CN114716230A - 一种具有高韧性的瓷砖及其制备方法 - Google Patents

一种具有高韧性的瓷砖及其制备方法 Download PDF

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CN114716230A
CN114716230A CN202210649351.XA CN202210649351A CN114716230A CN 114716230 A CN114716230 A CN 114716230A CN 202210649351 A CN202210649351 A CN 202210649351A CN 114716230 A CN114716230 A CN 114716230A
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parts
vermiculite
preparing
ceramic tile
high toughness
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CN114716230B (zh
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雷云
梁海潮
李林
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Guangxi Jianyi Ceramics Co ltd
Guangdong Jianyi Group Ceramics Co ltd
Qingyuan Jianyi Ceramics Co Ltd
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Guangdong Jianyi Group Ceramics Co ltd
Qingyuan Jianyi Ceramics Co Ltd
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Abstract

本发明涉及瓷砖领域，具体是涉及到一种具有高韧性的瓷砖及其制备方法；本申请提出的具有高韧性的瓷砖，包括坯体，所述坯体，包括以下重量份的原料：粘土30‑50份、长石30‑40份、石英10‑35份、蛭石组合物1.6‑3.3份；所述蛭石组合物，包括以下重量份的原料：蛭石0.5‑1份、硅灰石0.5‑1份、粘接剂0.1‑0.3份、碳化硅0.5‑1份，通过蛭石组合物的制备、备料、球磨、制粉、半成品制备而得；本发明制备得到的瓷砖，韧性等级≥3，具有高韧性。

Description

一种具有高韧性的瓷砖及其制备方法
技术领域
本发明涉及瓷砖领域，具体是涉及到一种具有高韧性的瓷砖及其制备方法。
背景技术
陶瓷材料具有其他材料无可比拟的优点，但是致命的弱点是它的脆性。因为陶瓷材料是由离子键或者共价键所组成的多晶结构，它缺乏能使材料变形的滑移***，加上陶瓷工艺制造中无法避免的材料表面存在微缺陷，也就是有可能构成裂纹源，一旦受到外力，造成裂纹的快速扩展和脆性断裂，如何改善这一性能减少陶瓷的脆性是目前急需解决的问题；
蛭石是一种层状硅酸盐矿物，为天然、无害的矿物，与蒙脱石相似的粘土矿物，颜色通常为黄色、褐色和暗绿色，加热后会变成灰色，可以用作建筑材料等，用途很广，在陶瓷行业目前尚未见以采用蛭石粉来提升瓷砖韧性的报道。
发明内容
为了克服现有技术的不足，本发明的第一目的是提供一种具有高韧性的瓷砖；
本发明的目的是提供一种具有高韧性的瓷砖的制备方法；
本发明解决其技术问题所采用的技术方案是：
一种具有高韧性的瓷砖，包括坯体，所述坯体，包括以下重量份的原料：粘土30-50份、长石30-40份、石英10-35份、蛭石组合物1.6-3.3份；
其中，所述蛭石组合物，包括以下重量份的原料：
蛭石0.5-1份、硅灰石0.5-1份、粘接剂0.1-0.3份、碳化硅0.5-1份；
