Preparation method and application of dry filling mud for ceramic repair

Abstract

The present application relates to the technical field of ceramics, in particular to a preparation method and application of dry repair mud for ceramic repair. The present application makes the repaired ceramic overcome the shortcomings of uneven color and short service life. The preparation method of the dry repair mud for ceramic repair is as follows: composite porcelain powder, modified reinforcing agent and composite fiber are first wet ball milled, then a dispersant mixture, modified thickening agent and calcium silicate are continuously wet ball milled, and the dry repair mud is obtained after drying; the dry repair mud is applied to ceramic body repair, the amount of composite porcelain powder, the proportion of each component in the composite porcelain powder and the control of ball milling time make the color difference of the repaired ceramic decrease; the addition of the modified reinforcing agent and the control of the water content make the repaired ceramic not crack; the control of the amount of the composite fiber and the dispersant mixture improves the wear resistance of the repaired ceramic; the addition of the modified thickening agent reduces the water absorption of the repaired ceramic; and the control of the amount of the calcium silicate and the parameters in the repair improves the strength of the repaired ceramic.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of ceramics, in particular to a preparation method and application of dry repair mud for ceramic repair. BACKGROUND

[0002] In the process of ceramic production, all processes will inevitably have the phenomenon of ceramic body cracking, brown eye, etc., and the handling between different processes will also have the phenomenon of knocking, thereby reducing the qualified rate of ceramic products, so it is crucial to repair the ceramic body, which can improve the service life of the ceramic to a certain extent and improve the production efficiency. Generally, small defects will use the body raw material mud of the ceramic itself for repair, which can achieve good results, but when encountering larger crack defects, only the body raw material mud can be used for repair to fill the space of the body cracking, but the internal particles that have been broken are not connected, and the second calcination is easy to cause cracking.

[0003] Patent CN106083018B discloses a repair body mud for ceramic dry body repair, a preparation method and application thereof, and provides two formulas, and the two formulas are mixed to form the repair body mud. The repair body mud provided by the application has small drying shrinkage after repair and drying, is consistent with the repaired body, and has a porcelainization degree close to the ceramic water absorption rate. However, the repair body mud in the application only changes the proportion of feldspar, quartz, dolomite and other raw materials, and can only simply repair the body, and the ceramic after firing has low compressive strength and short service life, and the repaired part is easy to be damaged again.

[0004] Patent CN101717268B discloses a ceramic mud body repair body material, a preparation method and a repair process. The ceramic mud body repair body material prepared by adding auxiliary modification materials has high tensile resistance, small shrinkage, and can perfectly combine with dry mud body materials. Due to the unique three-dimensional network structure of the ceramic mud body repair body material, the adhesion between the ceramic mud body particles is greatly enhanced, not only can the repair part be stabilized during the drying process, but also can be integrated with the ceramic body during the firing process, and can completely repair the drying cracking of the mud body. However, the addition of glass fibers will affect the strength and brittleness of the repair body material, making the repair body material have poor adhesion and being not easy to repair, and the glass fibers themselves are relatively expensive, increasing the production cost.

[0005] In summary, the dry repair mud for ceramic repair still has the problem of poor adhesion, which causes the repaired ceramic to have uneven color and short service life, and seriously affects the production efficiency.

[0006] Therefore, a preparation method and application of dry repair mud for ceramic repair are provided. SUMMARY

[0007] The application aims to design a preparation method and application of dry repair mud for ceramic repair. The application overcomes the shortcomings of uneven color and short service life of the repaired ceramic. The preparation method of the dry repair mud for ceramic repair comprises the following steps: wet ball milling of composite porcelain powder, modified reinforcing agent and composite fiber, addition of a dispersant mixture, modified thickening agent and calcium silicate for continuous wet ball milling after the particle size reaches a certain value, and drying to obtain the dry repair mud for ceramic repair. The dry repair mud is applied to the repair of ceramic green bodies. The color difference of the repaired ceramic is reduced by changing the amount of composite porcelain powder, the proportion of components in the composite porcelain powder and the ball milling time. The high temperature resistance of the repaired ceramic is improved by preparing a modified reinforcing agent and controlling the water content of the dry repair mud. The wear resistance of the repaired ceramic is improved by changing the amount of composite fiber and dispersant mixture and the proportion of components therein. The water absorption of the repaired ceramic is reduced by controlling the parameter conditions for preparing the modified thickening agent. The compressive strength and bending strength of the repaired ceramic are improved by changing the amount of calcium silicate and the parameters in the process of repairing the ceramic green body.

[0008] To achieve the above object, the application provides the following technical scheme.

[0009] The application provides a preparation method of dry repair mud for ceramic repair.

[0010] The waste porcelain chips are put into a pulverizer for pulverization to obtain waste porcelain powder. The waste porcelain powder, green body powder and glaze powder are mixed to obtain composite porcelain powder.

[0011] The mixture of mullite and potassium feldspar is modified by adding an acrylate copolymer to obtain a modified reinforcing agent.

[0012] The mixture of methyl cellulose and hydroxypropyl methyl cellulose is crosslinked by adding diisocyanate to obtain a modified thickening agent.

