High-strength through-body brick and preparation process thereof

Abstract

A kind of high-strength through-body brick and its preparation process, high-strength through-body brick includes the following raw materials: potassium feldspar, pigment particles, calcined alumina, burning talc, zircon, borax, kaolin, zinc oxide, magnesium oxide, titanium dioxide, frit;The application is by limiting the raw material composition of through-body brick, specially firing process is matched, so that the prepared through-body brick has higher bending strength and breaking strength under the condition of reducing product thickness, and has good wear resistance and stain resistance, is easy to clean and does not need surface maintenance, can be suitable for hospital, school, subway, high-speed rail and other places with large flow, with clear requirements for strength, similar civil air defense engineering or other places with requirements.

Description

Technical Field

[0001] This invention belongs to the field of ceramic tile preparation, specifically relating to a high-strength through-body tile and its preparation process. Background Technology

[0002] Unglazed ceramic tiles, also known as wear-resistant tiles, are made with the same material and color on both the front and back. Common unglazed ceramic tile products include wear-resistant tiles, polished tiles, antique tiles, plaza tiles, supermarket tiles, and exterior wall tiles, used for interior and exterior wall and floor decoration. Unglazed ceramic tiles have only a transparent glaze on the surface, without any colored glaze, resulting in a classic, elegant, and natural decorative effect. Furthermore, the artificially rough texture on the surface produces diffuse reflection when light shines on it, resulting in a soft, non-glaring shine that does not cause light pollution to the surrounding environment. Inorganic terrazzo is a decorative flooring material made from a mixture of cement, gravel, glass, and other materials. Its production process involves precast cement, and the product comes in a variety of colors. However, it has a long construction period, high maintenance costs, and is prone to cracking. With the continuous development of society, more and more people are trying to use unglazed ceramic tiles for floor decoration. However, existing unglazed ceramic tiles have monotonous colors, poor decorative effects, and low strength, failing to meet the strength requirements for decorative flooring, and require further improvement. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the prior art and provide a high-strength solid brick and its preparation process.

[0004] The present invention adopts the following technical solution:

[0005] A high-strength solid brick comprises the following raw materials in parts by weight: 15-18 parts potassium feldspar, 15-20 parts colorant particles, 10-15 parts calcined alumina, 3-5 parts calcined talc, 20-30 parts zircon, 2-5 parts borax, 12-15 parts kaolin, 2-6 parts zinc oxide, 1-3 parts magnesium oxide, 1-2 parts titanium dioxide, and 3-5 parts frit.

[0006] The pigment particles are composed of the following raw materials in parts by weight: 5-8 parts pigment powder, 12-18 parts kaolin, 8-10 parts attapulgite, 50-60 parts waste brick powder, 5-10 parts organic bentonite, 4-6 parts wood knot clay, 3-5 parts sepiolite powder, and 6-8 parts polyethylene wax.

[0007] Furthermore, the chemical composition of the fused block by mass percentage is as follows: SiO2: 61.26%, MgO: 4.86%, Al2O3: 16.35%, Na2O: 2.85%, K2O: 3.82%, TiO2: 1.21%, CaO: 5.78%, ZnO: 3.25%, La2O3: 0.62%.

[0008] Furthermore, the chemical composition of the main powder, by mass percentage, is as follows: SiO2: 62.98%, Al2O3: 13.26%, Fe2O3: 0.51%, CaO: 4.02%, MgO: 0.79%, K2O: 4.28%, Na2O: 5.86%, B2O3: 0.15%, ZrO2: 1.21%, IL: 6.94%.

[0009] Furthermore, the particle size of the colored particles is 1-10 mm, and the particle size of the waste brick powder is less than 80 mesh.

[0010] A manufacturing process for a high-strength solid-body brick specifically includes the following steps:

[0011] Step 1: Weigh and batch the raw materials according to the composition of the pigment granules, mix the raw materials, add water and knead evenly to make pigment with a moisture content of 15-20%; then, use a screen granulator to make pigment granules of different sizes.

