Sanitary ceramic material, sanitary ceramic and method for the production thereof

Abstract

This application relates to a sanitary ceramic material, a sanitary ceramic, and a method for preparing the same. The sanitary ceramic material comprises, by weight percentage: 57%–62% modified sanitary ceramic powder, 37%–41% organosilicon gel, and 1%–2% catalyst; wherein the modified sanitary ceramic powder comprises sanitary ceramic powder and a first silane coupling agent, the first silane coupling agent comprising 2%–3% by weight in the modified sanitary ceramic powder; the organosilicon gel comprises, by weight percentage: 57%–65% organosiloxane, 20%–25% second silane coupling agent, and 15%–19% solvent. The above-mentioned sanitary ceramic material can be used to prepare sanitary ceramics, improving the strength of sanitary ceramics and reducing the deformation rate.

Description

Technical Field

[0001] This application relates to the field of sanitary ceramics, and in particular to a sanitary ceramic material, sanitary ceramics, and a method for preparing the same. Background Technology

[0002] Miniature sanitary ceramics are sanitary ceramics whose shape and structure are scaled down to a small model (e.g., approximately 20cm in length and 10cm in width). These miniature sanitary ceramics are not only lightweight and small, but their internal structure is also clearly visible, allowing them to be held in one's hand for display. Traditional sanitary ceramics, on the other hand, are typically produced using a slip-casting process. However, the slip has a high water content and low density, resulting in low strength, significant shrinkage, and easy deformation during sintering. This leads to poor dimensional accuracy, making it difficult to produce miniature sanitary ceramics, such as miniature toilets. Summary of the Invention

[0003] Based on this, one aspect of this application provides a sanitary ceramic material that can be used to prepare sanitary ceramics, thereby improving the strength of sanitary ceramics and reducing the deformation rate.

[0004] In addition, this application also provides a sanitary ceramic and a method for preparing the same.

[0005] A sanitary ceramic material, by weight percentage, comprises: 57%~62% modified sanitary ceramic powder, 37%~41% organosilicon gel, and 1%~2% catalyst;

[0006] The modified sanitary ceramic powder comprises sanitary ceramic powder and a first silane coupling agent, wherein the first silane coupling agent comprises 2% to 3% by mass in the modified sanitary ceramic powder;

[0007] The organosilicon gel comprises, by mass percentage, the following components: 57% to 65% organosiloxane, 20% to 25% second silane coupling agent, and 15% to 19% solvent.

[0008] Optionally, the organosiloxane includes one or more of tetraethoxysilane, methyltriethoxysilane, and phenyltrimethoxysilane.

[0009] Optionally, the organosilicon gel comprises, by mass percentage, the following components: 35%–40% tetraethoxysilane, 22%–26% methyltriethoxysilane, 20%–25% disilane coupling agent, and 15%–19% solvent.

[0010] Optionally, the modified sanitary ceramic powder comprises, by mass percentage, the following components: 25%~29% ceramic frit, 43%~49% quartz, 10%~15% kaolin, 4.5%~8% alumina, 2%~3.5% dolomite, 2%~4% zirconium oxide, and 2%~3% first silane coupling agent;

[0011] The chemical composition of the ceramic frit, by mass percentage, includes: 63.3% SiO2, 12.7% Al2O3, 13.5% CaO, 2.1% MgO, 4.5% ZnO, 2.8% K2O, and 1.1% Na2O.

[0012] Optionally, the first silane coupling agent and the second silane coupling agent are each independently selected from one or more of KH-560, KH-570 and KH-550.

[0013] Optionally, the catalyst comprises one or more of tetramethylethylenediamine, tetramethylammonium hydroxide, and dibutyltin dilaurate.

[0014] A method for preparing sanitary ceramics includes the following steps:

[0015] Sanitary ceramic material is shaped and cross-linked and cured with organosilicon gel to prepare a green body. The sanitary ceramic material is a freshly prepared slurry or a pre-made slurry, and its composition is as described above.

[0016] The green body is sintered to prepare sanitary ceramics.

[0017] Optionally, the step of molding the sanitary ceramic material includes: injecting the sanitary ceramic material into a mold, heating it at 50°C to 60°C for 2 to 3 hours, and demolding it after cooling.

[0018] Optionally, in the step of crosslinking and curing the organosilicon gel, the temperature is 200℃~220℃ and the time is 1.5h~2h.

[0019] Optionally, in the step of sintering the green body, the sintering temperature is 1230℃~1240℃ and the time is 15h~17h.

[0020] Optionally, before the step of sintering the green body, the method further includes heating the green body to 550°C to 650°C at a heating rate of 0.3°C / h to 0.5°C / h and holding it at that temperature for 2h to 3h to remove the binder.

[0021] A sanitary ceramic, wherein the chemical composition of the sanitary ceramic, by mass percentage, comprises: SiO2 60.8%~64.3%, Al2O3 20.6%~25.5%, CaO 0.9%~2.1%, MgO 0.2%~1.1%, K2O 1.2%~2.9%, Na2O 0.9%~1.5%, ZnO 0.5%~1.2%, and ZrO2 1.5%~3.5%;

[0022] The sanitary ceramic has a deformation rate of 0.3%~0.7% and a dry flexural strength of 660 N / cm. 2 ~816N / cm 2 .

[0023] Optionally, the sanitary ceramic is prepared by the above-described preparation method.

[0024] Optionally, the sanitary ceramics include a toilet.

