A medium-temperature light-weight ceramic mud and a preparation process thereof

Abstract

The application relates to the technical field of ceramics, and particularly discloses a medium-temperature lightweight ceramic mud and a preparation process thereof. The medium-temperature lightweight ceramic mud comprises the following substances in parts by weight: 30-50 parts of dolomite; 10-15 parts of aluminum powder; 20-40 parts of feldspar; 10-20 parts of quartz; and 10-20 parts of sodium silicate; the feldspar comprises porous anorthite; and the preparation process comprises the following steps: S1, raw material preparation; and S2, ceramic mud preparation. The ceramic mud disclosed by the application 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 application relates to the technical field of ceramics, in particular to a medium-temperature light ceramic clay and a preparation process thereof. BACKGROUND

[0002] Different whiteness ceramics can be prepared by firing ceramic clay at different temperatures, but the weights of ceramics with different whiteness and types are similar. Since ceramics are relatively heavy products, some people with less strength, such as children and the elderly, are not able to move heavy ceramic containers, so it is necessary to improve the ceramic clay. SUMMARY

[0003] In order to improve the accidents caused by the over weight of ceramic products, the application provides a medium-temperature light ceramic clay and a preparation process thereof.

[0004] The application provides a medium-temperature light ceramic clay, which adopts the following technical scheme:

[0005] In a first aspect, the application provides a medium-temperature light ceramic clay, which comprises the following substances in parts by weight:

[0006] dolomite 30-50 parts;

[0007] aluminum powder 10-15 parts;

[0008] feldspar 20-40 parts;

[0009] quartz 10-20 parts;

[0010] sodium silicate 10-20 parts;

[0011] The feldspar comprises porous anorthite.

[0012] By adopting the above technical scheme, the dolomite is preferably used as the base material of the ceramic clay. The dolomite has a low water absorption rate and a light weight, can achieve the strength of stone porcelain, can be differentiated and degraded, and the ceramic product prepared from the ceramic clay of the application has a light weight and a suitable strength, so that the possibility of accidental damage caused by the over weight of the ceramic product is greatly reduced.

[0013] Meanwhile, the porous anorthite is selected and added to the ceramic clay. The anorthite has the advantages of small bulk density, excellent bulk stability, small thermal expansion coefficient and low thermal conductivity. The porous structure can further reduce the weight and density of the anorthite. The hollow structure introduced into the ceramic clay can further reduce the weight of the ceramic clay.

[0014] Optionally, the porous anorthite is an anorthite-mullite composite material.

[0015] By adopting the technical scheme, preferably, the anorthite is combined with the mullite to form the composite material, since the mullite has better mechanical properties, a high melting point, excellent slag resistance and the like, the mechanical strength of the composite material can be effectively improved, and the ceramic mud can have lighter mass while maintaining better strength.

[0016] Optionally, the coal gangue, clay and calcium carbonate are taken respectively, mixed, ball milled, hydraulically pressed, dried, sintered, and crushed to obtain the porous anorthite, wherein the mass ratio of the coal gangue, clay and calcium carbonate is 85-86:4:10-11.

[0017] By adopting the technical scheme, the mass ratio of the coal gangue, clay and calcium carbonate is optimized, and under the suitable mass ratio, the anorthite can be uniformly coated outside the mullite, so that the composite material has an optimal anorthite to mullite ratio, and the composite material has uniform pores, so that the ceramic mud can have uniform mass distribution and strength.

[0018] Optionally, the pressure of the hydraulic pressing in the preparation of the porous anorthite is 50-75 MPa.

[0019] By adopting the technical scheme, the hydraulic pressure is optimized, and under the suitable pressure, the particle packing condition is suitable, the particle spacing is suitable, and the gas generated by burning loss can be smoothly discharged, so that suitable pores can be formed in the composite material, the densification degree is moderate, and the composite material has light mass and high strength.

[0020] Optionally, the feldspar further includes uranite.

