Large-size ceramic rock plate and preparation method thereof

A large-scale, ceramic technology, applied in the field of ceramic tiles, can solve the problems of dry cracked bricks, many cracked bricks during transportation, troubles in the industry, and low drying pass rate, so as to improve the strength of green bodies, eliminate residual stress, and increase yields. Effect

Active Publication Date: 2020-09-11

FUJIAN DESHENG NEW BUILDING MATERIAL CO LTD

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AI-Extracted Technical Summary

Problems solved by technology

However, most of the existing rock slabs are 1200×1600mm in size 2 、2400×1800mm 2 、2400×1200mm 2 And other specifications, still unable to meet the requirements of large home decoration (cooktop, cabinet, bathroom cabinet, etc.)

On the other hand, the existing rock slab production system is immature, resulting in cracked bricks during drying and transportati...

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Method used

Wherein, low-temperature toughening agent refers to the material that plays toughening effect below 1000 ℃; Specifically, it can be cellulose ether, sodium polyacrylate, lignin, modified polysaccharide or tobermullite; Preferred is tobermolite; tobermolite is in the form of whiskers, which can improve the strength of the green body during the molding stage; when the firing temperature is lower than 1000°C, its main reaction is phase transformation, and It does not melt, and the whisker structure is maintained; thus, the thermal stress during the firing process is better eliminated.

[0051] The Al content in calcined kaolin can reach more than 40wt%, and a large number of acicular mullite whiskers will be formed in the subsequent firing process, thereby establishing a weak in...

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Abstract

The invention discloses a large-size ceramic rock plate which has a surface area of 3-12m<2> and a thickness of 12-30mm. The large-size ceramic rock plate comprises a green body layer, a ground coat layer, a pattern layer and a cover coat layer; wherein the thickness of the green body layer is 11.5-29.5mm; the green body layer is mainly prepared from the following raw materials by weight: 15-20 parts of potassium feldspar, 8-15 parts of albite, 15-20 parts of calcined kaolin, 12-20 parts of black mud, 8-15 parts of white mud, 15-20 parts of pyrophyllite and 1-10 parts of a toughening agent; wherein the sum of the weight parts of the raw materials is 100 parts. The ceramic rock plate can well adapt to a later deep processing technology, can be widely applied to the fields of floors, curtainwalls and veneers, and has the advantages of high strength, high hardness, acid and alkali resistance, high temperature resistance and the like.

Application Domain

Covering/linings

Technology Topic

Potassium feldsparKaolin clay +5

Image

Examples

Experimental program(6)
Comparison scheme(2)

Example Embodiment

[0057] Correspondingly, refer to figure 2 , the present invention also discloses a method for preparing the above-mentioned large-scale ceramic rock slab, which includes the following steps:

[0058] S1: Mix various raw materials evenly according to the formula, and ball mill to obtain slurry;

[0059] Specifically, the formula is: 15-20 parts of potassium feldspar, 8-15 parts of albite, 15-20 parts of calcined kaolin, 12-20 parts of black mud, 8-15 parts of white mud, 15-20 parts of pyrophyllite, 1-10 parts of the toughening agent; the sum of the parts by weight of the above raw materials is 100 parts. The above formula can be better applied to the existing production line, reduce drying breakage, breakage during transportation and firing breakage, and increase the yield of finished products. At the same time, this formula can also ensure that the deformation is relatively uniform during the drying and firing process, and the passing rate of drying and firing can be improved.

[0060] Preferably: 18 parts of potassium feldspar, 11 parts of albite, 18 parts of calcined kaolin, 16 parts of black mud, 10 parts of white mud, 17 parts of pyrophyllite, 2.5 parts of tobermolite, and 6.5 parts of forsterite.

[0061] Specifically, after ball milling, the fineness of the slurry should be controlled so that the residue on the 250-mesh sieve is <0.5%.

[0062] S2: Spray-dry the slurry, and obtain powder after sieving;

[0063] The ceramic rock slabs in the present invention have relatively high thickness and large specifications, which require high uniformity of cloth distribution. For this reason, it is necessary to control the particle size distribution of the powder. Specifically, the particle gradation of the powder in the present invention is: >20 mesh accounts for 1-4wt%; 20-40 mesh accounts for 30-40wt%; 40-60 mesh accounts for 25-35wt%, 60-120 Mesh accounts for 10-17wt%, 120-200 mesh accounts for 5-10wt%, and 200 mesh or less accounts for 1-5wt%.

[0064] The traditional ceramic brick powder or ceramic slab powder is relatively fine, and its proportion of more than 60 mesh is 30-50%. However, the present invention can account for 50-80%; the fluidity is greatly improved, and it is convenient for cloth.

[0065] Correspondingly, in order to obtain the powder with the above particle gradation, it is necessary to control the formula and milling process; specifically, in terms of formula, control black mud + white mud: pyrophyllite = 1-2.1. In terms of powder making process, after spray drying, add a sieving process; for example, the powder obtained by spraying the spray tower can be divided into two halves, one half of which passes through a 60-mesh sieve, and the other half does not pass through the sieve directly, and then mix the two , to obtain powder.

[0066] S3: pressing the powder to obtain a green body;

[0067] It should be noted that there are generally three methods for pressing large-scale ceramic plates, continuous roll forming, belt dry pressing and mold cavity dry pressing. In the present invention, belt dry pressing and mold cavity dry pressing can be selected; preferably, mold cavity dry pressing is used, which has low internal stress, and the green body obtained by pressing has good flatness and high dimensional accuracy.

