Foaming ceramic surface low-temperature firing colored glaze and secondary firing process method of foaming ceramic surface glaze

Abstract

According to the foamed ceramic surface low-temperature firing colored glaze and the secondary firing process method of the foamed ceramic surface glaze provided by the invention, the foamed ceramic surface low-temperature firing colored glaze is applied to foamed ceramic and is subjected to secondary low-temperature firing, so that a layer of thin and uniform glaze surface is formed on the surface of the foamed ceramic; the natural texture of the foamed ceramic is reserved, and the foamed ceramic is endowed with a new color. Meanwhile, the layer of glaze remarkably improves the anti-pollution performance of the foamed ceramic, effectively reduces the water absorption of the foamed ceramic, and remarkably improves the practicability and the aesthetic property of the material. In addition, the firing temperature of the low-temperature fired colored glaze on the surface of the foamed ceramic is obviously lower than that of the foamed ceramic, and the required firing time is short, so that the structure of the foamed ceramic cannot be damaged in the secondary low-temperature firing process.

Description

Technical Field

[0001] The invention belongs to the technical field of foamed ceramics, and in particular relates to a method for low-temperature firing of colored glaze on the surface of foamed ceramics and secondary firing of glaze on the surface of foamed ceramics. Background Art

[0002] Foamed ceramics are a kind of material made from renewable resources such as clay tailings, ceramic fragments, river silt and ceramic solid waste. It is a high-porosity closed-cell ceramic material made by adding special foaming agents, using wet or dry methods, forming materials through fabrication, and high-temperature kiln baking. It is highly praised for its light weight, thermal insulation, low deformation coefficient, high strength, waterproof and moisture-proof, fire retardant, anti-aging, stable performance, ecological and environmental protection, excellent compatibility with wall base and plastering layer, safety and stability, and long service life.

[0003] However, foamed ceramics may encounter some challenges during the firing process. Since the main raw materials of foamed ceramics are renewable resources and a large number of bubbles are generated inside during the firing process, the surface color of the finished product is uneven and unstable. In addition, since the surface of the product is porous after cutting and processing, foamed ceramics without surface treatment are prone to dust loss, moisture absorption, and are difficult to dry, easy to be contaminated, and difficult to clean. The above defects limit its direct use as a thermal insulation or decorative material, and the foamed ceramics need to be surface treated.

[0004] At present, the surface treatment of foamed ceramics usually includes a series of steps: first, let the material dry naturally, then use materials such as anti-cracking mortar to cover the pores on its surface to achieve surface flatness and reduce water absorption. Finally, spray decorative coatings such as real stone paint to enhance its appearance. This process is not only complicated to operate and has poor durability and weather resistance, but also has high requirements for construction technology. The thickness of the paint layer must be just right to ensure good stability and decorative effect. In addition, when performing surface treatment, in order to ensure the uniform coating of the decorative coating, the natural texture of the foamed ceramics is often covered, especially when the foamed ceramics are used for carving works, the expressiveness of the product is completely destroyed, which to a certain extent limits the range of choices for its decoration style. Summary of the invention

[0005] One of the purposes of the present invention is to overcome the defects of the prior art and provide a low-temperature fired colored glaze on the surface of a foamed ceramic.

[0006] Another object of the present invention is to provide a secondary firing process for foamed ceramic surface glaze.

[0007] The technical solution of the present invention is as follows:

[0008] A low-temperature fired colored glaze on the surface of a foamed ceramic has a firing temperature of 650-750°C. The solid materials thereof include the following components by weight: 2-3 parts of potassium feldspar, 2-3 parts of lithium feldspar, 2-3 parts of talc, 4.5-7 parts of calcite, 6-9 parts of kaolin, 20-30 parts of borax, 10-15 parts of zinc oxide, 16-25 parts of quartz, 6.5-10 parts of yellow mud clay and 4-6 parts of colorant.

[0009] Exemplarily, the colorants include chromium compounds (including chromium oxide, chromium hydroxide, potassium dichromate, lead chromate, etc.), cobalt compounds (including cobalt oxide, cobalt carbonate, cobalt phosphate, cobalt chromate, etc.), iron compounds (including ferrous sulfate, ferric oxide, ferric chromate, etc.), manganese compounds, copper compounds, antimony compounds, nickel compounds, cadmium compounds, zinc compounds, gold compounds, tin compounds, etc.

