High-strength foamed ceramic and process for producing the same

Abstract

The application discloses high-strength foamed ceramic, by weight parts, including the following components: sodium sand 5-15 parts, pressed mud 40-65 parts, ceramic fiber 0-3 parts, calcined talc 5-10 parts, frit 0-8 parts, potassium feldspar 8-18 parts, cordierite 0-5 parts, wollastonite 0-3 parts, foaming agent 0.05-0.45 parts, manganese oxide 0.1-0.5 parts, liquid debonder 0.5-1.5 parts, green body reinforcing agent 0-0.5 parts; or, sand 0-10 parts, mine tailings 10-30 parts, pressed mud 10-25 parts, glass tailings 0-10 parts, waste soil 10-22 parts, foamed ceramic waste (black) 5-40 parts, magnesia soil 4-6 parts, foaming agent 0.05-0.45 parts, manganese oxide 0.1-0.5 parts, liquid debonder 0.5-1.5 parts, green body reinforcing agent 0-0.5 parts. The foamed ceramic fired by the above formula has the characteristics of high wear resistance and high strength, can be applied to surface decoration materials, and greatly widens the application range of the foamed ceramic.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of building ceramics, in particular to a high-strength foamed ceramic and a production process thereof. BACKGROUND

[0002] Foamed ceramic is a new type of building material, which has a large number of closed pores inside, has the characteristics of light weight, high strength, heat preservation, sound insulation, waterproof, fire resistance, corrosion resistance, aging resistance, etc., and is a high-performance inorganic heat preservation wall material with the same service life as the building.

[0003] At present, foamed ceramic mostly uses silicon carbide or materials containing silicon carbide as a foaming agent to form a semi-molten suspension melt at high temperature, and the gas produced by the decomposition of the foaming agent is wrapped by the melt to form a closed pore, and the closed pore foam structure is formed during the cooling stage. Therefore, the mechanical properties and thermal insulation properties of foamed ceramic are mutually restricted. Most of the foamed ceramic products produced at present are limited to the density range of 500kg / m 3 Due to the requirement of building structure strength, foamed ceramic can only be used as an interior partition wall material, which seriously limits the application range of foamed ceramic.

[0004] In existing applications, the uneven effect of the surface layer of foamed ceramic is not used as the product texture for wall decoration. Usually, a glaze layer needs to be applied on the surface layer as a surface layer, which has poor wear resistance and is easy to cause the glaze layer to fall off after slight friction, thereby exposing the single-color foamed ceramic layer without decorative effect. The foamed ceramic plate with a density of 500kg / m 3 The bending strength of the foamed ceramic plate is usually less than 3.5Mpa, and the compressive strength is in the range of 7-9Mpa, which is easy to break, is not conducive to processing, transportation and installation, has poor wear resistance, and further affects its use as a decorative layer.

[0005] Therefore, there is an urgent need for a production process of high-strength foamed ceramic, which can improve the surface layer strength, decoration, stain resistance and wear resistance of foamed ceramic, so that it can be directly applied as a decorative layer in the building field. SUMMARY

[0006] The main purpose of the present application is to provide a high-strength foamed ceramic with high strength, impact resistance and wear resistance.

[0007] To achieve the above purpose, the present application provides a high-strength foamed ceramic, which comprises at least one formula system in parts by weight as follows:

[0008] Component one: sodium sand 5-15 parts, pressed mud 40-65 parts, ceramic fiber 0-3 parts, calcined talc 5-10 parts, frit 0-8 parts, potassium feldspar 8-18 parts, cordierite 0-5 parts, wollastonite 0-3 parts, foaming agent 0.05-0.45 parts, manganese oxide 0.1-0.5 parts, liquid debonder 0.5-1.5 parts, body strengthening agent 0-0.5 parts;

[0009] or,

[0010] Component two: sand 0-10 parts, mine tailings 10-30 parts, pressed mud 10-25 parts, glass tailings 0-10 parts, waste soil 10-22 parts, foamed ceramic waste (black) 5-40 parts, magnesia soil 4-6 parts, foaming agent 0.05-0.45 parts, manganese oxide 0.1-0.5 parts, liquid debonder 0.5-1.5 parts, body strengthening agent 0-0.5 parts.

[0011] The high-strength foamed ceramic disclosed by the application adjusts the hardness of the foamed ceramic particles in the sintering process by adjusting the raw material formula, so that the density of the sintered foamed ceramic is 700-800 kg / m 3 The surface Mohs hardness can reach more than 5 levels, the bending strength is > 6 Mpa, and the compressive strength is > 24 Mpa, so that the foamed ceramic has relatively high compressive and bending strengths.

[0012] Preferably, the raw material components of the high-strength foamed ceramic further include wear-resistant materials and / or known inorganic pigments, the wear-resistant materials including at least one of metal tailings, construction waste, sand tailings, ceramic waste particles, ceramic powder particles, high-temperature frit particles, metal smelting slag, and inorganic non-metal powder; preferably, the metal tailings are molybdenum tailings, copper tailings, iron tailings, and lithium tailings.

[0013] Preferably, the wear-resistant materials account for 10-35% based on the total amount of the raw materials of the high-strength foamed ceramic.

