A high-hardness and ultra-wear-resistant sanitary ceramic glaze and its preparation method

Abstract

The present application relates to the technical field of sanitary ceramics, and in particular to a high-hardness, ultra-wear-resistant sanitary ceramic glaze and a preparation method thereof. The invention comprises the following raw materials by weight: 20-30 parts potassium feldspar, 20-30 parts quartz powder, 2-6 parts kaolin, 3-8 parts corundum powder, 4-7 parts calcite, 1-5 parts dolomite, 0.3-1.3 parts zinc oxide, 1.5-4 parts strontium carbonate, and 7-10 parts zirconium silicate. The particle size distribution of the corundum powder and strontium carbonate is 10-15% between 325 mesh and 625 mesh, 20-25% between 625 mesh and 1250 mesh, and 60-70% below 1250 mesh. By precisely controlling the mass ratio of strontium carbonate to corundum powder and the particle size distribution, and utilizing the synergistic effect of corundum powder and strontium carbonate, the hardness and wear resistance of the sanitary ceramic glaze are improved.

Description

Technical Field

[0001] The present application relates to the technical field of sanitary ceramics, and in particular to a high-hardness and ultra-wear-resistant sanitary ceramic glaze and a preparation method thereof. Background Art

[0002] Sanitary ceramics are glazed ceramic products used in bathrooms, kitchens, and laboratories, also known as sanitary ware. They occupy a crucial position among building decoration materials, beloved for their warm color, smooth surface, and dense, impermeable texture. However, unlike decorative porcelain, sanitary ceramics are frequently washed and worn during use, leading to significant aging. This reduces the gloss and color of sanitary ceramics, significantly shortening their lifespan. The key to sanitary ceramic quality lies in the glaze layer, whose hardness and wear resistance are crucial for enhancing the wear resistance of sanitary ceramic products. Summary of the Invention

[0003] In order to improve the wear resistance of the sanitary ceramic glaze layer, the present application provides a high-hardness and super-wear-resistant sanitary ceramic glaze and a preparation method thereof.

[0004] In the first aspect, the present application provides a high-hardness, ultra-wear-resistant sanitary ceramic glaze and a preparation method thereof, which adopts the following technical solutions:

[0005] A high-hardness, ultra-wear-resistant sanitary ceramic glaze comprises the following raw materials in parts by mass: 20-30 parts of potassium feldspar, 20-30 parts of quartz powder, 2-6 parts of kaolin, 3-8 parts of corundum powder, 4-7 parts of calcite, 1-5 parts of dolomite, 0.3-1.3 parts of zinc oxide, 1.5-4 parts of strontium carbonate, and 7-10 parts of zirconium silicate. The particle size distribution of the corundum powder particles is as follows: 10-15% of the particles are between 325 mesh and 625 mesh, 20-25% of the particles are between 625 mesh and 1250 mesh, and 60-70% of the particles are smaller than 1250 mesh. The particle size distribution of the strontium carbonate particles is as follows: 10-15% of the particles are between 325 mesh and 625 mesh, 20-25% of the particles are between 625 mesh and 1250 mesh, and 60-70% of the particles are smaller than 1250 mesh.

[0006] By adopting the above technical solutions, potassium feldspar: can improve the crack resistance of the glaze, increase the strength and hardness of the glaze. Quartz powder: has high hardness and high wear resistance, which can improve the hardness and wear resistance of the glaze. Kaolin: can promote the mutual bonding between glazes, increase the adhesion of the glaze, and improve the strength. Corundum powder: as a high hardness material, can increase the wear resistance of the glaze and extend its service life. Calcite: has good corrosion resistance and can extend the service life of the glaze. Dolomite: can fill gaps and increase the compaction of the glaze, can increase the hardness and strength of the glaze, and increase moisture resistance and wear resistance. Zinc oxide: as a protective agent, it can prevent the glaze from being oxidized and corroded. Strontium carbonate: has good wear resistance and can increase the hardness and wear resistance of the glaze. Zirconium silicate: can increase the hardness and toughness of the glaze, and improve its wear resistance and impact resistance. The particle size distribution of corundum powder improves the hardness and impact resistance of high-wear-resistant ceramics, while the particle size distribution of strontium carbonate reduces their brittleness and increases their wear resistance. The different particle size distributions of corundum powder and strontium carbonate increase the density of the glaze, improving its wear resistance and hardness. The synergistic effect between corundum powder and strontium carbonate is crucial. Their particle size distributions provide fillers of varying sizes for the high-wear-resistant ceramics, effectively filling the gaps between the main materials and significantly enhancing the wear resistance of the ceramics. Furthermore, the physical and chemical properties of corundum powder and strontium carbonate complement each other, achieving an even better synergistic effect. Each component in the formula contributes to a unique effect, collectively enhancing the hardness, wear resistance, and gloss of the sanitary ceramic glaze.

