CN115490502B - 一种卫生陶瓷用低温快烧坯体 - Google Patents
一种卫生陶瓷用低温快烧坯体 Download PDFInfo
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Abstract
本发明涉及无机材料技术领域,尤其涉及一种卫生陶瓷用低温快烧坯体。所述坯体的泥料由以下质量百分比的原料组成:FFC料煅烧焦宝石28%~40%,高岭土35%~45%,白泥15%~25%,石英6%‑15%,透辉石1%~5%,长石1%~10%,滑石1%~3%,纤维状或针状硅灰石1%~5%。本发明通过对坯体泥料的组成和配比的控制,降低了烧成温度,且烧制过程中体积收缩小、周期短;同时制得的卫生陶瓷具有吸水率低、热稳定性、抗龟裂性和吸湿膨胀性优的特点,获得了性能优异的陶瓷制品,同时达到节能的目的。
Description
技术领域
本发明涉及无机材料技术领域,尤其涉及一种卫生陶瓷用低温快烧坯体。
背景技术
目前,卫生陶瓷洁具生产时采用的原料可分为传统长石、石英、黏土三元体系和陶质精细耐火粘土***(Fine Fire Clay,FFC)两类。
前者用于生产瓷质卫生陶瓷坯体,经1200℃左右高温烧成后坯体中含有玻璃相、莫来石、石英和气孔,产品吸水率通常≤0.5%。由于大量熔剂类原料长石等的使用,其在烧成过程中形成液相促进坯体瓷化的同时,也导致制品烧成收缩大(11-12%)、变形大,难以用于各种造型的大型柜式洗面器等卫生洁具生产。
后者采用FFC泥浆料生产的卫生洁具产品吸水率一般为8-13%,属于炻陶质卫生陶瓷,这类卫生陶瓷坯体的材质属于“精陶”,施釉后,可称为“施釉精陶”。
FFC泥浆配方中一般加入30%左右的煅烧粘土类熟料,同时加入的长石类原料量减少,玻璃相明显减少,高温塑性变形减小,烧成收缩和烧成变形远远小于传统三元配方体系,产品规整度也得到明显改善。同时由于煅烧粘土类熟料中带入一部分莫来石,莫来石的含量明显提高,可以保持足够的烧成抗折强度。尽管该配方体系引起气孔大幅度提高,造成制品吸水率较高,但是,由于烧成收缩小、变形率低、烧成合格率高,适合制作直角大台面柜式洗面器。为此,FFC泥浆制作卫生陶瓷已成为我国卫生陶瓷生产中的一个亮点。(Journalof the Australian Ceramic Society,2017,53:157-162;陶瓷,2019,4:62-67)
近几年来,随着天然气等燃料价格的上涨,卫生陶瓷烧成成本日益攀升。为了节约能源,提高生产效率和增加企业效益,采用低温烧成工艺是卫生陶瓷行业发展的必然趋势。其中,合理的坯料配方是低温烧成工艺成功的关键。卫生陶瓷的大部分理化指标以及泥浆的成形性能等都取决于坯料配方。
发明内容
针对以上技术问题,本发明提供了一种卫生陶瓷用低温快烧坯体,通过控制坯体泥料的组成及配比,在保证产品低变形率的前提下,实现卫生陶瓷低温快烧,降低产品烧成温度,缩短烧成周期,达到节能的目的。
本发明采用以下技术方案:
一种卫生陶瓷用低温快烧坯体,所述坯体的泥料由以下质量百分比的原料组成:FFC料煅烧焦宝石28%~40%,高岭土35%~45%,白泥15%~25%,石英6%-15%,透辉石1%~5%,长石1%~10%,滑石1%~3%,纤维状或针状硅灰石1%~5%。
本发明利用FFC坯体中莫来石含量相对较高的特点,在细磨FFC原料促进其烧成同时,引入一定量的透辉石、长石、滑石和纤维状或针状硅灰石作为助熔剂原料。引入纤维状或针状原料一方面可以防止坯体中微裂纹扩展,提高陶瓷断裂模量,另一方面还会在高温分解形成针状莫来石互锁网络增加制品机械强度和热稳定性。借助原料中引入碱金属氧化物和碱土金属氧化物双碱效应形成适量较高粘度的液相,通过液相毛细管作用重新排列颗粒,使其成为紧密堆积,促进小颗粒溶解进入液相,并经液相转移至粗颗粒表面析出,使坯体进一步致密化。