进一步的，所述粘接剂为质量浓度为15%磷酸二氢铝水溶液。
一种具有高韧性的瓷砖的制备方法，包括以下步骤：
S1.蛭石组合物的制备
按照重量份，进行蛭石组合物原料的备料；将蛭石、硅灰石混合后粉碎过20-50目筛，得到粉碎混合物；将粉碎混合物与盐酸溶液进行混合，在70-80℃下搅拌保温2-3h；降至室温，洗涤至中性，加入粘接剂和碳化硅，搅拌均匀；在90-110℃下保温4-5h，降至室温，烘干，得到蛭石组合物；
S2.备料
按照重量份，进行坯体原料的备料，将原料进行充分混合后，得到坯料混合物；使用球磨机对坯料混合物进行球磨处理，得到浆料；
S3.制粉
将步骤S2制备得到的浆料，使用喷雾塔进行制粉；制粉的颗粒级配控制在：30目上筛13-30%，60目上筛累计≥88%，60-100目筛≤10%，100目筛下≤2%；
S4.半成品制备
将步骤S3制备得到的粉末，经24h陈腐后压制、窑前干燥，最后烧成半成品坯体。
可以先采用盐酸对硅灰石、蛭石的表面进行处理后，再使用磷酸二氢铝水溶液作为粘结剂进行改性，确保硅灰石、蛭石的表面均匀包裹粘结剂，再与加入碳化硅；由于蛭石的层状结构，是由两层层状的硅氧骨架，通过硅灰石或碳化硅结合而形成双层硅氧四面体，这种结构有利于提升坯体的韧性。
进一步的，所述步骤S1中，盐酸浓度为0.8-1.3mol/L。
进一步的，所述步骤S2中，所述球磨处理要求：浆料水分控制在33-34%，浆料的细度控制在250-300目，浆料的细度筛余量为2-3%。
进一步的，所述步骤S4中，烧成温度为1150-1200℃。
本发明的有益效果是：
1、本发明通过加入蛭石组合物，可明显提升瓷砖韧性，韧性等级≥3，具有高韧性；
2、通过瓷砖抗冲击力的检测方法和不同高度的抗摔性，能测定瓷砖的韧性，说明本发明制备得到的瓷砖具有较高的抗冲击恢复系数。
具体实施方式
为了便于本领域技术人员的理解，下面结合实施例对本发明作进一步的说明，实施方式提及的内容并非对本发明的限定。
实施例1
一种具有高韧性的瓷砖，包括坯体，所述坯体，包括以下重量份的原料：粘土30份、长石30份、石英10份、蛭石组合物1.6份；
所述蛭石组合物，包括以下重量份的原料：
蛭石0.5份、硅灰石0.5份、粘接剂0.1份、碳化硅0.5份；
所述粘接剂为质量浓度为15%磷酸二氢铝水溶液。
所述碳化硅的粒径为100μm。
一种具有高韧性的瓷砖的制备方法，包括以下步骤：
S1.蛭石组合物的制备
按照重量份，进行蛭石组合物原料的备料；将蛭石、硅灰石混合后粉碎过20目筛，得到粉碎混合物；将粉碎混合物与浓度为0.8mol/L的盐酸溶液进行混合，在70℃下搅拌保温2h；降至室温，洗涤至中性，加入粘接剂和碳化硅，搅拌均匀；在90℃下保温4h，降至室温，烘干，得到蛭石组合物；
S2.备料
按照重量份，进行坯体原料的备料，将原料进行充分混合后，得到坯料混合物；使用球磨机对坯料混合物进行球磨处理，得到浆料；球磨处理要求：浆料水分控制在33-34%，浆料的细度控制在250目，浆料的细度筛余量为2%；
S3.制粉
将步骤S2制备得到的浆料，使用喷雾塔进行制粉；制粉的颗粒级配控制在30目上筛13-15%，60目上筛累计≥88%，60-100目筛≤10%，100目筛下≤2%；
S4.半成品制备
将步骤S3制备得到的粉末，经24h陈腐后压制成型、窑前干燥，最后在温度为1150-1160℃下烧成半成品坯体。
实施例2
一种具有高韧性的瓷砖，包括坯体，所述坯体，包括以下重量份的原料：粘土50份、长石40份、石英35份、蛭石组合物3.3份；
所述蛭石组合物，包括以下重量份的原料：
蛭石1份、硅灰石1份、粘接剂0.3份、碳化硅1份；
所述粘接剂为质量浓度为15%磷酸二氢铝水溶液。
所述碳化硅的粒径为200μm。
一种具有高韧性的瓷砖的制备方法，包括以下步骤：
S1.蛭石组合物的制备
