A large-sized floor and its production method

Abstract

The present invention discloses a production method for large-sized floor tiles, which comprises the steps of: (1) preparing ceramic slurry: after mixing ceramic raw materials, adding a certain amount of body strengthener, wet-milling in a ball mill and then sieving, and adding water to the slurry under the sieve to prepare ceramic slurry; (2) preparing a forming device: detachably installing a filter base plate fixedly assembled by one or more microporous ceramic filter plates on a conveying chain plate provided with filter holes, laying a filter cloth on the upper surface of the filter base plate, and then using a filter frame formed by trimming the microporous ceramic filter plate, covering the filter frame downward and fixedly on the filter base plate, and the filter base plate and the filter frame enclose a filter cavity; (3) filtering and dewatering: sending a certain mass of ceramic slurry to the filter cavity for standing, and performing suction filtration from the bottom of the filter base plate, so as to dehydrate the ceramic slurry to form a brick blank; (4) drying and then firing once; (5) firing twice.

Description

Technical Field

[0001] The present invention relates to the field of building ceramics, and particularly to a large-size floor and a production method thereof. Background Art

[0002] China is a major producer, consumer, and exporter of ceramic tiles. The output of ceramic tiles in China continues to increase at a relatively fast rate. While the ceramic tile industry is developing rapidly, there are also problems such as excessive consumption of raw materials and energy, and the "three wastes" aggravating environmental pollution, which seriously restrict the sustainable development of the ceramic industry. For ceramic tiles, the smaller the thickness and the larger the size, the lower the energy consumption; the smaller the thickness, the less the raw material consumption. In addition, it can also save water resources, reduce waste emissions, and save transportation costs. Therefore, the production of thin and reduced ceramic tiles is an important way for the ceramic tile industry to save resources, energy, and reduce emissions, and is also the future development direction of the ceramic tile industry.

[0003] Technically, the maximum size and thickness of ceramic tiles are greatly restricted by the strength of the green body, sintering deformation, and sintering strength. The larger the size and the thinner the thickness, the more prone the product is to crack during drying and warp during sintering, and the lower the final strength. Therefore, the thickness of existing ceramic tiles is usually above 8 mm, and the area is less than 1 square meter. The area sizes are usually 400×400 mm, 600×600 mm, 800×800 mm, 1000×1000 mm, etc. Generally, the thickness of 800×800 mm polished tiles is about 9 - 12 mm, and the thickness of 300×450 mm and 300×600 mm sized porcelain tiles is about 7 - 10 mm. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a large-size floor and a production method thereof, which can increase the size and reduce the thickness while ensuring the strength.

[0005] The technical solution adopted by the present invention to solve the technical problem is: a production method of a large-size floor, which includes the steps of:

[0006] (1) Prepare ceramic slurry: After mixing ceramic raw materials, add a certain amount of green body strengthening agent, wet grind in a ball mill and then pass through a sieve, and add water to the slurry under the sieve to adjust it into a ceramic slurry with a viscosity of 5000 - 6000 mPas;

[0007] (2) Prepare a forming device: Disassemblably install a filter substrate fixed and assembled by one or more microporous ceramic filter plates on a conveying chain plate provided with filter holes, lay a filter cloth on the upper surface of the filter substrate, and then use a filter frame cut from the microporous ceramic filter plate, and fix and cover the filter frame downward on the filter substrate. The filter substrate and the filter frame enclose a filter cavity;

[0008] (3) Filtration and dehydration: Send a certain mass of ceramic slurry to the filter cavity for static settlement, and conduct suction filtration from the bottom of the filter substrate, so as to dehydrate the ceramic slurry to form a brick blank;

[0009] (4) Drying and first firing: Send the brick blank into the drying room together with the forming device through the conveying chain plate for drying. After the moisture content of the brick blank is reduced to 5% - 6%, horizontally flip the brick blank 180° together with the forming device and send it to the conveying belt. Then, sequentially remove the filter substrate, filter cloth, and filter frame upward. The conveying belt sends the brick blank into the roller hearth kiln for first firing, and then grind the brick surface flat;

[0010] (5) Second firing: After the first firing, send it into the roller hearth kiln again for second firing, and then obtain the finished floor after trimming and polishing.