本发明通过引入合适的熔剂类原料,调整烧成过程中液相生成温度、粘度、润湿性及其随温度的变化,使烧成易于控制,减少产品变形,同时促进瓷坯中莫来石相含量增加并发育成针状晶体,在坯体中交叉排列成网状结构,提高瓷坯的机械强度、热稳定性。
进一步的,所述坯体的泥料由以下质量百分比的原料组成:FFC料煅烧焦宝石30%,高岭土37%,白泥18%,石英8%,透辉石1%,长石3%,滑石1%,纤维状或针状硅灰石2%。
进一步的,所述坯体的泥料原料干燥后的化学组成为:SiO2 63.6%,Al2O325.1%,CaO 1%,MgO 0.8%,Fe2O3 0.6%,TiO2 0.8%,K2O 2.8%,Na2O 1.3%,IL 4%。
进一步的,所述FFC料煅烧焦宝石的粒径为过325目筛后筛余量为4-6wt%。
进一步的,所述坯体采用以下方法制备:将上述原料依次加入球磨机中混合均匀,注浆成型,在1100-1160℃下烧成,降温,即得。
进一步的,原料混合前,还包括对FFC料煅烧焦宝石的预处理:将FFC料煅烧焦宝石球磨6-12h至过325目筛后筛余量为4-6wt%。通过对FFC料煅烧焦宝石进行球磨预处理,在保证原料充分细磨促进低温烧成的同时,还确保了泥料的成型性能。
进一步的,烧成时间为6-12h。
传统的陶瓷卫生洁具烧成温度在1200-1250℃之间,烧成周期为13-20h,能耗800-1200kcal/kg瓷。本发明通过调控坯体泥料的配方,使得在较低的烧成温度1100-1160℃、较短的烧成周期6-12h、较低的能耗450-800kcal/kg瓷下即可制备得到,实现有效节能。同时,产品制造过程中收缩小,干燥收缩≤3%,烧成收缩≤4%,总收缩6-8%之间,接近于FFC卫生洁具,比瓷质卫生洁具干燥收缩≥3.5%和烧成收缩小≥8%,总收缩11-13%要小很多。利用该发明坯体泥料配方生产的卫生陶瓷吸水率小,在0.2-3%,介于瓷器及炻瓷器之间,比国际级上流行的FFC卫生洁具吸水率≥10%低很多。标准变形度小(两端支撑法200×30×15MM):瓷质卫生洁具变形度19-24MM,本发明制得的产品标准变形度6-8MM。产品热稳定性、抗龟裂性、吸湿膨胀性远远优于FFC制品,与瓷质卫生洁具一致,有效避免了产品使用及安全问题。
本发明的卫生陶瓷用低温快烧坯体,通过对坯体泥料的组成和配比的控制,降低了烧成温度,且烧制过程中体积收缩小、周期短;同时制得的卫生陶瓷具有吸水率低、热稳定性、抗龟裂性和吸湿膨胀性优的特点,获得了性能优异的陶瓷制品,同时达到节能的目的。
具体实施方式
下面将结合本发明中的实施例,对本发明实施例中的技术方案进行清楚、完整的描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通的技术人员在没有做出创造性劳动的前提下所获得的所有其它实施例,都属于本发明的保护范围。
实施例1
一种卫生陶瓷用低温快烧坯体,所述坯体的泥料由以下质量百分比的原料组成:FFC料煅烧焦宝石30%,高岭土37%,白泥18%,石英8%,透辉石1%,长石3%,滑石1%,纤维状硅灰石2%。
其制备方法为:将上述原料依次加入球磨机中混合均匀,注浆成型,在1115℃下烧成,烧成周期为7h,能耗530kcal/kg瓷,降温,即得。
其中,FFC料煅烧焦宝石进行预处理,球磨10h过325目筛,筛余量为5wt%。
坯体的实验式如下:
(0.07CaO+0.077MgO+0.124K2O+0.088Na2O)·(0.983Al2O3+0.017Fe2O3)·4.27SiO2
实施例2
