CN106316350B - 一种保健抑菌耐磨瓷砖 - Google Patents

一种保健抑菌耐磨瓷砖 Download PDF

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CN106316350B
CN106316350B CN201610690832.XA CN201610690832A CN106316350B CN 106316350 B CN106316350 B CN 106316350B CN 201610690832 A CN201610690832 A CN 201610690832A CN 106316350 B CN106316350 B CN 106316350B
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parts
ceramic tile
health care
starch adhesive
resisting ceramic
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CN106316350A (zh
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韩学
张孝德
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Jiangmen Jinruibao Ceramics Co., Ltd.
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ZIBO JINMO INTELLECTUAL PROPERTY CONSULTANT CO Ltd
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Abstract

一种保健抑菌耐磨瓷砖，属于功能性瓷砖及其制备工艺领域。本发明在生坯和面浆层之间固定抗菌层，具有耐磨、高密度、高硬度、不会藏污纳垢、无异味残留、容易清洁等优点。在抗菌层上设置通孔和流道，用于灌入面浆，烧结后面浆与生坯结合呈一体，将抗菌层牢固固定在二者之间。由于面浆烧制后，面浆中的成分呈玻璃相变化，采用纳米氧化铝溶胶，颗粒间的结合强度高，颗粒形貌得到保持，制备的产品上表面玻璃相结构致密，即便抛光尺寸较深也不会大量产生开放式气口，保证了抛光砖的耐污能力；而功能性物质的存在，又使得釉面保留适当大小的功能性物质施放通道，便于砖坯和面釉层内的有效物质得到充分的施放，具备抗菌保健的功效。

