阅读说明：本技术 一种大规格陶瓷岩板及其生产工艺 (Large-size ceramic rock plate and production process thereof ) 是由 龚明 曾彦炽 胡江峰 兰书元 张开祥 袁文 向威 于 2019-11-01 设计创作，主要内容包括：本发明公开了一种大规格陶瓷岩板,其按重量百分比计,所述岩板坯用原料组成成分：中温沙40%~55%、低温沙15%~25%、球土16%~25%、烧滑石5%~10%、煅烧高岭土2%~5%和硅酸锆1%~3%。相比于传统的建材,它是一种新型材料,具有逼真的仿真3D纹理、细腻质感、坚硬而柔韧耐磨的特质。由于具有复杂多变的颜色和透光的材质,从传统到进阶建筑风格,从家居陈设到总体设计多方面都可以应用到。(The invention discloses a large-size ceramic rock slab which comprises, by weight, 40% ~ 55% of medium temperature sand, 15% ~ 25% of low temperature sand, 16% ~ 25% of ball clay, 5% ~ 10% of burnt talc, 2% ~ 5% of calcined kaolin and 1% ~ 3% of zirconium silicate, and compared with the traditional building material, the large-size ceramic rock slab is a novel material and has vivid simulated 3D texture, fine texture, hard, flexible and wear-resistant characteristics.)

1. A large-size ceramic rock plate, which is characterized in that,

the raw materials for the rock slab comprise, by weight, 40% ~ 55% of medium temperature sand, 15% ~ 25% of low temperature sand, 16% ~ 25% of ball clay, 5% ~ 10% of calcined talc, 2% ~ 5% of calcined kaolin and 1% ~ 3% of zirconium silicate;

the glaze for the rock plate comprises a ground glaze and a full-polished glaze:

the ground glaze comprises the following effective components, by weight, 22% of quartz sand ~ 26%, 8% of air-knife soil ~ 11%, 5% of ball clay ~ 8%, 7% of burnt talc ~ 11%, 13% of albite ~ 16%, 10% of nepheline powder ~ 14%, 8% of zirconium silicate ~ 12%, 11% of calcined kaolin ~ 15%, 0.08% of methyl ~ 0.12.12%, 0.2% of sodium tripolyphosphate ~ 0.6.6% and 30% of water ~ 33%;

the fully polished glaze comprises the following effective components, by weight, 18% of fusion cake ~ 22%, 8% of air-knife soil ~ 12%, 14% of calcite ~ 18%, 19% of albite ~ 23%, 9% of calcined talc ~ 12%, 6% of zirconium silicate ~ 9%, 3% of zinc oxide ~ 6%, 9% of barium carbonate ~ 12%, 0.08% of methyl ~ 0.12.12%, 0.1% of sodium tripolyphosphate ~ 0.5.5% and 37% of water ~ 41%.

2. The large format ceramic rock panel of claim 1, wherein the primer comprises the following active ingredients in weight percent: 24.24% of quartz sand, 9.16% of air-knife soil, 6.68% of ball clay, 9.19% of calcined talc, 14.87% of albite, 12.46% of nepheline powder, 10.14% of zirconium silicate, 13.26% of calcined kaolin, 0.1% of methyl, 0.4% of sodium tripolyphosphate and 31.25% of water;

the full-polished glaze comprises the following effective components in percentage by weight: 20.00 percent of clinker, 10.54 percent of air knife soil, 16.98 percent of calcite, 20.19 percent of albite, 10.12 percent of burning talc, 7.16 percent of zirconium silicate, 4.68 percent of zinc oxide, 10.33 percent of barium carbonate, 0.10 percent of methyl, 0.30 percent of sodium tripolyphosphate and 39.00 percent of water.

