Lightweight microcrystalline stone wallboard and method of making same

Abstract

The application discloses a kind of light microcrystalline stone wallboard and its preparation method, light microcrystalline stone wallboard includes thermal insulation layer and decorative layer, and the main raw material of thermal insulation layer is microcrystalline powder, and is added with ceramic fiber paper waste, light microcrystalline stone cutting material and light microcrystalline stone sediment recovery material;Joining proportion is as follows by weight fraction: microcrystalline powder 35~60 parts, ceramic fiber paper waste 0.5~3 parts, light microcrystalline stone cutting material 6~15 parts and light microcrystalline stone sediment recovery material 2~18 parts.Decorative layer material and thermal insulation layer material are sequentially layered and applied to mould into kiln and are fired into shape.By reasonably using waste material produced in production process, waste utilization is realized, not only reduce production cost, also effectively reduce the pollution of waste to environment.Ceramic fiber paper waste mixed in raw material can increase the proportion of mullite phase distributed in porous thermal insulation layer, thereby improve the toughness and strength of product.

Description

TECHNICAL FIELD

[0001] The present application relates to a building light weight thermal insulation wallboard, in particular to a light weight microcrystalline stone wallboard and a preparation method thereof. BACKGROUND

[0002] With the improvement of people's living standards, the quality of building outer wall has higher pursuit, not only to meet the enclosure function, but also has the characteristics of beauty, thermal insulation, light weight, high strength and so on. Light weight microcrystalline stone as a derivative product of microcrystalline stone, it has the same color, texture and high strength as natural stone, and also has the characteristics of light weight and thermal insulation. The material meets the development trend of building outer wall. The existing light weight microcrystalline stone outer wallboard uses newly prepared microcrystalline powder as the main raw material, the raw material cost is high, and the chemical composition of the light weight microcrystalline stone is easy to form wollastonite phase in SiO2-Al2O3-CaO ternary system phase diagram, which leads to insufficient toughness and strength of the light weight microcrystalline stone board. SUMMARY

[0003] The technical problem to be solved by the present application is to provide a light weight microcrystalline stone wallboard and a preparation method thereof, to reduce the production cost of the light weight microcrystalline stone wallboard and improve its toughness and strength.

[0004] The technical scheme adopted by the present application to solve the above technical problem is: a light weight microcrystalline stone wallboard, comprising a thermal insulation layer and a decorative layer attached to the outer side of the thermal insulation material, the thermal insulation layer is a porous light weight microcrystalline stone thermal insulation layer, the main raw material of which is microcrystalline powder, and ceramic fiber paper waste, light weight microcrystalline stone cutting material and light weight microcrystalline stone sediment recovery material are added to the raw material; the light weight microcrystalline stone cutting material is the remaining waste material in the cutting process of the light weight microcrystalline stone, and the light weight microcrystalline stone sediment recovery material is the waste material collected in the sedimentation tank with circulating water in the grinding process of the light weight microcrystalline stone board; the adding proportion of the microcrystalline powder, the ceramic fiber paper waste, the light weight microcrystalline stone cutting material and the light weight microcrystalline stone sediment recovery material is 35-60 parts of microcrystalline powder, 0.5-3 parts of ceramic fiber paper waste, 6-15 parts of light weight microcrystalline stone cutting material and 2-18 parts of light weight microcrystalline stone sediment recovery material by weight.

[0005] The ceramic fiber paper waste is the waste material formed by laying ceramic fiber paper in the mold during the forming and firing process of the light weight microcrystalline stone board.

[0006] The composition of the microcrystalline powder includes 50-70% SiO2, 6-12% Al2O3, 8-20% CaO, 0.5-3% MgO, 2-6% Na2O / K2O, 0-0.5% Fe2O3, 1-4% BaO, 1-4% B2O3 and 0-4% ZnO; the composition of the ceramic fiber paper waste includes 45-60% SiO2 and 40-55% Al2O3.

[0007] The raw material of the heat preservation layer comprises microcrystalline powder 35-60 parts, porcelain stone 2-8 parts, glass powder 2-10 parts, spodumene 0-6 parts, light microcrystalline stone cutting material 6-15 parts, light microcrystalline stone sediment recovery material 2-18 parts, ceramic fiber paper waste 0.5-3 parts, silica sand 8-20 parts, ceramic waste residue 0-10 parts, shale 2-8 parts, loess 1-5 parts, and silicon carbide 0.1-1.5 parts.

[0008] The light microcrystalline stone cutting material and the light microcrystalline stone sediment recovery material are collected in batches and added to the raw material of the heat preservation layer in a mixed and compounded manner.

[0009] The decorative layer is a microcrystalline stone decorative layer which is integrally formed with the heat preservation layer by sintering, and the initial melting temperature of the decorative layer during the sintering process is lower than that of the heat preservation layer, so that the decorative layer is melted and leveled before the heat preservation layer has fluidity.