按照重量份，进行蛭石组合物原料的备料；将蛭石、硅灰石混合后粉碎过50目筛，得到粉碎混合物；将粉碎混合物与浓度为1.3mol/L的盐酸溶液进行混合，在80℃下搅拌保温3h；降至室温，洗涤至中性，加入粘接剂和碳化硅，搅拌均匀；在110℃下保温5h，降至室温，烘干，得到蛭石组合物；
S2.备料
按照重量份，进行坯体原料的备料，将原料进行充分混合后，得到坯料混合物；使用球磨机对坯料混合物进行球磨处理，得到浆料；球磨处理要求：浆料水分控制在33-34%，浆料的细度控制在300目，浆料的细度筛余量为3%；
S3.制粉
将步骤S2制备得到的浆料，使用喷雾塔进行制粉；制粉的颗粒级配控制在30目上筛25-30%，60目上筛累计≥88%，60-100目筛≤10%，100目筛下≤2%；
S4.半成品制备
将步骤S3制备得到的粉末，经24h陈腐后压制成型、窑前干燥，最后在温度为1190-1200℃下烧成半成品坯体。
实施例3
一种具有高韧性的瓷砖，包括坯体，所述坯体，包括以下重量份的原料：粘土40份、长石35份、石英21份、蛭石组合物2.5份；
所述蛭石组合物，包括以下重量份的原料：
蛭石0.7份、硅灰石0.8份、粘接剂0.2份、碳化硅0.8份；
所述粘接剂为质量浓度为15%磷酸二氢铝水溶液。
所述碳化硅的粒径为150μm。
一种具有高韧性的瓷砖的制备方法，包括以下步骤：
S1.蛭石组合物的制备
按照重量份，进行蛭石组合物原料的备料；将蛭石、硅灰石混合后粉碎过40目筛，得到粉碎混合物；将粉碎混合物与浓度为1.1mol/L的盐酸溶液进行混合，在75℃下搅拌保温2.5h；降至室温，洗涤至中性，加入粘接剂和碳化硅，搅拌均匀；在100℃下保温4.5h，降至室温，烘干，得到蛭石组合物；
S2.备料
按照重量份，进行坯体原料的备料，将原料进行充分混合后，得到坯料混合物；使用球磨机对坯料混合物进行球磨处理，得到浆料；球磨处理要求：浆料水分控制在33-34%，浆料的细度控制在250目，浆料的细度筛余量为3%；
S3.制粉
将步骤S2制备得到的浆料，使用喷雾塔进行制粉；制粉的颗粒级配控制在30目上筛20-25%，60目上筛累计≥88%，60-100目筛≤10%，100目筛下≤2%；
S4.半成品制备
将步骤S3制备得到的粉末，经24h陈腐后压制成型、窑前干燥，最后在温度为1165-1175℃下烧成半成品坯体。
实施例4
一种具有高韧性的瓷砖，包括坯体，所述坯体，包括以下重量份的原料：粘土35份、长石39份、石英11份、蛭石组合物3份；
所述蛭石组合物，包括以下重量份的原料：
蛭石0.9份、硅灰石0.9份、粘接剂0.2份、碳化硅1份；
所述粘接剂为质量浓度为15%磷酸二氢铝水溶液。
所述碳化硅的粒径为110μm。
一种具有高韧性的瓷砖的制备方法，包括以下步骤：
S1.蛭石组合物的制备
按照重量份，进行蛭石组合物原料的备料；将蛭石、硅灰石混合后粉碎过50目筛，得到粉碎混合物；将粉碎混合物与浓度为0.8mol/L的盐酸溶液进行混合，在79℃下搅拌保温2.2h；降至室温，洗涤至中性，加入粘接剂和碳化硅，搅拌均匀；在95℃下保温4.8h，降至室温，烘干，得到蛭石组合物；
S2.备料
按照重量份，进行坯体原料的备料，将原料进行充分混合后，得到坯料混合物；使用球磨机对坯料混合物进行球磨处理，得到浆料；球磨处理要求：浆料水分控制在33-34%，浆料的浆料的细度控制在300目，浆料的细度筛余量为2%；
S3.制粉
将步骤S2制备得到的浆料，使用喷雾塔进行制粉；制粉的颗粒级配控制在30目上筛15-20%，60目上筛累计≥88%，60-100目筛≤10%，100目筛下≤2%；
S4.半成品制备
将步骤S3制备得到的粉末，经24h陈腐后压制成型、窑前干燥，最后在温度为1180-1190℃下烧成半成品坯体。
对比例1
未加入实施例1中的1.6份蛭石组合物，其余条件和实施例1一致；
对比例2
加入0.5份蛭石组合物，具体比例和按照实施例1的重量份进行对比后，适当调整加入，其余条件和实施例1一致。
实施例5
一种瓷砖韧性的评价方法，包括以下步骤：
S6.待检样品的制备
