CN113402258A - Building ceramic plate/brick and preparation method thereof - Google Patents
Building ceramic plate/brick and preparation method thereof Download PDFInfo
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- CN113402258A CN113402258A CN202110806954.1A CN202110806954A CN113402258A CN 113402258 A CN113402258 A CN 113402258A CN 202110806954 A CN202110806954 A CN 202110806954A CN 113402258 A CN113402258 A CN 113402258A
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- brick
- ceramic plate
- building ceramic
- wollastonite
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- 239000000919 ceramic Substances 0.000 title claims abstract description 93
- 239000011449 brick Substances 0.000 title claims abstract description 72
- 238000002360 preparation method Methods 0.000 title claims abstract description 10
- 239000010456 wollastonite Substances 0.000 claims abstract description 87
- 229910052882 wollastonite Inorganic materials 0.000 claims abstract description 87
- 239000000463 material Substances 0.000 claims abstract description 66
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 54
- 239000000835 fiber Substances 0.000 claims abstract description 50
- 239000002994 raw material Substances 0.000 claims abstract description 46
- 239000000654 additive Substances 0.000 claims abstract description 38
- 230000000996 additive effect Effects 0.000 claims abstract description 29
- 238000004519 manufacturing process Methods 0.000 claims abstract description 21
- 239000004033 plastic Substances 0.000 claims abstract description 15
- 239000012744 reinforcing agent Substances 0.000 claims abstract description 12
- 239000003638 chemical reducing agent Substances 0.000 claims abstract description 10
- 238000010304 firing Methods 0.000 claims description 70
- 239000000292 calcium oxide Substances 0.000 claims description 36
- 239000002002 slurry Substances 0.000 claims description 35
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 33
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims description 30
- 229910052593 corundum Inorganic materials 0.000 claims description 27
- 239000000126 substance Substances 0.000 claims description 27
- 229910001845 yogo sapphire Inorganic materials 0.000 claims description 27
- 239000000843 powder Substances 0.000 claims description 26
- 238000005245 sintering Methods 0.000 claims description 26
- KKCBUQHMOMHUOY-UHFFFAOYSA-N Na2O Inorganic materials [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 claims description 25
- 238000000034 method Methods 0.000 claims description 21
- 238000002156 mixing Methods 0.000 claims description 21
- 239000006063 cullet Substances 0.000 claims description 18
- 238000001694 spray drying Methods 0.000 claims description 18
- 239000000440 bentonite Substances 0.000 claims description 13
- 229910000278 bentonite Inorganic materials 0.000 claims description 13
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 claims description 13
- 239000011734 sodium Substances 0.000 claims description 13
- 239000005995 Aluminium silicate Substances 0.000 claims description 12
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 12
- 235000012211 aluminium silicate Nutrition 0.000 claims description 12
- 238000001035 drying Methods 0.000 claims description 12
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 12
- WUKWITHWXAAZEY-UHFFFAOYSA-L calcium difluoride Chemical compound [F-].[F-].[Ca+2] WUKWITHWXAAZEY-UHFFFAOYSA-L 0.000 claims description 11
- 229910052731 fluorine Inorganic materials 0.000 claims description 11
- 239000010436 fluorite Substances 0.000 claims description 11
- 229920001495 poly(sodium acrylate) polymer Polymers 0.000 claims description 11
- NNMHYFLPFNGQFZ-UHFFFAOYSA-M sodium polyacrylate Chemical compound [Na+].[O-]C(=O)C=C NNMHYFLPFNGQFZ-UHFFFAOYSA-M 0.000 claims description 11
- 238000000498 ball milling Methods 0.000 claims description 10
- 239000000203 mixture Substances 0.000 claims description 10
- 238000003825 pressing Methods 0.000 claims description 10
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims description 9
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 claims description 9
- 229910052796 boron Inorganic materials 0.000 claims description 9
- 229910052708 sodium Inorganic materials 0.000 claims description 9
- 238000010521 absorption reaction Methods 0.000 claims description 8
- 235000019353 potassium silicate Nutrition 0.000 claims description 7
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 7
- 239000004368 Modified starch Substances 0.000 claims description 6
- 229920000881 Modified starch Polymers 0.000 claims description 6
- 239000004927 clay Substances 0.000 claims description 6
- 229910052681 coesite Inorganic materials 0.000 claims description 6
- 229910052906 cristobalite Inorganic materials 0.000 claims description 6
- 235000019426 modified starch Nutrition 0.000 claims description 6
- 239000000377 silicon dioxide Substances 0.000 claims description 6
- 229910052682 stishovite Inorganic materials 0.000 claims description 6
- 229910052905 tridymite Inorganic materials 0.000 claims description 6
- KEZYHIPQRGTUDU-UHFFFAOYSA-N 2-[dithiocarboxy(methyl)amino]acetic acid Chemical compound SC(=S)N(C)CC(O)=O KEZYHIPQRGTUDU-UHFFFAOYSA-N 0.000 claims description 5
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 claims description 5
- 238000000465 moulding Methods 0.000 claims description 5
- 239000011574 phosphorus Substances 0.000 claims description 5
- 229910052698 phosphorus Inorganic materials 0.000 claims description 5
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 claims description 4
- 239000011737 fluorine Substances 0.000 claims description 4
- MOMKYJPSVWEWPM-UHFFFAOYSA-N 4-(chloromethyl)-2-(4-methylphenyl)-1,3-thiazole Chemical compound C1=CC(C)=CC=C1C1=NC(CCl)=CS1 MOMKYJPSVWEWPM-UHFFFAOYSA-N 0.000 claims description 3
- FUJCRWPEOMXPAD-UHFFFAOYSA-N Li2O Inorganic materials [Li+].[Li+].[O-2] FUJCRWPEOMXPAD-UHFFFAOYSA-N 0.000 claims description 3
- 229920002472 Starch Polymers 0.000 claims description 3
- XUCJHNOBJLKZNU-UHFFFAOYSA-M dilithium;hydroxide Chemical compound [Li+].[Li+].[OH-] XUCJHNOBJLKZNU-UHFFFAOYSA-M 0.000 claims description 3
- 239000007788 liquid Substances 0.000 claims description 3
- 229920000609 methyl cellulose Polymers 0.000 claims description 3
- 239000001923 methylcellulose Substances 0.000 claims description 3
- 235000010981 methylcellulose Nutrition 0.000 claims description 3
- 235000019983 sodium metaphosphate Nutrition 0.000 claims description 3
- 235000019832 sodium triphosphate Nutrition 0.000 claims description 3
- 239000008107 starch Substances 0.000 claims description 3
- 235000019698 starch Nutrition 0.000 claims description 3
- -1 synthetic frit Substances 0.000 claims description 2
- 238000005265 energy consumption Methods 0.000 abstract description 10
- 238000013461 design Methods 0.000 abstract description 7
- 239000012784 inorganic fiber Substances 0.000 abstract description 7
- 238000009766 low-temperature sintering Methods 0.000 abstract description 4
- 238000002844 melting Methods 0.000 abstract description 2
- 230000008018 melting Effects 0.000 abstract description 2
- 239000002585 base Substances 0.000 description 49
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 34
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N titanium dioxide Inorganic materials O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 27
- 239000011521 glass Substances 0.000 description 15
- 230000008569 process Effects 0.000 description 15
- 230000006872 improvement Effects 0.000 description 9
- 239000012071 phase Substances 0.000 description 9
- 230000003014 reinforcing effect Effects 0.000 description 9
- 239000011575 calcium Substances 0.000 description 8
- 230000000694 effects Effects 0.000 description 8
- 238000004321 preservation Methods 0.000 description 8
- 229910052791 calcium Inorganic materials 0.000 description 7
- 239000001506 calcium phosphate Substances 0.000 description 7
- 229910000389 calcium phosphate Inorganic materials 0.000 description 7
- 235000011010 calcium phosphates Nutrition 0.000 description 7
- 238000005034 decoration Methods 0.000 description 7
- 238000007641 inkjet printing Methods 0.000 description 7
- 238000010020 roller printing Methods 0.000 description 7
- 238000007650 screen-printing Methods 0.000 description 7
- QORWJWZARLRLPR-UHFFFAOYSA-H tricalcium bis(phosphate) Chemical compound [Ca+2].[Ca+2].[Ca+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O QORWJWZARLRLPR-UHFFFAOYSA-H 0.000 description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 239000010881 fly ash Substances 0.000 description 6
