Lightweight refractory ceramic material and method of making same

Abstract

The application discloses a kind of light high-temperature-resistant ceramic materials and its manufacturing method, belong to ceramic material technical field.Light high-temperature-resistant ceramic material includes the following components: kaolin, silicon oxide, waste ceramic powder, potassium feldspar, calcium carbonate, polyethylene glycol, zirconium oxide, dolomite, boron carbide, fibrous stainless steel and illite.The ceramic product prepared by the light high-temperature-resistant ceramic material has the performance of light weight, high temperature resistance and high strength.

Description

Technical Field

[0001] The present invention belongs to the technical field of ceramic materials, and in particular relates to a lightweight, high-temperature resistant ceramic material and a manufacturing method thereof. Background Art

[0002] As we all know, ceramics are a traditional product in my country from ancient times to the present day. However, with the passage of time and the advancement of technology, ceramics are no longer limited to traditional products. Due to the material of ceramics themselves, the weight of traditional ceramic products is relatively large. In particular, ceramic pots, large-sized ceramic tableware, and ceramic handicrafts are relatively bulky and inconvenient to handle.

[0003] Therefore, how to prepare ceramic products that are lighter and easier to pick up and place is a research and development project for many ceramic companies. The applicant is also developing lightweight ceramics that also have high temperature resistance. Summary of the Invention

[0004] The purpose of the present invention is to overcome the deficiencies of the prior art and provide a lightweight ceramic, while also making the prepared lightweight ceramic have high temperature resistance.

[0005] The present invention adopts the following technical solutions:

[0006] The lightweight, high-temperature resistant ceramic material includes the following components in parts by mass: 63-71 parts of kaolin, 20-28 parts of silicon oxide, 6-8 parts of waste ceramic powder, 10-15 parts of potassium feldspar, 8-11 parts of calcium carbonate, 5-7 parts of polyethylene glycol, 12-15 parts of zirconium oxide, 9-13 parts of dolomite, 11-12 parts of boron carbide, 7-10 parts of fibrous stainless steel, and 8-11 parts of illite.

[0007] Furthermore, the preparation method of the short fiber stainless steel is as follows:

[0008] The 304 stainless steel powder is melted at 1500°C and then drawn into a wire with a diameter of 20 to 30 μm. Finally, it is cut into fibrous stainless steel with a length of 1 to 2 mm.

[0009] Furthermore, a method for preparing a lightweight, high-temperature resistant ceramic material comprises the following steps:

[0010] Step 1: Crushing

[0011] The kaolin, silicon oxide, waste ceramic powder, potassium feldspar, calcium carbonate, zirconium oxide, dolomite, boron carbide and illite are mixed and crushed according to the mass fractions to obtain a crushed material;

[0012] Step 2: Ball milling

[0013] Ball milling the crushed material obtained in step 1 to obtain ball milled material;

[0014] Step 3: Mixing

[0015] The ball mill material obtained in step 2 is mixed with the polyethylene glycol and the fibrous stainless steel according to the mass fractions to obtain a lightweight, high-temperature resistant ceramic material.

[0016] Furthermore, the crushed material also requires a 200-250 mesh screen.

[0017] Furthermore, during the ball milling, a weight ratio of material: water: balls = 1:0.9 to 1.1:0.8 is used for ball milling, a rotation speed of 450 to 500 r / min, and the ball milling time is 1 to 1.5 days.

[0018] A method for preparing ceramic products using the lightweight, high-temperature resistant ceramic material is as follows:

[0019] First, the lightweight high-temperature resistant ceramic material is made into a ceramic body, which is then bisque-fired to obtain a ceramic body; then, the ceramic body is glazed, glaze-fired, and cooled to obtain a lightweight high-temperature resistant ceramic product.

[0020] Furthermore, during the biscuit firing, the temperature is 750-800° C. and the biscuit firing time is 30-40 minutes, so that a porous structure appears inside the ceramic body.

[0021] Compared with the prior art, the present invention has the following beneficial effects:

[0022] First, the lightweight, high-temperature resistant ceramic material of the present invention uses a large amount of traditional kaolin materials and waste ceramic powder to save energy, and is combined with silicon oxide and boron carbide to improve the strength of the product;

[0023] Second, in order to reduce the weight of ceramic products, the applicant made the ceramic products into porous ceramics, using calcium carbonate and polyethylene glycol as pore-forming agents. At the same time, in order to prevent the defect of low strength caused by the porous structure, fibrous stainless steel was added. The fibrous stainless steel material plays a supporting role on the ceramic body, thereby improving the strength of the ceramic body. DETAILED DESCRIPTION

[0024] The raw materials used in the present invention are all commercially available products.