[0025] The aforementioned sanitary ceramic material comprises modified sanitary ceramic powder, organosilicon gel, and a catalyst in a specific ratio. Surface modification is achieved by adding a certain amount of a first silane coupling agent to the modified sanitary ceramic powder, improving the compatibility between the powder and the organosilicon gel, increasing the solid content, thereby reducing shrinkage of the green body and improving the dimensional accuracy of small-sized sanitary ceramics. Introducing organosilicon gel into the sanitary ceramic material allows for injection molding, where the organosilicon gel cross-links and polymerizes into a three-dimensional network structure under the action of a catalyst, forming the ceramic green body in situ and improving its strength. Simultaneously, the sintering of the organosilicon gel yields the required silica component for sanitary ceramics, which, compared to other gel systems, helps reduce shrinkage and deformation. Therefore, the aforementioned sanitary ceramic material can be used to prepare sanitary ceramics, improving their strength, reducing deformation rates, and is beneficial for producing smaller versions of sanitary ceramics. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a process flow diagram of a method for preparing sanitary ceramic materials in some embodiments of this application;

[0028] Figure 2 This is a process flow diagram of a method for preparing sanitary ceramics in some embodiments of this application;

[0029] Figure 3This is a physical image of a sanitary ceramic in some embodiments of this application. Detailed Implementation

[0030] To facilitate understanding of this application, a more comprehensive description of the application will be provided below in conjunction with specific embodiments. Preferred embodiments of the application are given in the specific embodiments. However, this application can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of this application.

[0031] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein in the specification of this application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application.

[0032] Unless otherwise stated or in case of conflict, the terms or phrases used in this application shall have the following meanings:

[0033] In this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" and "second" may explicitly or implicitly include at least one of those features.

[0034] In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise expressly and specifically limited.

[0035] In this application, "one or more" refers to any one, any two, or any two or more of the listed items. "Several" refers to any two or more.

[0036] Unless otherwise specified, all percentage concentrations mentioned in this application refer to the final concentration. The final concentration refers to the proportion of the added component in the system after the addition of that component.

[0037] The terms "optionally" and similar expressions used in this application refer to embodiments of this application that may provide certain beneficial effects under certain circumstances. However, other embodiments may also be optional in the same or other circumstances. Furthermore, the description of one or more optional embodiments does not imply that other embodiments are unavailable, nor is it intended to exclude other embodiments from the scope of this application.

[0038] When a numerical range is disclosed in this application, the range is considered continuous and includes the minimum and maximum values ​​of the range, as well as every value between the minimum and maximum values. Furthermore, when the range refers to an integer, it includes every integer between the minimum and maximum values ​​of the range. Additionally, when multiple ranges are provided to describe a feature or characteristic, the ranges may be merged. In other words, unless otherwise specified, all ranges disclosed in this application should be understood to include any and all subranges to which they are included.

[0039] In this application, the technical features described in an open-ended manner include both closed technical solutions consisting of the listed features and open technical solutions that include the listed features.

[0040] The terms "comprising" and "having," and any variations thereof, used in the embodiments of this application, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to the steps or units listed, but may optionally include steps or units not listed, or may optionally include other steps or components inherent to such processes, methods, products, or devices.

[0041] In this application, the reference to "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a mutually exclusive, independent, or alternative embodiment. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described in this application can be combined with other embodiments.

[0042] The first aspect of this application provides a sanitary ceramic material, comprising, by weight percentage: 57%~62% modified sanitary ceramic powder, 37%~41% organosilicon gel, and 1%~2% catalyst;

[0043] The modified sanitary ceramic powder includes sanitary ceramic powder and a first silane coupling agent, wherein the mass percentage of the first silane coupling agent in the modified sanitary ceramic powder is 2% to 3%.

[0044] The organosilicon gel comprises, by mass percentage, the following components: 57%–65% organosiloxane, 20%–25% second silane coupling agent, and 15%–19% solvent.

[0045] In some embodiments, the modified sanitary ceramic powder comprises, by mass percentage: 25%–29% ceramic frit, 43%–49% quartz, 10%–15% kaolin, 4.5%–8% alumina, 2%–3.5% dolomite, 2%–4% zirconium oxide, and 2%–3% first silane coupling agent;

[0046] The chemical composition of the ceramic frit, by mass percentage, includes: 63.3% SiO2, 12.7% Al2O3, 13.5% CaO, 2.1% MgO, 4.5% ZnO, 2.8% K2O, and 1.1% Na2O.

[0047] In an optional example, the mass percentage of ceramic frit in the modified sanitary ceramic powder may be, but is not limited to, 25%, 25.5%, 26%, 26.5%, 27%, 27.5%, 28%, 28.5%, 29%, or any combination of these values. Introducing ceramic frit into the modified sanitary ceramic powder can lower the sintering temperature. Furthermore, due to the high silica and alumina content of the ceramic frit, the fired sanitary ceramic exhibits higher hardness and strength.

[0048] In an optional example, the mass percentage of quartz in the modified sanitary ceramic powder may be, but is not limited to, 43%, 44%, 45%, 46%, 47%, 48%, 49%, or a range of any two of these values.

[0049] In an optional example, the mass percentage of kaolin in the modified sanitary ceramic powder may be, but is not limited to, 10%, 11%, 12%, 13%, 14%, 15%, or a range of any two of these values.

[0050] In an optional example, the mass percentage of alumina in the modified sanitary ceramic powder may be, but is not limited to, 4.5%, 5%, 5.5%, 6%, 6.5%, 7%, 7.5%, 8%, or a range of any two of these values.

[0051] In an optional example, the mass percentage of dolomite in the modified sanitary ceramic powder may be, but is not limited to, 2%, 2.2%, 2.4%, 2.5%, 2.6%, 2.8%, 3%, 3.2%, 3.5%, or a range of any two of these values.

[0052] In an optional example, the mass percentage of zirconium oxide in the modified sanitary ceramic powder may be, but is not limited to, 2%, 2.2%, 2.4%, 2.5%, 2.6%, 2.8%, 3%, 3.2%, 3.5%, 3.8%, 4%, or any combination of these values.

[0053] In an optional example, the mass percentage of the second silane coupling agent in the modified sanitary ceramic powder may be, but is not limited to, 2%, 2.2%, 2.4%, 2.5%, 2.6%, 2.8%, 3%, or any combination of these values.

[0054] In some embodiments, the first silane coupling agent includes one or more of KH570, KH560, and KH-550.

[0055] In some embodiments, the average particle size of the modified sanitary ceramic powder is 0.1 μm to 0.2 μm. For example, the average particle size of the modified sanitary ceramic powder may be, but is not limited to, 0.1 μm, 0.12 μm, 0.14 μm, 0.16 μm, 0.18 μm, 0.2 μm, 0.1 μm, or any combination of these values.

