Spraying paint protection-free sagger material formula for talc porcelain and preparation method of sagger material formula

Abstract

The invention discloses a spray coating protection-free sagger material formula for talc porcelain and a preparation method of the sagger material formula. The sagger material is prepared from the following components in percentage by weight: 30-50% of coarse quartz; 10-20% of fine quartz; 1-5% of modified cordierite; 5-15% of washed kaolin; 5-15% of fused quartz; 1-5% of a composite plasticizer; 0.5 to 3% of albite; 5 to 15% of bentonite; the sagger material is subjected to burdening, mixing, forming and drying, and then is fired and formed at 1250-1350 DEG C. According to the formula, spraying-free paint protection is achieved through the synergistic effect of the components, the comprehensive performance reaches or is superior to that of a traditional technology, and cost is remarkably reduced.

Description

Technical Field

[0001] The invention belongs to the technical field of sagger material formula, and particularly relates to a sagger material formula for protection of talc porcelain by spray-free coating and a preparation method thereof. Background Art

[0002] Traditional steatite saggers require a protective coating to prevent adhesion between the body and the sagger. However, this coating process increases production costs and complexity, and the coating easily flakes off, causing product contamination. Existing uncoated saggers commonly suffer from liquid-phase adhesion to the steatite at high temperatures and poor thermal shock resistance, limiting their service life and cycle life. Therefore, developing a sagger material that requires no coating, is heat-resistant, and has a matching thermal expansion coefficient is of great practical significance. Summary of the Invention

[0003] The purpose of the present invention is to provide a formula of a sagger material for protecting talc porcelain with a spray-free coating and a preparation method thereof, which can completely solve the shortcomings of the above-mentioned prior art.

[0004] The purpose of the present invention is achieved through the following technical solutions:

[0005] A formula for a sagger material for steatite porcelain protected by a spray-free coating is composed of the following components in percentage by weight:

[0006] Rough quartz 30-50%;

[0007] Fine quartz 10-20%;

[0008] Modified cordierite 1-5%;

[0009] Washed kaolin 5-15%;

[0010] Fused silica 5-15%;

[0011] Composite plasticizer 1-5%;

[0012] Sodium feldspar 0.5-3%;

[0013] Bentonite 5-15%;

[0014] The sagger material is prepared, mixed, formed and dried, and then fired at 1250-1350° C. to form the sagger.

[0015] Preferably, the coarse quartz particle size is 80-200 mesh, and the fine quartz particle size is 325-400 mesh.

[0016] Preferably, the modified cordierite has a particle size of 60-80 mesh, and the fused quartz has a particle size of 180-200 mesh.

[0017] Preferably, the composite plasticizer is a mixture of carboxymethyl cellulose and polyvinyl alcohol in a mass ratio of 1:1.

[0018] Preferably, the composite plasticizer is a mixture of methyl cellulose and starch in a mass ratio of 3:1.

[0019] Preferably, the modified cordierite is presynthesized cordierite, and its preparation method comprises: mixing magnesia clay and quartz powder in a molar ratio of 2:1, calcining at 1300° C. for 2 hours, and crushing to 60-80 mesh.

[0020] A method for preparing the sagger material described in any one of the above items comprises the following steps:

[0021] a) mixing coarse quartz, fine quartz, modified cordierite, washed kaolin, fused quartz, composite plasticizer, albite, and bentonite, and then ball milling for 20-40 minutes;

[0022] b) After aging for 12-36 hours, the product is formed;

[0023] c) Drying to a moisture content of ≤5%;

[0024] d) calcining at 1250-1350°C and keeping the temperature for 30-60 minutes, and then naturally cooling to obtain a sagger product.

[0025] Compared with the prior art, the present invention has the following beneficial effects:

[0026] 1. Spray-free paint protection: Through the synergistic effect of coarse / fine quartz, modified cordierite and fused quartz, a refractory interface is formed with talc porcelain at high temperature to avoid liquid phase adhesion.

[0027] 2. High thermal shock stability: Fused quartz and modified cordierite reduce the thermal expansion coefficient, alleviate thermal cycling stress, and increase the number of sagger cycles (≥50 times).

[0028] 3. Low cost and environmental protection: eliminating the spraying process, reducing material consumption and environmental pollution, and reducing the overall cost by 15%-20%.

[0029] 4. Strong formability: The combination of composite plasticizer and bentonite significantly improves the plasticity of the green body, ensuring the molding density and strength. DETAILED DESCRIPTION

[0030] Exemplary embodiments of the present disclosure will be described in more detail below.

