CN110981427A - 利用废旧陶瓷制得的陶瓷工艺品及其制备方法 - Google Patents
利用废旧陶瓷制得的陶瓷工艺品及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种利用废旧陶瓷制得的陶瓷工艺品及其制备方法,所述利用废旧陶瓷制得的陶瓷工艺品包括以下重量份的原料组成:废旧陶瓷、碳酸盐、改性膨润土、镁基蒙脱土、助熔剂、钠长石、二氧化钛、纳米二氧化锆、滑石粉、硅酸锆和辅料。本发明的利用废旧陶瓷制得的陶瓷工艺品通过精选原料组成,并优化各原料含量,选择了适当配比的改性膨润土和镁基蒙脱土,既充分发挥各自的优点,又相互补充,相互促进,制得的利用废旧陶瓷制得的陶瓷工艺品具有优异的强度和耐磨性能;本发明陶瓷工艺品的制备方法工艺简单,成本低,是经过多段加热和保温后制得的,成品率较高。
Description
技术领域
本发明涉及陶瓷工艺品加工技术领域,具体涉及利用废旧陶瓷制得的陶瓷工艺品及其制备方法。
背景技术
随着陶瓷产业的迅猛发展,陶瓷废料的处理成为一大难题。陶瓷工业中产生的大量废料污染环境,而且废料处理给生产厂家增加了成本。
陶瓷生产的破损率在3%至5%之间。由于陶瓷碎片虽历千年亦难以风化,废弃品难以处理,陶瓷废弃物既加重陶瓷生产企业的环保费用,又增加企业的生产成本。而破损的废陶瓷回收再利用的成本比重新购买陶土生产的成本大,因此多数建陶企业并不愿意对废陶瓷进行回收再利用,在一定程度上造成资源的浪费。
但是,目前所使用的利用废旧陶瓷制得的陶瓷工艺品还存在以下问题:
1、产品稳定性差,极易出现残次品;
2、强度低,耐磨性差;
3、工艺复杂,成本较高。
发明内容
基于上述情况,本发明的目的在于提供利用废旧陶瓷制得的陶瓷工艺品及其制备方法,可有效解决以上问题。
为解决以上技术问题,本发明提供的技术方案是:
利用废旧陶瓷制得的陶瓷工艺品,包括以下重量份的原料组成:废旧陶瓷100~150份、碳酸盐15~25份、改性膨润土15~25份、镁基蒙脱土10~20份、助熔剂10~20份、钠长石15~20份、二氧化钛10~15份、纳米二氧化锆10~15份、滑石粉5~10份、硅酸锆0~5份和辅料10~15份。
优选的,包括以下重量份的原料组成:废旧陶瓷120份、碳酸盐25份、改性膨润土15份、镁基蒙脱土16份、助熔剂18份、钠长石20份、二氧化钛15份、纳米二氧化锆12份、滑石粉8份、硅酸锆2份和辅料12份。
优选的,所述改性膨润土由以下方法制得:将膨润土在350~500℃下煅烧3~5小时,冷却后放入20~30%碳酸氢钠溶液中浸泡2~3小时,过滤后用纯净水洗净,再放入15~25%醋酸溶液中浸泡1~2小时,过滤后用纯净水洗净,烘干粉碎至100~150目;再加入相当于膨润土重量35~40%的高温砂、12~20%的长石粉、3~5%的碳化钨粉,混合搅拌30~40分钟,然后再加入相当于膨润土重量10~15%的硅烷偶联剂,搅拌40~60分钟,即得。
优选的,所述辅料为增强剂或减水剂。
更优选的,所述增强剂选自硫酸钠、十水四硼酸钠和硫酸钙中的一种或多种。
更优选的,所述减水剂为偏硅酸钠。
优选的,所述碳酸盐选自碳酸三钙、碳酸钡、碳酸镁和碳酸锌中的一种或多种。
优选的,所述助熔剂为石灰石、方解石、透辉石、硅灰石、白云石、滑石的一种或多种。
本发明提供了一种利用废旧陶瓷制得的陶瓷工艺品的制备方法,包括下列步骤:
1)将废旧陶瓷洗净干燥后,置于球磨机中球磨至粒径为130~150目,加入相当于废旧陶瓷重量35~40%的5~10%的盐酸溶液,过滤洗净,再向其加入相当于废旧陶瓷重量50~60%的5~15%的碳酸氢钠溶液,过滤洗净,于200~250℃烘干,得废旧陶瓷处理料;
2)按重量份分别称取废旧陶瓷处理料、碳酸盐、改性膨润土、镁基蒙脱土、助熔剂和长石后混合搅拌均匀,研磨至粒径为500-700目,得研磨料;
3)按重量份分别称取二氧化钛、纳米二氧化锆、滑石粉、硅酸锆和辅料混合搅拌均匀,研磨至粒径为600-750目,再与步骤2所得研磨料加水混合均匀后,得含水量为15~20%的混合料;
4)将混合料置于成型机中,压制成型,得成型生坯;
5)将成型生坯置于窑炉内,烧制加热处理后,得高强度抗裂陶质工艺品。
优选的,所述烧制加热的过程包括:预热段,升温至250℃,预热30~45分钟;加热段,继续升温至950~1200℃,加热2~3小时;保温段,控温为1200±20℃,时长30~60分钟。
本发明与现有技术相比,具有以下优点及有益效果:
本发明的利用废旧陶瓷制得的陶瓷工艺品通过精选原料组成,并优化各原料含量,选择了适当配比的改性膨润土和镁基蒙脱土,既充分发挥各自的优点,又相互补充,相互促进,制得的利用废旧陶瓷制得的陶瓷工艺品具有优异的强度和耐磨性能。
本发明的利用废旧陶瓷制得的陶瓷工艺品中添加了适当比例的助熔剂,能够快速将废旧陶瓷与其他各原料充分混和均匀,与其他组分相互配合,起到良好的协同作用,使本发明的利用废旧陶瓷制得的陶瓷工艺品的强度大大提升。
本发明的利用废旧陶瓷制得的陶瓷工艺品的原料中,添加了适当比例的辅料,其具有增强各原料之间粘接力的特点,在本发明的利用废旧陶瓷制得的陶瓷工艺品的原料体系中相容性良好,与其他组分相互配合,起到良好的协同作用,使本发明的利用废旧陶瓷制得的陶瓷工艺品的成品率得到提升,不易开裂。
本发明的利用废旧陶瓷制得的陶瓷工艺品的原料中,添加了适当比例的纳米二氧化锆,其可以均匀填充在陶瓷工艺品孔隙中,与其他组分相互配合,起到良好的协同作用,消除气孔有助于提高烧结致密度,使本发明的利用废旧陶瓷制得的陶瓷工艺品的抗震性能和强度得到较大提升。
本发明的制备方法,工艺简单,成本低,是经过多段加热和保温后制得的,成品率较高,陶瓷在烧制的过程中,不易产生气孔或变形,制得的陶瓷工艺品粘接性好,强度高,节省了人力和设备成本。
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的优选实施方案进行描述,但是不能理解为对本专利的限制。
下述实施例中所述试验方法或测试方法,如无特殊说明,均为常规方法;所述试剂和材料,如无特殊说明,均从常规商业途径获得,或以常规方法制备。
本发明所述的硅烷偶联剂为A151(乙烯基三乙氧基硅烷)、A171(乙烯基三甲氧基硅烷)和A172(乙烯基三(β-甲氧乙氧基)硅烷)中的一种。
实施例1:
利用废旧陶瓷制得的陶瓷工艺品,包括以下重量份的原料组成:废旧陶瓷100~150份、碳酸盐15~25份、改性膨润土15~25份、镁基蒙脱土10~20份、助熔剂10~20份、钠长石15~20份、二氧化钛10~15份、纳米二氧化锆10~15份、滑石粉5~10份、硅酸锆0~5份和辅料10~15份。
优选的,包括以下重量份的原料组成:废旧陶瓷120份、碳酸盐25份、改性膨润土15份、镁基蒙脱土16份、助熔剂18份、钠长石20份、二氧化钛15份、纳米二氧化锆12份、滑石粉8份、硅酸锆2份和辅料12份。
