High hardness oxidation resistant pottery and method of production

Abstract

The present application relates to clay processing technology field, especially to a kind of high hardness antioxidant pottery and production method, the pottery includes embryo, embryo bubble filling solution, glaze solution;The embryo is made by kaolin, bentonite, water glass and water mixing;The embryo bubble filling solution raw material includes silica sol, methyl cellulose, ethanol and boric acid;The embryo bubble filling solution is prepared as follows: step 1, the solid content of silica sol is selected 30%;In the scheme, by bentonite, water glass, the binding force and density of green body are enhanced in green body preparation stage;Utilize specially-made embryo bubble filling solution, effectively fill the bubble in green body, eliminate defects;Adopt specially-made glaze solution composed of multiple high-performance components, form hard and antioxidant protective layer on the surface of pottery, realize the significant improvement of pottery in hardness and antioxidant performance, meet the market demand for high-quality pottery, have important practical application value and broad market prospect.

Description

Technical Field

[0001] This invention relates to the field of clay processing technology, and in particular to a high-hardness, oxidation-resistant ceramic and its production method. Background Technology

[0002] In the field of ceramic production and application, high-hardness, oxidation-resistant ceramics have always been a highly sought-after product due to their excellent physical properties and stable chemical properties, which have wide application needs in many fields such as building decoration, daily-use ceramics, and industrial ceramics.

[0003] Traditional pottery making uses only single or simple mixtures of raw materials, such as ordinary clay, in the preparation of the clay body. There is a lack of in-depth research and rational application of the synergistic effects between raw materials, resulting in a loose internal structure with many pores after shaping and firing, making it difficult to achieve a high level of hardness and strength. Traditional production processes have limited means to deal with defects such as air bubbles in the clay body, and have not fully considered the negative impact of air bubbles on the performance of pottery, resulting in inconsistent quality of finished products.

[0004] To address this, this invention proposes a high-hardness, oxidation-resistant ceramic and its production method. By carefully selecting and optimizing the proportions of raw materials such as kaolin, bentonite, and water glass, the bonding strength and density of the ceramic body are enhanced during the body preparation stage. A specially formulated bubble-filling solution effectively fills the internal bubbles of the ceramic body, eliminating defects. A specially formulated glaze composed of multiple high-performance components, combined with precise glazing and firing processes, forms a hard and oxidation-resistant protective layer on the ceramic surface. Through these innovative technical means, a significant improvement in the hardness and oxidation resistance of the ceramic is achieved, meeting the market demand for high-quality ceramics and possessing significant practical application value and broad market prospects. Summary of the Invention

[0005] Technical problem to be solved: Traditional pottery making has limited ability to handle air bubbles in the clay body, making it difficult to achieve a high level of hardness and strength.

[0006] To address the shortcomings of existing technologies, this invention provides a high-hardness, oxidation-resistant ceramic and its production method, thereby solving the technical problems mentioned in the background section.

[0007] To achieve the above objectives, the present invention provides the following technical solution:

[0008] A high-hardness, oxidation-resistant ceramic, the ceramic comprising a body, a body bubble-filling solution, and a glaze;

[0009] The embryo is made from a mixture of kaolin, bentonite, water glass and water;

[0010] The raw materials for the embryo bubble-filling solution include silica sol, methylcellulose, ethanol, and boric acid;

[0011] The embryo bubble-filling solution is prepared as follows:

[0012] Step 1: Select a silica sol with a solid content of 30%, use methylcellulose at 1% of the silica sol mass, use ethanol at 20% of the silica sol volume, and use boric acid at 3% of the silica sol mass.

[0013] Step 2: Slowly add the weighed methylcellulose to an appropriate amount of water and stir to dissolve;

[0014] Step 3: Mix silica sol and ethanol;

[0015] Step 4: Add the weighed boric acid to the mixture of silica sol and ethanol;

[0016] Step 5: Mix the solution from Step 2 and the solution from Step 4;

[0017] The glaze is made of silicon dioxide, aluminum oxide, calcium oxide, magnesium oxide, zinc oxide, borax, and colorant.