Description

一种保健抑菌耐磨瓷砖
技术领域
本发明属于功能性瓷砖及其制备工艺领域，具体涉及一种保健抑菌耐磨瓷砖。
背景技术
传统带有保健功能的瓷砖，诸如能够施放负离子等功效的瓷砖，实际在使用过程中，并没有达到宣传中的效果。这是因为上述瓷砖中所述的功能性添加物一般都是加入到砖坯中，而瓷砖的表面必须做封釉处理，所以上述功能性物质很难通过釉质层施放出来，也就无从发挥功效。
申请人经过长期实验，发明了一种保健抑菌耐磨瓷砖的制备方法，能够通过改善瓷砖的结构和生产工艺，令瓷砖中添加的功能性成分能够充分发挥作用，达到保健抗菌的目的。
发明内容
本发明所要解决的技术问题是提供一种保健抑菌耐磨瓷砖，能够通过改善瓷砖的结构和生产工艺，令瓷砖中添加的功能性成分能够充分发挥作用，达到保健抗菌的目的。
为解决上述技术问题，本发明的技术方案是：发明所述的一种保健抑菌耐磨瓷砖，其特征在于制备方法包括如下步骤：
（1）准备胚体粉料；
（2）在压砖机模腔中施布胚体粉料，通过50-80MPa的压力，压制形成生坯；
（3）制备抗菌层：将抗菌层纳米粉末在2000-2500摄氏度，300-450吨的压力下压合成带有通孔的陶瓷抗菌板材；所述陶瓷抗菌板材的上表面设置流道，流道将各通孔连接在一起；
（4）将抗菌层放置到生坯上；
（5）制备面浆；
（6）将制备好的面浆填充入流道和通孔中，制成半成品；
（7）将半成品放置到微波干燥器中进行微波干燥，干燥时间10-20min；
（8）将干燥好的半成品分两段进行烧制，第一段的烧制温度为1000-1050摄氏度，烧成时长为15-35分钟；第二段的烧制温度为1650-2000摄氏度，烧成时长为40-90分钟；而后保温30-120分钟后；
（9）用金刚石模具对烧制好的半成品磨边、磨面整形后包装，即得成品。
优选的，在步骤（1）中，胚体粉料的构成原料以重量份数计算，包括以下成分：
粘土 80-100份；
石英 20-50份；
方解石 35-45份；
长石 15-25份；
高岭土 6-10份；
麦饭石 5-8份；
云母石粉 2-5份；
电气石 2-5份；
硼酸 1-3份；
氧化钴 1-3份；
氧化钡 1-3份；
氧化锌 1-3份；
纯碱 0.5-1.5份；
烧结助剂 1-4份；
成型助剂 1-3份。
优选的，在步骤（3）中，抗菌层纳米粉末以重量份数计算，包括以下成分：
纳米氧化锆粉末 50-80份；
纳米氧化铝粉末 5-15份；
纳米氧化钡粉末 1-5份。
优选的，在步骤（4）中，面浆以重量份数计算，包括以下成分：
白泥 50-150份；
石英砂 30-65份；
甲壳素 5-25份；
电气石 5-10份；
桐油 3-5份；
松脂 3-5份；
α-氧化铝 5-10份；
稀土化合物 1-3份；
烧结助剂 1-4份；
成型助剂 1-3份
蒸馏水 50-80份；
纳米氧化铝溶胶 3-8份；
消泡剂 1-1.5份；
优选的，所述的纳米氧化铝溶胶的固含量为35-45%。
优选的，所述的稀土化合物为氧化钇或氧化镧。
优选的，所述的烧结助剂包括氧化镁或氧化硅。
优选的，所述的成型助剂包括甲基纤维素、羧甲基纤维素、或聚丙烯酰胺。
优选的，所述的消泡剂为乳化硅油。
与现有技术相比，本发明的有益效果是：
1、本发明在生坯和面浆层之间固定抗菌层，将纳米氧化锆等物质在高温高压下压合制得，具有耐磨、高密度、高硬度、无毛细孔、不会藏污纳垢、无异味残留、容易清洁等优点。在抗菌层上设置通孔和流道，用于灌入面浆，烧结后面浆与生坯结合呈一体，将抗菌层牢固固定在二者之间。由于面浆烧制后，面浆中的成分呈玻璃相变化，采用稀土氧化物、纳米氧化铝溶胶、烧结助剂进行混合，尤其用纳米氧化铝溶胶与α-氧化铝粉体结合，降低了烧成温度和产品的制造成本；提高了产品的强度、耐酸碱腐蚀性；同时采用纳米氧化铝溶胶，颗粒间的结合强度高，颗粒形貌得到保持，制备的产品上表面玻璃相结构致密，即便抛光尺寸较深也不会大量产生开放式气口，保证了抛光砖的耐污能力；而云母石粉、甲壳素和电气石等功能性物质的存在，又使得瓷砖上层保留适当大小的功能性物质施放通道，便于砖坯和面釉层内的有效物质得到充分的施放，达到保健的功效。
2、本发明采用分段烧制的技术，第一段的低温烧制有利于砖体的料体匀速干燥，防止裂痕和细缝产生；采用第二段的烧制温度并适当延长该阶段的烧制时长，有利于促进坯体的致密度，降低坯体的封闭气孔率，并可避免晶粒的粗化。烧制后进行瓷砖通过保温时间，能够令瓷砖内的各物质在烧结后温度均一性更佳，防止骤冷令瓷砖内部应力不均，产生细纹。
3、现有技术主要采用的烧结助剂，有玻璃相生成，烧成温度低，但耐腐蚀性差，使用寿命短。稀土氧化物属于难熔氧化物，同时起到细化晶粒和促进烧结致密的作用，因此本发明添加氧化钇、氧化镧等稀土化合物，提高了产品耐酸碱腐蚀性，延长了产品的使用寿命。
4、本发明制得的瓷砖与现有产品相比，各项综合性能指标也有极大的提升，十分适合用于有高质量要求的日用和商用建筑物的装饰，且具备抗菌保健之功效，经过小试、中试和批量投产实验，经济环保，适宜在业界推广普及。
具体实施方式
下面结合具体实施方式对本发明进行详细说明。
发明所述的一种保健抑菌耐磨瓷砖，其制备方法包括如下步骤：
（1）准备胚体粉料；
