CN101844910B - Thin-wall light-weighted sanitary ceramic body and manufacturing method thereof - Google Patents
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Abstract
The invention relates to a thin-wall light-weighted sanitary ceramic body and a manufacturing method thereof, which belong to the technical field of ceramic products and are used for solving the problems of large size, heavy weight, mineral resource consumption and the like of sanitary ceramic products. The invention is characterized in that the raw materials of the ceramic body comprises the following substances in parts by mass: 20 to 40 parts of ball clay, 15 to 30 parts of kaolin, 10 to 17 parts of porcelain stone, 5 to 15 parts of kaolinite, 10 to 18 parts of feldspar, 0.5 to 3 parts of talc, wherein particles which are less than 10 micrometer in the ball clay account for above 80 percent. The invention achieves the objectives of reducing body deformation, improving the strength and realizing thin wall and light weight of porcelain sanitary ceramic products by introducing an appropriate amount of ball clay which is characterized by low water absorption rate, low deformation and fine particles, reducing the flux content, controlling the particle size of slurry and other means. The standard deformation degree of the porcelain sanitary ceramic products produced through the method is below 18mm, the flexural strength can reach above 90MPa, and the water absorption rate is within 0.5 percent.
Description
Technical field
The present invention relates to a kind of sanitary ware and method of manufacture, particularly thin-wall light-weighted sanitary ceramic body and method of manufacture, belong to the ceramic technical field.
Background technology
In ceramic, snitaryware is a kind of complex-shaped, size and all bigger goods of weight, consume a large amount of Mineral resources and fuel energy.Wall thickness is thick more, and weight is heavy more, and raw material and energy consumption are also many more, and production cost is also high more, also corresponding transportation and the installation cost of having improved.In order to reduce production costs, alleviate hand labor intensity, improve and produce efficiency of movement, practice thrift limited Mineral resources, fuel energy, development thin-wall light-weighted sanitary ceramic product is the inevitable requirement of snitaryware industry Sustainable development.
For the security that guarantees that goods use; The folding strength general requirement of porcelain snitaryware product is between 70～80MPa; Generally (it is 9～11mm that single face is inhaled slurry position wall thickness to wall thickness, and two-sided suction slurry position wall thickness is 13～15mm), and degree of deformation is generally more than 22mm between 9～15mm.The sanitary ceramic body of identical material, after the wall thickness reduction, intensity can descend rapidly, and degree of deformation can obviously increase.Therefore use thin-wall light-weighted base substrate, must improve the base substrate folding strength to more than the 90Mpa, degree of deformation is less than 20mm.In patent documentation CN 1298373, propose to improve blank strength and to reduce degree of deformation through the raw material that use contains the raw material of corundum, mullite or in the goods sintering process, can produce corundum, mullite.The mineralogical composition of porcelain sanitary ceramic body is generally equated to form by quartz, mullite, glass; Aforesaid method has increased the corundum in the base substrate, mullite content; Will inevitably cause the alumina content in the body recipe obviously to increase; And the proportion of aluminum oxide is higher, has weakened the lightweight effect, and formulation cost also can obviously increase.
Summary of the invention
The present invention is used to overcome the defective of prior art and a kind of thin-wall light-weighted porcelain sanitary ceramic body and method of manufacture thereof is provided, and to reduce production costs, reduces labor intensity, and improves resource and energy utilization rate.
The alleged problem of the present invention solves through following technical scheme:
A kind of thin-wall light-weighted sanitary ceramic body, its special feature are that said blank raw material comprises following materials in parts by mass: ball clay 20-40; Kaolin 15-30, porcelain stone 10-17, kaolinite 5-15; Feldspar 10-18, talcum 0.5-3, wherein the particle less than 10 microns accounts for more than 80% in the ball clay.
Above-mentioned thin-wall light-weighted sanitary ceramic body, said blank raw material adds following materials in parts by mass: china clay 3-8, useless porcelain 5-10.