- 238000001816 cooling Methods 0.000 description 5
- 239000002241 glass-ceramic Substances 0.000 description 5
- 238000005406 washing Methods 0.000 description 5
- 230000009286 beneficial effect Effects 0.000 description 4
- 230000004907 flux Effects 0.000 description 4
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 3
- 238000005520 cutting process Methods 0.000 description 3
- 238000011161 development Methods 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 239000011591 potassium Substances 0.000 description 3
- 229910052700 potassium Inorganic materials 0.000 description 3
- 239000011435 rock Substances 0.000 description 3
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 2
- CSNNHWWHGAXBCP-UHFFFAOYSA-L Magnesium sulfate Chemical compound [Mg+2].[O-][S+2]([O-])([O-])[O-] CSNNHWWHGAXBCP-UHFFFAOYSA-L 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 239000003513 alkali Substances 0.000 description 2
- CNLWCVNCHLKFHK-UHFFFAOYSA-N aluminum;lithium;dioxido(oxo)silane Chemical compound [Li+].[Al+3].[O-][Si]([O-])=O.[O-][Si]([O-])=O CNLWCVNCHLKFHK-UHFFFAOYSA-N 0.000 description 2
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 239000013078 crystal Substances 0.000 description 2
- 238000009837 dry grinding Methods 0.000 description 2
- 230000005496 eutectics Effects 0.000 description 2
- 239000007791 liquid phase Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 229910052573 porcelain Inorganic materials 0.000 description 2
- 230000002787 reinforcement Effects 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 229910052642 spodumene Inorganic materials 0.000 description 2
- 238000001238 wet grinding Methods 0.000 description 2
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 229910052891 actinolite Inorganic materials 0.000 description 1
- 229910052656 albite Inorganic materials 0.000 description 1
- 229910052788 barium Inorganic materials 0.000 description 1
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 1
- 229910021538 borax Inorganic materials 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- GUJOJGAPFQRJSV-UHFFFAOYSA-N dialuminum;dioxosilane;oxygen(2-);hydrate Chemical compound O.[O-2].[O-2].[O-2].[Al+3].[Al+3].O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O GUJOJGAPFQRJSV-UHFFFAOYSA-N 0.000 description 1
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 239000010440 gypsum Substances 0.000 description 1
- 229910052602 gypsum Inorganic materials 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 1
- YOBAEOGBNPPUQV-UHFFFAOYSA-N iron;trihydrate Chemical compound O.O.O.[Fe].[Fe] YOBAEOGBNPPUQV-UHFFFAOYSA-N 0.000 description 1
- 239000002932 luster Substances 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 229910052943 magnesium sulfate Inorganic materials 0.000 description 1
- 235000019341 magnesium sulphate Nutrition 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 229910052901 montmorillonite Inorganic materials 0.000 description 1
- 238000010137 moulding (plastic) Methods 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 238000009702 powder compression Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 230000035484 reaction time Effects 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 229910021487 silica fume Inorganic materials 0.000 description 1
- 229910052604 silicate mineral Inorganic materials 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 239000004328 sodium tetraborate Substances 0.000 description 1
- 235000010339 sodium tetraborate Nutrition 0.000 description 1
- 239000002689 soil Substances 0.000 description 1
- 239000007790 solid phase Substances 0.000 description 1
- 230000002195 synergetic effect Effects 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 description 1
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- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/13—Compounding ingredients
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- C04B33/00—Clay-wares
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- C04B33/00—Clay-wares
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- C04B33/00—Clay-wares
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- C04B33/00—Clay-wares
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- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
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- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
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- C04B2235/44—Metal salt constituents or additives chosen for the nature of the anions, e.g. hydrides or acetylacetonate
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
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Abstract
The invention discloses a building ceramic plate/brick which is prepared from a base material and an additive, wherein the base material comprises 5-25 wt% of a plastic raw material, 40-60 wt% of a fluxing raw material and 25-45 wt% of wollastonite and/or wollastonite fiber; relative to the base material, the addition amount of the additive is 0.01-6 wt%, and the additive comprises one or a combination of an organic reinforcing agent and a water reducing agent. Correspondingly, the invention also discloses a preparation method of the building ceramic plate/brick. According to the invention, through the formula design, wollastonite and/or wollastonite fibers are introduced into the blank to reinforce and toughen, and meanwhile, low-temperature fluxing raw materials are introduced to realize low-temperature sintering and avoid the failure of inorganic fibers in high-temperature melting, so that the product performance is obviously improved, and the energy consumption and the production cost are reduced.
Description
Technical Field
The invention relates to the technical field of building ceramic materials, in particular to a building ceramic plate/brick suitable for ceramic tiles and decorative panels of houses, furniture and cabinets and a manufacturing method thereof.
Background
In the last two years, the building ceramic tiles are accelerated to transform and develop towards ceramic plates, and the building ceramic tiles gradually develop markets towards the fields of stones, houses, furniture and cabinet veneers. In 2020, more than 80 ceramic enterprises have increased 112 ceramic rock plate production lines in China. However, the ceramic plate is generally used as a veneer for home furnishing, furniture and cabinets, and has the problems of processing, cutting and high production energy consumption, and the two problems seriously restrict the development of the industry. In the prior art, the firing temperature of the ceramic plate/brick is about 1210 ℃, the breaking strength is about 40-60 MPa, the fracture toughness is about 1-1.5, and obvious defects and shortcomings exist in the aspects of products and technology.
The prior art 1 is a Chinese patent publication No. CN106977176A, a method for low-temperature sintering ceramic tiles by using high-calcium fly ash, which discloses a method for low-temperature sintering ceramic tiles by using high-calcium fly ash, comprising the following steps: 1) adding high calcium fly ash into 40-150g/L soluble alkali solution system, with reaction temperature of 50-200 deg.C, liquid-solid ratio of 2-8, and reaction time of 0.5-2 h; 2) filtering and washing the slurry reacted in the step 1), and obtaining filter residue which is high-calcium fly ash with a modified surface; 3) mixing the surface-modified high-calcium fly ash with clay and flux raw materials, adding water, mixing and grinding to obtain slurry after wet grinding, or dry grinding without adding water; 4) drying and granulating the slurry subjected to wet grinding in the step 3) into spherical powder with water content of 5-10% and a certain granularity, or adding water into the powder obtained after dry grinding in the step 3) and granulating into spherical powder with water content of 5-10% and a certain granularity, and feeding the spherical powder into a bin for staling for later use; 5) forming the spherical powder in the step 4) in a mould, and drying to obtain a ceramic tile green body; 6) heating, preserving heat and cooling the ceramic tile green blank obtained in the step 5) to obtain the ceramic tile.
Wherein the firing temperature range when firing the ceramic brick is 900-1100 ℃, the firing temperature range when firing the ceramic brick is 1000-1200 ℃, and the flux raw material comprises wollastonite raw material.
