CN119161168A - 一种可降解环保陶瓷砖制备方法 - Google Patents
一种可降解环保陶瓷砖制备方法 Download PDFInfo
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 25
- 238000000227 grinding Methods 0.000 claims description 22
- 229910052757 nitrogen Inorganic materials 0.000 claims description 17
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- JKWMSGQKBLHBQQ-UHFFFAOYSA-N diboron trioxide Chemical compound O=BOB=O JKWMSGQKBLHBQQ-UHFFFAOYSA-N 0.000 claims description 15
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 14
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- 235000010339 sodium tetraborate Nutrition 0.000 claims description 14
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- 239000004927 clay Substances 0.000 claims description 8
- 239000000395 magnesium oxide Substances 0.000 claims description 8
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 8
- POFFJVRXOKDESI-UHFFFAOYSA-N 1,3,5,7-tetraoxa-4-silaspiro[3.3]heptane-2,6-dione Chemical compound O1C(=O)O[Si]21OC(=O)O2 POFFJVRXOKDESI-UHFFFAOYSA-N 0.000 claims description 7
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- RQPZNWPYLFFXCP-UHFFFAOYSA-L barium dihydroxide Chemical compound [OH-].[OH-].[Ba+2] RQPZNWPYLFFXCP-UHFFFAOYSA-L 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
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- 229910001404 rare earth metal oxide Inorganic materials 0.000 description 1
- IATRAKWUXMZMIY-UHFFFAOYSA-N strontium oxide Inorganic materials [O-2].[Sr+2] IATRAKWUXMZMIY-UHFFFAOYSA-N 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
- 230000004580 weight loss Effects 0.000 description 1
- XLOMVQKBTHCTTD-UHFFFAOYSA-N zinc oxide Inorganic materials [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 1
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Abstract
