TWI823147B - 抗菌磁磚及其製造方法 - Google Patents
抗菌磁磚及其製造方法 Download PDFInfo
- Publication number
- TWI823147B TWI823147B TW110134887A TW110134887A TWI823147B TW I823147 B TWI823147 B TW I823147B TW 110134887 A TW110134887 A TW 110134887A TW 110134887 A TW110134887 A TW 110134887A TW I823147 B TWI823147 B TW I823147B
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- Prior art keywords
- antibacterial
- glaze
- zinc oxide
- oxide powder
- coated
- Prior art date
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- 230000000844 anti-bacterial effect Effects 0.000 title claims abstract description 151
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 30
- 239000000463 material Substances 0.000 claims abstract description 36
- 239000002689 soil Substances 0.000 claims abstract description 22
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 17
- 239000002002 slurry Substances 0.000 claims abstract description 16
- 239000000203 mixture Substances 0.000 claims abstract description 15
- 239000000843 powder Substances 0.000 claims abstract description 13
- 238000010304 firing Methods 0.000 claims abstract description 12
- 238000001035 drying Methods 0.000 claims abstract description 6
- 238000000465 moulding Methods 0.000 claims abstract description 5
- 238000000227 grinding Methods 0.000 claims abstract description 3
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims description 93
- 239000011787 zinc oxide Substances 0.000 claims description 34
- QPLDLSVMHZLSFG-UHFFFAOYSA-N Copper oxide Chemical compound [Cu]=O QPLDLSVMHZLSFG-UHFFFAOYSA-N 0.000 claims description 25
- 239000000725 suspension Substances 0.000 claims description 23
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 claims description 18
- 239000011248 coating agent Substances 0.000 claims description 15
- 238000000576 coating method Methods 0.000 claims description 15
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 claims description 13
- 239000002537 cosmetic Substances 0.000 claims description 9