[0010] Preferably, the yellow mud clay comprises the following components: 67-74% silicon dioxide, 14.5-17.99% aluminum oxide, 3.27-6.61% iron oxide, 0.75-1.68% calcium oxide, 0.89-2.07% magnesium oxide, 2-3% potassium oxide, 1.5-2% sodium oxide, and the rest are oxides of trace elements.

[0011] More preferably, the solid-to-liquid ratio is 0.8-1.2:1.

[0012] Further preferably, the average particle size of the low-temperature fired colored glaze on the surface of the foamed ceramic is 280-320 meshes.

[0013] A secondary firing process for a foamed ceramic surface glaze comprises the following steps:

[0014] (1) applying a colored glaze to the surface of the foamed ceramic by firing the surface of the foamed ceramic at a low temperature, and drying the glazed foamed ceramic;

[0015] (2) The glazed foamed ceramic is first heated uniformly from room temperature to 145-155°C in a kiln within 28-32 minutes, and kept at this temperature for 8-12 minutes. Then, the temperature is uniformly heated to 545-555°C within 58-62 minutes, and kept at this temperature for 18-22 minutes. Finally, the temperature is uniformly heated to 650-750°C within 28-32 minutes, and kept at this temperature for 18-22 minutes. The ceramic is then cooled in the kiln.

[0016] Preferably, the coating thickness of the low-temperature fired colored glaze on the surface of the foamed ceramic is less than 1 mm.

[0017] Preferably, the drying time in step (1) is 3-3.5 hours.

[0018] Preferably, before applying the colored glaze fired at low temperature on the surface of the foamed ceramic, the surface of the foamed ceramic is cleaned.

[0019] The present invention has at least the following beneficial effects:

[0020] The present invention provides a method for low-temperature fired colored glaze on the surface of foamed ceramics and secondary firing of glaze on the surface of foamed ceramics. By applying the low-temperature fired colored glaze on the surface of foamed ceramics to the foamed ceramics and performing secondary low-temperature firing, a thin and uniform glaze surface is formed on the surface of the foamed ceramics, which not only retains the natural texture of the foamed ceramics, but also gives it a new color. At the same time, this layer of glaze significantly improves the anti-fouling performance of the foamed ceramics and effectively reduces its water absorption, so that the material is significantly improved in both practicality and aesthetics. In addition, since the firing temperature of the low-temperature fired colored glaze on the surface of foamed ceramics is significantly lower than the firing temperature of the foamed ceramics and the required firing time is short, the structure of the foamed ceramics itself will not be damaged during the secondary low-temperature firing process. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 This is a photograph of the product obtained by applying a low-temperature fired colored glaze on the surface of a foamed ceramic to the surface of a foamed ceramic and then performing secondary firing of the foamed ceramic surface glaze in Example 2;

[0022] Figure 2 This is a photograph of the product obtained by applying a low-temperature fired colored glaze on the surface of a foamed ceramic to the surface of a foamed ceramic and performing secondary firing of the foamed ceramic surface glaze in Example 3;

[0023] Figure 3 This is a photograph of the product obtained by applying a low-temperature fired colored glaze on the surface of a foamed ceramic to the surface of the foamed ceramic and then performing secondary firing of the foamed ceramic surface glaze in Comparative Example 1;

[0024] Figure 4 This is a photograph of the product obtained by applying a low-temperature fired colored glaze on the surface of a foamed ceramic and performing secondary firing of the foamed ceramic surface glaze in Comparative Example 2;

[0025] Figure 5 This is a photograph of the product obtained by applying a low-temperature fired colored glaze on the surface of a foamed ceramic to the surface of the foamed ceramic and then performing secondary firing of the foamed ceramic surface glaze in Comparative Example 3;

[0026] Figure 6 This is a top view of the product obtained by applying a low-temperature fired colored glaze on the surface of a foamed ceramic and performing secondary firing of the foamed ceramic surface glaze in Comparative Example 4;

[0027] Figure 7 This is a side view of the product obtained by applying a low-temperature fired colored glaze on the surface of a foamed ceramic and then performing a secondary firing of the foamed ceramic surface glaze in Comparative Example 4. DETAILED DESCRIPTION

[0028] The technical solution of the present invention is further illustrated and described below through specific implementation methods.