[0013] 62-66 parts of the composite porcelain powder, 11-15 parts of the modified reinforcing agent and 3-7 parts of composite fiber are weighed according to the weight fraction, and 30 parts of deionized water is used as a medium for one-time wet ball milling for 2-5 hours, so that the number of particles with a particle size of 15 μm reaches more than 65%, and mud A is obtained.

[0014] 0.6-1 parts of a dispersant mixture, 0.1-0.4 parts of the modified thickening agent and 0.07-0.1 parts of calcium silicate are added to the mud A for secondary wet ball milling for 5-8 hours to obtain mud B.

[0015] The mud B is naturally dried until the water content is 13%-17% to obtain the dry repair mud for ceramic repair.

[0016] Preferably, the waste porcelain powder is selected from waste porcelain chips for secondary utilization, which can not only reduce environmental pollution, but also save resources, reduce costs and effectively improve production efficiency.

[0017] Preferably, the weight ratio of the waste porcelain powder, the body powder and the glaze powder is 5-8:1:0.5.

[0018] Preferably, the chemical composition of the waste porcelain powder is 63.2% SiO2, 18.8% Al2O3, 8.1% CaO, 4.5% MgO, 1.3% Fe2O3, 2.1% K2O, 0.9% Na2O and 1.1% TiO2; the chemical composition of the body powder is 62.7% SiO2, 27.4% Al2O3, 5.3% CaO, 2.0% MgO, 0.7% Fe2O3, 0.7% K2O, 0.8% Na2O and 0.4% TiO2; and the chemical composition of the glaze powder is 61.3% SiO2, 14.5% Al2O3, 13.1% CaO, 2.6% MgO, 1.9% Fe2O3, 3.7% K2O, 2.5% Na2O and 0.4% TiO2.

[0019] Preferably, the preparation method of the modified reinforcing agent is as follows: 14-18 parts of the mullite and 4 parts of the potassium feldspar are ground until the particle size reaches 10 μm to obtain a mixed powder; 1-4 parts of the acrylate copolymer and 8 parts of deionized water are added to the mixed powder, followed by stirring for 3-6 h until the mixture is uniform to obtain the modified reinforcing agent.

[0020] Preferably, the preparation method of the modified thickening agent is as follows: 2-6 parts of the methyl cellulose and 3 parts of the hydroxypropyl methyl cellulose are added to 6 parts of deionized water, and stirred until the mixture is uniform to obtain a cellulose mixture; 0.5-2 parts of the diisocyanate is added to the cellulose mixture, and stirred for 1 h to obtain a thickening agent precursor; the thickening agent precursor is transferred to a reaction kettle for crosslinking reaction at 115-130℃ for 3 h, and then cooled, centrifuged and dried to obtain the modified thickening agent.

[0021] Preferably, the composite fiber is a mixture of polypropylene fiber, polyester fiber and carbon fiber; and the weight ratio of the polypropylene fiber, the polyester fiber and the carbon fiber is 3-7:2:1.

[0022] Preferably, the dispersant mixture is a mixture of polyvinyl alcohol and polycarboxylic acid; and the weight ratio of the polyvinyl alcohol and the polycarboxylic acid is 6-9:2.

[0023] In another aspect, the application provides a dry repair mud for ceramic repair.

[0024] S1 clean the body crack, remove the ash and other impurities existing in the body crack, the cleaning depth is 1.5-2.5mm;

[0025] S2 wet the body crack with deionized water, and dry the crack naturally;

[0026] S3 fill part of the dry repair mud in the body crack, and compact it, then continue to fill the dry repair mud until the compacted part is higher than the body surface around the repair part, wet the repair part and the surrounding part with deionized water;

[0027] S4 after natural drying, remove the part of the body surface that is higher, and polish the repair part, then glaze and put it into the kiln, and finally complete the ceramic repair by firing at a temperature TE1 for a time TI1.

[0028] Preferably, the height of the body surface around the repair part in S3 is 1mm.

[0029] Preferably, the temperature TE1 in S4 is 1100-1140℃, and the time TI1 is 20-23h.

[0030] Compared with the prior art, the present application has the following advantages:

[0031] 1. By changing the amount of composite porcelain powder, the ratio of each component in the composite porcelain powder, and the ball milling time, the color difference of the repaired ceramic is reduced. The use of waste porcelain powder is a secondary utilization of waste porcelain chips, which reduces environmental pollution, saves resources, and effectively improves production efficiency. The waste porcelain powder, body powder and glaze powder are mixed, and the chemical composition of the mixture is similar to that of the ceramic body, which can effectively fill the cracks of the body and maintain a high similarity in color, so that the repaired ceramic has small color difference. The ball milling time determines the fineness of the composite porcelain powder. If the fineness is too coarse, the dry repair mud and the body will not be tightly combined, resulting in large color difference after calcination. If the fineness is too fine, it is easy to cause secondary cracking after calcination. The finally repaired ceramic has no color difference.

