CN109180170A - 一种复合泡沫玄武岩铸石板及其制备工艺 - Google Patents
一种复合泡沫玄武岩铸石板及其制备工艺 Download PDFInfo
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Abstract
本发明公开一种复合泡沫玄武岩铸石板及其制备工艺,所述制备工艺包括以下步骤:(1)将基料配以辅料制备成用于生产铸石板材的原料;(2)将泡沫玄武岩切割成需要的尺寸,装入模具加热到500~600℃;(3)将生产铸石板材的原料经高温熔化并将熔化的铸石岩浆浇注到模具内的泡沫玄武岩表面;(4)铸石岩浆表面固化后先进行脱模,得到复合板,将复合板进行结晶以及退火处理得到复合泡沫玄武岩铸石板。采用该制备工艺可以提高铸石板的抗冲击性能,增强铸石板材的粘接强度,并且该铸石板具有耐高温、耐腐蚀的特性。
Description
技术领域
本发明涉及一种建材的生产技术领域,具体涉及一种复合泡沫玄武岩铸石板及其制备工艺。
背景技术
铸石板是以天然岩石辉绿岩、玄武岩、页岩或工业废渣为原料,加入一定的附加剂如角闪岩,白云岩、萤石以及结晶剂如铬铁矿、钛镁矿等经溶化、浇铸、结晶、退火工序加工而成的一种非金属防腐耐磨材料。
泡沫玄武岩是利用玄武岩加工成粉料、掺和部分炉渣为主要原料,添加发泡济、改性剂、促进剂等经粉碎均匀混合成配合料,放置在特定模具中经过1100℃~1200℃熔化、发泡、退火形成的一种内部充满无数均匀气泡的多孔玄武岩材料。该玄武岩中气泡占总体积的80~95%,气泡的直径约为0.5~3mm,其密度为400~600kg/m3,仅有普通玄武岩的八分之一左右。
铸石板材在使用过程中不仅仅是耐磨,更大程度是要抵抗物料的冲击,由于现有的铸石板表面光滑,水泥砂浆粘贴不牢,即使用胶泥也不能保证粘接强度,所以经常造成物料冲击时铸石板碎裂、脱落,影响使用效果,维修量大,使用寿命较短,浪费资源等技术缺陷。
发明内容
有鉴于此,本申请提供一种复合泡沫玄武岩铸石板及其制备工艺,采用该制备工艺可以提高铸石板的抗冲击性能,增强铸石板材的粘接强度,并且该铸石板具有耐高温、耐腐蚀的特性。
为解决以上技术问题,本发明提供的技术方案是一种复合泡沫玄武岩铸石板的制备工艺,其特征在于,所述制备工艺包括以下步骤:(1)将基料配以辅料制备成用于生产铸石板材的原料;(2)将泡沫玄武岩切割成需要的尺寸,装入模具加热到500~600℃;(3)将生产铸石板材的原料经高温熔化并将熔化的铸石岩浆浇注到模具内的泡沫玄武岩表面;(4)铸石岩浆表面固化后先进行脱模,得到复合板,将复合板进行结晶以及退火处理得到复合泡沫玄武岩铸石板。
本发明采用多点式浇注法,在泡沫玄武岩处于固态状态下与铸石岩浆在熔融状态时流动性好,铸石岩浆容易进入泡沫玄武岩气孔,将两种性质接近的材料符合在一起,然后进行结晶、退火处理。
对于铸石原料,其应具有稳定的化学成分和矿物组成,并且有较低的熔化温度。制得的熔体应具有均匀的组成,易于脱气与均化,有足够的流动性和结晶能力,以及在硬化过程中收缩性较小。为了防止收缩变形,铸石件在软化温度和结晶温度之间应有足够的间隔。本申请中选用华蓥玄武岩结构细密,并含有一定量的K2O和Na2O,因此熔点较低,在1099℃~1215℃就可熔化,1350℃~1400℃就可制得符合浇注质量的熔体;这种玄武岩SiO2含量比页岩、辉绿岩低,不需加更多的碱性附加料,熔体粘度较低,适合浇注板材。为了降低合乎浇注质量的熔体温度,减小因玄武岩成分变化而引起的工艺因素不稳定,我们根据玄武岩成分变化加入适量的碱性附加料,降低其熔化温度,使其在1310℃~1350℃就能得到合符浇注质量的熔体。同时加入碱性附加料,在熔化过程中产生化学反应,减少气孔的产生,改变了玄武岩的斑晶结构,提高了制品成品率。华蓥玄武岩SiO2和氧化铁含量相对较高,其晶核主要为磁铁矿和TiO2。要达到流动性好,结晶能力强,结晶晶粒细,必须增加结晶中心的数目,同时加快晶体的生长速度。故而需加入适量的碱性附加料、助熔剂和能成为晶核的复合材料。