- 239000012065 filter cake Substances 0.000 claims description 9
- 239000000376 reactant Substances 0.000 claims description 9
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 claims description 9
- 238000000034 method Methods 0.000 claims description 8
- 229910000365 copper sulfate Inorganic materials 0.000 claims description 7
- ARUVKPQLZAKDPS-UHFFFAOYSA-L copper(II) sulfate Chemical compound [Cu+2].[O-][S+2]([O-])([O-])[O-] ARUVKPQLZAKDPS-UHFFFAOYSA-L 0.000 claims description 7
- 239000002245 particle Substances 0.000 claims description 7
- 239000004576 sand Substances 0.000 claims description 7
- 239000007921 spray Substances 0.000 claims description 7
- 239000001569 carbon dioxide Substances 0.000 claims description 6
- 229910002092 carbon dioxide Inorganic materials 0.000 claims description 6
- 241000588724 Escherichia coli Species 0.000 claims description 5
- 241000191967 Staphylococcus aureus Species 0.000 claims description 5
- 238000006243 chemical reaction Methods 0.000 claims description 5
- 239000004927 clay Substances 0.000 claims description 5
- 238000003756 stirring Methods 0.000 claims description 5
- 239000002244 precipitate Substances 0.000 claims description 4
- 238000001556 precipitation Methods 0.000 claims description 4
- 230000008569 process Effects 0.000 claims description 4
- JJLJMEJHUUYSSY-UHFFFAOYSA-L Copper hydroxide Chemical compound [OH-].[OH-].[Cu+2] JJLJMEJHUUYSSY-UHFFFAOYSA-L 0.000 claims description 3
- 239000005750 Copper hydroxide Substances 0.000 claims description 3
- 241000530268 Lycaena heteronea Species 0.000 claims description 3
- 229910001956 copper hydroxide Inorganic materials 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- 238000002156 mixing Methods 0.000 claims description 3
- 238000001354 calcination Methods 0.000 claims description 2
- 239000000701 coagulant Substances 0.000 claims 1
- 238000007641 inkjet printing Methods 0.000 claims 1
- 238000010020 roller printing Methods 0.000 claims 1
- 238000007650 screen-printing Methods 0.000 claims 1