[0032] 2. By preparing an improved reinforcing agent and controlling the moisture content of the dry repair mud, the high temperature resistance of the repaired ceramic is improved. The mullite in the improved reinforcing agent has the advantages of low shrinkage and low expansion, so that the repaired ceramic is not easy to crack, and the high temperature resistance of the repaired ceramic is effectively improved. The addition of acrylic acid ester copolymer modifies the mullite and potassium feldspar, effectively improves the adhesion of the dry repair mud, and makes the body and the dry repair mud more tightly combined, so that the ceramic is not easy to crack after calcination, and the service life is prolonged. If the moisture content of the dry repair mud is too high, it will increase the repair difficulty and cause the ceramic to collapse after calcination, resulting in poor repair effect. If the moisture content of the dry repair mud is too low, the body and the dry repair mud are not easy to adhere, and the ceramic is easy to crack after calcination, resulting in poor high temperature resistance. The finally repaired ceramic has strong high temperature resistance and no cracking phenomenon.

[0033] 3、By changing the amount of composite fiber and dispersant mixture and the proportion of each component, the wear resistance of the repaired ceramic is improved. The composite fiber can increase the adhesion between the dry repair mud and the ceramic body, and the reticular structure inside the fiber helps to enhance the adhesion of the dry repair mud, so that the wear resistance of the repaired ceramic is enhanced, and the service life of the ceramic is prolonged; the dispersant mixture makes the components uniformly dispersed, preventing the occurrence of caking phenomenon, and during the repair process of the ceramic body, uneven drying phenomenon does not occur, so that the wear resistance of the repaired ceramic is enhanced, and the durability is enhanced. The wear amount of the repaired ceramic is 2.0 cm 3 .

[0034] 4、By controlling the parameter conditions for preparing the modified thickening agent, the water absorption of the repaired ceramic is reduced. By cross-linking the mixture of methyl cellulose and hydroxypropyl methyl cellulose to improve the performance of the thickening agent, the viscosity and adhesion of the dry repair mud are improved by changing the parameters in the preparation process, so that the repaired ceramic is more dense and the surface is more smooth and flat, thereby reducing the water absorption of the repaired ceramic, reducing the erosion of water to the ceramic, and prolonging the service life of the ceramic. The water absorption of the repaired ceramic is 0.13%.

[0035] 5、By changing the amount of calcium silicate and the parameters during the repair of the ceramic body, the compressive strength and bending strength of the repaired ceramic are improved. Calcium silicate helps to enhance the compressive strength and bending strength of the repaired ceramic, because it can form a more stable phase, thereby improving the overall structural strength of the repaired ceramic, and it also has certain corrosion resistance, effectively prolonging the service life of the repaired ceramic; by controlling the parameter conditions during repair, too high firing temperature will affect the internal structure of the ceramic, reducing the compressive strength and bending strength, and also causing excessive shrinkage of the ceramic, resulting in secondary cracking, and too low firing temperature will cause the dry repair mud to not combine tightly with the ceramic body, the compressive strength and bending strength at the crack are low, and the service life is short. The compressive strength of the repaired ceramic is 118.2 MPa, and the bending strength is 28.4 MPa. BRIEF DESCRIPTION OF DRAWINGS

[0036] Figure 1 The compressive strength diagram of the present application examples 61, 65, 68, 71, 75-76 and comparative examples 10-14. DETAILED DESCRIPTION

[0037] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by a person of ordinary skill in the art without creative effort belong to the protection scope of the present application.

[0038] Specifically referring to Figure 1 The present application provides a preparation method and application of dry repair mud for ceramic repair, and the technical solutions are as follows.

[0039] Embodiment 1

[0040] The waste porcelain pieces are put into a pulverizer for pulverization to obtain waste porcelain powder; the waste porcelain powder, body powder and glaze powder are mixed in a weight ratio of 5:1:0.5 to obtain composite porcelain powder;

[0041] 14 parts of mullite and 4 parts of potassium feldspar are ground until the particle size reaches 10 μm to obtain mixed powder; 1 part of acrylate copolymer and 8 parts of deionized water are added to the mixed powder, followed by stirring for 3 h until uniform mixing to obtain a modified reinforcing agent;

[0042] 2 parts of methyl cellulose and 3 parts of hydroxypropyl methyl cellulose are added to 6 parts of deionized water and stirred until uniformly dispersed to obtain a cellulose mixture; 0.5 parts of diisocyanate is added to the cellulose mixture and stirred for 1 h to obtain a thickening agent precursor; the thickening agent precursor is transferred to a reaction kettle for crosslinking reaction at 115℃ for 3 h, and after cooling, centrifugal drying is performed to obtain a modified thickening agent;

[0043] Polypropylene fibers, polyester fibers and carbon fibers are mixed in a weight ratio of 3:2:1 to obtain composite fibers;

[0044] Polyvinyl alcohol and polycarboxylic acid are mixed in a weight ratio of 6:2 to obtain a dispersant mixture;

[0045] According to weight parts, 62 parts of the composite porcelain powder, 11 parts of the modified reinforcing agent and 3 parts of the composite fibers are weighed, and 30 parts of deionized water is used as a medium for one-time wet ball milling for 2 h, so that the number of particles with a particle size of 15 μm is more than 65%, to obtain mud A;

[0046] 0.6 parts of the dispersant mixture, 0.1 parts of the modified thickening agent and 0.07 parts of calcium silicate are added to the mud A, and secondary wet ball milling is performed for 5 h to obtain mud B;

[0047] The mud B is naturally dried until the water content is 13% to obtain the dry repair mud for ceramic repair.