优选的,所述步骤(3)中浇注方法为多点式浇注法,浇注温度为1200℃~1350℃。
更优选的,所述步骤(3)中浇注方法为多点式浇注法,浇注温度为1250℃~1300℃。
具体的,本申请采用计算机编程控制风、气配比,使其天然气充分燃烧,将浇注温度控制在1200℃~1350℃,采用多点式浇注法,即根据板材的大小由一头浇注到一定厚度,然后推动模具,逐步移动,直到板面与模具一样平整。
优选的,所述步骤(3)中浇注厚度为5~30mm。
更优选的,所述步骤(3)中浇注厚度为10~20mm。
优选的,所述步骤(4)中结晶温度为800~1000℃。
更优选的,所述步骤(4)中结晶温度为850~950℃。
优选的,所述步骤(4)中退火温度为600~800℃。
更优选的,所述步骤(4)中退火温度为680~750℃。
优选的,所述退火在隧道式退火窑中进行。
浇注后的复合发泡玄武岩铸石板,必须及时进行结晶热处理,否则铸石件要形成大量的玻璃相,这样的铸石件耐磨性及机械强度都满足不了质量要求。结晶温度一般在850~950℃(其中核化带温度一般控制在820~880℃,升温带的温度控制在860~950℃,晶化带的温度控制在880~920℃),结晶好的铸石件要装入隧道式退火窑进行退火,退火温度控制在680~750℃,退火目的是消除铸石件在结晶过程产生的内应力。
优选的,所述复合泡沫玄武岩铸石板的密度为1.1g/cm3~1.5g/cm3。
优选的,所述铸石板材的原料包括以下重量份数的原料:SiO2:43~48%,Al2O3:12~16%,Fe2O3+FeO:12~15%,CaO:8~13%,MgO:4~8%。
本发明还提供了一种由上述制备工艺制备得到的复合泡沫玄武岩铸石板。
本申请与现有技术相比,其详细说明如下:本申请提供了一种复合泡沫玄武岩铸石板及其制备方法,该方法将铸石板与泡沫玄武岩进行复合得到一种复合板,这两种材料性质基本一致,具有很强的相容性,复合发泡玄武岩铸石板既能达到铸石板材的防腐耐磨性能效果,又具有密度小,粘贴牢的优点,且可提高抗冲击性能;该复合板密度较低,可以显著降低铸石板安装的重量,减轻设备支撑负担;复合发泡玄武岩铸石板可以根据需要调色,表面进行抛光处理,可用于建筑领域,既起到装饰作用,又能达到环保要求。产品具有耐高温、低温、耐酸碱腐蚀、抗紫外线、抗氧化、绝热、绝缘、防火阻燃、吸湿率低、过滤性好、隔音性能佳、透波性能好、吸波性能优等特点,同时室内墙壁可直接冲洗。由于本产品属于多孔结构,当声音透过材料,声波在材料中产生散射及漫反射,将声音吸收在气孔里,声音转换成热能消耗掉,因此,此材料吸音性能极佳。
附图说明
图1为本发明的复合泡沫玄武岩铸石板的结构示意图。
具体实施方式
为了使本领域的技术人员更好地理解本发明的技术方案,下面结合具体实施例对本发明作进一步的详细说明。
实施例1
一种复合泡沫玄武岩铸石板的制备工艺,包括以下步骤:
(1)将将基料配以辅料制备成用于生产铸石板材的原料,其中铸石板材的原料包括以下重量份数的原料:SiO2:43~48%,Al2O3:12~16%,Fe2O3+FeO:12~15%,CaO:8~13%,MgO:4~8%;
(2)将泡沫玄武岩切割成需要的尺寸,装入模具加热到500~600℃;
(3)将生产铸石板材的原料在1300℃度下熔化并将熔化的铸石岩浆浇注到模具内的泡沫玄武岩表面,浇注5mm,采用多点式浇注法,根据板材的大小由一头浇注到一定厚度,然后推动模具,逐步移动,直到板面与模具一样平整,浇注温度控制在1250℃;
