CN114014686B - Porcelain tile blank with hollowing prevention function and preparation method thereof - Google Patents

Porcelain tile blank with hollowing prevention function and preparation method thereof Download PDF

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CN114014686B
CN114014686B CN202111280622.0A CN202111280622A CN114014686B CN 114014686 B CN114014686 B CN 114014686B CN 202111280622 A CN202111280622 A CN 202111280622A CN 114014686 B CN114014686 B CN 114014686B
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powder
pore
parts
compact
forming
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CN114014686A (en
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马超
柯善军
田维
蒙臻明
殷晓春
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Guangxi Oushennuo Ceramic Co ltd
Foshan Oceano Ceramics Co Ltd
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Guangxi Oushennuo Ceramic Co ltd
Foshan Oceano Ceramics Co Ltd
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    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/02—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding chemical blowing agents
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B33/00—Clay-wares
    • C04B33/02—Preparing or treating the raw materials individually or as batches
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3427—Silicates other than clay, e.g. water glass
    • C04B2235/3436—Alkaline earth metal silicates, e.g. barium silicate
    • C04B2235/3454—Calcium silicates, e.g. wollastonite
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
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    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3427—Silicates other than clay, e.g. water glass
    • C04B2235/3463—Alumino-silicates other than clay, e.g. mullite
    • C04B2235/3472—Alkali metal alumino-silicates other than clay, e.g. spodumene, alkali feldspars such as albite or orthoclase, micas such as muscovite, zeolites such as natrolite
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
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  • Porous Artificial Stone Or Porous Ceramic Products (AREA)

Abstract

The invention relates to the technical field of building ceramics, in particular to a porcelain tile blank with an anti-hollowing function and a preparation method thereof. The ceramic tile blank sequentially comprises a compact layer and a porous layer, wherein the compact layer comprises compact powder, and the porous layer comprises porous powder; the raw material components for preparing the porous powder comprise compact powder and pore-forming powder, the pore-forming powder comprises a pore-forming agent, and the pore-forming agent comprises silicon carbide and/or boron carbide. According to the porcelain tile blank with the hollowing prevention function, the proper pore-forming agent and the mode that the pore-forming powder is mixed into compact powder are adopted, the influence of the addition of the pore-forming agent on the water absorption rate, distribution and production forming of the powder is reduced, and the purpose of quickly and continuously producing the porcelain tile blank with the hollowing prevention function is finally achieved.

Description

Porcelain tile blank with hollowing prevention function and preparation method thereof
Technical Field
The invention relates to the technical field of building ceramics, in particular to a porcelain tile blank with an anti-hollowing function and a preparation method thereof.
Background
In recent years, with the wide application of digital ink-jet technology and the promotion of market demand for fine and colorful design patterns, a large number of ceramic building ceramic products become a choice for wall decoration; compared with ceramic tiles and other ceramic building ceramics, when the ceramic tiles are used as wall decoration building ceramics, the self weight of the ceramic tiles has more severe requirements on the wall bonding performance. Therefore, the bonding strength and the dead weight of the ceramic tile are reasonably adjusted, the hollowing phenomenon of the ceramic tile when the ceramic tile is used on the wall surface is further solved, the risk of falling off of the ceramic tile is reduced, the possibility of hurting people of the ceramic tile when the wall surface is used is reduced, and the ceramic tile is a great obstacle to the application of the ceramic tile to wall surface decoration.
Aiming at the anti-hollowing and anti-falling of the building ceramic on the wall surface in the market at present, on one hand, the weight of the building ceramic is reduced, for example, light bricks, thin ceramic tiles and the like are formed to reduce the self weight of the building ceramic tiles per unit area; on the other hand, the paving and pasting mode of the building ceramic is improved, for example, the dry hanging process is carried out on the ceramic tile, and the back of the building ceramic is treated by adopting an interface agent and the like; these can improve the hollowing phenomenon to some extent, but the difficulty of the preparation process, the construction cost and the like thereof are increased remarkably. At the same time, these methods have a greater impact on the cost of architectural ceramics for terrestrial applications.