[0021] By adopting the technical scheme, preferably, the uranite is combined as the feldspar, the uranite contains a plurality of trace rare earth elements, which can significantly reduce the sintering temperature of the ceramic, increase the strength of the ceramic, and form closed pores in the ceramic mud together with the mullite, so that the weight of the ceramic is further reduced while the strength of the ceramic is improved.

[0022] Optionally, 3-5 parts of a reinforcing material are further included, and the reinforcing material includes any one or more of cordierite whiskers, alumina whiskers and brown corundum powder.

[0023] By adopting the technical scheme, the introduction of the cordierite whiskers 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 be combined with the feldspar particles to form interpenetrating and interlaced structures, thereby stably enhancing the strength of the ceramic.

[0024] The introduction of the alumina whisker can not only construct the skeleton of the three-dimensional network structure in the ceramic mud, but also serve as a stable support structure in the ceramic product, effectively reduce the possibility of the collapse of the pore structure in the ceramic mud, maintain the pore structure and structural stability in the ceramic product, and make the ceramic obtain better strength and light weight. Moreover, the alumina whisker can promote the generation of secondary mullite in the ceramic mud, increase the mullite phase content in the ceramic mud, and the crystal phase in the ceramic mud changes during the sintering process. The newly generated mullite phase and the nanometer crystal boundary in the whisker can absorb energy, effectively improving the toughness of the ceramic product.

[0025] The introduction of the brown corundum powder can induce the generation of the reinforcing phase cordierite in the ceramic mud, further strengthen the skeleton structure in the ceramic product, and further improve the mechanical strength of the ceramic product. The addition amount of the brown corundum powder is optimized, and the appropriate addition amount can stably improve the mechanical strength of the ceramic product and maintain the light weight of the ceramic product.

[0026] Through the mutual cooperation among the brown corundum powder, the alumina whisker and the cordierite whisker, the content of the cordierite phase and the mullite phase in the ceramic product can be effectively improved, the excellent reinforcing skeleton structure is formed between the reinforcing phase and the fiber structure, and the ceramic product can obtain excellent characteristics such as light weight and high strength.

[0027] Optionally, 3-5 parts of gelatin microspheres are further included.

[0028] Through the above technical solution, the introduction of the gelatin microspheres can serve as a bonding phase to improve the bonding strength between the components in the ceramic mud, and can round some sharp corners in the ceramic mud, thereby improving the bonding strength between the components in the ceramic mud. Moreover, the hollow structure of the gelatin microspheres can make the ceramic obtain a regular pore structure, and the ceramic can obtain low weight and high strength.

[0029] Optionally, the gelatin microspheres are coated with bayerite powder or silicon carbide powder.

[0030] Through the above technical solution, the coating of the bayerite powder or the silicon carbide powder on the gelatin microspheres can form a regular micro-pore structure in the ceramic, and finally make the ceramic obtain uniform light quality.

[0031] 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 into an oil phase, stirred to obtain a gelatin microsphere suspension, frozen at low temperature, filtered, dried, and the bayerite powder or the silicon carbide powder is coated on the gelatin microspheres to obtain the gelatin microspheres.

[0032] In a second aspect, the application provides a preparation process of a medium-temperature light-weight ceramic mud, which adopts the following technical solution:

[0033] A preparation process of a medium-temperature light ceramic mud, comprising the following steps:

[0034] S1, raw material preparation: taking dolomite, aluminum powder, feldspar, quartz and sodium silicate by weight, adding water and ball milling;

[0035] S2, ceramic mud preparation: the slurry after ball milling is sieved, iron is removed, and pressure filtration is carried out, so that the ceramic mud with a water content of 23-23.5% is obtained.

[0036] In summary, the present application has the following beneficial effects:

[0037] 1, Since the present application preferably uses dolomite as the base material of the ceramic mud, the dolomite has a low water absorption rate and a light weight, which can achieve the strength of stone porcelain, and can also differentiate degradation, and the ceramic product prepared by the ceramic mud of the present application has a light weight and a suitable strength, thereby greatly reducing the possibility of accidental damage caused by too heavy ceramic preparation. At the same time, the present application selects porous calcium feldspar to be added to the ceramic mud, and the calcium feldspar has the advantages of small bulk density, excellent volume stability, small thermal expansion coefficient and low thermal conductivity, and the porous structure can further reduce the mass and density of the calcium feldspar, and the introduction of the hollow structure in the ceramic mud can further reduce the mass of the ceramic mud.