[0011] Preferably, the microporous ceramic filter plate is a 200 - mesh alumina ceramic filter plate, with a water absorption rate of 23.3%, a porosity of 35.2%, and a water permeability of 260.7 kg / m 2 .h.

[0012] Preferably, the filter cloth is a multifilament plain weave nylon filter cloth, with an air permeability of 150 - 500 L / m 2 .h.

[0013] Preferably, the body strengthening agent is water glass, with a particle size of 200 mesh, and its mass composition is 15% Na 2 O, 32% SiO 2 , with a density of 1580 kg / m 3 .

[0014] Preferably, the ceramic raw materials include 33.7 - 37.8 parts of kaolin, 8.9 - 13.1 parts of talc, 16.2 - 18.2 parts of Bo'ai clay, 4.4 - 6.8 parts of wollastonite, and 27.6 - 30.2 parts of quartz sand.

[0015] Preferably, glaze is applied on the brick surface after the first firing and before the second firing.

[0016] The present invention also claims to protect the large - sized floor obtained by the above - mentioned method.

[0017] The large - sized floor of the present invention has a dry shrinkage rate of only about 5.2%; relative to the size of the wet blank, the final total linear shrinkage rate of the large - sized floor of the present invention is about 15%. On the premise of meeting the strength requirements of GBT4100 - 2015, its thickness can be thinned to about 5 mm, and the area is as high as 1.62 m 2 , and there is no cracking phenomenon, having great application prospects in the building materials industry. Description of the Drawings

[0018] Figure 1Partial structural schematic diagram of the forming device of the present invention;

[0019] Figure 2 Cross-sectional view of the forming device of the present invention; Detailed implementation manners

[0020] Example 1:

[0021] (1) Prepare ceramic slurry: After mixing 37.8 parts of kaolin, 8.9 parts of talc, 16.2 parts of Bo'ai soil, 6.8 parts of wollastonite, and 30.2 parts of quartz sand, add 3% of water glass, and then wet grind in a ball mill for 16 h and pass through a 250-mesh sieve. Add water to the slurry under the sieve to adjust the viscosity to 5000 mPas to obtain the ceramic slurry, and the density of the obtained ceramic slurry is 1.7 kg / m 3 ;

[0022] (2) Prepare the forming device: As Figure 1 (for easy understanding, Figure 1 the filter cloth 25 is not shown in the figure), Figure 2 as shown in the figure, the filter substrate formed by fixedly assembling four microporous ceramic filter plates 23 is detachably installed on the conveying chain plate provided with filter holes ( Figure 1 only the conveying chain plates 1a, 1b, 1c, and 1d are shown in the figure). Lay the filter cloth 25 on the upper surface of the filter substrate, and then use the filter frame 24 (open at both the upper and lower ends) formed by trimming the edges of the microporous ceramic filter plate, and fixedly cover the filter frame 24 downward on the filter substrate. The filter substrate and the filter frame enclose a filter cavity 2S;

[0023] In this embodiment, the four microporous ceramic filter plates 23 are closely assembled to form a 2×2 rectangular array, and are fixedly assembled together by a rectangular lower die frame 21 made of stainless steel. The lower die frame 21 includes a filter substrate 21a and a frame 21b fixed to the upper edge of the filter substrate. The filter substrate 21a is provided with filter holes (aligned with the filter holes of the conveying chain plate). The four microporous ceramic filter plates 23 are embedded in the lower die frame 21. A total of two right-angle positioning members 11 are fixedly provided on the conveying chain plates 1a and 1d, one on the left and one on the right. The right-angle positioning members 11 position the lower die frame 21 on the conveying chain plates 1a, 1b, 1c, and 1d from the four corners. A total of two side positioning members 12 are fixedly provided on the conveying chain plates 1b and 1c, one on the left and one on the right, to assist in positioning the lower die frame 21 on the left and right sides.

[0024] The filter frame 24 is embedded in the upper die frame 22. The lower end of the filter frame 24 protrudes downward relative to the lower end of the filter frame 24 and can be buckled on the lower die frame 21.