优选的,所述改性膨润土由以下方法制得:将膨润土在350~500℃下煅烧3~5小时,冷却后放入20~30%碳酸氢钠溶液中浸泡2~3小时,过滤后用纯净水洗净,再放入15~25%醋酸溶液中浸泡1~2小时,过滤后用纯净水洗净,烘干粉碎至100~150目;再加入相当于膨润土重量35~40%的高温砂、12~20%的长石粉、3~5%的碳化钨粉,混合搅拌30~40分钟,然后再加入相当于膨润土重量10~15%的硅烷偶联剂,搅拌40~60分钟,即得。
优选的,所述辅料为增强剂或减水剂。
更优选的,所述增强剂选自硫酸钠、十水四硼酸钠和硫酸钙中的一种或多种。
更优选的,所述减水剂为偏硅酸钠。
优选的,所述碳酸盐选自碳酸三钙、碳酸钡、碳酸镁和碳酸锌中的一种或多种。
优选的,所述助熔剂为石灰石、方解石、透辉石、硅灰石、白云石、滑石的一种或多种。
本实施例提供了一种利用废旧陶瓷制得的陶瓷工艺品的制备方法,包括下列步骤:
1)将废旧陶瓷洗净干燥后,置于球磨机中球磨至粒径为130~150目,加入相当于废旧陶瓷重量35~40%的5~10%的盐酸溶液,过滤洗净,再向其加入相当于废旧陶瓷重量50~60%的5~15%的碳酸氢钠溶液,过滤洗净,于200~250℃烘干,得废旧陶瓷处理料;
2)按重量份分别称取废旧陶瓷处理料、碳酸盐、改性膨润土、镁基蒙脱土、助熔剂和长石后混合搅拌均匀,研磨至粒径为500-700目,得研磨料;
3)按重量份分别称取二氧化钛、纳米二氧化锆、滑石粉、硅酸锆和辅料混合搅拌均匀,研磨至粒径为600-750目,再与步骤2所得研磨料加水混合均匀后,得含水量为15~20%的混合料;
4)将混合料置于成型机中,压制成型,得成型生坯;
5)将成型生坯置于窑炉内,烧制加热处理后,得高强度抗裂陶质工艺品。
优选的,所述烧制加热的过程包括:预热段,升温至250℃,预热30~45分钟;加热段,继续升温至950~1200℃,加热2~3小时;保温段,控温为1200±20℃,时长30~60分钟。
实施例2:
利用废旧陶瓷制得的陶瓷工艺品,包括以下重量份的原料组成:废旧陶瓷100份、碳酸盐15份、改性膨润土15份、镁基蒙脱土12份、助熔剂15份、钠长石15份、二氧化钛12份、纳米二氧化锆10份、滑石粉5份、硅酸锆2份和辅料11份。
在本实施例中,所述改性膨润土由以下方法制得:将膨润土在450℃下煅烧4小时,冷却后放入25%碳酸氢钠溶液中浸泡2小时,过滤后用纯净水洗净,再放入20%醋酸溶液中浸泡2小时,过滤后用纯净水洗净,烘干粉碎至130目;再加入相当于膨润土重量35%的高温砂、12%的长石粉、3%的碳化钨粉,混合搅拌30~40分钟,然后再加入相当于膨润土重量10%的硅烷偶联剂,搅拌40~60分钟,即得。
在本实施例中,所述辅料为增强剂或减水剂。
在本实施例中,所述增强剂选自硫酸钠、十水四硼酸钠和硫酸钙中的一种或多种。
在本实施例中,所述减水剂为偏硅酸钠。
在本实施例中,所述碳酸盐选自碳酸三钙、碳酸钡、碳酸镁和碳酸锌中的一种或多种。
在本实施例中,所述助熔剂为石灰石、方解石、透辉石、硅灰石、白云石、滑石的一种或多种。
本实施例提供了一种利用废旧陶瓷制得的陶瓷工艺品的制备方法,包括下列步骤:
1)将废旧陶瓷洗净干燥后,置于球磨机中球磨至粒径为130~150目,加入相当于废旧陶瓷重量35%的5%的盐酸溶液,过滤洗净,再向其加入相当于废旧陶瓷重量50%的10%的碳酸氢钠溶液,过滤洗净,于200~250℃烘干,得废旧陶瓷处理料;