Above-mentioned thin-wall light-weighted sanitary ceramic body, said blank raw material is made up of following materials in parts by mass: ball clay 30, kaolin 25, porcelain stone 12, kaolinite 10, feldspar 13, talcum 2, china clay 3, useless porcelain 5.
Above-mentioned thin-wall light-weighted sanitary ceramic body, the chemical ingredients of said blank raw material is formed as follows: SiO
265.3-67.4%, Al
2O
323.4-26.1%, Fe
2O
31.2-1.3%, TiO
20.6-0.7%, CaO 0.9-1.1%, MgO 0.8-1.6%, K
2O 2.8-3.3%, Na
2O 1.3-1.6%.
A kind of thin-wall light-weighted sanitary ceramic body method of manufacture; It comprises steps such as raw material takes by weighing, ball milling, mudding up, injection forming, stripping drying; The hard material that will take by weighing by proportioning in said ball milling step grinding to following granularity in advance in superpressure T type mill :≤1 μ m 5% ,≤2 μ m 10% ,≤5 μ m 20% ,≤10 μ m 30% ,≤50 μ m 90%; And then mix with the soft material that takes by weighing by proportioning; Add entry, ionogen; In grinding in ball grinder to following granularity :≤1 μ m 10% ,≤2 μ m 20% ,≤5 μ m 40% ,≤10 μ m 55% ,≤50 μ m 90%, said hard material is porcelain stone, kaolinite, feldspar, talcum, useless porcelain, said soft material is ball clay, kaolin, china clay.
Above-mentioned thin-wall light-weighted sanitary ceramic body method of manufacture, the main technologic parameters of said mudding up step is following: concentration of hydraulic mixture (g/200ml) 356-360, inhale slurry speed (mm/45min) 5-6, mobile V
0(s) 50-60, V
30(s) 110-130.
The present invention is directed to that existing sanitary ware wall thickness dimension is big, weight big, consumption of mineral resources and the high problem of the energy improve; Have low water absorption in right amount through introducing, the ball clay of low distortion, subparticle characteristic, reduce means such as flux content and control mud granularity, reach and reduce blank deformation, improve intensity, realize the thin-wall light-weighted target of porcelain snitaryware product.Adopt the inventive method to produce porcelain sanitary ware standard degree of deformation below 18mm, folding strength can reach more than the 90MPa, and water-intake rate is in 0.5%; Can significantly reduce porcelain sanitary ware wall thickness; Wherein the goods single face is inhaled slurry position thickness between 7～8mm, and two-sided suction slurry position thickness is between 10～12mm, and product weight can reduce more than 10%; Thereby reduce production costs; Reduce labor intensity, practice thrift limited Mineral resources, fuel energy, improve resource and energy utilization rate.In addition, the inventive method is compared with the method for being out of shape raising intensity with reduction through increase corundum, mullite content, has lower cost advantage.
Embodiment
Raw material of the present invention comprises ball clay, kaolin, china clay, porcelain stone, kaolinite, feldspar, talcum, useless porcelain etc., and the chemical ingredients of blank raw material is formed (not containing loss on ignition LOI) as follows: SiO
265.3-67.4%, Al
2O
323.4-26.1%, Fe
2O
31.2-1.3%, TiO
20.6-0.7%, CaO 0.9-1.1%, MgO 0.8-1.6%, K
2O 2.8-3.3%, Na
2O 1.3-1.6%.Improving one of main points is in prescription, to add more ball clay, reduces flux content, contains a large amount of subparticles in the ball clay; Wherein account for more than 80% less than 10 microns particle; Less than 1%, near tight burning, and its degree of deformation is less than 10mm at 1200 ℃ of water-intake rates after burning till.Through a large amount of use ball clays, can significantly reduce the flux total amount in the base substrate, thereby distortion reduces.
