Antifouling ceramic tile and preparation method thereof

Abstract

The invention provides an antifouling ceramic tile and a preparation method thereof. The antifouling ceramic tile comprises the following components: 25-100 parts of waste brick powder, 20-50 parts of quartz sand, 20-30 parts of feldspar, 20-30 parts of bauxite, 5-8 parts of sodium tripolyphosphate, 3-5 parts of lanthanum oxide, 3-5 parts of zinc oxide and 1-3 parts of sodium carboxymethyl cellulose. The waste brick powder, the quartz sand, the feldspar and the bauxite are used as a silicon source and an aluminum source, the sodium tripolyphosphate, the lanthanum oxide, the zinc oxide and the sodium carboxymethyl cellulose are used as auxiliary additives, the stain resistance of the ceramic tile is improved through the synergistic effect of the raw materials, stains such as water and oil are effectively prevented from invading ceramic tile holes, and residues of the stains on the surface of the ceramic tile are reduced. By precisely controlling the sintering temperature, a crystal phase is formed on the surface of the ceramic tile, cracks are reduced, the water absorption rate of the ceramic tile is close to 0, and the antifouling property of the ceramic tile is further improved.

Description

Technical Field

[0001] The invention relates to the technical field of tile preparation, and in particular to an anti-fouling tile and a preparation method thereof. Background Art

[0002] Ceramic tiles are a kind of porcelain or stone material made of refractory metal oxides and semi-metal oxides through processes such as grinding, mixing, pressing, glazing and sintering. The raw materials used usually include clay raw materials such as kaolin, shale, etc., barren raw materials such as quartz, quartz sand, industrial waste slag, etc., solvent raw materials such as feldspar, wollastonite, talc, dolomite, etc., and auxiliary raw materials such as electrolytes, zircon, etc.

[0003] The types of tiles mainly include glazed tiles, full-body tiles, polished tiles, vitrified tiles, antique tiles, mosaics, etc. Among them, polished tiles are favored by consumers due to their low water absorption, good hardness, and excellent wear resistance. However, the poor stain resistance of polished tiles limits their application. The reasons are: first, polished tiles are a combination of various grains and grain boundaries, pores and glass phases. Although the density of the green body is increased by kiln firing, there are always residual pores in the final polished tile products. These pores, especially closed pores, will be exposed on the surface of the polished tiles after the polishing process. When pollutants contact the surface of the polished tiles, some of the pollutants will penetrate into these exposed pores to form stains, reducing the stain resistance of the polished tiles; secondly, in the process of low-temperature rapid firing of polished tiles, due to the large difference in the expansion coefficients of quartz and glass phases, if the quartz particles are too large at this time, the glass phase is easily subjected to large tensile stress during cooling and cracks are generated, and even cracks run through the entire polished tile. Moreover, during the polishing process, after the bricks have undergone three stress-bearing processes of coarse grinding, fine grinding and polishing, the micro cracks in the bricks will expand to varying degrees, resulting in the polished tiles having a surface covered with many tiny cracks and worn. When pollutants come into contact with the surface of the polished tiles, some of the pollutants will penetrate into these tiny cracks, further reducing the anti-fouling performance of the polished tiles and affecting the overall appearance and service life of the polished tiles.

[0004] With the rapid development of cities, a large amount of construction waste will be generated during the demolition of the original aging urban buildings. Since the most commonly used building type in my country is brick-concrete buildings, waste brick powder is the most common solid waste in the construction industry. Due to the complex composition of waste brick powder, it is difficult to directly reuse it, resulting in a large amount of waste brick powder being landfilled or piled up, which not only pollutes the land but also causes a huge waste of resources. How to reuse waste brick powder is a technical problem that needs to be solved urgently in this field. Summary of the invention

[0005] In view of this, the present invention provides an anti-fouling ceramic tile, comprising the following components in parts by weight: 25-100 parts of waste brick powder, 20-50 parts of quartz sand, 20-30 parts of feldspar, 20-30 parts of bauxite, 5-8 parts of sodium tripolyphosphate, 3-5 parts of lanthanum oxide, 3-5 parts of zinc oxide, and 1-3 parts of sodium carboxymethyl cellulose.