For the porcelain brick of the invention, the firing temperature of the prior art 1 is more than 1000 ℃, and the main component of the porcelain brick is high-calcium fly ash which needs to be added into a soluble alkali solution system for modification, and then a low-temperature firing process can be matched. The ceramic brick obtained by firing in the prior art 1 has the water absorption of less than 0.5 percent, the breaking strength of about 35MPa and the linear shrinkage of less than 20 percent, and can not meet the performance requirements of ceramic rock boards.
The prior art 2 is a chinese patent publication No. CN107555947B "a one-time low-temperature fast-firing light ceramic product and a manufacturing process thereof", which discloses a one-time low-temperature fast-firing light ceramic product, comprising a green body and a glaze layer applied on the surface of the green body, wherein the green body comprises the following raw materials in parts by weight: 35-40 parts of kaolin, 25-30 parts of wollastonite, 20-25 parts of Datong soil, 15-20 parts of bentonite, 15-20 parts of albite, 10-15 parts of silica fume, 8-10 parts of borocalcite, 5-8 parts of basalt, 5-8 parts of spodumene, 3-7 parts of mullite and 1-3 parts of borax; the glaze layer comprises the following raw materials in parts by weight: 20-25 parts of kaolin, 20-25 parts of wollastonite, 15-20 parts of montmorillonite, 10-15 parts of zirconia, 8-12 parts of zirconium silicate, 5-8 parts of magnesium sulfate, 5-8 parts of glass fiber, 5-8 parts of talc, 3-6 parts of gypsum, 1-3 parts of spodumene, 1-4 parts of fluorite and 1-3 parts of actinolite. The preparation method comprises the following steps: shaping the blank body pug to obtain a rough blank, and benefiting the blank to obtain a blank body; mixing glaze layer raw materials to obtain glaze layer slurry, adjusting the solid content of the glaze layer slurry and removing bubbles in vacuum to obtain glaze water, glazing the blank body by using the glaze water, and finally firing for 3-8 hours at the temperature of 1000-1050 ℃ to obtain the primary low-temperature fast-fired light ceramic product.
In the ceramic product of the prior art 2, kaolin, wollastonite and kaolin are used as main aggregates in the raw materials of the green body, and the ceramic product has excellent viscosity and lays a foundation for one-time firing of ceramic. The wollastonite is utilized to greatly reduce the firing temperature of the ceramic product, improve the mechanical property of the fired ceramic product, reduce the crack and the warpage of the ceramic product and improve the strength of a blank. However, the wollastonite in the prior art 2 is used in an amount of about 13 to 20% in terms of weight percent, in an amount of 25 to 30 parts. In addition, the plastic raw materials are more, the fluxing raw materials are less, and a large amount of kaolin, clay, bentonite and the like, and alumina (Al) thereof are adopted in the actual production2O3) The content of wollastonite is far more than 10%, so that the sintering temperature is inevitably higher (actually, the sintering temperature is 1000-1050 ℃), and wollastonite in the wollastonite is melted at high temperature due to the higher sintering temperature, so that the reinforcing and toughening effects are lost. In addition, the adding amount of the wollastonite in the formula is only 13-20%, and even if the wollastonite is not dissolved at high temperature, the whole sintered body is not sufficiently strengthened and toughened, and the cutting-caused cracking cannot be sufficiently resisted. In addition, the product molding method referred to in this patent is plastic molding. Therefore, the product related to the prior art 2 has low breaking strength and fracture toughness, and cannot meet the performance requirements of the ceramic rock plate.
Disclosure of Invention
The invention aims to solve the technical problem of providing a building ceramic plate/brick which can improve the product performance and reduce the energy consumption and the production cost.
The technical problem to be solved by the invention is to provide a preparation method of a building ceramic plate/brick, which has simple process and strong practicability, and can improve the product performance and reduce the energy consumption and the production cost.
In order to achieve the technical effects, the invention provides a building ceramic plate/brick which is prepared from a base material and an additive, wherein the base material comprises 5-25 wt% of a plastic raw material, 40-60 wt% of a fluxing raw material and 25-45 wt% of wollastonite and/or wollastonite fiber;
relative to the base material, the addition amount of the additive is 0.01-6 wt%, and the additive comprises one or a combination of an organic reinforcing agent and a water reducing agent.
As an improvement of the scheme, the chemical components comprise the following components in percentage by mass:
SiO2 45～75％、Na2O+K2O 3～10％、Al2O3 2～9％、Fe2O3 0.01～9％、P2O5 0～8％、F 0.5～5％、CaO+MgO+ZnO+BaO+SrO 15～33％。
as an improvement of the scheme, the chemical components comprise the following components in percentage by mass:
SiO2 45～75％、Na2O+K2O 3～10％、Al2O3 2～9％、Fe2O3 0.01～9％、P2O5 0～8％、F 0.5～5％、CaO+MgO+ZnO+BaO+SrO 15～33％、B2O3 0.1～6％、Li2O 0.1-1％。
as an improvement of the scheme, relative to the base material, the addition amount of the organic reinforcing agent is 0-4 wt%, and the addition amount of the water reducing agent is 0.01-2.0 wt%.
As an improvement of the scheme, the plastic raw material is one or a combination of clay, kaolin, bentonite, black mud, mixed mud and washing mud;
the fluxing raw material is one or the combination of cullet, synthetic frit, fluorite, boron-containing calcined material, phosphorus-containing calcined material or fluorine-containing calcined material;
the organic reinforcing agent is one or the combination of methyl cellulose, starch, modified starch and sodium polyacrylate;
the water reducing agent is one or the combination of sodium tripolyphosphate, water glass, sodium metasilicate pentahydrate, sodium metaphosphate, sodium humate and hydrated liquid sodium polyacrylate.
As an improvement of the scheme, the diameter of the wollastonite fiber is 1-20 μm, the length of the wollastonite fiber is 5-200 μm, and the length-diameter ratio of the wollastonite fiber is 5-20.
As an improvement of the scheme, the water absorption of the building ceramic plate/brick is less than 0.5%, the firing temperature is 800-980 ℃, the breaking strength is more than or equal to 80MPa, and the fracture toughness is 1.82-2.93.
Correspondingly, the invention also discloses a preparation method of the building ceramic plate/brick, which comprises the following steps:
(1) adding the base material and the additive of the building ceramic plate/brick according to the proportion, and performing ball milling and mixing by taking water as a medium to obtain slurry;
(2) carrying out spray drying on the slurry to prepare powder with the water content of 4-9 wt%;
(3) pressing and molding the powder by using a press, and drying to obtain a blank;
(4) and (3) glazing the surface of the blank, and then sintering at 800-980 ℃ to obtain the building ceramic plate/brick.
As an improvement of the scheme, the firing temperature in the step (4) is 820-950 ℃, the heat preservation time at the highest firing temperature is 5-60 min, and the firing period is 15-180 min.
As an improvement of the scheme, the green body obtained in the step (4) is subjected to firing treatment in a roller kiln to obtain the building ceramic plate/brick, wherein the water absorption rate of the building ceramic plate/brick is less than 0.5%, the breaking strength is more than or equal to 80MPa, and the fracture toughness is 1.82-2.93.
As an improvement of the scheme, when the green body in the step (4) is sintered in a roller kiln, the green body is directly placed on a roller rod and moves forward under the driving of the roller rod.
The implementation of the invention has the following beneficial effects:
according to the invention, through the formula design, wollastonite and/or wollastonite fibers are introduced into the blank, and the wollastonite and/or wollastonite fibers are added in a large amount, so that the reinforcement and toughening can be effectively carried out, and the problem of ceramic plate/brick cutting crack is greatly relieved and even fundamentally solved; meanwhile, by introducing low-temperature fluxing raw materials into the blank, the ceramic plate/brick can be fired at a low temperature of below 980 ℃, so that the problem that wollastonite and/or wollastonite fibers are/is melted at a high temperature to cause failure is avoided, the production cost is reduced, and the problem of high energy consumption is solved.