[0018] In one possible implementation, the embryo is prepared as follows:

[0019] Step 1: Kaolin, sieved through a 200-mesh sieve to remove impurities and larger particles; water glass solution with a modulus of 3.0-3.3 and a concentration of 30%-40%; water as needed;

[0020] Step 2: Mix bentonite and water in a ratio of 1:5-8, control the stirring speed at 200-300 rpm, and stir for 30-40 minutes to form a uniform bentonite slurry.

[0021] Step 3: Add water glass solution (15%-25% of the bentonite mass) to the bentonite slurry, stir for 20-30 minutes at a stirring speed of 300-400 rpm to obtain a mixture;

[0022] Step 4: Mix the kaolin and the mixture;

[0023] Step 5: Prepare the clay body according to the desired shape and size of the pottery;

[0024] Step 6: Drying the embryo.

[0025] In one possible implementation, the glaze is prepared as follows:

[0026] Step 1: 50% silica, 18% alumina, 12% calcium oxide, 8% magnesium oxide, 5% zinc oxide, 5% borax, and 2% colorant; pass the raw materials such as quartz powder, industrial alumina powder, calcite, talc powder, zinc oxide, and borax through a 200-mesh sieve to ensure uniform particle size.

[0027] Step 2: Put the weighed raw materials into a ball mill, add an appropriate amount of water and grinding media, mix thoroughly and grind finely to form a uniform glaze slurry;

[0028] Step 3: Add 0.8% of the binder by weight of the glaze slurry to the glaze slurry and stir at 120 rpm for 30 minutes;

[0029] Step 4: Transfer the glaze to an aging container and seal it. Aging at room temperature for 36 hours.

[0030] In one possible implementation, a method for producing high-hardness, oxidation-resistant ceramics specifically includes the following steps:

[0031] Step 1: Bubble treatment of the clay body. The pre-dried pottery clay body is completely immersed in the bubble-filling solution. The immersion time depends on the thickness and pore size of the clay body.

[0032] Step 2: After soaking, remove the embryo from the solution and place it on a rack to drain off excess solution naturally.

[0033] Step 3: Allow the drained embryos to air dry a second time;

[0034] Step 4: Glazing. Choose an appropriate glazing method according to the shape and size of the pottery, and control the glaze thickness between 0.1-0.3mm.

[0035] Step 5: Firing. Place the glazed body into the kiln and heat it to 350°C at a rate of 5°C / minute. Hold it at that temperature for 40 minutes. Then, continue to heat it to 900°C at a rate of 8°C / minute. Finally, raise the temperature to 1100°C and hold it for 2.5 hours.

[0036] Step 6: Cooling. Allow the pottery in the kiln to cool naturally to room temperature.

[0037] Beneficial effects compared to existing technologies:

[0038] 1. In this scheme, by scientifically selecting and rationally proportioning raw materials such as kaolin, bentonite, and water glass, the performance of the pottery body is optimized. Kaolin imparts basic plasticity, bentonite enhances the bonding force between particles, and water glass reacts with minerals at high temperatures to generate new phases. These raw materials work synergistically to make the body more resilient during forming, more stable in structure after firing, and increase internal density, laying a solid foundation for subsequently improving the hardness and strength of the pottery and effectively reducing defects in the body during the production process.

[0039] 2. In this scheme, by using a bubble-filling solution and appropriate processing techniques, the internal bubbles of the pottery are effectively filled and the density is increased. The solution, composed of silica sol, methylcellulose, ethanol, and boric acid, penetrates into the bubble pores through capillary action, and the silica particles solidify and fill the pores during air drying and firing. This not only eliminates internal bubbles but also enhances the integrity of the body, further improving the hardness, strength, and resistance to deformation of the pottery, making its physical properties even better.

[0040] 3. In this solution, a significant improvement in the surface properties of pottery is achieved by using a specially formulated glaze and precise glazing and firing processes. The various components in the glaze, such as silica and alumina, form hard glassy and crystalline phases at high temperatures, enhancing the glaze's hardness, wear resistance, and oxidation resistance. Reasonable control of glaze thickness and methods, along with strict control of temperature and atmosphere during firing, ensures the glaze reacts fully with the ceramic body, forming a uniform and dense protective film on the pottery surface. This effectively resists external erosion and improves the pottery's oxidation resistance and aesthetics. Attached Figure Description

[0041] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, the preferred embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0042] Figure 1 This is a flowchart illustrating the steps involved in producing high-hardness, oxidation-resistant ceramics. Detailed Implementation

[0043] Preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. However, the present invention can also be implemented in various different forms, and therefore the present invention is not limited to the embodiments described below.

