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CN109485379B - 一种具有低烧成收缩率的瓷质砖的制备方法 - Google Patents

一种具有低烧成收缩率的瓷质砖的制备方法 Download PDF

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CN109485379B
CN109485379B CN201811516390.2A CN201811516390A CN109485379B CN 109485379 B CN109485379 B CN 109485379B CN 201811516390 A CN201811516390 A CN 201811516390A CN 109485379 B CN109485379 B CN 109485379B
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柯善军
田维
马超
吴洋
倪成林
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GUANGXI OUSHENNUO CERAMIC Co.,Ltd.
Foshan Oceano Ceramics Co Ltd
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Abstract

本发明公开了一种具有低烧成收缩率的瓷质砖的制备方法，其包括：1)将普通瓷质砖原料组分按配比混合均匀，得湿法粉体；2)将回收的瓷质砖废弃料经分散、分级处理，得陶瓷废砖粉体；3)取湿法粉体和陶瓷废砖粉体按质量比为6:4～9:1混合得混合粉体，得陈腐料；4)陈腐料经压制成型，1150～1250℃高温烧成，得成品。本发明通过由回收的瓷质砖废弃料制得的陶瓷废砖粉体与传统瓷质砖制备中的湿法粉体混用，使得混合粉体具备堆积密度高、颗粒粒度分布范围宽等优点，同时瓷质砖坯体密度高、强度比传统瓷质砖生坯强度提高20％，烧成后收缩均匀，成品平直度为传统瓷质砖的1/3左右，显著降低了瓷质砖的切边量和切边废料的产生量。