[0007] Preferably, the corundum powder is modified corundum powder, and the modification method comprises the following steps:

[0008] Preparation of S21 corundum powder slurry: corundum powder and silane coupling agent si69 are mixed in a mass ratio of 1000:8-10 to form a mixture, and then water is added to make a slurry with a mass concentration of 80-85% and ground to form a corundum powder slurry;

[0009] Preparation of S22 titanium dioxide slurry: titanium dioxide, silane coupling agent si69, and silica sol are mixed in a mass ratio of 1000:5-7:10-30, and then water is added and stirred to prepare a titanium dioxide slurry with a mass concentration of 40-50%. The titanium dioxide particles have a particle size of 1-3 microns;

[0010] S23: The corundum powder slurry prepared in step S21 and the titanium dioxide slurry prepared in step S22 are mixed in a mass ratio of 10:1-2 to obtain a mixed slurry, and the mixed slurry is stirred evenly, filtered, dried, ball-milled, and sieved to obtain modified corundum powder. The particle size distribution of the modified corundum powder particles is 10-15% of 325 mesh-625 mesh, 20-25% of 625 mesh-1250 mesh, and 60-70% of less than 1250 mesh.

[0011] By adopting the above technical solution, corundum powder is modified with titanium dioxide, the yellowing of the glaze layer is improved, thereby increasing the service life of the sanitary ceramic glaze.

[0012] Preferably, the particle size distribution of the potassium feldspar particles is 10-15% between 325 mesh and 625 mesh, 10-15% between 625 mesh and 1250 mesh, and 70%-80% below 1250 mesh; the particle size distribution of the quartz powder particles is 10-15% between 325 mesh and 625 mesh, 10-15% between 625 mesh and 1250 mesh, and 70%-80% below 1250 mesh; the particle size distribution of the kaolin particles is 10-15% between 325 mesh and 625 mesh, 10-15% between 625 mesh and 1250 mesh, and 70%-80% below 1250 mesh; the particle size distribution of the calcite particles is 10-15% between 325 mesh and 625 mesh; The particle size distribution of the dolomite particles is 10-15% for 625-1250 mesh and 70%-80% for less than 1250 mesh; the particle size distribution of the zinc oxide particles is 10-15% for 325-625 mesh and 10-15% for 625-1250 mesh and 70%-80% for less than 1250 mesh; the particle size distribution of the zirconium silicate particles is 10-15% for 325-625 mesh and 10-15% for 625-1250 mesh and 70%-80% for less than 1250 mesh.

[0013] By adopting the above technical solution and precisely controlling the particle size distribution of the raw material particles, the density of the glaze layer can be improved, thereby improving the wear resistance of the glaze layer surface.

[0014] Preferably, the mass ratio of the strontium carbonate to the corundum powder is 1:1-2.

[0015] By adopting the above technical solution, and by carefully selecting the mass ratio of strontium carbonate to corundum powder, and leveraging the synergistic effect of corundum powder and strontium carbonate, the main effect is to alleviate the brittle fracture phenomenon caused by the excessive hardness of corundum materials, thereby improving the toughness and tightness of the glaze. Because corundum has a very high hardness, when it is used as the main component of the glaze, it may experience brittle fracture. Strontium carbonate, on the other hand, can fill the pores in the glaze, increasing the density and tightness of the glaze, while also providing a certain degree of toughness, thereby improving the glaze's wear resistance and impact resistance. Therefore, corundum and strontium carbonate can work synergistically to improve the wear resistance and toughness of the glaze.

[0016] Preferably, the Mohs hardness of the high-hardness and super-wear-resistant sanitary ceramic glaze is ≥5, and the wear resistance of the high-hardness and super-wear-resistant sanitary ceramic glaze is level 4.

