Antifouling wear-resistant composite ceramic and preparation process thereof

Abstract

The application discloses an anti-fouling wear-resistant composite ceramic, which comprises the following components in parts by weight: sintering aid 20-30 parts, alumina 15-18 parts, quartz 15-18 parts, magnesium oxide 16-18 parts, barium sulfate 8-10 parts, magnesium aluminate spinel 5-8 parts, dispersing agent 15-18 parts, binder 15-18 parts and kaolin 15-25 parts. The application also discloses a preparation process of the anti-fouling wear-resistant composite ceramic. The prepared daily-use ceramic product has excellent mechanical strength, good anti-fouling performance and high wear resistance.

Description

Technical Field

[0001] This invention relates to the field of ceramic technology, specifically to a stain-resistant and wear-resistant composite ceramic and its preparation process. Background Technology

[0002] Ceramic products possess the strength of metals, rich decorative effects, good wear resistance, and chemical stability, making them widely used in people's daily lives and deeply loved by people. With economic development and the improvement of people's living standards, people's performance requirements for daily-use ceramics are constantly increasing. They not only require products to be beautiful, but also to have stain resistance, strength, gloss, and wear resistance. Summary of the Invention

[0003] In view of this, the purpose of this invention is to provide a stain-resistant and wear-resistant composite ceramic and its preparation process, so that the resulting daily-use ceramic products have excellent mechanical strength, good stain resistance, and high wear resistance.

[0004] To achieve the above objectives, the present invention provides the following technical solution:

[0005] A stain-resistant and wear-resistant composite ceramic comprises the following components in parts by weight: 20-30 parts of sintering aid, 15-18 parts of alumina, 15-18 parts of quartz, 16-18 parts of magnesium oxide, 8-10 parts of barium sulfate, 5-8 parts of magnesium aluminum spinel, 15-18 parts of dispersant, 15-18 parts of binder, and 15-25 parts of kaolin.

[0006] Preferably, the dispersant is sodium polyacrylate and the binder is sodium carboxymethyl cellulose.

[0007] A process for preparing a stain-resistant and wear-resistant composite ceramic includes the following steps:

[0008] S1: Preparation of sintering aids;

[0009] S2: Mix sintering aid, alumina, quartz, magnesium oxide, barium sulfate, magnesium aluminum spinel, dispersant, binder and kaolin, ball mill and sieve, continue stirring to obtain molding material;

[0010] S3: The molding material obtained in step S2 is molded, degummed, fired, and cooled to obtain a stain-resistant and wear-resistant composite ceramic.

[0011] Preferably, the preparation process of the sintering aid in step S1 includes:

[0012] S11: Mix 2,2'-dihydroxydiethylamine, anhydrous methanol and methyl acrylate, and react at 35-50℃ for 4-6 h to obtain polymer monomer;

[0013] S12: Trimethylolpropane, p-toluenesulfonic acid and the polymer monomer obtained in step S11 are reacted at a constant temperature of 120-140℃ for 2-4 hours to obtain a sintering aid.

[0014] Preferably, the weight ratio of 2,2'-dihydroxydiethylamine, anhydrous methanol, and methyl acrylate is 1:6:2.

[0015] The weight ratio of trimethylolpropane, p-toluenesulfonic acid, and polymer monomers is 1:2:9.

[0016] Preferably, the process of molding the molding material in step S3 specifically includes:

[0017] The molding temperature is 150-180℃, and the molding time is 20-30 seconds at 3-6 MPa.

[0018] Preferably, the process of degumming the molding material in step S3 specifically includes:

[0019] Three-stage heating and degumming process: First stage: The temperature is increased from room temperature to 250℃ at a heating rate of 2℃ / min; Second stage: The temperature is increased from 250℃ to 500℃ at a heating rate of 1℃ / min; Third stage: The temperature is increased from 500℃ to 600℃ at a heating rate of 3℃ / min.

