CN107344823A - 一种含陶瓷碎片的人造石英石及其制备方法 - Google Patents
一种含陶瓷碎片的人造石英石及其制备方法 Download PDFInfo
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Abstract
本发明属于人造石材技术领域,涉及一种含陶瓷碎片的人造石英石,包含下述重量份的原料:石英砂40‑55份、陶瓷碎片15‑30份、固化树脂15‑20份、固化剂0.1‑1份、偶联剂0.1‑1份、抗老化剂0.2‑1份、抗菌剂0.05‑0.1份、色粉0.05‑0.3份、耐磨纤维0.5‑2份、抗菌防污涂料1‑2份,其制备步骤包括配料混料、压丕、涂膜、加压固化、最后经脱模、切割、定厚、抛光深加工处理,即制得人造石英石成品。本发明提高了人造石英石的结构强度和耐磨性,并且在表层固化了抗菌防污层,提高了人造石英石的耐磨性和自清洁能力,在耐磨纤维中负载磁性粒子,使得人造石英石具有电磁屏蔽功能。
Description
技术领域
本发明属于人造石材技术领域,涉及一种含陶瓷碎片的人造石英石及其制备方法。
背景技术
人造石英石是由质量比为:90%左右的石英石骨料及石英石粉末,和10%左右的其他添加剂粉末组成,如颜料、树脂、活性因子、添加剂等。经过充分混合搅拌,真空高压振动压制,常温固化,定厚打磨抛光等工序制得。
我国废弃陶瓷垃圾达千万吨,特别是景德镇瓷都,如此大量的陶瓷废品不仅是对资源的极大浪费,同时对环境造成极大污染 , 已经不是简单填埋可以解决的问题,而且随着经济的日益发展和社会的进步,环境已经成为人们关注的焦点,如何变废为宝,化废料为资源,成为了整个行业实现可持续发展的当务之急。因此,我公司首创将陶瓷碎片作为骨料加入到人造石英石中,不但解决了废弃陶瓷碎片的废物处理问题,而且因为陶瓷碎片有各种形状和色彩,增加了人造石英石图案丰富性,生产出的人造石英石广受市场的欢迎。
因为人造石英石是使用树脂粘合的,树脂的耐磨性低于传统瓷砖,为此人们致力于研究提高人造石英石耐磨性的配方,普遍采用添加高硬度填料,如碳化硅微粉、金刚砂、或者是添加耐磨纤维,这种方式虽然起到了增强耐磨性的作用,但是对石英石表面轻微磨损的抵抗力并不强,而表面轻微磨损产生的微磨痕很容易藏污纳垢,滋生细菌,而且清洁不方便。
部分建筑场所需要具有电磁屏蔽效果,现有的人造石英石尚未发现具有电磁屏蔽功能的相关报道,因此开发具备电磁屏蔽功能的人造石英石也非常有必要。
发明内容
基于现有技术的上述状况,本发明提供了一种含陶瓷碎片的人造石英石及其制备方法,在人造石英石内添加耐磨纤维,提高了人造石英石的结构强度和耐磨性,并且在表层固化了抗菌防污层,提高了人造石英石的耐磨性和自清洁能力,更特别的是,在耐磨纤维中负载磁性粒子,使得人造石英石具有电磁屏蔽功能。
本发明是通过下述技术方案来实现的。一种含陶瓷碎片的人造石英石,包含下述重量份的原料:石英砂40-55份、陶瓷碎片15-30份、固化树脂15-20份、固化剂0.1-1份、偶联剂0.1-1份、抗老化剂0.2-1份、抗菌剂0.05-0.1份、色粉0.05-0.3份、耐磨纤维0.5-2份、抗菌防污涂料1-2份。
更特别的是,所述耐磨纤维是负载了磁性粒子的短纤维材料,纤维的长度为1-3mm,磁性粒子是带磁性的纳米颗粒或微米颗粒。
更特别的是,所述丙烯酸树脂、环氧树脂、酚醛树脂和聚氨酯树脂中的一种或多种。
更特别的是,所述石英砂中不同粒度的石英砂的质量比为 :150 目石英砂 :80目石英砂 :4 目石英砂=100:(175-210):(25-60);所述陶瓷碎片是30-50 目的陶瓷颗粒。