[0017] In a second aspect, the present application provides a method for preparing a high-hardness and ultra-wear-resistant sanitary ceramic glaze, which adopts the following technical solution:

[0018] A method for preparing a high-hardness and super-wear-resistant sanitary ceramic glaze, using the raw materials of the high-hardness and super-wear-resistant sanitary ceramic glaze in various parts by mass, comprises the following steps:

[0019] S1 mixing: screening, weighing and uniformly mixing potassium feldspar, quartz powder, kaolin, corundum powder, calcite, dolomite, zinc oxide, strontium carbonate and zirconium silicate according to the formula ratio to obtain a glaze;

[0020] S2 glaze slurry preparation: placing the glaze into a stirring device, adding water and stirring and mixing to obtain a glaze slurry;

[0021] S3 glaze spraying: spray the obtained glaze slurry onto the surface of the green body by pressure glaze spraying method, and obtain a glazed product with a glaze layer thickness of 0.8-1.1mm;

[0022] S4 firing: The glazed product is dried at 120°C, placed in a kiln, fired, and then naturally cooled to room temperature to obtain a high-hardness and ultra-wear-resistant sanitary ceramic glazed product.

[0023] Preferably, in the step S2 of preparing the glaze slurry, the performance parameters of the glaze slurry are: specific gravity of 1.745 kg / L-1.755 kg / L, and viscosity of 120-140 seconds / 100 mL.

[0024] Preferably, in step S3 glazing, the pressure glazing is performed using automated spraying equipment, and the spraying pressure is 0.55-0.65 MPa.

[0025] Preferably, in step S3 of glazing, the green body is a sanitary ceramic green body with a dried surface.

[0026] Preferably, in step S4, the firing process is: heating from room temperature to 450-550°C at a heating rate of 3-4°C / min and keeping warm for 30 minutes, then heating to 950-1000°C at a heating rate of 4-5°C / min and keeping warm for 20-30 minutes, and finally heating to 1220-1240°C at a heating rate of 2-3°C / min and keeping warm for 20-30 minutes, to obtain a high-hardness and ultra-wear-resistant sanitary ceramic glaze.

[0027] By adopting the above technical solution and pressure glaze spraying, the water absorption of the body during the glazing process is reduced, the glaze flow phenomenon is reduced, and the glazing efficiency is improved, which is conducive to maintaining the strength of the body after glazing; the adhesion of the glaze layer to the body is also greatly enhanced, which can reduce defects such as glaze defects and glaze rubbing caused during transportation and kiln loading, and improve the product yield rate.

[0028] In summary, the beneficial technical effects of this application are:

[0029] 1) By precisely controlling the particle size distribution of the raw material particles, the surface density of the high-hardness and ultra-wear-resistant sanitary ceramic glaze is improved, and the obtained ceramic glaze has high hardness and ultra-wear resistance.

[0030] 2) By carefully selecting the mass ratio of strontium carbonate to corundum powder and leveraging the synergistic effect of corundum powder and strontium carbonate, the synergistic effect is primarily manifested in alleviating the brittle fracture caused by the excessive hardness of the corundum material and improving the toughness and density of the glaze. Because corundum has a high hardness, it may experience brittle fracture when used as a component of the glaze. Strontium carbonate, on the other hand, fills the pores in the glaze, increasing its density and density, while also providing a certain degree of toughness, thereby improving the wear resistance and impact resistance of the porcelain glaze. DETAILED DESCRIPTION

[0031] The embodiments of the present application will be described in detail below in conjunction with the examples and preparation examples, but it will be understood by those skilled in the art that the following examples and preparation examples are only used to illustrate the present application and should not be considered as limiting the scope of the present application. In the examples and preparation examples, if specific conditions are not specified, they are carried out according to conventional conditions or the conditions recommended by the manufacturer. The reagents or instruments used are conventional products that can be purchased commercially if the manufacturer is not specified.