[0006] Furthermore, the mass percentage of each component in the waste brick powder is as follows: SiO2 45.0%, Al2O3 38.3%, CaO 5.3%, Fe2O3 3.5%, MgO 3%, K2O 2.51%, TiO2 1.02%, CuO 1.1%, and unavoidable impurities 0.27%.

[0007] Furthermore, the feldspar includes potassium feldspar.

[0008] Furthermore, the main mineral phases of the bauxite are diaspore and kaolinite, and the mass percentages of the various components in the bauxite are as follows: SiO2 38.5%, Al2O3 59.3%, Fe2O3 0.1%, and TiO2 2.1%.

[0009] The present invention also provides a method for preparing the anti-fouling ceramic tile, comprising the following steps:

[0010] S1. Preparation of green bricks: weigh waste brick powder, quartz sand, feldspar, bauxite, sodium tripolyphosphate, lanthanum oxide, zinc oxide, and sodium carboxymethyl cellulose in proportion, put them in a ball mill, add water, and ball mill for 1-2 hours to obtain slurry, sieve the slurry to remove iron, spray dry, and obtain ingredients;

[0011] S2, pressing and molding: sending the ingredients into a mold for pressing and molding after aging to obtain a pre-treated blank;

[0012] S3, drying: drying the pretreated biscuit to obtain a dried biscuit;

[0013] S4, kiln firing: the dried green blank is moved into the sintering furnace for firing, and the firing is divided into three stages. In the first stage, the firing temperature is 100-350°C, and the heat preservation is 10-15min. In the second stage, the firing temperature is 350-1400°C, and the heat preservation is 20-30min. In the third stage, the green blank is cooled to below 180°C and taken out to obtain a sintered brick.

[0014] S5: Post-processing: The sintered bricks are sent to the polishing production line for edge grinding and polishing to obtain stain-resistant polished bricks.

[0015] Furthermore, the amount of water added in step S1 accounts for 46-68% of the total amount of raw materials, and the density of the slurry is 1.53-1.57 g / cm 3 .

[0016] Furthermore, the moisture content of the ingredients in step S1 is 5.5-6.8%, and the residue on the 120-mesh sieve is controlled at 1.0-1.8%.

[0017] Furthermore, the pressing pressure in step S2 is 400-500 MPa.

[0018] Furthermore, the drying temperature in step S3 is 150-200°C.

[0019] Furthermore, in step S4, the heating rate of the first stage is 10°C / min, the heating rate of the second stage is 60°C / min, the cooling rate of the third stage is 80°C / min, and the firing temperature of the second stage in step S4 is 1200-1400°C.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] As a kind of construction solid waste, waste brick powder has complex components and is difficult to handle. The accumulation of a large amount of waste brick powder will cause land pollution and great harm to the environment. The present invention provides a method for the secondary utilization of waste brick powder. The present invention uses waste brick powder, quartz sand, feldspar, and bauxite as silicon sources and aluminum sources, promotes the dissolution of internal soluble silicon dioxide and aluminum oxide through a ball milling step, improves the ability of the raw materials to react with water molecules, and increases the reaction activity. Sodium tripolyphosphate, lanthanum oxide, zinc oxide, and sodium carboxymethyl cellulose are used as auxiliary additives. Combined with the preparation process, it can effectively improve the anti-fouling ability of the tile surface, prevent water, oil and other stains from invading the pores of the tile, and also reduce the residue of stains on the tile surface. In addition, the present invention forms a crystalline phase on the surface of the polished tile through precise control of the sintering temperature, reduces the residual pores in the polished tile, and the water absorption rate of the polished tile is close to 0, which further improves the anti-fouling property of the polished tile. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a graph showing the water absorption performance test results of the products of Examples 1-3 and Comparative Examples 1-5 of the present invention. DETAILED DESCRIPTION

[0023] In some embodiments, the anti-fouling ceramic tile includes the following components in parts by weight: 25-100 parts of waste brick powder, 20-50 parts of quartz sand, 20-30 parts of feldspar, 20-30 parts of bauxite, 5-8 parts of sodium tripolyphosphate, 3-5 parts of lanthanum oxide, 3-5 parts of zinc oxide, and 1-3 parts of sodium carboxymethyl cellulose.