[0029] In the following examples, the water used can be one or more of distilled water, purified water, and drinking water; unless otherwise specified, the detection methods in the following examples are conventional detection methods; the reagents in the following examples are purchased from commercial channels unless otherwise specified.

[0030] In the following examples, a foamed ceramic and a preparation method thereof are provided, which are used to carry the low-temperature fired colored glaze (referred to as colored glaze) provided by the present invention on the surface of the foamed ceramic, but this should not be used as a limitation to the present invention. The colorant used in the following examples is a glaze color pigment made from Zhongqi glaze.

[0031] Example 1

[0032] A foamed ceramic with a density of 0.2 to 0.55 t / m 3 , is made of the following components in weight percentage: 50-59.9% of granite powder, 35-45% of solid solvent and 5-10% of swelling agent, wherein the solid solvent is composed of low-temperature sand and feldspar powder in a mass ratio of 2:1, and the swelling agent is composed of bentonite, heavy calcium carbonate, silicon micropowder, dolomite and silicon carbide powder in a mass ratio of 4:4:2:2:1.

[0033] The preparation method of the foamed ceramic comprises the following steps:

[0034] (1) Weighing each component according to the weight percentage and mass ratio;

[0035] (2) After drying, the granite powder is ball-milled to 260-300 meshes for later use;

[0036] (3) mixing low-temperature sand and feldspar powder, drying and then ball-milling to 260-300 meshes to prepare a solid solvent for standby use;

[0037] (4) Mix bentonite, heavy calcium carbonate, silica powder, dolomite and silicon carbide powder, dry them, and then ball-mill them to a size of 260-300 mesh to prepare a bulking agent for later use;

[0038] (5) After the materials of steps (2), (3) and (4) are uniformly mixed, a raw material powder having a moisture content of 5.8% and a particle size of 40 to 80 mesh is obtained through a dry granulation system;

[0039] (6) aging the raw material powder obtained in step (5) to achieve uniform humidity;

[0040] (7) After the material of step (6) is shaped, it is placed in a kiln for firing to obtain the fired stone honeycomb regeneration material. The waste heat of the kiln is used to dry the materials in the above steps (2) to (4). The firing process is: uniformly heating to 760°C in 2.2 hours, then keeping at 760°C for 0.4 hours, then uniformly heating to 1140°C in 2.2 hours, then keeping at 1140°C for 0.9 hours, and finally cooling in the furnace.

[0041] Example 2

[0042] (1) Preparation of low-temperature fired colored glaze on the surface of foamed ceramics

[0043] The solid materials for low-temperature firing of colored glaze on the surface of foamed ceramics are as follows: 9g kaolin, 25g quartz, 30g borax, 3g potassium feldspar, 3g lithium feldspar, 15g zinc oxide, 10g lead oxide, 7g calcite, 3g talc, 5g dolomite, 10g yellow mud clay and 5g black pigment.

[0044] Among them, the Yellow River clay includes the following components by weight: 14.94% aluminum oxide, 73.26% silicon dioxide, 4.59% iron oxide, 0.91% calcium oxide, 1.23% magnesium oxide, 2.66% potassium oxide, 1.70% sodium oxide and 0.71% titanium oxide.

[0045] The solid material is ground to an average particle size of 300 meshes, and then 120 g of water is added and mixed to obtain a low-temperature fired colored glaze on the surface of the foamed ceramic.

[0046] (2) The above-mentioned colored glaze fired at low temperature on the surface of the foamed ceramic is applied to the surface of the foamed ceramic prepared in Example 1 with a thickness of 1 mm and dried to obtain a glazed foamed ceramic.

[0047] (3) The glazed foamed ceramic is heated from room temperature to 150°C within 30 minutes, then kept at this temperature for 10 minutes, then heated to 550°C at a constant speed within 1 hour, kept at this temperature for 10 minutes, and finally heated to 750°C at a constant speed within 30 minutes, kept at this temperature for 20 minutes, and finally cooled in the furnace.

