过氧化钾铁抗菌釉施釉、烧制及冷却、二次干燥、抗菌离子沉积、成品抛光、表面防滑加强处理工艺步骤，加工制备的抗菌抛釉砖，对金色葡萄球菌、大肠埃希氏菌都有99％灭杀和持续灭杀效果，从而解决大部分由这两种细菌所造成的健康问题；同时加工制备的抗菌抛釉砖的防滑系数达到≥0.7，耐磨度达到Ⅴ度，可弥补现阶段陶瓷抛釉砖抗菌效果和防滑耐磨问题，更重要是同时满足消费者对抗菌抛釉砖的抗菌耐用和家居装饰性的要求，让人居空间的装饰效果和抗菌效果不再受局限，更有利于营造舒适、健康、典雅的人居环境，符合现代人们的生活理念。
Description
技术领域
本发明属于瓷砖生产加工技术领域，具体涉及一种抛釉瓷砖的生产工艺。
背景技术
随着社会的不断进步，人们在注重人居空间的舒适性和美观性的同时更加注重空间的卫生与健康，家居装饰材料如陶瓷砖产品倍受消费者青睐。抗菌抛釉砖是相对于传统的抛釉砖而言具有抗菌、杀菌功能的瓷砖，目前市场的抗菌瓷砖技术参差各异，抗菌效率不高、抗菌耐久性低，还有抗菌类问题，同时在使用时还存在瓷砖防滑系数不高、耐磨系数不高的问题，难以满足消费者对于抗菌抛釉砖的抗菌效果和防滑耐磨性能要求，即抗菌抛釉砖的抗菌耐用和家居装饰性的要求。
发明内容
针对现有技术的不足，本发明旨在提供一种能生产出抗菌杀菌功能好、抗菌耐久性好以及防滑、耐磨的抗菌抛釉砖的抗菌耐磨防滑抛釉瓷砖的生产工艺。
为实现上述目的，本发明采用如下技术方案：
一种抗菌耐磨防滑抛釉瓷砖的生产工艺，包括以下步骤：
S1、坯体成型，原料按配方要求配置并制粉后由压机压制成型；
S2、喷底釉，将步骤S1中制得的坯体在110-160℃的温度下干燥，再在70-90℃的条件下喷底釉；
S3、氧化锌离子抗菌釉施釉，在坯体的底釉层表面喷氧化锌离子抗菌釉，且该氧化锌离子抗菌釉的施釉量控制为所用抗菌釉总施量的3/4；
S4、印花，45℃条件下在氧化锌离子抗菌釉的表面喷墨印花；
S5、过氧化钾铁抗菌釉施釉，在喷墨印花层的表面喷过氧化钾铁抗菌釉，且该过氧化钾铁抗菌釉的施釉量控制为所用抗菌釉总施量的1/4；
S6、烧制及冷却，将经过步骤S5施釉处理后的坯体烧制后再冷却，获得抗菌抛釉砖初成品；
S7、二次干燥，将步骤S6获得的抗菌抛釉砖初成品送入加温窑均匀加热干燥，干燥时长10min，温度控制在200-300℃；
S8、抗菌离子沉积，将经过步骤S7干燥后的抗菌抛釉砖初成品马上送入抗菌离子沉积室，控制抗菌离子沉积室的气压在5.5-6.3mPa之间进行抗菌离子沉积，抗菌离子沉积结束后进行系统冷却；
S9、成品抛光，将经过抗菌离子沉积后的抗菌抛釉砖送入抛光线，并使用1200-6000目的磨块对抗菌抛釉砖的表面进行软磨抛光处理，磨块的切削厚度控制在0.15-0.195mm；
S10、表面防滑加强处理，在步骤S9抛光后的抗菌抛釉砖表面喷淋乳液型瓷砖防滑溶液，温度保持在220-350℃之间并保持15min，等瓷砖防滑层成型后，再选用5000-6000目的磨块打磨喷淋有乳液型瓷砖防滑溶液的瓷砖表面；