[0012] Step 2: Weigh the main powder and other raw materials according to the proportion, then mix and add water to knead evenly to obtain a slurry with a moisture content of 15-20%. Then, use a sieve granulator to granulate the slurry into main powder particles.

[0013] Step 3: Mix the obtained pigment particles with the main powder particles in a certain proportion, and then send them into a vacuum extruder to be extruded and cut into brick blanks.

[0014] Step four: After the prepared brick blanks are naturally dried for more than 24 hours, they are transferred to a kiln for firing. The specific firing process is as follows: First, the kiln is heated to 180-190℃ at a rate of 1℃ / min and held for 20-30 minutes. Then, the kiln is naturally cooled to room temperature, and then the temperature is increased to 610-630℃ at a rate of 2℃ / min and held for 1-2 hours. Next, the temperature is increased to 960-1020℃ at a rate of 1.5℃ / min and held for 2.5-3.5 hours. Then, the temperature is increased to 1260-1300℃ at a rate of 2℃ / min and held for 3-4 hours. Finally, the kiln is naturally cooled to room temperature, and the cooling time is extended to more than 12 hours to obtain the solid brick.

[0015] Furthermore, in step four, when the kiln temperature is raised to 1260-1300℃, the carbon monoxide concentration inside the kiln is controlled at 2.1-2.5%, and the free oxygen concentration is controlled at 0.8-1.2%.

[0016] Furthermore, in step four, the kiln temperature is raised to 960-1020℃, and the carbon monoxide concentration inside the kiln is controlled at 1.2-1.3%, and the free oxygen concentration at 2.6-2.8%.

[0017] Furthermore, in step three, the vacuum degree of the vacuum extruder is -0.08 to -0.1 MPa.

[0018] As can be seen from the above description of the present invention, compared with the prior art, the beneficial effects of the present invention are: by limiting the raw material composition of the through-body tile and using a special firing process, the present invention enables the produced through-body tile to have higher flexural strength and destructive strength while reducing the product thickness, and has good wear resistance and stain resistance. It is easy to clean and requires no surface maintenance, and is suitable for occasions with high traffic and clear strength requirements, such as hospitals, schools, subways, high-speed rail, etc., similar to civil defense projects or other places with requirements. At the same time, the surface and interior of the product are consistent, and there is no situation where the surface of the tile product is different from the base after wear, resulting in poor effect or unusability.

[0019] By introducing pigment particles into the raw material composition and using an extrusion molding process, the prepared through-body bricks are irregularly distributed with pigment particles of varying sizes on the surface and inside, forming a decorative effect similar to stone, suitable for outdoor decoration. Specifically, the raw material composition of the pigment particles is defined, with recycled waste powder as the main raw material. Wood-based clay is introduced to improve the adhesion between the raw materials, preventing the pigment particles from cracking in subsequent preparation processes, thus affecting the cross-sectional effect of the product. Sepiolite powder, attapulgite, and wood-based clay are combined and mixed. During the mixing process, the wood-based clay adheres to the surface of the sepiolite powder and attapulgite, effectively suppressing shrinkage during drying and firing caused by the introduction of wood-based clay, ensuring the desired particle size of the pigment particles is obtained. Organic bentonite and polyethylene wax are introduced in combination with other raw materials to prevent pigment powder sedimentation, which would result in uneven color of the prepared pigment particles.

[0020] The raw material composition incorporates calcined alumina, borax, and zircon to improve the overall strength of the prepared through-body bricks. Furthermore, it limits the chemical composition of the frit and combines it with a specific firing process to increase the internal density and grain boundary bonding of the brick, thereby effectively improving the flexural strength and destructive strength of the obtained through-body bricks. Attached Figure Description

[0021] Figure 1 Schematic diagram of the structure of the through-body brick prepared by the present invention Figure 1 ;

[0022] Figure 2 Schematic diagram of the structure of the through-body brick prepared by the present invention Figure 2 . Detailed Implementation

[0023] The present invention will be further described below through specific embodiments.