[0056] By adding a certain amount of first silane coupling agent to the modified sanitary ceramic powder for surface modification, the compatibility between the modified sanitary ceramic powder and organosilicon gel is improved, the solid content is increased, and the ester absorption rate of the modified sanitary ceramic powder is reduced, thereby reducing the shrinkage of the green body and improving the dimensional accuracy of small-sized sanitary ceramics.

[0057] In an optional example, the mass percentage of modified sanitary ceramic powder in the sanitary ceramic material may be, but is not limited to, 57%, 57.5%, 58%, 58.5%, 59%, 59.5%, 60%, 60.5%, 61%, 61.5%, 62%, or any combination of these values.

[0058] In an optional example, the mass percentage of organosiloxane in the silicone gel may be, but is not limited to, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, or a range of any two of these values.

[0059] In some embodiments, organosiloxanes include one or more of tetraethoxysilane, methyltriethoxysilane, and phenyltrimethoxysilane.

[0060] In an optional example, the mass percentage of the second silane coupling agent in the silicone gel may be, but is not limited to, 20%, 20.5%, 21%, 21.5%, 22%, 22.5%, 23%, 23.5%, 24%, 24.5%, 25%, or any combination of these values.

[0061] In some embodiments, the second silane coupling agent includes one or more of KH-560, KH-570, and KH-550. It is understood that the second silane coupling agent may be the same as or different from the first silane coupling agent. Adding a second silane coupling agent to the organosilicon gel can achieve a better coupling effect on organosiloxanes.

[0062] In an optional example, the mass percentage of the solvent in the silicone gel may be, but is not limited to, 15%, 15.5%, 16%, 16.5%, 17%, 17.5%, 18%, 18.5%, 19%, or a range of any two of these values.

[0063] In some embodiments, the solvent includes one or more of ethanol, toluene, and n-butanol.

[0064] In some embodiments, the silicone gel comprises, by mass percentage, the following components: 35%–40% tetraethoxysilane, 22%–26% methyltriethoxysilane, 20%–25% disilane coupling agent, and 15%–19% solvent.

[0065] In an optional example, the mass percentage of tetraethoxysilane in the silicone gel may be, but is not limited to, 35%, 35.5%, 36%, 36.5%, 37%, 37.5%, 38%, 38.5%, 39%, 39.5%, 40%, or a range of any two of these values.

[0066] In an optional example, the mass percentage of methyltriethoxysilane in the silicone gel may be, but is not limited to, 22%, 22.5%, 23%, 23.5%, 24%, 24.5%, 25%, 25.5%, 26%, or any combination of these values.

[0067] In one embodiment, the silicone gel comprises, by mass percentage, the following components: 35% to 40% tetraethoxysilane, 22% to 26% methyltriethoxysilane, 20% to 25% disilane coupling agent, and 15% to 19% ethanol.

[0068] By introducing organosilicon gel into sanitary ceramic materials, injection molding can be performed, and the cross-linked polymer can form a three-dimensional network structure, which can fix the ceramic body in situ and improve the strength of the body. In addition, after sintering, the organosilicon gel can obtain the silicon oxide component required for sanitary ceramics, reducing product deformation.

[0069] In an optional example, the mass percentage of silicone gel in the sanitary ceramic material may be, but is not limited to, 37%, 37.5%, 38%, 38.5%, 39%, 39.5%, 40%, 40.5%, 41%, or a range of any two of these values.

[0070] In an optional example, the mass percentage of the catalyst in the sanitary ceramic material may be, but is not limited to, 1%, 1.2%, 1.4%, 1.5%, 1.6%, 1.8%, 2%, or a range of any two of these values.

[0071] In some embodiments, the catalyst includes one or more of tetramethylethylenediamine, tetramethylammonium hydroxide, and dibutyltin dilaurate.

[0072] Currently, common sanitary ceramics on the market, such as toilets, are typically 65cm × 34cm × 74cm in size. This large size makes them inconvenient to carry and obscures the internal structure, hindering effective demonstration. Therefore, a smaller model (approximately 20cm long and 10cm wide) can be created to scale down the toilet's shape and structure. This smaller model is lightweight, compact, and allows for clear visualization of the internal structure, facilitating easy display. However, traditional sanitary ceramics are usually produced using slip casting. When manufacturing smaller versions of sanitary ceramics, such as smaller toilets, the resulting materials suffer from low strength, significant shrinkage, easy deformation, and poor dimensional accuracy. In contrast, the sanitary ceramic materials provided in some embodiments of this application incorporate organosilicon gel, enabling injection molding and cross-linking polymerization into a three-dimensional network structure. This allows for in-situ shaping of the ceramic body, improving its strength. Furthermore, the organosilicon gel, after sintering, yields the required silica content for sanitary ceramics, reducing product deformation. By adding a first silane coupling agent to the modified sanitary ceramic powder for surface modification, the ester absorption rate is reduced and the solid content is increased, thereby further reducing the shrinkage of the green body and improving the dimensional accuracy of small-sized sanitary ceramics. In addition, the introduction of ceramic frit into the modified sanitary ceramic powder can lower the sintering temperature. Furthermore, since the ceramic frit has a high silica and alumina content, the fired sanitary ceramics have high hardness and strength.

[0073] In some embodiments, the preparation steps of the sanitary ceramic material include: mixing and ball milling 57%~62% modified sanitary ceramic powder, 37%~41% organosilicon gel and 1%~2% catalyst by mass percentage to prepare the sanitary ceramic material.

[0074] In some of these embodiments, please refer to Figure 1 The preparation steps of sanitary ceramic materials include:

[0075] Step S110: Based on the mass percentage of the modified sanitary ceramic powder as 100%, 25%~29% ceramic frit, 43%~49% quartz, 10%~15% kaolin, 4.5%~8% alumina, 2%~3.5% dolomite, 2%~4% zirconium oxide and 2%~3% first silane coupling agent are mixed and ball-milled to prepare the modified sanitary ceramic powder.