[0010] The decorative layer is added with talc to reduce the initial melting temperature of the decorative layer.

[0011] The components of the decorative layer comprise microcrystalline powder 70-90 parts, porcelain stone 6-12 parts, spodumene 2-6 parts, glass powder 5-15 parts, kaolin 0-3 parts, talc 0-2 parts, and alumina 0-1 part.

[0012] The application further provides a preparation method of the light microcrystalline stone wallboard.

[0013] In the temperature rising process, the temperature is kept constant at 820-860 DEG C for 20-30 minutes, and kept constant at 1020-1050 DEG C for 20-30 minutes.

[0014] The beneficial effects of the present application are: in the raw material of the porous thermal insulation layer of the light microcrystalline stone wallboard, by reasonably using the ceramic fiber paper waste produced in the production process, and the cutting material and the sediment recovery material after the processing of the light microcrystalline stone, waste utilization is realized, not only the production cost is reduced, but also the pollution of these waste materials to the environment is effectively reduced. Moreover, due to the characteristics of high aluminum and high silicon of the added ceramic fiber paper waste, it is easier to precipitate mullite phase compared with microcrystalline stone powder, and the ceramic fiber paper waste mixed in the raw material can increase the proportion of mullite phase distributed in the porous thermal insulation layer, thereby improving the toughness and strength of the product. The light microcrystalline stone sediment recovery material powder recovered in the grinding process is small in fineness and attached with the wear of the polishing grinding wheel, and adding a certain amount of the raw material is helpful to the foaming of the product and can reduce the use of foaming agent. DETAILED DESCRIPTION

[0015] The technical solutions of the present application are described below in combination with examples. The specific contents listed in the following examples are not limited to the technical features necessary for the technical problems to be solved by the technical solutions described in the claims. At the same time, the enumeration is only a part of the present application, not all the examples.

[0016] The light microcrystalline stone wallboard of the present application includes a thermal insulation layer and a decorative layer, both of which use microcrystalline powder as the main raw material, and are formed into an integrated structure by co-firing in a mold. The microcrystalline powder can use the composition ratio used in the existing light microcrystalline stone thermal insulation board production, for example, 50~70% SiO2, 6~12% Al2O3, 8~20% CaO, 0.5~3% MgO, 2~6% Na2O / K2O, 0~0.5% Fe2O3, 1~4% BaO, 1~4% B2O3, 0~4% ZnO.

[0017] The heat preservation layer is added with components that can be foamed at high temperature, such as silicon carbide. After high-temperature firing, a porous lightweight microcrystalline stone heat preservation layer is formed. Ceramic fiber paper waste, lightweight microcrystalline stone cutting material and lightweight microcrystalline stone sediment recovery material are added to the raw material of the heat preservation layer to replace part of the microcrystalline powder and reduce the cost of raw materials. The lightweight microcrystalline stone cutting material is the remaining waste material in the cutting process of lightweight microcrystalline stone, which can be pretreated to 150-200 mesh. The lightweight microcrystalline stone sediment recovery material is a powder generated in the grinding process of lightweight microcrystalline stone plate, such as the powder generated when polishing the decorative layer of lightweight microcrystalline stone with a cold processing and polishing equipment. After entering the sedimentation tank with circulating water, it can be collected by sedimentation and used for the production of lightweight microcrystalline stone wallboard. The lightweight microcrystalline stone sediment recovery material powder is fine and has polishing wheel wear attached. Adding a certain amount of this raw material can help product foaming and reduce the use of foaming agent. The ceramic fiber paper waste is the waste material formed by laying ceramic fiber paper in the mold during the forming and firing process of lightweight microcrystalline stone plate, which can be pretreated to 200-325 mesh and mixed into the raw material. The composition of the ceramic fiber paper waste includes 45-60% SiO2 and 40-55% Al2O3, which can form mullite phase during the firing process of lightweight microcrystalline stone plate to improve the toughness and strength of the product.

[0018] The lightweight microcrystalline stone cutting material and the lightweight microcrystalline stone sediment recovery material are both waste materials that have been crystallized. Their initial melting point is relatively low, and the composition is complex. In order to reduce the impact of the fluctuation of the recovery material, the recovery material can be classified and collected by batch during recovery. When used, the recovery material of multiple batches is mixed and added to the raw material of the heat preservation layer, for example, three or more batches of recovery material. When the raw material is prepared, the microcrystalline powder, ceramic fiber paper waste, lightweight microcrystalline stone cutting material and lightweight microcrystalline stone sediment recovery material can be mixed in a ratio of 35-60 parts, 0.5-3 parts, 6-15 parts and 2-18 parts respectively (the parts or percentage in this article refer to weight).