[0025] Example 1

[0026] The lightweight, high-temperature resistant ceramic material includes the following components in parts by mass: 63 parts of kaolin, 20 parts of silicon oxide, 6 parts of waste ceramic powder, 10 parts of potassium feldspar, 8 parts of calcium carbonate, 5 parts of polyethylene glycol, 12 parts of zirconium oxide, 9 parts of dolomite, 11 parts of boron carbide, 7 parts of fibrous stainless steel, and 8 parts of illite.

[0027] The preparation method of short fiber stainless steel is as follows:

[0028] The 304 stainless steel powder was melted at 1500°C and then drawn into a wire with a diameter of 20 μm. Finally, it was cut to obtain fibrous stainless steel with a length of 1 mm.

[0029] A method for preparing a lightweight, high-temperature resistant ceramic material, characterized by comprising the following steps:

[0030] Step 1: Crushing

[0031] According to the mass fractions, the kaolin, silicon oxide, waste ceramic powder, potassium feldspar, calcium carbonate, zirconium oxide, dolomite, boron carbide and illite are mixed and crushed to obtain a crushed material, and the obtained crushed material is passed through a 200-mesh sieve;

[0032] Step 2: Ball milling

[0033] The crushed material obtained in step 1 was ball-milled at a weight ratio of material: water: ball = 1:0.9:0.8, a rotation speed of 450 r / min, and ball-milled for 1 day to obtain a ball-milled material;

[0034] Step 3: Mixing

[0035] The ball mill material obtained in step 2 is mixed with the polyethylene glycol and the fibrous stainless steel according to the mass fractions to obtain a lightweight, high-temperature resistant ceramic material.

[0036] The method for preparing ceramic products using the lightweight high-temperature resistant ceramic material is as follows:

[0037] First, the lightweight, high-temperature resistant ceramic material is made into a ceramic body, which is then bisque-fired at a temperature of 750°C for 30 minutes, so that a porous structure appears inside the ceramic body to obtain a ceramic body. Then, the ceramic body is glazed and finally glaze-fired. After cooling, a lightweight, high-temperature resistant ceramic product is obtained.

[0038] Example 2

[0039] The lightweight, high-temperature resistant ceramic material includes the following components in parts by mass: 71 parts of kaolin, 28 parts of silicon oxide, 8 parts of waste ceramic powder, 15 parts of potassium feldspar, 11 parts of calcium carbonate, 7 parts of polyethylene glycol, 15 parts of zirconium oxide, 13 parts of dolomite, 12 parts of boron carbide, 10 parts of fibrous stainless steel, and 11 parts of illite.

[0040] The preparation method of short fiber stainless steel is as follows:

[0041] The 304 stainless steel powder was melted at 1500°C and then drawn into a wire with a diameter of 30 μm. Finally, the wire was cut into fibrous stainless steel with a length of 2 mm.

[0042] A method for preparing a lightweight, high-temperature resistant ceramic material, characterized by comprising the following steps:

[0043] Step 1: Crushing

[0044] According to the mass fractions, the kaolin, silicon oxide, waste ceramic powder, potassium feldspar, calcium carbonate, zirconium oxide, dolomite, boron carbide and illite are mixed and crushed to obtain a crushed material, and the obtained crushed material is passed through a 250-mesh sieve;

[0045] Step 2: Ball milling

[0046] The crushed material obtained in step 1 is ball-milled at a weight ratio of material: water: ball = 1:1.1:0.8, a rotation speed of 500 r / min, and ball milling for 1 to 1.5 days to obtain a ball-milled material;

[0047] Step 3: Mixing

[0048] The ball mill material obtained in step 2 is mixed with the polyethylene glycol and the fibrous stainless steel according to the mass fractions to obtain a lightweight, high-temperature resistant ceramic material.

[0049] The method for preparing ceramic products using the lightweight high-temperature resistant ceramic material is as follows:

[0050] First, the lightweight, high-temperature resistant ceramic material is made into a ceramic body, which is then bisque-fired at a temperature of 800°C for 40 minutes, so that a porous structure appears inside the ceramic body to obtain a ceramic body. Then, the ceramic body is glazed and finally glaze-fired. After cooling, a lightweight, high-temperature resistant ceramic product is obtained.

[0051] Example 3

[0052] The lightweight, high-temperature resistant ceramic material includes the following components in parts by mass: 68 parts of kaolin, 25 parts of silicon oxide, 7 parts of waste ceramic powder, 13 parts of potassium feldspar, 10 parts of calcium carbonate, 6 parts of polyethylene glycol, 13 parts of zirconium oxide, 11 parts of dolomite, 11 parts of boron carbide, 9 parts of fibrous stainless steel, and 10 parts of illite.