- 238000004659 sterilization and disinfection Methods 0.000 abstract description 5
- 230000001954 sterilising effect Effects 0.000 abstract description 4
- 238000003825 pressing Methods 0.000 abstract description 2
- 241000894006 Bacteria Species 0.000 description 16
- 238000012360 testing method Methods 0.000 description 14
- 239000005751 Copper oxide Substances 0.000 description 7
- 229910000431 copper oxide Inorganic materials 0.000 description 7
- 230000001580 bacterial effect Effects 0.000 description 6
- 238000005516 engineering process Methods 0.000 description 5
- JPVYNHNXODAKFH-UHFFFAOYSA-N Cu2+ Chemical compound [Cu+2] JPVYNHNXODAKFH-UHFFFAOYSA-N 0.000 description 4
- 241000700605 Viruses Species 0.000 description 4
- 230000000845 anti-microbial effect Effects 0.000 description 4
- 230000008901 benefit Effects 0.000 description 4
- 229910001431 copper ion Inorganic materials 0.000 description 4
- 230000005484 gravity Effects 0.000 description 4
- 239000000047 product Substances 0.000 description 4
- 230000000694 effects Effects 0.000 description 3
- 239000007789 gas Substances 0.000 description 3
- 239000002086 nanomaterial Substances 0.000 description 3
- 230000003647 oxidation Effects 0.000 description 3
- 238000007254 oxidation reaction Methods 0.000 description 3
- UOURRHZRLGCVDA-UHFFFAOYSA-D pentazinc;dicarbonate;hexahydroxide Chemical compound [OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[Zn+2].[Zn+2].[Zn+2].[Zn+2].[Zn+2].[O-]C([O-])=O.[O-]C([O-])=O UOURRHZRLGCVDA-UHFFFAOYSA-D 0.000 description 3
- PTFCDOFLOPIGGS-UHFFFAOYSA-N Zinc dication Chemical compound [Zn+2] PTFCDOFLOPIGGS-UHFFFAOYSA-N 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 238000010924 continuous production Methods 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-M hydroxide Chemical compound [OH-] XLYOFNOQVPJJNP-UHFFFAOYSA-M 0.000 description 2
- 238000011534 incubation Methods 0.000 description 2
- 239000002105 nanoparticle Substances 0.000 description 2
- 239000011941 photocatalyst Substances 0.000 description 2