[0032] Example 1

[0033] A high-hardness, super-wear-resistant sanitary ceramic glaze comprises the following raw materials in parts by mass: 20 kg of potassium feldspar, 20 kg of quartz powder, 2 kg of kaolin, 3 kg of corundum powder, 4 kg of calcite, 1 kg of dolomite, 0.3 kg of zinc oxide, 3 kg of strontium carbonate, and 7 kg of zirconium silicate. The particle size distribution of the corundum powder particles is as follows: 10% is between 325 mesh and 625 mesh, 20% is between 625 mesh and 1250 mesh, and 70% is less than 1250 mesh. The particle size distribution of the strontium carbonate particles is as follows: 10% is between 325 mesh and 625 mesh, 20% is between 625 mesh and 1250 mesh, and 70% is less than 1250 mesh. The particle size distribution of the potassium feldspar particles is 10% between 325 mesh and 625 mesh, 10% between 625 mesh and 1250 mesh, and 80% below 1250 mesh. The particle size distribution of the quartz powder particles is 10% between 325 mesh and 625 mesh, 10% between 625 mesh and 1250 mesh, and 80% below 1250 mesh. The particle size distribution of the kaolin particles is 10% between 325 mesh and 625 mesh, 10% between 625 mesh and 1250 mesh, and 80% below 1250 mesh. The particle size distribution of the calcite particles is 325 mesh to 625 mesh. The particle size distribution of the dolomite particles is 10% for 325-625 mesh, 10% for 625-1250 mesh, and 80% for less than 1250 mesh. The particle size distribution of the zinc oxide particles is 10% for 325-625 mesh, 10% for 625-1250 mesh, and 80% for less than 1250 mesh. The particle size distribution of the zirconium silicate particles is 10% for 325-625 mesh, 10% for 625-1250 mesh, and 80% for less than 1250 mesh.

[0034] The corundum powder adopts modified corundum powder, and the modification method includes the following steps:

[0035] Preparation of S21 corundum powder slurry: corundum powder and silane coupling agent si69 are mixed in a mass ratio of 1000:8 to form a mixture, and then water is added to make a slurry with a mass concentration of 80% and ground to form a corundum powder slurry;

[0036] Preparation of S22 titanium dioxide slurry: titanium dioxide, silane coupling agent Si69, and silica sol are mixed in a mass ratio of 1000:5:10, and then water is added and stirred to prepare a titanium dioxide slurry with a mass concentration of 40%. The titanium dioxide particles have a particle size of 1-3 microns;

[0037] S23: The corundum powder slurry prepared in step S21 and the titanium dioxide slurry prepared in step S22 are mixed in a mass ratio of 10:1 to obtain a mixed slurry, and the mixed slurry is stirred evenly, filtered, dried, ball-milled, and sieved to obtain modified corundum powder, wherein the particle size distribution of the modified corundum powder particles is 10% between 325 mesh and 625 mesh, 20% between 625 mesh and 1250 mesh, and 70% less than 1250 mesh.

[0038] Example 2

[0039] A high-hardness, super-wear-resistant sanitary ceramic glaze comprises the following raw materials in parts by mass: 30 kg of potassium feldspar, 30 kg of quartz powder, 6 kg of kaolin, 8 kg of corundum powder, 7 kg of calcite, 5 kg of dolomite, 1.3 kg of zinc oxide, 4 kg of strontium carbonate, and 10 kg of zirconium silicate. The particle size distribution of the corundum powder is 15% between 325 mesh and 625 mesh, 25% between 625 mesh and 1250 mesh, and 60% below 1250 mesh. The particle size distribution of the strontium carbonate particles is 15% between 325 mesh and 625 mesh, 25% between 625 mesh and 1250 mesh, and 60% below 1250 mesh. The particle size distribution of the potassium feldspar particles is 15% between 325 mesh and 625 mesh, 15% between 625 mesh and 1250 mesh, and 70% below 1250 mesh. The particle size distribution of the quartz powder particles is 15% between 325 mesh and 625 mesh, 25% between 625 mesh and 1250 mesh, and 70% below 1250 mesh. The particle size distribution of the kaolin particles is 15% of 325 mesh-625 mesh, 15% of 625-1250 mesh, and 70% of less than 1250 mesh. The particle size distribution of the calcite particles is 15% of 325 mesh-625 mesh, 15% of 625-1250 mesh, and 70% of less than 1250 mesh. The particle size distribution of the dolomite particles is 15% of 325 mesh-625 mesh, 15% of 625-1250 mesh, and 70% of less than 1250 mesh. The particle size distribution of the zinc oxide particles is 15% of 325 mesh-625 mesh, 15% of 625-1250 mesh, and 70% of less than 1250 mesh. The particle size distribution of the zirconium silicate particles is 15% of 325 mesh-625 mesh, 15% of 625-1250 mesh, and 70% of less than 1250 mesh.