[0025] (3) Filtration and dehydration: Send a certain mass of ceramic slurry into the filter chamber 2S and let it stand still. Under the conveying chain plates 1a, 1b, 1c, and 1d, perform suction filtration from the bottom of the filter substrate through a square pipe connected to the suction filtration device (the vacuum degree is maintained between 10 Kpa and 20 Kpa during suction filtration), so as to dehydrate the ceramic slurry to form a brick blank;

[0026] (4) Drying and then first firing: Send the brick blank into the drying room together with the forming device through the conveying chain plate for drying (the front-end temperature of drying is 50 °C, and the back-end temperature of drying is 75 °C). After the moisture content of the brick blank drops to 5.5%, turn the brick blank horizontally by 180° together with the forming device and send it to the conveying belt. Then, remove the filter substrate, filter cloth, and filter frame upward in sequence. The conveying belt sends the brick blank into the roller hearth kiln for the first firing, and then grind the brick surface flat;

[0027] (5) Second firing: After the first firing, send it into the roller hearth kiln again for the second firing, and then obtain the finished floor after trimming and polishing (specimen number 1#).

[0028] Example 2:

[0029] (1) Prepare ceramic slurry: Mix 39.9 parts of kaolin, 9.6 parts of talc, 18.2 parts of Bo'ai soil, 4.6 parts of wollastonite, and 27.6 parts of quartz sand. After adding 4% of sodium silicate, wet grind in a ball mill for 14 h and then pass through a 250-mesh sieve. Add water to the slurry under the sieve to adjust it into a ceramic slurry with a viscosity of 5500 mPas. The density of the prepared ceramic slurry is 1.7 kg / m 3 ;

[0030] (2) Prepare the forming device: The same as in Example 1;

[0031] (3) Filtration and dehydration: The same as in Example 1;

[0032] (4) Drying and then first firing: Send the brick blank into the drying room together with the forming device through the conveying chain plate for drying (the front-end temperature of drying is 50 °C, and the back-end temperature of drying is 75 °C). After the moisture content of the brick blank drops to 6%, turn the brick blank horizontally by 180° together with the forming device and send it to the conveying belt. Then, remove the filter substrate, filter cloth, and filter frame upward in sequence. The conveying belt sends the brick blank into the roller hearth kiln for the first firing, and then grind the brick surface flat;

[0033] (5) Second firing: After the first firing, send it into the roller hearth kiln again for the second firing, and then obtain the finished floor after trimming and polishing (specimen number 2#).

[0034] Example 3:

[0035] (1) Preparation of ceramic slurry: After mixing 33.7 parts of kaolin, 13.1 parts of talc, 17.5 parts of Bo'ai clay, 4.4 parts of wollastonite, and 31.2 parts of quartz sand, 5% of water glass was added, and then wet-milled in a ball mill for 15 h and passed through a 250-mesh sieve. Water was added to the screened slurry to adjust it into a ceramic slurry with a viscosity of 6000 mPas. The density of the prepared ceramic slurry was 1.7 kg / m 3 ;

[0036] (2) Preparation of the forming device: The same as in Example 1;

[0037] (3) Filtration and dehydration: The same as in Example 1;

[0038] (4) First firing after drying: The green brick was sent into the drying oven together with the forming device through the conveying chain plate for drying (the front-end temperature of drying was 50 °C, and the back-end temperature of drying was 75 °C). After the moisture content of the green brick was reduced to 5%, the green brick was horizontally flipped 180° together with the forming device and then sent to the conveying belt. Then, the filter substrate, filter cloth, and filter frame were successively removed upward. The conveying belt sent the green brick into the roller hearth kiln for the first firing, and then the brick surface was ground flat;

[0039] (5) Second firing: After the first firing, it was sent into the roller hearth kiln again for the second firing, and then after trimming and polishing, the finished floor (specimen number 3#) was obtained.

[0040] In the present invention, the alumina ceramic filter plate was purchased from Pingxiang Hengchang Chemical New Materials Co., Ltd., with a specification of 800*800*70 mm (length × width × thickness), a water absorption rate of 23.3%, a porosity of 35.2%, and a water permeability of 260.7 kg / m 2 .h. The filter cloth was a multifilament plain nylon filter cloth (Henan Keyi Filter Cloth Co., Ltd., with an air permeability of 150 - 500 L / m 2 .h). The above-mentioned body strengthening agent was water glass, with a particle size of 200 mesh, and its effective component content was 15 wt% Na 2 O, 32 wt% SiO 2 , and a density of 1580 kg / m 3 .

[0041] In the above-mentioned examples, the sintering temperature of the first firing was 700 °C - 800 °C, and the sintering temperature of the second firing was 1300 ± 20 °C.