[0044] The technical solution in this application embodiment is to solve the problems mentioned in the background art, and the overall idea is as follows:

[0045] Example 1:

[0046] Please refer to Figure 1 As shown in the figure, this embodiment introduces a high-hardness, oxidation-resistant ceramic and its production method, including a body, a body bubble-filling solution, and a glaze liquid;

[0047] 1. Embryo raw material

[0048] 1.1 Kaolin, as the main raw material for pottery body, gives the body good plasticity and formability. During the firing process, the minerals in kaolin undergo a series of physical and chemical changes to form a stable crystal structure, which provides basic strength and hardness for pottery. In addition, the fine particle size and high purity of kaolin can ensure that the pottery has a uniform and delicate texture and reduce the generation of internal defects.

[0049] 1.2. Bentonite, whose main mineral is montmorillonite, has a unique layered structure. Bentonite has extremely strong water absorption and swelling properties, and forms a gel-like substance when it comes into contact with water. When mixed with kaolin, bentonite can enhance the bonding force between kaolin particles, making the body more tough and less prone to cracking during the molding process. During the firing process, bentonite fills the pores between kaolin particles, further increasing the density of the body and thus improving the hardness of the pottery.

[0050] 1.3 Water glass (sodium silicate solution), the main component of which is sodium silicate, with a modulus n generally between 3.0 and 3.3, and a concentration usually between 30% and 40%. Sodium silicate exists in water in ionic form and has strong chemical activity. Water glass reacts chemically with minerals in kaolin at high temperatures to generate new aluminosilicate mineral phases. These new mineral phases can enhance the bonding force between particles, making the structure of the pottery more stable. In addition, water glass can lower the firing temperature of kaolin, allowing kaolin to reach a better sintering state at a relatively lower temperature, reducing the damage of high temperature to the pottery structure, and further improving the hardness of the pottery.

[0051] 1.4 Water, as a solvent and lubricant, plays an important role in the fabrication process. It allows raw materials such as kaolin, bentonite and water glass to be fully mixed to form a uniform material. At the same time, water can also regulate the moisture content of the material, giving it suitable plasticity and facilitating molding operations.

[0052] 2. Preparation of embryo

[0053] 2.1 Raw material preparation

[0054] High-quality kaolin is selected and passed through a 200-mesh sieve to remove impurities and larger particles, ensuring the purity and uniform particle size of the kaolin; sodium-based bentonite is also selected and passed through a 200-mesh sieve to ensure that its particle size meets the requirements.

[0055] Prepare a water glass solution with a modulus of 3.0-3.3 and a concentration of 30%-40%; use purified water or softened water to avoid impurities in the water affecting the quality of the pottery;

[0056] 2.2 Preparation of the mixture

[0057] Add bentonite to water slowly at a ratio of 1:5-8, while simultaneously stirring mechanically at a speed of 200-300 rpm for 30-40 minutes, so that the bentonite can fully absorb water and expand to form a uniform bentonite slurry.

[0058] Add water glass solution accounting for 15%-25% of the bentonite mass to the bentonite slurry, and continue stirring for 20-30 minutes. The stirring speed can be appropriately increased to 300-400 rpm to ensure that the three are fully mixed and a uniform and stable mixture is obtained.

[0059] 2.3 Mixing of raw materials

[0060] The sieved kaolin is placed into a mixing device, and the prepared mixture is slowly added while stirring to ensure that the mixture is fully in contact with the kaolin and is evenly mixed. The moisture content of the mixture is controlled to keep it between 20% and 25% to facilitate subsequent molding operations. The mixing time is generally 30-60 minutes to ensure that the mixture is evenly mixed.

[0061] 2.4 Molding

[0062] Choose the appropriate forming method according to the shape and size of the pottery to be made, such as hand-throwing, mold forming, slip casting, etc. During the forming process, pay attention to maintaining the uniformity and integrity of the body and avoid defects such as air bubbles and cracks.