本发明公开了一种可降解环保陶瓷砖的制备方法，属于陶瓷砖制备技术领域。将原料按份数依次加入在球磨机中进行间歇式湿法球磨，球磨4‑5小时后过筛得到泥浆，利用水基流延成型法制成毛胚。最后将毛胚在高温窑炉中烧制，使其固化成为陶瓷砖。该方法工艺简单，降低了加工时的电耗，达到了节能减排的目的，可用于大规模工业化生产。通过上述方法制备得到的陶瓷砖破碎后在自然条件下自然放置一年后降解率可达到95％，而且在保证环保可降解的前提下陶瓷砖的耐磨率没有明显降低，能够满足使用过程中基本的耐磨要求。
Description
技术领域
本发明属于陶瓷砖制备技术领域，具体涉及一种可降解环保陶瓷砖制备方法。
背景技术
陶瓷是一种由黏土和其他无机非金属原料组成的历史悠久且应用广泛的材料，其独特性质和多种制备方法使它成为许多领域的理想选择，尤其是在建筑陶瓷行业，陶瓷制品如瓷砖(地板砖、外墙砖等)、陶瓷板及雕塑广泛用于室内外装饰以及建筑物的墙面、地面。它们不仅美观耐用，还具有良好的隔热隔音性能，是现代建筑的重要组成部分。陶瓷砖施工方便、易打理、耐磨防滑，并且具有独特的物理性质和装饰效果，在各类建筑中应用广泛，同时也不可避免伴随着废弃量大、废料多的问题。陶瓷砖的化学性质稳定，不易降解，这对自然环境产生了严峻挑战。
随着对人民生活品质需求的提高，市场竞争的日益激烈以及环保政策的日益严格，对陶瓷砖的环保化、个性化也提出了新的要求。专利CN108863324 A公布了一种可降解的低温共烧陶瓷的制备方案是以SiO2、SiO2·nH2O、H3BO3、B2O3、NaOH、KOH、Ba(OH)2·8H2O、Al(OH)3、MgO、CaO、SrO、ZnO及稀土氧化物为原料，经采用球磨、烘干、研磨、煅烧、造粒、成型、烧结工艺步骤得到产品。该发明以水作为陶瓷降解的触发相，通过该方法制到的陶瓷不适宜在我国南方以及潮湿条件下的应用。因此，为减少环境污染，节约工业成本，探索一种新的可降解环保陶瓷砖制备方法是有必要的。
发明内容
针对上述问题，本发明提供一种可降解环保陶瓷砖制备方法，
本发明的目的通过以下技术方案实现：
步骤一：将原料按份数依次加入在球磨机中进行间歇式湿法球磨，球磨时间4-5小时后过筛得到泥浆。
步骤二：将步骤一中泥浆按水基流延成型法制成毛胚。
步骤三：将毛胚在高温窑炉中烧成，使其固化成为陶瓷砖
优选的，步骤一中原料按重量分数计：高岭土30-36份；石英砂20-25份；陶土10-15份；二氧化硅10-15份；硼砂5-10份；氧化钡1-2份；轻质碳酸钙3-5份；氧化镁4-8份；三氧化二硼1-2份；碳酸硅1-2份；碳酸锶1-3份；氧化锆1-2份。富硼砂2-3份。
优选的，所述的步骤一间歇式球磨方法具体为：在球磨机中按比例投料，球磨设定四个阶段：第一阶段转速设定为480转/时，研磨0.5小时；第二阶段转速设定为650转/时，研磨2小时；第三阶段转速设定为480转/时，研磨1.5-2小时。
优选的，球磨机中投料比例为球：料：水＝30:46:24。
优选的，在球磨过程中加入聚乙烯醇作为粘结剂，甘油作为增塑剂。
优选的，所述的过筛为200目。
优选的，所述步骤二中水基流延成型方法具体为用刮刀将步骤一得到的料浆以一定厚度刮压涂敷在基带上，经干燥、固化后从上剥下成为生坯带的薄膜，然后对生坯带进行冲切、层合，制成待烧结的毛坯成品。
优选的，所述步骤三中高温窑分段煅烧
第一段将高温窑以10-15℃/分钟的速率从室温升至300-360℃在氮气中煅烧2-3.5小时。
第二段将高温窑以15-25℃/分钟的速率从300-360℃升至700-800℃在氮气中煅烧6-7小时。
第三段将高温窑以10-15℃/分钟的速率从700-800℃升至1150-1250℃在氮气中煅烧2-3.5小时。
本发明的有益效果包含以下几个方面：
(1)本发明通过调整各原料的比例，把陶瓷砖的降解触发条件调整为空气湿度下破碎后降解，增加了陶瓷砖的使用范围。
(2)采用本方法制得的陶瓷砖破碎后在自然条件下半年的降解率可达到35-45％，自然放置一年后降解率可达到95％。
(3)该方法球磨方式采用间歇湿法球磨，合理控制球磨中不同阶段的时间和转速，明显提高了球磨效率，降低了加工时的电耗，达到了节能减排的目的。
(4)传统的膜压成型工艺均匀性差，效率低，流延成型工艺的应用实现了生产的连续化和自动化，改善了陶瓷砖的质量。
具体实施方式
实施例1