[0019] The decorative layer lacks foaming components compared with the heat preservation layer. After firing, its structure is more fine and can form a good decorative effect after polishing. During the firing process, the material will undergo the process of "drying-shrinkage-initial melting-melting and foaming (melting and leveling)". The shrinkage of the powder during the product firing process will produce through shrinkage joints. In order to avoid the components of the heat preservation layer from leaking into the decorative layer through the shrinkage joints during the firing process and affecting the appearance of the finished product, an additive can be added to make the initial melting temperature of the decorative layer lower than that of the heat preservation layer, so that the decorative layer can melt and level first. When the heat preservation layer appears fluidity, the decorative layer has no shrinkage joint, so it can avoid the leakage of the heat preservation layer into the decorative layer and improve the yield of the product.

[0020] In one embodiment of the present application, the initial melting temperature of the decorative layer is reduced by adding talc. The main role of talc is to reduce the melting temperature to 900℃, which can avoid the severe shrinkage of the product at 750~850℃, prevent the side effects caused by severe shrinkage, and the addition amount can be controlled below 2 parts. In addition to the role of fluxing, talc also acts as a mineralizer, which is beneficial to the crystallization of the product.

[0021] In addition to the above-mentioned ingredients, mineralizers, fluxing agents and other ingredients can be selectively added to adjust the firing temperature and the expansion coefficient of the product. For example, in the insulation layer, porcelain stone 2~8 parts, glass powder 2~10 parts, spodumene 0~6 parts, silica sand 8~20 parts, ceramic waste 0~10 parts, shale 2~8 parts, loess 1~5 parts, silicon carbide 0.1~1.5 parts. Among them, the ceramic waste is the waste produced by the polishing brick on the market, which has high silicon and high aluminum chemical composition, and is also a clinker, the firing temperature is relatively low, 1190℃ can be foamed, and can be pretreated to not less than 325 mesh. Silicon carbide as a foaming agent, helps to form a porous structure in the insulation layer.

[0022] In the decorative layer, in addition to 70~90 parts of microcrystalline powder, porcelain stone 6~12 parts, spodumene 2~6 parts, glass powder 5~15 parts, kaolin 0~3 parts, talc 0~2 parts, and alumina 0~1 part can be selectively added. The introduction of kaolin and alumina is used to match the expansion coefficient of the insulation layer, so that the decorative layer and the insulation layer can be combined together, and the two have good adaptability.

[0023] The preparation method of the light microcrystalline stone wallboard of the present application comprises the following steps:

[0024] Step one, according to the particle size requirements of each material, the particle size of microcrystalline powder is 150~250 mesh, the particle size of light microcrystalline stone cutting material and light microcrystalline stone sedimentation recovery material is 150~200 mesh, the particle size of ceramic fiber paper waste material is 200~325 mesh, and the particle size of ceramic waste is not less than 325 mesh. The particle size of other raw materials is not less than 200 mesh.

[0025] Step two, prepare the decorative layer material and the porous structure insulation layer material for mixing according to the weight fraction, and spray 0.5~1.5% water during the mixing process to avoid dust caused by dry powder.

[0026] Step three: assemble the mold on the single layer conveying platform of the three-layer electric heating roller furnace, and lay the ceramic fiber paper in the mold cavity.

[0027] Step four: use the distributor to layer the decorative layer and insulation layer material into the mold, then transfer to the three-layer table into the kiln, and burn according to the set firing curve.

[0028] The temperature curve of the firing process is:

[0029] a. The temperature rising rate is 6-8℃ / min from room temperature to 820℃.

[0030] b. The temperature rising rate is 4-8℃ / min from 820℃ to 1030℃.

[0031] c. The temperature rising rate is 1-3℃ / min from 1030℃ to the highest temperature, and the highest temperature is kept for 50-90min, wherein the highest temperature is 1080-1140℃.

[0032] d. The quenching temperature should not be lower than 820℃, and the quenching rate is 3-8℃ / min.

[0033] e. The temperature decreasing rate is 0.5-2℃ / min after quenching.

[0034] In the firing process, the temperature rising rate is 6-8℃ / min from room temperature to 820℃, mainly to gradually increase the temperature, preheat and remove the water in the material. The temperature rising rate is 4-8℃ / min from 820℃ to 1030℃, mainly to give the foaming agent (SiC) enough time to start the slow reaction and form micropores. The temperature rising rate is 1-3℃ / min from 1030℃ to the highest temperature, mainly to make the micropores formed in the previous stage grow into pore structure uniformly. The rate should not be too fast or too slow, too fast will lead to underfiring and small pores, and too slow will affect the growth of internal pores in the quenching process, leading to uneven inside and outside. The quenching temperature should not be lower than 820℃, and the quenching rate is 3-8℃ / min, mainly because the plate is thick, and the internal heat of the plate is difficult to dissipate if the quenching process is too fast, which will cause a large temperature difference between the inside and outside and lead to thermal explosion. In addition, the temperature difference will also cause a large plate deformation due to the rapid temperature decrease.