- 239000004540 pour-on Substances 0.000 description 2
- 102000004169 proteins and genes Human genes 0.000 description 2
- 108090000623 proteins and genes Proteins 0.000 description 2
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- 241000201788 Staphylococcus aureus subsp. aureus Species 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 230000003385 bacteriostatic effect Effects 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000017531 blood circulation Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- BERDEBHAJNAUOM-UHFFFAOYSA-N copper(I) oxide Inorganic materials [Cu]O[Cu] BERDEBHAJNAUOM-UHFFFAOYSA-N 0.000 description 1
- KRFJLUBVMFXRPN-UHFFFAOYSA-N cuprous oxide Chemical compound [O-2].[Cu+].[Cu+] KRFJLUBVMFXRPN-UHFFFAOYSA-N 0.000 description 1
- 229940112669 cuprous oxide Drugs 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 238000001784 detoxification Methods 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 239000010433 feldspar Substances 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 229910001385 heavy metal Inorganic materials 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000011081 inoculation Methods 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000003595 mist Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- -1 oxygen ions Chemical class 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 238000003908 quality control method Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000012827 research and development Methods 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 238000003892 spreading Methods 0.000 description 1
- 230000007480 spreading Effects 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
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- C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
- C04B2235/606—Drying
Abstract
本發明涵蓋一種抗菌磁磚及其製造方法,該磁磚的製造包括形成磁磚本體、形成抗菌釉及燒成步驟。其中形成磁磚本體步驟包括:將土料研磨成泥漿,藉由熱空氣將泥漿乾燥成粉料,並透過成型機將粉料壓成坯體;將釉漿打點在坯體的表面以形成化妝土;將釉漿打點在化妝土形成底釉。其次抗菌釉形成:將表面釉與抗菌材以100:5~10之重量比混合成抗菌釉藥,再將水及抗菌釉藥以5~6: 4~5之重量比研磨成抗菌釉,將抗菌釉以打點在底釉層。燒成步驟:將磁磚結合抗菌釉於燒成溫度下快速燒製成抗菌磁磚。藉此,本發明抗菌磁磚製造方法所製得的抗菌磁磚在1000~1600°C燒成的情形下,24小時殺菌率仍可達99.9%以上。