按重量组分称取高岭土30份；石英砂20份；陶土15份；二氧化硅10份；硼砂7份；氧化钡2份；轻质碳酸钙5份；氧化镁5份；三氧化二硼1份；碳酸硅1份；碳酸锶1份；氧化锆1份；富硼砂1份作为原料，投料比例为铝球：料：水＝30:46:24依次加入在球磨机中，随后加入聚乙烯醇作为粘结剂，甘油作为增塑剂。首先转速设定为480转/时，研磨0.5小时；接着转速设定为650转/时，研磨2小时；最后转速设定为480转/时，研磨2小时后过200目筛得到泥浆。
将步骤一中泥浆用刮刀将步骤一得到的料浆以一定厚度刮压涂敷在基带上，110℃干燥10小时后从上剥下成为生坯带的薄膜，然后对生坯带进行冲切、层合，制成待烧结的毛坯成品。
将毛胚在高温窑炉首先将高温窑以10-15℃/分钟的速率从室温升300-360℃在氮气中煅烧3小时；其次将高温窑以15-25℃/分钟的速率从室温升至700-800℃在氮气中煅烧6小时；最后将高温窑以10-15℃/分钟的速率从室温升至1150-1250℃在氮气中煅烧3.5小时固化成为陶瓷砖。
实施例2
按重量组分称取高岭土33份；石英砂22份；陶土10份；二氧化硅10份；硼砂10份；氧化钡2份；轻质碳酸钙3份；氧化镁5份；三氧化二硼1份；碳酸硅1份；碳酸锶1份；氧化锆1份；富硼砂1份作为原料，投料比例为铝球：料：水＝30:46:24依次加入在球磨机中，随后加入聚乙烯醇作为粘结剂，甘油作为增塑剂。首先转速设定为480转/时，研磨0.5小时；接着转速设定为650转/时，研磨2小时；最后转速设定为480转/时，研磨1.8小时后过200目筛得到泥浆。
将步骤一中泥浆用刮刀将步骤一得到的料浆以一定厚度刮压涂敷在基带上，110℃干燥10小时后从上剥下成为生坯带的薄膜，然后对生坯带进行冲切、层合，制成待烧结的毛坯成品。
将毛胚在高温窑炉首先将高温窑以10-15℃/分钟的速率从室温升300-360℃在氮气中煅烧3小时；其次将高温窑以15-25℃/分钟的速率从室温升至700-800℃在氮气中煅烧6小时；最后将高温窑以10-15℃/分钟的速率从室温升至1150-1250℃在氮气中煅烧3.5小时固化成为陶瓷砖。
实施例3
按重量组分称取高岭土34份；石英砂22份；陶土10份；二氧化硅10份；硼砂7份；氧化钡2份；轻质碳酸钙3.5份；氧化镁5份；三氧化二硼1.5份；碳酸硅1.5份；碳酸锶1.5份；氧化锆1份；富硼砂1份作为原料，投料比例为铝球：料：水＝30:46:24依次加入在球磨机中，随后加入聚乙烯醇作为粘结剂，甘油作为增塑剂。首先转速设定为480转/时，研磨0.5小时；接着转速设定为650转/时，研磨2小时；最后转速设定为480转/时，研磨1.5小时后过200目筛得到泥浆。
将步骤一中泥浆用刮刀将步骤一得到的料浆以一定厚度刮压涂敷在基带上，110℃干燥10小时后从上剥下成为生坯带的薄膜，然后对生坯带进行冲切、层合，制成待烧结的毛坯成品。
将毛胚在高温窑炉首先将高温窑以10-15℃/分钟的速率从室温升300-360℃在氮气中煅烧3小时；其次将高温窑以15-25℃/分钟的速率从室温升至700-800℃在氮气中煅烧6小时；最后将高温窑以10-15℃/分钟的速率从室温升至1150-1250℃在氮气中煅烧3.5小时固化成为陶瓷砖。
实施例4
按重量组分称取高岭土28份；石英砂21份；陶土15份；二氧化硅10份；硼砂8份；氧化钡2份；轻质碳酸钙5份；氧化镁5份；三氧化二硼1份；碳酸硅1份；碳酸锶1份；氧化锆1份；富硼砂1份作为原料，投料比例为铝球：料：水＝30:46:24依次加入在球磨机中，随后加入聚乙烯醇作为粘结剂，甘油作为增塑剂。首先转速设定为480转/时，研磨0.5小时；接着转速设定为650转/时，研磨2小时；最后转速设定为480转/时，研磨2小时后过200目筛得到泥浆。
将步骤一中泥浆用刮刀将步骤一得到的料浆以一定厚度刮压涂敷在基带上，110℃干燥10小时后从上剥下成为生坯带的薄膜，然后对生坯带进行冲切、层合，制成待烧结的毛坯成品。
将毛胚在高温窑炉首先将高温窑以10-15℃/分钟的速率从室温升300-360℃在氮气中煅烧3小时；其次将高温窑以15-25℃/分钟的速率从室温升至700-800℃在氮气中煅烧6小时；最后将高温窑以10-15℃/分钟的速率从室温升至1150-1250℃在氮气中煅烧2小时固化成为陶瓷砖。
实施例5