在打磨好的瓷砖表面再喷淋溶剂型聚合防滑溶液，温度保持在180-280℃之间并保持10min，等瓷砖防滑层成型后，再选用8000-10000目的磨块对瓷砖表面进行打磨，制得抗菌耐磨防滑抛釉瓷砖成品。
氧化锌离子抗菌釉，包括第一层釉料，组分包括石英石40份、磷酸锆10份、磷酸钙8份、鲁道夫氧化银18份、氧化锌12份、氧化铝1.5份及氧化锑0.8份；第二层釉料，组分包括氧化铁21份、钾长石16份、硅石灰9.5份、硝酸钠5份、硅酸锆11份、氧化锌1.15份及酞青蓝1.2份；第三层釉料，组分包括玛瑙石13份、石黏土9份、方解石15.5份、氧化锑13.5份、硝酸钠11份、氧化锌1.15份及水性填充着色剂2.2份。
乳液型瓷砖防滑溶液按质量百分比包括：甲基硅油16％、含氢硅油5％、羟基硅油1.8％、聚醚嵌段氨基硅油5％、AEO-15乳化剂和过氧化氢助剂3.2％、氧化氢稀释剂70％。
溶剂型聚合防滑溶液按质量百分比包括：全氟含氢型聚甲基氢硅氧烷10％、多羟基聚硅氧烷5％、硼酸衍生物2％、多异氰酸酯1％、纳米氧化铝5％、氧化氢稀释剂78％。
采用这种生产工艺加工制备的抗菌抛釉砖，对金色葡萄球菌、大肠埃希氏菌都有99％灭杀和持续灭杀效果，从而解决大部分由这两种细菌所造成的健康问题；同时加工制备的抗菌抛釉砖的防滑系数达到≥0.7，耐磨度达到Ⅴ度，可弥补现阶段陶瓷抛釉砖抗菌效果和抗菌抛釉砖的防滑耐磨问题，更重要是同时满足消费者对抗菌抛釉砖的抗菌耐用和家居装饰性的要求，让人居空间的装饰效果和抗菌效果不再受局限，更有利于营造舒适、健康、典雅的人居环境，符合现代人们的生活理念。
本发明具有如下有益效果：
本发明抗菌耐磨防滑抛釉瓷砖的生产工艺，加工制备的抗菌抛釉砖，对金色葡萄球菌、大肠埃希氏菌都有99％灭杀和持续灭杀效果，从而解决大部分由这两种细菌所造成的健康问题；同时加工制备的抗菌抛釉砖的防滑系数达到≥0.7，耐磨度达到Ⅴ度，可弥补现阶段陶瓷抛釉砖抗菌效果和抗菌抛釉砖的防滑耐磨问题，更重要是同时满足消费者对抗菌抛釉砖的抗菌耐用和家居装饰性的要求，让人居空间的装饰效果和抗菌效果不再受局限，更有利于营造舒适、健康、典雅的人居环境，符合现代人们的生活理念。
附图说明
图1为本发明抗菌耐磨防滑抛釉瓷砖的生产工艺流程图；
图2为采用本发明抗菌耐磨防滑抛釉瓷砖的生产工艺制备的抗菌耐磨防滑抛釉瓷砖的抗菌性能测试报告。
具体实施方式
下面结合附图及具体实施例，对本发明作进一步的描述，以便于更清楚地理解本发明要求保护的技术思想。
如图1所示本发明抗菌耐磨防滑抛釉瓷砖的生产工艺，包括以下步骤：
S1、坯体成型，原料按配方要求配置并制粉后由压机压制成型；
S2、喷底釉，将步骤S1中制得的坯体在110-160℃的温度下干燥，再在70-90℃的条件下喷底釉；
S3、氧化锌离子抗菌釉施釉，在坯体的底釉层表面喷氧化锌离子抗菌釉，且该氧化锌离子抗菌釉的施釉量控制为所用抗菌釉总施量的3/4；
S4、印花，45℃条件下在氧化锌离子抗菌釉的表面喷墨印花；
S5、调配过氧化钾铁抗菌釉施釉，在喷墨印花层的表面喷过氧化钾铁抗菌釉，且该过氧化钾铁抗菌釉的施釉量控制为所用抗菌釉总施量的1/4；