[0024] Preferably, the anti-fouling ceramic tile comprises the following components in parts by weight: 35-60 parts of waste brick powder, 25-35 parts of quartz sand, 25-28 parts of feldspar, 25-28 parts of bauxite, 5-7 parts of sodium tripolyphosphate, 3-4 parts of lanthanum oxide, 3-4 parts of zinc oxide, and 1-2 parts of sodium carboxymethyl cellulose.

[0025] More preferably, the anti-fouling ceramic tile comprises the following components in parts by weight: 40 parts of waste brick powder, 32 parts of quartz sand, 27 parts of feldspar, 26 parts of bauxite, 6 parts of sodium tripolyphosphate, 4 parts of lanthanum oxide, 4 parts of zinc oxide, and 2 parts of sodium carboxymethyl cellulose.

[0026] In some embodiments, the mass percentage of each component in the waste brick powder is as follows: SiO2 45.0%, Al2O3 38.3%, CaO 5.3%, Fe2O3 3.5%, MgO 3%, K2O 2.51%, TiO2 1.02%, CuO 1.1%, and unavoidable impurities 0.27%.

[0027] In some embodiments, the waste brick powder has a particle size of less than 0.025 mm and a moisture content of between 1.5% and 2.0%.

[0028] In some embodiments, the feldspar includes potassium feldspar, and the thermal expansion coefficient of the potassium feldspar is 8.5×10 -6 The melting temperature is 1150℃, the crystal system is monoclinic, and the composition is SiO262.7%, Al2O317.4%, and K2O 19.9%.

[0029] In some embodiments, the main mineral phases of the bauxite are diaspore and kaolinite, and the mass percentages of the components in the bauxite are as follows: SiO2 38.5%, Al2O3 59.3%, Fe2O3 0.1%, TiO2 2.1%.

[0030] In some embodiments, the present invention also provides a method for preparing the anti-fouling ceramic tile, comprising the following steps:

[0031] S1. Preparation of green bricks: weigh waste brick powder, quartz sand, feldspar, bauxite, sodium tripolyphosphate, lanthanum oxide, zinc oxide, and sodium carboxymethyl cellulose in proportion, put them in a ball mill, add water, and ball mill for 1-2 hours to obtain slurry, sieve the slurry to remove iron, spray dry, and obtain ingredients;

[0032] S2, pressing and molding: sending the ingredients into a mold for pressing and molding after aging to obtain a pre-treated blank;

[0033] S3, drying: drying the pretreated biscuit to obtain a dried biscuit;

[0034] S4, kiln firing: the dried green blank is moved into the sintering furnace for firing, and the firing is divided into three stages. In the first stage, the firing temperature is 100-350°C, and the heat preservation is 10-15min. In the second stage, the firing temperature is 350-1400°C, and the heat preservation is 20-30min. In the third stage, the green blank is cooled to below 180°C and taken out to obtain a sintered brick.

[0035] S5: Post-processing: The sintered bricks are sent to the polishing production line for edge grinding and polishing to obtain stain-resistant polished bricks.

[0036] In some embodiments, the amount of water added in step S1 accounts for 46-68% of the total amount of raw materials, and the density of the slurry is 1.53-1.57 g / cm 3 .

[0037] Preferably, the amount of water added in step S1 accounts for 50-56% of the total amount of raw materials, and the density of the slurry is 1.53-1.57 g / cm 3 .

[0038] In some embodiments, the sieving in step S1 refers to sieving through a 120-mesh sieve, and the sieve residue is controlled at 1.0-1.8%, preferably, the sieve residue is controlled at 1.0-1.3%.

[0039] In some embodiments, the pressing pressure in step S2 is 400-500 MPa. Preferably, the pressing pressure in step S2 is 450 MPa.

[0040] In some embodiments, the drying temperature in step S3 is 150-200°C, preferably, the drying temperature in step S3 is 180°C.

[0041] In some embodiments, the heating rate of the first stage in step S4 is 10°C / min, the heating rate of the second stage is 60°C / min, and the cooling rate of the third stage is 80°C / min; the firing temperature of the second stage in step S4 is 1200-1400°C, preferably, the firing temperature of the second stage in step S4 is 1260°C.

