Preparation method of foamed ceramic composite brick and foamed ceramic composite brick

Abstract

The application discloses a preparation method of foamed ceramic composite bricks, which comprises the following steps: (1) preparing decorative layer powder by adopting ball milling, slurry preparation and spray granulation according to a raw material formula, spreading the decorative layer powder in refractory furnaces with a thickness of 10-25 mm, and scraping the decorative layer powder; (2) preparing foamed ceramic powder by adopting ball milling, slurry preparation and spray granulation according to a raw material formula, spreading the foamed ceramic powder on the upper layer of the decorative layer powder, and scraping the foamed ceramic powder; (3) sending the foamed ceramic powder into a kiln for firing, wherein the firing temperature is 1160-1170 DEG C, and the firing period is 8-13.5 h; and (4) removing the furnaces after cooling and taking out the foamed ceramic composite bricks; the decorative layer raw material comprises the following components in mass fractions: 25-95 parts of frit, 0-10 parts of talc, 0-5 parts of clay, 5-65 parts of mineral flux, and 0.15-0.5 parts of additives. The foamed ceramic composite bricks with a ceramic decorative layer and a foamed ceramic layer are fired at one time by adopting the method.

Description

Technical Field

[0001] This invention relates to the field of building ceramics, and in particular to a method for preparing foamed ceramic composite bricks and the foamed ceramic composite bricks themselves. Background Technology

[0002] Foamed ceramic porous materials are mostly used in wall insulation layers, but currently produced products suffer from severe lack of decorative appeal. Typically, the slabs need to be sculpted and then coated with paint to achieve a certain level of decoration, but this significantly reduces the decorative effect and durability, and the large amount of volatile organic compounds in the paint is environmentally unfriendly. Therefore, combining the decorative effects of ceramic tiles and microcrystalline glass with foamed ceramics would result in products possessing the dual properties of ceramic tiles or microcrystalline glass and foamed ceramics, reducing weight and providing excellent decorative appeal. However, current technologies typically involve combining sintered stone slabs or ceramic tile blanks with foamed ceramics, followed by a second firing to obtain foamed ceramic composite tiles bonded to the ceramic layer. This process is costly, and the surface decoration effect is prone to distortion. It usually requires a single-color ceramic decorative layer, making it difficult to flexibly adjust the decorative effect.

[0003] Therefore, there is an urgent need for a method for preparing foamed ceramic composite bricks to solve the above-mentioned problems in the existing technology. Summary of the Invention

[0004] The main objective of this invention is to propose a method for preparing foamed ceramic composite bricks. This method involves constructing a microcrystalline layer formulation system through the compounding of multiple components, directly stacking and molding the material using a multi-tube material feeding process, and then combining it with a foamed layer. The resulting foamed ceramic composite brick, which combines a ceramic decorative layer and a foamed ceramic layer, is then fired in one step.

[0005] To achieve the above objectives, this invention proposes a method for preparing foamed ceramic composite bricks, comprising the following steps:

[0006] (1) Prepare decorative layer powder by ball milling and spray granulation according to the raw material formula of decorative layer, spread the decorative layer powder in the refractory kiln furniture with a thickness of 10-25mm, and scrape it flat.

[0007] (2) According to the raw material formula of the foamed ceramic layer, the foamed ceramic powder is prepared by ball milling and spray granulation. The foamed ceramic powder is then spread on the upper layer of the decorative layer powder and leveled.

[0008] (3) The product is placed in a kiln for firing at a temperature of 1160-1170℃ for a period of 8-13.5 hours.

[0009] (4) After cooling and exiting the kiln, the kiln furniture is removed to obtain the foamed ceramic composite brick;

[0010] The decorative layer raw material, by mass, includes the following components: 25-95 parts frit, 0-10 parts talc, 0-5 parts clay, 5-65 parts mineral flux, and 0.15-0.5 parts additives.

[0011] This solution uses a mixture of raw and cooked materials to build a microcrystalline layer formulation system, which enhances the bond with the foamed ceramic layer and enables the production of foamed ceramic composite bricks with a ceramic decorative layer and a foamed ceramic layer in a single firing.

[0012] Preferably, the decorative layer raw material further includes 0-10 parts of inorganic pigment, 0-0.08 parts of silicon carbide, and 0-6 parts of whitening agent by weight.

[0013] Inorganic pigments and a small amount of silicon carbide can be added to the decorative layer material to give the decorative layer a slightly foamed pore structure, while also creating different colors to achieve a decorative effect.

[0014] Whitening agents can also be added to the decorative layer material to improve the whiteness of the decorative layer and prevent the base layer from showing when using a dark-colored foamed ceramic layer.

[0015] Preferably, the frit includes at least two of the following: LT-2 microcrystalline frit, zirconium white frit, CY1102 frit, and DJY-710 frit, and must include LT-2 microcrystalline frit;

[0016] The chemical composition of the LT-2 microcrystalline frit, by mass percentage, is: SiO2 56-60%, Al2O3 6-10%, Fe2O3 0-0.3%, TiO2 0-2%, CaO 16-20%, MgO 0-3%, K2O 0-1%, Na2O 4-6%, ZrO2 0-0.05%, ZnO 0-2%, LOI: 0-0.5%, with the balance being impurities.