[0020] Preferably, the process of firing the molding material in step S3 specifically includes:

[0021] The firing process is as follows: heat to 1500-1700℃ at a heating rate of 4℃ / min, and hold for 2-3 hours.

[0022] The addition of sintering aids in this invention provides lubrication between ceramic particles, reduces frictional resistance between ceramic particles in ceramic slurry, and fills the spaces between ceramic particles as a binder phase in ceramic powder. Furthermore, the sintering aids, after polymerization, have a large number of functional groups, which can form highly branched, topologically structured particles that are not easily cross-linked. This makes it easier for them to penetrate into ceramic particles and uniformly distribute to generate multi-point cross-linking, thus achieving filling, bonding, and coating effects. This significantly increases the surface thickness of ceramic particles, enhancing their anti-fouling properties and wear resistance.

[0023] Meanwhile, the present invention heats the ceramic body at a low heating rate, causing the organic matter inside the ceramic body to decompose slowly, which gradually increases the size of the grains and causes the internal pores to migrate slowly. The loose porous state after degreasing gradually becomes dense and stable, avoiding the excessive pore size caused by the decomposition of organic matter and the occurrence of interlayer bonding, thereby further improving thermal stability and wear resistance. Detailed Implementation

[0024] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. In addition, it should be specifically noted that the raw materials and equipment of the present invention are all commercially available and will not be listed one by one. Among them, the raw materials of the present invention are all commercially available and are well known to those skilled in the art.

[0025] Example 1:

[0026] A stain-resistant and wear-resistant composite ceramic comprises the following components in parts by weight: 20 parts sintering aid, 15 parts alumina, 15 parts quartz, 16 parts magnesium oxide, 8 parts barium sulfate, 5 parts magnesium aluminum spinel, 15 parts sodium polyacrylate, 15 parts sodium carboxymethyl cellulose and 15 parts kaolin.

[0027] A process for preparing a stain-resistant and wear-resistant composite ceramic includes the following steps:

[0028] S1: Preparation of sintering aids:

[0029] S11: 2,2'-dihydroxydiethylamine, anhydrous methanol and methyl acrylate are mixed in a weight ratio of 1:6:2 and reacted at 35°C for 4 hours to obtain polymer monomers;

[0030] S12: Trimethylolpropane, p-toluenesulfonic acid and the polymer monomer obtained in step S11 are mixed in a weight ratio of 1:2:9 and reacted at 120°C for 2 hours to obtain a sintering aid.

[0031] S2: Mix sintering aid, alumina, quartz, magnesium oxide, barium sulfate, magnesium aluminum spinel, dispersant, binder and kaolin, ball mill and sieve, continue stirring to obtain molding material;

[0032] S3: The molding material obtained in step S2 is molded at 150℃ and 3MPa for 20s, and then subjected to three-stage heating and debinding: the first stage: the temperature is increased from room temperature to 250℃ at a heating rate of 2℃ / min; the second stage: the temperature is increased from 250℃ to 500℃ at a heating rate of 1℃ / min; the third stage: the temperature is increased from 500℃ to 600℃ at a heating rate of 3℃ / min; and finally, the temperature is increased to 1500℃ at a heating rate of 4℃ / min, and held at this temperature for 2 hours to complete the firing. After cooling to room temperature, the anti-fouling and wear-resistant composite ceramic is obtained.

[0033] Example 2:

[0034] A stain-resistant and wear-resistant composite ceramic comprises the following components in parts by weight: 30 parts sintering aid, 18 parts alumina, 18 parts quartz, 18 parts magnesium oxide, 10 parts barium sulfate, 8 parts magnesium aluminum spinel, 18 parts sodium polyacrylate, 18 parts sodium carboxymethyl cellulose and 25 parts kaolin.