[0048] Finished product Figure 1 As shown, it can be seen that the foamed ceramic has almost no deformation visible to the naked eye, the surface of the foamed ceramic is evenly covered with black glaze and the texture of the foamed ceramic itself is retained.

[0049] Example 3

[0050] (1) Preparation of low-temperature fired colored glaze on the surface of foamed ceramics

[0051] The solid materials for low-temperature firing of colored glaze on the surface of foamed ceramics are as follows: 9g kaolin, 25g quartz, 30g borax, 3g potassium feldspar, 3g lithium feldspar, 15g zinc oxide, 10g lead oxide, 7g calcite, 3g talc, 5g dolomite, 10g yellow mud clay and 4.5g red pigment.

[0052] Among them, the Yellow River clay includes the following components by weight: 14.94% aluminum oxide, 73.26% silicon dioxide, 4.59% iron oxide, 0.91% calcium oxide, 1.23% magnesium oxide, 2.66% potassium oxide, 1.70% sodium oxide and 0.71% titanium oxide.

[0053] The solid material is ground to an average particle size of 300 meshes, and then 120 g of water is added and mixed to obtain a low-temperature fired colored glaze on the surface of the foamed ceramic.

[0054] (2) The above-mentioned colored glaze fired at low temperature on the surface of the foamed ceramic is applied to the surface of the foamed ceramic prepared in Example 1 with a thickness of 1 mm and dried to obtain a glazed foamed ceramic.

[0055] (3) The glazed foamed ceramic is heated from room temperature to 150°C within 30 minutes, then kept at this temperature for 10 minutes, then heated to 550°C at a constant speed within 1 hour, kept at this temperature for 10 minutes, and finally heated to 730°C at a constant speed within 30 minutes, kept at this temperature for 20 minutes, and finally cooled in the furnace.

[0056] Finished product Figure 2 As shown, it can be seen that the foamed ceramic has almost no deformation visible to the naked eye, the surface of the foamed ceramic is evenly covered with red glaze and the texture of the foamed ceramic itself is retained.

[0057] Comparative Example 1

[0058] (1) Preparation of low-temperature fired colored glaze on the surface of foamed ceramics

[0059] The solid materials for low-temperature firing of colored glaze on the surface of foamed ceramics are as follows: 9g kaolin, 25g quartz, 30g borax, 3g potassium feldspar, 3g lithium feldspar, 15g zinc oxide, 10g lead oxide, 7g calcite, 3g talc, 5g dolomite, 10g yellow mud clay and 5g black pigment.

[0060] Among them, the Yellow River clay includes the following components by weight: 14.94% aluminum oxide, 73.26% silicon dioxide, 4.59% iron oxide, 0.91% calcium oxide, 1.23% magnesium oxide, 2.66% potassium oxide, 1.70% sodium oxide and 0.71% titanium oxide.

[0061] The solid material is ground to an average particle size of 300 meshes, and then 120 g of water is added and mixed to obtain a low-temperature fired colored glaze on the surface of the foamed ceramic.

[0062] (2) The above-mentioned low-temperature fired colored glaze on the surface of the foamed ceramic is applied to the surface of the foamed ceramic prepared in Example 1 with a thickness of 3 mm and dried to obtain a glazed foamed ceramic.

[0063] (3) The glazed foamed ceramic is heated from room temperature to 150°C within 30 minutes, then kept at this temperature for 10 minutes, then heated to 550°C at a constant speed within 1 hour, kept at this temperature for 10 minutes, and finally heated to 750°C at a constant speed within 30 minutes, kept at this temperature for 20 minutes, and finally cooled in the furnace.

[0064] Finished product Figure 3 As shown, it can be seen that the foamed ceramic has almost no deformation visible to the naked eye, but the thickness of the black glaze on the surface of the foamed ceramic is too high, which causes the surface texture of the foamed ceramic to be destroyed and the aesthetics is low.