（2）在压砖机模腔中施布胚体粉料，通过50-80MPa的压力，压制形成生坯；
（3）制备抗菌层：将抗菌层纳米粉末在2000-2500摄氏度，300-450吨的压力下压合成带有通孔的陶瓷抗菌板材；所述陶瓷抗菌板材的上表面设置流道，流道将各通孔连接在一起；
（4）将抗菌层放置到生坯上；
（5）制备面浆；
（6）将制备好的面浆填充入流道和通孔中，制成半成品；
（7）将半成品放置到微波干燥器中进行微波干燥，干燥时间10-20min；
（8）将干燥好的半成品分两段进行烧制，第一段的烧制温度为1000-1050摄氏度，烧成时长为15-35分钟；第二段的烧制温度为1650-2000摄氏度，烧成时长为40-90分钟；而后保温30-120分钟后；本发明采用分段烧制的技术，第一段的低温烧制有利于砖体的料体匀速干燥，防止裂痕和细缝产生；采用第二段的烧制温度并适当延长该阶段的烧制时长，有利于促进坯体的致密度，降低坯体的封闭气孔率，并可避免晶粒的粗化。
（9）用金刚石模具对烧制好的半成品磨边、磨面整形后包装，即得成品。
在步骤（1）中，胚体粉料的构成原料以重量份数计算，包括以下成分：
粘土 80-100份；
石英 20-50份；
方解石 35-45份；
长石 15-25份；
高岭土 6-10份；
麦饭石 5-8份；
云母石粉 2-5份；
电气石 2-5份；
硼酸 1-3份；
氧化钴 1-3份；
氧化钡 1-3份；
氧化锌 1-3份；
纯碱 0.5-1.5份；
烧结助剂 1-4份；
成型助剂 1-3份。
在步骤（3）中，抗菌层纳米粉末以重量份数计算，包括以下成分：
纳米氧化锆粉末 50-80份；
纳米氧化铝粉末 5-15份；
纳米氧化钡粉末 1-5份。
在步骤（4）中，面浆以重量份数计算，包括以下成分：
白泥 50-150份；
石英砂 30-65份；
甲壳素 5-25份；
电气石 5-10份；
桐油 3-5份；
松脂 3-5份；
α-氧化铝 5-10份；
稀土化合物 1-3份；
烧结助剂 1-4份；
成型助剂 1-3份
蒸馏水 50-80份；
纳米氧化铝溶胶 3-8份；
消泡剂 1-1.5份；
所述的纳米氧化铝溶胶的固含量为35-45%。
所述的稀土化合物为氧化钇或氧化镧。
所述的烧结助剂包括氧化镁或氧化硅。
所述的成型助剂包括甲基纤维素、羧甲基纤维素、或聚丙烯酰胺。
所述的消泡剂为乳化硅油。
下面结合具体实施例，对本发明进一步说明。
表一：胚体粉料的具体实施例配料表：
成分 实施例一 实施例二 实施例三
粘土 80份 92份 100份
石英 20份 35份 50份
方解石 35份 40份 45份
长石 15份 20份 25份
高岭土 6份 8份 10份
麦饭石 5份 7份 8份
云母石粉 2份 4份 5份
电气石 2份 4份 5份
硼酸 1份 2份 3份
氧化钴 1份 2份 3份
氧化钡 1份 2份 3份
氧化锌 1份 2份 3份
纯碱 0.5份 1.2份 1.5份
烧结助剂 1份 3份 4份
成型助剂 1份 2份 3份
表二：抗菌层纳米粉末的具体实施例配料表：
成分 实施例一 实施例二 实施例三
纳米氧化锆粉末 50份 65份 80份
纳米氧化铝粉末 5份 10份 15份
纳米氧化钡粉末 1份 3.5份 5份
表三：面浆的具体实施例配料表：
成分 实施例一 实施例二 实施例三
白泥 50份 122份 150份
石英砂 30份 45份 65份
甲壳素 5份 20份 25份
电气石 5份 7份 10份
桐油 3份 4份 5份
松脂 3份 4份 5份
α-氧化铝 5份 8份 10份
稀土化合物 1份 2份 3份
烧结助剂 1份 2份 4份
成型助剂 1份 2份 3份
蒸馏水 50份 65份 80份
纳米氧化铝溶胶 3份 5份 8份
消泡剂 1份 1.2份 1.5份
上述实施例与普通日用瓷砖的对比检测实验结果如下：
由此可见，本发明制得瓷砖的各项常规性能指标均由于普通日用瓷。
本发明在生坯和面浆层之间固定抗菌层，将纳米氧化锆等物质在高温高压下压合制得，具有耐磨、高密度、高硬度、无毛细孔、不会藏污纳垢、无异味残留、容易清洁等优点。在抗菌层上设置通孔和流道，用于灌入面浆，烧结后面浆与生坯结合呈一体，将抗菌层牢固固定在二者之间。由于面浆烧制后，面浆中的成分呈玻璃相变化，采用稀土氧化物、纳米氧化铝溶胶、烧结助剂进行混合，尤其用纳米氧化铝溶胶与α-氧化铝粉体结合，降低了烧成温度和产品的制造成本；提高了产品的强度、耐酸碱腐蚀性；同时采用纳米氧化铝溶胶，颗粒间的结合强度高，颗粒形貌得到保持，制备的产品上表面玻璃相结构致密，即便抛光尺寸较深也不会大量产生开放式气口，保证了抛光砖的耐污能力；而木鱼石、甲壳素和电气石等功能性物质的存在，又使得釉面保留适当大小的功能性物质施放通道，便于砖坯和面釉层内的有效物质得到充分的施放，达到保健的功效。
以上所述，仅是本发明的较佳实施例而已，并非是对本发明作其它形式的限制，任何熟悉本专业的技术人员可能利用上述揭示的技术内容加以组合、变更或改型均为本发明的等效实施例。但是凡是未脱离本发明技术方案内容，依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化与改型，仍属于本发明技术方案的保护范围。