[0042] During the firing process of ceramic tiles, the present invention controls the heating and cooling rates to allow the waste brick powder in the green body to fully react, and the waste brick powder undergoes volume expansion to compensate for the volume shrinkage of the green body, thereby preventing the green body from being subjected to large tensile stress and cracking during the firing process, and reducing the generation of microcracks in the green body. In addition, the thermal expansion effect of the waste brick powder is utilized to help crush other raw materials and improve the reaction activity. During the specific firing process of the present invention, the aluminum ions, iron ions and potassium ions in the raw materials diffuse into the molten potassium feldspar glass phase, thereby increasing the viscosity of the liquid phase and increasing the crack resistance of the green body.

[0043] In order to make the purpose, technical solution and advantages of the present invention clearer, the technical solution of the present invention will be described clearly and completely below. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work belong to the scope of protection of the present invention.

[0044] The experimental methods or test methods described in the following examples are conventional methods unless otherwise specified; the raw materials and auxiliary agents are obtained from conventional commercial channels or prepared by conventional methods unless otherwise specified.

[0045] Example 1

[0046] A method for preparing anti-fouling ceramic tiles, the specific steps are as follows:

[0047] S1. Preparation of green bricks: Weigh 40 parts of waste brick powder, 32 parts of quartz sand, 27 parts of potassium feldspar, 26 parts of bauxite, 6 parts of sodium tripolyphosphate, 4 parts of lanthanum oxide, 4 parts of zinc oxide, and 2 parts of sodium carboxymethyl cellulose in proportion, put them in a ball mill, add water, and ball mill for 1 hour to obtain a slurry. The density of the slurry is 1.53 g / cm 3 The slurry is passed through a 120-mesh sieve, and the residue on the sieve is controlled to be 1.0%. After iron removal, the slurry is spray-dried to obtain a batch with a moisture content of 6%.

[0048] S2, pressing and molding: sending the ingredients into a mold for pressing and molding after aging, controlling the pressing pressure to be 450 MPa, and obtaining a pretreated green blank;

[0049] S3, drying: drying the pretreated biscuit at a drying temperature of 180° C. to obtain a dried biscuit;

[0050] S4, kiln firing: the dried green blank is moved into a sintering furnace for firing, and the firing is divided into three stages. In the first stage, the temperature of the sintering furnace is increased to 300°C at a heating rate of 10°C / min and kept warm for 10 minutes. In the second stage, the temperature of the sintering furnace is increased to 1260°C at a heating rate of 60°C / min and kept warm for 20 minutes. In the third stage, the temperature of the sintering furnace is reduced to below 180°C at a cooling rate of 80°C / min, and the sintered brick is taken out to obtain a sintered brick.

[0051] S5: Post-processing: The sintered bricks are sent to the polishing production line for edge grinding and polishing to obtain stain-resistant polished bricks.

[0052] Example 2

[0053] A method for preparing anti-fouling ceramic tiles, the specific steps are as follows:

[0054] S1. Preparation of green bricks: weigh 25 parts of waste brick powder, 20 parts of quartz sand, 20 parts of potassium feldspar, 20 parts of bauxite, 5 parts of sodium tripolyphosphate, 3 parts of lanthanum oxide, 3 parts of zinc oxide, and 1 part of sodium carboxymethyl cellulose in proportion, put them in a ball mill, add water, and ball mill for 1 hour to obtain a slurry. The density of the slurry is 1.56 g / cm 3 The slurry is passed through a 120-mesh sieve, and the residue on the sieve is controlled to be 1.5%. After iron removal, the slurry is spray-dried to obtain a batch with a moisture content of 7%.