一种卫生陶瓷用低温快烧坯体,所述坯体的泥料由以下质量百分比的原料组成:FFC料煅烧焦宝石35%,高岭土35%,白泥20%,石英6%,透辉石1%,长石1%,滑石1%,纤维状硅灰石2%。
其制备方法为:将上述原料依次加入球磨机中混合均匀,注浆成型,在1100℃下烧成,烧成周期为6h,能耗480kcal/kg瓷,降温,即得。
其中,FFC料煅烧焦宝石进行预处理,球磨12h过325目筛,筛余量为4.25wt%。
坯体的实验式如下:
(0.0679CaO+0.0761MgO+0.1092K2O+0.0771Na2O)·(0.977Al2O3+0.023Fe2O3)·3.944SiO2
实施例3
一种卫生陶瓷用低温快烧坯体,所述坯体的泥料由以下质量百分比的原料组成:FFC料煅烧焦宝石30%,高岭土37%,白泥15%,石英6%,透辉石1%,长石9%,滑石1%,针状硅灰石1%。
其制备方法为:将上述原料依次加入球磨机中混合均匀,注浆成型,在1130℃下烧成,烧成周期为8h,能耗640kcal/kg瓷,降温,即得。
其中,FFC料煅烧焦宝石进行预处理,球磨9h过325目筛,筛余量为5.5wt%。
坯体的实验式如下:
(0.0697CaO+0.0796MgO+0.1229K2O+0.0965Na2O)·(0.9786Al2O3+0.0214Fe2O3)·4.08SiO2
实施例4
一种卫生陶瓷用低温快烧坯体,所述坯体的泥料由以下质量百分比的原料组成:FFC料煅烧焦宝石30%,高岭土40%,白泥15%,石英10%,透辉石1%,长石2%,滑石1%,针状硅灰石1%。
其制备方法为:将上述原料依次加入球磨机中混合均匀,注浆成型,在1145℃下烧成,烧成周期为9h,能耗730kcal/kg瓷,降温,即得。
其中,FFC料煅烧焦宝石进行预处理,球磨11h过325目筛,筛余量为4.7wt%。
坯体的实验式如下:
(0.0717CaO+0.0812MgO+0.1183K2O+0.0913Na2O)·(0.978Al2O3+0.022Fe2O3)·4.3816SiO2
实施例5
一种卫生陶瓷用低温快烧坯体,所述坯体的泥料由以下质量百分比的原料组成:FFC料煅烧焦宝石28%,高岭土36%,白泥16%,石英8%,透辉石3%,长石2%,滑石2%,针状硅灰石5%。
其制备方法为:将上述原料依次加入球磨机中混合均匀,注浆成型,在1160℃下烧成,烧成周期为10h,能耗780kcal/kg瓷,降温,即得。
其中,FFC料煅烧焦宝石进行预处理,球磨10h过325目筛,筛余量为5wt%。
坯体的实验式如下:
(0.168CaO+0.1567MgO+0.1231K2O+0.091Na2O)·(0.978Al2O3+0.023Fe2O3)·4.484SiO2
对比例1
本对比例与实施例1基本一致,区别仅在于原料组成中纤维状硅灰石替换为颗粒状硅灰石。具体如下:
一种卫生陶瓷用坯体,所述坯体的泥料由以下质量百分比的原料组成:FFC料煅烧焦宝石30%,高岭土37%,白泥18%,石英8%,透辉石1%,长石3%,滑石1%,颗粒状硅灰石2%。
其制备方法为:将上述原料依次加入球磨机中混合均匀,注浆成型,在1115℃下烧成,烧成周期为13h,能耗820kcal/kg瓷,降温,即得。
其中,FFC料煅烧焦宝石进行预处理,球磨10h过325目筛,筛余量为5wt%。
对比例2
本对比例与实施例1基本一致,区别仅在于不对FFC料煅烧焦宝石进行球磨预处理,其粒度为8目以上。具体如下:
一种卫生陶瓷用低温快烧坯体,所述坯体的泥料由以下质量百分比的原料组成:FFC料煅烧焦宝石30%,高岭土37%,白泥18%,石英8%,透辉石1%,长石3%,滑石1%,纤维状硅灰石2%。