Based on the production and construction of ceramic tiles, the existing enterprises aim at the anti-hollowing research of the ceramic tiles, and the main research focuses on the adhesive and the bottom texture; in the aspect of the binder, the traditional cement mortar and the like are improved into tile glue, and a plurality of layers of binders are used for treatment; in the aspect of texture at the bottom of the porcelain tile, the depth of the texture, the arrangement direction of the stripes of the texture, the pattern shape of the texture and the like are improved; although the two types can improve the bonding performance of the ceramic tiles, the research on strengthening the architectural ceramics in the aspect of structure without changing the extension of the architectural ceramics in the aspect of structural ceramics is already a field for expanding the applicability of the architectural ceramics.
At present, the existing patents and products change the structure of the architectural ceramics to form the gradient architectural ceramics with a micro-porous structure. The bonding strength of the bonding agent and the porcelain tile is improved through the effect of the pore structure on the bonding agent, so that the hollowing prevention effect of the porcelain tile is realized. However, the gradient building ceramic has certain problems, firstly, the cost of the pore-forming agent is high, and the application and popularization of the gradient ceramic tile produced by the method are limited; secondly, the addition mode of the pore-forming agent needs to be independently set, which influences the continuous production of other porcelain tiles on the production line, in particular to the regulation and control of the water absorption of the powder and the distribution of the powder of the porcelain tiles with the mode. Therefore, improvements in pore-forming agents and the manner of adding pore-forming agents are required.
In view of the above, the present invention is particularly proposed.
Disclosure of Invention
The present invention is directed to solving at least one of the problems of the prior art described above. Therefore, the invention provides a porcelain tile blank with an anti-hollowing function and a preparation method thereof.
The invention conception of the invention is as follows: at present, ceramic tile powder with a compact layer-porous layer structure is oxidized by pore-forming agents such as carbon powder, starch, polystyrene, polymethyl methacrylate, polypropylene and polyethylene at high temperature (700 ℃) in the process of spray granulation, so that the pore-forming agents are ineffective. Therefore, the addition of the pore-forming agent for the ceramic tile having the dense layer-porous layer structure requires an additional process for mixing. The silicon carbide and the boron carbide do not have chemical reaction at 700 ℃, the silicon carbide or the boron carbide is selected as a pore-forming agent, the chemical reaction does not occur in the process of preparing the porous layer raw material by spray granulation, and the silicon carbide or the boron carbide participates in the oxidation reaction to generate gas to expand gaps among particles to form a porous structure in the process of firing ceramic tiles, so that the aim of forming a compact layer-porous layer structure without independently setting a process of additionally adding the pore-forming agent is fulfilled.
The invention provides a porcelain tile blank with an anti-hollowing function, which comprises a compact layer-porous layer structure, wherein the compact layer-porous layer structure comprises a compact layer and a porous layer, the compact layer comprises compact powder, and the porous layer comprises porous powder; the raw material components for preparing the porous powder comprise the compact powder and the pore-forming powder, the pore-forming powder comprises a pore-forming agent, and the pore-forming agent comprises silicon carbide and/or boron carbide.
Compared with the prior art, the invention has the following beneficial effects: silicon carbide or boron carbide is selected as a pore-forming agent, the silicon carbide or the boron carbide can not be subjected to oxidation reaction at high temperature (700 ℃) in the spray granulation process, and gas generated by the oxidation reaction is generated in the sintering process to enlarge gaps among particles to form a porous structure, so that the aim of additionally arranging the pore-forming agent in the process of manufacturing porous powder is fulfilled. The porous powder is formed by the pore-forming powder and the compact powder, the porosity of the porous layer can be controlled more easily by the method, and the ceramic brick blank body with the corresponding porosity and containing the compact layer-porous layer structure can be produced according to the corresponding proportion required to be set in the production process.
Preferably, the raw material components for preparing the porous powder comprise, by weight, 5-40 parts of pore-forming powder and 60-95 parts of compact powder.
