CN115611610A - 一种可调湿的泡沫陶瓷板及其专用粘结剂 - Google Patents
一种可调湿的泡沫陶瓷板及其专用粘结剂 Download PDFInfo
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Abstract
本发明提供一种可调湿的泡沫陶瓷板，利用锂渣为主要材料，杨絮和聚苯乙烯泡沫颗粒为填充料，经烧结工艺制备出一种质量轻盈、抗压强度高、导热系数小以及调湿效果优异的泡沫陶瓷板。该泡沫陶瓷板将锂渣作为主材料，不仅能形成材料骨架，且无需添加造孔剂和发泡剂，与传统添加外加剂的工艺有显著区别。利用杨絮和聚苯乙烯泡沫颗粒为填充料可起到助熔和提高材料调湿能力的作用。本发明还利用甜叶菊、小蓟草、泽漆和玉米秸秆、小麦面粉以及乙醇制备了一种所述泡沫陶瓷板的专用粘结剂，具有粘度高、性能稳定、成本低廉、无毒害且防腐变等优点。
Description
技术领域
本发明涉及泡沫陶瓷板，具体是一种可调湿的泡沫陶瓷板及其专用粘结剂。
背景技术
随着城镇化进程的不断加快，因保温和除湿而产生的建筑能耗也在持续增加。泡沫陶瓷是一种新型多孔陶瓷材料，具有强度高、导热系数低以及整体性能稳定等优点，在建筑领域有着广泛的应用前景。
锂渣是硫酸法生产碳酸锂的副产物，其主要成分为SiO2和Al2O3。根据相关统计，每生产1t碳酸锂约产生8～10t的锂渣，而总体利用率却不足30％。采用露天堆放等方式处理不仅占用大量土地，且严重威胁当地生态安全。探索将锂渣资源化服务于国家经济建设，具有重要现实意义。
杨树在我国农村属于常见树木，因在建筑业利用面广泛，近些年被大量种植。但每到4～6月份，户外会漂浮大量杨絮，容易引起呼吸道疾病和火灾。另一方面，随着塑料产业的快速发展，产生的废弃聚苯乙烯泡沫也在逐渐增多，因其质量轻、利用率低，容易造成白色污染，探索将杨絮和聚苯乙烯泡沫资源化用于工程建设，具有重要现实意义。
发明内容
针对上述现有技术，本发明提出一种可调湿的泡沫陶瓷板，该泡沫陶瓷板以锂渣为主要原料，杨絮和聚苯乙烯泡沫为填充料，具有质量轻盈、强度高、导热系数低、成本低廉且能调节室内空气湿度等优点，在开发功能性建筑材料、提高固废综合利用率等领域具有重要意义。
本发明提供的一种可调湿的泡沫陶瓷板，其原料包括锂渣、杨絮和聚苯乙烯泡沫颗粒。
所述锂渣取自江苏省南通市某化工厂，为碳酸锂渣，外观呈棕色，矿物组成见表1。
表1锂渣原料化学组分
所述杨絮呈灰白色，在未散落前进行机械收集。
优选地，按质量分数计，所述泡沫陶瓷板的原料包括85％～95％的锂渣、2.5％～7.5％的杨絮和2.5％～7.5％的聚苯乙烯泡沫颗粒。
优选地，按质量分数计，所述泡沫陶瓷板的原料由85％～95％的锂渣、2.5％～7.5％的杨絮和2.5％～7.5％的聚苯乙烯泡沫颗粒混合均匀后在1050～1150℃下烧结而成。
优选地，所述泡沫陶瓷板的制备方法具体包括下述步骤：
S1、将锂渣干燥后经研磨和筛分处理，细度在100～400目；
S2、将杨絮经清水冲洗后采用切割设备加工成长度≤0.1mm的类似粉状物，并于自然条件下风干；
S3、将聚苯乙烯泡沫水洗后于自然条件下风干，经设备切割形成粒径为1.5～2.0mm，堆积密度为5.5Kg/m3的颗粒体；
S4、将处理好的所述锂渣、杨絮和聚苯乙烯泡沫颗粒按设计比例搅拌均匀，装入模具内，并通过应力形成坯体；
