Medium-temperature light-weight ceramic clay and preparation process thereof

Abstract

The invention relates to the technical field of ceramics, and particularly discloses medium-temperature light-weight ceramic mud and a preparation process thereof. The medium-temperature light-weight ceramic clay comprises the following substances in parts by weight: 30-50 parts of dolomite; 10 to 15 parts of aluminum powder; 20 to 40 parts of feldspar; 10 to 20 parts of quartz; 10 to 20 parts of sodium silicate; the feldspar comprises porous anorthite; the preparation process comprises the following steps: S1, preparing raw materials; s2, preparing the ceramic mud. The ceramic clay provided by the invention can be used for firing ceramic containers and the like, and has the advantages of light weight and high strength.

Description

Technical Field

[0001] The present application relates to the technical field of ceramics, and more specifically, to a medium-temperature lightweight ceramic mud and a preparation process thereof. Background Art

[0002] Ceramic clay is fired at different temperatures to produce ceramics with different whiteness, but the weight of ceramics of different whiteness and types is similar. Since ceramics are a relatively heavy product, in daily life, if some people with less strength, such as children and the elderly, use larger ceramic containers to store food or other things, they are likely to be unable to lift them due to the weight and need an extra person to help. Therefore, it is necessary to improve ceramic clay. Summary of the invention

[0003] In order to improve some accidents caused by excessive weight of ceramic products, the present application provides a medium-temperature lightweight ceramic mud and a preparation process thereof.

[0004] The present application provides a medium-temperature lightweight ceramic mud, which adopts the following technical solution: In a first aspect, the present application provides a medium-temperature lightweight ceramic mud, comprising the following substances in parts by weight: 30-50 parts of dolomite; 10-15 parts of aluminum powder; Feldspar 20-40 parts; Quartz 10-20 parts; Sodium silicate 10-20 parts; The feldspar includes porous calcium feldspar.

[0005] By adopting the above technical scheme, dolomite is preferably used as the base material of ceramic mud. Dolomite has a low water absorption rate and a light weight, can achieve the strength of stone porcelain, and can also be differentiated and degraded. Therefore, the ceramic products prepared using the ceramic mud of the present application have a lighter weight and suitable strength, thereby greatly reducing the possibility of accidental damage caused by the ceramic preparation being too heavy.

[0006] At the same time, the present application selects porous calcium feldspar and adds it to the ceramic mud. Calcium feldspar has the advantages of low volume density, excellent volume stability, small thermal expansion coefficient, and low thermal conductivity. The porous structure can further reduce the mass and density of calcium feldspar. Introducing a hollow structure into the ceramic mud can further reduce the mass of the ceramic mud.

[0007] Optionally, the porous calcium feldspar is a calcium feldspar-mullite composite material.

[0008] By adopting the above technical scheme, it is preferred to use calcium feldspar and mullite to form a composite material. Since mullite has better mechanical properties, high melting point, excellent slag resistance, etc., it can effectively improve the mechanical strength of the composite material, so that the ceramic mud can obtain a lighter weight while maintaining better strength.

[0009] Optionally, coal gangue, clay and calcium carbonate are taken separately, mixed, ball-milled, hydraulically pressed, dried, sintered and crushed to obtain porous calcium feldspar, wherein the mass ratio of coal gangue, clay and calcium carbonate is 85-86:4:10-11.

[0010] By adopting the above technical scheme, the mass ratio of coal gangue, clay and calcium carbonate is optimized. At an appropriate mass ratio, calcium feldspar can be evenly wrapped outside the mullite, so that a better ratio of calcium feldspar to mullite can be obtained in the composite material, and the composite material has uniform pores, so that the ceramic mud can obtain uniform mass distribution and strength.

[0011] Optionally, the hydraulic pressure in the preparation of the porous calcium feldspar is 50-75 MPa.

[0012] By adopting the above technical solution, the hydraulic pressure is optimized, and under appropriate pressure, the particles can be appropriately stacked and the particle spacing can be appropriate, and the gas generated by burning can be discharged smoothly, thereby forming appropriate pores in the composite material and achieving a moderate degree of densification, so that the composite material has light weight and high strength.

