CN114907105A - Composite material for re-burning and repairing sanitary ceramics, preparation method and repairing method - Google Patents
Composite material for re-burning and repairing sanitary ceramics, preparation method and repairing method Download PDFInfo
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- CN114907105A CN114907105A CN202210598308.5A CN202210598308A CN114907105A CN 114907105 A CN114907105 A CN 114907105A CN 202210598308 A CN202210598308 A CN 202210598308A CN 114907105 A CN114907105 A CN 114907105A
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- 239000000919 ceramic Substances 0.000 title claims abstract description 119
- 239000002131 composite material Substances 0.000 title claims abstract description 47
- 238000002360 preparation method Methods 0.000 title claims abstract description 23
- 238000000034 method Methods 0.000 title claims abstract description 22
- 239000000843 powder Substances 0.000 claims abstract description 187
- 239000000463 material Substances 0.000 claims abstract description 161
- 239000002002 slurry Substances 0.000 claims abstract description 76
- 230000007547 defect Effects 0.000 claims abstract description 65
- DPXJVFZANSGRMM-UHFFFAOYSA-N acetic acid;2,3,4,5,6-pentahydroxyhexanal;sodium Chemical compound [Na].CC(O)=O.OCC(O)C(O)C(O)C(O)C=O DPXJVFZANSGRMM-UHFFFAOYSA-N 0.000 claims abstract description 57
- 239000001768 carboxy methyl cellulose Substances 0.000 claims abstract description 57
- 235000019812 sodium carboxymethyl cellulose Nutrition 0.000 claims abstract description 57
- 229920001027 sodium carboxymethylcellulose Polymers 0.000 claims abstract description 57
- XGZVUEUWXADBQD-UHFFFAOYSA-L lithium carbonate Chemical compound [Li+].[Li+].[O-]C([O-])=O XGZVUEUWXADBQD-UHFFFAOYSA-L 0.000 claims abstract description 31
- 229910052808 lithium carbonate Inorganic materials 0.000 claims abstract description 31
- IVMYJDGYRUAWML-UHFFFAOYSA-N cobalt(ii) oxide Chemical compound [Co]=O IVMYJDGYRUAWML-UHFFFAOYSA-N 0.000 claims abstract description 30
- 239000000049 pigment Substances 0.000 claims abstract description 30
- 239000002994 raw material Substances 0.000 claims abstract description 26
- 239000002699 waste material Substances 0.000 claims abstract description 24
- 229910052573 porcelain Inorganic materials 0.000 claims abstract description 23
- 239000007921 spray Substances 0.000 claims abstract description 21
- 230000008439 repair process Effects 0.000 claims description 143
- 238000000498 ball milling Methods 0.000 claims description 68
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 63
- 238000005303 weighing Methods 0.000 claims description 24
- 238000011049 filling Methods 0.000 claims description 23
- 238000005245 sintering Methods 0.000 claims description 23
- 239000011268 mixed slurry Substances 0.000 claims description 22
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 claims description 16
- 238000004140 cleaning Methods 0.000 claims description 15
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 claims description 15
- 229910052863 mullite Inorganic materials 0.000 claims description 15
- 238000010304 firing Methods 0.000 claims description 13
- 239000000203 mixture Substances 0.000 claims description 12
- 239000002245 particle Substances 0.000 claims description 12
- 229910001220 stainless steel Inorganic materials 0.000 claims description 12
- 239000010935 stainless steel Substances 0.000 claims description 12
- 239000004484 Briquette Substances 0.000 claims description 11
- 238000001035 drying Methods 0.000 claims description 11
- 238000004898 kneading Methods 0.000 claims description 11
- 239000000126 substance Substances 0.000 claims description 11
- 229910052602 gypsum Inorganic materials 0.000 claims description 9
- 239000010440 gypsum Substances 0.000 claims description 9
- 229910018072 Al 2 O 3 Inorganic materials 0.000 claims description 8
- 229910004298 SiO 2 Inorganic materials 0.000 claims description 8
- 230000005484 gravity Effects 0.000 claims description 8
- 229910010413 TiO 2 Inorganic materials 0.000 claims description 7
- 229910052708 sodium Inorganic materials 0.000 claims description 7
- 239000011734 sodium Substances 0.000 claims description 7
- 238000005507 spraying Methods 0.000 claims description 7
- 229910052878 cordierite Inorganic materials 0.000 claims description 4
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 claims description 4
- 238000005498 polishing Methods 0.000 claims description 3
- 238000012797 qualification Methods 0.000 abstract description 12
- 241000692783 Chylismia claviformis Species 0.000 abstract description 4
- 230000004075 alteration Effects 0.000 abstract description 2
- 230000000694 effects Effects 0.000 description 21
- 230000000052 comparative effect Effects 0.000 description 18
- 239000004927 clay Substances 0.000 description 15
- 238000012360 testing method Methods 0.000 description 15
- 238000001514 detection method Methods 0.000 description 9
- 238000004519 manufacturing process Methods 0.000 description 7
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 6
- 239000000292 calcium oxide Substances 0.000 description 6
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 6
- 238000000227 grinding Methods 0.000 description 6
- 239000012535 impurity Substances 0.000 description 5
- 230000008901 benefit Effects 0.000 description 4
- 238000005336 cracking Methods 0.000 description 4
- 238000005259 measurement Methods 0.000 description 4
- 238000004321 preservation Methods 0.000 description 4
- 230000002950 deficient Effects 0.000 description 3
- 230000002349 favourable effect Effects 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 238000012856 packing Methods 0.000 description 3
- XOFYZVNMUHMLCC-ZPOLXVRWSA-N prednisone Chemical group O=C1C=C[C@]2(C)[C@H]3C(=O)C[C@](C)([C@@](CC4)(O)C(=O)CO)[C@@H]4[C@@H]3CCC2=C1 XOFYZVNMUHMLCC-ZPOLXVRWSA-N 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 239000011787 zinc oxide Substances 0.000 description 3
- HBBGRARXTFLTSG-UHFFFAOYSA-N Lithium ion Chemical compound [Li+] HBBGRARXTFLTSG-UHFFFAOYSA-N 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 238000013112 stability test Methods 0.000 description 2
- 238000003756 stirring Methods 0.000 description 2
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 1
- 239000000378 calcium silicate Substances 0.000 description 1
- 229910052918 calcium silicate Inorganic materials 0.000 description 1
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical group [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000002537 cosmetic Substances 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 238000005485 electric heating Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000005457 ice water Substances 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
- 239000002689 soil Substances 0.000 description 1
- 238000011179 visual inspection Methods 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
- C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
- C04B35/185—Mullite 3Al2O3-2SiO2
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C8/00—Enamels; Glazes; Fusion seal compositions being frit compositions having non-frit additions
- C03C8/14—Glass frit mixtures having non-frit additions, e.g. opacifiers, colorants, mill-additions
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
- C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
- C04B35/195—Alkaline earth aluminosilicates, e.g. cordierite or anorthite
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- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/4572—Partial coating or impregnation of the surface of the substrate
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- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
- C04B41/5022—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with vitreous materials
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- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
- C04B41/5025—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with ceramic materials
- C04B41/5027—Oxide ceramics in general; Specific oxide ceramics not covered by C04B41/5029 - C04B41/5051
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- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
- C04B41/81—Coating or impregnation
- C04B41/85—Coating or impregnation with inorganic materials
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- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
- C04B41/81—Coating or impregnation
- C04B41/85—Coating or impregnation with inorganic materials
- C04B41/87—Ceramics
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P40/00—Technologies relating to the processing of minerals
- Y02P40/60—Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes
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Abstract
The invention discloses a re-burning repairing composite material applied to sanitary ceramics, a preparation method and a repairing method, and relates to the technical field of sanitary ceramics. The reburning repairing composite material comprises a repairing material mud cluster, a repairing glaze mud cluster and a spray repairing glaze slurry; calculating according to the mass parts of dry materials: the raw materials of the patching material mud pie comprise main powder, waste porcelain powder, glaze powder and sodium carboxymethyl cellulose; the raw materials for repairing the glaze paste mass comprise glaze powder, overglaze powder, lithium carbonate, cobalt black pigment and sodium carboxymethyl cellulose; the raw materials of the gunning glaze slip comprise glaze powder, overglaze powder, lithium carbonate, cobalt black pigment and sodium carboxymethyl cellulose. The heavy-burned repairing combined material disclosed by the invention is used for repairing large defects such as large green body cracks, brown eyes and the like on the sanitary ceramics, the thermal stability, the chromatic aberration and the like of the sanitary ceramics obtained after repairing are good, and the repairing trace cannot be seen by naked eyes, so that the repairing qualification rate is effectively improved, and the problem that the repairing qualification rate of the sanitary ceramics with the large defects is still at a lower level at present is solved.