S5、将所述坯体置于烧结炉中，升温至1050～1150℃，保温3～4h，经过自然冷却、边角修正以及板体打磨工艺形成可调湿的泡沫陶瓷板。
优选地，S1中，所述锂渣的干燥温度为100℃，干燥时间为12h。
优选地，S4中，所述应力为15MPa。
优选地，S5中，以5℃/min的速度升温至1050～1150℃。
针对该泡沫陶瓷板质量轻的特性并考虑到实际施工的可行性，本发明还提供一种所述的泡沫陶瓷板的专用粘结剂，其原料包括小蓟草、泽漆、玉米秸秆、甜叶菊、面粉和乙醇。
优选地，所述专用粘结剂的制备方法包括下述步骤：
S1、将小蓟草、泽漆、玉米秸秆和甜叶菊用清水洗净杂质后在自然条件下风干；
S2、待风干后将小蓟草、泽漆、玉米秸秆和甜叶菊投入粉碎设备切割成碎末料并搅拌均匀；
S3、在煮沸设备中加入所述碎末料和清水，并加热至沸腾，沸腾时间持续5～10min；
S4、待冷却后对煮沸设备中的碎末料进行过滤，将面粉投入滤饼中并搅拌均匀形成混合料，将混合料加热煮沸并持续3～5min；
S5、待混合料冷却后，投入乙醇并搅拌均匀，静置形成半固态物，即为泡沫陶瓷板的专用粘结剂。
优选地，按质量分数计，所述专用粘结剂的原料包括22～24％的小蓟草、22～24％的泽漆、21～22％的玉米秸秆、16～19％的甜叶菊和11～19％的面粉。
相对于现有技术，本发明的有益效果为：
1、本发明提供的一种泡沫陶瓷板，以锂渣为主要原料，在高温煅烧过程中，锂渣除了形成陶瓷板的整体骨架，还同时起到了发泡和造孔的作用，实现“一材多用”，与传统添加外加剂工艺有显著区别。另一方面，本发明利用杨絮和聚苯乙烯泡沫作为填充料，一方面杨絮和聚苯乙烯泡沫均易燃，起到助熔作用，另一方面填充料的燃烧物在 1050～1150℃下始终保持原固态相且均匀分散在泡沫陶瓷的内、外表面，可通过二者煅烧后形成的生成物增强泡沫陶瓷板的调湿能力。
2、本发明原材料简单，可实现就地取材，且具有质量轻、造价低、导热系数小以及调湿效果好等优点，适合批量生产。
3、本发明中泡沫陶瓷板的专用粘结剂利用植物成分为原材料，具有成本低廉、粘结力强且制备过程简单的优点。经验证，该粘结剂在常温下密封可保存30d以上。该粘结剂在使用后无毒害物质产生且不霉变，具有较强的抗冻及耐高温能力，属于绿色建筑材料。
附图说明
图1是本发明实施例中的泡沫陶瓷板的X射线衍射图谱。
图2是本发明试验例中实验组的框架结构示意图。
图3是本发明试验例中实验组和对照组的框架结构对比图。
图中，1、基层；2、粘结剂；3、泡沫陶瓷板；4、网格布；5、墙纸。
具体实施方式
为了使本发明所提供的技术手段、创作特征、达成目的与功效易于理解，同时也为验证锂渣细度、填充料用量和煅烧温度对可调湿泡沫陶瓷板抗压强度、导热系数和吸放湿平衡含湿量的影响规律，下面将通过正交试验的方式组织实施案例，对本发明进行详细说明。正交试验设计如表2所示。
表2正交试验设计表
实施例1
一种可调湿的泡沫陶瓷板，制备方法包括下述步骤：
S1、将锂渣置于100℃下干燥12h，经研磨和筛分处理，细度在100～200目；
S2、将杨絮经清水冲洗后采用切割设备加工成长度≤0.1mm的类似粉状物，并于自然条件下风干；
S3、将聚苯乙烯泡沫水洗后于自然条件下风干，经设备切割形成粒径为1.5～2.0mm、堆积密度为5.5Kg/m3的颗粒体；
S4、将处理好的锂渣、杨絮和聚苯乙烯泡沫颗粒搅拌均匀，装入内空尺寸为200mm×200mm×10mm的模具内，并以15MPa的应力形成坯体；其中，杨絮和聚苯乙烯泡沫颗粒的质量分数均为2.5％，余量为锂渣；