(4)铸石岩浆表面固化后先进行脱模,得到复合板,将复合板进行结晶以及退火处理得到复合泡沫玄武岩铸石板,其中结晶温度为850~950℃(其中核化带温度控制在820~880℃,升温带的温度控制在860~950℃,晶化带的温度控制在880~920℃),结晶好的复合板装入隧道式退火窑进行退火,退火温度控制在680~750℃,退火目的是消除铸石件在结晶过程产生的内应力。
由该方法制备得到的复合玄武岩泡沫铸石板密度为1.1g/cm3,防火等级为A级,PH值为7.5,熔点为1300℃。
实施例2
一种复合泡沫玄武岩铸石板的制备工艺,包括以下步骤:
(1)将将基料配以辅料制备成用于生产铸石板材的原料,其中铸石板材的原料包括以下重量份数的原料:SiO2:43~48%,Al2O3:12~16%,Fe2O3+FeO:12~15%,CaO:8~13%,MgO:4~8%;
(2)将泡沫玄武岩切割成需要的尺寸,装入模具加热到500~600℃;
(3)将生产铸石板材的原料在1350℃温度下熔化并将熔化的铸石岩浆浇注到模具内的泡沫玄武岩表面,浇注10mm,采用多点式浇注法,根据板材的大小由一头浇注到一定厚度,然后推动模具,逐步移动,直到板面与模具一样平整,浇注温度控制在1300℃;
(4)铸石岩浆表面固化后先进行脱模,得到复合板,将复合板进行结晶以及退火处理得到复合泡沫玄武岩铸石板,其中结晶温度为850~950℃(其中核化带温度控制在820~880℃,升温带的温度控制在860~950℃,晶化带的温度控制在880~920℃),结晶好的复合板装入隧道式退火窑进行退火,退火温度控制在680~750℃,退火目的是消除铸石件在结晶过程产生的内应力。
由该方法制备得到的复合玄武岩泡沫铸石板密度为1.2g/cm3,防火等级为A级,PH值为7.2,熔点为1300℃。
实施例3
一种复合泡沫玄武岩铸石板的制备工艺,包括以下步骤:
(1)将基料配以辅料制备成用于生产铸石板材的原料,其中铸石板材的原料包括以下重量份数的原料:SiO2:43~48%,Al2O3:12~16%,Fe2O3+FeO:12~15%,CaO:8~13%,MgO:4~8%;
(2)将泡沫玄武岩切割成需要的尺寸,装入模具加热到500~600℃;
(3)将生产铸石板材的原料在1400℃温度下熔化并将熔化的铸石岩浆浇注到模具内的泡沫玄武岩表面,浇注15mm,采用多点式浇注法,根据板材的大小由一头浇注到一定厚度,然后推动模具,逐步移动,直到板面与模具一样平整,浇注温度控制在1200℃;
(4)铸石岩浆表面固化后先进行脱模,得到复合板,将复合板进行结晶以及退火处理得到复合泡沫玄武岩铸石板,其中结晶温度为850~950℃(其中核化带温度控制在820~880℃,升温带的温度控制在860~950℃,晶化带的温度控制在880~920℃),结晶好的复合板装入隧道式退火窑进行退火,退火温度控制在680~750℃,退火目的是消除铸石件在结晶过程产生的内应力。
由该方法制备得到的复合玄武岩泡沫铸石板密度为1.3g/cm3,防火等级为A级,PH值为7.8,熔点为1300℃。
实施例4
一种复合泡沫玄武岩铸石板的制备工艺,包括以下步骤:
(1)将将基料配以辅料制备成用于生产铸石板材的原料,其中铸石板材的原料包括以下重量份数的原料:SiO2:43~48%,Al2O3:12~16%,Fe2O3+FeO:12~15%,CaO:8~13%,MgO:4~8%;
(2)将泡沫玄武岩切割成需要的尺寸,装入模具加热到500~600℃;
(3)将生产铸石板材的原料在1350℃温度下熔化并将熔化的铸石岩浆浇注到模具内的泡沫玄武岩表面,浇注20mm,采用多点式浇注法,根据板材的大小由一头浇注到一定厚度,然后推动模具,逐步移动,直到板面与模具一样平整,浇注温度控制在1350℃;