3. The large format ceramic slate of claim 1, wherein all raw materials are subjected to fine processing, wherein each part of the medium temperature sand has a chemical raw material content: al (Al)₂O₃13% -16% of Fe₂O₃≤0.05%，K₂O+Na₂O is 7 percent ~ 9 percent, I.L is less than or equal to 1 percent, and the chemical raw material content of each part of the low-temperature sand is Al₂O₃13% -15% of Fe₂O₃≤0.05%，K₂O≥2%，Na₂O is 5 percent ~ 7 percent, I.L is less than or equal to 1 percent, and the chemical raw material content of each part of the ball clay is Al₂O₃≥30%，Fe₂O₃Less than or equal to 0.8 percent, I.L less than or equal to 12 percent; the chemical materials for glaze are all selected from the calcined talc, the calcined kaolin and the zirconium silicate.

4. The large format ceramic rock panel of claim 1, wherein the formulation is precisely dosed with all raw material tolerances within 20 kilograms.

5. The process of producing large format ceramic rock panels of claim 1, comprising the steps of: batching → ball milling → slurry discharging and placing in a pool → spray granulation → powder material warehousing → press molding → green brick is placed in a drying kiln → green brick water spray → bottom glaze spraying → ink jet printing → glaze spraying and throwing → green brick is placed in a glaze firing kiln → firing → polishing → graded warehousing.

6. The production process of the large-size ceramic rock plate according to claim 5, wherein the ball mill uses medium-high alumina ball stones as ball milling media, and the ball milling fineness is less than 0.6.

7. The process of producing large format ceramic rock plates of claim 5, wherein the powder comprises the following chemical components in weight percent: al (Al)₂O₃19% ~ 22%, Fe₂O₃Not more than 0.3 percent, 1.0 percent of MgO ~ 1.5.5 percent, K₂O is 2.5% ~ 3.5.5%, Na₂O is 2.5% ~ 3.0.0%, I.L is 3% ~ 5%.

8. The process for producing large-size ceramic rock boards according to claim 5, wherein the glaze line is printed with a suitable pattern effect by using a large-size ink-jet printing machine, and the production flow of the glaze line is as follows: drying the green body → wiping the green body → spraying water → glazing → printing → applying protective glaze, wherein the glazing is ground glaze and the protective glaze is full-polished glaze.

9. The process of claim 5, wherein the kiln has a firing cycle of two hours, a firing temperature of 1180 ℃ and a kiln tail green brick temperature of 45 ~ 60 ℃.

Technical Field

The invention belongs to the technical field of ceramic decorative materials, and particularly relates to a large-size ceramic rock plate.

Background

With the continuous development of scientific technology and the continuous improvement of the living standard of human beings, the architectural decoration develops towards a novel decorative material which is environment-friendly, multifunctional, high in strength, light in weight, finished, standardized in installation and intelligent in control.

The existing natural stone has the following defects: a. because marble generally contains impurities, and calcium carbonate is easily weathered and corroded by carbon dioxide, carbide and water vapor in the atmosphere, the surface loses luster quickly; generally only for interior trim. Having radioactivity: natural marble is generally radioactive and has a certain effect on the human body.

The existing artificial stone has the following defects: the artificial stone contains chemical synthetic substances, and is partially harmful to human bodies, small in hardness, easy to scratch, not high-temperature resistant and easy to color.

Disclosure of Invention

The invention provides a large-size ceramic rock plate which is a novel material compared with the traditional building material and has the characteristics of vivid simulated 3D texture, fine texture, hardness, flexibility and wear resistance. Due to the fact that the light-transmitting material has complicated and varied colors and light-transmitting materials, the light-transmitting material can be applied to various aspects from the traditional to advanced architectural styles and from home furnishing to overall design.

The technical scheme of the invention is realized as follows:

the large-size ceramic rock plate comprises the following raw materials in percentage by weight: 40-55% of medium-temperature sand, 15-25% of low-temperature sand, 16-25% of ball clay, 5-10% of calcined talc, 2-5% of calcined kaolin and 1-3% of zirconium silicate;

the glaze for the rock plate comprises a ground glaze and a full-polished glaze:

the ground glaze comprises the following effective components in percentage by weight: 22 to 26 percent of quartz sand, 8 to 11 percent of air knife soil, 5 to 8 percent of ball clay, 7 to 11 percent of calcined talc, 13 to 16 percent of albite, 10 to 14 percent of nepheline powder, 8 to 12 percent of zirconium silicate, 11 to 15 percent of calcined kaolin, 0.08 to 0.12 percent of methyl, 0.2 to 0.6 percent of sodium tripolyphosphate and 30 to 33 percent of water;