S5、将所述坯体置于烧结炉中，以5℃/min的速度升温至1050℃，保温4h，经过自然冷却、边角修正以及板体打磨工艺形成可调湿的泡沫陶瓷板。
实施例2
一种可调湿的泡沫陶瓷板，重复实施例1的做法，锂渣取100～200目粒级，杨絮和聚苯乙烯泡沫颗粒的质量分数均为5.0％，烧结温度为1100℃。
实施例3
一种可调湿的泡沫陶瓷板，重复实施例1的做法，锂渣取100～200目粒级，杨絮和聚苯乙烯泡沫颗粒的质量分数均为7.5％，烧结温度为1150℃。
实施例4
一种可调湿的泡沫陶瓷板，重复实施例1的做法，锂渣取200～300目粒级，杨絮和聚苯乙烯泡沫颗粒的质量分数分别为2.5％和5.0％，烧结温度为1150℃。
实施例5
一种可调湿的泡沫陶瓷板，重复实施例1的做法，锂渣取200～300目粒级，杨絮和聚苯乙烯泡沫颗粒的质量分数分别为5.0％和7.5％，烧结温度为1050℃。
实施例6
一种可调湿的泡沫陶瓷板，重复实施例1的做法，锂渣取200～300目粒级，杨絮和聚苯乙烯泡沫颗粒的质量分数分别为7.5％和2.5％，烧结温度为1100℃。
实施例7
一种可调湿的泡沫陶瓷板，重复实施例1的做法，锂渣取300～400目粒级，杨絮和聚苯乙烯泡沫颗粒的质量分数分别为2.5％和7.5％，烧结温度为1100℃。
实施例8
一种可调湿的泡沫陶瓷板，重复实施例1的做法，锂渣取200～300目粒级，杨絮和聚苯乙烯泡沫颗粒的质量分数分别为5.0％和2.5％，烧结温度为1150℃。
实施例9
一种可调湿的泡沫陶瓷板，重复实施例1的做法，锂渣取200～300目粒级，杨絮和聚苯乙烯泡沫颗粒的质量分数分别为7.5％和5.0％，烧结温度为1050℃。
图1为烧结温度分别是1050℃、1100℃和1150℃时该泡沫陶瓷板的X射线衍射图谱，可见其主要成分均为莫来石，且不受烧结温度的影响。
分别测定实施例1-9得到的泡沫陶瓷板的抗压强度、导热系数和吸放湿平衡含湿量，结果如表3所示。
表3实施例数据统计
结合表3的数据，提高锂渣细度和烧结温度使泡沫陶瓷板抗压强度和导热系数增大，吸放湿平衡含湿量减小；提高填充料用量使吸放湿平衡含湿量增大，抗压强度和导热系数减小。该泡沫陶瓷板满足抗压强度≥9.70MPa，导热系数≤0.0475W/m.K，吸放湿平衡含湿量≥0.0465kg·kg-1。
实施例10
一种所述泡沫陶瓷板的专用粘结剂，其制备方法包括下述步骤：
S1、将新鲜小蓟草、泽漆、玉米秸秆和甜叶菊用清水洗净杂质后在自然条件下风干；
S2、按质量分数计，待风干后将23％的小蓟草、23％的泽漆、22％的玉米秸秆和18％的甜叶菊投入粉碎设备切割成碎末料并搅拌均匀；
S3、按照原材料：清水＝1：1.03的质量比在煮沸设备中加入所述碎末料和清水，并加热至沸腾，沸腾时间持续8min；
S4、待冷却后立即对煮沸设备中的碎末料进行过滤，将14％的小麦面粉投入滤饼中并快速搅拌均匀形成混合料，将混合料加热煮沸并持续4min；
S5、待混合料冷却后，投入混合料质量20％的乙醇并快速搅拌均匀，静置12h后形成半固态物，即为泡沫陶瓷板的专用粘结剂。
该专用粘结剂适用于以现浇混凝土和砖砌体为基层的墙面，使用时，取粘结剂均匀涂抹于泡沫陶瓷板背面1mm厚度，轻度按压固定于基层即可。根据标准验证，在常温条件下该粘结剂与泡沫陶瓷板的12h粘结强度≥0.65MPa，24h粘结强度≥1.10MPa。
试验例