Description
Technical Field
The invention relates to the technical field of sanitary ceramics, in particular to a re-burning repairing composite material applied to the sanitary ceramics, a preparation method and a repairing method.
Background
In the sanitary ceramic production process, because the sanitary ceramic has large volume, complex appearance structure and multiple manufacturing procedures, the sintered sanitary ceramic product has the defects of cracks, brown eyes and the like, so that the qualification rate of the sanitary ceramic product is very low, at present, a plurality of sanitary ceramic manufacturers mainly producing middle-grade and low-grade products comprehensively consider the factors such as production cost, sale price and the like, and basically cannot adopt a method of repairing and then re-burning defective products to improve the qualification rate of the sanitary ceramic product; although a large-scale sanitary ceramic manufacturer can improve the qualification rate of the sanitary ceramic product by repairing and re-burning, the large-scale sanitary ceramic manufacturer can only repair small cracks within 10mm in length and small brown holes within 3mm in diameter by using repair glaze at present, and the defects such as the cracks, the brown holes and the like exceeding the above range still have obvious color difference and repair traces after repairing and re-burning, and only can be used as waste products for scrapping treatment, so that the repair qualification rate of the sanitary ceramic product with large defects is still at a lower level.
Disclosure of Invention
Aiming at the problems brought forward by the background technology, the invention aims to provide a composite material for re-burning and repairing sanitary ceramics, which can repair the large defects of large blank cracks, brown eyes and the like on the sanitary ceramics, the thermal stability, the chromatic aberration and other properties of the sanitary ceramics obtained after repairing are good, and the repairing trace can not be seen by naked eyes, thereby effectively improving the repairing qualification rate and solving the problem that the repairing qualification rate of the sanitary ceramics with the large defects is still at a lower level at present.
The invention also aims to provide a preparation method of the re-burning repairing composite material applied to the sanitary ceramics, which has the advantages of simple whole preparation method and low preparation cost, and can reduce the production cost and improve the enterprise benefit.
The invention also aims to provide a sanitary ceramic repairing method, which can repair the large defects of the sanitary ceramic product by using the re-burning repairing composite material, and the repaired part has no color difference with the original product and no repair trace can be seen.
In order to achieve the purpose, the invention adopts the following technical scheme:
a reburning repairing composite material applied to sanitary ceramics comprises a repairing material mud cluster, a repairing glaze mud cluster and gunning glaze slurry;
calculating according to the mass parts of dry materials:
the raw materials of the patching material mud pie comprise 45-50 parts of main powder, 35-40 parts of waste porcelain powder, 20-25 parts of glaze powder and 0.3-0.5 part of sodium carboxymethyl cellulose, wherein the main powder is any one or a combination of two of mullite powder and cordierite powder;
the raw materials of the repaired glaze mud pie comprise 85-90 parts of glaze powder, 5-10 parts of overglaze powder, 1-5 parts of lithium carbonate, 0.01-0.02 part of cobalt black pigment and 0.3-0.5 part of sodium carboxymethylcellulose;
the gunning glaze slip comprises the following raw materials of 85-90 parts of glaze powder, 5-10 parts of overglaze powder, 1-5 parts of lithium carbonate, 0.01-0.02 part of cobalt black pigment and 0.3-0.5 part of sodium carboxymethylcellulose.
Further, the water content of the patching material mud mass is 15-18% by mass percent; the water content of the repair glaze mud pie is 15-18%.
Furthermore, the gunning glaze slurry has the specific gravity of 1.76-1.77, the fluidity of 200-220 degrees and the thixotropy of 50-80 degrees.
Further, in the repair material briquette:
the screen allowance of the main powder passing through a 160-mesh screen is less than 5 percent;
the fineness of the waste porcelain powder is 80-100 meshes;
the screen allowance of the glaze powder passing through a 325-mesh screen is less than 0.2 percent.
Further, in the patching material mud mass, the main powder material is mullite powder.
Further, the glaze powder comprises the following chemical components: SiO 2 2 ：58.5～61.5％、Al 2 O 3 ：8.5～10.0％、Fe 2 O 3 ：0～0.1％、TiO 2 ：0～0.1％、CaO：9.5～11.5％、MgO：0.5～0.8％、K 2 O：1.5～3.0％、Na 2 O: 1.0-2.5 percent, and the balance of ignition loss.
Further, the chemical composition of the glaze facing powder is as follows: SiO 2 2 ：59～62％、Al 2 O 3 ：7.5～9.0％、Fe 2 O 3 ：0～0.1％、TiO 2 ：0～0.1％、CaO：10～12％、MgO：0～0.1％、K 2 O：3.5～5.0％、Na 2 1.5-2.5% of O, ZnO: 14.0-16.0% and the balance of ignition loss.
A preparation method of a re-burning repairing composite material applied to sanitary ceramics is used for preparing the re-burning repairing composite material applied to the sanitary ceramics, and comprises the following steps:
(1) preparing a patching material mud cluster: weighing main powder and glaze powder according to a formula, adding water, ball milling for 3-5 min, adding the glaze powder and sodium carboxymethylcellulose, and continuing ball milling for 3-5 min to obtain mixed slurry; after the ball milling is finished, drying the mixed slurry to obtain a repair material primary product, and kneading the dried repair material primary product into a mud cluster shape by using a methyl solution to obtain a repair material mud cluster;
(2) preparing a repairing glaze mud briquette: weighing lithium carbonate and cobalt black pigment according to the formula, adding water, ball milling for 3-5 min, adding glaze powder, glaze facing powder and sodium carboxymethylcellulose, and continuing ball milling for 3-5 min; sucking water from the ball-milled slurry by using a gypsum mold until the water content is 15-18% so that the slurry is in a mud pie state to obtain a repaired glaze mud pie;
(3) preparing gunning glaze slurry: weighing lithium carbonate and a cobalt black pigment according to a formula, adding water, ball-milling for 3-5 min, adding glaze powder, overglaze powder and sodium carboxymethylcellulose, and continuing ball-milling for 3-5 min to obtain gunning glaze slurry; the repairing material, the repairing glaze and the spray repairing glaze slurry form a re-burning repairing composite material.
Further, the preparation method in the step (1) is as follows: weighing main powder and glaze powder according to a formula, adding water, ball-milling for 3-5 min, adding the glaze powder and sodium carboxymethylcellulose, and continuing ball-milling for 3-5 min until particles with the fineness of 10 mu m in the ball-milled mixed slurry account for 45-55%; and after the ball milling is finished, drying the mixed slurry to obtain a repair material primary product, and kneading the dried repair material primary product into a mud cluster shape by using a methyl solution to obtain a repair material mud cluster.