[0076] Specifically, in step S110, the mixing and ball milling time can be, but is not limited to, 1.5h to 2h.

[0077] In a specific example, the mixing and milling step can be, but is not limited to, performed in a planetary ball mill.

[0078] Step S120: Based on the total mass percentage of the organosilicon gel being 100%, mix 57%~65% organosiloxane, 20%~25% second silane coupling agent and 15%~19% solvent to prepare organosilicon gel.

[0079] Step S130: By mass percentage, 57%~62% of modified sanitary ceramic powder, 37%~41% of organosilicon gel and 1%~2% of catalyst are mixed and ball-milled to prepare sanitary ceramic material.

[0080] Specifically, in step S130, the mixing and ball milling time can be, but is not limited to, 6h~8h.

[0081] Specifically, in step S130, after ball milling, a vacuum degassing step is also included.

[0082] The second aspect of this application provides a method for preparing sanitary ceramics, comprising the following steps:

[0083] The sanitary ceramic material is shaped and the organosilicon gel is cross-linked and cured to prepare a green body. The sanitary ceramic material is a freshly prepared slurry or a pre-made slurry, and its composition is as described above.

[0084] The green body is sintered to prepare sanitary ceramics.

[0085] In some embodiments, the step of molding sanitary ceramic material includes: injecting sanitary ceramic material into a mold, heating it at 50°C to 60°C for 2 to 3 hours, and demolding it after cooling.

[0086] In some embodiments, the temperature for crosslinking and curing the silicone gel is 200°C to 220°C, and the time is 1.5h to 2h. For example, the crosslinking and curing temperature may be, but is not limited to, 200°C, 202°C, 205°C, 208°C, 210°C, 212°C, 215°C, 218°C, 220°C, or any combination of these values.

[0087] In some embodiments, the steps of molding sanitary ceramic material and cross-linking and curing the organosilicon gel to prepare the green body include: injecting the sanitary ceramic material into a mold, heating it at 50°C to 60°C for 2 to 3 hours, cooling it and demolding it, drying it at 50°C to 60°C, and heating it to 200°C to 220°C and holding it therefore for 1.5 to 2 hours after it is completely dry, so as to cross-link and cure the organosilicon gel to prepare the green body.

[0088] As can be understood, in this article, "completely dry" means that the difference between two consecutive weighings is less than 0.1%.

[0089] In some embodiments, during the sintering step of the green body, the sintering temperature is 1230℃~1240℃ and the time is 15h~17h.

[0090] In a specific example, the sintering temperature may be, but is not limited to, 1230°C, 1230°C, 1230°C, 1230°C, 1230°C, 1230°C, 1230°C, 1230°C, 1230°C, 1230°C, or any combination of these values. The sintering time may be, but is not limited to, 15h, 15.5h, 16h, 16.5h, 17h, or any combination of these values.

[0091] In some embodiments, the sintering step of the green body can be, but is not limited to, carried out in a tunnel kiln.

[0092] In some embodiments, prior to the sintering step of the green body, a step of removing the binder from the green body is further included. Specifically, the green body is heated to 550°C to 650°C at a heating rate of 0.3°C / h to 0.5°C / h and held at that temperature for 2h to 3h.

[0093] In one optional example, the discharge temperature may be, but is not limited to, 550°C, 560°C, 580°C, 600°C, 610°C, 630°C, 650°C, or a range of any two of these values.

[0094] In some embodiments, after the step of removing the binder from the green body and before the step of sintering the green body, a glazing step is also included. Specifically, the glazing method may be, but is not limited to, spraying glaze with a spray gun, so that the glaze thickness in the green state is controlled within the range of 0.15mm to 0.5mm.

[0095] It is understood that the above only provides one commonly used glazing method, but it is not limited to this. Other glazing methods in this field can also be used, and no particular limitation is made here.

[0096] Please see Figure 2 In some embodiments, the preparation steps of sanitary ceramics include:

[0097] Step S210: Inject the sanitary ceramic material into the mold, heat it at 50℃~60℃ for 2h~3h, cool it and demold it, dry it at 50℃~60℃, and after it is completely dry, heat it to 200℃~220℃ and keep it at that temperature for 1.5~2h to allow the organosilicon gel to crosslink and solidify, thus preparing the green body.

[0098] Step S220: Heat the blank to 550℃~650℃ at a heating rate of 0.3℃ / h~0.5℃ / h, hold for 2h~3h, and then remove the glue.

[0099] Step S230: Apply glaze to the blank after debinding.

[0100] Step S240: Sinter the glazed body at 1230℃~1240℃ for 15h~17h to prepare sanitary ceramics.

[0101] The above-mentioned method for preparing sanitary ceramics is simple and easy to industrialize.

[0102] A third aspect of this application provides a sanitary ceramic, the chemical composition of which, by weight percentage, comprises:

[0103] SiO260.8%~64.3%, Al2O320.6%~25.5%, CaO 0.9%~2.1%, MgO 0.2%~1.1%, K2O 1.2%~2.9%, Na2O 0.9%~1.5%, ZnO 0.5%~1.2% and ZrO2 1.5%~3.5%;

[0104] The sanitary ceramic has a deformation rate of 0.3%~0.7% and a dry flexural strength of 660 N / cm. 2 ~816N / cm 2 .

[0105] Optionally, the deformation rate of the sanitary ceramics is 0.3%~0.4%, and the flexural strength of the dry blank is 809 N / cm. 2 ~816N / cm 2 .

[0106] In some embodiments, the sanitary ceramics are prepared by the sanitary ceramics preparation method described in the second aspect above.

[0107] In some embodiments, sanitary ceramics may be, but are not limited to, toilets. The toilets are relatively small in size, for example, 20cm in length and 10cm in width, for ease of demonstration. Please refer to [link / reference]. Figure 3 , Figure 3 This is a physical image of a sanitary ceramic prepared in some embodiments of this application.

[0108] In other embodiments, sanitary ceramics can also be washbasins, urinals, bidets, etc.