the full-polished glaze comprises the following effective components in percentage by weight: 18 to 22 percent of fusion cake, 8 to 12 percent of air knife soil, 14 to 18 percent of calcite, 19 to 23 percent of albite, 9 to 12 percent of calcined talc, 6 to 9 percent of zirconium silicate, 3 to 6 percent of zinc oxide, 9 to 12 percent of barium carbonate, 0.08 to 0.12 percent of methyl, 0.1 to 0.5 percent of sodium tripolyphosphate and 37 to 41 percent of water.

In the large-size ceramic rock plate, the ground coat comprises the following effective components in percentage by weight: 24.24% of quartz sand, 9.16% of air-knife soil, 6.68% of ball clay, 9.19% of calcined talc, 14.87% of albite, 12.46% of nepheline powder, 10.14% of zirconium silicate, 13.26% of calcined kaolin, 0.1% of methyl, 0.4% of sodium tripolyphosphate and 31.25% of water;

the full-polished glaze comprises the following effective components in percentage by weight: 20.00 percent of clinker, 10.54 percent of air knife soil, 16.98 percent of calcite, 20.19 percent of albite, 10.12 percent of burning talc, 7.16 percent of zirconium silicate, 4.68 percent of zinc oxide, 10.33 percent of barium carbonate, 0.10 percent of methyl, 0.30 percent of sodium tripolyphosphate and 39.00 percent of water.

In the large-size ceramic rock plate, all raw materials are subjected to fine processing, wherein the chemical raw material content of each part of the medium-temperature sand is as follows: al (Al)₂O₃13% -16% of Fe₂O₃≤0.05％，K₂O+Na₂O is 7 to 9 percent, and I.L is less than or equal to 1 percent; the low-temperature sand comprises the following chemical raw materials in part: al (Al)₂O₃13% -15% of Fe₂O₃≤0.05％，K₂O≥2％，Na₂O is 5 to 7 percent, and I.L is less than or equal to 1 percent; each part of ball soilThe content of the chemical raw materials of the differentiation: al (Al)₂O₃≥30％，Fe₂O₃Less than or equal to 0.8 percent, I.L less than or equal to 12 percent; the chemical materials for glaze are all selected from the calcined talc, the calcined kaolin and the zirconium silicate.

In the large-size ceramic rock plate, the ingredients are accurately prepared according to the formula, and the error of all raw materials is within 20 kg.

The production process of the large-size ceramic rock plate comprises the following steps: batching → ball milling → slurry discharging and placing in a pool → spray granulation → powder material warehousing → press molding → green brick is placed in a drying kiln → green brick water spray → bottom glaze spraying → ink jet printing → glaze spraying and throwing → green brick is placed in a glaze firing kiln → firing → polishing → grading and warehousing.

In the production process of the large-size ceramic rock plate, the ball mill selects medium-high alumina ball stones as ball milling media, and the ball milling fineness is less than 0.6.

In the production process of the large-size ceramic rock plate, the powder comprises the following chemical components in percentage by weight: al (Al)₂O₃19 to 22 percent of Fe₂O₃Not more than 0.3 percent, MgO 1.0-1.5 percent, K₂2.5 to 3.5 percent of O and Na₂2.5 to 3.0 percent of O and 3 to 5 percent of I.L.

In the production process of the large-size ceramic rock plate, the glaze line adopts a large-size ink-jet printing machine to print a proper pattern effect, and the production flow of the glaze line is as follows: drying the green body → wiping the green body → spraying water → glazing → printing → applying protective glaze, wherein the glazing is ground glaze and the protective glaze is full-polished glaze.

In the production process of the large-size ceramic rock plate, the firing period of a kiln is two hours, the firing temperature is 1180 ℃, and the temperature of a kiln tail green brick is 45-60 ℃.