[0017] The chemical composition of the zirconium white ingot, by mass percentage, is as follows: SiO2 60-64%, Al2O3 4-8%, Fe2O3 0-0.4%, TiO2 0-0.5%, CaO 10-14%, MgO 2-6%, K2O 2-6%, Na2O 0-0.02%, ZrO2 4-8%, ZnO 4-8%, LOI: 0-0.5%, with the balance being impurities;

[0018] The chemical composition of the CY1102 frit, by mass percentage, is: SiO2 52-56%, Al2O3 6-10%, Fe2O3 0-0.3%, TiO2 0-0.5%, CaO 12-16%, MgO 0-0.5%, K2O 6-9%, Na2O 0-0.5%, ZrO2 0-0.05%, ZnO 10-14%, LOI: 0-0.5%, with the balance being impurities.

[0019] The chemical composition of the DJY-710 frit, by mass percentage, is: SiO2 62-66%, Al2O3 15-19%, Fe2O3 0-0.5%, TiO2 0-0.2%, CaO 2-5%, MgO 0-2%, K2O 2-6%, Na2O 4-8%, ZrO2 0-0.05%, ZnO 0-5%, LOI 0-0.5%, with the balance being impurities.

[0020] By using a combination of multiple frits that can generate a liquid phase for solid-phase reaction at a lower firing temperature, the firing temperature can be reduced and controlled within the range of 1160–1170°C. At the same time, colored frits can be used to enhance the decorative properties.

[0021] Preferably, the clay includes at least one of bentonite and ball clay; the mineral flux includes sodium feldspar and potassium feldspar; and the additives include sodium tripolyphosphate and sodium carboxymethyl cellulose.

[0022] Adjust the high-temperature viscosity of the system to ensure uniform pore size and stable foaming in the fired products.

[0023] Preferably, under conditions of 30–200°C and 30–600°C, the linear thermal expansion coefficient of the decorative layer material is greater than that of the foamed ceramic material, and is less than 0.3 × 10⁻⁶. -6 K -1 The difference between the linear thermal expansion coefficients of the two is ≤0.7×10 -6 K -1 .

[0024] Due to the thickness and porous nature of the board, it is necessary to control the coefficient of thermal expansion of the product within the temperature range of 100–600℃, especially at 200℃ and 600℃, ensuring the difference in the linear thermal expansion coefficient between the decorative layer material and the foamed ceramic material is within 0.3 × 10⁻⁶. -6 K -1 ~0.7×10 -6 K -1 Within a certain range, the generation of internal stress can be reduced, which can lead to cracking.

[0025] Preferably, the decorative layer powder in step (1) contains a transparent material and a pore-forming material, and the mass ratio of the transparent material, the pore-forming material and the decorative layer powder is 10-30:0-10:60-80; the particle size of the transparent material is ≥8 mesh, and the particle size of the pore-forming material is ≥8 mesh.

[0026] Preferably, the pore-forming material comprises the following components by mass: 60-80 parts zircon white frit, 0-5 parts calcined talc, 10-20 parts potassium feldspar, 8-20 parts sodium feldspar, 0-5 parts bentonite, 0-1 part green body reinforcing agent, 0.05-0.4 parts silicon carbide, and 0-0.3 parts sodium tripolyphosphate.

[0027] Preferably, the transparent material raw material comprises the following components by mass: 0-30 parts zircon white frit, 0-10 parts calcined talc, 0-20 parts potassium feldspar, 0-20 parts LT-2 microcrystalline frit, 45-60 parts DS-PJ06 frit, 0-10 parts sodium sand, 0-5 parts bentonite, 0-15 parts sodium feldspar, 0-1 part green body reinforcing agent, 0-0.4 parts sodium tripolyphosphate, and 0.15-0.4 parts carboxymethyl cellulose;

[0028] The chemical composition of the DS-PJ06 frit, by mass percentage, is: SiO2 65-68%, Al2O3 14-18%, Fe2O3 0-0.5%, TiO2 0-0.2%, CaO 6-10%, MgO 0-2%, K2O 0-5%, Na2O 0-0.2%, ZnO 0-5%, LOI 0-0.5%, with the balance being impurities.

[0029] By combining transparent and porous materials with the raw materials for the decorative layer, the decorative layer obtained after firing has the effect of imitating natural travertine.

[0030] Preferably, the decorative layer powder in step (1) contains an added functional material, and the mass ratio of the functional material to the decorative layer powder is 5-30:70-95.

[0031] Preferably, the functional material includes one of LT-2 microcrystalline frit, mica sheet, and zirconium silicate.

[0032] By using LT-2 microcrystalline frit, mica sheets, and zirconium silicate, and compounding them with the decorative layer raw materials, a variety of stone-like texture decorative effects that are similar to those of traditional stone or ceramics can be obtained.