[0048] The steps of applying the dry patching mud to the ceramic body for repairing are as follows:

[0049] S1, cleaning the body crack, removing the ash and other impurities existing in the body crack, the cleaning depth being 1.5 mm;

[0050] S2, wetting the body crack with deionized water and naturally drying the body crack;

[0051] S3, filling part of the dry patching mud at the body crack and compacting, then continuously filling the dry patching mud until the compacted part is higher than the surface of the body around the repaired part, wetting the repaired part and the surrounding part with deionized water;

[0052] S4, after natural drying, scraping off the part of the body surface that is higher, and polishing the repaired part, then glazing and putting into the kiln, and finally completing the ceramic repairing by firing at 1100℃ for 20h.

[0053] Examples 2-14

[0054] Referring to the preparation method and the application parameter conditions in Example 1, the specific differences are shown in Table 1.

[0055] Table 1 Parameter conditions of Examples 1-14

[0056]

[0057]

[0058] Comparative Example 1 Referring to the preparation method and the application parameter conditions in Example 1, the difference lies in that only waste porcelain powder is used as the raw material.

[0059] Comparative Example 2 Referring to the preparation method and the application parameter conditions in Example 1, the difference lies in that the time of the first wet ball milling is 0.5h and the time of the second wet ball milling is 2h.

[0060] Comparative Example 3 Referring to the preparation method and the application parameter conditions in Example 1, the difference lies in that the time of the first wet ball milling is 8h and the time of the second wet ball milling is 12h.

[0061] Example 15 Color difference test

[0062] The color difference of Examples 1-14 and Comparative Examples 1-3 is tested by using American Easylite X-Rite Ci60 colorimeter, and the color difference before and after the ceramic repairing is detected respectively. When measuring, the standard used is selected first, then the measuring port of the colorimeter is aligned with the ceramic, and the instrument is pressed to start the test. The value displayed on the screen after the measurement is completed is the color difference test result. When ΔE <1, and ΔL, Δa and Δb are within ±0.8, the color difference is qualified. The results are shown in Table 2.

[0063] Table 2 Color difference test of examples 1-14 and comparative examples 1-3

[0064]

[0065]

[0066] As can be seen from Table 1, in comparative example 1, only waste porcelain powder is used as raw material, and the color difference before and after repair is large, so other components need to be introduced to reduce the color difference of the repaired ceramic; in comparative examples 2-3, the ball milling time determines the fineness of the composite porcelain powder, and the fineness that is too coarse makes the dry repair mud not tightly combined with the body, and a large color difference is formed after calcination, and the fineness that is too fine is easy to cause secondary cracking after calcination. In examples 1-14, when the weight fraction ratio of waste porcelain powder, body powder and glaze powder is changed, the amount of composite porcelain powder and the wet ball milling time are unchanged, the color difference first decreases and then increases, and when the weight fraction ratio of waste porcelain powder, body powder and glaze powder is 7:1:0.5, the color difference of example 3 is the smallest; when the weight fraction ratio of waste porcelain powder, body powder and glaze powder is 7:1:0.5, the amount of composite porcelain powder is changed, and the wet ball milling time is unchanged, the color difference is the smallest when the amount of composite porcelain powder is 64 parts, and the color difference of example 6 is the smallest; when the weight fraction ratio of waste porcelain powder, body powder and glaze powder is 7:1:0.5, the amount of composite porcelain powder is 64 parts, and the wet ball milling time is changed, the color difference of example 9 is the smallest, and the wet ball milling time is 3h; when the weight fraction ratio of waste porcelain powder, body powder and glaze powder is 7:1:0.5, the amount of composite porcelain powder is 64 parts, and the wet ball milling time is 3h, the color difference is the smallest when the wet ball milling time is 6h, and the color difference of example 12 is the smallest, which is almost no color difference, because the chemical composition of the waste porcelain powder mixed with the body powder and the glaze powder is similar to that of the body, which can effectively fill the cracks of the body and maintain the high similarity of the color, so that the color difference of the repaired ceramic is small; controlling the wet ball milling time is equivalent to controlling the fineness of the raw material, and maintaining the appropriate fineness can make the dry repair mud and the body combine more tightly, and the color difference is small after calcination; and using waste porcelain powder is a secondary use of waste porcelain chips, which reduces environmental pollution, saves resources, and effectively improves production efficiency.

[0067] Examples 16-33

[0068] Referring to the preparation method and application parameter conditions in example 12, the difference is that the preparation parameters of the modified reinforcing agent and the water content of the dry repair mud are changed, as shown in Table 3.