[0014] By using metal tailings, construction waste, frit particles, metal smelting slag, and other raw materials, the formation of the glass phase in the matrix is promoted without affecting the formation and growth of the pores in the high-temperature melt, thereby improving the strength of the matrix and further improving the wear resistance and compressive and bending strengths of the foamed ceramic.

[0015] On the other hand, the application further provides a production process of high-strength foamed ceramic, including the following steps:

[0016] (1) preparing high-strength foamed ceramic powder: mixing the foamed ceramic raw materials in proportion, ball milling to prepare slurry, and spray granulation to obtain high-strength foamed ceramic powder;

[0017] (2) spreading the high-strength foamed ceramic powder in a predetermined thickness in a refractory kiln, and scraping it flat;

[0018] (3) send into the kiln firing, firing temperature is 1160~1170℃, firing period is 8~13.5h;

[0019] (4) cooling out of the kiln after removing refractory kiln furniture, namely the high strength foamed ceramic is obtained.

[0020] Using micro-foaming process, high wear resistance, high strength foamed ceramic is obtained at lower firing temperature.

[0021] Preferably, in the above production process, based on the total amount of high strength foamed ceramic powder, the high strength foamed ceramic powder further comprises 5~10% decorative material; the decorative material comprises the following components by mass fraction: 9033 zirconium white frit 65~85 parts, calcined talc 5~10 parts, potassium feldspar 10~20 parts, bentonite 3~8 parts, body strengthening agent 0~0.5 parts, foaming agent 0.05~0.3 parts.

[0022] After firing with the above formula components, shell-shaped large bubbles can be formed, so that the foamed ceramic has shell-shaped decorative effect, and good mechanical properties make it can be directly used as surface decorative material.

[0023] Preferably, in the above production process, based on the total amount of high strength foamed ceramic powder, the high strength foamed ceramic powder further comprises 35~100% functional material; the functional material contains attapulgite, and the attapulgite accounts for 25~50% of the total weight of the functional material by mass percentage.

[0024] Preferably, the functional material comprises the following components by mass fraction: pressed mud 30~60 parts, sodium sand 8~12 parts, foamed ceramic waste (white) 0~40 parts, potassium feldspar 5~15 parts, ZR-14 whitening agent 0~5 parts, attapulgite 25~45 parts, waste ceramic fiber paper 0~2 parts, liquid debonding agent 0.5~1.5 parts, manganese oxide 0~0.3 parts.

[0025] The introduction of rod-shaped attapulgite as the main material in the formula can further improve the compressive and bending strength of the fired product.

[0026] Preferably, in the above production process, based on the total amount of high strength foamed ceramic powder, the high strength foamed ceramic powder further comprises 15~30% antifouling material; the antifouling material is at least one of low temperature glaze powder, frit dry particles and glass powder.

[0027] The introduction of antifouling material can improve the poor antifouling effect of foamed ceramic due to its uneven characteristics.

[0028] Preferably, in the above production process, in the step (2), a layer of conventional foamed ceramic powder is spread before the high-strength foamed ceramic powder is spread.

[0029] The foamed ceramic with two different effects can be fired at one time, and two products can be obtained after cutting processing, thereby improving the utilization rate of the kiln. Meanwhile, the thickness of the foamed ceramic as the surface decoration layer can be adjusted, so that the conventional foamed ceramic material is used as the bottom layer, and the foamed ceramic material with decorative effect is used as the surface layer, thereby saving the production cost.

[0030] Preferably, in the above production process, the process parameters of the high-strength foamed ceramic powder are as follows: the water content of the powder is 5.5-6.0%, the bulk density is 0.87-0.88 g / ml, and the powder particles of more than 20 mesh and less than 100 mesh are less than or equal to 1.5% respectively. Through the control of the above conditions, the green strength of the powder can be greater than or equal to 1.3 Mpa.

[0031] By adjusting the uniformity of the powder particles, the particle strength, the particle gradation and the bulk density of the powder, the stability of the foaming process is ensured, and the high consistency of the thickness of the spread material and the thickness of the finished product from the kiln is ensured.

[0032] Compared with the prior art, the technical scheme of the present application has at least the following beneficial effects:

[0033] 1. The high-strength foamed ceramic disclosed by the present application, by adjusting the raw material formula, the foamed ceramic after firing has a bulk density of 700-1000 kg / m 3 , a surface Mohs hardness of greater than or equal to 5, a highest bending strength of 15 Mpa, and a highest compressive strength of 45 Mpa, has the characteristics of high wear resistance and high strength, can be applied to the surface decoration layer, and greatly widens the application range of the foamed ceramic;

[0034] 2. By adding a special formula of decorative material, a shell-shaped decorative effect can be simulated. The foamed ceramic has the shell-shaped decorative effect while ensuring the characteristics of high wear resistance and high strength, and can be applied to special decorative environments.

[0035] 3. By introducing antifouling material, the problem of poor antifouling effect caused by the uneven surface of the foamed ceramic can be solved. BRIEF DESCRIPTION OF DRAWINGS

[0036] In order to more clearly illustrate the technical schemes in the embodiments of the present application or the prior art, the drawings needed in the embodiment or prior art description will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the present application, and those skilled in the art can also obtain other related drawings according to these drawings without creating any creative labor.