Another improves ball milling and the mudding up step that main points are embodied in process method the present invention; Earlier with the hard material in the raw material (porcelain stone, kaolinite, feldspar, talcum, useless porcelain) grinding to following granularity in advance in superpressure T type mill :≤1 μ m 5% ,≤2 μ m 10% ,≤5 μ m 20% ,≤10 μ m 30% ,≤50 μ m 90%; Again with raw material in soft material (ball clay, kaolin, china clay) according to the proportioning weighing; Add entry, ionogen, at grinding in ball grinder to following particle diameter :≤1 μ m 10% ,≤2 μ m20% ,≤5 μ m 40% ,≤10 μ m 55% ,≤50 μ m 90%.The particle that influences mud suction slurry speed mainly is the subparticle less than 2 μ m.If too much, then can reduce the suction slurry speed of mud, thereby prolong the slip casting time of molding procedure less than 2 μ m particles.Therefore for keeping the injection forming time constant basically or only slightly prolong, must control mud in less than the quantity of 2 μ m particles within reasonable range.In order to guarantee fully sintering of mud, must reduce too thick mud particles quantity simultaneously, mainly be the quantity greater than 50 μ m particles.The method of tradition processing mud is that soft material of fine particle and coarse particles hard material are mixed into mill by proportioning; In ball mill together ball milling to stipulating particle diameter; This mud working method can cause the fine particle of soft material to become more carefully more, and the hard material coarse particles of difficult mill is still fully not levigate.The present invention adopts coarse particles hard material to carry out separately dry method grinding processing in advance; Control its particle size distribution; Reduce in these raw materials less than the minuteness particle of 2 μ m and greater than the oversize particle quantity of 50 μ m, and then even or be stirred to mix and get final product by proportioning short period of time (in 4 hours) ball milling with soft material.The suction slurry speed that so both can guarantee the mud in the mud is constant basically, also can guarantee fully sintering of base substrate.
Embodiments of the invention below are provided, and embodiment and comparative example proportioning raw materials are seen table 1.
Table 1
Product physicals with the foregoing description and the preparation of comparative example proportioning is seen table 2.
Table 2
Compare with embodiment 1, the ball clay content of embodiment 2 significantly increases, and distortion reduces, intensity improves, but dry shrinkage is bigger; The ball clay of embodiment 3 obviously reduces, and the base substrate density descends, and causes distortion bigger; Embodiment 4 kaolinite content increase, and sintering degree variation causes intensity to decrease; Embodiment 5 feldspars reduce, and sintering degree variation causes intensity to decrease; And embodiment 6 feldspars are more, though intensity is higher, are out of shape bigger; The useless porcelain content of embodiment 7 increases, because the glaze fusing point on useless porcelain surface is lower, causes blank deformation bigger; The talc content of embodiment 8# is higher, and content of magnesia is too much in causing filling a prescription, and high temperature can liquefy down in rapid fusion, reduces high temperature viscosity, causes blank deformation bigger; Embodiment 9# is then opposite, and content of magnesia is very few, and amount of liquid phase is not enough, though blank deformation is less, intensity is on the low side.Comprehensive above the analysis, embodiment 1 is the present invention's compositions of preferably filling a prescription, its physicals is ideal.
Hard material in the raw material that will take by weighing according to the foregoing description grinding to following granularity in advance in superpressure T type mill :≤1 μ m 5% ,≤2 μ m 10% ,≤5 μ m 20% ,≤10 μ m 30% ,≤50 μ m 90%; And then mix according to the soft material that proportioning takes by weighing; Add entry, ionogen, in grinding in ball grinder, sieve, deironing, old; The adjustment mud property is prepared into injection forming and uses mud to suitable.The injection forming of embodiment and comparative example is seen table 3 with the mud property processing parameter.
Table 3
Adopt slip casting, the mud of adjusting performance is injected the plaster mold or the resin mould of required product, the gypsum mould grouting time is that 1.5～2.5 hours, high-pressure resin model slip casting time are the demoulding after 40～60 minutes.
The sample that is used to detect contraction, distortion, intensity is after the demoulding, and first dry 12h under the environment of room temperature or 50 ℃, and then put into electrically heated drying cabinet is at 105～110 ℃ of dry 12h down; Sanitary product after the demoulding is placed in the dry indoor drying of carrying out, and according to humiture curve controlled drying temperature and humidity, high dry temperature is generally less than 80 ℃, and humidity is less than 90%.