[0069] Table 3 Parameter conditions of example 12 and examples 16-33

[0070]

[0071]

[0072] Comparative Example 4 refers to the preparation method and the application of the parameters in Example 12, the difference is that only mullite is used as reinforcing agent.

[0073] Comparative Example 5 refers to the preparation method and the application of the parameters in Example 12, the difference is that the moisture content of the dry patching mud is 50%.

[0074] Comparative Example 6 refers to the preparation method and the application of the parameters in Example 12, the difference is that the moisture content of the dry patching mud is 5%.

[0075] Example 34 High temperature resistance test

[0076] Observation is made on whether cracking occurs after calcination for Example 12, Examples 16-33 and Comparative Examples 4-6, and the results are shown in Table 4.

[0077] Table 4 High temperature resistance test of Example 12, Examples 16-33 and Comparative Examples 4-6

[0078]

[0079]

[0080] As can be seen from Table 4, the comparative example 4 only added mullite, and the repaired ceramic still had small cracks, indicating that single mullite was insufficient to improve the high temperature resistance, and it needed to be modified; in the comparative examples 5-6, the repaired ceramic cracked obviously, because the water content of the dry repair mud was too high, which increased the repair difficulty, and was easy to collapse after calcination, so the repair effect was poor, and the water content of the dry repair mud was too low, the body and the dry repair mud were not easy to bond, and were easy to crack after calcination, so the high temperature resistance was poor. In the examples 12, 16-33, when the amount of mullite, the amount of acrylic ester copolymer and modified reinforcing agent, the stirring time and the water content of the dry repair mud were unchanged, the repaired ceramic cracked. When the amount of mullite was 16 parts, the crack of example 17 was smaller; when the amount of mullite was 16 parts, the amount of acrylic ester copolymer, the stirring time, the amount of modified reinforcing agent and the water content of the dry repair mud were changed, the repaired ceramic cracked, and when the amount of acrylic ester copolymer was 3 parts, the crack of example 21 was smaller; when the amount of mullite was 16 parts, the amount of acrylic ester copolymer was 3 parts, the stirring time was changed, the amount of modified reinforcing agent and the water content of the dry repair mud were unchanged, the crack of example 24 was the smallest, and the stirring time was 5 h; when the amount of mullite was 16 parts, the amount of acrylic ester copolymer was 3 parts, the stirring time was 5 h, the amount of modified reinforcing agent was changed, and the water content of the dry repair mud was unchanged, the crack of example 27 was the smallest, and the amount of modified reinforcing agent was 13 parts; when the amount of mullite was 16 parts, the amount of acrylic ester copolymer was 3 parts, the stirring time was 5 h, and the amount of modified reinforcing agent was 13 parts, the water content of the dry repair mud was changed, and example 31 did not crack when the water content of the dry repair mud was 15%, because the mullite in the modified reinforcing agent had the advantages of low shrinkage and low expansion, the repaired ceramic was not easy to crack, and the high temperature resistance of the repaired ceramic was effectively improved; the modification of mullite and potassium feldspar by adding acrylic ester copolymer effectively improved the adhesion of the dry repair mud, so that the body and the dry repair mud were more closely combined, and were not easy to crack after calcination, so the service life was increased; the appropriate water content of the dry repair mud could make the dry repair mud maintain good adhesion, so that the body and the dry repair mud were closely combined, and finally the service life of the ceramic was prolonged.

[0081] Examples 35-49

[0082] Referring to the preparation method and application parameter conditions in example 31, the difference is that the amount of the composite fiber and the dispersant mixture and the proportion of each component therein are changed, as shown in Table 5.

[0083] Table 5 Parameter conditions of example 31 and examples 35-49

[0084]

[0085] Comparative Example 7 refers to the preparation method and application parameter conditions in Example 31, except that no composite fiber is added.

[0086] Comparative Example 8 refers to the preparation method and application parameter conditions in Example 31, except that no dispersant mixture is added.

[0087] Example 50 wear amount test

[0088] Examples 31, 35-49 and Comparative Examples 7-8 are polished for 24 hours, and the wear amount is tested, and the results are shown in Table 6.

[0089] Table 6 Wear amount test of Example 31, Examples 35-49 and Comparative Examples 7-8

[0090] Examples 24h wear volume / cm 3 ]] Example 31 3.2 Example 35 3.0 Example 36 2.9 Example 37 3.1 Example 38 3.2 Example 39 2.8 Example 40 2.7 Example 41 2.9 Example 42 3.0 Example 43 2.5 Example 44 2.4 Example 45 2.6 Example 46 2.3 Example 47 2.0 Example 48 2.2 Example 49 2.4 Comparative Example 7 3.5 Comparative Example 8 3.3

