Fiber-reinforced ceramic light-curing slurry, preparation method and reinforced ceramic material

By using zirconia and silicon oxide composite fibers in ceramic 3D printing for surface modification and combining short wavelength and long wavelength initiator, the problems of insufficient bonding force and uneven curing between layers in ceramic 3D printing are solved, and the preparation of high-precision and high-performance ceramic materials are achieved.

CN120157463BActive Publication Date: 2025-08-08苏州芯合半导体材料有限公司
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Patent Information

Application Number
CN202510647324.2
Authority / Receiving Office
CN · China
Patent Type
Patents(China)
Current Assignee / Owner
Filing Date
2025-05-20
Publication Date
2025-08-08
Estimated Expiration
2045-05-20

AI Technical Summary

Technical Problem

The existing ceramic 3D printing technology has problems such as concentrated interlayer interface stress, insufficient interlayer binding force, weak interface bonding between fiber and resin, uneven curing and insufficient deep curing. It is particularly obvious in colorant or high filler slurry, which limits its application in high reliability scenarios.

Method used

The surface modification treatment is carried out by zirconia and silicon oxide composite fibers, and combined with the coordinated use of short wavelength and long wavelength initiator, the surface-deep collaborative curing is formed through a composite system with photocuring resin as a matrix to improve the interface binding force and load transfer efficiency. At the same time, the bridging effect of zirconia fibers and the refractive index adjustment of silicon oxide fibers are used to improve the curing depth and uniformity.

Benefits of technology

It significantly improves the curing depth and mechanical properties of ceramic materials, realizes high-precision molding and the preparation of high-performance ceramic products, solves the problems of insufficient bonding between layers and uneven curing, and improves the strength and toughness of ceramic materials.

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Abstract

The present invention belongs to the technical field of ceramics and their slurries, and specifically relates to a fiber-reinforced ceramic photocuring slurry, a preparation method and a reinforced ceramic material. The slurry provided by the present invention is composed of ceramic powder, ceramic composite short fibers, photocuring resin, photoinitiator, dispersant, plasticizer, etc., wherein the ceramic composite short fibers are zirconium oxide and silicon oxide composite fibers; the photocuring resin contains photosensitive resin monomers and prepolymers; and the photoinitiator is a compound of short-wavelength and long-wavelength initiators. During preparation, the ceramic composite short fibers are first modified with a silane coupling agent, and then mixed with various materials, ball-milled, and degassed. The obtained slurry is subjected to 3D printing photocuring molding and degreasing and sintering to obtain a reinforced ceramic material. The slurry can be used to manufacture high-performance ceramic materials through the synergistic reinforcement of composite short fibers, synergistic curing of long and short wavelength initiators, and fiber surface modification, significantly improving the curing depth, three-point bending strength, and fracture toughness.
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Description

Technical Field

[0001] The present invention belongs to the technical field of ceramics and their slurries, and in particular relates to a fiber-reinforced ceramic light-curing slurry, a preparation method and a reinforced ceramic material. Background Art

[0002] Ceramic 3D printing, as an advanced manufacturing technology, enables the rapid fabrication of complex structures, demonstrating unique advantages in fields such as aerospace and medical implants. Stereolithography (SLA), with its high precision, smooth surface finish, and adaptability to complex structures, has become a key area of ceramic additive manufacturing. However, SLA's layer-by-layer curing mechanism has inherent drawbacks: interlayer interfaces become stress concentration zones and crack propagation pathways, resulting in lower strength and toughness than traditional molding processes. Especially for colored ceramic printing, the absorption of UV light by coloring oxides reduces light penetration, further reducing curing efficiency and exacerbating the problem of insufficient interlayer bonding, limiting its application in high-reliability applications.

[0003] Ceramic fiber reinforcement is an effective means of improving the mechanical properties of ceramic materials. Existing fiber reinforcement primarily utilizes fused deposition modeling (FDM), which adds ceramic fibers to a thermoplastic material containing ceramic powder and achieves reinforcement through layer-by-layer extrusion, melt deposition, and molding. However, this process suffers from surface roughness and low dimensional accuracy, making it difficult to meet the manufacturing requirements of complex and precise components. In contrast, if SLA can introduce ceramic fibers into the photosensitive resin slurry, it is expected to combine the dual advantages of "fiber reinforcement" and "photocuring high-precision molding." Summary of the Invention

[0004] In view of the deficiencies in the prior art, the present invention provides a fiber-reinforced ceramic light-curing slurry, a preparation method and a reinforced ceramic material.