[0038] 2, In the present application, Ulan tea crystal stone is preferably used as feldspar, which contains a plurality of trace rare earth elements, which can significantly reduce the sintering temperature of the ceramic, increase the strength of the ceramic, and due to the introduction of mullite, closed pores can be formed in the ceramic mud, thereby further reducing the weight of the ceramic while improving the strength of the ceramic.

[0039] 3, In the present application, the introduction of the cordierite whisker 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 whisker can cooperate with the feldspar particles to form interpenetrating, thereby stably enhancing the strength of the ceramic. Through the mutual cooperation between the brown corundum powder, the alumina whisker and the cordierite whisker, the content of the cordierite phase and the mullite phase in the ceramic product can be effectively improved, the cooperation between the phase and the fiber structure can form a relatively excellent reinforced skeleton structure, which is beneficial to the ceramic product to obtain the excellent characteristics of light weight and high strength. DETAILED DESCRIPTION

[0040] The present application will be further described in detail below in combination with examples.

[0041] Preparation Example

[0042] Preparation Example of Porous Calcium Feldspar

[0043] Preparation Example 1

[0044] Take coal gangue, clay and calcium carbonate respectively, mix, ball mill, 50 MPa hydraulic pressure, dry at 1300℃, sinter, crush to obtain porous anorthite, wherein the mass ratio of coal gangue, clay and calcium carbonate is 68:4:28.

[0045] Preparation Example 2

[0046] Take coal gangue, clay and calcium carbonate respectively, mix, ball mill, 50 MPa hydraulic pressure, dry at 1300℃, sinter, crush to obtain porous anorthite, wherein the mass ratio of coal gangue, clay and calcium carbonate is 81.2:4:14.8.

[0047] Preparation Example 3

[0048] Take coal gangue, clay and calcium carbonate respectively, mix, ball mill, 50 MPa hydraulic pressure, dry at 1300℃, sinter, crush to obtain porous anorthite, wherein the mass ratio of coal gangue, clay and calcium carbonate is 85.5:4:10.5.

[0049] Preparation Example 4

[0050] Take coal gangue, clay and calcium carbonate respectively, mix, ball mill, 75 MPa hydraulic pressure, dry at 1300℃, sinter, crush to obtain porous anorthite, wherein the mass ratio of coal gangue, clay and calcium carbonate is 81.2:4:14.8.

[0051] Gelatin microsphere preparation example

[0052] Preparation Example 5

[0053] Deionized water, gelatin and glucose (addition amount is 0.065g / L) are mixed in a beaker, and then a uniform 176.5g / L hot gelatin solution is obtained by rapid stirring at 50℃. The gelatin solution is added dropwise into the preheated oil phase (water / oil ratio is 1:5) by using a peristaltic pump, and stirred at 150rpm for 30min to obtain a gelatin microsphere suspension, which is then frozen at 4℃ for 2h using a low-temperature cooling liquid circulating pump. The upper oil phase is filtered off, and the lower microspheres are washed, filtered and dried to obtain finished gelatin microspheres.

[0054] Preparation Example 6

[0055] Deionized water, gelatin, glucose (addition amount is 0.065g / L) are mixed in a beaker, and then quickly stirred at 50℃ to obtain a uniform 176.5g / L hot gelatin solution. The gelatin solution is added to the preheated oil phase (water to oil ratio is 1:5) by using a peristaltic pump, and stirred at 150rpm for 30min to obtain a gelatin microsphere suspension, and then frozen at 4℃ for 2h using a low-temperature coolant circulating pump, the upper oil phase is filtered off, and the lower microspheres are washed, filtered, dried to obtain finished gelatin microspheres. The prepared gelatin balls are coated with pseudo-boehmite powder on the surface, and the composite microspheres are obtained by the pelletization method, and then dried and sintered to obtain gelatin microspheres with a coating layer.