[0040] The corundum powder adopts modified corundum powder, and the modification method includes the following steps:

[0041] Preparation of S21 corundum powder slurry: corundum powder and silane coupling agent si69 are mixed in a mass ratio of 1000:10 to form a mixture, and then water is added to form a slurry with a mass concentration of 80-85% and ground to form a corundum powder slurry;

[0042] Preparation of S22 titanium dioxide slurry: titanium dioxide, silane coupling agent Si69, and silica sol are mixed in a mass ratio of 1000:7:30, and then water is added and stirred to prepare a titanium dioxide slurry with a mass concentration of 50%. The titanium dioxide particles have a particle size of 1-3 microns;

[0043] S23: The corundum powder slurry prepared in step S21 and the titanium dioxide slurry prepared in step S22 are mixed in a mass ratio of 10:2 to obtain a mixed slurry, and the mixed slurry is stirred evenly, filtered, dried, ball-milled, and sieved to obtain modified corundum powder, wherein the particle size distribution of the modified corundum powder particles is 325 mesh-625 mesh (15%), 625-1250 mesh (25%), and less than 1250 mesh (60%).

[0044] Example 3

[0045] A high-hardness, ultra-wear-resistant sanitary ceramic glaze comprises the following raw materials in parts by mass: 25 kg of potassium feldspar, 25 kg of quartz powder, 4 kg of kaolin, 5 kg of corundum powder, 5 kg of calcite, 3 kg of dolomite, 0.8 kg of zinc oxide, 3 kg of strontium carbonate, and 8.5 kg of zirconium silicate. The particle size distribution of the corundum powder is 13% between 325 mesh and 625 mesh, 23% between 625 mesh and 1250 mesh, and 64% below 1250 mesh. The particle size distribution of the strontium carbonate particles is 13% between 325 mesh and 625 mesh, 23% between 625 mesh and 1250 mesh, and 64% below 1250 mesh. The particle size distribution of the potassium feldspar particles is 13% between 325 mesh and 625 mesh, 13% between 625 mesh and 1250 mesh, and 74% below 1250 mesh. The particle size distribution of the quartz powder particles is 13% between 325 mesh and 625 mesh, 23% between 625 mesh and 1250 mesh, and 74% below 1250 mesh. The particle size distribution of the kaolin particles is 13% for 325-625 mesh, 13% for 625-1250 mesh, and 74% for less than 1250 mesh. The particle size distribution of the calcite particles is 13% for 325-625 mesh, 13% for 625-1250 mesh, and 74% for less than 1250 mesh. The particle size distribution of the dolomite particles is 13% for 325-625 mesh, 13% for 625-1250 mesh, and 74% for less than 1250 mesh. The particle size distribution of the zinc oxide particles is 13% for 325-625 mesh, 13% for 625-1250 mesh, and 74% for less than 1250 mesh. The particle size distribution of the zirconium silicate particles is 13% for 325-625 mesh, 13% for 625-1250 mesh, and 74% for less than 1250 mesh.

[0046] The corundum powder adopts modified corundum powder, and the modification method includes the following steps:

[0047] Preparation of S21 corundum powder slurry: corundum powder and silane coupling agent si69 are mixed in a mass ratio of 1000:9 to form a mixture, and then water is added to form a slurry with a mass concentration of 80-85% and ground to form a corundum powder slurry;

[0048] Preparation of S22 titanium dioxide slurry: titanium dioxide, silane coupling agent si69, and silica sol are mixed in a mass ratio of 1000:6:20, and then water is added and stirred to prepare a titanium dioxide slurry with a mass concentration of 45%. The titanium dioxide particles have a particle size of 1-3 microns;

[0049] S23: The corundum powder slurry prepared in step S21 and the titanium dioxide slurry prepared in step S22 are mixed in a mass ratio of 10:1-2 to obtain a mixed slurry, and the mixed slurry is stirred evenly, filtered, dried, ball-milled, and sieved to obtain modified corundum powder. The particle size distribution of the modified corundum powder particles is 13% between 325 mesh and 625 mesh, 23% between 625 mesh and 1250 mesh, and 64% less than 1250 mesh.