[0068] Further, the pressing pressure during the control pressing process is not less than 400kg/cm 2; Because the powder particles in the present invention are relatively large and the air content is high, a larger pressure exhaust can be used to improve the degree of compaction of the green body, improve the drying pass rate, and the firing pass rate.

[0069] S4: applying a primer on the green body to form a primer layer;

[0070] Specifically, the green body is dried before applying the primer.

[0071] S5: inkjet printing on the underglaze layer to form a pattern layer;

[0072] S6: applying a top glaze on the pattern layer to form a top glaze layer to obtain a green body;

[0073] Specifically, prior art can be used for the base glaze, ink, and top glaze.

[0074] S7: firing the green body to obtain a finished large-scale ceramic rock slab;

[0075] Specifically, S7 includes:

[0076] S71: firing the green body; wherein, the firing temperature is 1200-1300° C., and the firing cycle is 60-150 minutes;

[0077] S72: Polishing the fired green body to obtain a finished large-sized ceramic rock plate.

Example Embodiment

[0079] Example 1

[0080] This embodiment provides a large-scale ceramic slab, its size is 3600 × 2000 × 20mm 3; Wherein, the thickness of green body layer is 19mm;

[0081] The formula of green body layer is:

[0082] 19 parts of potassium feldspar, 12 parts of albite feldspar, 16 parts of calcined kaolin, 18 parts of black mud, 10 parts of white mud, 18 parts of pyrophyllite, 1 part of low-temperature toughening agent, and 6 parts of high-temperature toughening agent;

[0083] Among them, 80% of the particles in the calcined kaolin have a particle size of less than 1 μm; methyl cellulose is used as the low-temperature toughening agent, and mullite whiskers are used as the high-temperature toughening agent;

[0084] Preparation method of ceramic rock plate:

[0085] (1) Mix various raw materials uniformly according to the formula, and ball mill to obtain slurry;

[0086] Wherein, the 250 mesh sieve of slurry is 0.2%;

[0087] (2) The slurry is spray-dried, and the powder is obtained after sieving;

[0088] Specifically, the particle size distribution of the powder is:

[0089]20 mesh accounted for 2wt%; 20-40 mesh accounted for 38wt%; 40-60 mesh accounted for 32wt%, 60-120 mesh accounted for 16wt%, 120-200 mesh accounted for 8wt%, 200 mesh accounted for 4wt% %.

[0090] (3) pressing the powder to obtain a green body;

[0091] Specifically, the HT36000 press is used for pressing, and the forming pressure is 450kg/cm 2.

[0092] (4) Applying a bottom glaze on the green body to form a bottom glaze layer;

[0093] (5) inkjet printing to the bottom glaze layer to form a pattern layer;

[0094] (6) Apply top glaze on the pattern layer to form a top glaze layer to obtain a green body;

[0095] (7) firing the green body to obtain the finished product of large-scale ceramic rock slab;

[0096] Wherein, the firing temperature is 1300° C., and the firing cycle is 120 minutes.

Example Embodiment

[0097] Example 2

[0098] This embodiment provides a large-scale ceramic slab, its size is 3600 × 1800 × 25mm 3; Wherein, the thickness of green body layer is 24.5mm;

[0099] The formula of green body layer is:

[0100] 19 parts of potassium feldspar, 12 parts of albite feldspar, 16 parts of calcined kaolin, 18 parts of black mud, 10 parts of white mud, 18 parts of pyrophyllite, 1 part of low-temperature toughening agent, and 6 parts of high-temperature toughening agent;

[0101] Among them, 90% of the particles in the calcined kaolin have a particle size of less than 1 μm; tobermolite is selected as the low-temperature toughening agent, and steatite is selected as the high-temperature toughening agent;

[0102] Preparation method of ceramic rock plate:

[0103] (1) Mix various raw materials uniformly according to the formula, and ball mill to obtain slurry;

[0104] Wherein, the 250 mesh sieve of slurry is 0.4%;

[0105] (2) The slurry is spray-dried, and the powder is obtained after sieving;

[0106] Specifically, the particle size distribution of the powder is:

[0107]20 mesh accounted for 2wt%; 20-40 mesh accounted for 37wt%; 40-60 mesh accounted for 33wt%, 60-120 mesh accounted for 16wt%, 120-200 mesh accounted for 9wt%, 200 mesh accounted for 3wt% %.

[0108] (3) pressing the powder to obtain a green body;

[0109] Specifically, the HT36000 press is used for pressing, and the forming pressure is 480kg/cm 2.

[0110] (4) Applying a bottom glaze on the green body to form a bottom glaze layer;

[0111] (5) inkjet printing to the bottom glaze layer to form a pattern layer;

[0112] (6) Apply top glaze on the pattern layer to form a top glaze layer to obtain a green body;

[0113] (7) firing the green body to obtain the finished product of large-scale ceramic rock slab;

[0114] Wherein, the firing temperature is 1280° C., and the firing cycle is 100 min.

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PUM

Property	Measurement	Unit
Depth	5.0 ~ 10.0	mm
The inside diameter of	495.0	mm
Outer diameter	500.0	mm
tensile		MPa
Particle size		Pa
strength	10

Description & Claims & Application Information

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the structure of the environmentally friendly knitted fabric provided by the present invention; figure 2 Flow chart of the yarn wrapping machine for environmentally friendly knitted fabrics and storage devices; image 3 Is the parameter map of the yarn covering machine

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Classification and recommendation of technical efficacy words

Relief of residual stress

Large-size ceramic rock plate and preparation method thereof

AI-Extracted Technical Summary

Problems solved by technology

Method used

Abstract

Image

Examples

Example Embodiment

Example Embodiment

Example Embodiment

PUM

Description & Claims & Application Information

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