[0013] Optionally, the feldspar also includes Ulan citrine.

[0014] By adopting the above technical scheme, it is preferred to use Ulan citrine as feldspar. Ulan citrine contains a variety of trace rare earth elements, which can significantly reduce the sintering temperature of ceramics, increase the strength of ceramics, and can be combined with mullite to form closed pores in ceramic mud, thereby further reducing the weight of ceramics while improving the strength of ceramics.

[0015] Optionally, 3-5 parts of reinforcing materials are also included, and the reinforcing materials include any one or more of cordierite whiskers, alumina whiskers and brown corundum powder.

[0016] By adopting the above technical solution, the introduction of cordierite whiskers can construct a three-dimensional network structure in the ceramic mud and enhance the bonding effect between the components in the ceramic mud. The cordierite whiskers can cooperate with the feldspar particles to form an interlaced structure, thereby stably enhancing the strength of the ceramic.

[0017] The introduction of alumina whiskers can not only build a three-dimensional network structure skeleton in ceramic mud, but also serve as a stable supporting structure in the finished ceramic product, which can effectively reduce the possibility of pore structure collapse in ceramic mud, maintain the pore structure and structural stability in the finished ceramic product, and enable the ceramic to obtain better strength and light weight. In addition, alumina whiskers can promote the formation of secondary mullite in ceramic mud, increase the mullite phase content in ceramic mud, and the crystal phase of ceramic mud changes during the sintering process. The newly formed mullite phase and the nano-grain boundaries in the whiskers can absorb energy, effectively improving the toughness of ceramic products.

[0018] The introduction of brown corundum powder, as it contains more alumina, can induce the formation of reinforcing phase cordierite in ceramic mud, further strengthen the skeleton structure in ceramic products, and further improve the mechanical strength of ceramic products. The addition amount of brown corundum powder is optimized, and the appropriate addition amount can enable brown corundum powder to stably improve the mechanical strength of ceramic products and maintain the lightweight of ceramic products.

[0019] Through the mutual coordination between brown corundum powder, alumina whiskers and cordierite whiskers, the content of cordierite phase and mullite phase in ceramic products can be effectively increased. The reinforcement phase and the fiber structure cooperate to form a better reinforcement skeleton structure, which is conducive to the ceramic products to obtain the excellent characteristics of light weight and high strength.

[0020] Optionally, 3-5 portions of gelatin microspheres are also included.

[0021] By adopting the above technical scheme, the introduction of gelatin microspheres can serve as a binding phase to improve the bonding strength between the components in the ceramic mud, and can round off some sharp edges in the ceramic mud to improve the bonding strength between the components in the ceramic mud. The hollow structure of the gelatin microspheres can enable the ceramic to obtain a regular pore structure, so that the ceramic has low weight and high strength.

[0022] Optionally, the gelatin microspheres are coated with diaspore powder or silicon carbide powder.

[0023] By adopting the above technical solution, encapsulating diaspore powder or silicon carbide powder outside the gelatin microspheres can form a regularly shaped microporous structure in the ceramic, and finally make the ceramic obtain uniform light weight.

[0024] Optionally, the gelatin microspheres are prepared as follows: water, gelatin and glucose are mixed to obtain a gelatin solution, the gelatin solution is added dropwise to the oil phase, stirred to obtain a gelatin microsphere suspension, low-temperature frozen, filtered, dried, and diaspore powder or silicon carbide powder is wrapped around the gelatin microspheres to obtain gelatin microspheres.

[0025] In the second aspect, the present application provides a process for preparing medium-temperature lightweight ceramic mud, which adopts the following technical solution: A process for preparing medium-temperature lightweight ceramic mud comprises the following steps: S1. Raw material preparation: Take dolomite, aluminum powder, feldspar, quartz and sodium silicate respectively by weight, add water, and ball grind; S2. Preparation of ceramic mud: The ball-milled slurry is sieved, iron removed, and filtered in sequence to obtain ceramic mud with a water content of 23-23.5%.