[0024] A high-strength solid brick comprises the following raw materials in parts by weight: 15-18 parts potassium feldspar, 15-20 parts colorant particles, 10-15 parts calcined alumina, 3-5 parts calcined talc, 20-30 parts zircon, 2-5 parts borax, 12-15 parts kaolin, 2-6 parts zinc oxide, 1-3 parts magnesium oxide, 1-2 parts titanium dioxide, and 3-5 parts frit; specifically, the particle size of the colorant particles is 1-10 mm, and the particle size of the waste brick powder is less than 80 mesh.

[0025] The chemical composition of the main powder, by mass percentage, is as follows: SiO2: 62.98%, Al2O3: 13.26%, Fe2O3: 0.51%, CaO: 4.02%, MgO: 0.79%, K2O: 4.28%, Na2O: 5.86%, B2O3: 0.15%, ZrO2: 1.21%, IL: 6.94%.

[0026] The pigment granules are composed of the following raw materials in parts by weight: 5-8 parts pigment powder, 12-18 parts kaolin, 8-10 parts attapulgite, 50-60 parts waste brick powder, 5-10 parts organic bentonite, 4-6 parts wood knot clay, 3-5 parts sepiolite powder, and 6-8 parts polyethylene wax.

[0027] The chemical composition of the fused ingot by mass percentage is as follows: SiO2: 61.26%, MgO: 4.86%, Al2O3: 16.35%, Na2O: 2.85%, K2O: 3.82%, TiO2: 1.21%, CaO: 5.78%, ZnO: 3.25%, La2O3: 0.62%.

[0028] A manufacturing process for a high-strength solid-body brick specifically includes the following steps:

[0029] Step 1: Weigh and batch the raw materials according to the composition of the pigment granules, mix the raw materials, add water and knead evenly to make pigment with a moisture content of 15-20%; then, use a screen granulator to make pigment granules of different sizes.

[0030] Step 2: Weigh the main powder and other raw materials according to the proportion, then mix and add water to knead evenly to obtain a slurry with a moisture content of 15-20%. Then, use a sieve granulator to granulate the slurry into main powder particles.

[0031] Step 3: Mix the obtained pigment particles with the main powder particles in a certain proportion, feed them into a vacuum extruder to extrude and cut them into brick blanks. The vacuum degree of the vacuum extruder is -0.08 to -0.1 MPa.

[0032] Step four: After the prepared brick blanks are naturally dried for more than 24 hours, they are transferred to a kiln for firing. The specific firing process is as follows: First, the kiln is heated to 180-190℃ at a rate of 1℃ / min and held for 20-30 minutes. Then, the kiln is naturally cooled to room temperature, and then the temperature is increased to 610-630℃ at a rate of 2℃ / min and held for 1-2 hours. Next, the temperature is increased to 960-1020℃ at a rate of 1.5℃ / min and held for 2.5-3.5 hours. Then, the temperature is increased to 1260-1300℃ at a rate of 2℃ / min and held for 3-4 hours. Finally, the kiln is naturally cooled to room temperature, and the cooling time is extended to more than 12 hours to obtain the solid brick.

[0033] In step four, when the kiln temperature is raised to 960-1020℃, the carbon monoxide concentration inside the kiln is controlled at 1.2-1.3%, and the free oxygen concentration is controlled at 2.6-2.8%; when the kiln temperature is raised to 1260-1300℃, the carbon monoxide concentration inside the kiln is controlled at 2.1-2.5%, and the free oxygen concentration is controlled at 0.8-1.2%.

[0034] Example 1

[0035] A high-strength solid brick with a thickness of 3cm comprises the following raw materials in parts by weight: 15 parts potassium feldspar, 15 parts colorant particles, 15 parts calcined alumina, 3 parts calcined talc, 20 parts zircon, 5 parts borax, 12 parts kaolin, 6 parts zinc oxide, 1 part magnesium oxide, 2 parts titanium dioxide, and 3 parts frit; specifically, the particle size of the colorant particles is 1-10mm, and the particle size of the waste brick powder is less than 80 mesh.

[0036] The pigment granules are composed of the following raw materials in parts by weight: 5 parts pigment powder, 18 parts kaolin, 8 parts attapulgite, 60 parts waste brick powder, 5 parts organic bentonite, 6 parts wood knot clay, 3 parts sepiolite powder, and 8 parts polyethylene wax.