[0063] 2.5. Embryo drying treatment

[0064] For initial drying, place the prepared embryos in a well-ventilated environment with a suitable temperature (generally 25-35℃) for natural drying, or use low-temperature drying equipment. The drying process should be slow to avoid excessive temperature or wind speed, which could cause the surface moisture of the embryos to evaporate too quickly and crack. The degree of drying is when the surface moisture of the embryos has basically disappeared, but the interior still contains a certain amount of moisture and is not sticky to the touch. Over-drying will cause the pores of the embryos to shrink, which is not conducive to the subsequent solution penetration. The drying time is generally 1-2 days, depending on the thickness of the embryos and environmental conditions.

[0065] 3. Raw materials for the embryo bubble-filling solution

[0066] 3.1 Silica sol is a dispersion of nano-sized silica particles in water. The particle size of silica particles is usually between 10-100 nm, and the solid content is generally between 20% and 40%. Silica sol has good permeability and can penetrate into the tiny air bubbles and pores of the ceramic body. During the air drying and firing process, the water in the silica sol gradually evaporates, and the silica particles will aggregate and solidify to form silica gel, thereby filling the air bubble space and improving the density and hardness of the ceramic.

[0067] 3.2 Methylcellulose, as a thickener and binder, can adjust the viscosity of the solution when added to it, so that it can better adhere to the pore surface of the ceramic body during the penetration process and prevent the solution from flowing out too quickly. At the same time, methylcellulose helps the silica particles to be evenly distributed, enhances the filling effect, and makes the filling more complete and uniform.

[0068] 3.3 Ethanol. As a solvent, ethanol is miscible with water and has a low surface tension. This allows ethanol to improve the permeability of the solution, making it easier for the solution to enter the tiny air bubbles in the ceramic body. In addition, ethanol evaporates quickly during the air drying process, which can accelerate the evaporation of water in the solution, promote the solidification of silica sol, and improve the filling efficiency.

[0069] 3.4 Boric acid acts as a flux during the firing process. It can lower the sintering temperature of the ceramic body, allowing the silica sol to better fuse with the minerals in the ceramic body. At the same time, boric acid can also improve the heat resistance and corrosion resistance of the ceramic, further increasing its hardness and strength.

[0070] 4. Treatment of embryo bubble filling solution

[0071] 4.1 Solution preparation: Accurately weigh a certain amount of silica sol, methylcellulose, ethanol and boric acid according to the required amount of solution. Select a silica sol solid content of 30%, use methylcellulose at 1% of the silica sol mass, use ethanol at 20% of the silica sol volume, and use boric acid at 3% of the silica sol mass.

[0072] 4.2 Slowly add the weighed methylcellulose to an appropriate amount of water while stirring. The stirring speed should be controlled at 100-150 rpm for 40 minutes to ensure that it is fully dissolved and forms a uniform methylcellulose solution.

[0073] 4.3 Mix silica sol and ethanol. Pour the weighed silica sol into a clean container, then slowly add ethanol while gently stirring with a glass rod or stirrer at a speed of 150 rpm for 18 minutes to ensure that the silica sol and ethanol are fully mixed and form a stable mixture.

[0074] 4.4 Add boric acid. Add the weighed boric acid to the above mixture and continue stirring for 12 minutes to completely dissolve the boric acid in the mixture. At this time, the solution may exhibit a slight exothermic phenomenon, which is normal.

[0075] 4.5 Add methylcellulose solution. Slowly pour the dissolved methylcellulose solution into the mixture containing silica sol, ethanol and boric acid while stirring. The stirring speed is 120 rpm and the stirring time is 25 minutes to ensure that all components are fully mixed and a uniform and stable highly permeable solution is formed.

[0076] 4.6 Filtration: Filter the prepared solution through a filter screen or filter to remove any impurities and undissolved particles, ensuring the purity and homogeneity of the solution. The filtered solution can then be used to process the ceramic body.

[0077] 5. Treatment of air bubbles in the embryo

[0078] 5.1 Immersion and Penetration

[0079] After the initial drying, the pottery body is completely immersed in the silica sol solution. The immersion time depends on the thickness and pore size of the body, and is generally 18 hours. During this period, the solution will gradually penetrate into the tiny bubbles and pores of the body through capillary action. To ensure the penetration effect, the solution can be gently stirred or the body can be turned over every 6 hours so that the solution can fully contact all parts of the body.

[0080] 5.2 Remove and drain.