[0109] A fourth aspect of this application provides a sanitary appliance comprising the aforementioned sanitary ceramics.

[0110] To make the objectives and advantages of this application clearer, the sanitary ceramics and their effects of this application are further described in detail below with reference to specific embodiments. It should be understood that the specific embodiments described herein are only for explaining this application and should not be used to limit this application. Unless otherwise specified, the following embodiments do not include components other than unavoidable impurities. Unless otherwise specified, the drugs and instruments used in the embodiments are conventional choices in the art. Experimental methods in the embodiments that do not specify specific conditions are implemented according to conventional conditions, such as those described in literature, books, or methods recommended by the manufacturer.

[0111] Example 1

[0112] This embodiment provides a sanitary ceramic product, the preparation steps of which are as follows:

[0113] (1) Preparation of modified sanitary ceramic powder

[0114] The following components were added to the planetary ball mill by weight percentage: 28% ceramic frit, 47% quartz, 12% kaolin, 5.5% alumina, 2.5% dolomite, 3% zirconium oxide, and 2% silane coupling agent KH-570. The ball mill was started and the mixture was ball-milled for 1.7 hours. After drying, modified sanitary ceramic powder with an average particle size of 0.15 μm was obtained.

[0115] (2) Preparation of organosilicon gel solution

[0116] The following components were added to the reactor by weight percentage: 37% tetraethoxysilane, 24% methyltriethoxysilane, 22% silane coupling agent KH-560, and 17% ethanol. The mixture was stirred until homogeneous to obtain an organosilicon gel solution.

[0117] (3) Preparation of sanitary ceramic materials

[0118] The following components were added to a planetary ball mill by weight percentage: 60.5% modified sanitary ceramic powder, 38% organosilicon gel solution and 1.5% tetramethylethylenediamine. The ball mill was turned on and the mixture was ball-milled for 7 hours. After vacuum degassing, the sanitary ceramic material was obtained.

[0119] (4) Preparation of raw blank

[0120] The above-mentioned sanitary ceramic material is injected into the mold, slowly heated to 55℃ and kept at that temperature for 2.5 hours. After natural cooling and demolding, it is dried in an oven at 55℃. After it is completely dry, it is heated to 210℃ and kept at that temperature for 1.8 hours to allow the organosilicon gel to crosslink and solidify, thus obtaining the green body.

[0121] (5) De-glue

[0122] The above-mentioned green blank is debonded in a box furnace, wherein the debonding temperature is 600℃, the heating rate is 0.4℃ / h, and the holding time is 2h.

[0123] (6) Glazing

[0124] After removing the glue, the unglazed body is glazed using a spray gun, so that the glaze thickness in the unglazed state is controlled within the range of 0.15-0.5mm.

[0125] (7) Sintering

[0126] The sanitary ceramics of this embodiment were obtained by firing in a tunnel kiln at 1235°C for 16 hours.

[0127] Example 2

[0128] This embodiment provides a sanitary ceramic product, the preparation steps of which are as follows:

[0129] (1) Preparation of modified sanitary ceramic powder

[0130] The following components were added to the planetary ball mill by weight percentage: 25% ceramic frit, 49% quartz, 10% kaolin, 8% alumina, 2% dolomite, 4% zirconium oxide and 2% silane coupling agent KH-570. The ball mill was turned on and ball milled for 2 hours. After drying, modified sanitary ceramic powder with an average particle size of 0.10 μm was obtained.

[0131] (2) Preparation of organosilicon gel solution

[0132] The following components were added to the reactor by weight percentage: 40% tetraethoxysilane, 25% methyltriethoxysilane, 20% silane coupling agent KH-560, and 15% ethanol. The mixture was stirred until homogeneous to obtain an organosilicon gel solution.

[0133] (3) Preparation of sanitary ceramic materials

[0134] The following components were added to a planetary ball mill by weight percentage: 62% modified sanitary ceramic powder, 37% organosilicon gel solution and 1% tetramethylethylenediamine. The ball mill was turned on and the mixture was ball-milled for 8 hours. After vacuum degassing, the sanitary ceramic material was obtained.

[0135] (4) Preparation of raw blank

[0136] The above-mentioned sanitary ceramic material is injected into the mold, slowly heated to 60°C and kept at that temperature for 2 hours. After natural cooling and demolding, it is dried in an oven at 60°C. After it is completely dry, it is heated to 200°C and kept at that temperature for 2 hours to allow the organosilicon gel to crosslink and solidify, thus obtaining the raw blank.

[0137] (5) De-glue

[0138] The above-mentioned green blank is debonded in a box furnace, wherein the debonding temperature is 650℃, the heating rate is 0.5℃ / h, and the holding time is 2h.

[0139] (6) Glazing

[0140] After removing the glue, the unglazed body is glazed using a spray gun, so that the glaze thickness in the unglazed state is controlled within the range of 0.15-0.5mm.

[0141] (7) Sintering

[0142] The sanitary ceramics of this embodiment were obtained by firing in a tunnel kiln at 1240°C for 15 hours.

[0143] Example 3

[0144] This embodiment provides a sanitary ceramic product, the preparation steps of which are as follows:

[0145] (1) Preparation of modified sanitary ceramic powder

[0146] The following components were added to the planetary ball mill by weight percentage: 29% ceramic frit, 43% quartz, 15% kaolin, 4.5% alumina, 3.5% dolomite, 2% zirconium oxide, and 3% silane coupling agent KH-570. The ball mill was started and the mixture was ball-milled for 1.5 hours. After drying, modified sanitary ceramic powder with an average particle size of 0.20 μm was obtained.

[0147] (2) Preparation of organosilicon gel solution

[0148] The following components were added to the reactor by weight percentage: 35% tetraethoxysilane, 22% methyltriethoxysilane, 24% silane coupling agent KH-560 and 19% ethanol. The mixture was stirred until homogeneous to obtain an organosilicon gel solution.