[0035] In addition, a holding period can be set in the temperature rising process in the range of 820-860℃, and the holding time is 20-30min, which can promote the formation of crystal nucleus. A holding period can also be set in the range of 1020-1050℃, and the holding time is 20-30min, which can homogenize the pores.

[0036] The above description of the specific embodiments is only used to help understand the technical concept and core idea of the present application. Although the technical solutions are described and explained using specific preferred embodiments, it should not be understood as a limitation of the present application itself. Those skilled in the art can make various changes in form and details without departing from the technical concept of the present application. These easily thought changes or replacements should be covered in the protection scope of the present application.

Claims

1. A method of making a lightweight microcrystalline stone wall panel, characterized by: The light-weight microcrystalline stone wallboard comprises a decorative layer and a thermal insulation layer, and the thermal insulation layer is a porous light-weight microcrystalline stone thermal insulation layer, the main raw material of which is microcrystalline powder, and ceramic fiber paper waste, light-weight microcrystalline stone cutting material and light-weight microcrystalline stone sediment recovery material are added in the raw material. The ceramic fiber paper waste is waste formed by laying ceramic fiber paper in the mold during the forming and firing process of the light-weight microcrystalline stone plate, the light-weight microcrystalline stone cutting material is residual waste in the cutting process of the light-weight microcrystalline stone, and the light-weight microcrystalline stone sediment recovery material is waste collected in the sedimentation tank through circulating water during the grinding process of the light-weight microcrystalline stone plate. The decorative layer is laid with ceramic fiber paper, and the decorative layer material and the thermal insulation layer material are sequentially layered and applied into the mold, and then fired in a kiln. The talc is added in the decorative layer to reduce the initial melting temperature of the decorative layer, so that the initial melting temperature of the decorative layer during the firing process is lower than the initial melting temperature of the thermal insulation layer, and the decorative layer is melted and leveled before the thermal insulation layer has fluidity. The kaolin and alumina are introduced into the decorative layer to match the expansion coefficient of the thermal insulation layer, so that the decorative layer and the thermal insulation layer form an integrated structure through sintering.

2. A method of making a lightweight microcrystalline stone wall panel according to claim 1, characterized in that: The highest firing temperature is 1080-1140℃, the temperature curve during the firing process is as follows: the temperature rising rate is 6-8℃ / min at room temperature-820℃, the temperature rising rate is 4-8℃ / min at 820℃-1030℃, the temperature rising rate is 1-3℃ / min at 1030℃-the highest temperature, the highest temperature is kept for 50-90min, the quenching temperature should not be lower than 820℃ after the temperature keeping is finished, the quenching rate is 3-8℃ / min, and the temperature decreasing rate is 0.5-2℃ / min after quenching.

3. The method for preparing a lightweight microcrystalline stone wall panel as described in claim 1, characterized in that: During the temperature rising process, the temperature is kept for 20-30min at 820-860℃, and the temperature is kept for 20-30min at 1020-1050℃. The composition of the microcrystalline powder comprises 50-70% SiO2, 6-12% Al2O3, 8-20% CaO, 0.5-3% MgO, 2-6% Na2O / K2O, 0-0.5% Fe2O3, 1-4% BaO, 1-4% B2O3 and 0-4% ZnO. The raw material of the thermal insulation layer comprises 35-60 parts of microcrystalline powder, 2-8 parts of porcelain stone, 2-10 parts of glass powder, 0-6 parts of spodumene, 6-15 parts of light-weight microcrystalline stone cutting material, 2-18 parts of light-weight microcrystalline stone sediment recovery material, 0.5-3 parts of ceramic fiber paper waste, 8-20 parts of silica sand, 0-10 parts of ceramic waste residue, 2-8 parts of shale, 1-5 parts of loess and 0.1-1.5 parts of silicon carbide.

4. The method for preparing a lightweight microcrystalline stone wall panel as described in claim 1, characterized in that: The light weight microcrystalline stone cutting material and the light weight microcrystalline stone sediment recovery material are collected in batches, and are added into the raw material of the thermal insulation layer in a mixed compounding manner of multiple batches of recovery materials.

5. The method for preparing a lightweight microcrystalline stone wall panel as described in claim 1, characterized in that: The components of the decorative layer include 70-90 parts of microcrystalline powder, 6-12 parts of porcelain stone, 2-6 parts of spodumene, 5-15 parts of glass powder, 0-3 parts of kaolin, 0-2 parts of talc and 0-1 part of alumina.