[0081] After soaking, remove the embryo from the solution and place it on a rack to drain off excess solution naturally. The draining time should be controlled within 1-2 hours, and should not be too long to avoid excessive accumulation of solution on the surface of the embryo, which would form an uneven coating.

[0082] 5.3 Secondary air drying

[0083] After draining, place the preform in a well-ventilated environment with suitable temperature and humidity (25-30℃, 40%-50%) to air dry. The air drying process should be slow to avoid excessive temperature or wind speed, which could cause the surface moisture of the preform to evaporate too quickly and crack. During the air drying process, the water in the solution gradually evaporates, and substances such as silica sol will solidify in the air bubbles, initially filling the air bubbles. The air drying time is generally 2-3 days, depending on the size of the preform and environmental conditions.

[0084] 6. Glaze raw materials

[0085] 6.1 Silica, with a purity generally above 98% and a particle size requirement of passing through a 200-mesh sieve, is the main component of glaze. At high temperatures, silica forms a continuous glassy phase that fills the pores on the surface of the pottery, making the glaze smoother and denser, thereby improving the hardness and gloss of the glaze.

[0086] 6.2 Alumina, with a purity of over 99% and a particle size passing through a 200-mesh sieve, can improve the chemical stability, hardness, and high-temperature resistance of glaze. At high temperatures, alumina reacts with other components to form a hard crystalline phase, enhancing the wear resistance and scratch resistance of the glaze surface.

[0087] 6.3 Calcium oxide, whose main component is calcium carbonate (CaCO3), has a purity of over 95% and needs to be ground to pass through a 200-mesh sieve. As a flux, calcium oxide can lower the melting point of the glaze, improve its fluidity and gloss, and enhance the bonding force between the glaze and the body, making the glaze surface less prone to peeling.

[0088] 6.4 Magnesium oxide, with a purity of over 90% and passing through a 200-mesh sieve, can improve the high-temperature performance of glaze, increase the smoothness and gloss of the glaze surface, and also improve the hardness and chemical stability of the glaze, making the glaze surface more resistant to acid and alkali corrosion.

[0089] 6.5 Zinc oxide, with a purity of over 99% and a particle size passing through a 200-mesh sieve, acts as a flux to lower the melting temperature of the glaze, improve its transparency and gloss, enhance its hardness and oxidation resistance, and form a protective film on the glaze surface to prevent oxygen and other harmful substances from corroding the pottery.

[0090] 6.6 Borax, with a purity of over 95%, provides boron, which lowers the melting point of the glaze, increases its transparency and gloss, and also improves its thermal shock resistance and chemical stability, making the glaze less prone to cracking under high temperatures and temperature changes.

[0091] 6.7 Colorants, such as copper oxide and iron oxide, are selected according to the desired color. The purity is above 98% and they pass through a 200-mesh sieve. Colorants give pottery different colors. They react chemically with other components in the glaze at high temperatures to produce a variety of bright colors.

[0092] 7. Glaze preparation

[0093] 7.1 Raw material preparation

[0094] Weigh the glaze raw materials according to the following mass ratio: 50% silica (quartz powder), 18% alumina (industrial alumina powder), 12% calcium oxide (calcite), 8% magnesium oxide (talc powder), 5% zinc oxide, 5% borax, and 2% colorant (added as needed). Pass the quartz powder, industrial alumina powder, calcite, talc, zinc oxide, and borax raw materials through a 200-mesh sieve to ensure uniform particle size.

[0095] 7.2 Ball milling and mixing

[0096] Place the weighed raw materials into a ball mill, add an appropriate amount of water and grinding media (such as ceramic balls), with the amount of water added being 35% of the total mass of the raw materials; set the speed of the ball mill to 180 rpm and the ball milling time to 18 hours to ensure that the raw materials are fully mixed and ground to form a uniform glaze slurry.

[0097] 7.3 Additives and Performance Adjustment

[0098] Add 0.8% (by weight) of binder (sodium carboxymethyl cellulose) to the glaze slurry while stirring at 120 rpm for 30 minutes to ensure the binder is fully dissolved and evenly dispersed in the glaze slurry. Add water as a diluent according to the actual consistency of the glaze slurry to adjust the Baume degree of the glaze slurry to 42Be', so that the glaze slurry has suitable fluidity and is easy to apply glaze in subsequent operations.