S6、烧制及冷却，将经过步骤S5施釉处理后的坯体烧制后再冷却，获得抗菌抛釉砖初成品；
S7、二次干燥，将步骤S6获得的抗菌抛釉砖初成品送入加温窑均匀加热干燥，干燥时长10min，温度控制在200-300℃；
S8、抗菌离子沉积，将经过步骤S7干燥后的抗菌抛釉砖初成品马上送入抗菌离子沉积室，控制抗菌离子沉积室的气压在5.5-6.3mPa之间进行抗菌离子沉积，抗菌离子沉积结束后进行系统冷却；
S9、成品抛光，将经过抗菌离子沉积后的抗菌抛釉砖送入抛光线，并使用1200-6000目的磨块对抗菌抛釉砖的表面进行软磨抛光处理，磨块的切削厚度控制在0.15-0.195mm；
S10、表面防滑加强处理，在步骤S9抛光后的抗菌抛釉砖表面喷淋乳液型瓷砖防滑溶液，温度保持在220-350℃之间并保持15min，等瓷砖防滑层成型后，再选用5000-6000目的磨块打磨喷淋有乳液型瓷砖防滑溶液的瓷砖表面；
在打磨好的瓷砖表面再喷淋溶剂型聚合防滑溶液，温度保持在180-280℃之间并保持10min，等瓷砖防滑层成型后，再选用8000-10000目的磨块对瓷砖表面进行打磨，制得抗菌耐磨防滑抛釉瓷砖成品。
在步骤S1中用于坯体压制成型的原料包括：石英61.3份、氧化铝27.85份、氧化铁0.81份、氧化钙1.15份、氧化镁0.42份、氧化钾2.15份、氧化钠2.01份及加减余量4.31份；以上各组分原料在压制成型前，经精选原料、精准配料、原料球磨、过筛除铁、贮料陈腐、喷雾制粉等工艺步骤制成粉料用于压制坯体。
氧化锌离子抗菌釉，包括第一层釉料，组分包括石英石40份、磷酸锆10份、磷酸钙8份、鲁道夫氧化银18份、氧化锌12份、氧化铝1.5份及氧化锑0.8份；第二层釉料，组分包括氧化铁21份、钾长石16份、硅石灰9.5份、硝酸钠5份、硅酸锆11份、氧化锌1.15份及酞青蓝1.2份；第三层釉料，组分包括玛瑙石13份、石黏土9份、方解石15.5份、氧化锑13.5份、硝酸钠11份、氧化锌1.15份及水性填充着色剂2.2份。
在步骤S5中的过氧化钾铁抗菌釉的组分：包括氧化铁16份、过氧化钾25份、方解石18份、鲁道夫氧化银12份、石黏土6份、过氧化氢8份、氧化锌6份、硅酸锆7份、氧化钠2份。
在步骤S8中进行抗菌离子沉积前对抗菌离子沉积室进行高温蒸洗，以保持抗菌离子沉积室内的杂质清除，提高抗菌离子纯净度，抗菌离子更加纯正、离子沉积更加均匀、抗菌耐久度更加持久。具体抗菌离子沉积室内输入1atm氦气，然后电离金属铝，进行电离铝离子沉积，沉积时间5-6min，控制温度为260°；然后抗菌离子沉积室内输入1.5atm氩气，电离金属银，进行电离银离子沉积，沉积时间4-4.5min，控制温度为260°。
在步骤S8中的系统冷却即抗菌离子沉积后对抗菌抛釉砖的冷却，采用冷水进行，水的温度控制在18-22℃，冷却时间为12-16min，可防止离子沉积室打开门后，室内的高温与外部的空气接触后产生水珠渗透而破坏抗菌离子涂层效果，同时能使抗菌离子涂层更好地和砖坯体融合。