Description
本發明係關於一種抗菌磁磚及其製造方法,特別是關於一種具有抗菌及類遠紅外線特性的抗菌磁磚及其製造方法。
人們想要有良好的生活起居條件,首先需要防範並有效抑制周圍環境細菌滋生,隨著奈米材料的發展,具有抗菌能力之奈米光觸媒微粒被廣泛地應用於日常用品中。透過光照射光觸媒而產生氫氧自由基,利用氫氧自由基的超氧化能力,可以使細菌、病毒的蛋白質變性,而達到殺菌的效果。
由於磁磚長時間受到人的踩踏、觸摸以及各種灰塵的污染,使得住家內外的磁磚充滿細菌或病毒。因此,利用光觸媒來進行抗菌及抑菌的作法開始運用在磁磚,讓磁磚具備抗菌能力。藉由將奈米材料結合在磁磚上,能對環境消毒與清潔帶來莫大幫助。在現今聞病毒色變的時代,對於環境衛生要求較高的場所,更需要安全且衛生的空間。
目前國內所使用的奈米材料需要多次過濾、洗滌、蒸發、分解等步驟以去除製造過程中所產生的雜質。其次,由於製造步驟繁雜導致設備繁多、佔地面積大且成本高,整個製造週期長、質量控制穩定性差。此外,產出的廢棄物多污染環境,進而使處理費用變高且耗能增加。
有鑑於此,本發明人投入眾多研發能量與精神,以革命性思維顛覆傳統製程框架,不斷於本領域突破及創新,盼能以新穎的技術手段解決習用之不足,除帶給社會更為安全良善的產品,亦促進產業發展。
本發明之主要目的係在提供一種抗菌磁磚及其製造方法。該抗菌磁磚所使用的抗菌材在陶瓷釉料中1000~1600°C燒成後,仍具有良好的抗菌能力及類遠紅外線特性;且該抗菌材製程簡易、成本低、無污染且可工業化自動連續生產,進而達到產品質量穩定。
為達成上述目的,本發明涵蓋一種抗菌磁磚包括:一坯體、一覆蓋於該坯體表面上之化妝土層、一覆蓋於該化妝土層上之底釉層;以及一覆蓋於該底釉層上之抗菌釉層。其中,將一表面釉與一抗菌材以100:5~10之重量比混合成一抗菌釉藥,再將水及該抗菌釉藥以5~6: 4~5之重量比研磨成一抗菌釉,比重調至1.30~1.50,將該抗菌釉以打點或噴或淋在該底釉層上以形成該抗菌釉層。
於本發明之抗菌磁磚中,該抗菌材係由一包覆奈米氧化鋅粉末、或一包覆奈米氧化銅粉末或者是該包覆奈米氧化鋅粉末與該包覆奈米氧化銅粉末的混合物。
於本發明之抗菌磁磚中,該抗菌材之該包覆奈米氧化鋅粉係為一矽溶膠包覆一奈米氧化鋅粉末而形成;以及該包覆奈米氧化銅粉末係為一砂包覆一奈米氧化銅粉末而形成。
於本發明之抗菌磁磚中,該抗菌材之該包覆奈米氧化鋅粉末的平均粒徑係為8~12奈米,比表面積為70~130平方公尺/克;以及該包覆奈米氧化銅粉末的平均粒徑係為30~35奈米,比表面積為150~180平方公尺/克;以及該矽溶膠細度為4nm~5nm。
於本發明之抗菌磁磚中,該抗菌磁磚對大腸桿菌的抗菌率大於99.9%。
於本發明之抗菌磁磚中,該抗菌磁磚對金黃色葡萄球菌的抗菌率大於99.9%。
為達成上述目的,本發明提供一種抗菌磁磚製造方法,包括形成一磁磚本體步驟、形成一抗菌釉步驟及燒成步驟。其中,該磁磚本體步驟包括:將一土料研磨成一泥漿,藉由熱空氣將該泥漿乾燥成一粉料,並透過一成型機將該粉料壓成該坯體;將一釉漿打點或噴或淋在該坯體的表面上,以形成一化妝土;及將該釉漿打點或噴或淋在該化妝土上,以形成一底釉。其次,將一表面釉與一抗菌材以100:5~10之重量比混合成一抗菌釉藥,再將水及該抗菌釉藥以5~6: 4~5之重量比研磨成該抗菌釉,將該抗菌釉以打點或噴或淋在底釉層上。再者,將該磁磚及該抗菌釉在一燒成溫度下快速燒成一抗菌磁磚。
於本發明之抗菌磁磚製造方法中,該抗菌材係為一包覆奈米氧化鋅粉末、或一包覆奈米氧化銅粉末或者是以100:3~8之重量比混合的該包覆奈米氧化鋅粉末與該包覆奈米氧化銅粉末之混合物。
於本發明之抗菌磁磚製造方法中,該抗菌材之該包覆奈米氧化鋅粉末的製造步驟包括:將6~10g的氧化鋅粉末加入至85℃的100ml水中,並放入磁石攪拌器充分攪拌混合,以形成一氧化鋅懸浮溶液;加熱該氧化鋅懸浮溶液至90~95°C,加熱過程中同時通入二氧化碳氣體於該氧化鋅懸浮溶液中,當到達90~95°C時,保溫3~5小時使其充分反應;然後停止二氧化碳輸入並加入8g的矽溶膠於該氧化鋅懸浮溶液中,保溫0.5小時;加入3g速凝劑進行沉澱,沉澱1~2小時後過濾該氧化鋅懸浮溶液;在200~250°C將該氧化鋅懸浮溶液進行烘乾,並使用一破碎機將烘乾後的該氧化鋅懸浮溶液進行破碎;以及於250~400°C進行鍛燒,以獲得該包覆奈米氧化鋅粉末。