The ingredients of the raw materials for the rock slab used in the present scheme are shown in the following table:

name of raw materials	SiO2	Al2O3	Fe2O3	CaO	MgO	K2O	Na2O	I.L
									Medium temperature sand	77.10	13.20	0.03	0.35	0.07	2.52	4.84	0.97
Low-temperature sand	75.19	13.64	0.04	0.20	0.05	5.48	5.56	0.95
									Ball clay	54.51	30.66	0.65	0.06	0.11	1.73	0.27	11.03
Burned talcum	60.00	0.52	0.12	3.58	33.22	0.18	0.32	1.29
									Calcined kaolin	52.14	44.74	0.53	0.58	0.17	0.22	0.49	0.40

The large-size ceramic rock plate has the following beneficial effects:

1. safety and sanitation: can be directly contacted with food, is made of pure natural materials, can be recovered by 100 percent, is non-toxic and non-radiative, simultaneously comprehensively considers the requirements of human sustainable development, and is healthy and environment-friendly.

2. Fireproof and high temperature resistant: the rock plate with the A1 grade fireproof performance does not deform when directly contacting high-temperature objects, does not shrink, crack or change color when meeting open fire at 2000 ℃, and does not emit any gas or smell.

3. Stain resistance: the rock plate has low water absorption rate, and no space for breeding bacteria is provided while stains cannot permeate.

4. Scratch and wear resistance: the Mohs hardness exceeds 5 grades, and can resist scratching and attempted scratching.

5. Corrosion resistance: resistant to various chemicals including solutions, disinfectants, and the like.

6. Easy cleaning: the cleaning agent can be cleaned only by wiping with a wet towel, has no special maintenance requirement, and is simple and quick to clean.

7. All-round application: the application boundary is broken through, the border is crossed from the decorative material to the application material, the design, the processing and the application are more diversified and wide, and the high-standard application requirements are met.

8. Flexible customization: the texture of the rock plate is rich and various, and can be customized according to the needs of users.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the embodiments of the present invention.

The rock plate is used as a brand new material, is a brand new concept developed on the basis of the ceramic thin plate and the ceramic large plate, has large-specification commonality with the ceramic thin plate and the ceramic large plate, forms obvious difference on product expression, and is a result of a new method and a fine classification for ceramic large plate enterprises. The main characteristics of the rock plate are large, thick and consistent in texture, and compared with ceramic tiles, the rock plate is more fire-resistant, high-temperature resistant, stain-resistant, corrosion-resistant and zero-penetration. The rock plate is generated at high temperature, the Mohs hardness exceeds 5 grade, the scratch resistance and wear resistance are extremely excellent, and the value of the rock plate is rich and exquisite stone texture, so that the advantages of the rock plate which is applied to kitchenware and furniture across the boundary are outstanding, and the rock plate is durable for a long time. From the product characteristics, the rock plate is very competitive-artificial stone and quartz contain resin, marble and granite have radioactivity, the rock plate is not good for environmental protection and health, meanwhile, the texture of the rock plate is artificially created, and is rich and diverse, and the advantages determine that the rock plate can move farther and farther on a plate-like road and firmly occupy a place. The large-size ceramic rock slab comprises the following raw materials in percentage by weight: 40-55% of medium-temperature sand, 15-25% of low-temperature sand, 16-25% of ball clay, 5-10% of calcined talc, 2-5% of calcined kaolin and 1-3% of zirconium silicate.

The raw materials are accurately mixed according to the formula, the error of all the raw materials is within 20 kg, and all the raw materials are finely processed. Wherein, the content of each part of chemical raw materials of the medium temperature sand is as follows: al (Al)₂O₃13% -16% of Fe₂O₃≤0.05％，K₂O+Na₂O is 7 to 9 percent, and I.L is less than or equal to 1 percent; the content of each part of chemical raw materials of the low-temperature sand is as follows: al (Al)₂O₃13% -15% of Fe₂O₃≤0.05％，K₂O≥2％，Na₂O is 5 to 7 percent, and I.L is less than or equal to 1 percent; the contents of chemical raw materials of all parts of the ball soil are as follows: al (Al)₂O₃≥30％，Fe₂O₃Less than or equal to 0.8 percent, I.L less than or equal to 12 percent; the chemical materials for glaze are all selected from the calcined talc, the calcined kaolin and the zirconium silicate.