2)按重量份分别称取废旧陶瓷处理料、碳酸盐、改性膨润土、镁基蒙脱土、助熔剂和长石后混合搅拌均匀,研磨至粒径为600目,得研磨料;
3)按重量份分别称取二氧化钛、纳米二氧化锆、滑石粉、硅酸锆和辅料混合搅拌均匀,研磨至粒径为700目,再与步骤2所得研磨料加水混合均匀后,得含水量为15%的混合料;
4)将混合料置于成型机中,压制成型,得成型生坯;
5)将成型生坯置于窑炉内,烧制加热处理后,得高强度抗裂陶质工艺品。
在本实施例中,所述烧制加热的过程包括:预热段,升温至250℃,预热30~45分钟;加热段,继续升温至950~1200℃,加热2~3小时;保温段,控温为1200±20℃,时长30~60分钟。
实施例3:
利用废旧陶瓷制得的陶瓷工艺品,包括以下重量份的原料组成:废旧陶瓷120份、碳酸盐20份、改性膨润土17份、镁基蒙脱土15份、助熔剂16份、钠长石15份、二氧化钛12份、纳米二氧化锆12份、滑石粉7份、硅酸锆2份和辅料12份。
在本实施例中,所述改性膨润土由以下方法制得:将膨润土在450℃下煅烧4小时,冷却后放入25%碳酸氢钠溶液中浸泡2小时,过滤后用纯净水洗净,再放入20%醋酸溶液中浸泡2小时,过滤后用纯净水洗净,烘干粉碎至130目;再加入相当于膨润土重量35%的高温砂、12%的长石粉、3%的碳化钨粉,混合搅拌30~40分钟,然后再加入相当于膨润土重量10%的硅烷偶联剂,搅拌40~60分钟,即得。
在本实施例中,所述辅料为增强剂或减水剂。
在本实施例中,所述增强剂选自硫酸钠、十水四硼酸钠和硫酸钙中的一种或多种。
在本实施例中,所述减水剂为偏硅酸钠。
在本实施例中,所述碳酸盐选自碳酸三钙、碳酸钡、碳酸镁和碳酸锌中的一种或多种。
在本实施例中,所述助熔剂为石灰石、方解石、透辉石、硅灰石、白云石、滑石的一种或多种。
本实施例提供了一种利用废旧陶瓷制得的陶瓷工艺品的制备方法,包括下列步骤:
1)将废旧陶瓷洗净干燥后,置于球磨机中球磨至粒径为130~150目,加入相当于废旧陶瓷重量35%的5%的盐酸溶液,过滤洗净,再向其加入相当于废旧陶瓷重量50%的10%的碳酸氢钠溶液,过滤洗净,于200~250℃烘干,得废旧陶瓷处理料;
2)按重量份分别称取废旧陶瓷处理料、碳酸盐、改性膨润土、镁基蒙脱土、助熔剂和长石后混合搅拌均匀,研磨至粒径为600目,得研磨料;
3)按重量份分别称取二氧化钛、纳米二氧化锆、滑石粉、硅酸锆和辅料混合搅拌均匀,研磨至粒径为700目,再与步骤2所得研磨料加水混合均匀后,得含水量为15%的混合料;
4)将混合料置于成型机中,压制成型,得成型生坯;
5)将成型生坯置于窑炉内,烧制加热处理后,得高强度抗裂陶质工艺品。
在本实施例中,所述烧制加热的过程包括:预热段,升温至250℃,预热30~45分钟;加热段,继续升温至950~1200℃,加热2~3小时;保温段,控温为1200±20℃,时长30~60分钟。
实施例4:
利用废旧陶瓷制得的陶瓷工艺品,包括以下重量份的原料组成:废旧陶瓷140份、碳酸盐25份、改性膨润土20份、镁基蒙脱土18份、助熔剂15份、钠长石17份、二氧化钛10份、纳米二氧化锆10份、滑石粉7份、硅酸锆4份和辅料15份。
在本实施例中,所述改性膨润土由以下方法制得:将膨润土在450℃下煅烧4小时,冷却后放入25%碳酸氢钠溶液中浸泡2小时,过滤后用纯净水洗净,再放入20%醋酸溶液中浸泡2小时,过滤后用纯净水洗净,烘干粉碎至130目;再加入相当于膨润土重量35%的高温砂、12%的长石粉、3%的碳化钨粉,混合搅拌30~40分钟,然后再加入相当于膨润土重量10%的硅烷偶联剂,搅拌40~60分钟,即得。