[0149] (3) Preparation of sanitary ceramic materials

[0150] The following components were added to a planetary ball mill by weight percentage: 57% modified sanitary ceramic powder, 41% organosilicon gel solution and 2% tetramethylethylenediamine. The ball mill was turned on and the mixture was ball-milled for 6 hours. After vacuum degassing, the sanitary ceramic material was obtained.

[0151] (4) Preparation of raw blank

[0152] The above-mentioned sanitary ceramic material is injected into the mold, slowly heated to 50°C and kept at that temperature for 3 hours. After natural cooling and demolding, it is dried in an oven at 50°C. After it is completely dry, it is heated to 220°C and kept at that temperature for 1.5 hours to allow the organosilicon gel to crosslink and solidify, thus obtaining the green body.

[0153] (5) De-glue

[0154] The above-mentioned green blank is debonded in a box furnace, wherein the debonding temperature is 550℃, the heating rate is 0.3℃ / h, and the holding time is 2h.

[0155] (6) Glazing

[0156] After removing the glue, the unglazed body is glazed using a spray gun, so that the glaze thickness in the unglazed state is controlled within the range of 0.15-0.5mm.

[0157] (7) Sintering

[0158] The sanitary ceramics of this embodiment were obtained by firing in a tunnel kiln at 1230°C for 17 hours.

[0159] Example 4

[0160] This embodiment provides a sanitary ceramic product, the preparation steps of which are as follows:

[0161] (1) Preparation of modified sanitary ceramic powder

[0162] The following components were added to the planetary ball mill by weight percentage: 21% ceramic frit, 47% quartz, 15% kaolin, 8% alumina, 3.5% dolomite, 3.5% zirconium oxide, and 2% silane coupling agent KH-570. The ball mill was started and the mixture was ball-milled for 1.7 hours. After drying, modified sanitary ceramic powder with an average particle size of 0.15 μm was obtained.

[0163] (2) Preparation of organosilicon gel solution

[0164] The following components were added to the reactor by weight percentage: 37% tetraethoxysilane, 24% methyltriethoxysilane, 22% silane coupling agent KH-560, and 17% ethanol. The mixture was stirred until homogeneous to obtain an organosilicon gel solution.

[0165] (3) Preparation of sanitary ceramic materials

[0166] The following components were added to a planetary ball mill by weight percentage: 60.5% modified sanitary ceramic powder, 38% organosilicon gel solution and 1.5% tetramethylethylenediamine. The ball mill was turned on and the mixture was ball-milled for 7 hours. After vacuum degassing, the sanitary ceramic material was obtained.

[0167] (4) Preparation of raw blank

[0168] The above-mentioned sanitary ceramic material is injected into the mold, slowly heated to 55℃ and kept at that temperature for 2.5 hours. After natural cooling and demolding, it is dried in an oven at 55℃. After it is completely dry, it is heated to 210℃ and kept at that temperature for 1.8 hours to allow the organosilicon gel to crosslink and solidify, thus obtaining the green body.

[0169] (5) De-glue

[0170] The above-mentioned green blank is debonded in a box furnace, wherein the debonding temperature is 600℃, the heating rate is 0.4℃ / h, and the holding time is 2h.

[0171] (6) Glazing

[0172] After removing the glue, the unglazed body is glazed using a spray gun, so that the glaze thickness in the unglazed state is controlled within the range of 0.15-0.5mm.

[0173] (7) Sintering

[0174] The sanitary ceramics of this embodiment were obtained by firing in a tunnel kiln at 1235°C for 17 hours.

[0175] Example 5

[0176] This embodiment provides a sanitary ceramic product, the preparation steps of which are as follows:

[0177] (1) Preparation of modified sanitary ceramic powder

[0178] The following components were added to the planetary ball mill by weight percentage: 28% ceramic frit, 47% quartz, 12% kaolin, 5.5% alumina, 2.5% dolomite, 3% zirconium oxide, and 2% silane coupling agent KH-570. The ball mill was started and the mixture was ball-milled for 1.7 hours. After drying, modified sanitary ceramic powder with an average particle size of 0.15 μm was obtained.

[0179] (2) Preparation of organosilicon gel solution

[0180] The following components were added to the reactor by weight percentage: 57% methyltriethoxysilane, 24% silane coupling agent KH-560 and 19% ethanol. The mixture was stirred until homogeneous to obtain an organosilicon gel solution.

[0181] (3) Preparation of sanitary ceramic materials

[0182] The following components were added to a planetary ball mill by weight percentage: 60.5% modified sanitary ceramic powder, 38% organosilicon gel solution and 1.5% tetramethylethylenediamine. The ball mill was turned on and the mixture was ball-milled for 7 hours. After vacuum degassing, the sanitary ceramic material was obtained.

[0183] (4) Preparation of raw blank

[0184] The above-mentioned sanitary ceramic material is injected into the mold, slowly heated to 55℃ and kept at that temperature for 2.5 hours. After natural cooling and demolding, it is dried in an oven at 55℃. After it is completely dry, it is heated to 210℃ and kept at that temperature for 1.8 hours to allow the organosilicon gel to crosslink and solidify, thus obtaining the green body.

[0185] (5) De-glue

[0186] The above-mentioned green blank is debonded in a box furnace, wherein the debonding temperature is 600℃, the heating rate is 0.4℃ / h, and the holding time is 2h.

[0187] (6) Glazing

[0188] After removing the glue, the unglazed body is glazed using a spray gun, so that the glaze thickness in the unglazed state is controlled within the range of 0.15-0.5mm.

[0189] (7) Sintering

[0190] The sanitary ceramics of this embodiment were obtained by firing in a tunnel kiln at 1235°C for 16 hours.

[0191] Comparative Example 1

[0192] Comparative Example 1 provides a sanitary ceramic, the preparation steps of which are as follows:

[0193] (1) Preparation of sanitary ceramic powder

[0194] The following components were added to the planetary ball mill by weight percentage: 28% ceramic frit, 47% quartz, 12% kaolin, 6.5% alumina, 2.5% dolomite and 4% zirconium oxide. The ball mill was started and the mixture was ball-milled for 1.7 hours. After drying, sanitary ceramic powder with an average particle size of 0.15 μm was obtained.