[0053] The preparation method of short fiber stainless steel is as follows:

[0054] The 304 stainless steel powder was melted at 1500°C and then drawn into a wire with a diameter of 25 μm. Finally, the wire was cut to obtain fibrous stainless steel with a length of 1.5 mm.

[0055] A method for preparing a lightweight, high-temperature resistant ceramic material, characterized by comprising the following steps:

[0056] Step 1: Crushing

[0057] According to the mass fractions, the kaolin, silicon oxide, waste ceramic powder, potassium feldspar, calcium carbonate, zirconium oxide, dolomite, boron carbide and illite are mixed and crushed to obtain a crushed material, and the obtained crushed material is passed through a 250-mesh sieve;

[0058] Step 2: Ball milling

[0059] The crushed material obtained in step 1 was ball-milled at a weight ratio of material: water: ball = 1:1:0.8, a rotation speed of 480 r / min, and ball-milled for 1 day to obtain a ball-milled material;

[0060] Step 3: Mixing

[0061] The ball mill material obtained in step 2 is mixed with the polyethylene glycol and the fibrous stainless steel according to the mass fractions to obtain a lightweight, high-temperature resistant ceramic material.

[0062] The method for preparing ceramic products using the lightweight high-temperature resistant ceramic material is as follows:

[0063] First, the lightweight, high-temperature resistant ceramic material is made into a ceramic body, which is then bisque-fired at a temperature of 780°C for 30 minutes, so that a porous structure appears inside the ceramic body to obtain a ceramic body. Then, the ceramic body is glazed and finally glaze-fired. After cooling, a lightweight, high-temperature resistant ceramic product is obtained.

[0064] The ceramic products coated with the ceramic products prepared in Examples 1 to 3 of the present invention were tested, wherein:

[0065] The test results are shown in Table 1 below:

[0066] Table 1: Test results

[0067]

[0068] As can be seen from Table 1, the ceramic products prepared have the properties of high temperature resistance and high strength. At the same time, when the products are held in the hand, they are lighter than ceramic products of the same volume.

[0069] The above is a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principles of the present invention, and these improvements and modifications are also considered to be within the scope of protection of the present invention.

Claims

1. Lightweight high temperature resistant ceramic material, characterized in that: The invention is composed of the following components in parts by mass: 63-71 parts of kaolin, 20-28 parts of silicon oxide, 6-8 parts of waste ceramic powder, 10-15 parts of potassium feldspar, 8-11 parts of calcium carbonate, 5-7 parts of polyethylene glycol, 12-15 parts of zirconium oxide, 9-13 parts of dolomite, 11-12 parts of boron carbide, 7-10 parts of fibrous stainless steel and 8-11 parts of illite.

2. The lightweight high temperature resistant ceramic material according to claim 1, characterized in that: The preparation method of the fibrous stainless steel is as follows: The 304 stainless steel powder is melted at 1500℃ and then drawn into a wire with a diameter of 20~30μm. Finally, it is cut into fibrous stainless steel with a length of 1~2mm.

3. The method for preparing the lightweight high-temperature resistant ceramic material according to claim 1, characterized in that: The steps include: Step 1: Crushing The kaolin, silicon oxide, waste ceramic powder, potassium feldspar, calcium carbonate, zirconium oxide, dolomite, boron carbide and illite are mixed and crushed according to the mass fractions to obtain a crushed material; Step 2: Ball milling Ball milling the crushed material obtained in step 1 to obtain ball milled material; Step 3: Mixing The ball mill material obtained in step 2 is mixed with the polyethylene glycol and the fibrous stainless steel according to the mass fractions to obtain a lightweight, high-temperature resistant ceramic material.

4. The preparation method according to claim 3, characterized in that The crushed material also requires a 200-250 mesh screen.

5. The preparation method according to claim 3, characterized in that During the ball milling, the weight ratio of material: water: ball = 1:0.9-1.1:0.8 is adopted for ball milling, the rotation speed is 450-500 r / min, and the ball milling is 1-1.5 days.

6. A method for preparing ceramic products using the lightweight, high-temperature resistant ceramic material according to claim 1, characterized in that: Here’s how: First, the lightweight high-temperature resistant ceramic material is made into a ceramic body, which is then bisque-fired to obtain a ceramic body; then, the ceramic body is glazed, glaze-fired, and cooled to obtain a lightweight high-temperature resistant ceramic product.

7. The method for preparing a ceramic product according to claim 6, wherein: During the biscuit firing, the temperature is 750-800° C. and the biscuit firing is performed for 30-40 minutes, so that a porous structure appears inside the ceramic body.

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