The re-burning repairing composite material for sanitary ceramic includes the following steps:
(1) polishing and cleaning the defect part of the sanitary ceramic;
(2) filling the defect position of the sanitary ceramic by using the repairing material mud mass, and compacting the repairing material mud mass by using a cylindrical stainless steel needle;
(3) filling the repairing glaze mud groups on the surface of the compacted repairing material mud groups, wherein the filling height of the repairing glaze mud groups is 0.2-0.4 mm higher than the original glaze height of the sanitary ceramics;
(4) spraying the spray repair glaze slurry on the area filled with the repair glaze paste groups;
(5) and (3) firing the repaired sanitary ceramic in the step (4) for 24-28 hours at 1170-1185 ℃ for 20-30 minutes.
The technical scheme has the following beneficial effects: aiming at the sanitary ceramic products with large cracks with the length of more than 10mm and/or the brown hole defects with the diameter of more than 3mm, the technical scheme repairs the large defects such as large blank cracks, brown holes and the like on the sanitary ceramic products by matching the use of the repair material mud mass, the repair glaze mud mass and the spray repair glaze slurry, when in repair, the repair material mud mass is used for filling the defect firstly, and then the repair glaze mud mass and the spray repair glaze slurry are used for repair, the sanitary ceramic products obtained after repair have good thermal stability, color difference and other properties, the repair traces can not be seen by naked eyes, the large defects such as large cracks, brown holes and the like can be effectively solved, thereby effectively improving the repair qualification rate, and solving the problem that the repair qualification rate of the current sanitary ceramic products with large defects is still at a lower level.
Detailed Description
The technical solution of the present invention will be further described with reference to the following embodiments.
A reburning repairing composite material applied to sanitary ceramics comprises a repairing material mud cluster, a repairing glaze mud cluster and a gunning glaze slurry;
calculating according to the mass parts of dry materials:
the raw materials of the patching material mud pie comprise 45-50 parts of main powder, 35-40 parts of waste porcelain powder, 20-25 parts of glaze powder and 0.3-0.5 part of sodium carboxymethylcellulose, wherein the main powder is any one or a combination of two of mullite powder and cordierite powder;
the raw materials for repairing the glaze paste mass comprise 85-90 parts of glaze powder, 5-10 parts of overglaze powder, 1-5 parts of lithium carbonate, 0.01-0.02 part of cobalt black pigment and 0.3-0.5 part of sodium carboxymethylcellulose;
the gunning glaze slip comprises 85-90 parts of glaze powder, 5-10 parts of overglaze powder, 1-5 parts of lithium carbonate, 0.01-0.02 part of cobalt black pigment and 0.3-0.5 part of sodium carboxymethylcellulose.
Although the qualification rate of sanitary ceramic products can be improved by large-scale sanitary ceramic manufacturers through repair and re-burning operation at present, the large-scale sanitary ceramic manufacturers can only repair small cracks within 10mm in length and small brown holes within 3mm in diameter by using repair glaze at present, and the defects such as cracks, brown holes and the like exceeding the above range still have obvious color difference and repair traces after repair and re-burning, and only can be used as waste products for scrapping treatment, so that the repair qualification rate of the sanitary ceramic products with large defects is still at a lower level.
The technical scheme aims at the sanitary ceramic product with large cracks with the length of more than 10mm and/or the brown hole defect with the diameter of more than 3mm, the repairing material mud mass, the repairing glaze mud mass and the spray repairing glaze slurry are used in a matching mode to repair the large defects such as large blank cracks, brown holes and the like on the sanitary ceramic product, when the repairing is carried out, the repairing material mud mass is used for filling the defect, then the repairing glaze mud mass and the spray repairing glaze slurry are used for repairing, the thermal stability, color difference and the like of the sanitary ceramic product obtained after the repairing are good, repairing traces cannot be seen by naked eyes, the large defects such as the large cracks, the brown holes and the like can be effectively solved, the repairing qualified rate is effectively improved, and the problem that the repairing qualified rate of the sanitary ceramic product with the large defects is still at a low level at present is solved.
Specifically, the main raw materials in the repairing material mud mass are mullite powder and/or cordierite powder which are high in firing temperature, low in shrinkage and low in expansion, and are matched with the waste porcelain powder and the glaze powder with the fluxing action, and as the chemical components of the waste porcelain powder are close to those of the blank glaze, the melting effect of the repairing material mud mass after firing and the blank body is good, and the cracking condition is not easy to occur; add the overglaze powder in mending glaze clay group and the gunning glaze slip, can reduce the firing temperature of frit, the temperature and the kiln temperature phase-match of frit when making sanitary ceramic product reburn in the shuttle kiln, let the frit can melt well, make the smooth fine and close of repair department glaze, and add the lithium carbonate in mending glaze clay group and the gunning glaze slip, lithium element has good fluxing effect, reduce the melting temperature of frit, be favorable to each other fusing of each component, and the ionic radius of lithium is little, the space in the glaze structure has been filled, make the glaze more compact, promote the roughness of glaze greatly, the existence of lithium element is favorable to fusing each other of each component in the blank glaze, be favorable to promoting the thermal stability of product again. Meanwhile, the temperature during the reburning is 20-30 ℃ lower than that during the first firing, so that the glaze color of the repaired sanitary ceramic product is white, namely the Delta L is large, and the increase of the Delta E (the size of the total color difference) exceeds the requirement of the color difference.
Specifically, the defective sanitary ceramic test article is repaired by adopting the reburning repair combined material of the technical scheme, the American Alice X-Rite Ci60 color difference meter is used for testing the color difference of the sanitary ceramic test article, the color difference before and after the repair of the sanitary ceramic test article is respectively detected, the color difference meter is a portable digital display instrument, the used standard is firstly selected during measurement, the measurement port of the color difference meter is aligned to the sanitary ceramic test article, the instrument is pressed down, the measurement can be automatically started, and the value displayed on the screen after the measurement is finished is the color difference result of the sample. The detection shows that the color difference of the sanitary ceramic test article before repair is delta E: 0.62,. DELTA.L: 0.53,. DELTA.a: -0.30,. DELTA.b: -0.13, the color difference of the repaired sanitary ceramic test article is Δ E: 0.65,. DELTA.L: 0.58,. DELTA.a: -0.22,. DELTA.b: -0.16, wherein the standard for evaluating whether the effect of color difference exists in the field of sanitary ceramics is that delta E is less than 1, and delta L, delta a and delta b are within +/-0.8, the color difference is judged to be qualified, and the color difference exceeds the standard when the range is exceeded, so that the color difference of the product obtained by adopting the re-burning repairing composite material of the technical scheme to repair the defective sanitary ceramics test product is not different, namely, the color difference does not exist.
It is worth pointing out that the repairing material mud pie has the function of combining with the blank body to well seal the defect, and then the repairing glaze mud pie and the spray repairing glaze slurry are used for repairing the glaze surface, so that the product after re-sintering has no defect. If the repair glaze clay mass is filled at the defect, the repair material clay mass is refilled, because the repair glaze clay mass contains glaze powder and surface glaze powder, the glaze materials can flow into the defect of the product when being sintered at high temperature, so that the defect on the product after being re-sintered can not be filled, the defect still exists, the repair material clay mass has no effect when being reused, the color of the repair material clay mass is close to that of the blank body, and the difference between the color of the repair material clay mass and the color of the surface of the sanitary ceramic product is obvious.
Specifically, the viscosity of the sodium carboxymethylcellulose used in the technical scheme is 905-1050 Mpa.s.
Further, the water content of the patching material mud mass is 15-18% by mass percent; the water content of the repaired glaze mud pie is 15-18%.