[0037] Figure 1 A high-strength foamed ceramic surface effect schematic diagram with shell-shaped large bubbles prepared for example 8-1.

[0038] The implementation, functional features and advantages of the present application will be further described with reference to the embodiments and the accompanying drawings. DETAILED DESCRIPTION

[0039] The technical solutions in the embodiments of the present application will be described clearly and completely below. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by a person of ordinary skill in the art without creative work are within the protection scope of the present application.

[0040] In addition, the technical solutions of various embodiments can be combined with each other, but it must be based on the fact that a person of ordinary skill in the art can realize it. When the combination of technical solutions appears to be contradictory or unachievable, it should be considered that the combination of technical solutions does not exist and is not within the protection scope of the present application.

[0041] The present application provides a high-strength foamed ceramic, at least comprising the following formula system in parts by weight:

[0042] Component one: sodium sand 5-15 parts, pressed mud 40-65 parts, ceramic fiber 0-3 parts, calcined talc 5-10 parts, frit 0-8 parts, potassium feldspar 8-18 parts, cordierite 0-5 parts, wollastonite 0-3 parts, foaming agent 0.05-0.45 parts, manganese oxide 0.1-0.5 parts, liquid de-bonding agent 0.5-1.5 parts, body strengthening agent 0-0.5 parts;

[0043] Or,

[0044] Component two: sand 0-10 parts, mine tailings 10-30 parts, pressed mud 10-25 parts, glass tailings 0-10 parts, waste soil 10-22 parts, foamed ceramic waste (black) 5-40 parts, magnesia soil 4-6 parts, foaming agent 0.05-0.45 parts, manganese oxide 0.1-0.5 parts, liquid de-bonding agent 0.5-1.5 parts, body strengthening agent 0-0.5 parts.

[0045] Specifically, the foaming agent can be silicon carbide powder, iron ore powder, carbon powder, calcium carbonate, aluminum sulfate, etc.

[0046] Frit is a commonly used raw material for making ceramics, which is obtained by high-temperature melting and quenching of some raw materials. In the present application, 9033 zirconium white frit is a high-zinc and zirconium-containing frit, which has a milky effect and can improve the whiteness of the product. The pressed mud in the present application is the pressed mud produced by flotation of lithium ore.

[0047] It should be noted that the present application can control the hardness of the foamed ceramic particles in the sintering process by using the above two formula systems, so that the density of the sintered foamed ceramic is 700-800 kg / m 3 If at least one component in the formula system is not within the above defined range, the sintering process will be affected, and the effect of improving the strength and hardness as described in the present application cannot be achieved.

[0048] In one embodiment, the raw material components of the high-strength foamed ceramic further include wear-resistant materials and / or known inorganic pigments, and the wear-resistant materials are at least one of metal tailings, construction waste, sand tailings, ceramic waste particle, ceramic powder particle, high-temperature clinker particle, metal smelting slag, and inorganic non-metal powder. Specifically, the metal tailings are molybdenum tailings, copper tailings, iron tailings, and lithium tailings.

[0049] Specifically, the wear-resistant materials account for 10-35% based on the total amount of the raw materials of the high-strength foamed ceramic.

[0050] By using metal tailings, construction waste, clinker particles, metal smelting slag and other raw materials, the formation of the glass phase in the matrix is promoted without affecting the formation and growth of the pores in the high-temperature melt, thereby improving the strength of the matrix and further improving the wear resistance and compressive and bending strength of the foamed ceramic.

[0051] It should be noted that the wear-resistant materials do not need to be ball milled and granulated together with other raw materials, but only need to be dried and sieved according to the particle requirements and then mixed with the powder. The particle size is controlled between 10-30 meshes. The large particles of the wear-resistant materials act as supports in the matrix network, thereby improving the wear resistance and strength as a whole. The particle size can be adjusted according to actual needs.

[0052] By adding known inorganic pigments, the foamed ceramic has a variety of different color textures, which is more decorative when applied to surface materials.

[0053] Correspondingly, the present application also proposes a production process of high-strength foamed ceramic, which comprises the following steps:

[0054] (1) Preparing high-strength foamed ceramic powder: mixing the foamed ceramic raw materials in proportion, ball milling, and spray granulating to obtain high-strength foamed ceramic powder. The process parameters of the powder are as follows: the water content of the powder is 5.5-6.0%, the bulk density is 0.87-0.88 g / ml, and the powder particles of 20 meshes or more and 100 meshes or less are ≤1.5% respectively. By controlling the above conditions, the green strength of the powder is ≥1.3 Mpa;

[0055] (2) Spreading the high-strength foamed ceramic powder in the refractory kiln, with a thickness of 67-72 mm, and scraping it flat;

[0056] (3) Put into the kiln for firing, the firing temperature is 1160-1170℃, and the firing period is 8-13.5h;

[0057] (4) After cooling out of the kiln, remove the refractory kiln furniture, and the high-strength foamed ceramic is obtained.

[0058] Through the micro-foaming process, the high-strength foamed ceramic with high wear resistance and high strength is obtained at a lower firing temperature.

[0059] In an embodiment, the high-strength foamed ceramic powder further comprises 5-10% of decorative material based on the total amount of the high-strength foamed ceramic powder; the decorative material comprises the following components in mass fraction: 65-85 parts of 9033 zirconium white frit, 5-10 parts of calcined talc, 10-20 parts of potassium feldspar, 3-8 parts of bentonite, 0-0.5 parts of body strengthening agent, and 0.05-0.3 parts of foaming agent.