[0050] Comparative Example 1

[0051] The same as Example 3, except that: the particle size distribution of the potassium feldspar, the quartz powder, the kaolin particles, the calcite, the dolomite, the zinc oxide and the zirconium silicate is 80% in the range of 325-625 mesh and 20% in the range of 625-1250 mesh.

[0052] Comparative Example 2

[0053] The same as Example 3, except that an equal amount of corundum powder is used instead of modified corundum powder.

[0054] Preparation Example 1

[0055] A method for preparing a high-hardness, ultra-wear-resistant sanitary ceramic glaze, using the raw materials in Example 1 in parts by mass, comprises the following steps:

[0056] S1 mixing: screening, weighing and uniformly mixing potassium feldspar, quartz powder, kaolin, corundum powder, calcite, dolomite, zinc oxide, strontium carbonate and zirconium silicate according to the formula ratio to obtain a glaze;

[0057] S2 glaze slurry preparation: placing the glaze into a stirring device, adding water and stirring and mixing to obtain a glaze slurry. The performance parameters of the glaze slurry are: specific gravity of 1.745 kg / L, viscosity of 120 seconds / 100 mL;

[0058] S3 glaze spraying: Use pressure glaze spraying to spray the obtained glaze slurry onto the surface of the dried sanitary ceramic green body. Pressure glaze spraying uses automatic spraying equipment with a spraying pressure of 0.55 MPa. The obtained glaze layer has a thickness of 0.8 mm.

[0059] S4 firing: After drying the glazed product at 120℃, it is loaded into the kiln. The firing process is as follows: heating from room temperature to 450℃ at a rate of 3℃ / min and keeping warm for 30 minutes, then heating to 950℃ at a rate of 4℃ / min and keeping warm for 20 minutes, and finally heating to 1220℃ at a rate of 2℃ / min and keeping warm for 30 minutes. After firing, it is naturally cooled to room temperature to obtain high-hardness and ultra-wear-resistant sanitary ceramic glazed products.

[0060] Preparation Example 2

[0061] A method for preparing a high-hardness, ultra-wear-resistant sanitary ceramic glaze, using the raw materials in Example 2 in parts by mass, comprises the following steps:

[0062] S1 mixing: screening, weighing and uniformly mixing potassium feldspar, quartz powder, kaolin, corundum powder, calcite, dolomite, zinc oxide, strontium carbonate and zirconium silicate according to the formula ratio to obtain a glaze;

[0063] S2 glaze slurry preparation: placing the glaze into a stirring device, adding water and stirring and mixing to obtain a glaze slurry. The performance parameters of the glaze slurry are: specific gravity of 1.755 kg / L, viscosity of 140 seconds / 100 mL;

[0064] S3 glaze spraying: The obtained glaze slurry is sprayed onto the surface of the dried sanitary ceramic green body by pressure glaze spraying. The pressure glaze spraying adopts automatic spraying equipment with a spraying pressure of 0.65 MPa. The obtained glaze layer thickness is 1.1 mm.

[0065] S4 firing: After drying the glazed product at 120℃, put it into the kiln. The firing process is: heat up from room temperature to 550℃ at a rate of 4℃ / min and keep warm for 30 minutes, then heat up to 1000℃ at a rate of 5℃ / min and keep warm for 30 minutes, and finally heat up to 1240℃ at a rate of 3℃ / min and keep warm for 20 minutes. After firing, cool it naturally to room temperature to obtain high-hardness and ultra-wear-resistant sanitary ceramic glazed products.

[0066] Preparation Example 3

[0067] A method for preparing a high-hardness, ultra-wear-resistant sanitary ceramic glaze, using the raw materials in parts by mass in Example 3, comprises the following steps:

[0068] S1 mixing: screening, weighing and uniformly mixing potassium feldspar, quartz powder, kaolin, corundum powder, calcite, dolomite, zinc oxide, strontium carbonate and zirconium silicate according to the formula ratio to obtain a glaze;

[0069] S2 glaze slurry preparation: placing the glaze into a stirring device, adding water and stirring and mixing to obtain a glaze slurry. The performance parameters of the glaze slurry are: specific gravity of 1.750 kg / L, viscosity of 130 seconds / 100 mL;

[0070] S3 glaze spraying: Use pressure glaze spraying to spray the obtained glaze slurry onto the surface of the dried sanitary ceramic green body. Pressure glaze spraying uses automatic spraying equipment with a spraying pressure of 0.60 MPa. The obtained glaze layer thickness is 0.95 mm.

