CN109293399B - 一种具有石纹浮凸感干粒砖及其制备方法 - Google Patents
一种具有石纹浮凸感干粒砖及其制备方法 Download PDFInfo
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Abstract
本发明涉及一种具有石纹浮凸感干粒砖及其制备方法,该制备方法包括以下步骤:在砖坯上施底釉、喷墨打印仿石材图案;在喷墨图案的石材纹理处施加胶水后在砖面上布干粒;以及在砖面上施覆盖釉,然后烧成。
Description
技术领域
本发明涉一种具有石纹浮凸感干粒砖及其制备方法,属于陶瓷砖生产制造技术领域。
背景技术
天然石材由于其耐用且厚重感强,被广泛应用于装饰领域,但是由于天然石材为非可再生资源,随着逐年开发,天然石材存储量会逐年减少且天然石材具有一定的放射性,随着人们对放射性的关注度越来越高,越来越多的消费者更加倾向于采用陶瓷砖来替代石材进行房屋的装修。在市场需求的刺激下,各大陶瓷生产企业都在开发仿石材陶瓷砖,且仿石材类陶瓷砖种类越来越多,花色质感已可与石材媲美。美中不足的是很难仿制出天然石材的晶体感及带晶体感的纹理。
发明内容
针对上述问题,本发明的目的在于提供一种具有石纹浮凸感干粒砖的制备方法以及由该制备方法制得的具有石纹浮凸感干粒砖。
一方面,本发明提供一种具有石纹浮凸感干粒砖的制备方法,包括以下步骤:
在砖坯上施底釉、喷墨打印仿石材图案;
在喷墨图案的石材纹理处施加胶水后在砖面上布干粒;以及
在砖面上施覆盖釉,然后烧成。
本发明通过将喷墨打印和布干粒相结合,提供了仿天然且具有石纹浮凸感干粒砖。
较佳地,所述干粒的化学组成为:按质量计,SiO2:55~60%、Al2O3:5~10%、CaO:6~10%、MgO:0.3~3%、K2O:5~8.0%、Na2O:1.5~3.0%、ZnO:6~12%、BaO:0.5~2%、PbO:0.5~1%、烧失:0.2~0.5%。
较佳地,所述干粒的颗粒级配为60目筛上0.1~2%,60~80目筛30~45%,80~100目筛25~30%,100~140目筛20~25%,140目筛以下:3~8%。
较佳地,在布干粒之后,去除未粘牢固干粒,优选用抽风机抽走未粘牢固干粒。
较佳地,所述底釉的化学组成为:按质量计,SiO2:57~60%、Al2O3:23~25%、Fe2O3:0.3~0.4%、TiO2:0.1~0.2%、CaO:0.3~0.4%、MgO:0.1~0.3%、K2O:4~6%、Na2O:2~3.0%、ZrO2:6~12%、烧失:3~5%。
较佳地,所述底釉的比重为1.40~1.45,施釉重量为40~550g/m2。
较佳地,所述覆盖釉的化学组成为:按质量计,SiO2:50~55%、Al2O3:12~16%、CaO:9~12.8%、MgO:3~6%、K2O:0.5~3.0%、Na2O:2~5.0%、ZnO:4~6%、烧失:3~5%。
较佳地,所述覆盖釉的比重为1.30~1.45,施釉量为200~400g/m2。
较佳地,最高烧成温度为1200~1220℃,烧成周期为40~60分钟。
另一方面,本发明提供一种由上述任一方法制得的具有石纹浮凸感干粒砖。
本发明生产的陶瓷砖,仿天然石材颜***真,纹理凸出自然,具有很好的凹凸感,且具有很好的防滑效果。
附图说明
图1是本发明一实施方式的生产流程图。
图2是本发明一实施方式中的喷墨机喷墨图案。
图3是本发明一实施方式中的胶水干粒机喷胶水图案。
图4是本发明一实施方式中的成品砖面图。
具体实施方式
以下结合附图和下述实施方式进一步说明本发明,应理解,附图和下述实施方式仅用于说明本发明,而非限制本发明。以下各百分含量如无特别说明均指质量百分含量。
图1示出本发明一实施方式的生产流程图。如图1所示,首先,制备坯体。坯体可由公知的陶瓷原料按常规方法制备,例如依次进行坯料球磨、喷粉造粒、压机干压成型、干燥窑干燥,得到干燥坯。干燥坯水分可控制在0.4%以内。