The water content of the repair material mud pie and the water content of the repair glaze mud pie are limited to 15-18%, so that repair operation is facilitated, if the water content of the repair material mud pie and the water content of the repair glaze mud pie are too high, the repair material mud pie and the repair glaze mud pie are too soft, when the defect of a sanitary ceramic product is repaired, the repair material mud pie and the repair glaze mud pie are difficult to fill in the defect and even flow out, the repair operation is difficult, and the water content of the repair glaze mud pie is too high, so that the sintered glaze is collapsed, and the repair effect cannot be achieved; if the water content of the patching material mud mass is too low, the component particles of the patching material mud mass cannot be tightly combined, and the patching material mud mass is easy to crack after being fired; if the water content of the repair glaze clay cluster is too low, the repair glaze clay cluster cannot be tightly combined with the green body, the bonding property with the repair material clay cluster is poor, and the glaze shrinkage phenomenon is easy to occur after the sintering.
Further, the gunning glaze slurry has the specific gravity of 1.76-1.77, the fluidity of 200-220 degrees and the thixotropy of 50-80 degrees.
It is worth explaining that the spray repair glaze slip is sprayed on the repair glaze mud mass, so that the glaze slip in a liquid state needs to be prepared, the technical scheme controls the specific gravity of the spray repair glaze slip to be 1.76-1.77, the fluidity to be 200-220 degrees and the thixotropy to be 50-80 degrees, so that the spray repair glaze is more convenient and faster, and the glaze effect is optimal within the parameter range, so that the repaired part after being re-fired has no difference with the surface of the blank body of the raw material.
Specifically, the technical scheme detects the fluidity and thixotropy of the gunning glaze slurryThe used instrument is a British Andren torsion viscometer which is suitable for the online detection of the production of daily porcelain and sanitary wares, the fluidity and the thixotropy of the spray-on glaze slurry in the technical scheme can be measured, the unit of the fluidity and the thixotropy obtained by the detection is degree (degree), the fluidity and the thixotropy are measured by adopting the torsion viscometer, the detection speed is high, and the operation is simple. The standard torsion viscometer is equipped with a 30swg torsion wire, a 11/16 torsion viscometer weight, a 360 degree dial, a flywheel, and a stainless steel cylindrical sample cup (VFC001, specification: VFC)
) And the like.
The method for detecting the fluidity of the gunning glaze slip in the technical scheme by using the England Andren torsion viscometer comprises the following steps:
the instrument adopted in the test is a British Andren torsion viscometer which is suitable for the online detection of the production of daily porcelain and sanitary wares, and can measure the fluidity and thixotropy of spray-repairing glaze slurry in the technical scheme, and the standard torsion viscometer is provided with a 30swg torsion wire, a 11/16-hour torsion viscometer weight, a 360-degree dial, a flywheel and a stainless steel cylindrical sample cup (VFC001, specification is that
) And the like. The concrete steps for measuring the fluidity index of the gunning glaze slurry are as follows: (1) checking the operation of the torque viscometer, rotating the flywheel 360 degrees clockwise, then allowing it to rotate, and checking whether the pointer stays between 355-0 degrees when it enters into the second rotation; then the flywheel rotates 360 degrees anticlockwise, and then whether the stopping position of the pointer of the second circle is between 0 and 5 degrees is checked; if the clockwise rotation and the anticlockwise rotation are within +/-5 degrees, the instrument is within the standard error range, the test can be started, and if not, the instrument needs to be recalibrated to be within the range; (2) pouring the gunning glaze slurry to be tested into a stainless steel cylindrical sample cup (the height of the gunning glaze slurry is slightly lower than that of the sample cup to prevent the gunning glaze slurry or the make-up clay slurry from being thrown out when being stirred), and thenPlacing the sampling cup under the center of a JB50-D type boosting electric mixer, putting down a mixing rod of the electric mixer to a position 1mm away from the bottom of the sample cup, starting a switch of the electric mixer, pressing a stopwatch switch, and starting to mix the glaze slurry or the cosmetic soil slurry in the sample cup and start timing by the stopwatch; (3) checking the timing of the stopwatch by eyes, pressing a closing button of the electric stirrer when stirring for 1 minute, lifting a stirring rod from the sample cup, cleaning the electric stirrer cleanly by using a wet sponge, and resetting the timing of the stopwatch to zero; (4) the sample cup is placed on a sample cup tray of the torsion viscometer, then the tray is lifted to a proper height, the balance hammer is ensured to be completely immersed in the center position of the glaze slurry in the sample cup, the pointer stop bolt is released, the flywheel rotates anticlockwise through a zero point, when the pointer rotates for the second time to reach the maximum point number, the pointer rotates after stopping at the point, and the point is the fluidity reading of the gunning glaze slurry. The unit is ° (degrees).
Further, in the repair material mud mass:
the screen allowance of the main powder passing through a 160-mesh screen is less than 5 percent;
the fineness of the waste porcelain powder is 80-100 meshes;
the glaze powder is sieved by a 325-mesh sieve, and the sieve allowance is less than 0.2 percent.
It is worth to say that the fineness of the main powder, the waste porcelain powder and the glaze powder has an influence on the performance of the repairing material mud pie. When the fineness of the main powder material, the waste porcelain powder and the glaze powder is too coarse to be combined most closely, cavities are easily formed at the defect positions after the repairing material mud mass is filled, so that the repairing material mud mass cannot play a role in filling the defects; if the fineness of the main powder, the waste porcelain powder and the glaze powder is too fine, cracking is easily caused after firing.
Further, in the repairing material mud mass, the main powder material is mullite powder.
The mullite powder has the advantages of high firing temperature, low shrinkage and low expansion, and is matched with the waste porcelain powder and the glaze powder with the fluxing function, so that the repairing material mud after being fired has a good melting effect with a blank body, and the cracking condition is not easy to occur.
In particular, the chemical components of the mullite powderComprising SiO 2 ：55～65％、Al 2 O 3 : 40-45% and the balance of ignition loss.
Further, the chemical composition of the glaze powder is as follows: SiO 2 2 ：58.5～61.5％、Al 2 O 3 ：8.5～10.0％、Fe 2 O 3 ：0～0.1％、TiO 2 ：0～0.1％、CaO：9.5～11.5％、MgO：0.5～0.8％、K 2 O：1.5～3.0％、Na 2 O: 1.0-2.5 percent, and the balance of ignition loss.
Further, the chemical composition of the overglaze powder is as follows: SiO 2 2 ：59～62％、Al 2 O 3 ：7.5～9.0％、Fe 2 O 3 ：0～0.1％、TiO 2 ：0～0.1％、CaO：10～12％、MgO：0～0.1％、K 2 O：3.5～5.0％、Na 2 1.5-2.5% of O, ZnO: 14.0-16.0% and the balance of ignition loss. In the chemical components of the overglaze powder, the fluxing agent has higher content of calcium oxide and zinc oxide, the firing temperature of the glaze can be reduced, the main crystal phase of the overglaze powder is a calcium silicate glass phase, and the glaze surface can be smooth and compact after firing, so the firing temperature of the glaze can be reduced by adding the overglaze powder, and the glaze surface is smoother and more compact.
Specifically, the chemical composition of the waste porcelain powder in the technical scheme is as follows: SiO 2 2 ：63.50～65.00％、Al 2 O 3 ：22.00～24.00％、Fe 2 O 3 ：1.04～1.24％、TiO 2 ：0.18～0.22％、CaO：0.96～1.16％、MgO：0.56～0.86％、K 2 O：2.36～2.86％、Na 2 O: 1.06-1.36%, IL: 0.44-0.64%. The chemical components of the waste porcelain powder are close to those of the blank glaze, so that the re-burning repairing composite material and the blank body can be better combined.