[0031] A formula for a sagger material for steatite porcelain protected by a spray-free coating is composed of the following components in percentage by weight:

[0032] 30-50% coarse quartz; 10-20% fine quartz; 1-5% modified cordierite; 5-15% washed kaolin; 5-15% fused quartz; 1-5% composite plasticizer; 0.5-3% albite; 5-15% bentonite; the sagger material is prepared by batching, mixing, molding, and drying, and then sintered at 1250-1350°C.

[0033] The coarse quartz has a particle size of 20-40 mesh, the fine quartz has a particle size of 100-200 mesh, the modified cordierite has a particle size of 60-80 mesh, and the fused quartz has a particle size of 200-400 mesh.

[0034] The composite plasticizer is a mixture of carboxymethyl cellulose and polyvinyl alcohol in a mass ratio of 1:1. The composite plasticizer is a mixture of methyl cellulose and starch in a mass ratio of 3:1.

[0035] The modified cordierite is presynthesized cordierite, and its preparation method includes: mixing magnesia clay and quartz powder in a molar ratio of 2:1, calcining at 1300° C. for 2 hours, and crushing to 60-80 mesh.

[0036] A method for preparing the sagger material described in any one of the above items comprises the following steps:

[0037] a) mixing coarse quartz, fine quartz, modified cordierite, washed kaolin, fused quartz, composite plasticizer, albite, and bentonite, and then ball milling for 20-40 minutes;

[0038] b) After aging for 12-36 hours, the product is formed;

[0039] c) Drying to a moisture content of ≤5%;

[0040] d) calcining at 1250-1350°C and keeping the temperature for 30-60 minutes, and then naturally cooling to obtain a sagger product.

[0041] Function of each component:

[0042] 1. Coarse quartz serves as the core matrix, providing the required gradation of sagger material particles. At high temperatures, it exhibits fire resistance relative to the talc porcelain body in contact with it, does not produce liquid phase adhesion with the talc porcelain, and does not require spray paint protection.

[0043] 2. Fine quartz mainly provides the particle grading required for sagger materials. At the same time, it shows refractory properties to talc porcelain at high temperatures, does not produce liquid phase adhesion, and does not require spray paint protection.

[0044] 3. The purpose of fused quartz is to reduce the thermal expansion coefficient of the sagger material system, slow down the stress caused by the volume change of the sagger during hot and cold cycles, increase the number of cycles in the kiln, and at the same time, increase the content of silica refractory materials in the system to prevent it from sticking to the talc porcelain blank.

[0045] 4. By adding modified cordierite, the thermal expansion coefficient of the sagger material is reduced, and at the same time, the magnesium oxide and silicon dioxide required by the sagger material are provided. These two oxides also show refractory properties to the talc porcelain body, do not produce liquid phase adhesion with the talc porcelain, and do not require spray paint protection.

[0046] 5. The function of washed kaolin is to increase the plasticity of sagger material, act as a molding binder, and provide the silica refractory material required by the sagger material system.

[0047] 6. Bentonite is a stronger molding binder than kaolin, and also provides the silica refractory material required by the sagger system.

[0048] 7. The composite plasticizer can significantly improve the molding plasticity of the sagger material, and at the same time produce a small amount of glass phase at high temperature, which has a bonding effect on the particles of the sagger material system.

[0049] 8. The main function of sodium feldspar is to produce glass phase at high temperature, which acts as a binder to bond the particles of the sagger system together at high temperature to form a solid whole.

[0050] Example 1

[0051] Formula (weight %): coarse quartz (30 mesh) 40%, fine quartz (150 mesh) 15%, modified cordierite (70 mesh) 3%, washed kaolin 10%, fused quartz (300 mesh) 10%, composite plasticizer (methyl cellulose: carboxymethyl cellulose = 1:1) 3%, albite 2%, bentonite 10%.

[0052] Preparation: The mixture was ball-milled for 30 minutes, aged for 18 hours, pressed into shape, dried, and calcined at 1300°C for 45 minutes.

[0053] Performance: Thermal expansion coefficient from room temperature to 1300℃≤2.5×10 -6 / ℃, and can be recycled for 55 times without cracking or sticking.

[0054] Example 2

[0055] Formula (weight %): coarse quartz (25 mesh) 50%, fine quartz (180 mesh) 12%, modified cordierite (60 mesh) 5%, washed kaolin 8%, fused quartz (250 mesh) 12%, composite plasticizer (polyvinyl alcohol: carboxymethyl cellulose = 2:1) 4%, albite 1%, bentonite 15%.