[0055] S2, pressing and molding: sending the ingredients into a mold for pressing and molding after aging, controlling the pressing pressure to be 450 MPa, and obtaining a pretreated green blank;

[0056] S3, drying: drying the pretreated biscuit at a drying temperature of 180° C. to obtain a dried biscuit;

[0057] S4, kiln firing: the dried green blank is moved into a sintering furnace for firing, and the firing is divided into three stages. In the first stage, the temperature of the sintering furnace is increased to 300°C at a heating rate of 10°C / min and kept warm for 10 minutes. In the second stage, the temperature of the sintering furnace is increased to 1260°C at a heating rate of 60°C / min and kept warm for 20 minutes. In the third stage, the temperature of the sintering furnace is reduced to below 180°C at a cooling rate of 80°C / min, and the sintered brick is taken out to obtain a sintered brick.

[0058] S5: Post-processing: The sintered bricks are sent to the polishing production line for edge grinding and polishing to obtain stain-resistant polished bricks.

[0059] Example 3

[0060] A method for preparing anti-fouling ceramic tiles, the specific steps are as follows:

[0061] S1. Preparation of green bricks: weigh 80 parts of waste brick powder, 52 parts of quartz sand, 30 parts of potassium feldspar, 30 parts of bauxite, 8 parts of sodium tripolyphosphate, 5 parts of lanthanum oxide, 5 parts of zinc oxide, and 2 parts of sodium carboxymethyl cellulose in proportion, put them in a ball mill, add water, and ball mill for 1.5 hours to obtain a slurry. The density of the slurry is 1.53 g / cm 3 The slurry is passed through a 120-mesh sieve, and the residue on the sieve is controlled to be 1.0%. After iron removal, the slurry is spray-dried to obtain a batch with a moisture content of 7%;

[0062] S2, pressing and molding: sending the ingredients into a mold for pressing and molding after aging, controlling the pressing pressure to be 450 MPa, and obtaining a pretreated green blank;

[0063] S3, drying: drying the pretreated biscuit at a drying temperature of 180° C. to obtain a dried biscuit;

[0064] S4, kiln firing: the dried green blank is moved into a sintering furnace for firing, and the firing is divided into three stages. In the first stage, the temperature of the sintering furnace is increased to 300°C at a heating rate of 10°C / min and kept warm for 10 minutes. In the second stage, the temperature of the sintering furnace is increased to 1260°C at a heating rate of 60°C / min and kept warm for 20 minutes. In the third stage, the temperature of the sintering furnace is reduced to below 180°C at a cooling rate of 80°C / min, and the sintered brick is taken out to obtain a sintered brick.

[0065] S5: Post-processing: The sintered bricks are sent to the polishing production line for edge grinding and polishing to obtain stain-resistant polished bricks.

[0066] Comparative Example 1

[0067] The difference from Example 1 is that albite is used to replace the potassium feldspar in Example 1, and the other steps are consistent with Example 1.

[0068] Comparative Example 2

[0069] The difference from Example 1 is that no waste brick powder is contained, and the other steps are consistent with Example 1.

[0070] Comparative Example 3

[0071] The difference from Example 1 is that lanthanum oxide is not contained, and the other steps are consistent with Example 1.

[0072] Comparative Example 4

[0073] The difference from Example 1 is that the pressing pressure is 300 MPa, and the other steps are consistent with Example 1.

[0074] Comparative Example 5

[0075] The difference from Example 1 is that no step-by-step firing is performed during the kiln firing stage. Instead, high-temperature firing at 1200°C is adopted, and the temperature is kept for 30 minutes to obtain sintered bricks. The remaining steps are consistent with Example 1.

[0076] In order to better illustrate the beneficial effects of the technical solution of the present invention, the stain resistance and water absorption performance of the products provided in Examples 1-3 and Comparative Examples 1-5 were tested, and the testing method was as follows:

[0077] The stain resistance detection method adopted in the present invention is: GB / T3810.4-2016 "Ceramic Tile Test Methods Part 14: Determination of Stain Resistance".

[0078] The water absorption detection method adopted in the present invention is: GB / T3810.3-2006 "Test methods for ceramic tiles Part 3: Determination of water absorption, apparent porosity, apparent relative density and bulk density".