[0065] Comparative Example 2

[0066] (1) Preparation of low-temperature fired colored glaze on the surface of foamed ceramics

[0067] The solid materials for low-temperature firing of colored glaze on the surface of foamed ceramics are as follows: 9g kaolin, 25g quartz, 30g borax, 3g potassium feldspar, 3g lithium feldspar, 15g zinc oxide, 10g lead oxide, 7g calcite, 3g talc, 5g dolomite, 10g yellow mud clay and 5g white pigment.

[0068] Among them, the Yellow River clay includes the following components by weight: 14.94% aluminum oxide, 73.26% silicon dioxide, 4.59% iron oxide, 0.91% calcium oxide, 1.23% magnesium oxide, 2.66% potassium oxide, 1.70% sodium oxide and 0.71% titanium oxide.

[0069] The solid material is ground to an average particle size of 300 meshes, and then 120 g of water is added and mixed to obtain a low-temperature fired colored glaze on the surface of the foamed ceramic.

[0070] (2) The above-mentioned low-temperature fired colored glaze on the surface of the foamed ceramic is applied to the surface of the foamed ceramic prepared in Example 1 with a thickness of 3 mm and dried to obtain a glazed foamed ceramic.

[0071] (3) The glazed foamed ceramic is heated from room temperature to 150°C within 30 minutes, then kept at this temperature for 10 minutes, then heated to 550°C at a constant speed within 1 hour, kept at this temperature for 10 minutes, and finally heated to 600°C at a constant speed within 30 minutes, kept at this temperature for 20 minutes, and finally cooled in the furnace.

[0072] Finished product Figure 4As shown, it can be seen that the foamed ceramic has almost no deformation visible to the naked eye, but the color glaze on the surface of the foamed ceramic is unevenly distributed. This may be due to the low firing temperature, which makes the color glaze have poor fluidity during the firing process.

[0073] Comparative Example 3

[0074] (1) Preparation of low-temperature fired colored glaze on the surface of foamed ceramics

[0075] The solid materials for low-temperature firing of colored glaze on the surface of foamed ceramics are as follows: 9g kaolin, 25g quartz, 30g borax, 3g potassium feldspar, 3g lithium feldspar, 15g zinc oxide, 10g lead oxide, 7g calcite, 3g talc, 5g dolomite, 10g yellow mud clay and 5g black pigment.

[0076] Among them, the Yellow River clay includes the following components by weight: 14.94% aluminum oxide, 73.26% silicon dioxide, 4.59% iron oxide, 0.91% calcium oxide, 1.23% magnesium oxide, 2.66% potassium oxide, 1.70% sodium oxide and 0.71% titanium oxide.

[0077] The solid material is ground to an average particle size of 300 meshes, and then 120 g of water is added and mixed to obtain a low-temperature fired colored glaze on the surface of the foamed ceramic.

[0078] (2) The above-mentioned low-temperature fired colored glaze on the surface of the foamed ceramic is applied to the surface of the foamed ceramic prepared in Example 1 with a thickness of 3 mm and dried to obtain a glazed foamed ceramic.

[0079] (3) The glazed foamed ceramic is heated from room temperature to 150°C within 30 minutes, then kept at this temperature for 10 minutes, then heated to 550°C at a constant speed within 1 hour, kept at this temperature for 10 minutes, and finally heated to 780°C at a constant speed within 30 minutes, kept at this temperature for 20 minutes, and finally cooled in the furnace.

[0080] Finished product Figure 5 As shown, it can be seen that the colored glaze can be evenly spread on the surface of the foamed ceramic, but due to the high firing temperature, part of the surface of the foamed ceramic falls off.

[0081] Comparative Example 4

[0082] (1) Preparation of low-temperature fired colored glaze on the surface of foamed ceramics

[0083] The solid materials for low-temperature firing of colored glaze on the surface of foamed ceramics are as follows: 9g kaolin, 25g quartz, 30g borax, 3g potassium feldspar, 3g lithium feldspar, 15g zinc oxide, 10g lead oxide, 7g calcite, 3g talc, 5g dolomite, 10g yellow mud clay and 5g black pigment.