A preparation method of a re-burning repairing composite material applied to sanitary ceramics is used for preparing the re-burning repairing composite material applied to the sanitary ceramics, and comprises the following steps:
(1) preparing a patching material mud cluster: weighing main powder and glaze powder according to a formula, adding water, ball-milling for 3-5 min, adding the glaze powder and sodium carboxymethylcellulose, and continuing ball-milling for 3-5 min to obtain mixed slurry; after ball milling is finished, drying the mixed slurry to obtain a repair material primary product, and kneading the dried repair material primary product into a mud cluster shape by using a methyl solution to obtain a repair material mud cluster;
(2) preparing a repairing glaze mud briquette: weighing lithium carbonate and a cobalt black pigment according to a formula, adding water, ball-milling for 3-5 min, adding glaze powder, overglaze powder and sodium carboxymethylcellulose, and continuing ball-milling for 3-5 min; sucking water of the ball-milled slurry by using a gypsum mold until the water content is 15-18%, so that the slurry is in a mud cluster state, and obtaining a repaired glaze mud cluster;
(3) preparing gunning glaze slurry: weighing lithium carbonate and a cobalt black pigment according to a formula, adding water, ball-milling for 3-5 min, adding glaze powder, overglaze powder and sodium carboxymethylcellulose, and continuing ball-milling for 3-5 min to obtain gunning glaze slurry; the repairing material, the repairing glaze and the spray repairing glaze slurry form a re-burning repairing composite material.
It is worth to be noted that, in the step (1), as the fineness of the main powder and the waste porcelain powder is thicker than that of the glaze powder, ball milling is carried out firstly, then the glaze powder and the sodium carboxymethylcellulose are added for mixing and ball milling, and ball milling is carried out twice, so that the fineness of the repairing material mud mass is ensured, the uniformity of each component is ensured, the closest packing is achieved, and the optimal repairing effect is realized; the sodium carboxymethyl cellulose and the methyl solution are added when the repairing material mud mass is prepared, so that the repairing material mud mass has good bonding performance, and finally the methyl solution is used for kneading, so that the components are more uniform, the repairing material mud mass can be well bonded with a blank body when the repairing material mud mass is filled in a large defect, and the repairing glaze mud mass is convenient to fill and repair in the subsequent process; and (3) the repair glaze mud dough is filled on the surface of the repair material mud dough, and the repair glaze mud dough can be better filled only by using the state of the mud dough, so that the slurry after the batching in the step (2) needs to be subjected to moisture absorption treatment by using a gypsum mold, and the moisture of the slurry can be effectively absorbed by utilizing the good water absorption performance of the gypsum mold, so that the repair glaze mud dough is prepared. The spray-repairing glaze slip is sprayed with glaze to repair the surface of the glaze mud mass, so that the glaze slip in a liquid state is needed, the glaze slip can be obtained only by carrying out wet ball milling according to the proportion of the formula, and the using effect during glaze spraying is optimal by controlling the parameters of the spray-repairing glaze slip.
Further, the ball milling mode of classifying by stages is adopted in the grinding process of the repair glaze mud mass to ensure that the using effect of the repair glaze mud mass reaches the best, and because the glaze powder and the overglaze powder reach the required fineness requirement, all the raw materials are added and uniformly mixed only during the second ball milling, otherwise, the repair glaze mud mass is too fine in fineness due to the overlong ball milling time, so that the repair glaze cracks after repair and burning. The parameters of the glaze slip limited in the spray repair glaze slip can better carry out the glaze spraying treatment, and the work efficiency of repair workers is improved.
Specifically, the preparation method of the patching material mud pie comprises the following steps: weighing main powder and glaze powder according to a formula, adding water accounting for 45-50% of the total mass, and performing ball milling for 3-5 min; adding glaze powder and sodium carboxymethylcellulose, and continuing to perform ball milling for 3-5 min to obtain mixed slurry; and after the ball milling is finished, drying the slurry to obtain a repair material primary product, kneading the dried repair material primary product into a mud mass shape by using a 1% methyl solution (5 g of sodium carboxymethylcellulose is added into 495g of water to prepare the 1% methyl solution), so as to obtain a repair material mud mass, wherein the water content of the prepared repair material mud mass is 15-18% by mass percent. The repairing material mud pie prepared by the method is well stored by a sealed container, and the phenomenon that the performance of the repairing material mud pie is influenced by the escape of moisture and further the using effect of the repairing material mud pie is influenced is prevented.
The preparation method of the repair glaze mud pie comprises the following steps: weighing lithium carbonate and a cobalt black pigment according to a formula, adding water accounting for 45-50% of the total mass, performing ball milling for 3-5 min, adding glaze powder, overglaze powder and sodium carboxymethylcellulose, and continuing performing ball milling for 3-5 min; and transferring the ball-milled slurry into a plastic beaker, pouring the ball-milled slurry into a gypsum mold, and sucking water for 45-55 hours until the water content is 15-18% after the water is sucked, so that the slurry becomes a mud pie state, and thus obtaining the repair glaze mud pie. The prepared repair glaze mud pie is well stored by a sealed container, so that the performance of the repair glaze mud pie is prevented from being influenced by the escape of moisture, and the using effect of the repair glaze mud pie is further influenced.
The preparation method of the gunning glaze slurry comprises the following steps: weighing lithium carbonate and a cobalt black pigment according to a formula, adding water accounting for 45-50% of the total mass, performing ball milling for 3-5 min, adding glaze powder, overglaze powder and sodium carboxymethylcellulose, and performing ball milling for 3-5 min to obtain gunning glaze slurry, wherein the gunning glaze slurry has a specific gravity of 1.76-1.77, a fluidity of 200-220 degrees and a thixotropy of 50-80 degrees.
It is worth explaining that the preparation method of the re-burning repairing composite material in the technical scheme is simple, the required raw materials are easy to obtain, the preparation cost is low, the production cost can be reduced, and the enterprise benefit is improved.
Further, the preparation method in the step (1) is as follows: weighing main powder and glaze powder according to a formula, adding water, ball-milling for 3-5 min, adding the glaze powder and sodium carboxymethylcellulose, and continuing ball-milling for 3-5 min until particles with the fineness of 10 mu m in the ball-milled mixed slurry account for 45-55%; and after the ball milling is finished, drying the mixed slurry to obtain a repair material primary product, and kneading the dried repair material primary product into a mud cluster shape by using a methyl solution to obtain a repair material mud cluster.
It is worth pointing out that when the particle with the fineness of 10 μm accounts for 45-55% of the mixed slurry, the optimal repairing effect can be realized, the closest packing is achieved, if the particle fineness in the mixed slurry is too large, the particles filled in the sanitary ceramic product blank are too coarse and have poor tightness, and the bonding property with the repairing glaze mud cluster is poor, so that the repairing effect is extremely poor; if the fineness of the particles in the mixed slurry is too small, the particles are easy to crack after being fired, the defects of cracking are easily caused after filling and repairing the glaze paste mass, and the repairing effect is poor.
The re-burning repairing composite material for sanitary ceramic includes the following steps:
(1) polishing and cleaning the defect part of the sanitary ceramic;
(2) filling the defect position of the sanitary ceramic by using the repairing material mud mass, and compacting the repairing material mud mass by using a cylindrical stainless steel needle;
(3) filling the repairing glaze mud groups on the surface of the compacted repairing material mud groups, wherein the filling height of the repairing glaze mud groups is 0.2-0.4 mm higher than the original glaze height of the sanitary ceramics;
(4) spraying the spray repair glaze slurry on the area filled with the repair glaze paste groups;
(5) and (3) firing the repaired sanitary ceramic in the step (4) for 24-28 hours at 1170-1185 ℃ for 20-30 minutes.
Specifically, in the step (1), after the defect of the sanitary ceramic product is vibrated away by the pneumatic vibration pen, impurities on the surface of the product are cleaned up by the air gun, and the defect is vibrated away by the pneumatic vibration pen, so that the defect on the sanitary ceramic product can be completely exposed, and the repair material mud mass can be conveniently filled.