Preferably, the raw material components for preparing the porous powder comprise, by weight, 10-30 parts of pore-forming powder and 70-90 parts of compact powder.
Preferably, the raw material components for preparing the porous powder comprise, by weight, 20-30 parts of pore-forming powder and 70-80 parts of compact powder.
Preferably, the particle size of the silicon carbide and the boron carbide is 1000 mesh to 1500 mesh.
Preferably, the thickness of the porous layer accounts for 10% -50% of the thickness of the porcelain tile blank.
Preferably, the thickness of the porous layer accounts for 10% -20% of the thickness of the porcelain tile blank.
Preferably, the thickness of the porous layer accounts for 20% -30% of the thickness of the porcelain tile blank.
Preferably, the compact powder comprises potash feldspar, potassium sand, potassium-sodium feldspar, clay, bentonite, bauxite, talc and recycled powder; the pore-forming powder material also comprises potassium feldspar, potassium sand, albite, potassium-sodium feldspar, clay, bentonite, wollastonite, talc and recovery powder. The pore-forming powder of the porous layer is composed of a pore-forming agent and raw materials which are adaptive to the chemical composition of the compact layer, so that the bonding firmness degree of the porous layer and the compact layer can be further improved, and cracking and layering caused by the difference of the shrinkage and expansion degrees of the porous layer and the compact layer are prevented.
Preferably, the compact powder comprises, by weight, 10-20 parts of potassium feldspar, 10-20 parts of potassium sand, 15-25 parts of potassium-sodium feldspar, 25-35 parts of clay, 5-7 parts of bentonite, 1-3 parts of bauxite, 1-3 parts of talc and 5-10 parts of recovery powder; the pore-forming powder comprises, by weight, 10-20 parts of potassium feldspar, 10-20 parts of potassium sand, 5-10 parts of albite, 15-25 parts of potassium-sodium feldspar, 25-35 parts of clay, 5-7 parts of bentonite, 3-10 parts of wollastonite, 1-3 parts of talc, 5-10 parts of recovery powder and 0.3-3 parts of pore-forming agent.
Preferably, the chemical components of the compact powder material comprise: siO 2 2 、Al 2 O 3 、Fe 2 O 3 、TiO 2 、CaO、MgO、K 2 O、Na 2 O; the pore-forming powder comprises the following chemical components: siO 2 2 、Al 2 O 3 、Fe 2 O 3 、TiO 2 、CaO、MgO、K 2 O、Na 2 O。
Preferably, the chemical components of the compact powder material comprise: 65-70% of SiO 2 、19-23％Al 2 O 3 、1.5％Fe 2 O 3 、0.5％TiO 2 、0.2-1.5％CaO+MgO、4-8％K 2 O+Na 2 O and a loss on ignition of less than 5%; the pore-forming powder comprises the following chemical components: 68-73% of SiO 2 、16-20％Al 2 O 3 、1.5％Fe 2 O 3 、0.5％TiO 2 、1-3％CaO+MgO、6-10％K 2 O+Na 2 O and a loss on ignition of less than 6%.
The second aspect of the invention provides a preparation method of the ceramic tile blank, which comprises the following steps: (1) Respectively carrying out spray granulation on the pore-forming powder and the compact powder and then mixing the pore-forming powder and the compact powder together to obtain the porous powder; (2) Layering the compact powder and the porous powder prepared in the step (1) and jointly performing dry pressing forming to prepare a primary blank containing a compact layer and a porous layer; (3) And (3) firing the primary blank containing the compact layer and the porous layer, which is prepared in the step (2), to prepare the ceramic tile blank.