然后,在坯体上施底釉。施底釉可以起遮盖坯体和便于发色的作用。
一实施方式中,底釉的化学组成为:按质量计,SiO2:57~60%、Al2O3:23~25%、Fe2O3:0.3~0.4%、TiO2:0.1~0.2%、CaO:0.3~0.4%、MgO:0.1~0.3%、K2O:4~6%、Na2O:2~3.0%、ZrO2:6~12%、烧失:3~5%。该化学组成的底釉白度较高,烧成温度范围较宽且多种陶瓷墨水的发色都较好。
施底釉方式包括但不限于喷釉、淋釉等。底釉釉浆的细度可为325目筛余小于0.6%。底釉釉浆的比重可为1.40~1.45,在该比重下喷釉后砖面细腻平整。底釉釉浆的流速可为20~25秒,这里的流速是指将流速杯装满待测物,打开流速杯下面小孔,将待测物从开始到流尽后的时间记为待测物的流速。单位面积所施的底釉重量可为400~550g/m2,优选为480~500g/m2。采用该施釉量可使釉面平整且带入的水分能够及时排出。底釉层的厚度可为0.05~0.10mm。
然后,喷墨打印仿石材文件。可以采用数码喷墨打印机打印。使用的陶瓷墨水主要有蓝色、棕色、桔黄色、柠檬黄、黑色、红色等。喷墨打印图案例如如图2所示。
在喷墨图案的石材纹理处施加胶水墨水。胶水墨水的材质没有特别限定,可以是本领域公知的胶水。施加方式可为数码打印等。一实施方式中,采用数码胶水干粒机来喷胶水墨水。图3示出一个示例的胶水干粒机喷胶水图案。喷胶水墨水量根据喷胶水图案设计灰度变化而不同,灰度范围可控制在30~100%。图案的线条纹路宽度范围最小可达到1mm,最宽可根据石材纹理变化,例如可为100mm。胶水墨水的施加量可为25~50g/m2。采用该胶水量可使粘结干粒量适中,数码打印机可达到且能够稳定喷印。
施加胶水墨水后,在砖面均匀布干粒熔块(简称干粒或干粒釉)。一实施方式中,施加胶水墨水和布干粒可以均采用数码胶水干粒机来进行。
优选实施方式中,干粒的化学组成为:按质量计,SiO2:55~60%、Al2O3:5~10%、CaO:6~10%、MgO:0.3~3%、K2O:5~8.0%、Na2O:1.5~3.0%、ZnO:6~12%、BaO:0.5~2%、PbO:0.5~1%、烧失:0.2~0.5%。其中,ZnO能够降低干粒的高温粘度且有助于陶瓷墨水的发色,PbO能够大大降低干粒的软化温度,更加有助于干粒能够熔融。
更优选实施方式中,熔块干粒釉的化学组成为:按质量计,SiO2:55.5~60%、Al2O3:6.5~10%、CaO:9~10%、MgO:2.2~2.8%、K2O:5.5~6.5%、Na2O:1.5~2.0%、ZnO:10~12%、BaO:1.5~2.0%、PbO:0.5~0.7%,烧失:0.25~0.30%。
优选实施方式中,干粒的颗粒级配为60目筛上0.1~2%,60~80目筛30~45%,80~100目筛25~30%,100~140目筛20~28%,140目筛以下:3~8%。这种颗粒级配的干粒,在布料的时候能够形成紧密堆积,且在熔融过程中细小的颗粒能够对空隙进行填充,烧成后干粒釉层熔融效果好,无气泡等缺陷存在。
干粒的布施量可为400~600g/m2。采用该布施量时砖面干粒效果佳,所有的干粒都能够很好的粘结住,且成本适中。干粒的布施厚度可为1.0~2.0mm。采用该布施厚度时浮凸感强,对砖型的影响较小。
优选实施方式中,在布干粒之后,去除未粘牢固干粒。去除的干粒可以再回收利用。一个示例中,用抽风机抽走未粘结的干粒。然后可将得到的干粒回收过筛后再利用。
然后,在布施了干粒的砖面上施覆盖釉,从而能够在干粒釉层表面增加一层保护层,提高了干粒釉粘附力,防止干粒在窑炉烧成过程中被窑炉内的气流吹掉。覆盖釉可以是透明釉。
优选实施方式中,覆盖釉的化学组成为:按质量计,SiO2:50~53%、Al2O3:12~16%、CaO:9~12.8%、MgO:3~6%、K2O:0.5~3.0%、Na2O:2~5.0%、ZnO:4~6%、烧失:3~5%。该覆盖釉具有较好的通透性,光泽度适中,烧成后手感细腻。