The chemical components of the prepared building ceramic plate/brick comprise SiO through the formula design and the specific low-temperature firing conditions2 45～75％、Na2O+K2O 3～10％、Al2O3 2～9％、Fe2O3 0.01～9％、P2O50-8%, F0.5-5%, CaO + MgO + ZnO + BaO + SrO 15-33%. Wherein, the components are matched with each other, the components are all in a specific content range, and the components play a synergistic effect, so that the sintering temperature can be reduced, and the strength of a sintered body can be ensured. Compared with the prior art, the invention has less alumina content, and a small amount of alumina is beneficial to improving the strength of a glass phase, reducing the firing temperature and avoiding wollastonite from being melted.
Through the formula design, the prepared building ceramic plate/brick blank has extremely high viscosity and ideal high-temperature deformation resistance, and the blank can directly walk on a roller rod of a roller kiln without deformation under the high-temperature condition during sintering without a refractory supporting plate, so that bare firing can be realized. In the sintering process, the invention reduces the heat loss caused by the refractory supporting plate, can greatly reduce the energy consumption in the sintering process and reduce the production cost. In addition, the temperature of the green body can be increased more quickly in the firing process by naked firing, and the temperature of the green body is reduced more quickly in the cooling process, so that the firing period is shortened, and the daily output is increased. In addition, the blank body can be heated more uniformly in the firing process by naked firing, and the blank body is cooled more uniformly in the cooling process, so that the finished product rate of the product is improved, and the comprehensive performance index of the product is improved.
The preparation method of the building ceramic plate/brick provided by the invention has the advantages of simple process and low equipment requirement, can greatly save energy consumption, remarkably improves the product performance, and is beneficial to promoting the technical application and development of the building ceramic plate/brick industry.
Drawings
FIG. 1 is a schematic view of the maximum deflection test of the blank of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be described in further detail with reference to the accompanying drawings.
The invention provides a building ceramic plate/brick which is prepared from a base material and an additive, wherein the base material comprises 5-25 wt% of a plastic raw material, 40-60 wt% of a fluxing raw material and 25-45 wt% of wollastonite and/or wollastonite fiber;
relative to the base material, the addition amount of the additive is 0.01-6 wt%, and the additive comprises one or a combination of an organic reinforcing agent and a water reducing agent.
Preferably, the base material comprises 10-20 wt% of plastic raw materials, 45-55 wt% of fluxing raw materials and 28-41 wt% of wollastonite and/or wollastonite fibers; relative to the base material, the addition amount of the additive is 0.01-5 wt%.
Preferably, the base material comprises 15-20 wt% of plastic raw materials, 50-55 wt% of fluxing raw materials and 30-35 wt% of wollastonite and/or wollastonite fibers; relative to the base material, the addition amount of the additive is 0.01-5 wt%.
Through the formula design, wollastonite and/or wollastonite fiber is introduced into the blank to serve as inorganic fiber for reinforcing and toughening, and meanwhile, low-temperature fluxing raw materials are introduced to realize low-temperature sintering and avoid the failure of high-temperature melting of the inorganic fiber, so that the product performance is improved, the energy consumption and the production cost are reduced, and the technical application and development of the building ceramic plate/brick industry are promoted.
Specifically, the building ceramic plate/brick comprises the following chemical components in percentage by mass:
SiO2 45～75％、Na2O+K2O 3～10％、Al2O3 2～9％、Fe2O3 0.01～9％、P2O5 0～8％、F 0.5～5％、CaO+MgO+ZnO+BaO+SrO 15～33％。
SiO of the invention2The high-temperature-resistant glass ceramic is a main component, the ratio of the high-temperature-resistant glass ceramic is up to 45-75%, the high-temperature-resistant glass ceramic is mainly derived from wollastonite, a fluxed raw material and a plastic raw material, the high-temperature-resistant glass ceramic mainly plays a role in improving the high-temperature viscosity and the strength of a glass phase, and the high-temperature-resistant glass ceramic is helpful for protecting the wollastonite from being dissolved by a flux at high temperature. Na (Na)2O+K2O with SiO at high temperature2The reaction is carried out to generate a certain amount of liquid phase, the sintering temperature is reduced, and the sintering of the green body is promoted. The proportion of the organic silicon is 3-10%. Below 3%, the green body is difficult to sinter at low temperature, above 10%, the glass phase strength is low, and the strength of the sintered body is also reduced. Meanwhile, the deformation resistance of the blank at high temperature is poor, so that the blank is softened and deformed at high temperature. CaO in the five oxides of CaO + MgO + ZnO + BaO + SrO is mainly derived from wollastonite, a small amount of fluxing raw materials such as calcium phosphate and fluorite are also derived from the wollastonite, calcium oxide derived from the wollastonite plays a role in reinforcing and toughening fibers in the wollastonite, and MgO, ZnO, BaO and SrO play a role in protecting the wollastonite from being melted and play a role in forming a low eutectic liquid phase together with the calcium oxide and reducing the firing temperature. The proportion of the water-soluble organic solvent is 15-33%. When the content is less than 15%, it is equivalent to that sufficient wollastonite cannot be introduced, and when the content is more than 33%, it is difficult to form a low eutectic phase, and the green body is difficult to sinter, so that the sintering temperature is rather increased. When the firing temperature is increased, the wollastonite is easily melted. In addition, Al2O3、Fe2O3、P2O5And less F, Al2O3 2～9％、Fe2O3 0.01～9％、P2O50 to 8% of F, 0.5 to 5% of F. A small amount of alumina contributes to the strength of the glass phase, and above 9% will increase the firing temperature significantly, causing the wollastonite to be melted. The introduction of iron trioxide is generally undesirable because the higher the iron, the lower the whiteness of the bodies, but a certain amount of iron is inevitably contained in most raw materials at all times. However, when black bricks or colored bricks are manufactured, a certain amount of ferric oxide can be added. However, when the content of iron sesquioxide is more than 9%, the firing temperature is also significantly increased. Therefore, the addition amount is not preferably more than 9%. P2O5And F both play a role in lowering the firing temperature. However, when the amount is too large, the strength of the glass phase is greatly reduced and the viscosity at high temperature is too low, resulting in poor deformation resistance and collapse and softening of the green body at high temperature.
Preferably, the chemical components comprise the following components in percentage by mass:
SiO2 45～75％、Na2O+K2O 3～10％、Al2O3 2～9％、Fe2O3 0.01～9％、P2O5 0～8％、F 0.5～5％、CaO+MgO+ZnO+BaO+SrO 15～33％、B2O3 0.1～6％、Li2O 0-1％。
invention B2O3The content of the boron is limited to 0.1-6%, so that the sintering temperature can be reduced, the high-temperature deformation resistance of the blank can be improved, and when the content of the boron is too high, the high-temperature viscosity is reduced, the glass phase strength is influenced, and the strength and toughness of the product are reduced.
Preferably, relative to the base material, the adding amount of the organic reinforcing agent is 0-4 wt%, and the adding amount of the water reducing agent is 0.01-2.0 wt%.
The plastic raw material mainly plays a role in forming, and endows the green body with wet strength and dry strength after forming, and can be one or a combination of clay, kaolin, bentonite, black mud, mixed mud and washing mud. As the content of iron and titanium contained in the plastic raw materials such as clay and the like is higher, the whiteness is influenced, so that the general whiteness is higher when the adding amount is low. For this reason, when the amount of the moldable material added is small (e.g., 5 wt%), an organic reinforcing agent may be appropriately added instead to improve the green wet strength and dry strength. When the amount of the plastic raw material is large (for example, > 25 wt%), the organic reinforcing agent may be added little or not.