Compared with the prior art, the invention has the following beneficial effects: the ceramic tile blank production method has the advantages that the pore-forming powder containing the pore-forming agent and the compact powder are respectively subjected to spray granulation and then mixed together, the step of adding the pore-forming agent is not additionally arranged, additional foaming is not required, the powder can be mixed more uniformly, the bonding strength of the ceramic tile blank is improved, the influence of the addition of the pore-forming agent on the water absorption rate and delivery of the powder can be reduced, and the purpose of quickly and continuously producing the ceramic tile blank with the hollowing prevention function is finally achieved. Because the pore-forming powder containing the pore-forming agent and the compact powder are respectively sprayed, granulated and mixed together, the components of the pore-forming powder are matched with the components of the compact powderThe difference between the porous layer and the dense layer of the whole porcelain green body is mainly the difference of the porosity. The porous layer and the compact layer of the porcelain tile body are combined more firmly and are not easy to delaminate and crack. In addition, other pore formers such as NH 4 HCO 3 、NaCl、CaSO 4 And the like react with water, the pore-forming agent loses the structure in wet ball milling, and partial sodium and calcium oxides are introduced to influence the firing temperature and the shape flatness of the architectural ceramic blank. And the silicon carbide and the boron carbide as pore forming agents do not react with water in ball milling, particularly wet ball milling, and other sodium and calcium oxides are not introduced to influence the firing temperature and the shape flatness of the architectural ceramic blank.
Preferably, in the preparation method of the ceramic tile blank, in the step (1), before the pore-forming powder and the compact powder are respectively subjected to spray granulation, the pore-forming powder and the compact powder are respectively subjected to ball milling.
Preferably, the ball milling is wet ball milling.
Preferably, in the preparation method of the porcelain tile blank, the particle size distribution of the compact powder and the pore-forming powder in the step (1) is 99-100% of 20-100 meshes.
Preferably, the preparation method of the ceramic tile blank comprises the following steps of: 0 to 1 percent of 100 meshes-60 meshes, 95 to 100 percent of 60 meshes-40 meshes, 0 to 5 percent of 40 meshes-20 meshes and 0 to 1 percent of more than 20 meshes; the volume weight of the powder is not less than 0.80 g/cc.
Preferably, the ceramic tile blank is prepared by dry pressing in the step (2) to form secondary cloth dry pressing.
Preferably, in the step (2), the ceramic tile blank is formed by dry pressing in a secondary material distribution and direct beating mode in which porous powder is arranged at the bottom and compact powder is arranged at the top.
Preferably, in the preparation method of the ceramic tile blank, the firing parameters in the step (3) are as follows: the firing cycle is 120-180min, the maximum firing temperature is 1160-1210 ℃, and the holding time of the maximum temperature is 30-45min.
A second aspect of the invention provides the use of the above-mentioned ceramic tile body in the field of construction.
Compared with the prior art, the invention has the following beneficial effects:
(1) The invention adopts a mode of mixing a proper pore-forming agent (silicon carbide and/or boron carbide) and pore-forming powder into compact powder, reduces the influence of the addition of the pore-forming agent on the water absorption rate, distribution and production forming of the powder, and finally achieves the purpose of realizing the rapid and continuous production of the porcelain tile blank with the hollowing prevention function.
(2) The thickness of the porous layer is further limited, and the weight counting parts of pore-forming powder and compact powder in the porous powder are further limited, so that the porcelain tile blank can obtain proper water absorption and the bonding strength is improved.
(3) The addition of the pore-forming agent is set to be that the pore-forming powder containing the pore-forming agent and the compact powder are respectively sprayed, granulated and mixed together to prepare porous powder, thus achieving the purpose of realizing the rapid and continuous production of the ceramic tile blank with the compact layer and the porous layer.
Detailed Description
In order to make the technical solutions of the present invention more apparent to those skilled in the art, the following examples are given for illustration. It should be noted that the following examples are not intended to limit the scope of the claimed invention.
The starting materials, reagents or apparatuses used in the following examples are conventionally commercially available or can be obtained by conventionally known methods, unless otherwise specified.
Example 1
A porcelain brick blank with an anti-hollowing function sequentially comprises a compact layer and a porous layer, wherein the compact layer comprises compact powder, and the porous layer comprises porous powder; the raw material components for preparing the porous powder comprise compact powder and pore-forming powder, wherein the pore-forming powder comprises a pore-forming agent, and the pore-forming agent comprises silicon carbide.