In the step (2), the defect position is filled and leveled (the height is parallel to the blank body of the sanitary ceramic product) by using the repairing material mud mass, then the repairing material mud mass filled in the defect position is compacted in the defect position by using small cylindrical stainless steel needles, and the surface of the repaired position of the product is cleaned after the operation is finished, in the step. The method is characterized in that a special tool (a cylindrical stainless steel needle) is used for compacting the repairing material mud mass at the defect position in the defect, the sintered repairing material mud mass can achieve the best fusion effect with a blank body to fill the defect by virtue of the adhesiveness and the closest packing principle of the repairing material mud mass, the bonding property of the repairing material mud mass and the blank body is good, the repairing glaze mud mass in the subsequent process can be conveniently filled, otherwise, the repairing glaze mud mass after being sintered is mixed in the repairing material due to the fact that the repairing material mud mass is not compacted, the repairing effect is poor, and the repairing failure is caused.
In the step (3), the defect position and the periphery are ground flat by using a pneumatic air grinding pen, the repairing glaze mud groups are filled on the surface of the compacted repairing material mud groups after cleaning, the height of the filling of the repairing glaze mud groups is 0.2-0.4 mm higher than the original glaze height of the sanitary ceramic, the repairing glaze mud groups can shrink (namely melt) after being burnt, so that the filling height of the repairing glaze mud groups is higher than the original glaze height of the sanitary ceramic product, and the glaze of the repairing position of the burnt product is completely consistent with the glaze of the original product.
In the step (4), a layer of gunning glaze slurry is sprayed on the surface of the repaired glaze paste mass, so that the glaze surface is smoother and more compact, and the repaired part has no color difference with the original product and no repair trace can be seen.
The technical scheme of the invention is further illustrated by combining specific examples and comparative examples.
Example 1
A reburning repairing composite material applied to sanitary ceramics comprises a repairing material mud cluster, a repairing glaze mud cluster and a gunning glaze slurry; wherein, calculated according to the mass portion of the dry material, the raw materials of the patching material mud pie comprise 48 portions of main powder (mullite powder), 36 portions of waste porcelain powder, 20 portions of glaze powder and 0.3 portion of sodium carboxymethylcellulose; the raw materials for repairing the glaze clay lumps comprise 85 parts of glaze powder, 10 parts of overglaze powder, 4 parts of lithium carbonate, 0.01 part of cobalt black pigment and 0.5 part of sodium carboxymethylcellulose; the raw materials of the gunning glaze slip comprise 85 parts of glaze powder, 10 parts of overglaze powder, 4 parts of lithium carbonate, 0.01 part of cobalt black pigment and 0.5 part of sodium carboxymethylcellulose;
the preparation method of the composite material for re-sintering and repairing the sanitary ceramics comprises the following steps:
(1) preparing a patching material mud cluster: weighing main powder and glaze powder according to a formula, adding water accounting for 45% of the total mass, performing ball milling for 5min, adding the glaze powder and sodium carboxymethylcellulose, and continuing performing ball milling for 3min to enable particles with the fineness of 10 microns in the mixed slurry after ball milling to account for 55%; after the ball milling is finished, drying the mixed slurry to obtain a repair material primary product, kneading the dried repair material primary product into a mud cluster shape by using a 1% methyl solution (5 g of sodium carboxymethylcellulose is added into 495g of water to prepare the 1% methyl solution), so as to obtain a repair material mud cluster, wherein the water content of the repair material mud cluster is 17%;
(2) preparing a repairing glaze mud briquette: weighing lithium carbonate and cobalt black pigment according to the formula, adding water accounting for 45% of the total mass, performing ball milling for 4min, adding glaze powder, overglaze powder and sodium carboxymethylcellulose, and continuing ball milling for 4 min; sucking water from the ball-milled slurry by using a gypsum mold for 50 hours until the water content is 15%, and turning the slurry into a mud cluster state to obtain a repaired glaze mud cluster;
(3) preparing gunning glaze slurry: weighing lithium carbonate and a cobalt black pigment according to a formula, adding water accounting for 45% of the total mass, carrying out ball milling for 4min, adding glaze powder, overglaze powder and sodium carboxymethylcellulose, and carrying out ball milling for 4min to obtain gunning glaze slurry, wherein the specific gravity of the prepared gunning glaze slurry is 1.77, the fluidity is 209 degrees, and the thixotropy is 70 degrees; the repairing material, the repairing glaze and the spray repairing glaze slurry form a re-burning repairing composite material.
Example 2
A reburning repairing composite material applied to sanitary ceramics comprises a repairing material mud cluster, a repairing glaze mud cluster and a gunning glaze slurry; wherein the raw materials of the patching material mud pie comprise 45 parts of main powder (mullite powder), 40 parts of waste porcelain powder, 25 parts of glaze powder and 0.4 part of sodium carboxymethylcellulose; the raw materials for repairing the glaze clay lumps comprise 90 parts of glaze powder, 5 parts of overglaze powder, 5 parts of lithium carbonate, 0.02 part of cobalt black pigment and 0.4 part of sodium carboxymethylcellulose; the gunning glaze slip comprises 90 parts of glaze powder, 5 parts of overglaze powder, 5 parts of lithium carbonate, 0.02 part of cobalt black pigment and 0.4 part of sodium carboxymethylcellulose;
the preparation method of the reburning repairing composite material applied to the sanitary ceramics comprises the following steps:
(1) preparing a patching material mud cluster: weighing main powder and glaze powder according to a formula, adding water accounting for 50% of the total mass, performing ball milling for 4min, adding the glaze powder and sodium carboxymethylcellulose, and continuing performing ball milling for 3min to enable particles with the fineness of 10 microns in the mixed slurry after ball milling to account for 50%; after the ball milling is finished, drying the mixed slurry to obtain a repair material primary product, kneading the dried repair material primary product into a mud cluster shape by using a 1% methyl solution (5 g of sodium carboxymethylcellulose is added into 495g of water to prepare the 1% methyl solution), so as to obtain a repair material mud cluster, wherein the water content of the repair material mud cluster is 17%;
(2) preparing a repairing glaze mud pie: weighing lithium carbonate and cobalt black pigment according to the formula, adding water accounting for 48 percent of the total mass, performing ball milling for 5min, adding glaze powder, overglaze powder and sodium carboxymethylcellulose, and continuing ball milling for 4 min; sucking water from the ball-milled slurry by using a gypsum mold for 55 hours until the water content is 16 percent, and changing the slurry into a mud pie state to obtain a repaired glaze mud pie;
(3) preparing gunning glaze slurry: weighing lithium carbonate and a cobalt black pigment according to a formula, adding water accounting for 48% of the total mass, carrying out ball milling for 5min, adding glaze powder, overglaze powder and sodium carboxymethylcellulose, and carrying out ball milling for 4min to obtain gunning glaze slurry, wherein the specific gravity of the prepared gunning glaze slurry is 1.765, the fluidity is 214 degrees, and the thixotropy is 65 degrees; the repairing material, the repairing glaze and the spray repairing glaze slurry form a re-burning repairing composite material.