如图2、3所示，采用240mm×115mm×53mm的水泥砖和C20混凝土砌筑两组尺寸均为2.0m×2.0m×2.0m的封闭的框架结构，框架结构的外表面均用M5水泥砂浆密封作为基层1，一组作为实验组，另一组作为对照组，实验组中基层1的外侧依次设置1mm的粘结剂2、实施例1得到的泡沫陶瓷板3、网格布4和墙纸5，对照组中除用水泥砂浆抹灰层替代泡沫陶瓷板2，其余做法与实验组相同。在冬季晴天室外温度为-5～-3℃的情况下，在两组框架结构内放置300g水和温湿度传感器，记录8：00～20:00的温湿度变化，实验数据如表4，结合表4的数据，该泡沫陶瓷板具有较好的保温及调湿能力。
表4室外模拟数据统计
以上仅为本发明的实施方式，并非因此限制本发明的专利范围，凡是利用本发明说明书及附图内容所作的等效结构，直接或间接运用在其他相关的技术领域，均同理在本发明的专利保护范围。
Claims (10)
1.一种可调湿的泡沫陶瓷板，其特征在于，其原料包括锂渣、杨絮和聚苯乙烯泡沫颗粒。
2.如权利要求1所述的泡沫陶瓷板，其特征在于，按质量分数计，所述泡沫陶瓷板的原料包括85%～95%的锂渣、2.5%～7.5%的杨絮和2.5%～7.5%的聚苯乙烯泡沫颗粒。
3.如权利要求1所述的泡沫陶瓷板，其特征在于，按质量分数计，所述泡沫陶瓷板的原料由85%～95%的锂渣、2.5%～7.5%的杨絮和2.5%～7.5%的聚苯乙烯泡沫颗粒混合均匀后在1050～1150℃下烧结而成。
4.如权利要求1-3任一项所述的泡沫陶瓷板，其特征在于，其制备方法具体包括下述步骤：
S1、将锂渣干燥后经研磨和筛分处理，细度在100～400目；
S2、将杨絮水洗后加工成长度≤0.1mm的类似粉状物，并于自然条件下风干；
S3、将聚苯乙烯泡沫水洗后于自然条件下风干，切割形成粒径为1.5～2.0mm的颗粒体；
S4、将处理好的所述锂渣、杨絮和聚苯乙烯泡沫颗粒按设计比例搅拌均匀，装入模具内，并通过应力形成坯体；
S5、将所述坯体置于烧结炉中，升温至1050～1150℃，保温3～4h。
5.如权利要求4所述的泡沫陶瓷板，其特征在于，S1中，所述锂渣的干燥温度为100℃，干燥时间为12h。
6.如权利要求4所述的泡沫陶瓷板，其特征在于，S4中，所述应力为15MPa。
7.如权利要求4所述的泡沫陶瓷板，其特征在于，S5中，以5℃/min的速度升温至1050～1150℃。
8.一种如权利要求1-7任一项所述的泡沫陶瓷板的专用粘结剂，其特征在于，其原料包括小蓟草、泽漆、玉米秸秆、甜叶菊、面粉和乙醇。
9.如权利要求8所述的专用粘结剂，其特征在于，其制备方法包括下述步骤：
S1、将小蓟草、泽漆、玉米秸秆和甜叶菊洗净后在自然条件下风干；
S2、待风干后将小蓟草、泽漆、玉米秸秆和甜叶菊切割成碎末料并搅拌均匀；
S3、在煮沸设备中加入所述碎末料和清水，并加热至沸腾，沸腾时间持续5～10min；
S4、待冷却后对煮沸设备中的碎末料进行过滤，将面粉投入滤饼中并搅拌均匀形成混合料，将混合料加热煮沸并持续3～5min；
S5、待混合料冷却后，投入乙醇并搅拌均匀，静置形成半固态物，即为泡沫陶瓷板的专用粘结剂。
10.如权利要求8或9所述的专用粘结剂，其特征在于，按质量分数计，所述专用粘结剂的原料包括22～24%的小蓟草、22～24%的泽漆、21～22%的玉米秸秆、16～19%的甜叶菊和11～19%的面粉。
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