The raw material components of the porous powder comprise 10 parts by weight of porous powder and 90 parts by weight of compact powder; the thickness of the porous layer accounts for 10% of the thickness of the porcelain tile blank.
The compact powder comprises the following components in parts by weight: 10 parts of potash feldspar, 10 parts of potash sand, 25 parts of potash-soda feldspar, 35 parts of clay, 7 parts of bentonite, 3 parts of bauxite, 3 parts of talc and 7 parts of recovery powder; the chemical components of the prepared raw material of the compact layer comprise the following components in percentage by mass: 70% of SiO 2 、19.6％Al 2 O 3 、1.2％Fe 2 O 3 、0.3％TiO 2 、1.5％CaO+MgO、4％K 2 O+Na 2 O and loss on ignition of 3.4%.
The powder material of the pore-forming layer comprises the following components in parts by weight: 10 parts of potassium feldspar, 10 parts of potassium sand, 10 parts of albite, 15 parts of potassium-sodium feldspar, 35 parts of clay, 7 parts of bentonite, 3 parts of wollastonite, 2 parts of talc, 8 parts of recovery powder and 1 part of pore-forming agent; the prepared pore-forming raw material comprises the following chemical components in percentage by mass: 69.2% of SiO 2 、16％Al 2 O 3 、0.8％Fe 2 O 3 、0.4％TiO 2 、2.1％CaO+MgO、6.9％K 2 O+Na 2 O and 4.6% loss on ignition; the pore-forming agent is silicon carbide and the particle size is 1500 meshes.
The preparation method of the porcelain tile green body with the hollowing-proof function comprises the following steps:
(1) And performing wet ball milling and spray granulation on the compact powder, and performing wet ball milling and spray granulation on the pore-forming powder. The particle size distribution of the pore-forming powder and the compact powder is as follows: 0 to 1 percent of 100 meshes-60 meshes, 95 to 100 percent of 60 meshes-40 meshes, 0 to 5 percent of 40 meshes-20 meshes and 0 to 1 percent of more than 20 meshes; the volume weight of the powder is not less than 0.80 g/cubic centimeter. According to the weight portion, 10 portions of pore-forming powder and 90 portions of compact powder are mixed to prepare the porous powder.
(2) And pressing and molding the compact powder and the porous powder by adopting a secondary material distribution and direct hitting mode of the porous powder at the lower part and the compact powder at the upper part to prepare a primary blank containing a compact layer and a porous layer, wherein the thickness of the porous layer accounts for 10 percent of the thickness of the ceramic tile blank.
(3) And drying and firing the primary blank containing the compact layer and the porous layer for 150min, wherein the firing maximum temperature is 1180 ℃, and the heat preservation time at the maximum temperature is 40min to obtain a ceramic brick blank.
Example 2
A porcelain brick blank with an anti-hollowing function sequentially comprises a compact layer and a porous layer, wherein the compact layer comprises compact powder, and the porous layer comprises porous powder; the raw material components for preparing the porous powder comprise compact powder and pore-forming powder, wherein the pore-forming powder comprises a pore-forming agent, and the pore-forming agent comprises silicon carbide.
The porous powder comprises 20 parts of porous powder and 80 parts of compact powder in parts by weight; the thickness of the porous layer accounts for 20% of the thickness of the porcelain tile blank.
The compact powder comprises the following components in parts by weight: 13 parts of potassium feldspar, 15 parts of potassium sand, 20 parts of potassium-sodium feldspar, 34 parts of clay, 5 parts of bentonite, 2 parts of bauxite, 1 part of talc and 10 parts of recovery powder; the chemical components of the prepared raw material of the compact layer comprise the following components in percentage by mass: 67.8% of SiO 2 、20.2％Al 2 O 3 、0.9％Fe 2 O 3 、0.3％TiO 2 、0.7％CaO+MgO、7％K 2 O+Na 2 O and loss on ignition of 3.1%.