[0056] Preparation Example 7

[0057] Deionized water, gelatin, glucose (addition amount is 0.065g / L) are mixed in a beaker, and then quickly stirred at 50℃ to obtain a uniform 176.5g / L hot gelatin solution. The gelatin solution is added to the preheated oil phase (water to oil ratio is 1:5) by using a peristaltic pump, and stirred at 150rpm for 30min to obtain a gelatin microsphere suspension, and then frozen at 4℃ for 2h using a low-temperature coolant circulating pump, the upper oil phase is filtered off, and the lower microspheres are washed, filtered, dried to obtain finished gelatin microspheres. The prepared gelatin balls are coated with pseudo-boehmite powder on the surface, and the composite microspheres are obtained by the pelletization method, and then dried and sintered to obtain gelatin microspheres with a coating layer.

[0058] Example

[0059] Examples 1-3

[0060] In one aspect, the present application provides a medium-temperature light ceramic mud, which comprises dolomite, aluminum powder, feldspar, quartz and sodium silicate.

[0061] The feldspar is the porous anorthite prepared in Preparation Example 1.

[0062] In another aspect, the present application provides a preparation process of the medium-temperature light ceramic mud, which comprises the following steps:

[0063] S1, raw material preparation: take dolomite, aluminum powder, feldspar, quartz and sodium silicate according to weight parts, add water, and ball mill;

[0064] S2, ceramic mud preparation: the ball-milled slurry is passed through a 180-mesh screen, iron is removed, and then passed through a 200-mesh screen, iron is removed, pressure filtration is performed, and a ceramic mud with a water content of 23.5% is obtained.

[0065] Table 1 composition of examples 1-3

[0066]

[0067] Example 4

[0068] The difference from Example 2 is that the same mass of the porous anorthite prepared in Preparation Example 2 is used to replace the feldspar in Example 2 to prepare the ceramic mud.

[0069] Example 5

[0070] The difference from Example 2 is that the same mass of the porous anorthite prepared in Preparation Example 3 is used to replace the feldspar in Example 2 to prepare the ceramic mud.

[0071] Example 6

[0072] The difference from Example 2 is that the same mass of the porous anorthite prepared in Preparation Example 4 is used to replace the feldspar in Example 2 to prepare the ceramic mud.

[0073] Example 7

[0074] The difference from Example 2 is that the feldspar includes the porous anorthite prepared in Preparation Example 2 and the Ulanite in a mass ratio of 2:1.

[0075] Example 8

[0076] The difference from Example 2 is that the ceramic mud further includes 4 kg of cordierite whiskers.

[0077] Example 9

[0078] The difference from Example 2 is that the ceramic mud further includes a reinforcing material, and the reinforcing material includes 2 kg of cordierite whiskers, 1 kg of alumina whiskers, and 1 kg of brown corundum powder.

[0079] The reinforcing material is pre-mixed, ball-milled, sieved, and dried to obtain the reinforcing material.

[0080] Preferably, the particle size of the brown corundum is 40-50 μm.

[0081] Example 10

[0082] The difference from Example 8 is that the ceramic mud further includes 4 kg of the gelatin microspheres prepared in Preparation Example 5.

[0083] Example 11

[0084] The difference from Example 8 is that the ceramic mud further includes 4 kg of the gelatin microspheres with a coating layer prepared in Preparation Example 6.

[0085] Example 12

[0086] The difference from Example 8 is that the ceramic mud further includes 4 kg of the gelatin microspheres with a coating layer prepared in Preparation Example 7.

[0087] Example 13

[0088] The difference from Example 12 is that the ceramic mud further comprises 2 kg of guanyin soil, the guanyin soil 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.

[0089] Comparative Example

[0090] Comparative Example 1

[0091] The difference between the present comparative example and Example 2 is that the same mass of clay is used to replace dolomite in the present comparative example.