In the scheme, the organic reinforcing agent is an organic high molecular substance dissolved in water, has certain viscosity and certain adhesiveness after being dissolved in water, and can be one or the combination of methyl cellulose, starch, modified starch and sodium polyacrylate. The water reducing agent has the main function of dispergating the slurry, namely the slurry has lower viscosity under the same solid phase concentration, is beneficial to spray drying of the slurry, and can be one or the combination of sodium tripolyphosphate, water glass, sodium metasilicate pentahydrate, sodium metaphosphate, sodium humate and hydrated liquid sodium polyacrylate.
The fluxing raw material of the invention has the function of sintering the green body at low temperature, and simultaneously ensures that the added inorganic fiber is not melted by the flux at high temperature and loses the reinforcing and toughening functions. For this reason, firstly, the green body must be sintered at a temperature below 980 ℃, otherwise, if the temperature is too high and exceeds 980 ℃, oxides such as calcium, magnesium, barium, zinc and the like start to act as fluxing agents, so that the inorganic fibers are melted and the reinforcing and toughening functions are lost; secondly, in order to enable the blank to travel on a roller rod of the roller kiln without deformation at high temperature during sintering, the blank is required to have enough high-temperature deformation resistance, and thus the fluxing raw material is required to have enough high viscosity after being melted at high temperature.
Preferably, in order to ensure that the green body is sintered at a temperature below 980 ℃ and that the green body has a sufficiently high resistance to deformation at high temperatures, it is required that the content of potassium, sodium, phosphorus, and boron in the fluxing agent of the present invention is not too high. Na (Na)2O+K2O＜10％，P2O5＜8％、F＜5％、B2O3Less than 6 percent, because when the content of the potassium, the sodium, the phosphorus, the fluorine and the boron is too high, on one hand, the high-temperature viscosity is obviously reduced, so that the high-temperature deformation resistance of a blank is reduced to cause collapse deformation, and on the other hand, the strength of a glass phase is obviously reduced, so that the strength and the toughness of a product are reduced.
The wollastonite and/or wollastonite fiber plays a role in reinforcing and toughening, and the addition amount of the wollastonite and/or wollastonite fiber is 25-45 wt%, so that uniform mixing is facilitated, and the reinforcing and toughening effects are further improved.
It should be noted that wollastonite belongs to the group of single-chain silicate minerals, and the main component is Ca3Si3O9. The triclinic system is usually a sheet, radial or fibrous aggregate, and has a glass luster and a hardness of 4.5 to 5.0. Wollastonite is a kind of chain metasilicate, and is also a kind of fibrous and needle-like silicate. Because of the special crystal morphology crystal structure, the wollastonite has good insulativity, high whiteness, good dielectric property and high heat resistance and weather resistance. The invention is added withWollastonite and/or wollastonite fiber are/is matched with other raw materials, and play a role in good reinforcement and toughening under a specific firing curve, so that the flexural strength of the building ceramic plate/brick can be greatly increased.
The inorganic fiber of the present invention may be a single wollastonite fiber, or a combination of a wollastonite and a wollastonite fiber. Preferably, the building ceramic plate/brick of the invention is made of wollastonite fiber. Preferably, the building ceramic plate/brick is made of wollastonite fibers with the diameter of 1-20 microns, the length of 5-200 microns and the length-diameter ratio of 5-20. The diameter of the wollastonite fiber is 1 to 20 μm, the length is 5 to 200 μm, and the length-diameter ratio is 5 to 20. Generally, the smaller the diameter of the fiber, the better (the diameter is small enough, and the length-diameter ratio is not too large, such as less than 20, i.e. the whisker), and the synthetic wollastonite fiber or whisker is not generally accepted because of its high cost. The reasonable selection of the length-diameter ratio of the fibers is important, the length-diameter ratio is too small, the fiber toughening has no pull-out effect, the toughening effect is poor, the length-diameter ratio is too large, the fibers are difficult to be uniformly mixed with a matrix, and even the fibers can be agglomerated, so that the toughening effect is also influenced. A large number of experiments prove that when the length-diameter ratio is 5-20, a better reinforcing and toughening effect can be obtained, the strength and toughness of a finished ceramic plate can be greatly improved, and the problem of cutting and cracking of ceramic tiles and plates is solved.
The building ceramic plate/brick is fired at a low temperature, wherein the firing temperature is 800-980 ℃, and 820-950 ℃ is preferred. The ceramic plate/brick is fired at low temperature, so that the problem that inorganic fibers are melted at high temperature to lose effectiveness is avoided, the production cost is reduced, and the problem of high energy consumption is solved. The water absorption rate of the building ceramic plate/brick obtained after firing is less than 0.5%, the breaking strength is more than or equal to 80MPa, and the fracture toughness is 1.82-2.93. Preferably, the water absorption rate of the building ceramic plate/brick is less than 0.4%, the breaking strength is 80-150 MPa, and the fracture toughness is 2.35-2.93.
Due to reasonable formula design, the invention has the following advantages: 1) the added wollastonite fiber can be stored to room temperature without being melted, and the fiber reinforcing and toughening effects are fully exerted; 2) the added wollastonite has large quantity, but can realize sintering at lower temperature, and generally, more than 25 percent of wollastonite is added into a green body and is difficult to sinter at the temperature below 980 ℃; 3) the reasonable proportion and the total amount of potassium, sodium, phosphorus, fluorine and boron determine that the blank can be sintered at low temperature, the strength of a glass phase is not reduced, the high-temperature deformation resistance of the blank is not reduced, and the blank is ensured to directly run on a roller without deformation without backing up a supporting plate at high temperature.
Specifically, regarding the high temperature deformation resistance of the present invention, the maximum deformation amount d of the body is 1.5 to 3 mm. The maximum deformation is measured under the following experimental conditions:
as shown in figure 1, a blank body 1 with the thickness of 5mm, the width of 18mm and the length of 60mm is taken, the blank body 1 is placed on a refractory support 2 with the width of 55mm, and sintering is carried out for 15min under the high-temperature condition of 980 ℃. Before sintering, the upper surface of the green body is at a horizontal line A, and after sintering, the lowest point of the upper surface of the green body is at a horizontal line B. The distance between horizontal line a and horizontal line B is the maximum amount of deformation d. The maximum deformation d was measured to be less than 3 mm.
It should be noted that, in the current ceramic preparation, the maximum deformation of the green body is less than or equal to 4 mm, and the brick body can directly run on the roller rod.
Correspondingly, the invention also discloses a preparation method of the building ceramic plate/brick, which comprises the following steps:
(1) adding the base material and the additive of the building ceramic plate/brick according to the proportion, and performing ball milling and mixing by taking water as a medium to obtain slurry;
(2) carrying out spray drying on the slurry to prepare powder with the water content of 4-9 wt%;
(3) pressing and molding the powder by using a press, and drying to obtain a blank;
in general, the requirement of dry powder compression molding on blank plasticity is low, so that the formula of the invention can be matched, and less alumina is introduced to reduce the sintering temperature. On the contrary, plastic forming has high plasticity to the blank, and a large amount of plastic raw materials containing high alumina, such as kaolin, mud and the like, must be added into the blank, so that the sintering temperature is high.
(4) And (3) glazing the surface of the blank, and then sintering at 800-980 ℃ to obtain the building ceramic plate/brick.
Preferably, the firing temperature in the step (4) is 820-950 ℃, the heat preservation time at the highest firing temperature is 5-60 min, and the firing period is 15-180 min. And (4) sintering the green body in the step (4) in a roller kiln, but the method is not limited to the firing treatment.