Description

一种具有低烧成收缩率的瓷质砖的制备方法
技术领域
本发明涉及陶瓷建材领域，特别涉及一种瓷质砖的制备方法。
背景技术
瓷质砖又称为玻化砖、其吸水率在0.5%以下，其有天然石材的质感，具有高光性、高硬度、高耐磨、高抗污性、色差少、规格多样化和色彩丰等特点，被广泛应用墙面和地面的装饰中。据2017年《中国瓷砖产能报告》统计，我国建筑陶瓷年产量为136亿平方米，其中瓷质砖（抛釉砖、抛光砖及仿古砖）产量为76.4亿平方米，占总产量的56.2%。目前，瓷质砖由传统喷雾造粒（湿法制粉）粉体，经干压、烧制而成。由于湿法造粒粉体为空心粉体、堆积密度低，在压制过程中会造成坯体中的大量气体无法排出，造成坯体在烧结过程中产生约9%的线收缩。过大的烧成收缩，不仅会使瓷质砖开裂缺陷增多，而且易造成瓷质砖的大小头及凹凸边（也称为窄腰、收腰、鼓肚、大肚）缺陷，使装饰图案在边缘出现扭曲及造成烧制成品砖型难于控制。在实际的生产过程中，为保证瓷质砖成品的直角度和边直度在合适的范围内，需对陶瓷砖进行切边处理，而这些被切边陶瓷的面积约占成品瓷质砖面积的4.5%、产生约1000万吨每年瓷质砖切割废料，造成资源的严重浪费。
发明内容
本发明的目的在于针对上述现有技术的不足，提供一种具有低烧成收缩率的瓷质砖的制备方法。
本发明所采取的技术方案是：一种具有低烧成收缩率的瓷质砖的制备方法，其包括如下工艺步骤：
1）将普通瓷质砖原料组分按配比混合均匀，经球磨、喷雾造粒，分级处理，得湿法粉体；
2）将回收的瓷质砖废弃料经分散、分级处理，得陶瓷废砖粉体；
3）取湿法粉体和陶瓷废砖粉体按质量比为6:4~9:1置于连续式混料机中进行混合得混合粉体，经分级处理、陈腐处理，得陈腐料；
4）陈腐料经压制成型制备得瓷质砖坯体，后经干燥、表面装饰、1150~1250℃高温烧成45~65min，得成品。
作为上述方案的进一步改进，步骤1）中所述湿法粉体的含水量为6.0~8.5%。
作为上述方案的进一步改进，步骤1）中所述分级处理的粉体颗粒级配为20目以上颗粒≤1.0%、40.0%≤40~100目颗粒≤60.0%、100目以下颗粒≤4.5%。
作为上述方案的进一步改进，步骤2）中所述分级处理的粉体颗粒级配为20目以上颗粒≤1.0%、40.0%≤40~100目颗粒≤60.0%、100目以下颗粒≤20.0%。
作为上述方案的进一步改进，步骤3）中所述混合粉体的含水量为5.1~7.0%。
作为上述方案的进一步改进，步骤3）中所述分级处理的粉体颗粒级配为20目以上颗粒≤1.0%、40%≤40~100目颗粒≤60.0%、100目以下颗粒≤10.0%。
本发明的有益效果是：
本发明通过由回收的瓷质砖废弃料制得的陶瓷废砖粉体与传统瓷质砖制备中的湿法粉体混用并严格限定各阶段的粉体颗粒级配，不仅对废瓷回收利用推广起积极的推进作用，且使得混合粉体具备堆积密度高、颗粒粒度分布范围宽等优点，同时瓷质砖坯体密度高、强度比传统瓷质砖生坯强度提高20%，烧成后收缩均匀，成品平直度为传统瓷质砖的1/3左右，显著降低了瓷质砖的切边量和切边废料的产生量。
本发明的制备方法工艺简单，易操作，有利于大规模工业化生产。
具体实施方式
下面结合实施例对本发明进行具体描述，以便于所属技术领域的人员对本发明的理解。有必要在此特别指出的是，实施例只是用于对本发明做进一步说明，不能理解为对本发明保护范围的限制，所属领域技术熟练人员，根据上述发明内容对本发明作出的非本质性的改进和调整，应仍属于本发明的保护范围。
同时下述所提及的原料未详细说明的，均为市售产品，如普通瓷质砖原料的各组分；未详细提及的工艺步骤或制备方法为均为本领域技术人员所知晓的工艺步骤或制备方法，如普通瓷质砖原料的配比。
实施例1
一种具有低烧成收缩率的瓷质砖的制备方法，其包括如下工艺步骤：
1）将普通瓷质砖原料组分按配比混合均匀，经球磨、喷雾造粒，分级处理得粉体颗粒级配为20目以上颗粒为0.5%、40~100目颗粒为60.0%、100目以下颗粒为4.1%，得含水量为8.5%的湿法粉体；
2）将回收的瓷质砖废弃料经分散、分级处理得粉体颗粒级配为20目以上颗粒为1.0%、40～100目颗粒为40.0%、100目以下颗粒为20.0%的粉体，得陶瓷废砖粉体；
3）取湿法粉体和陶瓷废砖粉体按质量比为6:4置于连续式混料机中进行混合得含水量为5.1%的混合粉体，经分级处理得粉体颗粒级配为20目以上颗粒为1%、40~100目颗粒为45%、100目以下颗粒为10.0%的粉体，后进行陈腐处理，得陈腐料；
4）陈腐料经压制成型制备得瓷质砖坯体，后经干燥，再进行淋面釉、喷墨打印、淋抛釉等表面装饰，于1180℃高温烧成55min，得实施例1成品。
实施例2
一种具有低烧成收缩率的瓷质砖的制备方法，其包括如下工艺步骤：
1）将普通瓷质砖原料组分按配比混合均匀，经球磨、喷雾造粒，分级处理得粉体颗粒级配为20目以上颗粒为0.5%、40~100目颗粒为49.8%、100目以下颗粒为3.5%的粉体，得含水量为7.5%的湿法粉体；
2）将回收的瓷质砖废弃料经分散、分级处理得粉体颗粒级配为20目以上颗粒为0.8%、40~100目颗粒为60.0%、100目以下颗粒为9.8%的粉体，得陶瓷废砖粉体；
3）取湿法粉体和陶瓷废砖粉体按质量比为7:3置于连续式混料机中进行混合得含水量为5.3%的混合粉体，经分级处理得粉体颗粒级配为20目以上颗粒为0.9%、40~100目颗粒为59.8%、100目以下颗粒为8.1%的粉体，后进行陈腐处理，得陈腐料；
4）陈腐料经压制成型制备得瓷质砖坯体，后经干燥，再进行淋面釉、喷墨打印、淋抛釉等表面装饰，于1180℃高温烧成55min，得实施例2成品。
实施例3
一种具有低烧成收缩率的瓷质砖的制备方法，其包括如下工艺步骤：
1）将普通瓷质砖原料组分按配比混合均匀，经球磨、喷雾造粒，分级处理得粉体颗粒级配为20目以上颗粒为0.5%、40~100目颗粒为49.8%、100目以下颗粒为3.5%的粉体，得含水量为6.0%的湿法粉体；
2）将回收的瓷质砖废弃料经分散、分级处理得粉体颗粒级配为20目以上颗粒为0.8%、40~100目颗粒为60.0%、100目以下颗粒为9.8%的粉体，得陶瓷废砖粉体；
3）取湿法粉体和陶瓷废砖粉体按质量比为9:1置于连续式混料机中进行混合得含水量为5.4%的混合粉体，经分级处理得粉体颗粒级配为20目以上颗粒为1%、40~100目颗粒为45%、100目以下颗粒为10%的粉体，后进行陈腐处理，得陈腐料；
4）陈腐料经压制成型制备得瓷质砖坯体，后经干燥，再进行淋面釉、喷墨打印、淋抛釉等表面装饰，于1180℃高温烧成55min，得实施例3成品。
对比例
一种瓷质砖的制备方法，其包括如下工艺步骤：
1）将普通瓷质砖原料组分按配比混合均匀，经球磨、喷雾造粒，得含水量为6.0%的湿法粉体，陈腐处理，得陈腐料；
2）陈腐料经压制成型制备得瓷质砖坯体，后经干燥，再进行淋面釉、喷墨打印、淋抛釉等表面装饰，于1180℃高温烧成55min，得对比例成品。
实施例4：性能检测
分别对上述实施例1~3成品及对比例成品进行吸水率、烧成线收缩及边直度测试，其各项性能检测结果如下表1所示。从表1中可以看出，本发明所制备得到的瓷质砖不仅烧成线收缩率低，而且烧成后收缩均匀、边直度较对比例传统的瓷质砖有明显改善，可显著降低瓷质砖的切边量，大幅度减少切边废料的产生量。
Figure 147671DEST_PATH_IMAGE001
上述实施例为本发明的优选实施例，凡与本发明类似的工艺及所作的等效变化，均应属于本发明的保护范畴。