[0037] A manufacturing process for a high-strength solid-body brick specifically includes the following steps:

[0038] Step 1: Weigh and batch the raw materials according to the composition of the pigment granules, mix the raw materials, add water and knead evenly to make pigment with a moisture content of 15-20%; then, use a screen granulator to make pigment granules of different sizes.

[0039] Step 2: Weigh the main powder and other raw materials according to the proportion, then mix and add water to knead evenly to obtain a slurry with a moisture content of 15-20%. Then, use a sieve granulator to granulate the slurry into main powder particles.

[0040] Step 3: Mix the obtained pigment particles with the main powder particles in a certain proportion, feed them into a vacuum extruder to extrude and cut them into brick blanks. The vacuum degree of the vacuum extruder is -0.08MPa.

[0041] Step four: After the prepared brick blanks are naturally dried for more than 24 hours, they are transferred to a kiln for firing. The specific firing process is as follows: First, the kiln is heated to 180°C at a rate of 1°C / min and held for 30 minutes. Then, the kiln is naturally cooled to room temperature, and then the temperature is increased to 610°C at a rate of 2°C / min and held for 1-2 hours. Next, the temperature is increased to 960°C at a rate of 1.5°C / min and held for 3.5 hours. Then, the temperature is increased to 1260°C at a rate of 2°C / min and held for 4 hours. Finally, the kiln is naturally cooled to room temperature, and the cooling time is extended to more than 12 hours to obtain the solid brick.

[0042] In step four, when the kiln temperature reaches 960℃, the carbon monoxide concentration inside the kiln is controlled at 1.2% and the free oxygen concentration at 2.6%; when the kiln temperature reaches 1260℃, the carbon monoxide concentration inside the kiln is controlled at 2.5% and the free oxygen concentration at 1.2%.

[0043] Example 2

[0044] A high-strength solid brick with a thickness of 2cm comprises the following raw materials in parts by weight: 18 parts potassium feldspar, 20 parts colorant particles, 10 parts calcined alumina, 5 parts calcined talc, 30 parts zircon, 2 parts borax, 15 parts kaolin, 2 parts zinc oxide, 3 parts magnesium oxide, 1 part titanium dioxide, and 5 parts frit; specifically, the particle size of the colorant particles is 1-10mm, and the particle size of the waste brick powder is less than 80 mesh.

[0045] The pigment granules are composed of the following raw materials in parts by weight: 8 parts pigment powder, 12 parts kaolin, 10 parts attapulgite, 50 parts waste brick powder, 10 parts organic bentonite, 4 parts wood knot clay, 5 parts sepiolite powder, and 6 parts polyethylene wax.

[0046] A manufacturing process for a high-strength solid-body brick specifically includes the following steps:

[0047] Step 1: Weigh and batch the raw materials according to the composition of the pigment granules, mix the raw materials, add water and knead evenly to make pigment with a moisture content of 15-20%; then, use a screen granulator to make pigment granules of different sizes.

[0048] Step 2: Weigh the main powder and other raw materials according to the proportion, then mix and add water to knead evenly to obtain a slurry with a moisture content of 15-20%. Then, use a sieve granulator to granulate the slurry into main powder particles.

[0049] Step 3: Mix the obtained pigment particles with the main powder particles in a certain proportion, feed them into a vacuum extruder to extrude and cut them into brick blanks. The vacuum degree of the vacuum extruder is -0.1MPa.

[0050] Step four: After the prepared brick blanks are naturally dried for more than 24 hours, they are transferred to a kiln for firing. The specific firing process is as follows: First, the kiln is heated to 190°C at a rate of 1°C / min and held for 20 minutes. Then, the kiln is naturally cooled to room temperature, and then the temperature is increased to 630°C at a rate of 2°C / min and held for 1 hour. Next, the temperature is increased to 1020°C at a rate of 1.5°C / min and held for 2.5 hours. Then, the temperature is increased to 1300°C at a rate of 2°C / min and held for 3 hours. Finally, the kiln is naturally cooled to room temperature, and the cooling time is extended to more than 12 hours to obtain the solid brick.