[0033] Preferably, the process parameters of the decorative powder are: powder moisture content 6.0-7.5%, bulk density ≥0.87g / ml, ≤2% for powders above 20 mesh, 55-75% for powders above 40 mesh, 80-95% for powders between 20 and 60 mesh, and ≤3% for powders below 100 mesh.

[0034] Preferably, the process parameters of the foamed ceramic powder are as follows: powder moisture content 5.5-6.0%, bulk density ≥0.87g / ml, 1-2% above 20 mesh sieve, 45-70% of 20-40 mesh, 80-97% of 20-60 mesh, and ≤1.5% below 100 mesh sieve.

[0035] Adjust the powder processing parameters to stabilize the powder performance and ensure that the thickness of the powder is consistent with the thickness of the finished product after firing.

[0036] On the other hand, the present invention also provides a foamed ceramic composite brick prepared by the preparation method described above. A foamed ceramic composite brick with a ceramic decorative layer and a foamed ceramic layer is obtained by a single firing process. Through the compounding of multiple components, the ceramic decorative layer achieves different stone-like decorative effects. Attached Figure Description

[0037] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0038] Figure 1 This is a schematic diagram of the surface effect of the foamed ceramic composite brick prepared in Example 2-1;

[0039] Figure 2 This is a schematic diagram of the surface effect of the foamed ceramic composite brick prepared in Example 3;

[0040] Figure 3 This is a schematic diagram of the surface effect of the foamed ceramic composite brick prepared in Example 4;

[0041] Figure 4 This is a schematic diagram of the surface effect of the foamed ceramic composite brick prepared in Example 5;

[0042] Figure 5 This is a schematic diagram of the surface effect of the foamed ceramic composite brick prepared in Example 6;

[0043] Figure 6 This is a schematic diagram of the surface effect of the foamed ceramic composite brick prepared in Example 7.

[0044] The realization of the purpose, functional features and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0045] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0046] Furthermore, the technical solutions of the various embodiments can be combined with each other, but only if they are feasible for those skilled in the art. If the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0047] A method for preparing foamed ceramic composite bricks includes the following steps:

[0048] (1) Decorative layer powder was prepared by ball milling and spray granulation according to the raw material formula of the decorative layer. The powder process parameters were as follows: powder moisture content 6.0-7.5%, bulk density ≥0.87g / ml, ≤2% for powders above 20 mesh, 55-75% for powders above 40 mesh, 80-95% for powders between 20 and 60 mesh, and ≤3% for powders below 100 mesh. The decorative layer powder was spread in the refractory kiln furniture to a thickness of 10-25mm and leveled.

[0049] (2) Foamed ceramic powder was prepared by ball milling and spray granulation according to the raw material formula of the foamed ceramic layer. The powder process parameters were as follows: powder moisture content 5.5-6.0%, bulk density ≥0.87g / ml, 1-2% above 20 mesh sieve, 45-70% of 20-40 mesh, 80-97% of 20-60 mesh, and ≤1.5% below 100 mesh sieve. The foamed ceramic powder was spread on the upper layer of the decorative layer powder to a thickness of 25-75mm and leveled.

[0050] (3) The product is placed in a kiln for firing at a temperature of 1160-1170℃ for a period of 8-13.5 hours.

[0051] (4) After cooling and exiting the kiln, the kiln furniture is removed to obtain the foamed ceramic composite brick;

[0052] The decorative layer raw material, by mass, includes the following components: 25-95 parts frit, 0-10 parts talc, 0-5 parts clay, 5-65 parts mineral flux, and 0.15-0.5 parts additives.

[0053] In this embodiment, by combining clinker and raw materials, a microcrystalline layer formulation system is constructed as the raw material for the decorative layer, which enhances the bonding with the foamed ceramic layer, enabling the one-time firing of a foamed ceramic composite brick with a ceramic decorative layer and a foamed ceramic layer.

[0054] It should be noted that the formula for the decorative layer needs to be homogenized by ball milling and then spray-granulated. Before spreading, it can be crushed and pulverized by a pulverizer or granulated by a granulator. The choice depends on the specific formula and desired post-firing decorative effect. This method eliminates the need for stamping; firing is achieved directly using kiln car spreading. A multi-tube spreading method is employed for the decorative layer, with the spreading thickness controlled within 10-25mm, ensuring the finished decorative layer thickness is within 10mm.

[0055] Furthermore, by weight, the decorative layer raw materials also include 0-10 parts of inorganic pigment, 0-0.08 parts of silicon carbide, and 0-6 parts of whitening agent.

[0056] Inorganic pigments and a small amount of silicon carbide can be added to the decorative layer material to give the decorative layer a slightly foamed pore structure, while also creating different colors to achieve a decorative effect.

[0057] Whitening agents can also be added to the decorative layer material to improve the whiteness of the decorative layer and prevent the base layer from showing when using a dark-colored foamed ceramic layer.