[0056] Preparation: ball milling for 40 minutes, aging for 24 hours, drying after slip casting, calcination at 1280℃ for 60 minutes.

[0057] Performance: Thermal shock resistance (1200℃ water cooling cycle) ≥60 times, sagger surface is smooth without peeling.

[0058] Example 3

[0059] Formula (weight %): coarse quartz (35 mesh) 45%, fine quartz (120 mesh) 18%, modified cordierite (80 mesh) 2%, washed kaolin 12%, fused quartz (350 mesh) 8%, composite plasticizer (methyl cellulose) 2%, albite 0.5%, bentonite 15%.

[0060] Preparation: ball milling for 20 minutes, aging for 12 hours, extrusion molding and drying, calcination at 1320℃ for 30 minutes.

[0061] Performance: Flexural strength at room temperature ≥25MPa, no adhesive residue on the contact surface with talc porcelain.

[0062] Control experiment

[0063] Comparative Example 1 (lack of fused quartz): Fused quartz was removed from the formulation, and the rest was the same as in Example 1. Result: The thermal expansion coefficient increased to 3.2×10 -6 / ℃, edge cracking occurs after 30 cycles.

[0064] Comparative Example 2 (unmodified cordierite): Ordinary cordierite (not pre-synthesized) was used instead, and the other conditions were the same as those in Example 2. Results: Local adhesion to steatite porcelain occurred at high temperature, and the number of cycles was reduced to 40.

[0065] Comparative Example 3 (conventional formulation): Using commercially available sagger material (containing zircon sand and alumina), spraying the protective coating resulted in a 25% increase in cost and only 45 cycles.

[0066] Conclusion: The formula of the present invention achieves spray-free coating protection through the synergistic effect of components, and the comprehensive performance reaches or exceeds that of traditional processes, with significantly reduced costs.

[0067] Furthermore, those skilled in the art will appreciate that although some embodiments herein include certain features and not other features included in other embodiments, the combination of features from different embodiments is intended to be within the scope of the present invention and to form different embodiments.

[0068] It should be noted that the above embodiments illustrate rather than limit the invention, and that those skilled in the art may devise alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between brackets should not be construed as limiting the claims. The word "comprising" does not exclude the presence of elements or steps not listed in the claims. The word "a" or "an" preceding an element does not exclude the presence of a plurality of such elements. The present invention may be implemented by means of hardware comprising several different elements and by means of appropriately programmed computers. In a unit claim enumerating several means, several of these means may be embodied by the same item of hardware. The use of the words first, second, and third etc. does not indicate any order. These words may be interpreted as names.

[0069] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A sagger material formula for steatite porcelain protected by a spray-free coating, characterized in that: It is composed of the following components in percentage by weight: Rough quartz 30-50%; Fine quartz 10-20%; Modified cordierite 1-5%; Washed kaolin 5-15%; Fused silica 5-15%; Composite plasticizer 1-5%; Sodium feldspar 0.5-3%; Bentonite 5-15%; The sagger material is prepared, mixed, formed and dried, and then fired at 1250-1350° C. to form the sagger.

2. The sagger material formula according to claim 1, characterized in that: The coarse quartz has a particle size of 20-40 meshes, and the fine quartz has a particle size of 100-200 meshes.

3. The sagger material formula according to claim 1, characterized in that: The modified cordierite has a particle size of 60-80 meshes, and the fused quartz has a particle size of 200-400 meshes.

4. The sagger material formula according to claim 1, characterized in that: The composite plasticizer is a mixture of carboxymethyl cellulose and polyvinyl alcohol in a mass ratio of 1:

2.

5. The sagger material formula according to claim 1, characterized in that: The composite plasticizer is a mixture of methyl cellulose and carboxymethyl cellulose in a mass ratio of 1:

1.

6. The sagger material formula according to claim 1, characterized in that: The modified cordierite is presynthesized cordierite, and its preparation method includes: mixing magnesia clay and quartz powder in a molar ratio of 2:1, calcining at 1300° C. for 2 hours, and crushing to 60-80 mesh.

7. A method for preparing the sagger material according to any one of claims 1 to 6, characterized in that: The following steps are involved: a) mixing coarse quartz, fine quartz, modified cordierite, washed kaolin, fused quartz, composite plasticizer, albite, and bentonite, and then ball milling for 20-40 minutes; b) After aging for 12-36 hours, the product is formed; c) Drying to a moisture content of ≤5%; d) calcining at 1250-1350°C and keeping the temperature for 30-60 minutes, and then naturally cooling to obtain a sagger product.