Example 3
A reburning repairing composite material applied to sanitary ceramics comprises a repairing material mud cluster, a repairing glaze mud cluster and a gunning glaze slurry; the repairing material mud pie comprises, by mass, 50 parts of main powder (mullite powder), 35 parts of waste porcelain powder, 23 parts of glaze powder and 0.5 part of sodium carboxymethylcellulose; the raw materials for repairing the glaze clay lumps comprise 88 parts of glaze powder, 9 parts of overglaze powder, 3 parts of lithium carbonate, 0.01 part of cobalt black pigment and 0.3 part of sodium carboxymethylcellulose; the gunning glaze slip comprises 88 parts of glaze powder, 9 parts of overglaze powder, 3 parts of lithium carbonate, 0.01 part of cobalt black pigment and 0.3 part of sodium carboxymethylcellulose;
the preparation method of the composite material for re-sintering and repairing the sanitary ceramics comprises the following steps:
(1) preparing a patching material mud cluster: weighing main powder and glaze powder according to a formula, adding water accounting for 18% of the total mass, performing ball milling for 3min, adding the glaze powder and sodium carboxymethylcellulose, and continuing performing ball milling for 3min to enable particles with the fineness of 10 microns in the mixed slurry after ball milling to account for 45%; after the ball milling is finished, drying the mixed slurry to obtain a repair material primary product, kneading the dried repair material primary product into a mud cluster shape by using a 1% methyl solution (5 g of sodium carboxymethylcellulose is added into 495g of water to prepare the 1% methyl solution), so as to obtain a repair material mud cluster, wherein the water content of the repair material mud cluster is 15%;
(2) preparing a repairing glaze mud briquette: weighing lithium carbonate and cobalt black pigment according to the formula, adding water accounting for 50% of the total mass, performing ball milling for 3min, adding glaze powder, glaze facing powder and sodium carboxymethylcellulose, and continuing to perform ball milling for 3 min; sucking water from the ball-milled slurry by using a gypsum mold for 45 hours to ensure that the water content of the slurry is 18 percent, and the slurry becomes a mud pie state to obtain a repaired glaze mud pie;
(3) preparing gunning glaze slurry: weighing lithium carbonate and cobalt black pigment according to a formula, adding water accounting for 50% of the total mass, carrying out ball milling for 4min, adding glaze powder, surface glaze powder and sodium carboxymethylcellulose, and continuing carrying out ball milling for 3min to obtain gunning glaze slurry, wherein the prepared gunning glaze slurry has the specific gravity of 1.76, the fluidity of 219 degrees and the thixotropy of 63 degrees; the repairing material, the repairing glaze and the spray repairing glaze slurry form a re-burning repairing composite material.
Example 4
The re-fired repair composition materials prepared in examples 1 to 3 were used to repair 3 sanitary ceramics having large defects by the following sanitary ceramics repair methods, to obtain sample 1, sample 2, and sample 3, respectively.
The sanitary ceramic repairing method comprises the following steps:
(1) vibrating the defect part of the sanitary ceramic sample by using a pneumatic vibrating pen, and cleaning impurities on the surface of the product by using an air gun;
(2) filling and leveling the defect of the sanitary ceramic sample by using the repairing material mud mass, compacting the repairing material mud mass by using a cylindrical stainless steel needle, and cleaning the surface of the repaired part of the product after the operation is finished;
(3) grinding the defect and the periphery by using a pneumatic air grinding pen, cleaning, and filling the repairing glaze mud groups on the surface of the compacted repairing material mud groups, wherein the filling height of the repairing glaze mud groups is 0.3mm higher than the original glaze height of the sanitary ceramics;
(4) spraying the spray repair glaze slurry on the area filled with the repair glaze paste groups;
(5) and (5) placing the ceramic sanitary ware sample repaired in the step (4) into a shuttle kiln for sintering, wherein the sintering time is 24 hours, the sintering temperature is 1180 ℃, and the heat preservation time is 25 minutes.
Specifically, sample 1, sample 2 and sample 3 obtained in example 4 were subjected to visual inspection for the repairing effect, and the thermal stability test was performed according to the following methods, respectively:
and (3) testing thermal stability: the sample is placed in an electric heating air blast constant temperature drying oven to be baked for 3 hours at the temperature of 130 ℃, then is placed in ice water at the temperature of 3 ℃, is placed in a container filled with red ink water solution to be soaked for 10 minutes (the red ink water solution is immersed in an object to be detected) after the temperature of the sample is reduced to the normal temperature, and is taken out to observe whether the glaze surface has cracks or not after the operation is carried out for 3 times. The evaluation standard of the thermal stability is 3-130 ℃, three operations are carried out, no crack exists, and the standard is met.
Specifically, the results of the tests of sample 1, sample 2 and sample 3 are shown in table 1 below:
TABLE 1 test results of samples 1 to 3
As can be seen from the detection results in Table 1, the repaired parts of the samples 1 to 3 have no color difference from the original products, and have no cracks after no repair trace is seen, so that the composite material for re-sintering repair can repair the defects of cracks, brown eyes and the like of large blanks on sanitary ceramic products, the thermal stability, the color difference and the like of the repaired products are good, and the repair trace cannot be seen by naked eyes.
Comparative example 1
The re-sintering repairing composite material used for the sanitary ceramics is a repairing material mud briquette in the comparative example, the raw materials of the repairing material mud briquette comprise 48 parts of main powder (mullite powder), 36 parts of waste ceramic powder, 20 parts of glaze powder and 0.3 part of sodium carboxymethyl cellulose according to the mass parts of dry materials, and the preparation method of the repairing material mud briquette is the same as that of the example 1, so that the re-sintering repairing composite material is prepared. The refiring repair composite material prepared by the comparative example is used for repairing the sanitary ceramics with large defects by the following repairing method: vibrating the defect part of the sanitary ceramic sample by using a pneumatic vibration pen, and cleaning impurities on the surface of the product by using an air gun; filling the defect of the sanitary ceramic sample by using the reburning repairing combined material (repairing material mud mass) prepared by the comparative example, compacting the repairing material mud mass by using a cylindrical stainless steel needle, and cleaning the surface of the repairing part of the product after the operation is finished; and (3) putting the repaired sanitary ceramic sample into a shuttle kiln for sintering, wherein the sintering time is 24 hours, the sintering temperature is 1180 ℃, and the heat preservation time is 25 minutes, so that a comparative sample 1 is obtained.
Comparative example 2
A reburning repairing composite material applied to sanitary ceramics comprises a repairing material mud cluster and a repairing glaze mud cluster; wherein, calculated according to the mass portion of the dry material, the raw materials of the patching material mud pie comprise 48 portions of main powder (mullite powder), 36 portions of waste porcelain powder, 20 portions of glaze powder and 0.3 portion of sodium carboxymethylcellulose; the raw materials for repairing the glaze clay lumps comprise 85 parts of glaze powder, 10 parts of overglaze powder, 4 parts of lithium carbonate, 0.01 part of cobalt black pigment and 0.5 part of sodium carboxymethylcellulose;
the preparation methods of the repairing material mud pie and the repairing glaze mud pie are the same as the example 1, and the re-sintering repairing composite material is prepared.
The heavy-burned repairing combined material prepared by the comparative example is used for repairing the sanitary ceramics with large defects by the following repairing method:
(1) vibrating the defect part of the sanitary ceramic sample by using a pneumatic vibrating pen, and cleaning impurities on the surface of the product by using an air gun;
(2) filling and leveling the defect of the sanitary ceramic sample by using the repairing material mud mass, compacting the repairing material mud mass by using a cylindrical stainless steel needle, and cleaning the surface of the repaired part of the product after the operation is finished;
(3) grinding the defect and the periphery by using a pneumatic air grinding pen, cleaning, and filling the repairing glaze mud groups on the surface of the compacted repairing material mud groups, wherein the filling height of the repairing glaze mud groups is 0.3mm higher than the original glaze height of the sanitary ceramics;
(4) and (4) putting the repaired sanitary ceramic sample in the step (3) into a shuttle kiln for sintering, wherein the sintering time is 24 hours, the sintering temperature is 1180 ℃, and the heat preservation time is 25 minutes, so as to obtain a comparative sample 2.
Comparative example 3
A reburning repairing composite material applied to sanitary ceramics comprises a repairing material mud cluster and gunning glaze slurry; wherein, calculated according to the mass portion of the dry material, the raw materials of the patching material mud pie comprise 48 portions of main powder (mullite powder), 36 portions of waste porcelain powder, 20 portions of glaze powder and 0.3 portion of sodium carboxymethylcellulose; the gunning glaze slip comprises the raw materials of 85 parts of glaze powder, 10 parts of overglaze powder, 4 parts of lithium carbonate, 0.01 part of cobalt black pigment and 0.5 part of sodium carboxymethylcellulose;
the preparation methods of the patching material mud pie and the gunning glaze slurry are the same as that of the embodiment 1, and the reburning patching composite material is prepared.