[0026] In summary, this application has the following beneficial effects: 1. Since the present application preferably uses dolomite as the base material of ceramic mud, dolomite has a low water absorption rate and a light weight, can achieve the strength of stone porcelain, and can also be differentiated and degraded, and the ceramic products prepared using the ceramic mud of the present application have a light weight and suitable strength, thereby greatly reducing the possibility of accidental damage caused by the ceramic preparation being too heavy. At the same time, the present application selects porous calcium feldspar to be added to the ceramic mud. Calcium feldspar has the advantages of low bulk density, excellent volume stability, small thermal expansion coefficient, and low thermal conductivity. The porous structure can further reduce the mass and density of calcium feldspar. Introducing a hollow structure into the ceramic mud can further reduce the mass of the ceramic mud.

[0027] 2. In this application, Ulan citrine is preferably used as feldspar. Ulan citrine contains a variety of trace rare earth elements, which can significantly reduce the sintering temperature of ceramics and increase the strength of ceramics. In addition, the introduction of mullite can form closed pores in ceramic mud, thereby further reducing the weight of ceramics while improving the strength of ceramics.

[0028] 3. In this application, due to the introduction of cordierite whiskers, a three-dimensional network structure can be constructed in the ceramic mud, and the bonding effect between the components in the ceramic mud can be enhanced. The cordierite whiskers can cooperate with the feldspar particles to form an interlaced structure, which can stably enhance the strength of the ceramic. Through the mutual cooperation between brown corundum powder, alumina whiskers and cordierite whiskers, the content of cordierite phase and mullite phase in the ceramic product can be effectively increased, and the reinforcing phase and the fiber structure can cooperate to form a relatively good reinforcing skeleton structure, which is conducive to the ceramic product to obtain the excellent characteristics of light weight and high strength. DETAILED DESCRIPTION

[0029] The present application is further described in detail below with reference to the embodiments.

[0030] Preparation Example Preparation example of porous calcium feldspar Preparation Example 1 Coal gangue, clay and calcium carbonate are taken separately, mixed, ball-milled, hydraulically pressed at 50 MPa, dried at 1300°C, sintered and crushed to obtain porous calcium feldspar, wherein the mass ratio of coal gangue, clay and calcium carbonate is 68:4:28.

[0031] Preparation Example 2 Coal gangue, clay and calcium carbonate are taken separately, mixed, ball-milled, hydraulically pressed at 50 MPa, dried at 1300°C, sintered and crushed to obtain porous calcium feldspar, wherein the mass ratio of coal gangue, clay and calcium carbonate is 81.2:4:14.8.

[0032] Preparation Example 3 Coal gangue, clay and calcium carbonate are taken separately, mixed, ball-milled, hydraulically pressed at 50 MPa, dried at 1300°C, sintered and crushed to obtain porous calcium feldspar, wherein the mass ratio of coal gangue, clay and calcium carbonate is 85.5:4:10.5.

[0033] Preparation Example 4 Coal gangue, clay and calcium carbonate are taken separately, mixed, ball-milled, hydraulically pressed at 75 MPa, dried at 1300°C, sintered and crushed to obtain porous calcium feldspar, wherein the mass ratio of coal gangue, clay and calcium carbonate is 81.2:4:14.8.

[0034] Gelatin microsphere preparation example Preparation Example 5 Deionized water, gelatin, and glucose (added at 0.065 g / L) were mixed in a beaker, and then stirred rapidly at 50°C to obtain a uniform 176.5 g / L hot gelatin solution. The gelatin solution was added dropwise to the preheated oil phase (water-oil ratio of 1:5) using a peristaltic pump, and stirred at 150 rpm for 30 min to obtain a gelatin microsphere suspension, which was then frozen at 4°C for 2 h using a low-temperature coolant circulation pump, the upper oil phase was filtered off, and the lower microspheres were washed, filtered, and dried to obtain the finished gelatin microspheres.