[0099] 7.4. Stale / Outdated

[0100] The adjusted glaze slurry is transferred to a special aging container, sealed, and aged at room temperature for 36 hours to allow the various components in the glaze slurry to undergo further physical and chemical changes, thereby improving the stability of the glaze slurry and the glazing effect.

[0101] 8. Glazing

[0102] 8.1 Selection of glazing method: Select an appropriate glazing method based on the shape and size of the pottery, such as dipping, spraying, or brushing.

[0103] Glazing: The body is completely immersed in the glaze liquid and then quickly removed so that the glaze liquid evenly covers the surface of the body. The glazing time depends on the water absorption of the body and the concentration of the glaze liquid, and is generally 2-3 seconds.

[0104] Glazing: Use a spray gun to evenly spray the glaze onto the surface of the body. When glazing, pay attention to controlling the pressure and distance of the spray gun to make the glaze layer thickness uniform. The glazing pressure is generally 0.2-0.4MPa, and the distance between the spray gun and the body is 20-30cm.

[0105] Glazing: Use a brush to evenly apply the glaze to the surface of the body. When glazing, pay attention to the direction and pressure of the brush to avoid brush marks.

[0106] 8.2 Glaze Thickness Control

[0107] The glaze thickness should be uniform, generally controlled between 0.1-0.3mm. An excessively thick glaze layer is prone to problems such as glaze flow and cracking during firing, while an excessively thin glaze layer will affect the hardness and gloss of the glaze surface.

[0108] 9. Firing

[0109] 9.1 Preheating Stage

[0110] The glazed body is placed in the kiln and heated to 350°C at a rate of 5°C / minute, and held for 40 minutes. The purpose of this stage is to remove residual moisture and organic matter from the body and prevent the body from cracking due to rapid evaporation of moisture at high temperatures.

[0111] 9.2 Heating Stage

[0112] Continue heating at a rate of 8℃ / minute to 900℃, allowing the minerals in the green body to gradually undergo chemical reactions and form a preliminary sintered structure. During the heating process, it is necessary to closely monitor the temperature changes inside the kiln to ensure a uniform heating rate.

[0113] 9.3 High-temperature insulation stage

[0114] The temperature is raised to 1100℃ and held for 2.5 hours. Under high temperature, the glaze reacts fully with the body, and the silica in the silica sol further fuses with the minerals in the body. Boric acid acts as a flux to promote the reaction, allowing the filler to better bond with the body and form a hard ceramic structure. At the same time, various components in the glaze also undergo chemical reactions to form a smooth and dense glass layer, which improves the hardness and oxidation resistance of the pottery.

[0115] 9.4 Cooling Stage

[0116] After firing, allow the pottery in the kiln to cool naturally to room temperature, which usually takes 12-16 hours. During the cooling process, it is important to control the cooling rate to avoid cracking of the pottery due to excessive thermal stress caused by excessive cooling. Slow cooling helps stabilize the internal structure of the pottery, making the crystal structure more complete and further improving the hardness and strength of the pottery.

[0117] Comparative Example 1:

[0118] 1. Preparation of embryo raw materials and mixture

[0119] 1.1 Kaolin: Passed through a 200-mesh sieve to ensure purity and uniform particle size, serving as the main raw material for the green body and providing the basis for basic formability and strength after sintering;

[0120] 1.2. Adhesive: Sodium carboxymethyl cellulose is selected as the binder to enhance the bonding force between kaolin particles;

[0121] 1.3 Water: Used as a solvent and to regulate humidity, ensuring the raw materials are mixed evenly and possess plasticity;

[0122] 2. Preparation of the mixture: Put the kaolin into the mixing equipment, add sodium carboxymethyl cellulose at 0.5% of the mass of the kaolin, add while stirring, and slowly add an appropriate amount of water to control the moisture content of the mixed material at 20%-25%, and stir for 30-60 minutes until uniform.

[0123] 3. Subsequent steps: The subsequent stages are the same as in Example 1;

[0124] Comparative Example 2:

[0125] 1.1. Preparation of embryo: In the embryo preparation stage, the preparation of raw materials, preparation of mixed solution, mixing of embryo material, molding and drying are the same as in Example 1. That is, high-quality kaolin and sodium bentonite are selected and sieved, bentonite, water glass and water are mixed in proportion to make a mixed solution, and then mixed with kaolin to form embryo material. After molding, it is initially dried to a suitable degree in a well-ventilated environment at 25-35℃.