[0058] Fused frit is a commonly used raw material in ceramic production, obtained by melting certain raw materials at high temperatures and then quenching them. Specifically, the frit includes at least two of the following: LT-2 microcrystalline frit, zirconium white frit, CY1102 frit, and DJY-710 frit, and must include LT-2 microcrystalline frit. Using a combination of multiple frits that can generate a liquid phase for solid-phase reaction at lower firing temperatures can reduce the firing temperature, allowing it to be controlled within the 1160–1170℃ range. Simultaneously, colored frits enhance the decorative effect. The coefficient of thermal expansion of the frit used is matched to that of the base material to prevent cracking during firing and cooling. Its particle size is controlled between 8 and 60 mesh, adjusted according to different decorative effects.

[0059] The chemical composition of the LT-2 microcrystalline frit, by mass percentage, is: SiO2 56-60%, Al2O3 6-10%, Fe2O3 0-0.3%, TiO2 0-2%, CaO 16-20%, MgO 0-3%, K2O 0-1%, Na2O 4-6%, ZrO2 0-0.05%, ZnO 0-2%, LOI: 0-0.5%, with the balance being impurities.

[0060] The chemical composition of the zirconium white ingot, by mass percentage, is as follows: SiO2 60-64%, Al2O3 4-8%, Fe2O3 0-0.4%, TiO2 0-0.5%, CaO 10-14%, MgO 2-6%, K2O 2-6%, Na2O 0-0.02%, ZrO2 4-8%, ZnO 4-8%, LOI: 0-0.5%, with the balance being impurities;

[0061] The chemical composition of the CY1102 frit, by mass percentage, is: SiO2 52-56%, Al2O3 6-10%, Fe2O3 0-0.3%, TiO2 0-0.5%, CaO 12-16%, MgO 0-0.5%, K2O 6-9%, Na2O 0-0.5%, ZrO2 0-0.05%, ZnO 10-14%, LOI: 0-0.5%, with the balance being impurities.

[0062] The chemical composition of the DJY-710 frit, by mass percentage, is: SiO2 62-66%, Al2O3 15-19%, Fe2O3 0-0.5%, TiO2 0-0.2%, CaO 2-5%, MgO 0-2%, K2O 2-6%, Na2O 4-8%, ZrO2 0-0.05%, ZnO 0-5%, LOI 0-0.5%, with the balance being impurities.

[0063] In the above preparation method, the clay includes at least one of bentonite and ball clay; the mineral flux includes albite and potassium feldspar; and the additives include sodium tripolyphosphate and sodium carboxymethyl cellulose. By adjusting the high-temperature viscosity of the melt, uniform pore size and stable foaming of the fired product are ensured. The mineral flux used in this method is a naturally mined mineral that can be used to adjust the melting point of the melt and act as a flux, such as albite and potassium feldspar.

[0064] Furthermore, under conditions of 30–200℃ and 30–600℃, the linear thermal expansion coefficient of the decorative layer material is greater than that of the foamed ceramic material, and 0.3 × 10⁻⁶. -6 K -1 The difference between the linear thermal expansion coefficients of the two is ≤0.7×10 -6 K -1 .

[0065] It should be noted that due to the thickness and porous nature of the board, a temperature difference of nearly 100°C will occur between the outer layer and the core layer during the high-temperature cooling process. Therefore, it is necessary to control the change in the coefficient of thermal expansion in the 100–600°C range to avoid stress-induced cracking. Simultaneously, the cooling rate in the 600–100°C range must be optimally controlled. Specifically, the board should be kept warm around 600°C and 200°C to reduce the temperature difference between the inside and outside of the board, allowing for rapid cooling after complete stress release. Therefore, controlling the difference in the linear coefficient of thermal expansion between the decorative layer and the foamed ceramic layer is also particularly important under conditions of 30–200°C and 30–600°C.

[0066] Furthermore, the decorative layer powder in step (1) contains a transparent material and a pore-forming material, and the mass ratio of the transparent material, the pore-forming material and the decorative layer powder is 10-30:0-10:60-80; the particle size of the transparent material is ≥8 mesh, and the particle size of the pore-forming material is ≥8 mesh.

[0067] Specifically, by mass, the pore-forming material comprises the following components: 60-80 parts zircon white frit, 0-5 parts calcined talc, 10-20 parts potassium feldspar, 8-20 parts sodium feldspar, 0-5 parts bentonite, 0-1 part green body reinforcing agent, 0.05-0.4 parts silicon carbide, and 0-0.3 parts sodium tripolyphosphate.

[0068] The pore-forming material used has a low firing temperature, requiring only a small amount of silicon carbide to create larger pores. Compared to traditional methods of creating pores in ceramic tiles and travertine, this is more economical, convenient, and meets practical needs. Existing technologies use paraffin wax as the pore-forming material, combined with a stamping process. However, the pores formed after the paraffin wax burns away during sintering continue to shrink, making it difficult for the finished product to achieve a natural "pore" effect. In contrast, by using low-temperature frit material with a trace amount of silicon carbide as a foaming agent, and employing powder stacking molding, the originally shrinking powder expands locally, while the pore size or density in other areas remains uniform, achieving a natural "pore" effect similar to traditional travertine.