[0079] The test results are shown in Table 1:

[0080] Table 1 Test results of stain resistance and water absorption performance of products of Examples 1-3 and Comparative Examples 1-5

[0081] Group Anti-fouling grade (grade) Water absorption (%) Example 1 5 0.072 Example 2 5 0.085 Example 3 5 0.081 Comparative Example 1 4 0.178 Comparative Example 2 4 0.392 Comparative Example 3 3 0.259 Comparative Example 4 4 0.181 Comparative Example 5 3 0.420

[0082] It can be seen from Table 1 that the anti-fouling ceramic tiles prepared in Examples 1-3 have excellent anti-fouling performance; compared with Comparative Examples 1-5, Examples 1-3 of the present invention greatly reduce the number of holes and cracks in the ceramic tiles by adjusting the type of raw materials and setting a staged firing process, effectively improving the density of the ceramic tiles, making the open porosity close to 0, and significantly reducing the water absorption rate of the finished polished tiles, further improving the anti-fouling performance of the polished tiles.

[0083] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principle of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A stain-resistant tile, characterized in that: The invention comprises the following components in parts by weight: 25-100 parts of waste brick powder, 20-50 parts of quartz sand, 20-30 parts of feldspar, 20-30 parts of bauxite, 5-8 parts of sodium tripolyphosphate, 3-5 parts of lanthanum oxide, 3-5 parts of zinc oxide and 1-3 parts of sodium carboxymethyl cellulose.

2. The anti-fouling ceramic tile according to claim 1, characterized in that: The mass percentages of the components in the waste brick powder are as follows: SiO2 45.0%, Al2O3 38.3%, CaO 5.3%, Fe2O3 3.5%, MgO 3%, K2O 2.51%, TiO2 1.02%, CuO 1.1%, and unavoidable impurities 0.27%.

3. The anti-fouling ceramic tile according to claim 1, characterized in that: The feldspar includes potassium feldspar.

4. The anti-fouling ceramic tile according to claim 1, characterized in that: The main mineral phases of the bauxite are diaspore and kaolinite. The mass percentages of the various components in the bauxite are as follows: SiO2 38.5%, Al2O3 59.3%, Fe2O3 0.1%, and TiO2 2.1%.

5. The method for preparing the anti-fouling ceramic tile according to any one of claims 1 to 4, characterized in that: The following steps are involved: S1. Preparation of green bricks: weigh waste brick powder, quartz sand, feldspar, bauxite, sodium tripolyphosphate, lanthanum oxide, zinc oxide, and sodium carboxymethyl cellulose in proportion, put them in a ball mill, add water, and ball mill for 1-2 hours to obtain slurry, sieve the slurry to remove iron, spray dry, and obtain ingredients; S2, pressing and molding: sending the ingredients into a mold for pressing and molding after aging to obtain a pre-treated blank; S3, drying: drying the pretreated biscuit to obtain a dried biscuit; S4, kiln firing: the dried green blank is moved into the sintering furnace for firing, and the firing is divided into three stages. In the first stage, the firing temperature is 100-350°C, and the heat preservation is 10-15min. In the second stage, the firing temperature is 350-1400°C, and the heat preservation is 20-30min. In the third stage, the green blank is cooled to below 180°C and taken out to obtain a sintered brick. S5: Post-processing: The sintered bricks are sent to the polishing production line for edge grinding and polishing to obtain stain-resistant polished bricks.

6. The method for preparing the anti-fouling ceramic tile according to claim 5, characterized in that: The amount of water added in step S1 accounts for 46-68% of the total amount of raw materials, and the density of the slurry is 1.53-1.57 g / cm 3 .

7. The method for preparing the antifouling ceramic tile according to claim 5, characterized in that: The moisture content of the ingredients in step S1 is 5.5-6.8%, and the residue on the 120-mesh sieve is controlled at 1.0-1.8%.

8. The method for preparing the anti-fouling ceramic tile according to claim 5, characterized in that: The pressing pressure in step S2 is 400-500Mpa.

9. The method for preparing the anti-fouling ceramic tile according to claim 5, characterized in that: The drying temperature in step S3 is 150-200°C.

10. The method for preparing antifouling ceramic tiles according to claim 5, characterized in that: In step S4, the heating rate of the first stage is 10°C / min, the heating rate of the second stage is 60°C / min, the cooling rate of the third stage is 80°C / min, and the firing temperature of the second stage in step S4 is 1200-1400°C.

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