The heavy-burned repairing combined material prepared by the comparative example is used for repairing the sanitary ceramics with large defects by the following repairing method:
(1) vibrating the defect part of the sanitary ceramic sample by using a pneumatic vibrating pen, and cleaning impurities on the surface of the product by using an air gun;
(2) filling and leveling the defect of the sanitary ceramic sample by using the repairing material mud mass, compacting the repairing material mud mass by using a cylindrical stainless steel needle, and cleaning the surface of the repaired part of the product after the operation is finished;
(3) spraying the gunning glaze slurry on the area filled with the patching material mud mass;
(4) and (4) putting the repaired sanitary ceramic sample in the step (3) into a shuttle kiln for sintering, wherein the sintering time is 24 hours, the sintering temperature is 1180 ℃, and the heat preservation time is 25 minutes, so that a comparative sample 3 is obtained.
Specifically, the comparative samples 1, 2 and 3 obtained in the comparative examples 1 to 3 were visually observed for repairing effects, and the thermal stability test and the color difference test were respectively performed according to the above methods, and the detection results are shown in the following table 2:
TABLE 2 test results of comparative examples 1 to 3
From the detection result of the comparative example 1, if the repair material of the technical scheme is only used for repairing the large defect of the sanitary ceramic, the obtained product has obvious repair trace and rough glaze surface, and is an unqualified product. From the detection results of the comparative example 2 and the comparative example 3, if the reburning repairing composite material is the combination of the repairing material pug and the repairing glaze pug, or the combination of the repairing material pug and the gunning glaze slurry, the reburning repairing composite material is adopted to repair the sanitary ceramic product with large defects, the repairing effect is poor, slight color difference exists, the glaze effect is poor, and the qualified standard cannot be achieved.
The technical principle of the present invention is described above in connection with specific embodiments. The description is made for the purpose of illustrating the principles of the invention and should not be construed in any way as limiting the scope of the invention. Based on the explanations herein, those skilled in the art will be able to conceive of other embodiments of the present invention without inventive effort, which would fall within the scope of the present invention.
Claims (10)
1. The re-burning repairing composite material for sanitary ceramic is characterized by comprising a repairing material mud ball, a repairing glaze mud ball and a spray repairing glaze slip;
calculating according to the mass parts of dry materials:
the raw materials of the patching material mud pie comprise 45-50 parts of main powder, 35-40 parts of waste porcelain powder, 20-25 parts of glaze powder and 0.3-0.5 part of sodium carboxymethyl cellulose, wherein the main powder is any one or a combination of two of mullite powder and cordierite powder;
the raw materials of the repaired glaze mud pie comprise 85-90 parts of glaze powder, 5-10 parts of overglaze powder, 1-5 parts of lithium carbonate, 0.01-0.02 part of cobalt black pigment and 0.3-0.5 part of sodium carboxymethylcellulose;
the gunning glaze slip comprises the following raw materials of 85-90 parts of glaze powder, 5-10 parts of overglaze powder, 1-5 parts of lithium carbonate, 0.01-0.02 part of cobalt black pigment and 0.3-0.5 part of sodium carboxymethylcellulose.
2. The re-sintering repair composite material applied to sanitary ceramics according to claim 1, characterized in that the water content of the repair material mud mass is 15-18% by mass; the water content of the repair glaze mud pie is 15-18%.
3. The re-burning repair composition for sanitary ceramics according to claim 1, wherein the gunning glaze slurry has a specific gravity of 1.76 to 1.77, a fluidity of 200 to 220 °, and a thixotropy of 50 to 80 °.
4. The refinishing and repair composition for sanitary ceramics according to claim 1, wherein in the refinishing material briquette:
the screen allowance of the main powder passing through a 160-mesh screen is less than 5 percent;
the fineness of the waste porcelain powder is 80-100 meshes;
the screen allowance of the glaze powder passing through a 325-mesh screen is less than 0.2 percent.
5. The re-sintering repair composition material for sanitary ceramics according to claim 1, wherein in the repair material briquette, the main powder is mullite powder.
6. The re-burning repair composition for sanitary ceramics according to claim 1, wherein the glaze powder has a chemical composition of: SiO 2 2 ：58.5～61.5％、Al 2 O 3 ：8.5～10.0％、Fe 2 O 3 ：0～0.1％、TiO 2 ：0～0.1％、CaO：9.5～11.5％、MgO：0.5～0.8％、K 2 O：1.5～3.0％、Na 2 O: 1.0-2.5 percent, and the balance of ignition loss.
7. The re-burning repair composition for sanitary ceramics according to claim 1, wherein the glaze powder has a chemical composition of: SiO 2 2 ：59～62％、Al 2 O 3 ：7.5～9.0％、Fe 2 O 3 ：0～0.1％、TiO 2 ：0～0.1％、CaO：10～12％、MgO：0～0.1％、K 2 O：3.5～5.0％、Na 2 1.5-2.5% of O, ZnO: 14.0-16.0% and the balance of ignition loss.
8. A method for preparing a re-burning repairing composite material for sanitary ceramics, which is used for preparing the re-burning repairing composite material for sanitary ceramics of any one of claims 1 to 7, and comprises the following steps:
(1) preparing a patching material mud cluster: weighing main powder and glaze powder according to a formula, adding water, ball-milling for 3-5 min, adding the glaze powder and sodium carboxymethylcellulose, and continuing ball-milling for 3-5 min to obtain mixed slurry; after ball milling is finished, drying the mixed slurry to obtain a repair material primary product, and kneading the dried repair material primary product into a mud cluster shape by using a methyl solution to obtain a repair material mud cluster;
(2) preparing a repairing glaze mud briquette: weighing lithium carbonate and a cobalt black pigment according to a formula, adding water, ball-milling for 3-5 min, adding glaze powder, overglaze powder and sodium carboxymethylcellulose, and continuing ball-milling for 3-5 min; sucking water from the ball-milled slurry by using a gypsum mold until the water content is 15-18% so that the slurry is in a mud pie state to obtain a repaired glaze mud pie;
(3) preparing gunning glaze slurry: weighing lithium carbonate and a cobalt black pigment according to a formula, adding water, ball-milling for 3-5 min, adding glaze powder, overglaze powder and sodium carboxymethylcellulose, and continuing ball-milling for 3-5 min to obtain gunning glaze slurry; the repairing material, the repairing glaze and the spray repairing glaze slurry form a re-burning repairing composite material.
9. The method for preparing the re-sintering repair composition for sanitary ceramics according to claim 8, wherein the preparation method in the step (1) is as follows: weighing main powder and glaze powder according to a formula, adding water, ball-milling for 3-5 min, adding the glaze powder and sodium carboxymethylcellulose, and continuing ball-milling for 3-5 min until particles with the fineness of 10 mu m in the ball-milled mixed slurry account for 45-55%; and after the ball milling is finished, drying the mixed slurry to obtain a repair material primary product, and kneading the dried repair material primary product into a mud cluster shape by using a methyl solution to obtain a repair material mud cluster.
10. A sanitary ware repairing method using the re-firing repairing composition for sanitary ware according to any one of claims 1 to 8, comprising the steps of:
(1) polishing and cleaning the defect part of the sanitary ceramic;
(2) filling the defect position of the sanitary ceramic by using the repairing material mud mass, and compacting the repairing material mud mass by using a cylindrical stainless steel needle;
(3) filling the repairing glaze mud clusters on the surface of the compacted repairing material mud clusters, wherein the filling height of the repairing glaze mud clusters is 0.2-0.4 mm higher than the original glaze height of the sanitary ceramic;
(4) spraying the spray repair glaze slurry on the area filled with the repair glaze paste groups;
(5) and (5) firing the sanitary ceramic repaired in the step (4) for 24-28 hours at 1170-1185 ℃ for 20-30 minutes.
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