更优选实施方式中,覆盖釉的化学组成为:按质量计,SiO2:52.2~54.8%、Al2O3:13.2~16.5%、CaO:10.2~12.8%、MgO:3.1~4.2%、K2O:1.3~2.2%、Na2O:3.2~3.6%、ZnO:5.2~5.8%、烧失:3.5~4.8%。
施覆盖釉方式包括但不限于喷釉、淋釉等。覆盖釉釉浆的细度可为0.6~0.8%(325目筛余)。覆盖釉釉浆的比重可为1.30~1.45,在该比重下喷釉雾化效果好烧成后砖面细腻。覆盖釉釉浆的流速可为8~12秒。单位面积所施的覆盖釉重量可为200~400g/m2,优选为240~300g/m2。采用该施釉量釉料能够均匀的分布在干粒上且不影响干粒的性能。覆盖釉层的厚度可为0.05~0.08mm。采用该厚度有很好的手感的同时能够和干粒很好的融合,砖面防污性能更优异。
然后进行烧成。可以采用低温快烧,例如,烧成周期可为40~60分钟,最高烧成温度可为1200~1220℃。
然后可进行抛光、磨边、分级。抛光厚度可为0.05~0.08mm。
图4示出本发明一实施方式中所得的产品,可以看出其仿天然石材颜***真,纹理凸出自然,具有很好的凹凸感,且具有很好的防滑效果。本发明的瓷砖光泽度可在5~20°,便面柔和,且静摩擦系数可达到0.6~0.85。
下面进一步例举实施例以详细说明本发明。同样应理解,以下实施例只用于对本发明进行进一步说明,不能理解为对本发明保护范围的限制,本领域的技术人员根据本发明的上述内容作出的一些非本质的改进和调整均属于本发明的保护范围。下述示例具体的工艺参数等也仅是合适范围中的一个示例,即本领域技术人员可以通过本文的说明做合适的范围内选择,而并非要限定于下文示例的具体数值。
实施例1
压机干压成型。
干燥窑干燥,干燥坯水分0.4%以内。
喷面釉(或称底釉),比重1.42,施釉重量480g/m2,面釉化学组成:SiO2:58.3%、Al2O3:24.2%、Fe2O3:0.31%、TiO2:0.13%、CaO:0.34%、MgO:0.23%、K2O:4.86%、Na2O:2.5%、ZrO2:8.5%、烧失:3.66%。
喷墨打印仿石材文件,采用数码喷墨打印机(购自福禄公司)打印,使用陶瓷墨水主要有蓝色、棕色、桔黄色、柠檬黄、黑色、红色等。
在喷墨图案的石材纹理处数码打印胶水墨水,喷完胶水后随即就用数码胶水干粒机(购自B&T公司)在砖面均匀布一层干粒熔块,熔块量为600g/m2;干粒釉的颗粒级配为60目筛上0.18%,60-80目筛40.6%,80-100目筛26.9%,100-140目筛27.1%,140目筛以下:5.22%。干粒釉的成分为SiO2:59.4%、Al2O3:6.8%、CaO:9.6%、MgO:2.5%、K2O:5.8%、Na2O:1.7%、ZnO:11.5%、BaO:1.8%、PbO:0.6%,烧失:0.3%。
用抽风机抽走未粘结的干粒回收过筛后再利用。
喷覆盖釉,覆盖釉比重1.35,施釉量250g/m2,覆盖釉化学组成:SiO2:54.5%、Al2O3:14.6%、CaO:11.4%、MgO:4.0%、K2O:2.0%、Na2O:3.4%、ZnO:5.5%、烧失:4.6%。
采用辊道窑烧成快速烧成,最高烧成温度1200-1220℃,烧成周期40-60min。
磨边分级,打包入库。
通过光泽度仪检测光泽度;通过摩擦系数检测仪检测静摩擦系数。通过检测,本实施例的瓷砖光泽度在13°,便面柔和,且静摩擦系数达到0.75以上,具有很好的防滑作用。
实施例2
基本同实施例1,不同之处在于,干粒釉的化学成分为:SiO2:57.1%、Al2O3:9.2%、CaO:9.3%、MgO:2.2%、K2O:6.0%、Na2O:1.8%、ZnO:12%、BaO:1.6%、PbO:0.5%,烧失:0.3%。