更特别的是,所述固化剂为过氧化-2-乙基己酸叔丁酯,所述偶联剂为乙烯基三乙氧基硅烷或苯胺甲基三乙氧基硅烷,所述抗老化剂为二丁基羟基甲苯。
更特别的是,所述抗菌剂是季铵盐类抗菌剂。
更特别的是,所述抗菌防污涂料由有机硅树脂或氟碳树脂50-100份、超疏水的纳米氧化锌10-30份、碳化硅微粉20-30份、抗老化剂1-2、纳米银1-2份组成。纳米氧化锌具有超疏水性,并且硬度高,可改善人造石英石表面性质,使得人造石英石的表面具备自清洁能力,碳化硅微粉加入抗菌防污涂料中,可显著改善其耐磨性,纳米银具有良好的杀菌性能,杀菌抗菌时效长。
上述含陶瓷碎片的人造石英石的制备方法如下:
步骤一、将石英砂、陶瓷碎片、耐磨纤维一起搅拌混合,使耐磨纤维和陶瓷碎片、石英砂混合在一起得到骨料组合物;将固化剂、偶联剂、抗老化剂、抗菌剂和色粉加入固化树脂中混合均匀得到粘结剂组合物;
步骤二、将粘结剂组合物与骨料组合物混合后装填在模具板中,然后采用真空振压机振压成型,得到人造石英石毛坯;
步骤三、采用涂抹辊在人造石英石毛坯的上表面涂一层抗菌防污涂料膜;
步骤四、将步骤三涂膜后的人造石英石毛坯转移至人造石固化装置中固化,所述人造石固化装置包括上热压板和下热压板,上热压板和下热压板通过热压油加热,并且至少上热压板上设有液压推杆装置,通过液压推杆装置推动上热热压板,从而使得上热压板给予人造石英石毛坯一定的压力,使得抗菌防污涂料向人造石英石毛坯的表面的微细孔中渗透,并使抗菌防污涂料膜表面平整;
步骤五、固化结束后,经脱模、切割、定厚、抛光深加工处理,即制得人造石英石成品。
进一步优选,耐磨纤维是负载了磁性粒子的短纤维材料,其制备过程如下:将100质量份竹碳纤维和5质量份磁性粉末混合,然后加入高速剪切机中,并加入30质量份丙烯腈、30份质量份丙烯酸甲酯、20质量份硫代二丙酸二月桂酯、15质量份十二烷基磺酸钠、8质量份脂肪酰二乙醇胺、5质量份偏重亚硫酸钠、5质量份份十六烷基三甲基溴化铵、5质量份羟乙基淀粉、3质量份硅烷偶联剂、150质量份的水,在高速剪切机中搅拌1小时,然后350℃下熔融,使用螺杆挤出机挤出成型得到负载了磁性粒子的耐磨纤维,耐磨纤维的直径小于0.5mm,然后将耐磨纤维切割成长度1-3mm,备用。
进一步优选,步骤一中的石英砂原料预先采用风管式烘干机烘干,风管式烘干机的顶部设有进料口,风管式烘干机的底部设有出料口,风管式烘干机内部布置多层热风管组,热风管的间距满足使烘干的石英砂可以通过热风管组下落到出料口,但湿的石英砂因为相互之间吸附力大而被堵在热风管组间被烘干。石英砂通过这样的方式被烘干,石英砂烘干时不会发黑(传统的回转炉烘干因为局部过热会使石英砂变色发黑),制作的人造石英石更漂亮。
本发明的具有如下优点:
1.利用了陶瓷碎片,实现了废物再利用,而且制作的人造石英石可看到陶瓷碎片,各自陶瓷碎片呈不同的颜色,更为漂亮,增加色粉可以适当人造石英石呈现不同的色彩风格。
2.采用风管式烘干机烘干石英砂原料,不但节能,而可保证石英砂不变色,色泽良好。
3. 人造石英石内添加了耐磨纤维,耐磨性好,并且提高了人造石英石的抗折强度,添加抗菌剂,使得人造石英石抗菌效果好。
4.将磁性粒子成型在耐磨纤维内部,使得耐磨纤维具有磁性,从而使得人造石英石具有磁性,扩展人造石英石的应用,可用于磁屏蔽场所。
5.在人造石英石表面制作抗菌防污涂料膜,使得人造石英石具有良好的自清洁性、耐磨性、抗菌性,而且制备工艺相对简单,并且抗菌防污涂料膜与人造石英石一起加压固化,抗菌防污涂料膜与人造石英石的结合性好,后期使用过程中不会剥落。
具体实施方式
下面结合实施例进一步详细阐明本发明。
原材料准备:
将石英砂原料预先采用风管式烘干机烘干,风管式烘干机的顶部设有进料口,风管式烘干机的底部设有出料口,风管式烘干机内部布置多层热风管组,热风管的间距满足使烘干的石英砂可以通过热风管组下落到出料口,但湿的石英砂因为相互之间吸附力大而被堵在热风管组间被烘干,烘干后的石英砂备用。烘干后的石英砂石英砂过筛,得到不同目数的石英砂,然后按质量比为 :150 目石英砂 :80 目石英砂 :4 目石英砂=100:(175-210):(25-60)配制石英砂。
将破碎机破碎陶瓷碎片,然后过筛,得到30-50 目的陶瓷颗粒。
耐磨纤维制备:将100质量份竹碳纤维和5质量份磁性粉末混合,然后加入高速剪切机中,并加入30质量份丙烯腈、30份质量份丙烯酸甲酯、20质量份硫代二丙酸二月桂酯、15质量份十二烷基磺酸钠、8质量份脂肪酰二乙醇胺、5质量份偏重亚硫酸钠、5质量份份十六烷基三甲基溴化铵、5质量份羟乙基淀粉、3质量份硅烷偶联剂、150质量份的水,在高速剪切机中搅拌1小时,然后350℃下熔融,使用螺杆挤出机挤出成型得到负载了磁性粒子的耐磨纤维,耐磨纤维的直径小于0.5mm,然后将耐磨纤维切割成长度1-3mm,备用。
抗菌防污涂料制备:将有机硅树脂或氟碳树脂50-100份、超疏水的纳米氧化锌10-30份、碳化硅微粉20-30份、抗老化剂1-2、纳米银1-2份混合,搅拌均匀,备用。
实施例1
步骤一、将40kg石英砂、30kg陶瓷碎片、1Kg耐磨纤维一起搅拌混合,使耐磨纤维和陶瓷碎片、石英砂混合在一起得到骨料组合物;将0.1kg过氧化-2-乙基己酸叔丁酯、0.1kg苯胺甲基三乙氧基硅烷、0.2kg二丁基羟基甲苯、0.05kg季铵盐类抗菌剂和0.05kg色粉加入15kg丙烯酸树脂中混合均匀得到粘结剂组合物;
步骤二、将粘结剂组合物与骨料组合物混合后装填在模具板中,然后采用真空振压机振压成型,得到人造石英石毛坯;
步骤三、采用涂抹辊在人造石英石毛坯的上表面涂1kg抗菌防污涂料,得到一层抗菌防污涂料膜;
步骤四、将步骤三涂膜后的人造石英石毛坯转移至人造石固化装置中固化,所述人造石固化装置包括上热压板和下热压板,上热压板和下热压板通过热压油加热,并且至少上热压板上设有液压推杆装置,通过液压推杆装置推动上热热压板,从而使得上热压板给予人造石英石毛坯一定的压力,使得抗菌防污涂料向人造石英石毛坯的表面的微细孔中渗透,并使抗菌防污涂料膜表面平整; 上热压板的压力为2MPa,固化温度为80℃。
步骤五、固化结束后,经脱模、切割、定厚、抛光深加工处理,即制得人造石英石成品。
实施例2
步骤一、将55kg石英砂、15kg陶瓷碎片、0.5Kg耐磨纤维一起搅拌混合,使耐磨纤维和陶瓷碎片、石英砂混合在一起得到骨料组合物;将1kg过氧化-2-乙基己酸叔丁酯、1kg乙烯基三乙氧基硅烷、1kg二丁基羟基甲苯、0.1kg季铵盐类抗菌剂和0.3kg色粉加入20kg环氧树脂中混合均匀得到粘结剂组合物;
步骤二、将粘结剂组合物与骨料组合物混合后装填在模具板中,然后采用真空振压机振压成型,得到人造石英石毛坯;
步骤三、采用涂抹辊在人造石英石毛坯的上表面涂2kg抗菌防污涂料,得到一层抗菌防污涂料膜;
步骤四、将步骤三涂膜后的人造石英石毛坯转移至人造石固化装置中固化,所述人造石固化装置包括上热压板和下热压板,上热压板和下热压板通过热压油加热,并且至少上热压板上设有液压推杆装置,通过液压推杆装置推动上热热压板,从而使得上热压板给予人造石英石毛坯一定的压力,使得抗菌防污涂料向人造石英石毛坯的表面的微细孔中渗透,并使抗菌防污涂料膜表面平整; 上热压板的压力为2MPa,固化温度为80℃。
步骤五、固化结束后,经脱模、切割、定厚、抛光深加工处理,即制得人造石英石成品。
实施例3