[0195] (2) Preparation of organosilicon gel solution

[0196] The following components were added to the reactor by weight percentage: 37% tetraethoxysilane, 24% methyltriethoxysilane, 22% silane coupling agent KH-560, and 17% ethanol. The mixture was stirred until homogeneous to obtain an organosilicon gel solution.

[0197] (3) Preparation of sanitary ceramic materials

[0198] The following components were added to a planetary ball mill by weight percentage: 41% sanitary ceramic powder, 57.5% organosilicon gel solution and 1.5% tetramethylethylenediamine. The ball mill was turned on and the mixture was ball-milled for 7 hours. After vacuum degassing, the sanitary ceramic material was obtained.

[0199] (4) Preparation of raw blank

[0200] The above-mentioned sanitary ceramic material is injected into the mold, slowly heated to 55℃ and kept at that temperature for 2.5 hours. After natural cooling and demolding, it is dried in an oven at 55℃. After it is completely dry, it is heated to 210℃ and kept at that temperature for 1.8 hours to allow the organosilicon gel to crosslink and solidify, thus obtaining the green body.

[0201] (5) De-glue

[0202] The above-mentioned green blank is debonded in a box furnace, wherein the debonding temperature is 600℃, the heating rate is 0.4℃ / h, and the holding time is 2h.

[0203] (6) Glazing

[0204] After removing the glue, the unglazed body is glazed using a spray gun, so that the glaze thickness in the unglazed state is controlled within the range of 0.15-0.5mm.

[0205] (7) Sintering

[0206] The sanitary ceramics of Comparative Example 1 were obtained by firing in a tunnel kiln at 1235°C for 16 hours.

[0207] Comparative Example 2

[0208] Comparative Example 2 provides a sanitary ceramic, the preparation steps of which are as follows:

[0209] (1) Preparation of modified sanitary ceramic powder

[0210] The following components were added to the planetary ball mill by weight percentage: 28% ceramic frit, 47% quartz, 12% kaolin, 5.5% alumina, 2.5% dolomite, 3% zirconium oxide, and 2% silane coupling agent KH-570. The ball mill was started and the mixture was ball-milled for 1.7 hours. After drying, modified sanitary ceramic powder with an average particle size of 0.15 μm was obtained.

[0211] (2) Preparation of organosilicon gel solution

[0212] The following components were added to the reactor by weight percentage: 37% tetraethoxysilane, 24% methyltriethoxysilane, 22% silane coupling agent KH-560, and 17% ethanol. The mixture was stirred until homogeneous to obtain an organosilicon gel solution.

[0213] (3) Preparation of sanitary ceramic materials

[0214] The following components were added to a planetary ball mill by weight percentage: 68% modified sanitary ceramic powder, 30.5% organosilicon gel solution and 1.5% tetramethylethylenediamine. The ball mill was turned on and the mixture was ball-milled for 7 hours. After vacuum degassing, the sanitary ceramic material was obtained.

[0215] (4) Preparation of raw blank

[0216] The above-mentioned sanitary ceramic material is injected into the mold, slowly heated to 55℃ and kept at that temperature for 2.5 hours. After natural cooling and demolding, it is dried in an oven at 55℃. After it is completely dry, it is heated to 210℃ and kept at that temperature for 1.8 hours to allow the organosilicon gel to crosslink and solidify, thus obtaining the green body.

[0217] (5) De-glue

[0218] The above-mentioned green blank is debonded in a box furnace, wherein the debonding temperature is 600℃, the heating rate is 0.4℃ / h, and the holding time is 2h.

[0219] (6) Glazing

[0220] After removing the glue, the unglazed body is glazed using a spray gun, so that the glaze thickness in the unglazed state is controlled within the range of 0.15-0.5mm.

[0221] (7) Sintering

[0222] The sanitary ceramics of Comparative Example 2 were obtained by firing in a tunnel kiln at 1235°C for 16 hours.

[0223] Comparative Example 3

[0224] Comparative Example 3 provides a sanitary ceramic, the preparation steps of which are as follows:

[0225] (1) Preparation of modified sanitary ceramic powder

[0226] The following components were added to the planetary ball mill by weight percentage: 28% ceramic frit, 47% quartz, 12% kaolin, 5.5% alumina, 2.5% dolomite, 3% zirconium oxide, and 2% silane coupling agent KH-570. The ball mill was started and the mixture was ball-milled for 1.7 hours. After drying, modified sanitary ceramic powder with an average particle size of 0.15 μm was obtained.

[0227] (2) Preparation of ordinary gel solutions

[0228] The following components were added to the reactor by weight percentage: 20% acrylamide, 2% N,N-methylenebisacrylamide and 78% water. The mixture was stirred until homogeneous to obtain a common gel solution.

[0229] (3) Preparation of sanitary ceramic materials

[0230] The following components were added to a planetary ball mill by weight percentage: 60.5% modified sanitary ceramic powder, 38% ordinary gel solution and 1.5% tetramethylethylenediamine. The ball mill was turned on and the mixture was ball-milled for 7 hours. After vacuum degassing, the sanitary ceramic material was obtained.

[0231] (4) Preparation of raw blank

[0232] The above-mentioned sanitary ceramic material is injected into the mold, slowly heated to 55℃ and kept at that temperature for 2.5 hours. After natural cooling and demolding, it is dried in an oven at 55℃. After it is completely dry, it is heated to 210℃ and kept at that temperature for 1.8 hours to allow the organosilicon gel to crosslink and solidify, thus obtaining the green body.

[0233] (5) De-glue

[0234] The above-mentioned green blank is debonded in a box furnace, wherein the debonding temperature is 600℃, the heating rate is 0.4℃ / h, and the holding time is 2h.

[0235] (6) Glazing

[0236] After removing the glue, the unglazed body is glazed using a spray gun, so that the glaze thickness in the unglazed state is controlled within the range of 0.15-0.5mm.