And (4) when the green body in the step (4) is sintered in a roller kiln, directly placing the green body on a roller rod, and driving the green body to move forwards under the rotation of the roller rod. Specifically, the green body of the building ceramic plate/brick prepared by the formula design has extremely high-temperature viscosity and ideal high-temperature deformation resistance, and the green body can directly walk on a roller rod of a roller kiln without deformation under a high-temperature condition during sintering without a refractory supporting plate, so that bare firing can be realized. In the sintering process, the invention reduces the heat loss caused by the refractory supporting plate, can greatly reduce the energy consumption in the sintering process and reduce the production cost. In addition, the temperature of the green body can be increased more quickly in the firing process by naked firing, and the temperature of the green body is reduced more quickly in the cooling process, so that the firing period is shortened, and the daily output is increased. In addition, the blank body can be heated more uniformly in the firing process by naked firing, and the blank body is cooled more uniformly in the cooling process, so that the finished product rate of the product is improved, and the comprehensive performance index of the product is improved.
The building ceramic plate/brick prepared by the invention has the water absorption rate of less than 0.5%, the breaking strength of more than or equal to 80MPa and the fracture toughness of 1.82-2.93.
The invention is further illustrated by the following specific examples:
example 1
The formula (I) is as follows: consists of a base material and an additive;
the raw material composition of the base material is 5 wt% of bentonite, 35 wt% of high borosilicate cullet, 7 wt% of common cullet, 35 wt% of wollastonite, 4 wt% of fluorite, 4 wt% of calcined calcium phosphate and 10 wt% of kaolin; relative to the base material, the additives are 0.5 wt% of modified starch and 0.5 wt% of water glass.
Wherein the bentonite comprises the following chemical components in percentage by mass: SiO 22 72.10％、Na2O+K2O 1.51％、Al2O315.84％、Fe2O3 1.12％、CaO+MgO 6.5％、TiO20.15% and 2.78% loss on ignition.
The high borosilicate cullet comprises the following chemical components in percentage by mass: SiO 22 81.12％、Na2O+K2O 2.29％、Al2O32.84％、Fe2O3 0.11％、CaO+MgO+ZnO+BaO+SrO 0.43％、TiO2 0.15％、B2O3 13.06％。
The common glass cullet comprises the following chemical components in percentage by mass: SiO 22 71.33％、Na2O+K2O 15.26％、Al2O32.84％、Fe2O3 0.21％、CaO+MgO+ZnO+BaO+SrO 10.21％、TiO2 0.15％。
The wollastonite comprises the chemical components of SiO in percentage by mass253.30%, CaO 42.80% and loss on ignition 3.90%.
(II) the manufacturing method of the building ceramic plate/brick of the embodiment comprises the following steps:
(1) mixing the base materials and the additives according to the proportion, and carrying out ball milling and mixing in a ball mill by taking water as a medium for 12 hours to obtain slurry, wherein the water content of the slurry is 39.6 percent;
(2) spray drying the slurry by a spray drying tower to prepare powder with the water content of 7 wt%;
(3) pressing the powder material by a press to form, and drying to obtain a blank;
(4) applying base coat, decoration (such as screen printing, roller printing or ink-jet printing) and surface coat (such as glaze slip or dry grain glaze) on the surface of the blank, putting the blank into a roller kiln, directly placing the blank on a roller rod, advancing under the drive of the rotation of the roller rod, and firing at 870 ℃, wherein the heat preservation time at the highest firing temperature is 10min, and the firing period is 60min, so that the building ceramic plate/brick is prepared, and has the breaking strength of 86MPa and the fracture toughness of 1.86.
Example 2
The formula (I) is as follows: consists of a base material and an additive;
the raw material composition of the base material is 6 wt% of bentonite, 46 wt% of high borosilicate cullet, 30 wt% of wollastonite fiber, 4 wt% of fluorite, 4 wt% of calcined calcium phosphate and 10 wt% of kaolin; relative to the base material, the additives are 0.5 wt% of modified starch and 0.5 wt% of water glass.
Wherein the bentonite comprises the following chemical components in percentage by mass: SiO 22 72.10％、Na2O+K2O 1.51％、Al2O315.84％、Fe2O3 1.129％、CaO+MgO 6.5％、TiO20.15% and 2.78% loss on ignition.
The high borosilicate cullet comprises the following chemical components in percentage by mass: SiO 22 81.12％、Na2O+K2O 2.29％、Al2O32.84％、Fe2O3 0.11％、CaO+MgO+ZnO+BaO+SrO 0.43％、TiO2 0.15％、B2O3 13.06％。
The diameter of the wollastonite fiber is 2-5 μm, the length is 16-60 μm, the length-diameter ratio is 8-12, and the wollastonite fiber comprises SiO in percentage by mass253.30%, CaO 42.80% and loss on ignition 3.90%.
(II) the manufacturing method of the building ceramic plate/brick of the embodiment comprises the following steps:
(1) mixing the base materials and the additives according to the proportion, and carrying out ball milling and mixing in a ball mill for 10 hours by taking water as a medium to obtain slurry, wherein the water content of the slurry is 39.9%;
(2) spray drying the slurry in a spray drying tower to obtain powder with water content of 6.5 wt%;
(3) pressing the powder material by a press to form, and drying to obtain a blank;
(4) applying base coat, decoration (such as screen printing, roller printing or ink-jet printing) and surface coat (such as glaze slip or dry grain glaze) on the surface of the blank, putting the blank into a roller kiln, directly placing the blank on a roller rod, driving the blank to move forward under the rotation of the roller rod, and firing at 910 ℃, wherein the heat preservation time at the highest firing temperature is 20min, and the firing period is 80min, so that the building ceramic plate/brick is prepared, and the breaking strength is 116Mpa and the fracture toughness is 2.36.
Example 3
The formula (I) is as follows: consists of a base material and an additive;
the raw material composition of the base material is 20 wt% of black mud, 45 wt% of common cullet, 30 wt% of wollastonite fiber, 2 wt% of fluorite and 3 wt% of calcined calcium phosphate; relative to the base material, the additive is 0.2 wt% of sodium polyacrylate and 0.5 wt% of sodium metasilicate pentahydrate.
The black mud comprises the following chemical components in percentage by mass: SiO 22 63.23％、Na2O+K2O 0.81％、Al2O323.84％、Fe2O3 1.81％、CaO+MgO+ZnO+BaO+SrO 0.33％、TiO20.35% and 9.63% loss on ignition.
The common glass cullet comprises the following chemical components in percentage by mass: SiO 22 71.33％、Na2O+K2O 15.26％、Al2O32.84％、Fe2O3 0.21％、CaO+MgO+ZnO+BaO+SrO 10.21％、TiO2 0.15％。
The diameter of the wollastonite fiber is 2-5 μm, the length is 16-60 μm, the length-diameter ratio is 8-12, and the wollastonite fiber comprises SiO in percentage by mass253.30%, CaO 42.80% and loss on ignition 3.90%.
(II) the manufacturing method of the building ceramic plate/brick of the embodiment comprises the following steps:
(1) mixing the base materials and the additives according to the proportion, and carrying out ball milling and mixing in a ball mill for 9 hours by taking water as a medium to obtain slurry, wherein the water content of the slurry is 40.5 percent.
(2) Spray drying the slurry by a spray drying tower to prepare powder with the water content of 7 wt%;
(3) pressing the powder material by a press to form, and drying to obtain a blank;
(4) applying base glaze, decoration (such as screen printing, roller printing or ink-jet printing) and surface glaze (such as glaze slip or dry grain glaze) on the surface of the blank, putting the blank into a roller kiln, directly placing the blank on a roller rod, driving the blank to move forward under the rotation of the roller rod, and firing at 950 ℃, wherein the heat preservation time at the highest firing temperature is 60min, and the firing period is 120min, so that the building ceramic plate/brick is prepared, and the breaking strength is 80Mpa and the fracture toughness is 1.85.