步骤一、将50kg石英砂、20kg陶瓷碎片、1Kg耐磨纤维一起搅拌混合,使耐磨纤维和陶瓷碎片、石英砂混合在一起得到骨料组合物;将0.5kg过氧化-2-乙基己酸叔丁酯、0.5kg乙烯基三乙氧基硅烷、0.5kg二丁基羟基甲苯、0.05kg季铵盐类抗菌剂和0.1kg色粉加入20kg酚醛树脂中混合均匀得到粘结剂组合物;
步骤二、将粘结剂组合物与骨料组合物混合后装填在模具板中,然后采用真空振压机振压成型,得到人造石英石毛坯;
步骤三、采用涂抹辊在人造石英石毛坯的上表面涂0.5kg抗菌防污涂料,得到一层抗菌防污涂料膜;
步骤四、将步骤三涂膜后的人造石英石毛坯转移至人造石固化装置中固化,所述人造石固化装置包括上热压板和下热压板,上热压板和下热压板通过热压油加热,并且至少上热压板上设有液压推杆装置,通过液压推杆装置推动上热热压板,从而使得上热压板给予人造石英石毛坯一定的压力,使得抗菌防污涂料向人造石英石毛坯的表面的微细孔中渗透,并使抗菌防污涂料膜表面平整; 上热压板的压力为2MPa,固化温度为80℃。
步骤五、固化结束后,经脱模、切割、定厚、抛光深加工处理,即制得人造石英石成品。
石英砂40-55份、陶瓷碎片15-30份、固化树脂15-20份、固化剂0.1-1份、偶联剂0.1-1份、抗老化剂0.2-1份、抗菌剂0.05-0.1份、色粉0.05-0.3份、耐磨纤维0.5-2份、抗菌防污涂料1-2份。
实施例4
步骤一、将45kg石英砂、20kg陶瓷碎片、1Kg耐磨纤维一起搅拌混合,使耐磨纤维和陶瓷碎片、石英砂混合在一起得到骨料组合物;将0.3kg过氧化-2-乙基己酸叔丁酯、0.3kg乙烯基三乙氧基硅烷、0.5kg二丁基羟基甲苯、0.1kg季铵盐类抗菌剂和0.1kg色粉加入15kg聚氨酯树脂中混合均匀得到粘结剂组合物;
步骤二、将粘结剂组合物与骨料组合物混合后装填在模具板中,然后采用真空振压机振压成型,得到人造石英石毛坯;
步骤三、采用涂抹辊在人造石英石毛坯的上表面涂1kg抗菌防污涂料,得到一层抗菌防污涂料膜;
步骤四、将步骤三涂膜后的人造石英石毛坯转移至人造石固化装置中固化,所述人造石固化装置包括上热压板和下热压板,上热压板和下热压板通过热压油加热,并且至少上热压板上设有液压推杆装置,通过液压推杆装置推动上热热压板,从而使得上热压板给予人造石英石毛坯一定的压力,使得抗菌防污涂料向人造石英石毛坯的表面的微细孔中渗透,并使抗菌防污涂料膜表面平整; 上热压板的压力为5MPa,固化温度为90℃。
步骤五、固化结束后,经脱模、切割、定厚、抛光深加工处理,即制得人造石英石成品。
将实施例1-4所制备的人造石英石作性能测试分析,结果如表1所示:
表一
检测项目 | 实施例1 | 实施例2 | 实施例3 | 实施例4 |
吸水率(%) | 0 | 0 | 0 | 0 |
密度(g/m3) | 2.31 | 2.32 | 2.31 | 2.29 |
耐磨性能(g/m2) | 1.72*10-3 | 1.50*10-3 | 1.92*10-3 | 1.79*10-3 |
莫氏硬度 | 7.5 | 7.5 | 7.3 | 7.4 |
抗折强度(MPa) | 52.5 | 52.1 | 47.1 | 48.1 |
抗压强度(MPa) | 231.3 | 218.1 | 245.8 | 234.7 |
由上表可知,本发明的人造石英石强度高,耐磨性好,上述耐磨性测试是以涂有抗菌防污涂料膜的一面测试的。并且人造石英石中含有抗菌剂,抗菌性好,并还有磁性粒子以提供一定的磁性和电磁屏蔽性能,而且防污涂料膜具有自清洁效果。
Claims (10)
1.一种含陶瓷碎片的人造石英石,其特征是:包含下述重量份的原料:石英砂40-55份、陶瓷碎片15-30份、固化树脂15-20份、固化剂0.1-1份、偶联剂0.1-1份、抗老化剂0.2-1份、抗菌剂0.05-0.1份、色粉0.05-0.3份、耐磨纤维0.5-2份、抗菌防污涂料1-2份。