The powder material of the pore-forming layer comprises the following components in parts by weight: 15 parts of potassium feldspar, 15 parts of potassium sand, 8 parts of albite, 18 parts of potassium-albite, 25 parts of clay, 5 parts of bentonite, 5 parts of wollastonite, 2 parts of talc, 6.5 parts of recycled powder and 0.5 part of pore-forming agent; the prepared pore-forming raw material comprises the following chemical components in percentage by mass: 68.4% of SiO 2 、17.2％Al 2 O 3 、0.6％Fe 2 O 3 、0.3％TiO 2 、2.4％CaO+MgO、7.8％K 2 O+Na 2 O and loss on ignition of 3.3%; the pore-forming agent silicon carbide has a particle size of 1000 meshes.
The preparation method of the porcelain tile green body with the hollowing-proof function comprises the following steps:
(1) And performing wet ball milling and spray granulation on the compact powder, and performing wet ball milling and spray granulation on the pore-forming powder. The particle size distribution of the pore-forming powder and the compact powder is as follows: 0 to 1 percent of 100 meshes-60 meshes, 95 to 100 percent of 60 meshes-40 meshes, 0 to 5 percent of 40 meshes-20 meshes and 0 to 1 percent of more than 20 meshes; the volume weight of the powder is not less than 0.80 g/cubic centimeter. According to the weight portion, 20 portions of pore-forming powder and 80 portions of compact powder are mixed to prepare the porous powder.
(2) And the compact powder and the porous powder are pressed and formed in a secondary material distribution and direct hitting mode with the porous powder at the lower part and the compact powder at the upper part to prepare an initial blank containing a compact layer and a porous layer, wherein the thickness of the porous layer accounts for 20% of the thickness of the ceramic tile blank.
(3) And (3) drying and firing the primary blank containing the compact layer and the porous layer for 180min, wherein the firing period is 180min, the maximum temperature is 1200 ℃, and the maximum temperature is kept for 30min, so that a ceramic tile blank is prepared.
Example 3
A porcelain brick blank with an anti-hollowing function sequentially comprises a compact layer and a porous layer, wherein the compact layer comprises compact powder, and the porous layer comprises porous powder; the raw material components for preparing the porous powder comprise compact powder and pore-forming powder, wherein the pore-forming powder comprises a pore-forming agent, and the pore-forming agent comprises silicon carbide.
The porous powder comprises 20 parts of porous powder and 80 parts of compact powder in parts by weight; the thickness of the porous layer accounts for 20% of the thickness of the porcelain tile blank.
The compact powder comprises the following components in parts by weight: 20 parts of potassium feldspar, 17 parts of potassium sand, 15 parts of potassium-sodium feldspar, 30 parts of clay, 6 parts of bentonite, 2 parts of bauxite, 2 parts of talc and 8 parts of recovered powder; the chemical components of the prepared compact layer raw material comprise the following components in percentage by mass: 65.6% of SiO 2 、21.3％Al 2 O 3 、0.7％Fe 2 O 3 、0.3％TiO 2 、1.1％CaO+MgO、7.8％K 2 O+Na 2 O and loss on ignition of 3.2%.
The powder material of the pore-forming layer comprises the following components in parts by weight: 18 parts of potassium feldspar, 12 parts of potassium sand, 5 parts of albite, 19 parts of potassium-sodium feldspar, 26 parts of clay, 7 parts of bentonite, 3 parts of wollastonite, 2 parts of talc, 6 parts of recycled powder and 2 parts of pore-forming agent; the prepared pore-forming raw material comprises the following chemical components in percentage by mass: 70.2% of SiO 2 、17.1％Al 2 O 3 、0.5％Fe 2 O 3 、0.2％TiO 2 、1.2％CaO+MgO、7.1％K 2 O+Na 2 O and loss on ignition of 3.7%; the pore-forming agent silicon carbide has a particle size of 1500 meshes.