[0126] Subsequent steps: Skip the body bubble filling solution treatment step and directly proceed to glaze preparation, glazing and firing. For glaze preparation, weigh out raw materials such as silica, alumina, calcium oxide, magnesium oxide, zinc oxide, borax, and colorant according to the mass ratio, ball mill and mix, add additives to adjust the properties, and glaze after aging. The glazing method and thickness control are the same as in Example 1, and the temperature and time settings for each stage of the firing process are also the same as in Example 1.

[0127] Comparative Example 3:

[0128] 1. Glaze preparation

[0129] 1.1 Glaze raw materials: mainly feldspar, quartz, clay and other common ceramic glaze raw materials;

[0130] 1.2 Preparation process: Feldspar, quartz and clay are mixed in a certain proportion (e.g., 40% feldspar, 30% quartz and 30% clay), an appropriate amount of water is added, and the mixture is placed in a ball mill and ball-milled until a uniform glaze slurry is formed. The ball milling time is about 10 hours. No additives are added, performance is adjusted and aging is performed.

[0131] 1.3 Other steps: The preparation of the body and the treatment of the body bubble filling solution (if any) are the same as in Example 1. When glazing, the glazing method is selected according to the shape and size of the pottery, such as dipping, spraying or brushing, and the glaze thickness is controlled to be 0.1-0.3 mm. The firing process is the same as in Example 1, and the operation is carried out in the stages of preheating, heating, high temperature holding and cooling. The temperature and time settings of each stage remain unchanged.

[0132] Experimental example:

[0133] The pottery prepared according to Example 1 and the three comparative examples was subjected to strength, hardness and oxidation resistance tests.

[0134]

[0135] 1. Results Analysis

[0136] 1.1 Compressive strength and flexural strength

[0137] Example 1: Due to the use of bentonite to enhance the bonding force between kaolin particles, the reaction of water glass with kaolin at high temperature to generate new mineral phases to enhance structural stability, and the filling of air bubbles in the body with a bubble-filling solution to increase density, the pottery of Example 1 has high compressive and flexural strength. These factors work together to make the internal structure of the pottery more compact and able to withstand greater pressure and bending force.

[0138] Comparative Example 1: Only water, kaolin and adhesive were used to mix the ingredients. The adhesive had a relatively limited bonding effect and could not undergo a chemical reaction at high temperatures to strengthen the structure like water glass. Moreover, there was no filling and strengthening effect of bentonite, resulting in a strength that was significantly lower than that of Example 1.

[0139] Comparative Example 2: After removing the bubble-filling solution from the pottery body, the bubbles in the pottery body were not effectively filled, resulting in more pores inside and reducing the overall strength of the pottery. Despite the effects of bentonite and water glass, the presence of bubbles weakened the continuity of the structure, making the strength less than that of Example 1.

[0140] Comparative Example 3: Using ordinary glaze, the glaze has a relatively weak effect on improving the strength of the pottery and cannot make up for the structural deficiencies of the body itself; although its strength is slightly higher than that of Comparative Example 2, it is still lower than that of Example 1, indicating that the performance of the glaze has a certain influence on the strength of the pottery, but it is not a decisive factor.

[0141] 1.2. Hardness

[0142] Example 1: Silica sol fills air bubbles to form silica gel. Multiple components in the glaze form a hard glassy phase and a crystalline phase at high temperature, which together improve the hardness of the pottery, making its Mohs hardness reach 6-7.

[0143] Comparative Example 1: Lacking the chemical reaction enhancement effect of water glass and the filling reinforcement of the preform bubble filling solution, the hardness is relatively low, only 4-5;

[0144] Comparative Example 2: Without the filling of the preform bubble-filling solution, the preform density was insufficient, and the hardness was affected, with a Mohs hardness of 5-6.

[0145] Comparative Example 3: Ordinary glaze is not as effective as the glaze in Example 1 in improving hardness, so its hardness is similar to that of Comparative Example 2, which is 5-6.