[0071] S4 firing: After drying the glazed product at 120℃, it is loaded into the kiln. The firing process is as follows: heating from room temperature to 500℃ at a rate of 3.5℃ / min and keeping warm for 30 minutes, then heating to 980℃ at a rate of 4.5℃ / min and keeping warm for 25 minutes, and finally heating to 1230℃ at a rate of 2.5℃ / min and keeping warm for 25 minutes. After firing, it is naturally cooled to room temperature to obtain high-hardness and ultra-wear-resistant sanitary ceramic glazed products.

[0072] Preparation Example 4

[0073] The same as Preparation Example 3, except that the materials in Comparative Example 1 were used.

[0074] Preparation Example 5

[0075] The same as Preparation Example 3, except that the materials in Comparative Example 2 were used.

[0076] Performance Testing

[0077] The high hardness and ultra-wear-resistant sanitary ceramic glaze products of Preparation Examples 1-5 were sampled and tested, and the test results are shown in Table 1.

[0078] Abrasion resistance: The test method for determining the surface wear resistance of glazed tiles, as specified in GB / T3810.7-2016, Test Methods for Ceramic Tiles, is used. Gloss: The gloss of the ceramic is measured using a gloss meter, testing each specimen at a 60° angle. The instrument shines a beam of light onto the ceramic surface, measures the amount of reflected light, and displays the result as a value. Generally speaking, a higher value indicates better gloss.

[0079] Mohs Hardness: Place the high-wear-resistant sanitary ceramic steadily on a hard support, glaze facing up. Use standard stones of varying Mohs values, ranging from small to large, to scratch the surface of the specimen. Use the new edge of the stone to apply force evenly and vertically to the surface. Be careful to apply moderate force; the edge of the standard stone should not break due to excessive force, resulting in double or multiple scratch marks. The lowest hardness value that just produces a noticeable scratch is considered the test result.

[0080] Table 1

[0081] Mohs hardness / grading wear resistance Glossiness / GU Preparation Example 1 5 6000r, Level 4 101 Preparation Example 2 5 6500r, Level 4 99 Preparation Example 3 6 7200r, Level 4 105 Preparation Example 4 4 4600r, Level 4 95 Preparation Example 5 5 3900r, Level 4 89

[0082] Combining Preparation Examples 1-3 and Preparation Examples 4-5, and in combination with Table 1, it can be seen that the hardness, wear resistance and glossiness of the high-hardness and super-wear-resistant sanitary ceramic glaze in Preparation Examples 1-3 are better than the hardness, wear resistance and glossiness in Preparation Examples 4-5, indicating that the high-hardness and super-wear-resistant sanitary ceramic glaze prepared using the formula of this application has good wear resistance and helps to improve gloss.

[0083] Combining Preparation Examples 1-3 and Preparation Example 4, and in combination with Table 1, it can be seen that the particle size of the raw material is larger than that of Preparation Examples 1-3, and the wear resistance of the obtained high-hardness and ultra-wear-resistant sanitary ceramic glaze is poor. This is mainly because the particle size of the raw material is large, and the high-hardness and ultra-wear-resistant sanitary ceramic glaze obtained after spraying has poor density and pores, so the wear resistance is poor.

[0084] Combining Preparation Examples 1-3 and Preparation Example 5, and combining with Table 1, it can be seen that from the analysis of Preparation Example 5, the wear performance and glossiness in Preparation Examples 1-3 are better than those in Preparation Example 5, indicating that the modification of corundum powder by titanium dioxide helps to increase the wear resistance of the glaze layer, prevent the glaze layer from yellowing, and improve the glossiness of the glaze layer.

[0085] The above embodiments and preparation examples are only used to illustrate the technical solutions of the present invention rather than to limit the same. Although the above embodiments and preparation examples provide a detailed description of the present invention, relevant technical personnel should understand that the specific implementation methods of the present invention can still be modified or replaced by equivalents. Any modifications and equivalent replacements that do not depart from the spirit and scope of the present invention should be included in the scope of the claims of the present invention.