在本实施例中,所述辅料为增强剂或减水剂。
在本实施例中,所述增强剂选自硫酸钠、十水四硼酸钠和硫酸钙中的一种或多种。
在本实施例中,所述减水剂为偏硅酸钠。
在本实施例中,所述碳酸盐选自碳酸三钙、碳酸钡、碳酸镁和碳酸锌中的一种或多种。
在本实施例中,所述助熔剂为石灰石、方解石、透辉石、硅灰石、白云石、滑石的一种或多种。
本实施例提供了一种利用废旧陶瓷制得的陶瓷工艺品的制备方法,包括下列步骤:
1)将废旧陶瓷洗净干燥后,置于球磨机中球磨至粒径为130~150目,加入相当于废旧陶瓷重量35%的5%的盐酸溶液,过滤洗净,再向其加入相当于废旧陶瓷重量50%的10%的碳酸氢钠溶液,过滤洗净,于200~250℃烘干,得废旧陶瓷处理料;
2)按重量份分别称取废旧陶瓷处理料、碳酸盐、改性膨润土、镁基蒙脱土、助熔剂和长石后混合搅拌均匀,研磨至粒径为600目,得研磨料;
3)按重量份分别称取二氧化钛、纳米二氧化锆、滑石粉、硅酸锆和辅料混合搅拌均匀,研磨至粒径为700目,再与步骤2所得研磨料加水混合均匀后,得含水量为15%的混合料;
4)将混合料置于成型机中,压制成型,得成型生坯;
5)将成型生坯置于窑炉内,烧制加热处理后,得高强度抗裂陶质工艺品。
在本实施例中,所述烧制加热的过程包括:预热段,升温至250℃,预热30~45分钟;加热段,继续升温至950~1200℃,加热2~3小时;保温段,控温为1200±20℃,时长30~60分钟。
对比例1:
与实施例4的区别在于,废旧陶瓷未经过处理,其他与实施例4相同。
对比例2:
与实施例4的区别在于,没有镁基蒙脱土,其他与实施例4相同。
对比例3:
与实施例4的区别在于,使用未改性的膨润土,其他与实施例4相同。
对比例4:
与实施例4的区别在于,没有纳米二氧化锆,其他与实施例4相同。
对比例5:
与实施例4的区别在于,不添加助熔剂,其他与实施例4相同。
对比例6:
与实施例4的区别在于,不添加辅料,其他与实施例4相同。
下面对本发明实施例2至实施例4、对比例1至对比例6得到的利用废旧陶瓷制得的陶瓷工艺品以及利用现有配方工艺制得的普通废旧陶瓷工艺品进行性能测试,测试结果如表1所示:
表1
从上表分析可知,对比例1和实施例4对比可知:废旧陶瓷经过处理后,与其他组分相互配合,起到良好的协同作用,使本发明利用废旧陶瓷制得的陶瓷工艺品的次品率大大降低。
从上表分析可知,对比例2、5和6分别与实施例4对比可知:添加适当比例的镁基蒙脱土、助熔剂或辅料,与其他组分相互配合,起到良好的协同作用,使本发明的利用废旧陶瓷制得的陶瓷工艺品的强度得到增强。
从上表分析可知,对比例3和实施例4对比可知:添加适当比例的改性膨润土,与其他组分相互配合,起到良好的协同作用,使本发明的利用废旧陶瓷制得的陶瓷工艺品强度和耐磨性能均得到提升。
从上表分析可知,对比例4和实施例4对比可知:添加适当比例的纳米二氧化锆,与其他组分相互配合,起到良好的协同作用,使本发明的利用废旧陶瓷制得的陶瓷工艺品的耐磨性能得到提升,同时降低了次品率。
综上所述,本发明的利用废旧陶瓷制得的陶瓷工艺品在各方面性能上表现俱佳,各方面性能相较于普通废旧陶瓷工艺品均具有显著的提升,可大大满足市场的需求,另外在对比下,实施例4制得的利用废旧陶瓷制得的陶瓷工艺品性能最优,其相应的配方用量及制备方法为最佳方案。