本發明之抗菌磁磚製造方法中,該抗菌材之該包覆奈米氧化銅粉末的製造步驟包括:將體積莫耳濃度比為1:2的硫酸銅溶液與氫氧化鈉溶液混合;按照1:1的流量將硫酸銅溶液與氫氧化鈉溶液輸入一反應器中,並均勻攪拌混合,以生成淡藍色的氫氧化銅沉澱及一反應溶液;緩慢加熱該反應物溶液至50°C使其充分反應至溶液由淡藍色變成紅褐色,最後變成黑色,將該反應物溶液進行過濾形成一濾餅;藉由清水洗滌該濾餅,並將濾餅進行烘乾粉碎,以獲得一包覆奈米氧化銅粉末。
於本發明之抗菌磁磚製造方法中,該燒成溫度係為1000~1600°C。
以下係藉由具體實施例說明本發明之實施方式,熟習此技藝之人士可由本說明書所揭示之內容輕易地了解本發明之其他優點與功效。此外,本發明亦可藉由其他不同具體實施例加以施行或應用,在不悖離本發明之精神下進行各種修飾與變更。
請參照圖1,圖1係為本發明抗菌磁磚製造方法之流程圖。
如圖1所示,本發明涵蓋一種抗菌磁磚製造方法,包括:形成一磁磚本體步驟、形成一抗菌釉步驟及燒成步驟;其中,在提供磁磚本體步驟中包括:形成一坯體、形成一化妝土及形成一底釉。將一土料研磨成一泥漿,藉由熱空氣將該泥漿乾燥成一粉料,並透過一成型機將該粉料壓成該坯體;將一釉漿打點或噴或淋在該坯體的表面上,以形成該化妝土;及將該釉漿打點或噴或淋在該化妝土上,以形成該底釉。具體而言,將20~30wt%的陶土、60~70wt%的長石及5~10wt%的砂研磨成該泥漿,在中高鋁球石中研磨10~11小時,在法國球石中研磨18~19小時;其中,檢測標準比重為1.72±0.02、殘渣1.0g±0.3g及黏度300cps±100cps,檢測不合格時需調整至合格才可洩漿。其次,將該泥漿由泵浦輸送至噴霧塔内,經由高壓產生霧狀,塔內溫度範圍在570~650℃,該泥漿由液態含水率32~35%經高溫瞬乾燥至5.5~6.5%產生粒狀顆粒並輸送儲存於粉料桶;將粉料經高壓300~400kgf/cm²成型,生坯抗折控制在12~20kgf/cm²,輸送至直立式乾燥烘房等待施釉。以20×20公分規格的磁磚為例,第一道先上比重1.50~1.60、釉重18g~21g之間的化粧土,第二道於化粧土上施予比重1.55~1.65、釉重18g~21g之間的面釉。
在形成一抗菌釉步驟中,將一表面釉與一抗菌材以100: 5~10之重量比混合成一抗菌釉藥,再將水及該抗菌釉藥以5~6: 4~5之重量比研磨成該抗菌釉,比重調至1.30~1.50,將該抗菌釉以打點或噴或淋在底釉層上,在一實施例中,在20×20公分規格施釉重8~12g噴於半成品面釉上,以達到抗菌效果後儲存於台車上待窯爐燒成;其中,該抗菌材係為一包覆奈米氧化鋅粉末、或一包覆奈米氧化銅粉末或該包覆奈米氧化鋅粉末與該包覆奈米氧化銅粉末之混合物。該包覆奈米氧化鋅粉末的製造步驟包括:將8g的氧化鋅粉末加入至85°C的100ml水中,並放入磁石攪拌器充分攪拌混合,以形成一氧化鋅懸浮溶液;加熱該氧化鋅懸浮溶液至90~95°C,同時通入飽和純二氧化碳氣體於該氧化鋅懸浮溶液中,當到達設定溫度後,保溫5小時使其充分反應;加入8g的矽溶膠於該氧化鋅懸浮溶液中,保溫0.5小時;加入少量8g速凝劑沉澱,沉澱2小時後過濾該氧化鋅懸浮溶液;在200~250°C將該氧化鋅懸浮溶液進行烘乾,並使用一破碎機將烘乾後的該氧化鋅懸浮溶液進行破碎;以及於250~400°C進行鍛燒,以獲得該抗菌材。其次,該包覆奈米氧化銅粉末的製造步驟包括:將20g的硫酸銅及20g的氫氧化鈉分別溶於60ml的水中;將體積莫耳濃度比為1:2的硫酸銅溶液與氫氧化鈉溶液混合;按照1:1的流量將硫酸銅溶液與氫氧化鈉溶液輸入一反應器中,並均勻攪拌混合,以生成一反應物溶液及淡藍色的氫氧化銅沉澱;緩慢加熱該反應物溶液至50°C,該反應物溶液由淡藍色變成紅褐色,最後變成黑色,並將該反應物溶液過濾形成一濾餅;藉由清水洗滌該濾餅,並將該濾餅進行烘乾粉碎,以獲得一包覆奈米氧化銅粉末。在一實施例中,以100:3~8之重量比的該包覆奈米氧化鋅粉末與該包覆奈米氧化銅粉末之混合物作為抗菌材。其中,將該抗菌材加入反應爐中均勻攪拌,使包覆奈米氧化鋅產生負電荷及包覆奈米氧化銅產生正電荷,兩者均勻攪拌後製成包覆奈米氧化鋅銅離子材;再者,將該磁磚及該抗菌釉結合,在1000~1600°C的燒成溫度下燒成一抗菌磁磚。
在一較佳實施例中,該燒成溫度為1180~1195°C、窯速32~45分之間,燒成曲線由室溫至1180~1195℃後急速冷卻完成,讓成品在最後溫度下坯土、釉、噴墨、抗菌釉順利燒結。
請參照圖2,圖2係為本發明抗菌磁磚之剖面示意圖。