[0091] As can be seen from Table 6, in Comparative Example 7, no composite fiber is added, and the wear amount of the repaired ceramic is large, and the service life of the ceramic is short; in Comparative Example 8, no dispersant mixture is added, and the components in the dry repair mud are prone to agglomeration, thereby forming lumps, and finally the wear amount of the repaired ceramic is large. In Examples 31 and 35-49, when the weight fraction ratio of polypropylene fiber, polyester fiber and carbon fiber is changed, the amount of composite fiber, the weight fraction ratio of polyvinyl alcohol and polycarboxylic acid and the amount of dispersant mixture remain unchanged, the wear amount first decreases and then increases, and when the weight fraction ratio of polypropylene fiber, polyester fiber and carbon fiber is 5:2:1, the wear amount is the smallest, and the wear amount of Example 36 is 2.9 cm 3 ; when the weight fraction ratio of polypropylene fiber, polyester fiber and carbon fiber is 5:2:1, the amount of composite fiber is changed, and the weight fraction ratio of polyvinyl alcohol and polycarboxylic acid and the amount of dispersant mixture remain unchanged, the wear amount of Example 40 is the smallest, which is 2.7 cm 3 ; when the weight fraction ratio of polypropylene fiber, polyester fiber and carbon fiber is 5:2:1, the amount of composite fiber is 5 parts, the weight fraction ratio of polyvinyl alcohol and polycarboxylic acid is changed, and the amount of dispersant mixture remains unchanged, the wear amount is the smallest when the weight fraction ratio of polyvinyl alcohol and polycarboxylic acid is 8:2, and the wear amount of Example 44 is 2.4 cm 3 ; when the weight fraction ratio of polypropylene fiber, polyester fiber and carbon fiber is 5:2:1, the amount of composite fiber is 5 parts, the weight fraction ratio of polyvinyl alcohol and polycarboxylic acid is 8:2, and the amount of dispersant mixture is changed, the wear amount of Example 47 is the smallest when the amount of dispersant mixture is 0.8 parts, which is 2.0 cm 3Because the composite fiber can increase the adhesion between the dry patching mud and the ceramic body, the reticular structure inside the fiber helps to enhance the adhesion of the dry patching mud, so that the wear resistance of the repaired ceramic is enhanced, and the service life of the ceramic is prolonged; the dispersant mixture makes the components uniformly dispersed, prevents the occurrence of caking phenomenon, and does not appear uneven drying phenomenon in the ceramic body repairing process, so that the wear resistance of the repaired ceramic is enhanced, and the service life of the repaired ceramic is prolonged.

[0092] Examples 51-63

[0093] With reference to the preparation method and application parameter conditions in Example 47, the difference lies in changing the preparation parameters of the modified thickening agent and the amount of the modified thickening agent, as shown in Table 7.

[0094] Comparative Example 9 refers to the preparation method and application parameter conditions in Example 47, the difference lies in not adding the modified thickening agent.

[0095] Example 64 Water Absorption Test

[0096] Examples 47, Examples 51-63 and Comparative Example 9 were dried at 105°C to a constant weight; the dried samples were immersed in water for 24 hours; the samples were taken out and the surface water was gently wiped off; the weight after immersion was measured. The water absorption rate (%) was calculated according to the following formula: water absorption rate (%) = (weight after immersion-dry weight) / dry weight x 100%, and the results are shown in Table 7.

[0097] Table 7 Water Absorption Test of Example 47, Examples 51-63 and Comparative Example 9

[0098]

[0099]

[0100] From Table 7, it can be found that the water absorption rate of Comparative Example 9 is 0.51%, which exceeds the industry standard, and the repaired ceramic does not meet the standard. In Example 47 and Examples 51-63, when the amount of methyl cellulose is changed, the amount of diisocyanate, the temperature of cross-linking reaction and the amount of modified thickening agent remain unchanged, the water absorption rate first decreases and then increases, and the water absorption rate of Example 53 is the smallest when the amount of methyl cellulose is 5 parts, which is 0.29%. When the amount of methyl cellulose is 5 parts, the amount of diisocyanate is changed, the temperature of cross-linking reaction and the amount of modified thickening agent remain unchanged, the water absorption rate is the smallest when the amount of diisocyanate is 1.5 parts, and the water absorption rate of Example 56 is 0.23%. When the amount of methyl cellulose is 5 parts and the amount of diisocyanate is 1.5 parts, the temperature of cross-linking reaction is changed, and the amount of modified thickening agent remains unchanged, the water absorption rate of Example 59 is the smallest, because the temperature of cross-linking reaction affects the performance of the final modified thickening agent, thereby affecting the water absorption rate of the repaired ceramic. When the amount of methyl cellulose is 5 parts, the amount of diisocyanate is 1.5 parts, and the temperature of cross-linking reaction is 125°C, the amount of modified thickening agent is changed, and the water absorption rate is the smallest when the amount of modified thickening agent is 0.2 parts, and the water absorption rate of Example 61 is 0.13%. Because the cross-linking reaction of the mixture of methyl cellulose and hydroxypropyl methyl cellulose can improve the performance of the thickening agent, by changing the parameters in the preparation process, the viscosity and adhesion of the dry repair mud can be improved, the repaired ceramic is more compact and the surface is smoother, thereby reducing the water absorption rate of the repaired ceramic, reducing the erosion of water to the ceramic, and prolonging the service life of the ceramic. Controlling the amount of modified thickening agent can make the dry repair mud have the strongest adhesion, making the dry repair mud combine more closely at the crack of the body, reducing the water absorption rate of the repaired ceramic, and enhancing the durability of the repaired ceramic.