Claims

1. A high-hardness and ultra-wear-resistant sanitary ceramic glaze, characterized in that: The invention comprises the following raw materials in parts by mass: 20-30 parts of potassium feldspar, 20-30 parts of quartz powder, 2-6 parts of kaolin, 3-8 parts of corundum powder, 4-7 parts of calcite, 1-5 parts of dolomite, 0.3-1.3 parts of zinc oxide, 1.5-4 parts of strontium carbonate, and 7-10 parts of zirconium silicate. The particle size distribution of the corundum powder is 10-15% of 325-625 mesh, 20-25% of 625-1250 mesh, and 60-70% of less than 1250 mesh. The particle size distribution of the strontium carbonate particles is 10-15% of 325-625 mesh, 20-25% of 625-1250 mesh, and 60-70% of less than 1250 mesh. The mass ratio of the strontium carbonate to the corundum powder is 1:1-2. The corundum powder is modified corundum powder, and the modification method comprises the following steps: Preparation of S21 corundum powder slurry: corundum powder and silane coupling agent si69 are mixed in a mass ratio of 1000:810 to form a mixture, and then water is added to form a slurry with a mass concentration of 80-85% and ground to form a corundum powder slurry; Preparation of S22 titanium dioxide slurry: titanium dioxide, silane coupling agent si69, and silica sol are mixed in a mass ratio of 1000:5-7:10-30, and then water is added and stirred to prepare a titanium dioxide slurry with a mass concentration of 40-50%. The titanium dioxide particles have a particle size of 1-3 microns; S23: The corundum powder slurry prepared in step S21 and the titanium dioxide slurry prepared in step S22 are mixed in a mass ratio of 10:1-2 to obtain a mixed slurry, and the mixed slurry is stirred evenly, filtered, dried, ball-milled, and sieved to obtain modified corundum powder, wherein the particle size distribution of the modified corundum powder particles is 10-15% of 325-625 mesh, 20-25% of 625-1250 mesh, and 60-70% of less than 1250 mesh.

2. The high-hardness and ultra-wear-resistant sanitary ceramic glaze according to claim 1, characterized in that: The particle size distributions of the potassium feldspar, the quartz powder, the kaolin, the calcite, the dolomite, the zinc oxide and the zirconium silicate are 10-15% in the range of 325-625 mesh, 10-15% in the range of 625-1250 mesh and 70%-80% in the range of less than 1250 mesh.

3. A high-hardness, super-wear-resistant sanitary ceramic glaze according to any one of claims 1-2, characterized in that: The Mohs hardness of the high-hardness and super-wear-resistant sanitary ceramic glaze is ≥5, and the wear resistance of the high-hardness and super-wear-resistant sanitary ceramic glaze is level 4.

4. A method for preparing a high-hardness and ultra-wear-resistant sanitary ceramic glaze, characterized in that: The preparation method of the high-hardness and ultra-wear-resistant sanitary ceramic glaze according to any one of claims 1 to 3 comprises the following steps: S1 mixing: screening, weighing and uniformly mixing potassium feldspar, quartz powder, kaolin, corundum powder, calcite, dolomite, zinc oxide, strontium carbonate and zirconium silicate according to the formula ratio to obtain a glaze; S2 glaze slurry preparation: placing the glaze into a stirring device, adding water and stirring and mixing to obtain a glaze slurry; S3 glazing: spraying the obtained glaze slurry onto the surface of the green body by pressure spraying to obtain a glazed product with a glaze layer thickness of 0.8-1.1mm; S4 firing: drying the glazed product at 120°C, loading it into a kiln, firing it, and then naturally cooling it to room temperature to obtain a high-hardness and ultra-wear-resistant sanitary ceramic glazed product; In step S2 of preparing the glaze slurry, the performance parameters of the glaze slurry are: specific gravity of 1.745 kg / L-1.755 kg / L, and viscosity of 120-140 seconds / 100 mL; In step S3, the pressure glaze spraying is performed using automated spraying equipment at a spraying pressure of 0.55-0.65 MPa. In step S3 of glazing, the green body is a sanitary ceramic green body with a dried surface layer; In step S4, the firing process is as follows: heating the temperature from room temperature to 450-550°C at a heating rate of 3-4°C / min and keeping it warm for 30 minutes, then heating the temperature to 950-1000°C at a heating rate of 4-5°C / min and keeping it warm for 20-30 minutes, and finally heating the temperature to 1220-1240°C at a heating rate of 2-3°C / min and keeping it warm for 20-30 minutes to obtain a high-hardness and ultra-wear-resistant sanitary ceramic glaze.