[0092] Comparative Example 2

[0093] The difference between the present comparative example and Example 2 is that the same mass of anorthite is used to replace porous anorthite in the present comparative example.

[0094] Performance detection test

[0095] 400 g of ceramic mud in Examples and Comparative Examples is taken, the moisture content is 23.5%, a 7-inch plate is rolled, the green weight is also 270 g, and sintering is performed at 1200°C in the same kiln to obtain a ceramic plate. The ceramic mud is poured into a mold, and after sintering, a ceramic body is prepared, and the strength of the ceramic body is tested.

[0096] (1) Compressive strength: the compressive strength of the ceramic body prepared from the ceramic mud is tested according to the method specified in GB / T2832-1996.

[0097] (2) Weight test: the weight of the ceramic plate is tested.

[0098] Table 2 Performance detection

[0099]

[0100] It can be found from the comparison of Table 2 performance detection that:

[0101] 1. It can be found from the comparison of Examples 1-3 and Comparative Examples 1-2 that the weight of the ceramic product prepared from the ceramic mud in Examples 1-3 is reduced, and the compressive strength is relatively flat, which shows that the dolomite in the present application has a lower water absorption rate and a lighter mass, and can achieve the strength of stone porcelain, and can also differentiate and degrade, so that the ceramic product prepared from the ceramic mud of the present application has a lighter weight and a suitable strength, thereby greatly reducing the possibility of accidental damage caused by the ceramic product being too heavy. At the same time, porous anorthite is selected to be added to the ceramic mud, and the anorthite has the advantages of small bulk density, excellent bulk stability, small thermal expansion coefficient, low thermal conductivity, etc., and the porous structure can further reduce the mass and density of the anorthite, and the introduction of the hollow structure in the ceramic mud can further reduce the mass of the ceramic mud.

[0102] 2, it can be found by comparing examples 4-6 and example 2 that the weight and the compressive strength of the ceramic product prepared by the ceramic mud prepared in examples 4-6 are improved, which shows that in the present application, the complex material is formed by the cooperation of the anorthite and the mullite, and due to the better mechanical properties, high melting point and excellent slag resistance of the mullite, the mechanical strength of the complex material is effectively improved, so that the ceramic mud can obtain lighter weight while maintaining better strength.

[0103] 3, it can be found by comparing example 7 and example 2 that the compressive strength of the ceramic product prepared by the ceramic mud prepared in example 7 is improved, which shows that in the present application, the ulanite is used as feldspar, and the ulanite contains a plurality of trace rare earth elements, which can significantly reduce the sintering temperature of the ceramic, increase the strength of the ceramic, and form closed pores in the ceramic mud with the mullite, thereby further reducing the weight of the ceramic while improving the strength of the ceramic.

[0104] 4, it can be found by comparing examples 8-9 and example 2 that the compressive strength of the ceramic product prepared by the ceramic mud prepared in examples 8-9 is improved, which shows that in the present application, the introduction of the cordierite whisker can construct a three-dimensional network structure in the ceramic mud, enhance the binding effect between the components in the ceramic mud, and the cordierite whisker can cooperate with the feldspar particles to form interpenetrating and interlocking, thereby stably enhancing the strength of the ceramic. Through the cooperation between the brown corundum powder, the alumina whisker and the cordierite whisker, the content of the cordierite phase and the mullite phase in the ceramic product can be effectively improved, the cooperation between the phases and the fiber structure can form a relatively excellent reinforced skeleton structure, which is beneficial to the ceramic product to obtain the excellent characteristics of light weight and high strength.

[0105] The particle size of the brown corundum powder is optimized, and the brown corundum powder with a particle size of 40-50 microns has a relatively tight combination between particles in the ceramic product, so that the structure of the ceramic product is relatively uniform, and a relatively uniform reinforced skeleton can be formed, thereby making the ceramic product obtain uniform strength and maintain the lightweight of the ceramic product, and improving the use effect of the lightweight ceramic.