[0101] Examples 65-76

[0102] Referring to the preparation method and application parameter conditions in Example 61, the difference is that the amount of calcium silicate and the parameters in the process of repairing the ceramic body are changed, as shown in Table 8.

[0103] Table 8 Parameter conditions of Example 61 and Examples 65-76

[0104]

[0105]

[0106] Comparative Example 10 refers to the preparation method and application parameter conditions in Example 61, the difference is that no calcium silicate is added.

[0107] Comparative Example 11 refers to the preparation method and application parameter conditions in Example 61, the difference is that the treatment depth is 0 mm.

[0108] Comparative Example 12 refers to the preparation method and application parameters in Example 61, except that the treatment depth is 6 mm.

[0109] Comparative Example 13 refers to the preparation method and application parameters in Example 61, except that the sintering temperature is 1500°C and the sintering time is 30 h.

[0110] Comparative Example 14 refers to the preparation method and application parameters in Example 61, except that the sintering temperature is 800°C and the sintering time is 10 h.

[0111] Example 77 Compression and Bending Strength Test

[0112] The compression strength was tested using a compression testing machine, which gradually applied pressure until the repaired ceramic was damaged; the following formula was used for calculation: σ = P / A. In the formula, σ is the compression strength (MPa); P is the maximum load applied (N); A is the force area of the sample (mm 2 ).

[0113] The bending strength was tested using a three-point bending test device, which applied uniform force in the middle of the sample until the repaired ceramic was damaged or significantly deformed; the following formula was used for calculation: Bending strength (MPa) = 3PL / 2bd 2 . In the formula, P is the maximum load applied (N); L is the support spacing (mm); b is the sample width (mm); and d is the sample thickness (mm).

[0114] The results obtained are shown in Table 9 and Figure 1 .

[0115] Table 9 Compression and Bending Strength Test of Example 61, Examples 65-76, and Comparative Examples 10-14

[0116]

[0117]

[0118] Table 9 and Figure 1It can be found that the compressive strength and the bending strength of the repaired ceramic in Comparative Example 10 are obviously lowered without adding calcium silicate, because it can form more stable phases during firing, thereby improving the overall structural strength of the repaired ceramic, and it also has certain corrosion resistance, effectively prolonging the service life of the repaired ceramic; in Comparative Examples 11-12, the compressive strength and the bending strength are weak, because the too shallow treatment depth can cause the dry repair mud to be unable to provide sufficient supporting force, so that the direct combination with the ceramic body is not tight, and the too deep treatment depth can cause the local material to be unstable, thereby affecting the strength of the repaired ceramic; the compressive strength and the bending strength of Comparative Examples 13-14 are very low, because the too high firing temperature can affect the internal structure of the ceramic, so that the compressive strength and the bending strength are reduced, and it can also cause excessive shrinkage of the ceramic, resulting in secondary cracking, and the too low firing temperature can cause the dry repair mud to be not tightly combined with the ceramic body, the compressive strength and the bending strength at the crack are low, and the service life is short. In Example 61 and Examples 65-76, when the amount of calcium silicate is changed, the treatment depth, the firing temperature and the time are unchanged, the compressive strength and the bending strength first increase and then decrease, when the amount of calcium silicate is 0.08 parts, the strength of Example 65 is the largest, the compressive strength is 115.2 MPa, and the bending strength is 26.0 MPa; when the amount of calcium silicate is 0.08 parts, the treatment depth is changed, the firing temperature and the time are unchanged, the compressive strength and the bending strength first increase and then decrease, when the treatment depth is 2.0 mm, the strength of Example 68 is the largest, the compressive strength is 115.9 MPa, and the bending strength is 26.4 MPa; when the amount of calcium silicate is 0.08 parts, the treatment depth is 2.0 mm, the firing temperature is changed, and the firing time is unchanged, the compressive strength and the bending strength are the largest when the firing temperature is 1120℃, the compressive strength of Example 71 is 117.1 MPa, and the bending strength is 27.5 MPa; when the amount of calcium silicate is 0.08 parts, the treatment depth is 2.0 mm, and the firing temperature is 1120℃, the firing time is changed, the compressive strength and the bending strength of Example 75 reach the maximum when the firing time is 22 h, at this time, the compressive strength is 118.2 MPa, and the bending strength is 28.4 MPa, because the appropriate amount of calcium silicate can improve the overall strength of the repaired ceramic; the appropriate treatment depth can ensure that the dry repair mud fully penetrates and is firmly combined with the crack, thereby enhancing the overall strength of the repaired ceramic; the appropriate firing temperature and time ensure that the dry repair mud is fully combined with the internal structure of the ceramic body, the ceramic does not crack again, the compressive strength and the bending strength are improved, and the service life of the repaired ceramic is prolonged.

[0119] While embodiments of the application have been shown and described, it is to be understood that the embodiments described are merely exemplary of the principles and application of the present application. Numerous modifications and adaptions can be effected without departing from the spirit and scope of the present application, which is not limited to the exact construction and arrangement described. It is intended, therefore, to cover all modifications and adaptions that fall within the scope of the claims and their equivalents.