[0051] In step four, when the kiln temperature is raised to 1020℃, the carbon monoxide concentration in the kiln is controlled at 1.3% and the free oxygen concentration at 2.8%; when the kiln temperature is raised to 1300℃, the carbon monoxide concentration in the kiln is controlled at 2.1% and the free oxygen concentration at 0.8%.

[0052] Example 3

[0053] A high-strength solid brick with a thickness of 1.8 cm comprises the following raw materials in parts by weight: 16 parts potassium feldspar, 18 parts colorant particles, 12 parts calcined alumina, 4 parts calcined talc, 25 parts zircon, 3 parts borax, 13 parts kaolin, 4 parts zinc oxide, 2 parts magnesium oxide, 1.5 parts titanium dioxide, and 4 parts frit; specifically, the particle size of the colorant particles is 1-10 mm, and the particle size of the waste brick powder is less than 80 mesh.

[0054] The pigment granules are composed of the following raw materials in parts by weight: 6 parts pigment powder, 15 parts kaolin, 9 parts attapulgite, 55 parts waste brick powder, 8 parts organic bentonite, 5 parts wood knot clay, 4 parts sepiolite powder, and 7 parts polyethylene wax.

[0055] A manufacturing process for a high-strength solid-body brick specifically includes the following steps:

[0056] Step 1: Weigh and batch the raw materials according to the composition of the pigment granules, mix the raw materials, add water and knead evenly to make pigment with a moisture content of 15-20%; then, use a screen granulator to make pigment granules of different sizes.

[0057] Step 2: Weigh the main powder and other raw materials according to the proportion, then mix and add water to knead evenly to obtain a slurry with a moisture content of 15-20%. Then, use a sieve granulator to granulate the slurry into main powder particles.

[0058] Step 3: Mix the obtained pigment particles with the main powder particles in a certain proportion, feed them into a vacuum extruder to extrude and cut them into brick blanks. The vacuum degree of the vacuum extruder is -0.09MPa.

[0059] Step four: After the prepared brick blanks are naturally dried for more than 24 hours, they are transferred to a kiln for firing. The specific firing process is as follows: First, the kiln is heated to 185°C at a rate of 1°C / min and held for 25 minutes. Then, the kiln is naturally cooled to room temperature, and then the temperature is increased to 620°C at a rate of 2°C / min and held for 1.5 hours. Next, the temperature is increased to 990°C at a rate of 1.5°C / min and held for 3 hours. Then, the temperature is increased to 1280°C at a rate of 2°C / min and held for 3.5 hours. Finally, the kiln is naturally cooled to room temperature, and the cooling time is extended to more than 12 hours to obtain the solid brick.

[0060] In step four, when the kiln temperature reaches 990℃, the carbon monoxide concentration inside the kiln is controlled at 1.25% and the free oxygen concentration at 2.7%; when the kiln temperature reaches 1280℃, the carbon monoxide concentration inside the kiln is controlled at 2.3% and the free oxygen concentration at 1.0%.

[0061] The solid bricks prepared in Examples 1-3 were subjected to relevant tests, and the following data were obtained:

[0062] Table 1 Test Data Table

[0063] Test Project Example 1 Example 2 Example 3 Thickness / cm 3 2 1.8 Resistance to damage / N 20000 8000 7000 Abrasion-resistant / grade 5 5 5 Stain resistant / grade 5 5 5

[0064] In summary, this invention, by limiting the raw material composition of through-body tiles and using a special firing process, produces through-body tiles with higher flexural strength and destructive strength while reducing product thickness. These tiles are unaffected by temperature and possess excellent wear resistance, stain resistance, and acid and alkali resistance. They are easy to clean and require no surface maintenance, making them suitable for high-traffic areas such as hospitals, schools, subways, and high-speed rail stations where strength requirements are stringent, similar to civil defense projects or other demanding locations. Furthermore, the product's surface and interior are uniformly consistent, eliminating the issue of surface wear leading to poor performance or unusability. The wear resistance and stain resistance ratings are consistently at level 5, meeting the needs of outdoor applications. When the through-body tile thickness is 1.8cm, its destructive strength is ≥7000N, exceeding that of 3.0cm inorganic terrazzo. When the through-body tile thickness is 3.0cm, its strength reaches that of 5cm natural stone, allowing it to replace stone and improve product workability.