[0146] 1.3 Antioxidant properties

[0147] Example 1: The zinc oxide, borax and other components in the glaze, as well as the boric acid in the filling solution, form a dense protective film on the surface of the pottery, which effectively prevents the erosion of oxygen and other harmful substances. Therefore, there is no obvious change on the surface after being placed in a specific oxidizing environment for 100 hours.

[0148] Comparative Example 1: Due to its lower strength and density, the internal structure is relatively loose, making it easier for oxygen to enter, resulting in slight oxidation discoloration and a small amount of rust spots on the surface;

[0149] Comparative Example 2: The embryo body had unfilled air bubbles and many pores, which provided channels for oxygen, resulting in poor oxidation resistance and obvious oxidation discoloration, many rust spots and slight corrosion marks on the surface.

[0150] Comparative Example 3: The antioxidant properties of ordinary glaze are limited. Although it can protect the surface of pottery to a certain extent, it cannot achieve the effect of Example 1. Therefore, the surface has a certain degree of oxidation discoloration, rust spots and slight corrosion.

[0151] Finally, it should be noted that the above embodiments are merely examples for clearly illustrating the present invention and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A method for preparing high-hardness, oxidation-resistant ceramics, characterized in that, The method includes the following steps: Step 1: Bubble treatment of the clay body. The pre-dried pottery clay body is completely immersed in the bubble-filling solution. The immersion time depends on the thickness and pore size of the clay body. The method for preparing the embryo bubble-filling solution is as follows: Step 1.1: Select a silica sol with a solid content of 30%, use methylcellulose at 1% of the silica sol mass, use ethanol at 20% of the silica sol volume, and use boric acid at 3% of the silica sol mass; Step 1.2: Slowly add the weighed methylcellulose to an appropriate amount of water and stir to dissolve; Step 1.3: Mix silica sol and ethanol; Step 1.4: Add the weighed boric acid to the mixture of silica sol and ethanol; Step 1.5: Mix the solution from step 1.2 and the solution from step 1.4; Step 2: After soaking, remove the embryo from the solution and place it on a rack to drain off excess solution naturally. Step 3: Allow the drained embryos to air dry a second time; Step 4: Apply glaze. Select an appropriate glazing method according to the shape and size of the pottery. Control the glaze thickness between 0.1-0.3mm. The glaze is prepared as follows: Step 4.1: 50% silica, 18% alumina, 12% calcium oxide, 8% magnesium oxide, 5% zinc oxide, 5% borax, and 2% colorant; quartz powder, industrial alumina powder, calcite, talc powder, zinc oxide, and borax are each passed through a 200-mesh sieve to ensure uniform particle size of the raw materials. Step 4.2: Place the weighed raw materials into a ball mill, add an appropriate amount of water and grinding media, mix thoroughly and grind finely to form a uniform glaze slurry; Step 4.3: Add 0.8% of the binder by weight of the glaze slurry to the glaze slurry and stir at 120 rpm for 30 minutes; Step 4.4: Transfer the glaze to an aging container and seal it. Aging at room temperature for 36 hours. Step 5: Firing. Place the glazed body into the kiln and heat it to 350°C at a rate of 5°C / minute. Hold it at that temperature for 40 minutes. Then, continue to heat it to 900°C at a rate of 8°C / minute. Finally, raise the temperature to 1100°C and hold it for 2.5 hours. Step 6: Cooling. Allow the pottery in the kiln to cool naturally to room temperature.

2. The method for preparing a high-hardness, oxidation-resistant ceramic as described in claim 1, characterized in that, The embryo was prepared as follows: Step 1: Kaolin, sieved through a 200-mesh sieve to remove impurities and larger particles; water glass solution with a modulus of 3.0-3.3 and a concentration of 30%-40%; water as needed; Step 2: Mix bentonite and water in a ratio of 1:5-8, control the stirring speed at 200-300 rpm, and stir for 30-40 minutes to form a uniform bentonite slurry. Step 3: Add water glass solution (15%-25% of the bentonite mass) to the bentonite slurry, stir for 20-30 minutes at a stirring speed of 300-400 rpm to obtain a mixture; Step 4: Mix the kaolin and the mixture; Step 5: Prepare the clay body according to the desired shape and size of the pottery; Step 6: Drying the embryo.

3. A high-hardness, oxidation-resistant ceramic, characterized in that, The pottery is prepared by the method for preparing high-hardness, antioxidant pottery according to any one of claims 1 to 2.

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