如圖2所示,本發明提供一種藉由上述方法所製作而成的抗菌磁磚1,包括:一坯體11、一化妝土層12、一底釉層13及一抗菌釉層14。該化妝土層12覆蓋於該坯體11的一表面上;該底釉層13覆蓋於該化妝土層12上;以及該抗菌釉層14覆蓋於該底釉層13上。其中,將一表面釉與一抗菌材以100:5~10之重量比混合成一抗菌釉藥,再將水及該抗菌釉藥以5~6: 4~5之重量比研磨成一抗菌釉,比重調至1.30~1.50,將該抗菌釉以打點或噴或淋在該底釉層上以形成該抗菌釉層14。在一實施例中,在20×20公分規格施釉重8~12g噴於半成品面釉上,以達到抗菌效果後儲存於台車上待窯爐燒成。該抗菌材係由一包覆奈米氧化鋅粉末、一包覆奈米氧化銅粉末或該包覆奈米氧化鋅粉末及該包覆奈米氧化銅粉末混合所構成,且該包覆奈米氧化鋅粉末係藉由一矽溶膠包覆一奈米氧化鋅粉末而形成;以及該包覆奈米氧化銅粉末係藉由砂包覆一奈米氧化銅粉末而形成。其中,該包覆奈米氧化銅粉末的包覆技術可達到兩個功效,第一不容易產生氧化作用;第二由於該奈米氧化銅屬於重金屬,經過包覆後較無危險性,相對也較為安全。此外,該奈米氧化銅在包覆後並不影響銅離子的釋放,因為銅離子來自於氧化性,具有本身的磁場力。其次,包覆技術所使用的砂具有兩優點,第一藉由砂的包覆技術來保護奈米氧化銅的屬性,不會因為高溫而變質,若是一般未經包覆的奈米氧化銅在1100°C左右的高溫時會變成氧化亞銅;第二個優點就是可阻止繼續氧化,也能使原料穩定性較高。
由於氧化鋅在水中溶解度低,鋅離子緩慢與飽和二氧化碳溶液發生反應,生成溶解度更低的鹼式碳酸鋅沉澱,整個是一個動態的過程,鋅離子不斷電離,鹼式碳酸鋅不斷沉澱;藉由氧化鋅的用量、二氧化碳氣單位量、水的比例以及溫度控制,可以調整鹼式碳酸鋅的粒度;加入矽溶膠包覆,並通過烘乾和鍛燒以分解多餘水分和碳酸根,得到活性包覆奈米氧化鋅粉末。奈米氧化鋅在製作過程中會堆積形成緊密的六方體,每一六方體都具備一負電荷,藉由各六方體彼此間的互相碰撞、高速運轉產生熱能,進而製造出氫氧根及超級氧離子,就可以直接殺菌;並且包覆奈米氧化鋅具備88~92奈米波長類遠紅外線功能,協助人體血液循環。其次,包覆奈米氧化銅帶有的正電荷銅離子具有更強的殺菌力,可直接依附在細菌細胞,病毒的蛋白質薄膜上,直接破壞其結構以達到殺菌滅毒之功效。由於引進包覆技術,使得奈米氧化鋅在釉料中在1000~1600°C燒成的情形下,24小時殺菌率仍可達99.9%以上,且具備類遠紅外線功能,法向發射率達0.92。
本發明的抗菌磁磚經由JIS Z 2801:210 Antimicrobial products-Test for antimicrobial activity and efficacy 之檢測方法檢測,在作用時間24小時下,測試結果如下表1。
表1 抗菌磁磚檢測結果表
菌株名稱 | 無抗菌材試料生菌數之平均值 (CFU/cm 2) | 無抗菌材試料生菌數之平均Log值 | 具抗菌材試料生菌數之平均值 (CFU/cm 2) | 具抗菌材試料生菌數之平均Log值 | 抗菌值 (R) |
大腸桿菌 ( Escherichia coli) | 4.0×10 5 | 5.60 | <1 | 0.00 | 5.60 |
金黃色葡萄球菌 ( Staphylococcus aureus) | 6.4×10 4 | 4.81 | <1 | 0.00 | 4.81 |
在表1中,抗菌值(R)=[無抗菌材試料生菌數之平均Log值-具抗菌材試料生菌數之平均Log值],若抗菌值(R) ≥2.0,則表示有抗菌效果。
本發明的抗菌磁磚經由ISO 22196:2011 Plastic-Measurement of antibacterial activity on plastics surfaces之檢驗方法,測試結果如下表2及表3。
表2抗菌磁磚檢測結果表
測試菌種 | 大腸桿菌 | ( Esch erich ia coli) | ATCC 8739 |
試驗組別 | 菌量數(CFU/cm 2) | Log | 抗菌值 (R) |
對照組0小時 菌數(U0) | 1.9×10 4 | 4.27 | 4.93 |
對照組24小時 菌數(Ut) | 6.9×10 5 | 5.83 | |
樣品組24小時 菌數(At) | 8.10 | 0.90 |
表3抗菌磁磚檢測結果表
測試菌種 | 金黃色葡萄球菌 | ( Staph ylococcus aureussubsp. aureus) | ATCC 6538P |
試驗組別 | 菌量數(CFU/cm 2) | Log | 抗菌值 (R) |
對照組0小時 菌數(U0) | 1.0×10 4 | 4.00 | 3.05 |
對照組24小時 菌數(Ut) | 2.1×10 3 | 3.32 | |
樣品組24小時 菌數(At) | 1.90 | 0.27 |
在表2及表3中,U0:無抗菌材樣品接種後立即測試之菌數,其應介於6.2×10
3~2.5×10
4(CFU/cm