[0237] (7) Sintering

[0238] The sanitary ceramics of Comparative Example 3 were obtained by firing in a tunnel kiln at 1235°C for 16 hours.

[0239] The sanitary ceramics prepared in the above embodiments and comparative examples were tested, and the experimental data are shown in Table 1 below. The water absorption rate and crack resistance tests were conducted according to standard GB6952-2015; the deformation rate test method was as follows: the sanitary ceramics of the embodiments and comparative examples were made into samples of 100mm×100mm×5mm, and the deformation value A after sintering was measured, where the deformation rate = A / 100×100%; the heat resistance test was conducted according to standard Q / JMJCP009002-2016; the salt spray resistance test was conducted according to standard GB / T10125-2012; the dry blank flexural strength test method was as follows: the sanitary ceramics of the embodiments and comparative examples were made into cylindrical specimens of ∅50 mm×120 mm, and their flexural strength was tested on a universal testing machine. The criteria for judging whether the sanitary ceramics are qualified are: if any of the following occurs—glaze cracking, blank cracking, or bending—the sanitary ceramics are unqualified; otherwise, the sanitary ceramics are qualified.

[0240] Table 1 Performance data of sanitary ceramics in each embodiment and comparative example

[0241]

[0242] As can be seen from the table above, the sanitary ceramics prepared in the examples not only have a small deformation rate and high strength, but also excellent crack resistance, heat resistance and salt spray resistance.

[0243] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0244] The embodiments described above are merely illustrative of several implementation methods of this application, intended to facilitate a detailed understanding of the technical solutions of this application, but should not be construed as limiting the scope of protection of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the scope of protection of this application. It should be understood that technical solutions obtained by those skilled in the art based on the technical solutions provided in this application through logical analysis, reasoning, or limited experimentation are all within the scope of protection of the appended claims. Therefore, the scope of protection of this patent application should be determined by the content of the appended claims, and the specification and drawings can be used to interpret the content of the claims.

Claims

1. A sanitary ceramic material, characterized in that, By weight percentage, it includes: 57%~62% modified sanitary ceramic powder, 37%~41% organosilicon gel, and 1%~2% catalyst; The modified sanitary ceramic powder comprises sanitary ceramic powder and a first silane coupling agent, wherein the first silane coupling agent comprises 2% to 3% by mass in the modified sanitary ceramic powder; The organosilicon gel comprises, by mass percentage, the following components: 57% to 65% organosiloxane, 20% to 25% second silane coupling agent, and 15% to 19% solvent.

2. The sanitary ceramic material according to claim 1, characterized in that, The organosiloxanes include one or more of tetraethoxysilane, methyltriethoxysilane, and phenyltrimethoxysilane.

3. The sanitary ceramic material according to claim 2, characterized in that, The organosilicon gel comprises, by mass percentage, the following components: 35%–40% tetraethoxysilane, 22%–26% methyltriethoxysilane, 20%–25% disilane coupling agent, and 15%–19% solvent.

4. The sanitary ceramic material according to claim 1, characterized in that, The modified sanitary ceramic powder comprises, by mass percentage: 25%–29% ceramic frit, 43%–49% quartz, 10%–15% kaolin, 4.5%–8% alumina, 2%–3.5% dolomite, 2%–4% zirconium oxide, and 2%–3% first silane coupling agent; The chemical composition of the ceramic frit, by mass percentage, includes: 63.3% SiO2, 12.7% Al2O3, 13.5% CaO, 2.1% MgO, 4.5% ZnO, 2.8% K2O, and 1.1% Na2O.

5. The sanitary ceramic material according to any one of claims 1 to 4, characterized in that, The first silane coupling agent and the second silane coupling agent are each independently selected from one or more of KH-560, KH-570 and KH-550.

6. The sanitary ceramic material according to any one of claims 1 to 4, characterized in that, The catalyst includes one or more of tetramethylethylenediamine, tetramethylammonium hydroxide, and dibutyltin dilaurate.

7. A method for preparing sanitary ceramics, characterized in that, Including steps such as: The sanitary ceramic material is shaped and the organosilicon gel is cross-linked and cured to prepare a green body. The sanitary ceramic material is a freshly prepared slurry or a pre-made slurry, and its composition is as described in any one of claims 1 to 6. The green body is sintered to prepare sanitary ceramics.

8. The method for preparing sanitary ceramics according to claim 7, characterized in that, The steps for molding sanitary ceramic materials include: injecting the sanitary ceramic material into a mold, heating it at 50℃~60℃ for 2h~3h, and demolding it after cooling.

9. The method for preparing sanitary ceramics according to claim 7, characterized in that, In the step of crosslinking and curing the organosilicon gel, the temperature is 200℃~220℃ and the time is 1.5h~2h.

10. The method for preparing sanitary ceramics according to claim 7, characterized in that, In the step of sintering the green body, the sintering temperature is 1230℃~1240℃ and the time is 15h~17h.

11. The method for preparing sanitary ceramics according to any one of claims 7 to 10, characterized in that, Before the sintering step of the green body, the method further includes heating to 550℃~650℃ at a heating rate of 0.3℃ / h~0.5℃ / h and holding at that temperature for 2h~3h to remove the binder from the green body.

12. A sanitary ceramic, characterized in that, The chemical composition of the sanitary ceramics, by mass percentage, includes: SiO2 60.8%~64.3%, Al2O3 20.6%~25.5%, CaO 0.9%~2.1%, MgO 0.2%~1.1%, K2O 1.2%~2.9%, Na2O 0.9%~1.5%, ZnO 0.5%~1.2%, and ZrO2 1.5%~3.5%. The sanitary ceramic has a deformation rate of 0.3%~0.7% and a dry flexural strength of 660 N / cm. 2 ~816N / cm 2 ; The sanitary ceramic is made from the sanitary ceramic material as described in claim 1.

13. The sanitary ceramics according to claim 12, characterized in that, The sanitary ceramic is prepared by the preparation method according to any one of claims 7 to 11.

14. The sanitary ceramics according to claim 12 or 13, characterized in that, The sanitary ceramics include toilets.

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