[0084] Among them, the Yellow River clay includes the following components by weight: 14.94% aluminum oxide, 73.26% silicon dioxide, 4.59% iron oxide, 0.91% calcium oxide, 1.23% magnesium oxide, 2.66% potassium oxide, 1.70% sodium oxide and 0.71% titanium oxide.

[0085] The solid material is ground to an average particle size of 300 meshes, and then 120 g of water is added and mixed to obtain a low-temperature fired colored glaze on the surface of the foamed ceramic.

[0086] (2) The above-mentioned low-temperature fired colored glaze on the surface of the foamed ceramic is applied to the surface of the foamed ceramic prepared in Example 1 with a thickness of 3 mm and dried to obtain a glazed foamed ceramic.

[0087] (3) The glazed foamed ceramic is heated from room temperature to 150°C within 30 minutes, then kept at this temperature for 10 minutes, then heated to 550°C at a constant speed within 1 hour, kept at this temperature for 10 minutes, and finally heated to 800°C at a constant speed within 30 minutes, kept at this temperature for 20 minutes, and finally cooled in the furnace.

[0088] Finished product Figure 6 and 7 As shown, it can be seen that the colored glaze can be evenly spread on the surface of the foamed ceramic, but due to the high firing temperature, the foamed ceramic is severely deformed and breaks during the firing process.

[0089] The above description is only a preferred embodiment of the present invention, and therefore cannot be used to limit the scope of the present invention. That is, equivalent changes and modifications made according to the patent scope of the present invention and the contents of the specification should still fall within the scope of the present invention.

Claims

1. A low-temperature fired colored glaze on the surface of a foamed ceramic, characterized in that: The sintering temperature is 650-750°C, and the solid materials include the following components by weight: 2-3 parts of potassium feldspar, 2-3 parts of lithium feldspar, 2-3 parts of talc, 4.5-7 parts of calcite, 6-9 parts of kaolin, 20-30 parts of borax, 10-15 parts of zinc oxide, 16-25 parts of quartz, 6.5 parts to 10 parts of yellow mud clay and 4-6 parts of colorant.

2. The low-temperature fired colored glaze on the surface of foamed ceramics as claimed in claim 1, characterized in that: The yellow mud clay comprises the following components: 67-74% silicon dioxide, 14.5-17.99% aluminum oxide, 3.27-6.61% iron oxide, 0.75-1.68% calcium oxide, 0.89-2.07% magnesium oxide, 2-3% potassium oxide, 1.5-2% sodium oxide, and the rest are oxides of trace elements.

3. The low-temperature fired colored glaze on the surface of foamed ceramics according to claim 1 or 2, characterized in that: The solid-liquid ratio is 0.8-1.2:

1.

4. The low-temperature fired colored glaze on the surface of foamed ceramics according to claim 1 or 2, characterized in that: The average particle size of the low-temperature fired colored glaze on the surface of the foamed ceramic is 280-320 meshes.

5. A method for secondary firing of foamed ceramic surface glaze, characterized in that: The steps include: (1) applying the low-temperature fired colored glaze on the surface of the foamed ceramic according to any one of claims 1 to 4 to the surface of the foamed ceramic, and drying the glazed foamed ceramic; (2) The glazed foamed ceramic is first heated uniformly from room temperature to 145-155° C. in a kiln within 28-32 minutes, and kept at this temperature for 8-12 minutes. Then, the temperature is uniformly heated to 545-555° C. within 58-62 minutes, and kept at this temperature for 18-22 minutes. Finally, the temperature is uniformly heated to 650-750° C. within 48-52 minutes, and kept at this temperature for 18-22 minutes. The ceramic is then cooled in the kiln.

6. The foamed ceramic surface glaze secondary firing process as claimed in claim 5, characterized in that: The coating thickness of the low-temperature fired colored glaze on the surface of the foamed ceramic is less than 1 mm.

7. The foamed ceramic surface glaze secondary firing process as claimed in claim 5, characterized in that: The drying time in step (1) is 3-3.5 hours.

8. The foamed ceramic surface glaze secondary firing process as claimed in claim 5, characterized in that: Before applying the colored glaze fired at low temperature on the surface of the foamed ceramic to the surface of the foamed ceramic, the surface of the foamed ceramic is cleaned.

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