[0042] In the present invention, four microporous ceramic filter plates with a specification of 800*800*70 mm were rectangularly assembled into a filter substrate with a length and width of 1600*1600 mm. In the present invention, the glazing thickness was not important. For the convenience of comparison, the glazing thickness was set to 0.5 mm. The inner dimensions of the filter frame were all set to 1500*1500*7 mm (length × width × thickness).

[0043] The composition of the ceramic raw materials used in the present invention is shown in Table 1.

[0044] Table 1

[0045]

[0046] Test data:

[0047] The test data of the specimens obtained in the above embodiments are shown in Table 2.

[0048] Table 2

[0049]

[0050] Among them, the dimension data with * in Table 2 are non-measured values, which are the same as the inner dimensions of the filter frame.

[0051] The large-sized floor of the present invention has a drying shrinkage rate of only about 5.2%; relative to the size of the wet blank, the final total linear shrinkage rate of the large-sized floor of the present invention is about 15%. On the premise of meeting the strength requirements of GBT4100-2015, its thickness can be reduced to about 5 mm, and the area is as high as 1.62 m 2 , and there is no cracking phenomenon, and it has great application prospects in the building materials industry.

[0052] In some other embodiments, after the first firing and before the second firing, the brick surface can also be glazed and / or printed.

[0053] The above are only the preferred embodiments of the present invention. It should be noted that for those of ordinary skill in the art, without departing from the principle of the present invention, several improvements and refinements can be made, and these improvements and refinements should also be regarded as the protection scope of the present invention.

Claims

1. A production method of large-sized floor tiles, characterized in that, it includes the steps of: (1) Preparing ceramic slurry: After mixing ceramic raw materials, adding a certain amount of body strengthening agent, wet grinding in a ball mill and then sieving, adding water to the slurry under the sieve to adjust it into a ceramic slurry with a viscosity of 5000 - 6000 mPas; (2) Preparing the forming device: Removably installing a filter substrate fixed and assembled by one or more microporous ceramic filter plates on a conveying chain plate provided with filter holes, laying a filter cloth on the upper surface of the filter substrate, and then using a filter frame cut from the microporous ceramic filter plate, covering the filter frame downward and fixing it on the filter substrate, and the filter substrate and the filter frame enclose a filter cavity; (3) Filtering and dewatering: Sending a certain mass of ceramic slurry into the filter cavity to stand, performing suction filtration from the bottom of the filter substrate, and thus dehydrating the ceramic slurry to form a brick blank; (4) Drying and then firing once: Sending the brick blank into a drying room together with the forming device through the conveying chain plate for drying, after the moisture content of the brick blank drops to 5% - 6%, horizontally flipping the brick blank together with the forming device by 180° and then sending it onto a conveying belt, then successively removing the filter substrate, the filter cloth and the filter frame upward, and the conveying belt sends the brick blank into a roller hearth kiln for firing once, and then grinding the brick surface flat; (5) Firing twice: After firing once, sending it into the roller hearth kiln again for firing twice, and then obtaining the finished floor tiles after trimming and polishing.

2. The production method of large-sized floor tiles according to claim 1, characterized in that, The microporous ceramic filter plate is a 200-mesh alumina ceramic filter plate, with a water absorption rate of 23.3%, a porosity of 35.2%, and a water permeability of 260.7 kg / m 2 .h.

3. The production method of large-sized floor tiles according to claim 1, characterized in that, The filter cloth is a multifilament plain nylon filter cloth with an air permeability of 150 - 500 L / m 2 .h.

4. The production method of large-sized floor tiles according to claim 1, characterized in that, The green body strengthening agent is water glass with a particle size of 200 mesh, and its mass composition is 15% Na 2 O, 32% SiO 2 , with a density of 1580 kg / m 3 .

5. The production method of large-sized floor tiles according to claim 1, characterized in that, the ceramic raw materials include 33.7 - 37.8 parts of kaolin, 8.9 - 13.1 parts of talc, 16.2 - 18.2 parts of Bo'ai soil, 4.4 - 6.8 parts of wollastonite, 27.6 - 30.2 parts of quartz sand.

6. The production method of large-sized floor tiles according to claim 1, characterized in that, glazing is applied to the brick surface after firing once and before firing twice.

7. A large-sized floor tile, characterized in that, it is made by the method described in any one of claims 1 - 6.

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