其制备方法为:将上述原料依次加入球磨机中混合均匀,注浆成型,在1115℃下烧成,烧成周期为18h,能耗1055kcal/kg瓷,降温,即得。
对比例3
本对比例与实施例1基本一致,区别仅在于原料组成中不包含长石。具体如下:
一种卫生陶瓷用坯体,所述坯体的泥料由以下质量百分比的原料组成:FFC料煅烧焦宝石30%,高岭土37%,白泥18%,石英11%,透辉石1%,滑石1%,纤维状硅灰石2%。
其制备方法为:将上述原料依次加入球磨机中混合均匀,注浆成型,在1225℃下烧成,烧成周期为20h,能耗1180kcal/kg瓷,降温,即得。
其中,FFC料煅烧焦宝石进行预处理,球磨10h过325目筛,筛余量为5wt%。
将实施例1-5和对比例1-3制得的坯料性能进行测试,结果如表1所示。
表1
由实施例1-5及表1测试结果可知,采用本发明的坯体泥料配方,在降低能耗的前提下,产品在制造过程中收缩小,其中干燥收缩率≤3%,烧成收缩率≤4%,总收缩率在6-8%之间,同时其吸水率也比国际级上流行的FFC卫生洁具吸水率≥10%低很多;变形度也低于瓷质卫生洁具的变形度19-24MM。产品具有优异的热稳定性、抗龟裂性以及吸湿膨胀性。由实施例1及对比例1的测试结果比对可见,实施例1的收缩率和变形度要低于对比例1,主要是由于本发明采用的针状或纤维状的硅灰石结构,与颗粒状硅灰石结构相比,更有助于防止坯体中微裂纹的扩展;由实施例1及对比例2的测试结果比对可见,通过对FFC料煅烧焦宝石的充分细磨,在低温烧成条件下得到的坯料性能更佳;由实施例1及对比例3的测试结果比对可见,通过引入碱金属氧化物和碱土金属氧化物双碱效应,有助于促进小颗粒进入液相,使坯体进一步致密化。
综上所述,本发明的卫生陶瓷用低温快烧坯体,通过对坯体泥料的组成和配比的控制,在较低的烧成温度、较短的烧成时间下,制得的产品具有吸水率低、热稳定性、抗龟裂性和吸湿膨胀性优的特点,获得了性能优异的陶瓷制品。
以上借助具体实施例对本发明做了进一步描述,但是应该理解的是,这里具体的描述,不应理解为对本发明的实质和范围的限定,本领域内的普通技术人员在阅读本说明书后对上述实施例做出的各种修改,都属于本发明所保护的范围。
Claims (6)
1.一种卫生陶瓷用低温快烧坯体,其特征在于,所述坯体的泥料由以下质量百分比的原料组成:FFC料煅烧焦宝石28%~40%,高岭土35%~45%,白泥15%~25%,石英6%-15%,透辉石1%~5%,长石1%~10%,滑石1%~3%,纤维状或针状硅灰石1%~5%;所述FFC料煅烧焦宝石的粒径为过325目筛后筛余量为4-6wt%。
2.根据权利要求1所述的卫生陶瓷用低温快烧坯体,其特征在于,由以下质量百分比的原料组成:FFC料煅烧焦宝石30%,高岭土37%,白泥18%,石英8%,透辉石1%,长石3%,滑石1%,纤维状或针状硅灰石2%。
3.根据权利要求2所述的卫生陶瓷用低温快烧坯体,其特征在于,所述坯体的泥料原料干燥后的化学组成为:SiO2 63.6%,Al2O3 25.1%,CaO 1%,MgO 0.8%,Fe2O3 0.6%,TiO20.8%,K2O 2.8%,Na2O 1.3%,IL 4%。
4.根据权利要求1-3中任一项所述的卫生陶瓷用低温快烧坯体,其特征在于,采用以下方法制备:将上述原料加入球磨机中混合均匀,注浆成型,在1100-1160℃下烧成,降温,即得。
5.根据权利要求4所述的卫生陶瓷用低温快烧坯体,其特征在于,原料混合前,还包括对FFC料煅烧焦宝石的预处理:将FFC料煅烧焦宝石球磨6-12h至过325目筛后筛余量为4-6wt%。
6.根据权利要求4所述的卫生陶瓷用低温快烧坯体,其特征在于,烧成时间为6-12h。
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