Example 4
The formula (I) is as follows: consists of a base material and an additive;
the raw material composition of the base material is 20 wt% of black mud, 48 wt% of common cullet, 25 wt% of wollastonite fiber, 2 wt% of fluorite and 5 wt% of calcined calcium phosphate; relative to the base material, the additive is 0.2 wt% of sodium polyacrylate and 0.5 wt% of sodium metasilicate pentahydrate.
The black mud comprises the following chemical components in percentage by mass: SiO 22 63.23％、Na2O+K2O 0.81％、Al2O323.84％、Fe2O3 1.81％、CaO+MgO+ZnO+BaO+SrO 0.33％、TiO20.35% and 9.63% loss on ignition.
The common glass cullet comprises the following chemical components in percentage by mass: SiO 22 71.33％、Na2O+K2O 15.26％、Al2O32.84％、Fe2O3 0.21％、CaO+MgO+ZnO+BaO+SrO 10.21％、TiO2 0.15％。
The diameter of the wollastonite fiber is 2-5 μm, the length is 16-60 μm, the length-diameter ratio is 8-12, and the wollastonite fiber comprises SiO in percentage by mass253.30%, CaO 42.80% and loss on ignition 3.90%.
(II) the manufacturing method of the building ceramic plate/brick of the embodiment comprises the following steps:
(1) mixing the base materials and the additives according to the proportion, and carrying out ball milling and mixing in a ball mill for 9 hours by taking water as a medium to obtain slurry, wherein the water content of the slurry is 40.2%.
(2) Spray drying the slurry in a spray drying tower to obtain powder with water content of 6.7 wt%;
(3) pressing the powder material by a press to form, and drying to obtain a blank;
(4) applying base glaze, decoration (such as screen printing, roller printing or ink-jet printing) and surface glaze (such as glaze slip or dry grain glaze) on the surface of the blank, putting the blank into a roller kiln, directly placing the blank on a roller rod, driving the blank to move forward under the rotation of the roller rod, and firing at 980 ℃, wherein the heat preservation time at the highest firing temperature is 15min, and the firing period is 65min, so that the building ceramic plate/brick is prepared, and the breaking strength is 83Mpa and the fracture toughness is 1.86.
Example 5
The formula (I) is as follows: consists of a base material and an additive;
the raw material composition of the base material comprises 11 wt% of washing mud, 7 wt% of black mud, 5 wt% of boron-containing calcined material, 40 wt% of common cullet, 28 wt% of wollastonite fiber, 5 wt% of wollastonite powder and 4 wt% of fluorite; relative to the base material, the additive is 1.0 wt% of sodium polyacrylate and 0.3 wt% of sodium humate.
The black mud comprises the following chemical components in percentage by mass: SiO 22 66.23％、Na2O+K2O 0.81％、Al2O321.84％、Fe2O3 0.81％、CaO+MgO+ZnO+BaO+SrO 0.33％、TiO20.35% and 9.63% loss on ignition.
The chemical composition mass percentage of the washing mud is as follows: SiO 22 65.23％、Na2O+K2O 1.21％、Al2O324.99％、Fe2O3 0.31％、CaO+MgO+ZnO+BaO+SrO 0.43％、TiO20.15% and loss of heat 7.68%.
The boron-containing calcined material comprises the following chemical components in percentage by mass: SiO 22 42.11％、Na2O+K2O 0.17％、Al2O39.89％、Fe2O3 0.19％、CaO+MgO+ZnO+BaO+SrO 24.43％、TiO2 0.15％、B2O3 23.06％。
The common glass cullet comprises the following chemical components in percentage by mass: SiO 22 71.33％、Na2O+K2O 15.26％、Al2O32.84％、Fe2O3 0.21％、CaO+MgO+ZnO+BaO+SrO 10.21％、TiO2 0.15％。
The diameter of the wollastonite fiber is 2-5 μm, the length is 16-60 μm, the length-diameter ratio is 8-12, and the wollastonite fiber comprises SiO in percentage by mass253.30%, CaO 42.80% and loss on ignition 3.90%.
(II) the manufacturing method of the building ceramic plate/brick of the embodiment comprises the following steps:
(1) mixing the base materials and the additives according to the proportion, and carrying out ball milling and mixing for 11h in a ball mill by taking water as a medium to obtain slurry, wherein the water content of the slurry is 40.5%.
(2) Spray drying the slurry by a spray drying tower to prepare powder with the water content of 7 wt%;
(3) pressing the powder material by a press to form, and drying to obtain a blank;
(4) applying base coat, decoration (such as screen printing, roller printing or ink-jet printing) and surface coat (such as glaze slip or dry grain glaze) on the surface of the blank, putting the blank into a roller kiln, directly placing the blank on a roller rod, advancing under the drive of the rotation of the roller rod, and firing at 935 ℃ for 30min at the highest firing temperature and 90min at the firing period to obtain the building ceramic plate/brick with the breaking strength of 119MPa and the fracture toughness of 2.55.
Example 6
The formula (I) is as follows: consists of a base material and an additive;
the raw material composition of the base material is 2 wt% of bentonite, 3 wt% of black mud, 24 wt% of calcined calcium phosphate, 35 wt% of common glass cullet, 1 wt% of fluorite and 35 wt% of wollastonite fiber; relative to the base material, the additive comprises 1.0 wt% of sodium polyacrylate, 0.3 wt% of sodium humate and 0.6 wt% of water glass.
Wherein the bentonite comprises the following chemical components in percentage by mass: SiO 22 72.10％、Na2O+K2O 1.51％、Al2O315.84％、Fe2O3 1.129％、CaO+MgO 6.5％、TiO20.15% and 2.78% loss on ignition.
The black mud comprises the following chemical components in percentage by mass: SiO 22 66.23％、Na2O+K2O 0.81％、Al2O3 21.84％、Fe2O3 0.81％、CaO+MgO+ZnO+BaO+SrO 0.33％、TiO20.35% and 9.63% loss on ignition.
The common glass cullet comprises the following chemical components in percentage by mass: SiO 22 71.33％、Na2O+K2O 15.26％、Al2O32.84％、Fe2O3 0.21％、CaO+MgO+ZnO+BaO+SrO 10.21％、TiO2 0.15％。
The diameter of the wollastonite fiber is 2-5 μm, the length is 16-60 μm, the length-diameter ratio is 8-12, and the wollastonite fiber comprises SiO in percentage by mass253.30%, CaO 42.80% and loss on ignition 3.90%.
(II) the manufacturing method of the building ceramic plate/brick of the embodiment comprises the following steps:
(1) mixing the base materials and the additives according to the proportion, and carrying out ball milling and mixing in a ball mill for 10 hours by taking water as a medium to obtain slurry, wherein the water content of the slurry is 35.5%;
(2) spray drying the slurry by a spray drying tower to prepare powder with the water content of 6 wt%;
(3) pressing the powder material by a press to form, and drying to obtain a blank;
(4) applying base glaze, decoration (screen printing, roller printing or ink-jet printing or the like) and surface glaze (glaze slip or dry grain glaze) on the surface of the blank, putting the blank into a roller kiln, directly placing the blank on a roller rod, driving the blank to move forward under the rotation of the roller rod, and firing at 820 ℃, wherein the heat preservation time at the highest firing temperature is 30min, and the firing period is 90min, so that the building ceramic plate/brick is prepared, and the breaking strength is 96Mpa and the fracture toughness is 1.98.