通过检测,本实施例的瓷砖光泽度在10.5°,便面柔和,且静摩擦系数达到0.82,具有很好的防滑作用。
实施例3
基本同实施例1,不同之处在于,干粒釉的颗粒级配为60目筛上2%,60-80目筛40%,80-100目筛26%,100-140目筛27%,140目筛以下:5%。
通过检测,本实施例的瓷砖光泽度在9.5°,便面柔和,且静摩擦系数达到0.85,具有很好的防滑作用。
实施例4
基本同实施例1,不同之处在于,干粒釉的成分为SiO2:56.2%、Al2O3:10%、CaO:9.0%、MgO:2.3%、K2O:6.5%、Na2O:2.0%、ZnO:11.5%、BaO:2.0%、PbO:0.5%,烧失:0.3%。通过检测,本实施例的瓷砖光泽度在8.4°,便面柔和,且静摩擦系数达到0.82。
实施例5
基本同实施例1,不同之处在于,干粒釉的颗粒级配为:60目筛上2%,60-80目筛40%,80-100目筛30%,100-140目筛25%,140目筛以下:3%。通过检测,本实施例的瓷砖光泽度在9.5°,便面柔和,且静摩擦系数达到0.86。
对比例1
基本同实施例1,不同之处在于,干粒釉的成分为SiO2:58.7%、Al2O3:15%、CaO:9.5%、MgO:2.3%、K2O:6.5%、Na2O:6.0%、:11.5%、BaO:2.0%、,烧失:0.3%。此配方不含有ZnO及PbO,通过增加配方中CaO、K2O、Na2O来达到降低干粒釉熔融温度的目的,通过对比,此配方烧成后陶瓷墨水的发色变暗,且含有较多的小气泡。ZnO、PbO能够促使釉料中的气泡排除。
Claims (7)
1.一种具有石纹浮凸感干粒砖的制备方法,其特征在于,包括以下步骤:
在砖坯上施底釉、喷墨打印仿石材图案;
在喷墨图案的石材纹理处施加胶水后在砖面上布干粒;所述干粒的化学组成为:按质量计,SiO2:55~60%、Al2O3:5~10%、CaO:6~10%、MgO:0.3~3%、K2O:5~8.0%、Na2O:1.5~3.0%、ZnO:6~12%、BaO:0.5~2%、PbO:0.5~1%、烧失:0.2~0.5%;所述干粒的颗粒级配为:60目筛以上0.1~2%,60~80目筛30~45%,80~100目筛25~30%,100~140目筛20~25%,140目筛以下:3~8%;所述干粒的施釉量为 400~600g/m2;以及
在砖面上施覆盖釉;所述覆盖釉的化学组成为:按质量计,SiO2:50~53%、Al2O3:12~16%、CaO:9~12.8%、MgO:3~6%、K2O:0.5~3.0%、Na2O:2~5.0%、ZnO:4~6%、烧失:3~5%;所述覆盖釉的比重为1.30~1.45,施釉量为200~400g/m2;
然后烧成;
所述具有石纹浮凸感干粒砖的光泽度为 5~20°,静摩擦系数为0.6~0.85。
2.根据权利要求1所述的制备方法,其特征在于,在布干粒之后,去除未粘牢固干粒。
3.根据权利要求2所述的制备方法,其特征在于,用抽风机抽走未粘牢固干粒。
4.根据权利要求1所述的制备方法,其特征在于,所述底釉的化学组成为:按质量计,SiO2:57~60%、Al2O3:23~25%、Fe2O3:0.3~0.4%、TiO2:0.1~0.2%、CaO:0.3~0.4%、MgO:0.1~0.3%、K2O:4~6%、Na2O:2~3.0%、ZrO2:6~12%、烧失:3~5%。
5.根据权利要求1所述的制备方法,其特征在于,所述底釉的比重为1.40~1.45,施釉量为40~550g/m2。
6.根据权利要求1所述的制备方法,其特征在于,最高烧成温度为1200~1220℃,烧成周期为40~60分钟。
7.一种由权利要求1至6中任一项所述的制备方法制得的具有石纹浮凸感干粒砖。
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