[0060] The introduction of the foaming component in the formula system generates gas to form large pores during firing, and can form large bubbles in the shape of shells after firing, thus having a certain decorative effect. By adjusting the amount of the decorative material, the size of the bubbles can be controlled to form different decorative effects. Specifically, the decorative material can be introduced in a multi-pipe distribution manner, so that it is mainly distributed in the surface layer or the local part close to the surface layer, and the addition amount of the decorative material is controlled to be 5-10%. A small amount of decorative material will not have a great impact on the overall performance of the basic formula of the high-strength foamed ceramic.

[0061] In an embodiment, the high-strength foamed ceramic powder further comprises 35-100% of functional material based on the total amount of the high-strength foamed ceramic powder; the functional material contains attapulgite, and the attapulgite accounts for 25-50% of the total weight of the functional material in mass percentage.

[0062] Optionally, in an embodiment, the functional material comprises the following components in mass fraction: 30-60 parts of pressed mud, 8-12 parts of sodium sand, 0-40 parts of foamed ceramic waste (white), 5-15 parts of potassium feldspar, 0-5 parts of ZR-14 whitening agent, 25-45 parts of attapulgite, 0-2 parts of waste ceramic fiber paper, 0.5-1.5 parts of liquid debonding agent, and 0-0.3 parts of manganese oxide.

[0063] The introduction of the functional material containing attapulgite can further improve the compressive and bending strength of the foamed ceramic after firing.

[0064] In an embodiment, the high-strength foamed ceramic powder further comprises 15-30% of anti-fouling material based on the total amount of the high-strength foamed ceramic powder; the anti-fouling material is at least one of low-temperature glaze powder, frit dry particles, and glass powder.

[0065] Specifically, in the present application, two kinds of foamed ceramics with different decorative effects can be fired at one time. Preferably, in step (2), a layer of conventional foamed ceramic powder is spread before the high-strength foamed ceramic powder is spread.

[0066] The foamed ceramics with two different effects can be fired at one time, and two products can be obtained after cutting processing, thereby improving the utilization rate of the kiln. Meanwhile, the thickness of the foamed ceramic as the surface decorative layer can be adjusted, so that the bottom layer adopts the conventional foamed ceramic material, and the surface layer adopts the foamed ceramic material with decorative effect, thereby saving the production cost.

[0067] The technical solutions of the present application are further described in detail below in combination with specific embodiments. It should be understood that the following embodiments are only used to explain the present application, and are not used to limit the present application.

[0068] The specific chemical compositions of the raw materials for preparing each ceramic in the following embodiments are provided, and the details are shown in the following table (in mass percentage, unit: %):

[0069]

[0070]

[0071] Raw material name SiO2 Al2O3 Fe2O3 TiO2 CaO MgO K2O Na2O L.O.I ZrO2 ZnO 9033 zircon white clinker 61.02 6.18 0.17 0.37 10.94 3.58 4.09 0.01 0.34 6.3 6.16 Molybdenum tailings 75.02 12.34 1.85 0.16 0.94 0.42 5.65 2.31 1.31 - -

[0072] Note: If the chemical composition of the raw materials in the above table is not 100%, it is mainly due to the presence of other undetected impurities.

[0073] In the present scheme, the ceramic fiber is waste ceramic fiber paper. In actual situations, other ceramic fibers can also be selected according to needs, such as alumina fiber. In the present scheme, the foaming agent is green silicon CF-25, i.e., silicon carbide with a purity of more than 98.5%, which is purchased from Foshan Changyuan New Material Co., Ltd. The manganese oxide used in the present scheme is purchased from Foshan Yuhui Trade Co., Ltd., the body reinforcing agent is purchased from Foshan Xingjin Trade Co., Ltd., and the liquid debonding agent is purchased from Jiangxi Keben New Material Technology Co., Ltd.

[0074] The components of the liquid debonding agent mainly include inorganic salts and polyelectrolytes. The liquid debonding agent of inorganic salts mainly includes water glass, sodium carbonate, sodium tripolyphosphate, and sodium hexametaphosphate.

[0075] The green body reinforcing agent is divided into organic green body reinforcing agent and inorganic green body reinforcing agent. The organic green body reinforcing agent usually includes polyvinyl alcohol (PVA), carboxymethyl cellulose (CMC), modified starch, sodium polyacrylate, modified polysaccharide, polyacrylate and lignin, etc. The organic green body reinforcing agent can improve the plasticity, fluidity and suspensibility of the green body, and improve the dry strength and wear resistance. The inorganic green body reinforcing agent includes water glass, phosphate, bentonite, sodium humate, lignosulfonate and alkali lignin, etc. The inorganic green body reinforcing agent can enhance the compactness and wear resistance of the green body, and improve the plasticity and rheological property thereof.