[0069] Specifically, by mass fraction, the transparent material raw material comprises the following components: 0-30 parts zircon white frit, 0-10 parts calcined talc, 0-20 parts potassium feldspar, 0-20 parts LT-2 microcrystalline frit, 45-60 parts DS-PJ06 frit, 0-10 parts sodium sand, 0-5 parts bentonite, 0-15 parts sodium feldspar, 0-1 part green body reinforcing agent, 0-0.4 parts sodium tripolyphosphate, and 0.15-0.4 parts carboxymethyl cellulose.

[0070] The chemical composition of the DS-PJ06 frit, by mass percentage, is: SiO2 65-68%, Al2O3 14-18%, Fe2O3 0-0.5%, TiO2 0-0.2%, CaO 6-10%, MgO 0-2%, K2O 0-5%, Na2O 0-0.2%, ZnO 0-5%, LOI 0-0.5%, with the balance being impurities.

[0071] The transparent material used has good light transmittance after high-temperature sintering and can be used as a transparent crystal for decorative layer.

[0072] By combining base material, pore-forming material and transparent material in a multi-component compound, a natural travertine-like stone effect is created.

[0073] Furthermore, the decorative layer powder in step (1) contains an added functional material, and the mass ratio of the functional material to the decorative layer powder is 5-30:70-95.

[0074] Specifically, the functional material includes one of LT-2 microcrystalline frit, mica sheet, and zirconium silicate.

[0075] By adding different ingredients, adjusting the particle size, and introducing well-known colorants, a variety of different decorative effects can be achieved.

[0076] The technical solution of the present invention will be further described in detail below with reference to specific embodiments. It should be understood that the following embodiments are only used to explain the present invention and are not intended to limit the present invention.

[0077] The specific chemical composition of each ceramic preparation raw material in the following embodiments is provided in the table below (in mass percentage, unit is %):

[0078]

[0079]

[0080]

[0081] Note: If the chemical composition of the raw materials in the table above is less than 100%, it is mainly due to the presence of other undetected impurities.

[0082] The green silicon CF-25 used in the examples is silicon carbide with a purity of over 98.5%, purchased from Foshan Changyuan New Materials Co., Ltd.; the high-alumina whitening agent used in the examples was purchased from Foshan Yuanda Glaze Co., Ltd.; the manganese oxide used in the examples was purchased from Foshan Yuhui Trading Co., Ltd.; the sodium tripolyphosphate used in the examples was purchased from Jingdezhen Jiatao Ceramic Materials Co., Ltd.; the sodium carboxymethyl cellulose and carboxymethyl cellulose used in the examples were purchased from Foshan Chancheng Yingyuan Trading Co., Ltd.; and the body reinforcement agent used in the examples was purchased from Foshan Xinjinhui Economic and Trade Co., Ltd.

[0083] Green body reinforcing agents are classified into organic and inorganic types. Organic green body reinforcing agents typically include polyvinyl alcohol (PVA), carboxymethyl cellulose (CMC), modified starch, sodium polyacrylate, modified polysaccharides, polyacrylates, and lignin. Organic green body reinforcing agents can improve the plasticity, flowability, and suspension properties of the green body, as well as increase its drying strength and abrasion resistance. Inorganic green body reinforcing agents include water glass, phosphates, bentonite, sodium humate, lignin sulfonate, and alkali lignin. Inorganic green body reinforcing agents can enhance the density and abrasion resistance of the green body, while also improving its plasticity and rheological properties.

[0084] The test standard for the linear thermal expansion coefficient of ceramic raw materials and foamed ceramic raw materials is the national standard GB / T7320-2018, and the test method is the well-known top bar method in this field. The density test standard for foamed ceramic composite bricks is T / CBCSA12-2019, and the test method is the same as T / CBCSA12-2019.

[0085] Example 1

[0086] In Example 1, the same foamed ceramic formulation system was used as the foamed ceramic layer. The stability of various properties was improved by adjusting the formulation of the decorative layer. The raw materials for the foamed ceramic layer, by mass parts, include the following components (unit: parts):

[0087] Xizhi tailings 12 Cutting slag black 20 Quanzhe tailings 15 Snow Feather Sand 9 Phase III wasteland 20 Rongping Magnesia Soil 4 Xia Ming's leftover materials 15 Shi Rong leftover materials 5 Green Silicon CF-25 1.2 Green body strengthening agent 0.3 manganese oxide 0.3

[0088] The components of the decorative layer raw materials in Example 1, by mass parts, are shown in the table below (unit: parts):

[0089]

[0090]

[0091] The differences in the linear thermal expansion coefficients of the decorative layer material and the foamed ceramic layer material in the 30–200℃ and 30–600℃ ranges are shown in the table below:

[0092]

[0093] The preparation method of the foamed ceramic composite brick in Example 1 includes the following steps:

[0094] (1) Decorative layer powder was prepared by ball milling and spray granulation according to the above-mentioned raw material formula. The powder process parameters were as follows: powder moisture content 6.0-7.5%, bulk density ≥0.87g / ml, ≤2% for powders above 20 mesh, 55-75% for powders above 40 mesh, 80-95% for powders between 20 and 60 mesh, and ≤3% for powders below 100 mesh. The decorative layer powder was spread in the refractory kiln furniture to a thickness of 25mm and leveled.