(4)铸石岩浆表面固化后先进行脱模,得到复合板,将复合板进行结晶以及退火处理得到复合泡沫玄武岩铸石板,其中结晶温度为850~950℃(其中核化带温度控制在820~880℃,升温带的温度控制在860~950℃,晶化带的温度控制在880~920℃),结晶好的复合板装入隧道式退火窑进行退火,退火温度控制在680~750℃,退火目的是消除铸石件在结晶过程产生的内应力。
由该方法制备得到的复合玄武岩泡沫铸石板密度为1.4g/cm3,防火等级为A级,PH值为8,熔点为1300℃。
实施例5
一种复合泡沫玄武岩铸石板的制备工艺,包括以下步骤:
(1)将将基料配以辅料制备成用于生产铸石板材的原料,其中铸石板材的原料包括以下重量份数的原料:SiO2:43~48%,Al2O3:12~16%,Fe2O3+FeO:12~15%,CaO:8~13%,MgO:4~8%;
(2)将泡沫玄武岩切割成需要的尺寸,装入模具加热到500~600℃;
(3)将生产铸石板材的原料在1300℃温度下熔化并将熔化的铸石岩浆浇注到模具内的泡沫玄武岩表面,浇注30mm,采用多点式浇注法,根据板材的大小由一头浇注到一定厚度,然后推动模具,逐步移动,直到板面与模具一样平整,浇注温度控制在1350℃;
(4)铸石岩浆表面固化后先进行脱模,得到复合板,将复合板进行结晶以及退火处理得到复合泡沫玄武岩铸石板,其中结晶温度为850~950℃(其中核化带温度控制在820~880℃,升温带的温度控制在860~950℃,晶化带的温度控制在880~920℃),结晶好的复合板装入隧道式退火窑进行退火,退火温度控制在680~750℃,退火目的是消除铸石件在结晶过程产生的内应力。
由该方法制备得到的复合玄武岩泡沫铸石板密度为1.5g/cm3,防火等级为A级,PH值为8,熔点为1300℃。
以上仅是本发明的优选实施方式,应当指出的是,上述优选实施方式不应视为对本发明的限制,本发明的保护范围应当以权利要求所限定的范围为准。对于本技术领域的普通技术人员来说,在不脱离本发明的精神和范围内,还可以做出若干改进和润饰,这些改进和润饰也应视为本发明的保护范围。
Claims (9)
1.一种复合泡沫玄武岩铸石板的制备工艺,其特征在于,所述制备工艺包括以下步骤:(1)将基料配以辅料制备成用于生产铸石板材的原料;(2)将泡沫玄武岩切割成需要的尺寸,装入模具加热到500~600℃;(3)将生产铸石板材的原料经高温熔化并将熔化的铸石岩浆浇注到模具内的泡沫玄武岩表面;(4)铸石岩浆表面固化后先进行脱模,得到复合板,将复合板进行结晶以及退火处理得到复合泡沫玄武岩铸石板。
2.根据权利要求1所述的复合泡沫玄武岩铸石板的制备工艺,其特征在于,所述步骤(3)中浇注方法为多点式浇注法,浇注温度为1200℃~1350℃。
3.根据权利要求1所述的复合泡沫玄武岩铸石板的制备工艺,其特征在于,所述步骤(3)中浇注厚度为5~30mm。
4.根据权利要求1所述的复合泡沫玄武岩铸石板的制备工艺,其特征在于,所述步骤(4)中结晶温度为800~1000℃。
5.根据权利要求1所述的复合泡沫玄武岩铸石板的制备工艺,其特征在于,所述步骤(4)中退火温度为600~800℃。
6.根据权利要求5所述的复合泡沫玄武岩铸石板的制备工艺,其特征在于,所述退火在隧道式退火窑中进行。
7.根据权利要求1所述的复合泡沫玄武岩铸石板的制备工艺,其特征在于,所述复合泡沫玄武岩铸石板的密度为1.1g/cm3~1.5g/cm3。
8.根据权利要求1所述的复合泡沫玄武岩铸石板的制备工艺,其特征在于,所述铸石板材的原料包括以下重量份数的原料:SiO2:43~48%,Al2O3:12~16%,Fe2O3+FeO:12~15%,CaO:8~13%,MgO:4~8%。
9.一种由权利要求1~8所述的复合泡沫玄武岩铸石板的制备工艺制备得到的复合泡沫玄武岩铸石板。
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