[0035] Preparation Example 6 Deionized water, gelatin, and glucose (addition amount of 0.065 g / L) were mixed in a beaker, and then stirred rapidly at 50°C to obtain a uniform 176.5 g / L hot gelatin solution. The gelatin solution was added dropwise to the preheated oil phase (water-oil ratio of 1:5) using a peristaltic pump, and stirred at 150 rpm for 30 min to obtain a gelatin microsphere suspension, which was then frozen at 4°C for 2 h using a low-temperature coolant circulation pump, the upper oil phase was filtered out, and the lower microspheres were washed, filtered, and dried to obtain finished gelatin microspheres. The surface of the prepared gelatin spheres was coated with pseudo-boehmite powder, and composite microspheres were obtained by a granulation method, which were then dried and sintered to obtain gelatin microspheres with a coating layer.

[0036] Preparation Example 7 Deionized water, gelatin, and glucose (added at 0.065 g / L) were mixed in a beaker, and then stirred rapidly at 50°C to obtain a uniform 176.5 g / L hot gelatin solution. The gelatin solution was added dropwise to the preheated oil phase (water-oil ratio of 1:5) using a peristaltic pump, and stirred at 150 rpm for 30 min to obtain a gelatin microsphere suspension, which was then frozen at 4°C for 2 h using a low-temperature coolant circulation pump, the upper oil phase was filtered out, and the lower microspheres were washed, filtered, and dried to obtain finished gelatin microspheres. The surface of the prepared gelatin spheres was coated with silicon carbide powder, and composite microspheres were obtained by a pelletization method, which were then dried and sintered to obtain gelatin microspheres with a coating layer.

[0037] On the one hand, the present application provides a medium-temperature lightweight ceramic mud, comprising dual-morphology lithium iron phosphate, including dolomite, aluminum powder, feldspar, quartz and sodium silicate.

[0038] The feldspar is the porous calcium feldspar prepared in Preparation Example 1.

[0039] On the other hand, the present application provides a process for preparing medium-temperature lightweight ceramic mud, comprising the following steps: S1. Raw material preparation: Take dolomite, aluminum powder, feldspar, quartz and sodium silicate respectively by weight, add water, and ball grind; S2. Preparation of ceramic mud: The ball-milled slurry was passed through a 180-mesh sieve to remove iron, and then passed through a 200-mesh sieve to remove iron, and filtered to obtain ceramic mud with a water content of 23.5%.

[0040] Table 1 Composition of Examples 1-3 The difference from Example 2 is that an equal mass of porous calcium feldspar prepared in Preparation Example 2 is used to replace the feldspar in Example 2 to prepare ceramic mud.

[0041] The difference from Example 2 is that an equal mass of porous calcium feldspar prepared in Preparation Example 3 is used to replace the feldspar in Example 2 to prepare ceramic mud.

[0042] The difference from Example 2 is that an equal mass of porous calcium feldspar prepared in Preparation Example 4 is used to replace the feldspar in Example 2 to prepare ceramic mud.

[0043] The difference from Example 2 is that the feldspar includes the porous calcium feldspar and the Ulan citrine prepared in Preparation Example 2 in a mass ratio of 2:1.

[0044] The difference from Example 2 is that the ceramic mud also includes 4 kg of cordierite whiskers.

[0045] The difference from Example 2 is that the ceramic mud also includes a reinforcing material, which includes 2 kg of cordierite whiskers, 1 kg of alumina whiskers and 1 kg of brown corundum powder.

[0046] The reinforcing material is pre-mixed, ball-milled, sieved, and dried to obtain the reinforcing material.

[0047] The preferred particle size of brown corundum is 40-50 μm.

[0048] The difference from Example 8 is that the ceramic mud also includes 4 kg of gelatin microspheres prepared in Preparation Example 5.

[0049] The difference from Example 8 is that the ceramic mud also includes 4 kg of gelatin microspheres with a coating layer prepared in Preparation Example 6.

[0050] The difference from Example 8 is that the ceramic mud also includes 4 kg of gelatin microspheres with a coating layer prepared in Preparation Example 7.

[0051] The difference from Example 12 is that the ceramic mud also includes 2 kg of Guanyin clay, the Guanyin clay is mixed with feldspar and ball-milled in advance, and then dolomite, aluminum powder, quartz and sodium silicate are added to prepare the ceramic mud.

[0052] Comparative Example Comparative Example 1 The difference between this comparative example and Example 2 is that in this comparative example, clay of equal mass is used to replace dolomite.