[0095] (2) According to the above-mentioned raw material formula for the foamed ceramic layer, foamed ceramic powder was prepared by ball milling and spray granulation. The powder process parameters were as follows: powder moisture content 5.5-6.0%, bulk density ≥0.87g / ml, 1-2% above 20 mesh sieve, 45-70% of 20-40 mesh, 80-97% of 20-60 mesh, and ≤1.5% below 100 mesh sieve. The foamed ceramic powder was spread on the upper layer of the decorative layer powder to a thickness of 65mm and leveled.

[0096] (3) The kiln is fired at a temperature of 1165℃ for 8 hours.

[0097] (4) After cooling and exiting the kiln, the kiln furniture is removed to obtain the foamed ceramic composite brick.

[0098] The performance of the foamed ceramic composite brick in Example 1 was tested, and the results are shown in Table 1:

[0099] Table 1

[0100]

[0101] Note: A small amount of delamination cracking is permissible in industrial production; generally, a cracking rate below 10% is considered to indicate good industrialization characteristics. We use this as our testing standard.

[0102] As shown in Table 1, the foamed ceramic composite bricks prepared in Examples 1-1 to 1-8 were all fired in a single firing process and exhibited good bonding. However, in Examples 1-1 to 1-4, the linear thermal expansion coefficient between the decorative layer and the foamed ceramic layer at 200℃ and 600℃ was not within the optimal range, specifically 0.3 × 10⁻⁶. -6 K -1 ~0.7×10 -6 K -1Therefore, the decorative layer has micropores after sintering, and the composite brick of Example 1-1 showed slight dark cracks after polishing; the composite brick of Example 1-2 had large pores at the junction of the decorative layer and the foaming layer, resulting in poor weather resistance; while the composite bricks of Examples 1-3 to 1-4 showed a small number of cracks (4%) at the junction of the decorative layer and the foaming layer. The foamed ceramic composite bricks of Examples 1-5 to 1-8 had no pores in the decorative layer and no large pores at the junction of the decorative layer and the foaming layer, resulting in better performance. After using a whitening agent in Examples 1-8, the whiteness of the decorative layer increased, the transparency decreased, the hiding power increased, and darker powders could be used in the foaming layer.

[0103] Example 2

[0104] The same process parameters and preparation steps as in Examples 1-6 were used, except that a pore-forming material and a transparent material were added to the decorative layer powder. The pore-forming material and the transparent material were granulated to a particle size of 8 mesh or larger, mixed evenly with the decorative layer powder, and then fired. The raw material composition of the pore-forming material and the transparent material by mass is shown in the table below (unit: parts):

[0105] 9033 Zirconium White Fuse 80 70 8 28 - - Burning talc 5 5 5 5 5 5 Potassium feldspar 5 13 15 15 15 10 Sodium feldspar 10 12 - - 10 15 Sodium bentonite 5 5 5 5 5 - LT-2 microcrystalline frit - - 12 - 20 5 DS-PJ06 frit - - 55 47 45 60 Banks sodium sand - - - 5 - - Green body strengthening agent 0.5 0.5 - 0.5 - - Green Silicon CF-25 0.12 0.08 - - - - Sodium tripolyphosphate 0.25 - 0.25 0.25 0.25 0.25 Carboxymethyl cellulose - - 0.3 - 0.3 0.3

[0106] The mixing ratios of decorative layer powder, pore-forming material, and transparent material are shown in the table below (by mass, unit: parts):

[0107]

[0108]

[0109] The performance of the foamed ceramic composite bricks in Example 2 was tested, and the results are shown in Table 2:

[0110] Table 2

[0111]

[0112] As shown in Table 2, the foamed ceramic composite bricks obtained in Examples 2-1 and 2-3 exhibit good bonding properties. The decorative layer achieves the expected pore-forming effect, with varying pore sizes and a smooth transition between transparent materials. After polishing, the decorative layer achieves a travertine effect similar to traditional travertine stone. (See Table 2 for details.) Figure 1 Example 2-2 involves adding only transparent material, resulting in a patchy transparent effect in the fired decorative layer. The two transparent materials also have a good transition, creating a decorative effect similar to natural crystal.

[0113] Example 3

[0114] The same process parameters and preparation steps as in Examples 1-6 were used, the only difference being that LT-2 frit particles were added to the decorative layer powder. The frit particles were granulated to a particle size of 8-20 mesh. After mixing, the mixture was laid out and fired. The mixing ratio of the decorative layer powder to the LT-2 frit particles was 80:20. The performance of the fired foamed ceramic composite bricks was tested, and the results are shown in Table 3.