[0076] Reference Example

[0077] Firstly, a set of raw material formula system for producing conventional foamed ceramics is provided, which includes foamed ceramic waste (black) 15 parts, pressed mud 55 parts, foamed ceramic waste (white) 21 parts, magnesia soil 9 parts, silicon carbide 0.35 parts, liquid debonding agent 1.5 parts, green body reinforcing agent 0.15 parts, and manganese oxide 0.1 part in terms of mass fraction. The above formula components are calculated into oxides according to chemical analysis as shown in the following table (in mass percentage, unit: %)

[0078] SiO2 Al2O3 Fe2O3 TiO2 CaO MgO K2O Na2O L.O.I Reference example 68.27 17.18 1.1 0.16 1.14 2.78 2.93 3.72 2.72

[0079] The foamed ceramics are prepared according to the above raw material components, specifically including the following steps:

[0080] (1) The foamed ceramic raw materials are ball milled into slurry according to the above mass ratio, and the slurry bulk density is 0.87 g / ml; spray granulation is performed to obtain foamed ceramic powder with a water content of 6%, and the powder particles of 20 mesh or more and 100 mesh or less are 1.5% respectively; through the control of the above conditions, the green body strength of the powder is ≥1.3 Mpa;

[0081] (2) The foamed ceramic powder is spread in the refractory kiln furniture with a thickness of 69 mm, and is scraped flat;

[0082] (3) The foamed ceramic powder is sent into the kiln for firing, the firing temperature is 1165℃, and the firing period is 13.5 h;

[0083] (4) After cooling out of the kiln, the refractory kiln furniture is removed, and the foamed ceramic product is obtained after cutting, polishing and grinding.

[0084] The obtained foamed ceramic product is tested, and the testing method and testing standard are shown in the following table:

[0085] Detection standard Detection method Density (kg / m 3 )]]> T / CBCSA 12-2019 See T / CBCSA 12-2019 for details Surface Mohs hardness JC / T 872-2000 See JC / T 872-2000 for details Compressive strength (Mpa) GB / T 23451-2009 See GB / T 23451-2009 for details Flexural strength (Mpa) GB / T 3810-2006 See GB / T 3810-2006 for details

[0086] The performance parameters of the reference example are shown in Table 1:

[0087] Table 1

[0088]

[0089] The foamed ceramic product is a thermal insulation material commonly used in the prior art for wall partitions. Due to its limited density and compressive and bending strength, it is not suitable for surface decoration materials, greatly limiting its application range.

[0090] Examples 1-6

[0091] The raw material formulation components used in Examples 1-6 are shown in the following table (in parts by mass), wherein Examples 1-3 use the formulation system of Component One, and Examples 4-6 use the formulation system of Component Two.

[0092]

[0093]

[0094] The production process for preparing the high-strength foamed ceramic of Examples 1-6 specifically includes the following steps:

[0095] (1) Preparation of high-strength foamed ceramic powder: After mixing the foamed ceramic raw materials according to the above ratio, ball milling is performed to prepare a slurry, and spray granulation is performed to obtain a high-strength foamed ceramic powder. The process parameters of the powder are as follows: water content of the powder is 5.5-6.0%, bulk density is 0.87-0.88 g / ml, and the powder particle size of 20 mesh or more and 100 mesh or less is 1.5%, respectively. By controlling the above conditions, the green strength of the powder is ≥1.3 MPa;

[0096] (2) The high-strength foamed ceramic powder is spread in a refractory kiln, with a thickness of 69 mm, and is leveled;

[0097] (3) The kiln is sent to the furnace for firing, with a firing temperature of 1165°C and a firing period of 13.5 h;

[0098] (4) After cooling and removing the refractory kiln, the high-strength foamed ceramic is obtained.

[0099] Comparative Examples 1-4

[0100] Comparative Examples 1-4 use the same preparation process as Example 2, with the only difference being the raw material formulation. The raw material formulation components used are shown in the following table (in parts by mass):

[0101] Raw material name Comparative example 1 Comparative example 2 Comparative example 3 Comparative example 4 Sodium sand 20 - - - Extruded mud 50 75 20 20 Waste ceramic fiber paper - 5 - - Calcined talc 8 5 - - 9033 zircon white clinker 9 10 - - Potassium feldspar 10 6 - - Cordierite 2 3 - - Wollastonite 1 1 - - Foamed ceramic waste (black) - - 20 20 Sand - - 11 5 Mine tailings - - - 17 Glass tailings - - 5 10 Waste clay - - 40 24 Magnesia clay - - 4 4 Carbide silicon 0.23 0.25 0.35 0.32 Oxidized manganese 0.25 0.25 0.5 0.5 Liquid debonder 1.2 1.2 1.2 1.2 Body enhancer 0.3 0.3 0.3 0.3

[0102] The properties of the high-strength foamed ceramic prepared in Examples 1-6 and Comparative Examples 1-4 were tested, and the test results are shown in Table 2:

[0103] Table 2

[0104]

[0105]