[0053] Comparative Example 2 The difference between this comparative example and Example 2 is that anorthite of equal mass is used in this comparative example to replace porous anorthite.

[0054] Performance testing 400 grams of the ceramic mud in the embodiment and the comparative example, with a water content of 23.5%, were taken to roll a 7-inch plate, and the weight of the dried embryo was also 270 grams, and sintered in the same kiln at 1200° C. to obtain a ceramic plate. The ceramic mud was injected into the mold, and after sintering, a ceramic blank was prepared, and the strength of the ceramic blank was tested.

[0055] (1) Compressive strength: The compressive strength of the ceramic green body prepared from ceramic mud was tested according to the method specified in GB / T2832-1996.

[0056] (2) Weight test: Test the weight of the ceramic plate.

[0057] Table 2 Performance test Combining the performance test comparison in Table 2, we can find that: 1. By comparing Examples 1-3 with Comparative Examples 1-2, it can be found that the weight of the ceramic products prepared from the ceramic mud prepared in Examples 1-3 is reduced, and the compressive strength is relatively the same, which shows that the dolomite in the present application has a lower water absorption rate and a lighter weight, can reach the strength of stone porcelain, and can also be differentiated and degraded, and then the ceramic products prepared using the ceramic mud of the present application have a lighter weight and suitable strength, thereby greatly reducing the possibility of accidental damage caused by the ceramic preparation being too heavy. At the same time, the present application selects porous calcium feldspar to be added to the ceramic mud. Calcium feldspar has the advantages of low bulk density, excellent volume stability, small thermal expansion coefficient, low thermal conductivity, etc., and the porous structure can further reduce the mass and density of calcium feldspar. Introducing a hollow structure into the ceramic mud can further reduce the mass of the ceramic mud.

[0058] 2. By comparing Examples 4-6 with Example 2, it can be found that the weight and compressive strength of the ceramic products prepared from the ceramic mud prepared in Examples 4-6 are improved, which shows that in the present application, calcium feldspar and mullite are combined to form a composite material. Since mullite has better mechanical properties, high melting point, excellent slag resistance, etc., it can effectively improve the mechanical strength of the composite material, so that the ceramic mud has a lighter weight while maintaining better strength.

[0059] 3. By comparing Example 7 with Example 2, it can be found that the compressive strength of the ceramic products prepared from the ceramic mud prepared in Example 7 is improved, which means that in the present application, Ulan citrine is used as feldspar. Ulan citrine contains a variety of trace rare earth elements, which can significantly reduce the sintering temperature of ceramics and increase the strength of ceramics. It can also be combined with mullite to form closed pores in the ceramic mud, thereby further reducing the weight of the ceramic while improving the strength of the ceramic.

[0060] 4. By comparing Examples 8-9 with Example 2, it can be found that the compressive strength of the ceramic products prepared from the ceramic mud obtained in Examples 8-9 is improved, which shows that the introduction of cordierite whiskers in this application can construct a three-dimensional network structure in the ceramic mud, enhance the bonding effect between the components in the ceramic mud, and the cordierite whiskers can cooperate with the feldspar particles to form an interlaced interlacing, thereby stably enhancing the strength of the ceramic. Through the mutual cooperation between brown corundum powder, alumina whiskers and cordierite whiskers, the content of cordierite phase and mullite phase in the ceramic product can be effectively increased, and the reinforcing phase and the fiber structure cooperate to form a relatively good reinforcing skeleton structure, which is conducive to the ceramic product to obtain the excellent characteristics of light weight and high strength.

[0061] The particle size of brown corundum powder has been optimized. The particles of brown corundum powder with a particle size of 40-50 microns are more tightly bound in ceramic products, making the structure of ceramic products more uniform and forming a more uniform reinforced skeleton, so that ceramic products can obtain uniform strength and maintain the lightweight of ceramic products, thereby improving the use effect of lightweight ceramics.