The preparation method of the porcelain tile green body with the hollowing-proof function comprises the following steps:
(1) And performing wet ball milling and spray granulation on the compact powder, and performing wet ball milling and spray granulation on the pore-forming powder. The particle size distribution of the pore-forming powder and the compact powder is as follows: 0 to 1 percent of 100 meshes-60 meshes, 95 to 100 percent of 60 meshes-40 meshes, 0 to 5 percent of 40 meshes-20 meshes and 0 to 1 percent of more than 20 meshes; the volume weight of the powder is not less than 0.80 g/cubic centimeter. According to the weight portion, 20 portions of pore-forming powder and 80 portions of compact powder are mixed to prepare the porous powder.
(2) And pressing and molding the compact powder and the porous powder by adopting a secondary material distribution and direct hitting mode of the porous powder at the lower part and the compact powder at the upper part to prepare a primary blank containing a compact layer and a porous layer, wherein the thickness of the porous layer accounts for 20 percent of the thickness of the ceramic tile blank.
(3) And (3) drying and firing the primary blank containing the compact layer and the porous layer, wherein the firing period is 170min, the maximum firing temperature is 1190 ℃, and the maximum temperature heat preservation time is 45min, so as to obtain a ceramic tile blank.
Example 4
Example 4 differs from example 1 in that boron carbide was used as the pore former instead of the silicon carbide pore former.
Example 5
Example 5 differs from example 2 in that boron carbide was used as the pore former instead of the silicon carbide pore former.
Example 6
Example 6 differs from example 3 in that boron carbide was used as the pore former instead of the silicon carbide pore former.
Comparative example 1
This comparative example differs from example 1 in that the dense powder of example 1 was used in place of the pore-forming powder of example 1, i.e., the porous powder was also a dense powder.
Comparative example 2
Comparative example 2 and examplesExample 1 differs in that NH is used 4 HCO 3 The pore-forming agent is used to replace silicon carbide pore-forming agent.
Comparative example 3
Comparative example 3 differs from example 1 in the manufacturing steps, and comparative example 3 includes:
(1) And (3) ageing the compact powder after ball milling and spray granulation.
(2) Ball milling and spray granulation (the water content is slightly higher than that of compact powder) of porous layer raw materials (except pore-forming agents).
(3) The pore-forming agent is dry mixed with the porous layer raw material (completed by conveying the mixed material by a conveyor belt).
(4) And ageing the mixture of the pore-forming agent and the porous layer raw material to obtain the porous powder.
(5) And (3) laminating the compact powder and the porous powder respectively from top to bottom to form the product.
(6) The transverse rod brush and the transverse rod air injection pipe are used for cleaning mixed materials on the forming platform together.
(7) And laminating the compact powder and the porous powder respectively from top to bottom to form the composite powder.
Product effectiveness testing
The porcelain tile green bodies provided in examples 1 to 6 and comparative examples 1 to 3 were subjected to water absorption, 28-day bond strength (tested in accordance with standard JC/T547-2017), and production efficiency tests, and the results are shown in Table 1 below.
Table 1:
water absorption rate 28 days bond strength Single press production forming speed (one/minute)
Example 1 0.20％ 0.38MPa 6
Example 2 0.33％ 0.55MPa 6
Example 3 0.46％ 0.74Mpa 6
Example 4 0.21％ 0.40MPa 6
Example 5 0.35％ 0.60MPa 6
Example 6 0.48％ 0.78Mpa 6
Comparative example 1 0.05％ 0.22MPa 6
Comparative example 2 0.18％ 0.35MPa 6
Comparative example 3 0.16％ 0.32MPa 3
The experimental data on the table show that the ceramic tile green body with the hollowing-proof function prepared by the method obviously improves the bonding strength between the ceramic tile and the matrix, thereby achieving the purpose of preventing the hollowing and the falling of the ceramic tile; the water absorption can be in a proper range by selecting silicon carbide or boron carbide as a pore-forming agent and limiting the pore-forming agent and the way of mixing pore-forming powder into compact powder, and the bonding strength can be reduced due to too low water absorption; meanwhile, the pore-forming powder accounts for 20wt% of the porous powder, and the thickness of the porous layer accounts for 20% of the thickness of the compact layer-porous layer structure, so that the bonding strength of the ceramic tile blank body can be improved.