按重量组分称取高岭土30份；石英砂20份；陶土15份；二氧化硅10份；硼砂7份；氧化钡2份；轻质碳酸钙5份；氧化镁5份；三氧化二硼1份；碳酸硅1份；碳酸锶1份；氧化锆1份；富硼砂1份作为原料，投料比例为铝球：料：水＝30:46:24依次加入在球磨机中，随后加入聚乙烯醇作为粘结剂，甘油作为增塑剂。首先转速设定为480转/时，研磨0.5小时；接着转速设定为650转/时，研磨2小时；最后转速设定为480转/时，研磨1.5小时后过200目筛得到泥浆。
将步骤一中泥浆用刮刀将步骤一得到的料浆以一定厚度刮压涂敷在基带上，110℃干燥10小时后从上剥下成为生坯带的薄膜，然后对生坯带进行冲切、层合，制成待烧结的毛坯成品。
将毛胚在高温窑炉首先将高温窑以10-15℃/分钟的速率从室温升300-360℃在氮气中煅烧3小时；其次将高温窑以15-25℃/分钟的速率从室温升至700-800℃在氮气中煅烧6小时；最后将高温窑以10-15℃/分钟的速率从室温升至1150-1250℃在氮气中煅烧3小时固化成为陶瓷砖。
将上述实施例中制备的陶瓷砖进行性能测试。
降解率
将按实施例1-5烧制的陶瓷砖破碎至块状，以现有的普通陶瓷砖作为对比例，置于自然环境下一年，每隔60天称量放置前后的质量，计算其失重率。测试结果见表1。
表1
耐磨性
以现有的普通陶瓷砖作为对比例，将上述实施例1～5中制备的陶瓷砖进行耐磨性测试，测试结果见表2
表2
| 组别 | 耐磨转数 |
| 实施例1 | 15350 |
| 实施例2 | 14258 |
| 实施例3 | 15012 |
| 实施例4 | 14015 |
| 实施例5 | 14925 |
| 对比例 | 14623 |
从上表可知通过本发明所述的实施例得到的陶瓷砖不仅降解率好，而且在保证环保可降解的前提下陶瓷砖的耐磨率没有明显降低，能够满足使用过程中基本的耐磨要求。
上面结合本发明的实施例进行了描述，但是本发明并不局限于上述的具体实施方式，上述的具体实施方式仅仅是示意性的，而不是限制性的，本领域的普通技术人员在本发明的启示下，在不脱离本发明宗旨和权利要求所保护的范围情况下，还可做出很多变化，均属于本发明的保护之内。
Claims (9)
1.一种可降解环保陶瓷砖制备方法，其特征在于，包括
步骤一：将原料按份数依次加入在球磨机中进行间歇式湿法球磨，球磨时间4-5小时后过筛得到泥浆。
步骤二：将步骤一中泥浆水基流延成型制成毛胚。
步骤三：将毛胚在高温窑炉中烧成，使其固化成为陶瓷砖。
2.根据的权利要求1所述的可降解环保陶瓷砖的制备方法，其特征在于，步骤一中原料按重量分数计：
高岭土28-35份；
石英砂20-25份；
陶土10-15份；
二氧化硅10-15份；
硼砂5-10份；
氧化钡1-2份；
轻质碳酸钙3-5份；
氧化镁4-8份；
三氧化二硼1-2份；
碳酸硅1-2份；
碳酸锶1-3份；
氧化锆1-2份；
富硼砂2-3份。
3.根据权利要求1所述的制备方法，其特征在于，所述的步骤一间歇式球磨方法具体为：在球磨机中按比例投料，球磨设定四个阶段：第一阶段转速设定为480转/时，研磨0.5小时；第二阶段转速设定为650转/时，研磨2小时；第三阶段转速设定为480转/时，研磨1.5-2小时。
4.根据权利要求3所述的球磨方法，其特征在于，球磨机中投料比例为球：料：水＝30:46:24。
5.根据权利要求3所述的球磨方法，其特征在于，在球磨过程中加入聚乙烯醇作为粘结剂，甘油作为增塑剂。
6.根据权利要求1所述的制备方法，其特征在于，所述的过筛为200目。
7.根据权利要求1所述的制备方法，其特征在于，所述步骤二中水基流延成型方法具体为用刮刀将步骤一得到的料浆以一定厚度刮压涂敷在基带上，经干燥、固化后从上剥下成为生坯带的薄膜，然后对生坯带进行冲切、层合，制成待烧结的毛坯成品。
8.根据权利要求1所述的制备方法，其特征在于，所述步骤三中高温窑分段煅烧
第一段将高温窑以10-15℃/分钟的速率从室温升至300-360℃在氮气中煅烧2-3.5小时。
第二段将高温窑以15-25℃/分钟的速率从300-360℃升至700-800℃在氮气中煅烧6-7小时。
第三段将高温窑以10-15℃/分钟的速率从700-800℃升至1150-1250℃在氮气中煅烧2-3.5小时。
9.权利要求1～8任一项所述制备方法可得到可降解环保陶瓷砖。
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