按照GB/T3810.5-2016要求制备待检样品，待检样品大小为0.75*0.75mm；
S7.抗冲击恢复系数检测
利用CHY型恢复系数测定仪，测定待检样品的抗冲击恢复系数；
S71.旋转手轮调整托板至到指定位置，将待检样品从夹具后部放入指定位置，再反向旋转手轮夹紧待检样品；
S72.接通电源，把钢球（直径19mm±0.05mm）放进机头的球窝内，在吸/落灯亮时，电磁铁吸取钢球；
S73.按下吸/落按钮，钢球下落（击中待检样品的中部），待回跳后，屏幕显示抗冲击恢复系数和回跳高度，记录抗冲击恢复系数；
S74.取出待检样品，准备下次试验，试验全部完成后，关闭电源，清洗仪器。
通过检测得到的抗冲击恢复系数，来评价待检样品的韧性等级；
韧性等级评价标准为：
设定K值，将待检样品的抗冲击恢复系数X和K值进行对比；所述K值为0.55；当待检样品的抗冲击恢复系数X大于K值，则待检样品的韧性等级≥1；
当待检样品的抗冲击恢复系数X小于K值，则待检样品的韧性等级为0；
当待检样品的抗冲击恢复系数为0.55≤X≤0.70，则待检样品的韧性等级为1；
当待检样品的抗冲击恢复系数为0.71≤X≤0.85，则待检样品的韧性等级为2；
当待检样品的抗冲击恢复系数为0.86≤X≤1.0，则待检样品的韧性等级为3；
当待检样品的抗冲击恢复系数为1.01≤X≤1.2，则待检样品的韧性等级为4；
当待检样品的抗冲击恢复系数为X＞1.2，则待检样品的韧性等级为5；
具体评价标准的来自下述过程，即在指定位置的高度上，对同一待检样品（来自同一型号以及在同一范围内的抗冲击恢复系数的待检瓷砖），进行100次的汇总分析而得；具体过程参见下表1：
表1
Figure 615684DEST_PATH_IMAGE001
根据上述结果，韧性评价等级对应的抗摔要求为：
当评价等级为0级时，钢球下落高度1.0米时的碎裂率≤80%；
当评价等级为1级时，钢球下落高度1.0米时的碎裂率≤21%，钢球下落高度1.5米时的碎裂率≤72%；
当评价等级为2级时，钢球下落高度1.0米时待检样品完好无损；钢球下落高度1.5米时的碎裂率≤41%；
当评价等级为3级时，此时钢球下落高度1.0米时待检样品完好无损；钢球下落高度1.5米时的碎裂率≤13%；钢球下落高度1.8米时的碎裂率≤32%；
当评价等级为4级时，此时钢球下落高度1.0米时待检样品完好无损；钢球下落高度1.5米时待检样品完好无损；钢球下落高度1.8米时的碎裂率≤15%；钢球下落高度2.0米时的碎裂率≤24%；
当评价等级为5级时，此时钢球下落高度1.0米时待检样品完好无损；钢球下落高度1.5米时待检样品完好无损；钢球下落高度1.8米时待检样品完好无损；钢球下落高度2.0米时待检样品完好无损。
随机选择市面上的瓷砖，按照实施例5所述评价方法，进行抗冲击恢复系数X的测定（1个高度测试10块），再根据实施例5的评价方法，进行韧性等级的评价，具体结果参见下表2：
表2
Figure 988897DEST_PATH_IMAGE002
而在表2，我们可以看出：
测试组1，0.86＜X=0.93＜1.0，按照评价方法，韧性等级为3级，说明该待检样品具有较高的韧性，不容易碎裂；此时钢球下落高度1.0米时待检样品完好无损；钢球下落高度1.5米时的碎裂率为10%；钢球下落高度1.8米时的碎裂率为20%；符合表1中记载的抗摔性测试碎裂率要求，可以用来评价待检样品的韧性；
测试组2，1.2＜X=1.3，按照评价方法，韧性等级为5级，说明该待检样品具有非常高的韧性，很难碎裂；此时钢球下落高度1米时待检样品完好无损；钢球下落高度1.5米时待检样品完好无损；钢球下落高度1.8米时待检样品完好无损；钢球下落高度2.0米时待检样品完好无损；符合表1中记载的抗摔性测试碎裂率要求，可以用来评价待检样品的韧性；
测试组3，0.55＞X=0.4，按照评价方法，韧性等级为0级，说明该待检样品具有非常低的韧性，非常易碎；此时钢球下落高度1米时的碎裂率为70%；符合表1中记载的抗摔性测试碎裂率要求，可以用来评价待检样品的韧性；