In conclusion, the ceramic tile blank with the hollowing prevention function provided by the invention adopts a proper pore-forming agent and a mode of mixing the pore-forming powder material into compact powder material aiming at the cost of the pore-forming agent and the adding mode of the pore-forming agent, so that the influence of the addition of the pore-forming agent on the water absorption rate, distribution and production forming of the powder material is reduced, and the aim of quickly and continuously producing the ceramic tile blank with the hollowing prevention function is finally fulfilled.
The porcelain brick blank with the hollowing-proof function or the porcelain brick blank and the porcelain brick prepared by the preparation method can be widely applied to the field of buildings.

Claims (7)

1. A porcelain tile blank is characterized by sequentially comprising a compact layer and a porous layer, wherein the compact layer comprises compact powder, and the porous layer comprises porous powder; the thickness of the porous layer accounts for 20% -30% of the thickness of the porcelain tile blank;
the raw material components for preparing the porous powder comprise 70-80 parts of the compact powder and 20-30 parts of pore-forming powder, wherein the pore-forming powder comprises a pore-forming agent, and the pore-forming agent is silicon carbide and/or boron carbide;
the compact powder material comprises, by weight, 10-20 parts of potash feldspar, 10-20 parts of potash sand, 15-25 parts of potash-soda feldspar, 25-35 parts of clay, 5-7 parts of bentonite, 1-3 parts of bauxite, 1-3 parts of talc and 5-10 parts of recycled powder;
the pore-forming powder material comprises, by weight, 10-20 parts of potassium feldspar, 10-20 parts of potassium sand, 5-10 parts of albite, 15-25 parts of potassium-sodium feldspar, 25-35 parts of clay, 5-7 parts of bentonite, 3-10 parts of wollastonite, 1-3 parts of talc, 5-10 parts of recovery powder and 0.3-3 parts of pore-forming agent;
the preparation method of the porcelain tile green body comprises the following steps:
(1) Respectively carrying out spray granulation on the pore-forming powder and the compact powder and then mixing the pore-forming powder and the compact powder together to obtain the porous powder;
(2) Layering the compact powder and the porous powder prepared in the step (1) and jointly performing dry pressing forming to prepare a primary blank containing a compact layer and a porous layer;
(3) And (3) firing the primary blank containing the compact layer and the porous layer, which is prepared in the step (2), so as to prepare the porcelain tile blank.
2. The method for preparing a porcelain tile body according to claim 1, comprising the steps of:
(1) Respectively carrying out spray granulation on the pore-forming powder and the compact powder and then mixing the pore-forming powder and the compact powder together to obtain the porous powder;
(2) Layering the compact powder and the porous powder prepared in the step (1) and jointly performing dry pressing forming to prepare a primary blank containing a compact layer and a porous layer;
(3) And (3) firing the primary blank containing the compact layer and the porous layer, which is prepared in the step (2), so as to prepare the porcelain tile blank.
3. The method of claim 2, comprising the steps of: in the step (1), before the pore-forming powder and the compact powder are respectively subjected to spray granulation, the pore-forming powder and the compact powder are respectively subjected to ball milling.
4. The preparation method according to claim 2, wherein in the step (1), the particle size distribution of the dense powder and the pore-forming powder is 99-100% of 20-100 meshes.
5. The production method according to claim 2, wherein in the step (2), the dry-pressing is secondary cloth dry-pressing.
6. The method according to claim 2, wherein in the step (3), the parameters of the firing are: the firing cycle is 120-180min, the maximum firing temperature is 1160-1210 ℃, and the holding time of the maximum temperature is 30-45min.
7. Use of the green ceramic tile according to claim 1 in the construction sector.
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