Adopt craft or mechanical manipulator method, glaze slip is sprayed at billet surface, glaze layer total thickness is 0.4～1.0mm.The physicals of used glaze slip is seen table 4.
Table 4
The sample of the glazing that drying is good and product are placed in tunnel or the shuttle kiln and burn till, and calcining system is: firing period is 16～21h, and maximum sintering temperature is 1200～1220 ℃, and soaking time is 30～60min, oxidizing atmosphere.
Claims (5)
1. a thin-wall light-weighted sanitary ceramic body is characterized in that, said blank raw material comprises following materials in parts by mass: ball clay 20-40; Kaolin 15-30, porcelain stone 10-17, kaolinite 5-15; Feldspar 10-18, talcum 0.5-3, wherein the particle less than 10 microns accounts for more than 80% in the ball clay;
Said base substrate is prepared from following method: comprise that raw material takes by weighing, ball milling, mudding up, injection forming, stripping drying step; The hard material that will take by weighing by proportioning in said ball milling step grinding to following granularity in advance in superpressure T type mill :≤1 μ m 5% ,≤2 μ m 10% ,≤5 μ m 20% ,≤10 μ m 30% ,≤50 μ m 90%; And then mix with the soft material that takes by weighing by proportioning; Add entry, ionogen; In grinding in ball grinder to following granularity :≤1 μ m 10% ,≤2 μ m20% ,≤5 μ m 40% ,≤10 μ m 55% ,≤50 μ m 90%; Said hard material is porcelain stone, kaolinite, feldspar, talcum, useless porcelain, and said soft material is ball clay, kaolin, china clay; The main technologic parameters of said mudding up step is following: concentration of hydraulic mixture 356-360g/200ml, inhale slurry speed 5-6mm/45min, mobile V
050-60s, V
30110-130s.
2. thin-wall light-weighted sanitary ceramic body according to claim 1 is characterized in that: said blank raw material adds following materials in parts by mass: china clay 3-8, useless porcelain 5-10.
3. thin-wall light-weighted sanitary ceramic body according to claim 2 is characterized in that: said blank raw material is made up of following materials in parts by mass: ball clay 30, kaolin 25, porcelain stone 12, kaolinite 10, feldspar 13, talcum 2, china clay 3, useless porcelain 5.
4. according to claim 1 or 2 or 3 described thin-wall light-weighted sanitary ceramic bodies, it is characterized in that the chemical ingredients of said blank raw material is formed as follows: SiO
265.3-67.4%, Al
2O
323.4-26.1%, Fe
2O
31.2-1.3%, TiO
20.6-0.7%, CaO 0.9-1.1%, MgO 0.8-1.6%, K
2O 2.8-3.3%, Na
2O 1.3-1.6%.
5. thin-wall light-weighted sanitary ceramic body method of manufacture, it comprises, and raw material takes by weighing, ball milling, mudding up, injection forming, stripping drying step, and it is characterized in that: said blank raw material comprises following materials in parts by mass: ball clay 20-40; Kaolin 15-30; Porcelain stone 10-17, kaolinite 5-15, feldspar 10-18; Talcum 0.5-3, wherein the particle less than 10 microns accounts for more than 80% in the ball clay; The hard material that will take by weighing by proportioning in said ball milling step grinding to following granularity in advance in superpressure T type mill :≤1 μ m 5% ,≤2 μ m 10% ,≤5 μ m 20% ,≤10 μ m 30% ,≤50 μ m 90%; And then mix with the soft material that takes by weighing by proportioning and to add entry, ionogen; In grinding in ball grinder to following granularity :≤1 μ m10% ,≤2 μ m20% ,≤5 μ m 40% ,≤10 μ m55% ,≤50 μ m 90%; Said hard material is porcelain stone, kaolinite, feldspar, talcum, useless porcelain, and said soft material is ball clay, kaolin, china clay; The main technologic parameters of said mudding up step is following: concentration of hydraulic mixture 356-360g/200ml, inhale slurry speed 5-6mm/45min, mobile V
050-60s, V
30110-130s.
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