[0005] During the implementation of the present invention, it was found that fiber-reinforced slurries for SLA face multiple technical challenges. The first is the weak interfacial bonding between the fiber and the resin, and the poor compatibility between the surface polarity of the ceramic fiber and the photosensitive resin, which leads to low load transfer efficiency, easy fiber pullout, and difficulty in fully exerting the reinforcing effect. The second is uneven curing and insufficient curing depth. The single photoinitiator has a narrow wavelength range for ultraviolet light absorption, and shallow curing and deep curing are not synchronized. Especially in slurries containing colorants or high fillers, the light attenuation is significant, and the problem of insufficient deep curing is exacerbated. Thirdly, the fibers are not easy to fully disperse. The large aspect ratio of ceramic fibers leads to large steric hindrance, and there is a large interfacial energy between their surface polarity and the non-polar resin matrix, which together lead to the ceramic fibers tending to entangle and aggregate with each other, rather than uniform distribution, affecting the structural consistency and mechanical properties after curing.

[0006] The object of the present invention is to provide a ceramic light-curing slurry and a high-performance ceramic product that can be formed with high precision and has excellent mechanical properties.

[0007] The first aspect of the present invention is to provide a fiber-reinforced ceramic photocurable slurry, which includes ceramic powder, ceramic composite fiber, photocurable resin, photoinitiator, coloring oxide, dispersant, and plasticizer.

[0008] The ceramic powder is one or more of zirconia, alumina, zirconia toughened alumina, and alumina toughened zirconia.

[0009] The ceramic composite fiber is a composite fiber of zirconium oxide fiber and silicon oxide fiber, accounting for 1.5%-4.0% of the mass of the ceramic powder, wherein the mass ratio of zirconium oxide to silicon oxide is 1-2; and the ceramic composite fiber is subjected to silane coupling surface treatment before being prepared into slurry.

[0010] Photocurable resins include photosensitive resin monomers and prepolymers; the photosensitive resin monomers are a mixture of hexanediol diacrylate (HDDA), isodecyl acrylate (IDA), trimethylolpropane triacrylate (TMPTA), and pentaerythritol tetraacrylate (PPTTA), accounting for 75%-85% of the mass of the photocurable resin; the prepolymers are one or more of epoxy acrylate resin (EA), polyurethane acrylate resin (PUA), and bisphenol A epoxy acrylate resin (BPA-EP), accounting for 15%-25% of the mass of the photocurable resin.

[0011] Photoinitiators include short-wavelength initiators and long-wavelength initiators, among which the short-wavelength initiator is an ultraviolet photoinitiator with an absorption wavelength in the range of 240-280nm, and the long-wavelength initiator is an ultraviolet photoinitiator with an absorption wavelength in the range of 320-400nm. The mass ratio of the short-wavelength initiator to the long-wavelength initiator is 0.5-2, and the total amount of photoinitiator accounts for 1.2%-2.2% of the mass of the photocurable resin.

[0012] As a further optimization solution for the fiber-reinforced ceramic photocuring slurry, the composite fiber has a length of 5-20 μm and a diameter of 1-4 μm.

[0013] As a further optimization scheme for fiber-reinforced ceramic photocurable paste, the short-wavelength initiator is selected from 1-hydroxycyclohexylphenyl ketone (184) and 2-hydroxy-2-methyl-1-phenylpropanone (1173), and the long-wavelength initiator is selected from benzoin diethyl ether (651), phenylbis(2,4,6-trimethylbenzoyl)phosphine oxide (819), and 2,4,6-trimethylbenzoyl-diphenylphosphine oxide (TPO).

[0014] As a further optimization solution for fiber-reinforced ceramic photocuring slurry, the coloring oxide is one or more of iron oxide, cobalt oxide, cerium oxide, niobium oxide, and erbium oxide, accounting for 0.8%-1.5% of the mass of the ceramic powder.

