CN113929435A - 一种新型轻量化卫生陶瓷制品及其制备方法 - Google Patents

一种新型轻量化卫生陶瓷制品及其制备方法 Download PDF

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CN113929435A
CN113929435A CN202111237081.3A CN202111237081A CN113929435A CN 113929435 A CN113929435 A CN 113929435A CN 202111237081 A CN202111237081 A CN 202111237081A CN 113929435 A CN113929435 A CN 113929435A
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sanitary ceramic
slurry
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raw materials
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梁健
劳新斌
江伟辉
洪翔
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Jingdezhen Ceramic Institute
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Abstract

本发明公开了一种新型轻量化卫生陶瓷制品，其原料组成为：瓷土6～15wt％、钾钠砂6～12wt％、水洗砂6～12wt％、煅烧滑石0.01～2wt％、水洗泥35～45wt％、高岭土10～15wt％、蓝晶石10～15wt％、黑泥3～8wt％、锂瓷石0.5～3wt％。此外，还公开了上述新型轻量化卫生陶瓷制品的制备方法。本发明通过配方设计，实现了产品的轻量化并具有强度高、变形小的优异性能。制备方法工艺简单，易于产业化推广，有效降低了原料成本和能耗，能够为建设资源节约型、环境友好型社会，增强可持续发展能力提供强有力的保障。

Description

一种新型轻量化卫生陶瓷制品及其制备方法
技术领域
本发明涉及建筑卫生陶瓷技术领域，尤其涉及一种卫生陶瓷制品及其制备方法。
背景技术
在陶瓷制品中，卫生陶瓷是一种结构比较复杂、体型较大和自身单个重量较重的制品，其制备过程中需要消耗大量的人力和物力，同时还需消耗大量不可再生的矿产资源和燃料能源。同等条件下制品厚度越厚、重量越重，原料及能源消耗也越多，工艺生产成本也越高，也相应提高了运输和安装成本。
为缓解资源环境约束、应对全球气候变化，推进节能减排工作、促进经济发展方式转变，建设资源节约型、环境友好型社会具有重要意义。现有卫生陶瓷的重量重、坯体厚，需消耗大量的不可再生资源，与节能减排、降低原料消耗和能源消耗的社会要求相违背。为此，卫生陶瓷坯体薄壁轻量化技术，是降低原料消耗和能耗的有效方法。目前现有技术卫生陶瓷制品的厚度一般为12～17mm，厚度偏厚；成瓷强度为50～70MPa，生坯的强度为2.0～3.0MPa，均普遍偏低；弯曲变形＞22mm，变形普遍偏大。为实现碳中和目标，更好地推行资源节约、节能减排、环境友好的生产工艺，同时也为了降低生产成本、减轻劳动强度，亟需研究开发一种制品强度更高、变形小的新型轻量化卫生陶瓷制品。
发明内容
本发明的目的在于克服现有技术的不足，提供一种新型轻量化卫生陶瓷制品，通过配方设计，以利于实现轻量化并具有强度高、变形小的优异性能。本发明的另一目的在于提供上述新型轻量化卫生陶瓷制品的制备方法。
本发明的目的通过以下技术方案予以实现：
本发明提供的一种新型轻量化卫生陶瓷制品，其原料组成为：瓷土6～15wt％、钾钠砂6～12wt％、水洗砂6～12wt％、煅烧滑石0.01～2wt％、水洗泥35～45wt％、高岭土10～15wt％、蓝晶石10～15wt％、黑泥3～8wt％、锂瓷石0.5～3wt％。
上述方案中，本发明所述新型轻量化卫生陶瓷制品的化学组成为二氧化硅58～65wt％、三氧化铝21～28.5wt％、三氧化二铁0.2～1.5wt％、二氧化钛0～0.5wt％、氧化钙0.2～1wt％、氧化镁0.2～1wt％、氧化钾0.2～3wt％、氧化钠0.2～1.5wt％、氧化锂0.1～1wt％、烧失3～10wt％。
本发明的另一目的通过以下技术方案予以实现：
本发明提供的上述新型轻量化卫生陶瓷制品的制备方法，包括以下步骤：
(1)将所述原料中除水洗泥以外的其他各组成进行配料后加入球磨机内，并加入水、水玻璃和聚丙烯酸钠球磨6～10h，得到中位粒径为6～12μm、比重为1.70～1.80g/mL的基础泥浆；
(2)将所述基础泥浆与水洗泥搅拌混合均匀，再将混合均匀的泥浆过筛后，加入水调节至比重为1.70～1.80g/mL、流速为60～90秒，即得到卫生陶瓷泥浆；
(3)所述卫生陶瓷泥浆经陈腐7～10天、注浆成型、干燥后得到卫生陶瓷坯体；
(4)所述卫生陶瓷坯体上釉后进行烧成，烧成温度为1180～1230℃，烧成周期为14～20h，即制得新型轻量化卫生陶瓷制品。
上述方案中，本发明制备方法所述步骤(1)中水玻璃和聚丙烯酸钠的用量分别为配料的0.8～1.2wt％和0.1～0.2wt％。
本发明具有以下有益效果：
(1)本发明新型轻量化卫生陶瓷制品的配方体系中，引入膨胀系数小且助熔效果佳的氧化锂替代部分氧化钾和氧化钠，提升了配方产品的热稳定性和制品的抗变形能力；引入部分蓝晶石，有效提高配方体系的铝含量，在锂、钠、钾三元助熔作用下，生成较多的莫来石晶相，在制品中起到骨架作用，从而提升制品的成瓷强度和抗变形能力；通过调整配方体系中塑性料的比例，使得生坯的强度高(≥3.5MPa)、制品成瓷强度高(≥80MPa)，具有制品变形小(弯曲变形为15～22mm)、规整度高等优异的特性。
(2)本发明轻量化卫生陶瓷坯体具有优异的坯釉结合性，通过含锂原料及蓝晶石的引入，所得制品耐急冷急热性能好，成瓷强度高，且重量大大减轻(减轻幅度在10～35wt％)。工艺简单，易于产业化推广，可有效降低原料成本和能耗，能够为建设资源节约型、环境友好型社会，增强可持续发展能力提供强有力的保障。
附图说明
下面将结合实施例和附图对本发明作进一步的详细描述。
图1是本发明实施例制备得到的新型轻量化卫生陶瓷制品的SEM照片。
具体实施方式
本发明实施例一种新型轻量化卫生陶瓷制品，其原料组成为：瓷土6～15wt％、钾钠砂6～12wt％、水洗砂6～12wt％、煅烧滑石0.01～2wt％、水洗泥35～45wt％、高岭土10～15wt％、蓝晶石10～15wt％、黑泥3～8wt％、锂瓷石0.5～3wt％。各实施例的原料组成如表1所示。
表1本发明实施例的原料组成(wt％)
Figure BDA0003318044680000031
上述各实施例新型轻量化卫生陶瓷制品的制备方法，其步骤如下：
(1)将上述原料中除水洗泥以外的其他原料进行配料后加入球磨机内，加入水、并加入水玻璃和聚丙烯酸钠(用量分别为配料的0.9wt％和0.1wt％)作为解胶剂球磨6～10h，得到中位粒径为6～12μm、比重为1.70～1.80g/ml的基础泥浆；
(2)将所述基础泥浆与水洗泥进行搅拌混合均匀，再将混合均匀的泥浆进行40目筛网、60目筛网、80目筛网和100目筛网阶梯过筛后，加入水调节至比重为1.70～1.80g/mL(比重杯测得)、流速为60～90秒(用涂-4黏度计测得)，即得到卫生陶瓷泥浆；
(3)上述卫生陶瓷泥浆经陈腐8天、注浆成型、干燥后得到卫生陶瓷坯体；
(4)上述卫生陶瓷坯体上釉后进行烧成，烧成温度为1180～1230℃，烧成周期为14～20h，即制得新型轻量化卫生陶瓷制品。
上述各实施例制备方法的工艺参数如表2所示。
表2本发明实施例制备方法的工艺参数
Figure BDA0003318044680000032
以普通卫生陶瓷制品为对比例，其原料组成为：花泥8wt％、瓷土7wt％、水洗白泥10wt％、钾钠砂5wt％、水洗砂11wt％、欣雨砂5％、煅烧滑石3wt％、精致水洗泥15wt％、超细水洗泥28wt％、高岭土5wt％、黑泥3wt％。
上述各实施例和对比例的化学组成如表3所示。
表3本发明实施例和对比例的化学组成
Figure BDA0003318044680000041
如图1所示，本发明实施例制备的新型轻量化卫生陶瓷制品中具有大量的莫来石晶体。各实施例陶瓷制品以及对比例陶瓷制品的性能指标如表4所示。
表4本发明实施例以及对比例陶瓷制品的性能指标
Figure BDA0003318044680000042