[0106] As shown in Table 2, the performance indicators of the foamed ceramics prepared in Examples 1-6 are all better than those of the reference examples. The bulk density is in the range of 700-800 kg / m 3 , the surface Mohs hardness is ≥ 5, the bending strength is > 6 MPa, and the compressive strength is > 24 MPa, which are higher than those of conventional foamed ceramics in the prior art, and the wear resistance is improved, so that the foamed ceramics can be applied to the surface decoration layer. In Examples 2-3, the content of potassium feldspar is adjusted to be in the range of 8-15 parts, and in Examples 4-5, the content of waste clay is adjusted to be in the range of 10-20 parts, so that the sintering temperature is reduced, the sintering degree is improved, the compressive strength of the sintered product is more stable, and the compressive strength can be > 25 MPa. In Comparative Examples 1-4, the ratio of the raw material components is adjusted so as to be out of the range of the present scheme, which breaks the balance of the formula system, and the bulk density, hardness, and compressive and bending strength of the foamed ceramics obtained after sintering are all decreased. It should be noted that the bulk density, hardness, and compressive and bending strength of the foamed ceramics obtained after sintering are all decreased when the remaining components in the formula system of the present scheme are adjusted similarly, which will not be described here. Therefore, when the raw material components are sodium sand 5-15 parts, pressed mud 40-65 parts, ceramic fiber 0-3 parts, calcined talc 5-10 parts, frit 0-8 parts, potassium feldspar 8-18 parts, cordierite 0-5 parts, wollastonite 0-3 parts, foaming agent 0.05-0.45 parts, manganese oxide 0.1-0.5 parts, liquid de-bonding agent 0.5-1.5 parts, and body strengthening agent 0-0.5 parts; or, sand 0-10 parts, mine tailings 10-30 parts, pressed mud 10-25 parts, glass tailings 0-10 parts, waste clay 10-22 parts, foamed ceramic waste (black) 5-40 parts, magnesia clay 4-6 parts, foaming agent 0.05-0.45 parts, manganese oxide 0.1-0.5 parts, liquid de-bonding agent 0.5-1.5 parts, and body strengthening agent 0-0.5 parts, the hardness of the foamed ceramic particles in the sintering process is adjusted, the formation of the glass phase in the matrix is promoted, the strength of the matrix is improved, and foamed ceramics with a bulk density of 700-800 kg / m 3 , a surface Mohs hardness of ≥ 5, a bending strength of > 6 MPa, and a compressive strength of > 24 MPa can be obtained. When the content of potassium feldspar is in the range of 8-15 parts and the content of waste clay is in the range of 10-20 parts, the effect is better, and the compressive strength can be > 25 MPa. Further, when the formula of Example 2 and Example 5 is used, the comprehensive performance is better.

[0107] Example 7

[0108] Example 7 uses the same preparation process parameters as Examples 1-6, the only difference is that the ratio of raw material components is adjusted, and inorganic color and wear-resistant material are added. The wear-resistant material specifically includes metal tailings, construction slag, microcrystalline frit, etc., such as 9033 zirconium white frit, waste soil, molybdenum tailings, etc. The inorganic color includes wrapped orange YD2201, wrapped red YD1254, wrapped yellow YD3671, YD-513 zirconium iron red, etc., all purchased from Foshan Yuanda Glaze Technology Co., Ltd. First, the raw material formula used in Example 2 (hereinafter referred to as Component A) is used to prepare the corresponding raw material formula component with different colors by adding the above-mentioned inorganic color. The addition ratio is shown in the following table (in mass parts, unit: parts):

[0109] Beige formula Ochre formula Brick red formula Wrapped orange YD2201 0.35 0.25 1 Wrapped red YD1254 0.05 0.15 1 Wrapped yellow YD3671 0.15 0.35 - YD-513 zirconium iron red - - 1.5 Component A 100 100 100

[0110] The raw material formula of Example 7 uses the combination of Component A, the raw material formula in Example 5 (hereinafter referred to as Component B), beige formula, earthy yellow formula, brick red formula, and wear-resistant material. The specific raw material components are shown in the following table (in mass parts, unit: parts):

[0111] Raw material / component name Example 7 Component A 40 Component B 5 Brick red formula 13 Ochre formula 6 Beige formula 6 9033 zircon white clinker 5 Waste clay 5 Molybdenum tailings 20

[0112] The performance parameters of the foamed ceramics prepared in Example 7 were detected, and the results are shown in Table 3:

[0113] Table 3

[0114]

[0115] As can be seen from Table 3, the surface hardness of the foamed ceramics prepared in Example 7 is improved due to the introduction of molybdenum tailings and waste soil particles, which improves the wear resistance, and the introduction of 9033 zirconium white frit improves the combination between particles, further improving the strength of the matrix. The compressive strength can reach 30Mpa, and the bending strength reaches 6.8Mpa.

[0116] Examples 8-1-8-2

[0117] Examples 8-1-8-2 use the same preparation process as Example 7, the only difference is that the decorative material is added based on the formula component of Example 7 (hereinafter referred to as Component C). The raw material composition of the decorative material is shown in the following table (in mass parts, unit: parts):

[0118] Raw material name Decoration 1 Decoration 2 9033 zircon white clinker 81 74 Calcined talc 6 8 Potassium feldspar 10 13 Bentonite 3 5 Body enhancer 0.5 0.5 Carbide silicon 0.08 0.25

[0119] The component ratio of Example 8-1-8-2 is shown in the following table:

[0120]

[0121] The properties of the foamed ceramics prepared in Examples 8-1 to 8-2 were detected, and the results are shown in Table 4.