The glaze for the rock plate comprises a ground glaze and a full-polished glaze:

the ground glaze comprises the following effective components in percentage by weight: 22 to 26 percent of quartz sand, 8 to 11 percent of air knife soil, 5 to 8 percent of ball clay, 7 to 11 percent of calcined talc, 13 to 16 percent of albite, 10 to 14 percent of nepheline powder, 8 to 12 percent of zirconium silicate, 11 to 15 percent of calcined kaolin, 0.08 to 0.12 percent of methyl, 0.2 to 0.6 percent of sodium tripolyphosphate and 30 to 33 percent of water;

the full-polished glaze comprises the following effective components in percentage by weight: 18 to 22 percent of fusion cake, 8 to 12 percent of air knife soil, 14 to 18 percent of calcite, 19 to 23 percent of albite, 9 to 12 percent of calcined talc, 6 to 9 percent of zirconium silicate, 3 to 6 percent of zinc oxide, 9 to 12 percent of barium carbonate, 0.08 to 0.12 percent of methyl, 0.1 to 0.5 percent of sodium tripolyphosphate and 37 to 41 percent of water.

The production process of the large-size ceramic rock plate comprises the following steps: batching → ball milling → slurry discharging in a pool (iron removal) → spray granulation → powder warehousing → press molding → green brick drying kiln entering → green brick water spraying → ground glaze pouring → ink jet printing → glaze pouring → green brick glaze firing kiln → firing → polishing → graded warehousing.

Wherein, the ball mill selects medium-high alumina ball stone as ball milling medium, and the ball milling fineness is less than 0.6.

The powder comprises the following chemical components in percentage by weight: al (Al)₂O₃19 to 22 percent of Fe₂O₃Not more than 0.3 percent, MgO 1.0-1.5 percent, K₂2.5 to 3.5 percent of O and Na₂2.5 to 3.0 percent of O and 3 to 5 percent of I.L.

In order to meet production requirements, a large-tonnage press is used for press forming in a press workshop, and the maximum pressure of the press is 16800 tons. Wherein the press grinding tool size is 870mm 2828mm, the green size: 875mm 2845mm 16.5 mm.

The glaze line adopts a large-specification ink-jet printing machine to print a proper pattern effect, and the production flow of the glaze line is as follows: drying the green body → wiping the green body → spraying water → glazing → printing → applying protective glaze, wherein the glazing is ground glaze and the protective glaze is full-polished glaze.

The firing period of the kiln is longer, and reaches two hours. The firing temperature is 1180 ℃, and the kiln tail green brick temperature is 45-60 ℃. The size of the glaze firing finished product is as follows: the short edge is 795-800 mm, the long edge is 2582-2589 mm, the thickness is 14.8-15.2 mm, the whiteness of the white blank is 60-65 degrees, the water absorption rate is 0.01-0.03, the breaking strength is 6200-6500N, and the modulus of rupture is 42-45 Mpa.

During production, aiming at the characteristic of high requirement of white rock board on whiteness, the iron oxide content is reduced according to the formula, and meanwhile, the needed raw materials are deeply processed by cooperating with related raw material production enterprises and improving equipment for removing iron and the like of the raw materials, so that the iron content of the feldspar type raw materials is further reduced to be below 0.03 from 0.2, and the iron content of the ball clay type raw materials is reduced to be below 0.6 from 1.0. In order to ensure that the powder has lower ignition loss and strength, the strength of the powder is improved by adding a small amount of reinforcing agent while reducing the dosage of ball clay. All raw materials used in the process of the pilot plant are subjected to fine processing, wherein the content of iron in the feldspar raw materials is below 0.03%, the content of iron in the ball clay is less than 0.6, and meanwhile, zirconium silicate is properly added to improve whiteness. Aiming at the characteristics of large and thick rock plates, the flatness and the stability of the production line are further improved by introducing a 1.68 ten thousand ton press. The proportion of various raw materials in the formula is determined by the attack of related departments and the existing conditions of companies, and products meeting the requirements are finally prepared through a plurality of pilot tests. The rock plate ash is improved on the basis of the formula of the rock plate white.