[0106] 5, it can be found by comparing examples 10-12 and example 2 that the weight of the ceramic product prepared by the ceramic mud prepared in examples 10-12 is reduced, and the compressive strength is improved, which shows that in the present application, the introduction of the gelatin microspheres can improve the binding strength between the components in the ceramic mud as a binding phase, and can round some sharp corners in the ceramic mud, thereby improving the binding strength between the components in the ceramic mud, and the hollow structure of the gelatin microspheres can make the ceramic obtain a regular pore structure, so that the ceramic obtains low weight and high strength. The boehmite powder or the silicon carbide powder can form a regular micro-pore structure in the ceramic, and finally make the ceramic obtain uniform light weight.

[0107] 6、Combined with the comparison of example 13 and example 2, it can be found that the weight of the ceramic product prepared by the ceramic mud in example 13 is reduced, and the compressive strength is improved, which shows that it is preferred to add guanyin soil to the ceramic mud in the present application. Guanyin soil has a layered structure and can be loaded and inserted between the cordierite fibers in the ceramic mud, improving the firmness of the fiber structure in the ceramic product and improving the strength of the ceramic product. And the guanyin soil is pre-milled with feldspar, and the guanyin soil can be wrapped around the corners of the calcium feldspar powder to reduce the generation of undesirable voids in the ceramic, while effectively reducing the weight of the ceramic product while improving the strength of the ceramic product.

[0108] The specific embodiments are only an explanation of the present application, and are not a limitation of the present application. Those skilled in the art can make modifications to the embodiments without creative contribution after reading the specification, as long as the modifications are within the scope of the claims of the present application.

Claims

1.A medium-temperature lightweight ceramic mud, characterized in that, comprising the following ingredients by weight: dolomite 30-50 parts; aluminum powder 10-15 parts; feldspar 20-40 parts; quartz 10-20 parts; sodium silicate 10-20 parts; the feldspar comprises porous anorthite; and further comprising 3-5 parts of gelatin microspheres, and the porous anorthite is prepared as follows: taking coal gangue, clay and calcium carbonate respectively, mixing, ball milling, hydraulic pressing, drying, sintering, crushing to obtain the porous anorthite, wherein the mass ratio of the coal gangue, the clay and the calcium carbonate is 81-86:4:10-15. 2.The medium-temperature lightweight ceramic mud according to claim 1, characterized in that: the porous anorthite is anorthite-mullite composite material. 3.The medium-temperature lightweight ceramic mud according to claim 1, characterized in that: the pressure of the hydraulic pressing in the preparation of the porous anorthite is 50-75 MPa. 4.The medium-temperature lightweight ceramic mud according to claim 1, characterized in that: the feldspar further comprises ulanite. 5.The medium-temperature lightweight ceramic mud according to claim 1, characterized in that: further comprising 3-5 parts of reinforcing material, and the reinforcing material comprises any one or more of cordierite whiskers, alumina whiskers and brown corundum powder. 6.The medium-temperature lightweight ceramic mud according to claim 1, characterized in that: the gelatin microspheres are provided with a coating layer, and the coating layer is composed of bayerite powder or silicon carbide powder. 7.The medium-temperature lightweight ceramic mud according to claim 6, characterized in that: the gelatin microspheres are prepared as follows: mixing water, gelatin and glucose to obtain a gelatin solution, dropping the gelatin solution into an oil phase, stirring to obtain a gelatin microsphere suspension, low-temperature freezing, filtering, drying, and coating the gelatin microspheres with bayerite powder or silicon carbide powder to obtain gelatin microspheres with a coating layer. 8.A preparation process of the medium-temperature lightweight ceramic mud according to any one of claims 1-7, characterized in that, comprising the following steps: S1, raw material preparation: taking dolomite, aluminum powder, feldspar, quartz and sodium silicate by weight, adding water, and ball milling; S2, ceramic mud preparation: screening, iron removal, pressure filtration of the slurry after ball milling to obtain ceramic mud with a water content of 23-23.5%.

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