[0122] Table 4

[0123]

[0124] The foamed ceramics prepared in Examples 8-1 to 8-2 were added with decorative materials, and the particle size of the powder of the decorative materials was controlled to be about 5 mm. After firing, the products had white shell-shaped large bubbles (as shown in Figure 1 Table 4), and had unique decorative effects. According to the adjustment of the component ratio of the foaming agent in the decorative materials, the size of the shell-shaped large bubbles after foaming could be adjusted to be between 5 mm and 30 mm. As can be seen from Table 4, the foamed ceramics prepared in Examples 8-1 to 8-2 also had the characteristics of high hardness and high strength, and in combination with the unique shell-shaped decorative effect, greatly expanded the application range.

[0125] Examples 9-1 to 9-3

[0126] Examples 9-1 to 9-3 used the same preparation process as Example 7, and the only difference was that functional materials were additionally added on the basis of Component C. The raw material composition of the functional materials is shown in the following table (in mass fraction, unit: parts):

[0127] Raw material name Functional material 1 Functional material 2 Functional material 3 Sodium sand 10 10 5 Extruded mud 50 50 35 Foamed ceramic waste (white) - 5 13 Potassium feldspar 5 5 10 ZR-14 whitening agent 3 3 - Attapulgite 35 30 35 Waste ceramic fiber paper 1 1 2 Liquid debonder 0.8 0.8 0.8 Oxidized manganese 0.25 0.25 0.25

[0128] Among them, ZR-14 whitening agent was purchased from Foshan Yuanda Glaze Co., Ltd.; Attapulgite is a crystalline hydrated magnesium aluminum silicate mineral, which is mined from Linze County, Gansu Province. Functional material 1 does not add foamed ceramic waste and does not have foaming effect, and functional material 2 adds a small amount of foamed ceramic waste and has a slight foaming effect.

[0129] The component ratio of Examples 9-1 to 9-3 is shown in the following table:

[0130]

[0131] The properties of the foamed ceramics prepared in Examples 9-1 to 9-3 were detected, and the results are shown in Table 5:

[0132] Table 5

[0133]

[0134] As can be seen from Table 5, after the introduction of the functional materials, the strength and hardness of the foamed ceramics were greatly improved. The density of the obtained foamed ceramics was in the range of 800 to 1000 kg / m 3 , the compressive strength was more than 30 MPa, and the highest reached 45 MPa; the bending strength was more than 8 MPa, and the highest reached 15 MPa.

[0135] Example 10

[0136] Example 10 adopts the same preparation process as Example 7, with the difference being that the raw material components are adjusted, and inorganic pigments are added to component A and component B, and low-temperature frits are mixed to improve the anti-fouling performance of the foamed ceramic. The specific component ratio is shown in the following table (in mass parts, unit: parts):

[0137] Raw material / component name Example 10 Component A 53 Component B 5 Brick red formula 13 Ochre formula 6 Beige formula 6 9033 zircon white clinker 17

[0138] Note: The particle size of 9033 zirconium white frit is 60-120 mesh.

[0139] The performance parameters of Example 10 were detected, and the results are shown in Table 6:

[0140] Table 6

[0141]

[0142] As can be seen from Table 6, the foamed ceramic of Example 10 has high hardness and compressive and bending strength, and by adding 9033 zirconium white frit for mixing and granulation, the sintering degree is higher, the out-of-kiln aperture is <0.5 mm, the anti-fouling performance is improved, and the surface of the fired product has shiny white granular points, which has certain decorative effect.

[0143] Example 11

[0144] Example 11 uses the same formula components as Example 10, with the difference being that the components of component A, component B, brick red formula, earth yellow formula, and rice yellow formula are mixed and granulated, and after the material distribution is completed, the zirconium white frit is prepared into dry powder particles and sprayed or scattered on the surface, and then enters the kiln for firing.

[0145] The performance parameters of Example 11 were detected, and the results are shown in Table 7:

[0146] Table 7

[0147]

[0148] As can be seen from Table 7, the foamed ceramic prepared in Example 11 has improved compressive and bending strength compared to Example 10. Since the 9033 zirconium white frit is directly scattered on the surface during the material distribution process, the surface of the fired product is overall shiny, and the sludge and dust covering the foamed ceramic surface layer can be easily washed clean with clean water, further improving the anti-fouling performance.

[0149] Example 12

[0150] Example 12 uses the same process parameters and preparation steps as Example 8-1, except that on the basis of the formulation of Example 8-1, the foamed ceramic powder of Example 8-1 is used as a surface decoration layer, and before the surface decoration layer powder is spread, a bottom foamed layer is first spread, and the raw material components of the bottom foamed layer are as shown in the following table in mass fraction:

[0151] Raw material name Bottom foamed layer 9033 zircon white clinker 5 Potassium feldspar 13 Extruded mud 61 Sodium sand 8 Calcined talc 8 Wollastonite 1 Cordierite 4 Carbide silicon 0.2 Body enhancer 0.3 Oxidized manganese 0.25 Liquid debonder 1.2

[0152] In the preparation step, the powder of the bottom foamed layer is first spread, with a thickness of 54 mm, and then leveled; then the foamed ceramic powder in Example 8-1 is spread, with a thickness of 4 mm. After firing, two foamed ceramic boards with different effects can be obtained, the bottom layer is a conventional foamed ceramic, and the surface layer is a foamed ceramic with a shell-shaped decorative effect; by cutting along the middle line, two kinds of foamed ceramic boards can be obtained, while saving the amount of surface decoration layer, saving the firing cost, and applying two kinds of boards to different scenes at one time, improving the utilization rate of the kiln.