步骤S9中对抗菌抛釉砖进行抛光前，需要对抗菌抛釉砖喷保护釉，再喷抛光液进行抛光。并且步骤S9中抛光线的工作面与底座之间设有一层弹性橡胶以缓冲对抗菌抛釉砖的釉面过度抛光，可以在抛光时对砖釉面产生保护作用形成软磨抛光。
步骤S10中的乳液型瓷砖防滑溶液，按质量百分比包括：甲基硅油16％、含氢硅油5％、羟基硅油1.8％、聚醚嵌段氨基硅油5％、AEO-15乳化剂和过氧化氢助剂3.2％、氧化氢稀释剂70％。步骤S10中的溶剂型聚合防滑溶液，按质量百分比包括：全氟含氢型聚甲基氢硅氧烷10％、多羟基聚硅氧烷5％、硼酸衍生物2％、多异氰酸酯1％、纳米氧化铝5％、氧化氢稀释剂78％。在抗菌抛釉砖表面加入这两种溶液，能分别提升瓷砖的防滑系数和耐磨度，且不破坏瓷砖表面的抗菌釉层。
采用这种生产工艺加工制备的抗菌抛釉砖，如图2所示的由国家陶瓷检测重点实验室联盟、国家建筑卫生陶瓷检测重点实验室及佛山海关综合技术中心出具的检测报告所示，对金色葡萄球菌、大肠埃希氏菌都有99％灭杀和持续灭杀效果，符合倡导的健康抗菌理念，从而解决大部分由这两种细菌所造成的健康问题；同时加工制备的抗菌抛釉砖的防滑系数达到≥0.7，耐磨度达到Ⅴ度，可弥补现阶段陶瓷抛釉砖抗菌效果和抗菌抛釉砖的防滑耐磨问题，更重要是同时满足消费者对抗菌抛釉砖的抗菌耐用和家居装饰性的要求，让人居空间的装饰效果和抗菌效果不再受局限，更有利于营造舒适、健康、典雅的人居环境，符合现代人们的生活理念。
对于本领域的技术人员来说，可根据以上描述的技术方案以及构思，做出其它各种相应的改变以及变形，而所有的这些改变以及变形都应该属于本发明权利要求的保护范围之内。
Claims (10)
1.一种抗菌耐磨防滑抛釉瓷砖的生产工艺，包括以下步骤：S1、坯体成型，原料按配方要求配置并制粉后由压机压制成型；
S2、喷底釉，将步骤S1中制得的坯体在110-160℃的温度下干燥，再在70-90℃的条件下喷底釉；
S3、氧化锌离子抗菌釉施釉，在坯体的底釉层表面喷氧化锌离子抗菌釉，且该氧化锌离子抗菌釉的施釉量控制为所用抗菌釉总施量的3/4；
S4、印花，45℃条件下在氧化锌离子抗菌釉的表面喷墨印花；
S5、过氧化钾铁抗菌釉施釉，在喷墨印花层的表面喷过氧化钾铁抗菌釉，且该过氧化钾铁抗菌釉的施釉量控制为所用抗菌釉总施量的1/4；
S6、烧制及冷却，将经过步骤S5施釉处理后的坯体烧制后再冷却，获得抗菌抛釉砖初成品；
S7、二次干燥，将步骤S6获得的抗菌抛釉砖初成品送入加温窑均匀加热干燥，干燥时长10min，温度控制在200-300℃；
S8、抗菌离子沉积，将经过步骤S7干燥后的抗菌抛釉砖初成品马上送入抗菌离子沉积室，控制抗菌离子沉积室的气压在5.5-6.3mPa之间进行抗菌离子沉积，抗菌离子沉积结束后进行系统冷却；
S9、成品抛光，将经过抗菌离子沉积后的抗菌抛釉砖送入抛光线，并使用1200-6000目的磨块对抗菌抛釉砖的表面进行软磨抛光处理，磨块的切削厚度控制在0.15-0.195mm；