[0015] As a further optimization solution for fiber-reinforced ceramic photocuring slurry, the dispersant is one or more of BYK110, BYK218, BYK111, and KOS110, accounting for 1%-3% of the mass of the ceramic powder.

[0016] As a further optimization solution for fiber-reinforced ceramic photocuring slurry, the plasticizer is one or more of polyethylene glycol 200 (PEG200), polyethylene glycol 400 (PEG400), polypropylene glycol 400 (PPG400), dibutyl phthalate (DBP), and dioctyl phthalate (DOP), accounting for 20%-25% of the mass of the photocuring resin.

[0017] As a further optimization solution for fiber-reinforced ceramic photocuring slurry, a leveling agent is also included. The leveling agent is one or more of TEGO450 and TEGOPREN5847, accounting for 8%-15% of the mass of the photocuring resin.

[0018] As a further optimization solution for fiber-reinforced ceramic photocuring slurry, a defoaming agent is also included. The defoaming agent is Foamex N, which accounts for 5%-10% of the mass of the photocuring resin.

[0019] The second aspect of the present invention is to provide a method for preparing the above-mentioned fiber-reinforced ceramic photocurable slurry, comprising the following steps:

[0020] Step (1): using a silane coupling agent to modify the surface of the ceramic composite fiber;

[0021] Step (2): The surface-modified ceramic composite fiber is uniformly mixed with other materials according to the formula amount and degassed to obtain a fiber-reinforced ceramic light-curing slurry.

[0022] As a further optimization scheme of the above preparation method, the following steps are included:

[0023] Step (1): adding the ceramic composite fiber to an ethanol solution containing 2-4 wt% of a silane coupling agent γ-methacryloxypropyltrimethoxysilane, ultrasonically dispersing the solution for 20-40 minutes, filtering the solution, drying the solution at 55-70°C for 3-6 hours, and then heat treating the solution at 170-190°C for 0.5-2 hours;

[0024] Step (2) The surface-modified ceramic composite fiber is added to a mixing container together with a photocurable resin, a photoinitiator, a dispersant, a plasticizer, and optional coloring oxides, a leveling agent, and a defoaming agent. The mixture is vacuum degassed and mixed at a speed of 500-2000 rpm for 5-12 minutes. Then, the ceramic powder is added and transferred to a planetary ball mill. The mixture is ball milled and mixed at a speed of 100-300 rpm for 5-12 hours. Finally, the mixture is vacuum degassed again for 10-30 minutes to obtain a fiber-reinforced ceramic photocurable slurry.

[0025] A third aspect of the present invention is to provide a reinforced ceramic material, which is obtained by 3D printing, photocuring molding, degreasing, and sintering the above-mentioned fiber-reinforced ceramic photocuring slurry.

[0026] Beneficial effects

[0027] The fiber-reinforced photocurable ceramic slurry provided by the present invention utilizes zirconium oxide and silicon oxide composite fibers in a composite system with a photocurable resin as the matrix and ceramic powder as the aggregate. The synergistic effect of the two fibers creates a bridging effect during matrix crack propagation, improving the material's refractive index and acting as a sintering aid, thereby enhancing interfacial bonding with the resin matrix and load transfer efficiency. Furthermore, the photoinitiator utilizes a combination of short-wavelength and long-wavelength initiators to achieve "surface-deep synergistic curing," improving the insufficient photocuring depth of colored ceramics while also improving the temporal and spatial uniformity of curing and reducing internal stress concentration. Furthermore, surface modification of the ceramic composite fibers further enhances the interfacial bonding between the fibers and the resin matrix. These measures work together to significantly improve the curing depth of the slurry after curing and the mechanical properties of the ceramic after sintering. The present invention provides a high-quality slurry for the preparation of high-performance reinforced ceramic materials. The slurry is suitable for 3D printing photocuring molding and can produce a reinforced ceramic material with excellent performance after degreasing and sintering. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 1-3 is a diagram of the composition of the light-curing ceramic slurry formula.

[0029] Figure 2 1 is a diagram showing the composition of the light-curing ceramic slurry formulations for comparative examples 1-3.