[0115] Table 3

[0116]

[0117] As shown in Table 3, the foamed ceramic composite bricks obtained in Example 3 exhibit good bonding properties, have micropores after polishing, and possess a decorative effect resembling natural stone. (See Table 3 for details.) Figure 2 .

[0118] Example 4

[0119] The same process parameters and preparation steps as in Examples 1-6 were used, the only difference being that silver mica flakes were added to the decorative layer powder. The silver mica flakes were processed into powder with a particle size of 10-30 mesh. The decorative layer powder and silver mica flakes were mixed at a ratio of 95:5 and then fired. The performance of the fired foamed ceramic composite bricks was tested, and the results are shown in Table 4.

[0120] Table 4

[0121]

[0122] As shown in Table 4, the foamed ceramic composite bricks obtained in Example 4 exhibit good bonding properties. After polishing, they have pores with a metallic luster at the pores, providing a decorative effect similar to sandstone. (See Table 4 for details.) Figure 3 .

[0123] Example 5

[0124] The same process parameters and preparation steps as in Examples 1-6 were used, the only difference being that green silicon CF-25 and inorganic pigments were added to the decorative layer powder. Based on the total amount of decorative layer powder, green silicon CF-25 accounted for 0.02%, and inorganic pigments accounted for 8%. The inorganic pigments used were encapsulated orange-red YD2201, encapsulated red YD1254, and YD-513 zirconium iron red, all purchased from Foshan Yuanda Glaze Technology Co., Ltd. The mixing ratio of encapsulated orange-red YD2201, encapsulated red YD1254, and YD-513 zirconium iron red was 1:1:1.5. The performance of the fired foamed ceramic composite bricks was tested, and the results are shown in Table 5.

[0125] Table 5

[0126]

[0127] As shown in Table 5, the foamed ceramic composite bricks obtained in Example 5 exhibit good bonding properties and can produce a brick-red decorative layer with a slightly foamed porous effect, resulting in a good decorative effect. (See Table 5 for details.) Figure 4 .

[0128] Example 6

[0129] The same process parameters and preparation steps as in Examples 1-6 were used, the only difference being that zirconium silicate was added to the decorative layer raw material. The mixing ratio of the decorative layer raw material to zirconium silicate was 85:15. After mixing the zirconium silicate and decorative layer raw material, the mixture was ball-milled, slurried, and spray-granulated into powder. The performance of the fired foamed ceramic composite bricks was tested, and the results are shown in Table 6.

[0130] Table 6

[0131]

[0132] As shown in Table 6, the foamed ceramic composite bricks obtained in Example 6 exhibit good bonding properties and achieve a pure white decorative layer effect. (See Table 6 for details.) Figure 5 .

[0133] Example 7

[0134] Based on the decorative layer powder in Examples 1-6, decorative layer powders of different colors are obtained by adding various pigments. The specific mixing ratios are shown in the table below. Among them, the inorganic pigments encapsulated orange-red YD2201, encapsulated red YD1254, encapsulated yellow YD3671, and YD-513 zirconium iron red were all purchased from Foshan Yuanda Glaze Technology Co., Ltd.

[0135]

[0136]

[0137] The base decorative layer powder and the above-mentioned colored powder are granulated into powder with a particle size of 10-20 mesh. Then, the transparent material with a particle size of 8 mesh or more and the pore-forming material with a particle size of 9-10 mesh are mixed according to the proportions in the table below, and then fired after being distributed through a multi-tube system (by mass parts, unit: parts).

[0138]

[0139] The performance of the fired foamed ceramic composite bricks was tested, and the results are shown in Table 7.

[0140] Table 7

[0141]

[0142] The decorative layer obtained in Example 7 has a texture similar to natural stone, resulting in a good decorative effect. See [link / reference]. Figure 6 .