Claims (8)

1.一种保健抑菌耐磨瓷砖，其特征在于制备方法包括如下步骤：
(1)准备胚体粉料；
(2)在压砖机模腔中施布胚体粉料，通过50-80MPa的压力，压制形成生坯；
(3)制备抗菌层：将抗菌层纳米粉末在2000-2500摄氏度，300-450吨的压力下压合成带有通孔的陶瓷抗菌板材；所述陶瓷抗菌板材的上表面设置流道，流道将各通孔连接在一起；
(4)将抗菌层放置到生坯上；
(5)制备面浆；
(6)将制备好的面浆填充入流道和通孔中，制成半成品；
(7)将半成品放置到微波干燥器中进行微波干燥，干燥时间10-20min；
(8)将干燥好的半成品分两段进行烧制，第一段的烧制温度为1000-1050摄氏度，烧成时长为15-35分钟；第二段的烧制温度为1650-2000摄氏度，烧成时长为40-90分钟；而后保温30-120分钟后；
(9)用金刚石模具对烧制好的半成品磨边、磨面整形后包装，即得成品；
在步骤(3)中，抗菌层纳米粉末以重量份数计算，由以下成分组成：
纳米氧化锆粉末 50-80份；
纳米氧化铝粉末 5-15份；
纳米氧化钡粉末 1-5份。
2.根据权利要求1所述的保健抑菌耐磨瓷砖，其特征在于：在步骤(1)中，胚体粉料的构成原料以重量份数计算，由以下成分组成：
3.根据权利要求2所述的保健抑菌耐磨瓷砖，其特征在于：在步骤(5)中，面浆以重量份数计算，由以下成分组成：
4.根据权利要求3所述的保健抑菌耐磨瓷砖，其特征在于：所述的纳米氧化铝溶胶的固含量为35-45％。
5.根据权利要求4所述的保健抑菌耐磨瓷砖，其特征在于：所述的稀土化合物为氧化钇或氧化镧。
6.根据权利要求5所述的保健抑菌耐磨瓷砖，其特征在于：所述的烧结助剂包括氧化镁或氧化硅。
7.根据权利要求6所述的保健抑菌耐磨瓷砖，其特征在于：所述的成型助剂包括甲基纤维素、羧甲基纤维素、或聚丙烯酰胺。
8.根据权利要求7所述的保健抑菌耐磨瓷砖，其特征在于：所述的消泡剂为乳化硅油。
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