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 (10)
1.利用废旧陶瓷制得的陶瓷工艺品,其特征在于,包括以下重量份的原料:废旧陶瓷100~150份、碳酸盐15~25份、改性膨润土15~25份、镁基蒙脱土10~20份、助熔剂10~20份、钠长石15~20份、二氧化钛10~15份、纳米二氧化锆10~15份、滑石粉5~10份、硅酸锆0~5份和辅料10~15份。
2.根据权利要求1所述的利用废旧陶瓷制得的陶瓷工艺品,其特征在于,包括以下重量份的原料:废旧陶瓷120份、碳酸盐25份、改性膨润土15份、镁基蒙脱土16份、助熔剂18份、钠长石20份、二氧化钛15份、纳米二氧化锆12份、滑石粉8份、硅酸锆2份和辅料12份。
3.根据权利要求1所述的利用废旧陶瓷制得的陶瓷工艺品,其特征在于,所述改性膨润土由以下方法制得:将膨润土在350~500℃下煅烧3~5小时,冷却后放入20~30%碳酸氢钠溶液中浸泡2~3小时,过滤后用纯净水洗净,再放入15~25%醋酸溶液中浸泡1~2小时,过滤后用纯净水洗净,烘干粉碎至100~150目;再加入相当于膨润土重量35~40%的高温砂、12~20%的长石粉、3~5%的碳化钨粉,混合搅拌30~40分钟,然后再加入相当于膨润土重量10~15%的硅烷偶联剂,搅拌40~60分钟,即得。
4.根据权利要求1所述的利用废旧陶瓷制得的陶瓷工艺品,其特征在于,所述辅料为增强剂或减水剂。
5.根据权利要求4所述的利用废旧陶瓷制得的陶瓷工艺品,其特征在于,所述增强剂选自硫酸钠、十水四硼酸钠和硫酸钙中的一种或多种。
6.根据权利要求4所述的利用废旧陶瓷制得的陶瓷工艺品,其特征在于,所述减水剂为偏硅酸钠。
7.根据权利要求1所述的利用废旧陶瓷制得的陶瓷工艺品,其特征在于,所述碳酸盐选自碳酸三钙、碳酸钡、碳酸镁和碳酸锌中的一种或多种。
8.根据权利要求1所述的利用废旧陶瓷制得的陶瓷工艺品,其特征在于,所述助熔剂为石灰石、方解石、透辉石、硅灰石、白云石、滑石的一种或多种。
9.一种如权利要求1至8任一项所述的利用废旧陶瓷制得的陶瓷工艺品的制备方法,其特征在于,包括下列步骤:
1)将废旧陶瓷洗净干燥后,置于球磨机中球磨至粒径为130~150目,加入相当于废旧陶瓷重量35~40%的5~10%的盐酸溶液,过滤洗净,再向其加入相当于废旧陶瓷重量50~60%的5~15%的碳酸氢钠溶液,过滤洗净,于200~250℃烘干,得废旧陶瓷处理料;
2)按重量份分别称取废旧陶瓷处理料、碳酸盐、改性膨润土、镁基蒙脱土、助熔剂和钠长石后混合搅拌均匀,研磨至粒径为500-700目,得研磨料;
3)按重量份分别称取二氧化钛、纳米二氧化锆、滑石粉、硅酸锆和辅料混合搅拌均匀,研磨至粒径为600-750目,再与步骤2所得研磨料加水混合均匀后,得含水量为15~20%的混合料;
4)将混合料置于成型机中,压制成型,得成型生坯;
5)将成型生坯置于窑炉内,烧制加热处理后,得高强度抗裂陶质工艺品。
10.根据权利要求9所述的利用废旧陶瓷制得的陶瓷工艺品的制备方法,其特征在于,所述烧制加热的过程包括:预热段,升温至250℃,预热30~45分钟;加热段,继续升温至950~1200℃,加热2~3小时;保温段,控温为1200±20℃,时长30~60分钟。
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