Claims (3)

1.一种具有低烧成收缩率的瓷质砖的制备方法，其特征在于包括如下工艺步骤：
1)将普通瓷质砖原料组分按配比混合均匀，经球磨、喷雾造粒，分级处理，得湿法粉体；
2)将回收的瓷质砖废弃料经分散、分级处理，得陶瓷废砖粉体；
3)取湿法粉体和陶瓷废砖粉体按质量比为6:4～9:1置于连续式混料机中进行混合得混合粉体，经分级处理、陈腐处理，得陈腐料；
4)陈腐料经压制成型制备得瓷质砖坯体，后经干燥、表面装饰、1150～1250℃高温烧成45～65min，得成品；
步骤1)中所述分级处理的粉体颗粒级配为20目以上颗粒≤1.0％、40.0％≤40～100目颗粒≤60.0％、100目以下颗粒≤4.5％；
步骤2)中所述分级处理的粉体颗粒级配为20目以上颗粒≤1.0％、40.0％≤40～100目颗粒≤60.0％、100目以下颗粒≤20.0％；
步骤3)中所述分级处理的粉体颗粒级配为20目以上颗粒≤1.0％、40％≤40～100目颗粒≤60.0％、100目以下颗粒≤10.0％。
2.根据权利要求1所述的一种具有低烧成收缩率的瓷质砖的制备方法，其特征在于：步骤1)中所述湿法粉体的含水量为6.0～8.5％。
3.根据权利要求1所述的一种具有低烧成收缩率的瓷质砖的制备方法，其特征在于：步骤3)中所述混合粉体的含水量为5.1～7.0％。
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