[0153] The above description is only the preferred embodiments of the present application, and does not limit the patent scope of the present application, and any equivalent structural transformation made by using the content of the present application, or direct / indirect application in other related technical fields is included in the patent protection scope of the present application.

Claims

1. A high-strength foamed ceramic, characterized in that, By weight, it shall include at least one of the following formulation systems: Component 1: Sodium sand 5-15 parts, pressed mud 40-65 parts, ceramic fiber 0-3 parts, calcined talc 5-10 parts, frit 0-8 parts, potassium feldspar 8-18 parts, cordierite 0-5 parts, wollastonite 0-3 parts, foaming agent 0.05-0.45 parts, manganese oxide 0.1-0.5 parts, liquid deflocculant 0.5-1.5 parts, green body reinforcing agent 0-0.5 parts; or, Component 2: 0-10 parts sand, 10-30 parts mine tailings, 10-25 parts pressed mud, 0-10 parts glass tailings, 10-22 parts waste soil, 5-40 parts black foamed ceramic waste, 4-6 parts magnesia clay, 0.05-0.45 parts foaming agent, 0.1-0.5 parts manganese oxide, 0.5-1.5 parts liquid degumming agent, and 0-0.5 parts body strengthening agent; The production process of the high-strength foamed ceramic includes the following steps: (1) Preparation of high-strength foamed ceramic powder: After mixing the foamed ceramic raw materials in proportion, the mixture is ball-milled into a slurry and spray-granulated to obtain high-strength foamed ceramic powder; (2) Spread the high-strength foamed ceramic powder in the refractory kiln furniture according to the preset thickness and scrape it level; (3) The product is sent into 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 refractory kiln furniture is removed to obtain the high-strength foamed ceramic. Based on the total amount of the high-strength foamed ceramic powder, the high-strength foamed ceramic powder also includes 15-30% anti-fouling material; the anti-fouling material is at least one of low-temperature glaze powder, frit dry granules, and glass powder.

2. The high-strength foamed ceramic as described in claim 1, characterized in that, The raw material components of the high-strength foamed ceramic also include abrasive materials and / or known inorganic colorants. The abrasive materials include at least one of metal tailings, construction waste, sand and gravel tailings, ceramic waste particles, ceramic powder particles, high-temperature frit particles, and metal smelting slag.

3. The high-strength foamed ceramic as described in claim 2, characterized in that, The metal tailings are molybdenum tailings, copper tailings, iron tailings, and lithium tailings.

4. A high-strength foamed ceramic as described in claim 2, characterized in that, Based on the total amount of raw materials for the high-strength foamed ceramic, the wear-resistant material accounts for 10-35%.

5. A production process for high-strength foamed ceramics as described in any one of claims 1 to 4, characterized in that, Includes the following steps: (1) Preparation of high-strength foamed ceramic powder: After mixing the foamed ceramic raw materials in proportion, the mixture is ball-milled into a slurry and spray-granulated to obtain high-strength foamed ceramic powder; (2) Spread the high-strength foamed ceramic powder in the refractory kiln furniture according to the preset thickness and scrape it level; (3) The product is sent into 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 refractory kiln furniture is removed to obtain the high-strength foamed ceramic.

6. The production process of high-strength foamed ceramics as described in claim 5, characterized in that, Based on the total amount of the high-strength foamed ceramic powder, the high-strength foamed ceramic powder further includes 5-10% decorative material; the decorative material, by mass parts, includes the following components: 65-85 parts of 9033 zircon white frit, 5-10 parts of calcined talc, 10-20 parts of potassium feldspar, 3-8 parts of bentonite, 0-0.5 parts of green body reinforcing agent, and 0.05-0.3 parts of foaming agent.

7. The production process of high-strength foamed ceramics as described in claim 5, characterized in that, Based on the total amount of the high-strength foamed ceramic powder, the high-strength foamed ceramic powder also includes 35% to 100% functional material; the functional material contains attapulgite, and by mass percentage, the attapulgite accounts for 25% to 50% of the total weight of the functional material.

8. The production process of high-strength foamed ceramics as described in claim 7, characterized in that, The functional material, by weight, comprises the following components: 30-60 parts of pressed mud, 8-12 parts of sodium sand, 0-40 parts of white foamed ceramic waste, 5-15 parts of potassium feldspar, 0-5 parts of ZR-14 whitening agent, 25-45 parts of attapulgite, 0-2 parts of waste ceramic fiber paper, 0.5-1.5 parts of liquid degumming agent, and 0-0.3 parts of manganese oxide.

9. The production process of high-strength foamed ceramics as described in claim 5, characterized in that, In step (2), a layer of conventional foamed ceramic powder is first spread before spreading high-strength foamed ceramic powder.

10. The production process of high-strength foamed ceramics as described in claim 5, characterized in that, The process parameters of the high-strength foamed ceramic powder are as follows: green strength of powder ≥1.3 MPa, moisture content of powder 5.5-6.0%, bulk density 0.87-0.88 g / ml, and powder particles of 20 mesh and 100 mesh ≤1.5% respectively.

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