[0062] 5. By comparing Examples 10-12 with Example 2, it can be found that the weight of the ceramic products prepared from the ceramic mud prepared in Examples 10-12 is reduced and the compressive strength is improved, which shows that the introduction of gelatin microspheres in the present application can serve as a binding phase to improve the bonding strength between the components in the ceramic mud, and can round off some sharp corners in the ceramic mud, thereby improving the bonding strength between the components in the ceramic mud. In addition, the hollow structure of gelatin microspheres can obtain a regular pore structure in the ceramic, so that the ceramic has low weight and high strength. Diaspore powder or silicon carbide powder can form a regular microporous structure in the ceramic, and finally make the ceramic uniformly light.

[0063] 6. By comparing Example 13 with Example 2, it can be found that the weight of the ceramic product prepared from the ceramic mud prepared in Example 13 is reduced and the compressive strength is improved, which shows that in this application, it is preferred to add Guanyin soil to the ceramic mud. Guanyin soil has a layered structure and can be loaded and interspersed with the cordierite fibers in the ceramic mud, thereby improving the firmness of the fiber structure in the ceramic product and improving the strength of the ceramic product. In addition, Guanyin soil is pre-ball-milled with feldspar, and Guanyin soil can be wrapped around the corners of calcium feldspar powder to reduce the generation of bad gaps in the ceramic, effectively reducing the weight of the ceramic product while improving the strength of the ceramic product.

[0064] This specific embodiment is merely an explanation of the present application and is not a limitation of the present application. After reading this specification, those skilled in the art may make modifications to the present embodiment without any creative contribution as needed, but such modifications are protected by the patent law as long as they are within the scope of the claims of the present application.

Claims

1. A medium temperature lightweight ceramic mud, characterized in that: The following materials are included in parts by weight: 30-50 parts of dolomite; 10-15 parts of aluminum powder; Feldspar 20-40 parts; Quartz 10-20 parts; Sodium silicate 10-20 parts; The feldspar includes porous calcium feldspar.

2. The medium-temperature lightweight ceramic mud according to claim 1, characterized in that: The porous calcium feldspar is a calcium feldspar-mullite composite material.

3. The medium-temperature lightweight ceramic mud according to claim 2, characterized in that: The porous calcium feldspar is prepared as follows: respectively taking coal gangue, clay and calcium carbonate, mixing, ball milling, hydraulic pressure, drying, sintering and crushing to obtain porous calcium feldspar, wherein the mass ratio of coal gangue, clay and calcium carbonate is 81-86:4:10-15.

4. The medium-temperature lightweight ceramic mud according to claim 3, characterized in that: The hydraulic pressure in the preparation of the porous calcium feldspar is 50-75 MPa.

5. The medium-temperature lightweight ceramic mud according to claim 1, characterized in that: The feldspar also includes Ulan citrine.

6. The medium-temperature lightweight ceramic mud according to claim 1, characterized in that: It also includes 3-5 parts of reinforcing materials, wherein the reinforcing materials include any one or more of cordierite whiskers, alumina whiskers and brown corundum powder.

7. The medium-temperature lightweight ceramic mud according to claim 1, characterized in that: Also included are 3-5 parts of gelatin microspheres.

8. The medium-temperature lightweight ceramic mud according to claim 7, characterized in that: The gelatin microspheres are provided with a coating layer, which is composed of diaspore powder or silicon carbide powder.

9. The medium-temperature lightweight ceramic mud according to claim 8, characterized in that: The preparation of the gelatin microspheres is as follows: water, gelatin and glucose are mixed to obtain a gelatin solution, the gelatin solution is dripped into the oil phase, stirred to obtain a gelatin microsphere suspension, low-temperature frozen, filtered, dried, and diaspore powder or silicon carbide powder is wrapped outside the gelatin microspheres to obtain gelatin microspheres with a coating layer.

10. A process for preparing medium-temperature lightweight ceramic mud according to any one of claims 1 to 9, characterized in that: The following steps are involved: S1. Raw material preparation: Take dolomite, aluminum powder, feldspar, quartz and sodium silicate respectively by weight, add water, and ball grind; S2. Preparation of ceramic mud: The ball-milled slurry is sieved, iron removed, and filtered in sequence to obtain ceramic mud with a water content of 23-23.5%.

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