[0035] A process for preparing a stain-resistant and wear-resistant composite ceramic includes the following steps:

[0036] S1: Preparation of sintering aids:

[0037] S11: 2,2'-dihydroxydiethylamine, anhydrous methanol and methyl acrylate are mixed in a weight ratio of 1:6:2 and reacted at 50°C for 6 hours to obtain polymer monomers;

[0038] S12: Trimethylolpropane, p-toluenesulfonic acid and the polymer monomer obtained in step S11 are mixed in a weight ratio of 1:2:9 and reacted at 140°C for 4 hours to obtain a sintering aid.

[0039] S2: Mix sintering aid, alumina, quartz, magnesium oxide, barium sulfate, magnesium aluminum spinel, dispersant, binder and kaolin, ball mill and sieve, continue stirring to obtain molding material;

[0040] S3: The molding material obtained in step S2 is molded at 180℃ and 6MPa for 30 seconds, followed by a three-stage heating and debinding process: First stage: heating from room temperature to 250℃ at a rate of 2℃ / min; Second stage: heating from 250℃ to 500℃ at a rate of 1℃ / min; Third stage: heating from 500℃ to 600℃ at a rate of 3℃ / min; Finally, heating to 1700℃ at a rate of 4℃ / min and holding for 3 hours to complete the firing. After cooling to room temperature, the anti-fouling and wear-resistant composite ceramic is obtained.

[0041] Example 3:

[0042] A stain-resistant and wear-resistant composite ceramic comprises the following components in parts by weight: 25 parts sintering aid, 16 parts alumina, 16 parts quartz, 17 parts magnesium oxide, 9 parts barium sulfate, 6 parts magnesium aluminum spinel, 16 parts sodium polyacrylate, 16 parts sodium carboxymethyl cellulose, and 20 parts kaolin.

[0043] A process for preparing a stain-resistant and wear-resistant composite ceramic includes the following steps:

[0044] S1: Preparation of sintering aids:

[0045] S11: Mix 2,2'-dihydroxydiethylamine, anhydrous methanol and methyl acrylate in a weight ratio of 1:6:2 and react at 35-50℃ for 4-6 hours to obtain polymer monomers;

[0046] S12: Trimethylolpropane, p-toluenesulfonic acid and the polymer monomer obtained in step S11 are mixed in a weight ratio of 1:2:9 and reacted at a constant temperature of 120-140℃ for 2-4 hours to obtain a sintering aid.

[0047] S2: Mix sintering aid, alumina, quartz, magnesium oxide, barium sulfate, magnesium aluminum spinel, dispersant, binder and kaolin, ball mill and sieve, continue stirring to obtain molding material;

[0048] S3: The molding material obtained in step S2 is molded at 150-180℃ and 3-6 MPa for 20-30 seconds, and then subjected to three-stage heating and debinding: the first stage: the temperature is increased from room temperature to 250℃ at a heating rate of 2℃ / min; the second stage: the temperature is increased from 250℃ to 500℃ at a heating rate of 1℃ / min; the third stage: the temperature is increased from 500℃ to 600℃ at a heating rate of 3℃ / min; and finally, the temperature is increased to 1500-1700℃ at a heating rate of 4℃ / min, and held at this temperature for 2-3 hours to complete the firing. After cooling to room temperature, the anti-fouling and wear-resistant composite ceramic is obtained.

[0049] Comparative Example 1:

[0050] The preparation process of Comparative Example 1 is basically the same as that of Example 1, except that no sintering aid is used and the glue is directly removed, specifically:

[0051] A stain-resistant and wear-resistant composite ceramic comprises the following components in parts by weight: 15 parts alumina, 15 parts quartz, 16 parts magnesium oxide, 8 parts barium sulfate, 5 parts magnesium aluminum spinel, 15 parts sodium polyacrylate, 15 parts sodium carboxymethyl cellulose, and 15 parts kaolin.