[0030] Figure 3 This is a diagram showing the composition of the light-curing ceramic slurry formulations for Comparative Examples 4-6.

[0031] Figure 4 Graph showing the performance test results of the embodiments and comparative examples. DETAILED DESCRIPTION

[0032] The present invention is further illustrated below by means of specific examples. These examples are exemplary and are intended to illustrate the problem and explain the present invention, but are not intended to be limiting.

[0033] The fiber-reinforced ceramic photocuring slurry of the present invention comprises ceramic powder, ceramic composite fiber, photocuring resin, photoinitiator, coloring oxide, dispersant, plasticizer, leveling agent and defoaming agent.

[0034] The ceramic powder is one or more of zirconia (ZrO2), alumina (Al2O3), zirconia toughened alumina (ZTA), and alumina toughened zirconia (ATZ).

[0035] The ceramic composite fiber is a composite fiber of zirconium oxide fiber and silicon oxide fiber, accounting for 1.5%-4.0% of the mass of the ceramic powder, with a fiber length of 5-20 μm and a diameter of 1-4 μm, wherein the mass ratio of zirconium oxide to silicon oxide is 1-2.

[0036] Photocurable resins include photosensitive resin monomers and oligomers (prepolymers). The photosensitive resin monomers are a mixture of hexanediol diacrylate (HDDA), isodecyl acrylate (IDA), trimethylolpropane triacrylate (TMPTA), and pentaerythritol tetraacrylate (PPTTA), accounting for 75%-85% of the mass of the photocurable resin; the oligomers are one or more of epoxy acrylate resin (EA), polyurethane acrylate resin (PUA), and bisphenol A epoxy acrylate resin (BPA-EP), accounting for 15%-25% of the mass of the photocurable resin.

[0037] The photoinitiator is a mixture of a short-wavelength initiator and a long-wavelength initiator, wherein the short-wavelength initiator is selected from 1-hydroxycyclohexylphenyl ketone (184) and 2-hydroxy-2-methyl-1-phenylacetone (1173); the long-wavelength initiator is selected from benzoin diethyl ether (651), phenylbis(2,4,6-trimethylbenzoyl)phosphine oxide (819) and 2,4,6-trimethylbenzoyl-diphenylphosphine oxide (TPO); the mass ratio of the short-wavelength initiator to the long-wavelength initiator is between 0.5 and 2, and the total amount of the photoinitiator accounts for 1.2% to 2.2% of the mass of the photocurable resin.

[0038] The coloring oxide is one or more of iron oxide, cobalt oxide, cerium oxide, niobium oxide and erbium oxide, accounting for 0.8-1.5% of the mass of the ceramic powder.

[0039] The dispersant is one or more of BYK110, BYK218, BYK111, and KOS110, accounting for 1%-3% of the mass of the ceramic powder.

[0040] The plasticizer is one or more of polyethylene glycol 200 (PEG200), polyethylene glycol 400 (PEG400), polypropylene glycol 400 (PPG400), dibutyl phthalate (DBP), and dioctyl phthalate (DOP), accounting for 20%-25% of the mass of the light-curing resin.

[0041] The leveling agent is one or more of TEGO450 and TEGOPREN5847, accounting for 8%-15% of the mass of the light-curing resin.

[0042] The defoaming agent is Foamex N, which accounts for 5%-10% of the mass of the light-curing resin.

[0043] Source of raw materials:

[0044] Zirconia powder: Saint-Gobain Xipu Grinding (Handan) Co., Ltd.

[0045] Alumina powder: Hangzhou Wanjing New Materials Co., Ltd.

[0046] Zirconia toughened alumina (ZTA) powder: obtained by mixing the above-mentioned zirconia powder and alumina powder, with the mass ratio of zirconia powder to alumina powder being 1:4;

[0047] Alumina-toughened zirconia (ATZ) powder: obtained by mixing the zirconia powder and alumina powder from the above sources, with the mass ratio of zirconia powder to alumina powder being 4:1;

[0048] Epoxy acrylic resin (EA): L-6111 from Guangdong Lankelu New Materials Co., Ltd.