[0065] The above description is merely a preferred embodiment of the present invention and should not be construed as limiting the scope of the present invention. All equivalent changes and modifications made in accordance with the scope of the present invention and the contents of the specification should still fall within the scope of the present invention.

Claims

1. A high-strength solid-body brick, characterized in that: The raw materials include the following parts by weight: 15-18 parts potassium feldspar, 15-20 parts colorant granules, 10-15 parts calcined alumina, 3-5 parts calcined talc, 20-30 parts zircon, 2-5 parts borax, 12-15 parts kaolin, 2-6 parts zinc oxide, 1-3 parts magnesium oxide, 1-2 parts titanium dioxide, and 3-5 parts frit. The pigment particles are composed of the following raw materials in parts by weight: 5-8 parts pigment powder, 12-18 parts kaolin, 8-10 parts attapulgite, 50-60 parts waste brick powder, 5-10 parts organic bentonite, 4-6 parts wood knot clay, 3-5 parts sepiolite powder, and 6-8 parts polyethylene wax.

2. The high-strength solid-body brick according to claim 1, characterized in that: The chemical composition of the fused block by mass percentage is as follows: SiO2: 61.26%, MgO: 4.86%, Al2O3: 16.35%, Na2O: 2.85%, K2O: 3.82%, TiO2: 1.21%, CaO: 5.78%, ZnO: 3.25%, La2O3: 0.62%.

3. The high-strength solid-body brick according to claim 1, characterized in that: The particle size of the pigment particles is 1-10 mm, and the particle size of the waste brick powder is less than 80 mesh.

4. The preparation process of a high-strength through-body brick according to claim 1, characterized in that: Specifically, the steps include the following: Step 1: Weigh and batch the raw materials according to the composition of the pigment granules, mix the raw materials, add water and knead evenly to make pigment with a moisture content of 15-20%; then, use a screen granulator to make pigment granules of different sizes. Step 2: Weigh the main powder and other raw materials according to the proportion, then mix and add water to knead evenly to obtain a slurry with a moisture content of 15-20%. Then, use a sieve granulator to granulate the slurry into main powder particles. Step 3: Mix the obtained pigment particles with the main powder particles in a certain proportion, and then send them into a vacuum extruder to be extruded and cut into brick blanks. Step four: After the prepared brick blanks are naturally dried for more than 24 hours, they are transferred to a kiln for firing. The specific firing process is as follows: First, the kiln is heated to 180-190℃ at a rate of 1℃ / min and held for 20-30 minutes. Then, the kiln is naturally cooled to room temperature, and then the temperature is increased to 610-630℃ at a rate of 2℃ / min and held for 1-2 hours. Next, the temperature is increased to 960-1020℃ at a rate of 1.5℃ / min and held for 2.5-3.5 hours. Then, the temperature is increased to 1260-1300℃ at a rate of 2℃ / min and held for 3-4 hours. Finally, the kiln is naturally cooled to room temperature, and the cooling time is extended to more than 12 hours to obtain the solid brick.

5. The preparation process of a high-strength through-body brick according to claim 4, characterized in that: In step four, when the kiln temperature is raised to 1260-1300℃, the carbon monoxide concentration in the kiln is controlled at 2.1-2.5%, and the free oxygen concentration is controlled at 0.8-1.2%.

6. The preparation process of a high-strength through-body brick according to claim 4, characterized in that: In step four, the kiln temperature is raised to 960-1020℃, and the carbon monoxide concentration inside the kiln is controlled at 1.2-1.3%, and the free oxygen concentration is controlled at 2.6-2.8%.

7. The preparation process of a high-strength solid-body brick according to claim 4, characterized in that: In step three, the vacuum degree of the vacuum extruder is -0.08 to -0.1 MPa.

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