Claims

1. A method for preparing a ceramic repair dry putty, characterized in that: The preparation method of the ceramic repair dry repair mud is as follows: The waste porcelain chips are put into a pulverizer for pulverization to obtain waste porcelain powder; the waste porcelain powder, body powder and glaze powder are mixed to obtain composite porcelain powder; The mixture of mullite and potassium feldspar is modified by adding acrylic ester copolymer to obtain an improved reinforcing agent; the preparation method of the improved reinforcing agent is as follows: 16 parts of the mullite and 4 parts of the potassium feldspar are ground until the particle size reaches 10 microns to obtain a mixed powder; 3 parts of the acrylic ester copolymer and 8 parts of deionized water are added to the mixed powder, followed by stirring for 5 hours until the mixture is uniform to obtain the improved reinforcing agent; The mixture of methyl cellulose and hydroxypropyl methyl cellulose is crosslinked by adding diisocyanate to obtain a modified thickening agent; According to weight parts, 62-66 parts of the composite porcelain powder, 13 parts of the improved reinforcing agent and 3-7 parts of composite fiber are weighed, 30 parts of deionized water is used as a medium for one-time wet ball milling for 2-5 hours, so that the number of particles with a particle size of 15 microns is more than 65%, and mud A is obtained; 0.6-1 parts of a dispersant mixture, 0.1-0.4 parts of the modified thickening agent and 0.07-0.1 parts of calcium silicate are added to the mud A for secondary wet ball milling for 5-8 hours to obtain mud B; The mud B is naturally dried until the water content is 15% to obtain the ceramic repair dry repair mud.

2. The method for preparing a dry patching mud for ceramic repair according to claim 1, characterized in that: The weight part ratio of the waste porcelain powder, the body powder and the glaze powder is 5-8:1:0.

5.

3. The method for preparing a dry patching mud for ceramic repair according to claim 2, characterized in that: The chemical composition of the waste porcelain powder is 63.2% SiO2, 18.8% Al2O3, 8.1% CaO, 4.5% MgO, 1.3% Fe2O3, 2.1% K2O, 0.9% Na2O and 1.1% TiO2; the chemical composition of the body powder is 62.7% SiO2, 27.4% Al2O3, 5.3% CaO, 2.0% MgO, 0.7% Fe2O3, 0.7% K2O, 0.8% Na2O and 0.4% TiO2; and the chemical composition of the glaze powder is 61.3% SiO2, 14.5% Al2O3, 13.1% CaO, 2.6% MgO, 1.9% Fe2O3, 3.7% K2O, 2.5% Na2O and 0.4% TiO2.

4. The method for preparing a dry patching mud for ceramic repair according to claim 1, characterized in that: The preparation method of the modified thickening agent is as follows: 2-6 parts of the methyl cellulose and 3 parts of the hydroxypropyl methyl cellulose are added to 6 parts of deionized water and stirred until the mixture is uniformly dispersed to obtain a cellulose mixture; 0.5-2 parts of the diisocyanate is added to the cellulose mixture and stirred for 1 hour to obtain a thickening agent precursor; the thickening agent precursor is transferred into a reaction kettle for crosslinking reaction at 115-130 degrees Celsius for 3 hours, and the modified thickening agent is obtained after cooling, centrifugation and drying.

5. The method for preparing a dry patching ceramic patching mud according to claim 1, characterized in that: The composite fiber is a mixture of polypropylene fiber, polyester fiber and carbon fiber; the weight part ratio of the polypropylene fiber, the polyester fiber and the carbon fiber is 3-7:2:

1.

6. The method for preparing a dry patching mud for ceramic repair according to claim 1, characterized in that: The dispersant mixture is a mixture of polyvinyl alcohol and polycarboxylic acid; the weight ratio of the polyvinyl alcohol to the polycarboxylic acid is 6-9:

2.

7. Use of a ceramic repair dry putty, characterized in that: The dry patching mud prepared by the preparation method of any one of claims 1-6 is used in the step of repairing a ceramic body, and the repairing process comprises the following steps: S1 cleaning the body crack, removing the ash and impurities existing in the body crack, and the cleaning depth is 1.5-2.5 mm; S2 wetting the body crack with deionized water and naturally drying the body crack; S3 filling part of the dry patching mud into the body crack and compacting, then continuously filling the dry patching mud until the compacted part is higher than the body surface around the repaired part, wetting the repaired part and the surrounding part with deionized water; S4 after natural drying, scraping off the part higher than the body surface around the repaired part, polishing the repaired part, then glazing and putting into a kiln, firing at a temperature TE1 for a time TI1, and finally completing the ceramic repairing.

8. Use of a ceramic dry patching mud according to claim 7, characterized in that: The height of the part higher than the body surface around the repaired part in S3 is 1 mm.

9. Use of a ceramic dry patching mud according to claim 7, characterized in that: The temperature TE1 in S4 is 1100-1140℃; and the time TI1 is 20-23 h.

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