Example 7
The formula (I) is as follows: consists of a base material and an additive;
the raw material composition of the base material is 15 wt% of bentonite, 26 wt% of high borosilicate cullet, 35 wt% of wollastonite fiber, 4 wt% of fluorite, 10 wt% of calcined calcium phosphate and 10 wt% of kaolin; relative to the base material, the additive comprises 0.3 wt% of modified starch, 0.5 wt% of water glass, 0.5 wt% of sodium polyacrylate and 0.2 wt% of sodium humate.
Wherein the bentonite comprises the following chemical components in percentage by mass: SiO 22 72.10％、Na2O+K2O 1.51％、Al2O315.84％、Fe2O3 1.129％、CaO+MgO 6.5％、TiO20.15% and 2.78% loss on ignition.
The high borosilicate cullet comprises the following chemical components in percentage by mass: SiO 22 81.12％、Na2O+K2O 2.29％、Al2O32.84％、Fe2O3 0.11％、CaO+MgO+ZnO+BaO+SrO 0.43％、TiO2 0.15％、B2O3 13.06％。
The diameter of the wollastonite fiber is 2-5 μm, the length is 16-60 μm, the length-diameter ratio is 8-12, and the wollastonite fiber comprises SiO in percentage by mass253.30%, CaO 42.80% and loss on ignition 3.90%.
(II) the manufacturing method of the building ceramic plate/brick of the embodiment comprises the following steps:
(1) mixing the base materials and the additives according to the proportion, and carrying out ball milling and mixing for 10 hours in a ball mill by taking water as a medium to obtain slurry, wherein the water content of the slurry is 42.5 percent.
(2) Spray drying the slurry by a spray drying tower to prepare powder with the water content of 7 wt%;
(3) pressing the powder material by a press to form, and drying to obtain a blank;
(4) applying base glaze, decoration (such as screen printing, roller printing or ink-jet printing) and surface glaze (such as glaze slip or dry grain glaze) on the surface of the blank, putting the blank into a roller kiln, directly placing the blank on a roller rod, driving the blank to move forward under the rotation of the roller rod, and firing at 980 ℃, wherein the heat preservation time at the highest firing temperature is 20min, and the firing period is 70min, so that the building ceramic plate/brick is prepared, and the breaking strength is 96Mpa and the fracture toughness is 1.96.
While the foregoing is directed to the preferred embodiment of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention.
Claims (10)
1. The building ceramic plate/brick is characterized by being prepared from a base material and an additive, wherein the base material comprises 5-25 wt% of a plastic raw material, 40-60 wt% of a fluxing raw material and 25-45 wt% of wollastonite and/or wollastonite fiber;
relative to the base material, the addition amount of the additive is 0.01-6 wt%, and the additive comprises one or a combination of an organic reinforcing agent and a water reducing agent.
2. A building ceramic plate/brick according to claim 1, characterized in that its chemical composition comprises, in mass%:
SiO2 45～75％、Na2O+K2O 3～10％、Al2O3 2～9％、Fe2O3 0.01～9％、P2O5 0～8％、F 0.5～5％、CaO+MgO+ZnO+BaO+SrO 15～33％。
3. a building ceramic plate/brick according to claim 2, characterized in that its chemical composition comprises, in mass%:
SiO2 45～75％、Na2O+K2O 3～10％、Al2O3 2～9％、Fe2O3 0.01～9％、P2O5 0～8％、F 0.5～5％、CaO+MgO+ZnO+BaO+SrO 15～33％、B2O3 0.1～6％、Li2O 0.1-1％。
4. a building ceramic board/brick according to claim 1 wherein the plastic raw material is one or a combination of clay, kaolin, bentonite, black mud, mixed mud, washed mud;
the fluxing raw material is one or the combination of cullet, synthetic frit, fluorite, boron-containing calcined material, phosphorus-containing calcined material or fluorine-containing calcined material;
relative to the base material, the adding amount of the organic reinforcing agent is 0-4 wt%, and the adding amount of the water reducing agent is 0.01-2.0 wt%;
the organic reinforcing agent is one or the combination of methyl cellulose, starch, modified starch and sodium polyacrylate;
the water reducing agent is one or the combination of sodium tripolyphosphate, water glass, sodium metasilicate pentahydrate, sodium metaphosphate, sodium humate and hydrated liquid sodium polyacrylate.
5. A building ceramic board/brick as claimed in claim 1 wherein the wollastonite fiber has a diameter of 1 to 20 μm, a length of 5 to 200 μm, and an aspect ratio of 5 to 20.
6. A building ceramic plate/brick as claimed in claim 1 or 2, wherein said building ceramic plate/brick has a water absorption of less than 0.5%, a firing temperature of 800 to 980 ℃, a flexural strength of not less than 80MPa, and a fracture toughness of 1.82 to 2.93.
7. A method of manufacturing a building ceramic plate/brick according to any one of claims 1-6, comprising:
(1) adding the base material and the additive of the building ceramic plate/brick according to the proportion, and performing ball milling and mixing by taking water as a medium to obtain slurry;
(2) carrying out spray drying on the slurry to prepare powder with the water content of 4-9 wt%;
(3) pressing and molding the powder by using a press, and drying to obtain a blank;
(4) and (3) glazing the surface of the blank, and then sintering at 800-980 ℃ to obtain the building ceramic plate/brick.
8. The method for preparing a building ceramic plate/brick according to claim 7, wherein the firing temperature in the step (4) is 820 to 950 ℃, the holding time at the maximum firing temperature is 5 to 60min, and the firing period is 15 to 180 min.
9. The preparation method of a building ceramic plate/brick as claimed in claim 7, wherein the green body of step (4) is fired in a roller kiln to obtain the building ceramic plate/brick with water absorption less than 0.5%, flexural strength not less than 80MPa, and fracture toughness of 1.82-2.93.
10. A method for preparing building ceramic plates/bricks as claimed in claim 7 wherein the green bodies of step (4) are directly placed on the roller rods and advanced by the rotation of the roller rods during firing in a roller kiln.
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| CN114380574A (en) * | 2021-02-10 | 2022-04-22 | 况学成 | Ceramic building material and preparation method thereof |
| CN113831114A (en) * | 2021-10-27 | 2021-12-24 | 德化县后井窑瓷业有限责任公司 | High-strength and drop-resistant ceramic product and preparation method thereof |
| CN115521133A (en) * | 2021-11-19 | 2022-12-27 | 张德欢 | Ceramic plate for inner wall and preparation method thereof |
| CN114136807A (en) * | 2021-11-25 | 2022-03-04 | 东莞市唯美陶瓷工业园有限公司 | Laboratory prediction method for bending performance of ceramic rock plate |
| CN114436625A (en) * | 2022-01-28 | 2022-05-06 | 江西唯美陶瓷有限公司 | Ultra-thin ceramic rock plate and preparation method thereof |
| CN114956799A (en) * | 2022-08-02 | 2022-08-30 | 佛山市道易生科技有限公司 | Dry-method powder-making ceramic tile/board and preparation method thereof |
| CN115536361A (en) * | 2022-11-28 | 2022-12-30 | 蒙娜丽莎集团股份有限公司 | High-strength ceramic sheet and preparation method thereof |
| CN117185831A (en) * | 2023-09-13 | 2023-12-08 | 信阳中毅高热材料有限公司 | Environment-friendly refractory ceramic plate and production process thereof |
| CN117185831B (en) * | 2023-09-13 | 2024-04-26 | 信阳中毅高热材料有限公司 | Environment-friendly refractory ceramic plate and production process thereof |
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| CN112876216A (en) | 2021-06-01 |
| CN114380574A (en) | 2022-04-22 |
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