2);Ut:無抗菌材樣品經24小時培養後之菌數;At:具抗菌材樣品經24小時培養後之菌數。抗菌值(R)= Ut- At,上述試驗數據之試驗委託SGS-食品實驗室-高雄執行及SGS-UTIS-台北執行。藉由下列公式將抗菌值轉換成百分比數值:[(Ut- At)/ Ut] ×100%,則大腸桿菌抗菌率為:[(6.9×10
5- 8.10)/ 6.9×10
5] ×100%=99.99;則金黃色葡萄球菌抗菌率為:[(2.1×10
3- 1.90)/ 2.1×10
3] ×100%=99.91。
如上所述,本發明的抗菌磁磚引進包覆技術,使得奈米氧化鋅及奈米氧化銅在釉料中在1000~1600°C燒成的情形下,24小時殺菌率仍可達99.9%以上,且具備類遠紅外線功能,法向發射率達0.92。其次,本發明抗菌磁磚的製造方法製成簡易、成本低、無污染,且可工業化自動連續生產,並具有產品質量穩定的優點。
惟以上所述僅為本發明之較佳實施例,非意欲侷限本發明的專利保護範圍,故舉凡運用本發明說明書及圖式內容所為的等效變化,均同理皆包含於本發明的權利保護範圍內,合予陳明。
1:抗菌磁磚
11:坯體
12:化妝土層
13:底釉層
14:抗菌釉層
圖1係為本發明抗菌磁磚製造方法之流程圖;以及
圖2係為本發明抗菌磁磚之剖面示意圖。
1:抗菌磁磚
11:坯體
12:化妝土層
13:底釉層
14:抗菌釉層
Claims (6)
- 一種抗菌磁磚製造方法,包括:形成一磁磚本體步驟,包括:形成一坯體,將一土料研磨成一泥漿,藉由熱空氣將該泥漿乾燥成一粉料,並透過一成型機將該粉料壓成該坯體;形成一化妝土,將一釉漿打點或噴或淋在該坯體的表面上,以形成該化妝土;及形成一底釉,將該釉漿打點或淋或噴墨印刷或網版印刷或滾筒印刷在該化妝土上,以形成該底釉;形成一抗菌釉步驟,將一表面釉與一抗菌材以100:5~10之重量比混合成一抗菌釉藥,再將水及該抗菌釉藥以5~6:4~5之重量比研磨成該抗菌釉,將該抗菌釉以打點或噴或淋在底釉層上;以及燒成步驟,將該磁磚及該抗菌釉在1000~1600℃的一燒成溫度下快速燒成一抗菌磁磚;其中,該抗菌材係為一包覆奈米氧化鋅粉末、或一包覆奈米氧化銅粉末或以100:3~8之重量比混合的該包覆奈米氧化鋅粉末與該包覆奈米氧化銅粉末之混合物;其中,該抗菌材之該包覆奈米氧化鋅粉末的製造步驟包括:將6~10g的氧化鋅粉末加入至85℃的100ml水中,並放入磁石攪拌器充分攪拌混合,以形成一氧化鋅懸浮溶液;加熱該氧化鋅懸浮溶液至90~95℃;加入8g的矽溶膠於該氧化鋅懸浮溶液中,保溫0.5小時;加入3g速凝劑沉澱1~2小時,沉澱後過濾該氧化鋅懸浮溶液;在200~250℃將該氧化鋅懸浮溶液進行烘乾,並使用一破碎機將烘乾後的該氧化鋅懸浮溶液進行破碎;以及於250~400℃進行鍛燒,以獲得一矽溶膠包覆一奈米氧化鋅粉末; 其中,該包覆奈米氧化銅粉末的製造步驟包括:將體積莫耳濃度比為1:2的硫酸銅溶液與氫氧化鈉溶液混合,以生成淡藍色的氫氧化銅沉澱及一反應物溶液;將該反應物溶液進行過濾形成一濾餅;藉由清水洗滌該濾餅,並將該濾餅進行烘乾粉碎,以獲得一砂包覆一奈米氧化銅粉末。
- 如申請專利範圍第1項所述之抗菌磁磚製造方法,其中,在加熱該氧化鋅懸浮溶液過程中同時通入二氧化碳氣體於該氧化鋅懸浮溶液中,當到達90~95℃時,保溫該氧化鋅懸浮溶液3~5小時使其充分反應;在充分反應後,停止二氧化碳氣體通入。
- 如申請專利範圍第1項所述之抗菌磁磚製造方法,其中,按照1:1的流量將硫酸銅溶液與氫氧化鈉溶液輸入一反應器中,並均勻攪拌混合;緩慢加熱該反應物溶液至50℃使其充分反應至溶液由淡藍色變成紅褐色,最後變成黑色。
- 一種使用如申請專利範圍第1至3項所述之方法而製成之抗菌磁磚,包括:一坯體;一化妝土層,覆蓋於該坯體的一表面上;一底釉層,覆蓋於該化妝土層上;以及一抗菌釉層,覆蓋於該底釉層上;其中,將一表面釉與一抗菌材以100:5~10之重量比混合成一抗菌釉藥,再將水及該抗菌釉藥以5~6:4~5之重量比研磨成一抗菌釉,將該抗菌釉以打點或噴或淋在該底釉層上以形成該抗菌釉層;其中,該抗菌材係為一包覆奈米氧化鋅粉末、或一包覆奈米氧化銅粉末或者是該包覆奈米氧化鋅粉末及該包覆奈米氧化銅粉末的混合物;該抗菌材之該包覆奈米氧化鋅粉末係為一矽溶膠包覆一奈米氧化鋅粉末而形成;以及該包覆奈 米氧化銅粉末係為一砂包覆一奈米氧化銅粉末而形;該抗菌材之該包覆奈米氧化鋅粉末的平均粒徑係為8~12奈米,比表面積為70~130平方公尺/克;以及該包覆奈米氧化銅粉末的平均粒徑係為30~35奈米,比表面積為150~180平方公尺/克。
- 如申請專利範圍第4項所述之抗菌磁磚,其中,該抗菌磁磚對大腸桿菌的抗菌率大於99.9%。
- 如申請專利範圍第4項所述之抗菌磁磚,其中,該抗菌磁磚對金黃色葡萄球菌的抗菌率大於99.9%。
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