S10、表面防滑加强处理，在步骤S9抛光后的抗菌抛釉砖表面喷淋乳液型瓷砖防滑溶液，温度保持在220-350℃之间并保持15min，等瓷砖防滑层成型后，再选用5000-6000目的磨块打磨喷淋有乳液型瓷砖防滑溶液的瓷砖表面；
在打磨好的瓷砖表面再喷淋溶剂型聚合防滑溶液，温度保持在180-280℃之间并保持10min，等瓷砖防滑层成型后，再选用8000-10000目的磨块对瓷砖表面进行打磨，制得抗菌耐磨防滑抛釉瓷砖成品。
2.如权利要求1所述的抗菌耐磨防滑抛釉瓷砖的生产工艺，其特征在于，步骤S1中的所述原料包括：石英61.3份、氧化铝27.85份、氧化铁0.81份、氧化钙1.15份、氧化镁0.42份、氧化钾2.15份、氧化钠2.01份及加减余量4.31份。
3.如权利要求1所述的抗菌耐磨防滑抛釉瓷砖的生产工艺，其特征在于，所述氧化锌离子抗菌釉包括第一层釉料，组分包括石英石40份、磷酸锆10份、磷酸钙8份、鲁道夫氧化银18份、氧化锌12份、氧化铝1.5份及氧化锑0.8份；
第二层釉料，组分包括氧化铁21份、钾长石16份、硅石灰9.5份、硝酸钠5份、硅酸锆11份、氧化锌1.15份及酞青蓝1.2份；
第三层釉料，组分包括玛瑙石13份、石黏土9份、方解石15.5份、氧化锑13.5份、硝酸钠11份、氧化锌1.15份及水性填充着色剂2.2份。
4.如权利要求1所述的抗菌耐磨防滑抛釉瓷砖的生产工艺，其特征在于，在进行抗菌离子沉积前对抗菌离子沉积室进行高温蒸洗。
5.如权利要求1或4所述的抗菌耐磨防滑抛釉瓷砖的生产工艺，其特征在于，抗菌离子沉积室内输入1atm氦气，然后电离金属铝，进行电离铝离子沉积，沉积时间5-6min，控制温度为260°；然后抗菌离子沉积室内输入1.5atm氩气，电离金属银，进行电离银离子沉积，沉积时间4-4.5min，控制温度为260°。
6.如权利要求1所述的抗菌耐磨防滑抛釉瓷砖的生产工艺，其特征在于，步骤S8中的系统冷却采用冷水进行，水的温度控制在18-22℃，冷却时间为12-16min。
7.如权利要求1所述的抗菌耐磨防滑抛釉瓷砖的生产工艺，其特征在于，步骤S9中抗菌抛釉砖喷保护釉，再喷抛光液进行抛光。
8.如权利要求1所述的抗菌耐磨防滑抛釉瓷砖的生产工艺，其特征在于，步骤S9中抛光线的工作面与底座之间设有一层弹性橡胶以缓冲对抗菌抛釉砖的釉面过度抛光。
9.如权利要求1所述的抗菌耐磨防滑抛釉瓷砖的生产工艺，其特征在于，步骤S10中的乳液型瓷砖防滑溶液，按质量百分比包括：甲基硅油16％、含氢硅油5％、羟基硅油1.8％、聚醚嵌段氨基硅油5％、AEO-15乳化剂和过氧化氢助剂3.2％、氧化氢稀释剂70％。
10.如权利要求1或9所述的抗菌耐磨防滑抛釉瓷砖的生产工艺，其特征在于，步骤S10中的溶剂型聚合防滑溶液，按质量百分比包括：全氟含氢型聚甲基氢硅氧烷10％、多羟基聚硅氧烷5％、硼酸衍生物2％、多异氰酸酯1％、纳米氧化铝5％、氧化氢稀释剂78％。
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