[0143] The above description is only a preferred embodiment of the present invention and does not limit the patent scope of the present invention. All equivalent structural transformations made using the contents of the present invention under the inventive concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A method for preparing foamed ceramic composite bricks, characterized in that, Includes the following steps: (1) Prepare decorative layer powder by ball milling and spray granulation according to the raw material formula of decorative layer, spread the decorative layer powder in the refractory kiln furniture with a thickness of 10-25mm, and scrape it flat; (2) Prepare foamed ceramic powder by ball milling and spray granulation according to the raw material formula of foamed ceramic layer, spread the foamed ceramic powder on the upper layer of decorative layer powder, and scrape it flat; (3) The product is placed in a kiln for firing at a temperature of 1160-1170℃ for a period of 8-13.5 hours. (4) After cooling and exiting the kiln, the kiln furniture is removed to obtain the foamed ceramic composite brick; The decorative layer raw material, by weight, comprises the following components: 25-95 parts frit, 0-10 parts talc, 5 parts clay, 5-65 parts mineral flux, and 0.15-0.5 parts additives; The raw materials for the foamed ceramic layer, by weight, include the following components: 12 parts of Xizhi tailings, 20 parts of cutting slag black, 15 parts of Quanzhe tailings, 9 parts of Xueyu sand, 20 parts of Phase III waste soil, 4 parts of Rongping magnesia clay, 15 parts of Xiaming tailings, 5 parts of Shirong tailings, 1.2 parts of green silicon CF-25, 0.3 parts of green body reinforcing agent, and 0.3 parts of manganese oxide; The frit includes at least two of the following: LT-2 microcrystalline frit, zirconium white frit, CY1102 frit, and DJY-710 frit, and must include LT-2 microcrystalline frit; The chemical composition of the LT-2 microcrystalline frit, by mass percentage, is: SiO2 56-60%, Al2O3 6-10%, Fe2O3 0-0.3%, TiO2 0-2%, CaO 16-20%, MgO 0-3%, K2O 0-1%, Na2O 4-6%, ZrO2 0-0.05%, ZnO 0-2%, LOI 0-0.5%, with the balance being impurities. The chemical composition of the zirconium white ingot, by mass percentage, is as follows: SiO2 60-64%, Al2O3 4-8%, Fe2O3 0-0.4%, TiO2 0-0.5%, CaO 10-14%, MgO 2-6%, K2O 2-6%, Na2O 0-0.02%, ZrO2 4-8%, ZnO 4-8%, LOI: 0-0.5%, with the balance being impurities; The chemical composition of the CY1102 frit, by mass percentage, is: SiO2 52-56%, Al2O3 6-10%, Fe2O3 0-0.3%, TiO2 0-0.5%, CaO 12-16%, MgO 0-0.5%, K2O 6-9%, Na2O 0-0.5%, ZrO2 0-0.05%, ZnO 10-14%, LOI: 0-0.5%, with the balance being impurities. The chemical composition of the DJY-710 frit, by mass percentage, is: SiO2 62-66%, Al2O3 15-19%, Fe2O3 0-0.5%, TiO2 0-0.2%, CaO 2-5%, MgO 0-2%, K2O 2-6%, Na2O 4-8%, ZrO2 0-0.05%, ZnO 0-5%, LOI 0-0.5%, with the balance being impurities. The mineral flux includes sodium feldspar and potassium feldspar; the additives include sodium tripolyphosphate and sodium carboxymethyl cellulose. Under conditions of 30–200℃ and 30–600℃, the linear thermal expansion coefficient of the decorative layer material is greater than that of the foamed ceramic layer material, and 0.3 × 10⁻⁶. -6 K -1 The difference between the linear thermal expansion coefficients of the two is ≤0.7×10 - 6 K -1 .

2. The method for preparing a foamed ceramic composite brick as described in claim 1, characterized in that, The decorative layer material also includes 0-10 parts of inorganic pigment, 0-0.08 parts of silicon carbide, and 0-6 parts of whitening agent by weight.

3. The method for preparing a foamed ceramic composite brick as described in claim 1, characterized in that, The decorative layer powder in step (1) contains a transparent material and a pore-forming material. The mass ratio of the transparent material, the pore-forming material and the decorative layer powder is 10-30:0-10:60-80. The particle size of the transparent material is ≥8 mesh, and the particle size of the pore-forming material is ≥8 mesh.

4. The method for preparing a foamed ceramic composite brick as described in claim 3, characterized in that, The pore-forming material comprises the following components by mass: 60-80 parts zircon white frit, 0-5 parts calcined talc, 10-20 parts potassium feldspar, 8-20 parts sodium feldspar, 0-5 parts bentonite, 0-1 part green body reinforcing agent, 0.05-0.4 parts silicon carbide, and 0-0.3 parts sodium tripolyphosphate.

5. The method for preparing a foamed ceramic composite brick as described in claim 3, characterized in that, The transparent material raw material comprises the following components by mass: 0-30 parts zircon white frit, 0-10 parts calcined talc, 0-20 parts potassium feldspar, 0-20 parts LT-2 microcrystalline frit, 45-60 parts DS-PJ06 frit, 0-10 parts sodium sand, 0-5 parts bentonite, 0-15 parts sodium feldspar, 0-1 part green body reinforcing agent, 0-0.4 parts sodium tripolyphosphate, and 0.15-0.4 parts carboxymethyl cellulose; The chemical composition of the DS-PJ06 frit, by mass percentage, is: SiO2 65-68%, Al2O3 14-18%, Fe2O3 0-0.5%, TiO2 0-0.2%, CaO 6-10%, MgO 0-2%, K2O 0-5%, Na2O 0-0.2%, ZnO 0-5%, LOI 0-0.5%, with the balance being impurities.

6. The method for preparing a foamed ceramic composite brick as described in claim 1, characterized in that, The decorative layer powder in step (1) contains an added functional material, and the mass ratio of the functional material to the decorative layer powder is 5-30:70-95.

7. The method for preparing a foamed ceramic composite brick as described in claim 6, characterized in that, The functional material includes one of LT-2 microcrystalline frit, mica sheets, and zirconium silicate.

8. A foamed ceramic composite brick, characterized in that, It is obtained by the preparation method of a foamed ceramic composite brick according to any one of claims 1-7.

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