测试组4，0.55＜X=0.6＜0.70，按照评价方法，韧性等级为1级，说明该待检样品具有较低的韧性，容易易碎；此时钢球下落高度1.0米时的碎裂率为0，钢球下落高度1.5米时的碎裂率为50%；符合表1中记载的抗摔性测试碎裂率要求，可以用来评价待检样品的韧性；
因此，可以看出瓷砖的韧性好坏可以由抗冲击恢复系数的大小和抗摔性来衡量，抗冲击恢复系数越大且抗摔性越好，说明瓷砖的韧性越好，否则韧性就越差。如果瓷砖的抗冲击恢复系数小于0.55表明瓷砖的韧性不好，抗冲击恢复系数大于0.90表明瓷砖的韧性较好；
同时上述的抗摔结果，也在评价方法中的碎裂范围之内，说明本发明的韧性评价方法，具有一定的适用性，可以通过测得的对抗冲击恢复系数X，直接和K值进行对比，然后按照韧性等级的评价方法进行瓷砖的韧性评价，评价瓷砖的韧性等级，方便筛选出韧性高和韧性较差的瓷砖产品。
对实施例1-4以及对比例1-2制备得到的瓷砖坯体，进行韧性评价，具体评价方法，按照实施例5来进行(每个测试组10块，每个高度测10块)，相关结果汇总至下表3：
表3
Figure 852947DEST_PATH_IMAGE003
由上表1，实施例1-实施例4制备得到的瓷砖，抗冲击恢复系数＞0.9，韧性等级≥3，具有较高的韧性，不容易碎裂；且抗摔性测试均符合表1抗摔性测试碎裂率要求；
而对比例1未加入蛭石组合物，抗冲击恢复系数仅仅为0.39，瓷砖的韧性没有得到增加，韧性等级为0级，韧性非常差，非常容易碎裂；
对比例2，进入的蛭石组合物量比较少，略微提升了瓷砖的抗冲击恢复系数，其结果略微大于K值，韧性等级为1级，韧性较差，容易碎裂；
上述实施例为本发明较佳的实现方案，除此之外，本发明还可以其它方式实现，在不脱离本发明构思的前提下任何显而易见的替换均在本发明的保护范围之内。

Claims (7)

1.一种具有高韧性的瓷砖，其特征在于，包括坯体，所述坯体，包括以下重量份的原料：粘土30-50份、长石30-40份、石英10-35份、蛭石组合物1.6-3.3份；
所述蛭石组合物，包括以下重量份的原料：
蛭石0.5-1份、硅灰石0.5-1份、粘接剂0.1-0.3份、碳化硅0.5-1份。
2.根据权利要求1所述的一种具有高韧性的瓷砖，其特征在于，所述粘接剂为质量浓度为15%的磷酸二氢铝水溶液。
3.根据权利要求1所述的一种具有高韧性的瓷砖，其特征在于，所述碳化硅的粒径为100-200μm。
4.一种如权利要求1-3任一项所述的具有高韧性的瓷砖的制备方法，其特征在于，包括以下步骤：
S1.蛭石组合物的制备
按照重量份，进行蛭石组合物原料的备料；将蛭石、硅灰石混合后粉碎过20-50目筛，得到粉碎混合物；将粉碎混合物与盐酸溶液进行混合，在70-80℃下搅拌保温2-3h；降至室温，洗涤至中性，加入粘接剂和碳化硅，搅拌均匀；在90-110℃下保温4-5h，降至室温，烘干，得到蛭石组合物；
S2.备料
按照重量份，进行坯体原料的备料，将原料进行充分混合后，得到坯料混合物；使用球磨机对坯料混合物进行球磨处理，得到浆料；
S3.制粉
将步骤S2制备得到的浆料，使用喷雾塔进行制粉；制粉的颗粒级配控制在：30目上筛13-30%，60目上筛累计≥88%，60-100目筛≤10%，100目筛下≤2%；
S4.半成品制备
将步骤S3制备得到的粉末，经24h陈腐后压制、窑前干燥，最后烧成半成品坯体。
5.根据权利要求4所述的一种具有高韧性的瓷砖的制备方法，其特征在于，所述步骤S1中，盐酸浓度为0.8-1.3mol/L。
6.根据权利要求4所述的一种具有高韧性的瓷砖的制备方法，其特征在于，所述步骤S2中，球磨处理要求：浆料水分控制在33-34%，浆料的细度控制在250-300目，浆料的细度筛余量为2-3%。
7.根据权利要求4所述的一种具有高韧性的瓷砖的制备方法，其特征在于，所述步骤S4中，烧成温度为1150-1200℃。
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