2.根据权利要求1所述的一种含陶瓷碎片的人造石英石,其特征是:所述耐磨纤维是负载了磁性粒子的短纤维材料。
3.根据权利要求1所述的一种含陶瓷碎片的人造石英石,其特征是:耐磨纤维的长度为1-3mm,磁性粒子是带磁性的纳米颗粒或微米颗粒。
4.根据权利要求1所述的一种含陶瓷碎片的人造石英石,其特征是:所述抗菌剂是季铵盐类抗菌剂。
5.根据权利要求1所述的一种含陶瓷碎片的人造石英石,其特征是:所述抗菌防污涂料由有机硅树脂或氟碳树脂50-100份、超疏水的纳米氧化锌10-30份、碳化硅微粉20-30份、抗老化剂1-2、纳米银1-2份组成。
6.根据权利要求1所述的一种含陶瓷碎片的人造石英石,其特征是:所述丙烯酸树脂、环氧树脂、酚醛树脂和聚氨酯树脂中的一种或多种;所述石英砂中不同粒度的石英砂的质量比为 :150 目石英砂 :80 目石英砂 :4 目石英砂=100:(175-210):(25-60);所述陶瓷碎片是30-50 目的陶瓷颗粒;所述固化剂为过氧化-2-乙基己酸叔丁酯,所述偶联剂为乙烯基三乙氧基硅烷或苯胺甲基三乙氧基硅烷,所述抗老化剂为二丁基羟基甲苯。
7.一种如权利要求1所述的含陶瓷碎片的人造石英石的制备方法,其特征在于步骤如下:
步骤一、将石英砂、陶瓷碎片、耐磨纤维一起搅拌混合,使耐磨纤维和陶瓷碎片、石英砂混合在一起得到骨料组合物;将固化剂、偶联剂、抗老化剂、抗菌剂和色粉加入固化树脂中混合均匀得到粘结剂组合物;
步骤二、将粘结剂组合物与骨料组合物混合后装填在模具板中,然后采用真空振压机振压成型,得到人造石英石毛坯;
步骤三、采用涂抹辊在人造石英石毛坯的上表面涂一层抗菌防污涂料膜;
步骤四、将步骤三涂膜后的人造石英石毛坯转移至人造石固化装置中固化,所述人造石固化装置包括上热压板和下热压板,上热压板和下热压板通过热压油加热,并且至少上热压板上设有液压推杆装置,通过液压推杆装置推动上热热压板,从而使得上热压板给予人造石英石毛坯一定的压力,使得抗菌防污涂料向人造石英石毛坯的表面的微细孔中渗透,并使抗菌防污涂料膜表面平整;
步骤五、固化结束后,经脱模、切割、定厚、抛光深加工处理,即制得人造石英石成品。
8.根据权利要求7所述的一种含陶瓷碎片的人造石英石的制备方法,其特征在于:步骤一中的石英砂原料预先采用风管式烘干机烘干,风管式烘干机的顶部设有进料口,风管式烘干机的底部设有出料口,风管式烘干机内部布置多层热风管组,热风管的间距满足使烘干的石英砂可以通过热风管组下落到出料口,但湿的石英砂因为相互之间吸附力大而被堵在热风管组间被烘干。
9.根据权利要求7所述的一种含陶瓷碎片的人造石英石的制备方法,其特征在于:所述抗菌防污涂料由有机硅树脂或氟碳树脂50-100份、超疏水的纳米氧化锌10-30份、碳化硅微粉20-30份、抗老化剂1-2、纳米银1-2份混合而成。
10.根据权利要求7所述的一种含陶瓷碎片的人造石英石的制备方法,其特征在于:所述耐磨纤维是负载了磁性粒子的短纤维材料,其制备过程如下:将100质量份竹碳纤维和5质量份磁性粉末混合,然后加入高速剪切机中,并加入30质量份丙烯腈、30份质量份丙烯酸甲酯、20质量份硫代二丙酸二月桂酯、15质量份十二烷基磺酸钠、8质量份脂肪酰二乙醇胺、5质量份偏重亚硫酸钠、5质量份份十六烷基三甲基溴化铵、5质量份羟乙基淀粉、3质量份硅烷偶联剂、150质量份的水,在高速剪切机中搅拌1小时,然后350℃下熔融,使用螺杆挤出机挤出成型得到负载了磁性粒子的耐磨纤维,耐磨纤维的直径小于0.5mm,然后将耐磨纤维切割成长度1-3mm,备用。
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