[0052] A process for preparing a stain-resistant and wear-resistant composite ceramic includes the following steps:

[0053] S1: Mix alumina, quartz, magnesium oxide, barium sulfate, magnesium aluminum spinel, dispersant, binder and kaolin, ball mill and sieve, continue mixing to obtain molding material;

[0054] S2: The molding material obtained in step S2 is molded at 150℃ and 3MPa for 20s, then debonded at 600℃, and finally heated to 1500℃ at a heating rate of 4℃ / min, held for 2h to complete the firing, and cooled to room temperature to obtain anti-fouling and wear-resistant composite ceramic.

[0055] The following tests were conducted on the ceramic products obtained from Examples 1 to 3 of the present invention, Comparative Example 1, and ordinary ceramic products (purchased from Shenzhen Suhui Ceramics Co., Ltd.). The test results are shown in Table 1.

[0056] Abrasion resistance test: The test shall be conducted in accordance with GB / T3810.6-2016.

[0057] Mechanical strength test: The test shall be conducted in accordance with GB / T 4740-1999.

[0058] Anti-fouling: Apply ink to the product surface and observe for any obvious traces.

[0059] Table 1. Test data for Examples 1-3, commercially available ceramics, and Comparative Example 1.

[0060]

[0061]

[0062] As can be seen from the table above, Examples 1-3 have good wear resistance and anti-fouling ability, and also have good compressive strength and fracture toughness.

[0063] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A preparation process for a stain-resistant and wear-resistant composite ceramic, characterized in that, Includes the following steps: S1: Preparation of sintering aids; S2: Mix sintering aid, alumina, quartz, magnesium oxide, barium sulfate, magnesium aluminum spinel, dispersant, binder and kaolin, ball mill and sieve, continue stirring to obtain molding material; S3: The molding material obtained in step S2 is molded, debonded, fired, and cooled to obtain a stain-resistant and wear-resistant composite ceramic. The preparation process of the sintering aid mentioned in step S1 includes: S11: Mix 2,2'-dihydroxydiethylamine, anhydrous methanol and methyl acrylate, and react at 35-50℃ for 4-6 h to obtain polymer monomer; S12: Trimethylolpropane, p-toluenesulfonic acid and the polymer monomer obtained in step S11 are reacted at a constant temperature of 120-140℃ for 2-4 hours to obtain a sintering aid. The anti-fouling and wear-resistant composite ceramic comprises the following components in parts by weight: 20-30 parts sintering aid, 15-18 parts alumina, 15-18 parts quartz, 16-18 parts magnesium oxide, 8-10 parts barium sulfate, 5-8 parts magnesium aluminum spinel, 15-18 parts dispersant, 15-18 parts binder, and 15-25 parts kaolin. The process of degumming the molding material in step S3 specifically includes: Three-stage heating and degumming process: First stage: The temperature is increased from room temperature to 250℃ at a heating rate of 2℃ / min; Second stage: The temperature is increased from 250℃ to 500℃ at a heating rate of 1℃ / min; Third stage: The temperature is increased from 500℃ to 600℃ at a heating rate of 3℃ / min.

2. The preparation process of the anti-fouling and wear-resistant composite ceramic as described in claim 1, characterized in that, The dispersant is sodium polyacrylate, and the binder is sodium carboxymethyl cellulose.

3. The preparation process of the anti-fouling and wear-resistant composite ceramic as described in claim 1, characterized in that, The weight ratio of 2,2'-dihydroxydiethylamine, anhydrous methanol, and methyl acrylate is 1:6:

2. The weight ratio of trimethylolpropane, p-toluenesulfonic acid, and polymer monomers is 1:2:

9.

4. The preparation process of the anti-fouling and wear-resistant composite ceramic as described in claim 1, characterized in that, The specific process of molding the molding material in step S3 includes: The molding temperature is 150-180℃, and the molding time is 20-30 seconds at 3-6 MPa.

5. The preparation process of the anti-fouling and wear-resistant composite ceramic as described in claim 1, characterized in that, The process of firing the molding material in step S3 specifically includes: The firing process is as follows: heat to 1500-1700℃ at a heating rate of 4℃ / min, and hold for 2-3 hours.

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