Claims (4)

1.一种新型轻量化卫生陶瓷制品，其特征在于原料组成为：瓷土6～15wt％、钾钠砂6～12wt％、水洗砂6～12wt％、煅烧滑石0.01～2wt％、水洗泥35～45wt％、高岭土10～15.5wt％、蓝晶石10～15wt％、黑泥3～8wt％、锂瓷石0.5～3wt％。
2.根据权利要求1所述的新型轻量化卫生陶瓷制品，其特征在于化学组成为：二氧化硅58～65wt％、三氧化铝21～28.5wt％、三氧化二铁0.2～1.5wt％、二氧化钛0～0.5wt％、氧化钙0.2～1wt％、氧化镁0.2～1wt％、氧化钾0.2～3wt％、氧化钠0.2～1.5wt％、氧化锂0.1～1wt％、烧失3～10wt％。
3.权利要求1或2所述新型轻量化卫生陶瓷制品的制备方法，其特征在于包括以下步骤：
(1)将所述原料中除水洗泥以外的其他各组成进行配料后加入球磨机内，并加入水、水玻璃和聚丙烯酸钠球磨6～10h，得到中位粒径为6～12μm、比重为1.70～1.80g/mL的基础泥浆；
(2)将所述基础泥浆与水洗泥搅拌混合均匀，再将混合均匀的泥浆过筛后，加入水调节至比重为1.70～1.80g/mL、流速为60～90秒，即得到卫生陶瓷泥浆；
(3)所述卫生陶瓷泥浆经陈腐7～10天、注浆成型、干燥后得到卫生陶瓷坯体；
(4)所述卫生陶瓷坯体上釉后进行烧成，烧成温度为1180～1230℃，烧成周期为14～20h，即制得新型轻量化卫生陶瓷制品。
4.根据权利要求3所述的新型轻量化卫生陶瓷制品的制备方法，其特征在于：所述步骤(1)中水玻璃和聚丙烯酸钠的用量分别为配料的0.8～1.2wt％和0.1～0.2wt％。
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