[0049] Polyurethane acrylic resin (PUA): Changxing Chemical Industry Co., Ltd. 6145-100;

[0050] Bisphenol A epoxy acrylate resin (BPA-EP): IBW-71281-65-7 from Hubei Langbowan Biopharmaceutical Co., Ltd.

[0051] Zirconia ceramic fiber: Forsman Technology (Beijing) Co., Ltd., zirconia ultra-short fiber (4008006);

[0052] Silica ceramic fiber: Forsman Technology (Beijing) Co., Ltd., nano silica fiber (1407231).

[0053] The fiber-reinforced ceramic photocuring slurry of the present invention is prepared by the following steps:

[0054] (1) Surface modification of ceramic composite fibers

[0055] First, the surface of the ceramic composite fiber is modified: the ceramic composite fiber (a composite of zirconium oxide and silicon oxide fibers) is added to an ethanol solution containing 2-4wt% silane coupling agent and ultrasonically dispersed for 20-40 minutes to fully disperse the fibers in the solution. After dispersion, the fibers are filtered and separated. The filtered fibers are placed in a dry environment at 55-70°C for 3-6 hours to remove the ethanol solvent. The dried fibers are then transferred to a heat treatment at 170-190°C for 0.5-2 hours to complete the surface modification and enhance the interfacial bonding between the fibers and the resin matrix.

[0056] (2) Slurry mixing preparation

[0057] According to the formula, the surface-modified ceramic composite fiber is added to the mixing container together with the coloring oxide, photosensitive resin monomer, oligomer, dispersant, plasticizer, leveling agent, defoamer, and initiator. The mixing container is placed in a vacuum degassing machine and mixed at a speed of 500-2000rpm for 5-12 minutes to ensure that the components are initially mixed evenly. Next, ceramic powder is added to the evenly mixed system, and the mixture is transferred to a planetary ball mill and ball-milled at a speed of 100-300rpm for 5-12 hours to ensure that the ceramic powder and other components are fully dispersed and mixed. After the ball milling is completed, the slurry is placed in a vacuum environment again for degassing treatment. The degassing time is 10-30 minutes to remove bubbles introduced during the mixing process, and finally a uniform and stable fiber-reinforced ceramic photocuring slurry is obtained.

[0058] Examples 1-3 and Comparative Examples 1-6

[0059] In Example 1-3, the light-cured ceramic slurry is Figure 1 The light-curing ceramic slurry in Comparative Example 1-3 was prepared according to the formula shown in FIG. Figure 2 The light-curing ceramic slurry in Comparative Examples 4-6 was prepared according to the formula shown in FIG. Figure 3 Prepare the recipe as shown.

[0060] The preparation of the light-curing ceramic slurry is carried out according to the following steps.

[0061] (1) Surface modification of ceramic composite fibers

[0062] First, the ceramic composite fibers were surface modified: ceramic composite fibers (a composite of zirconium oxide and silicon oxide fibers) were added to an ethanol solution containing 3wt% of a silane coupling agent (γ-methacryloxypropyltrimethoxysilane). Ultrasonic dispersion was performed for 30 minutes to fully disperse the fibers in the solution. After dispersion, the fibers were separated by filtration and dried at 60°C for 4 hours to remove the ethanol solvent. The dried fibers were then heat-treated at 180°C for 1 hour to complete the surface modification and enhance the interfacial bonding between the fibers and the resin matrix.

[0063] (2) Slurry mixing preparation

[0064] According to the formula, the surface-modified ceramic composite fiber is added to the mixing container together with the coloring oxide, photosensitive resin monomer, oligomer, dispersant, plasticizer, leveling agent, defoamer, and initiator. The mixing container is placed in a vacuum degassing machine and mixed at a speed of 1500 rpm for 8 minutes to ensure that the components are initially mixed evenly. Next, ceramic powder is added to the evenly mixed system, and the mixture is transferred to a planetary ball mill and ball-milled at a speed of 200 rpm for 10 hours to ensure that the ceramic powder and other components are fully dispersed and mixed. After the ball milling is completed, the slurry is placed in a vacuum environment again for defoaming treatment. The defoaming time is 20 minutes to remove the bubbles introduced during the mixing process, and finally a uniform and stable fiber-reinforced ceramic light-curing slurry is obtained.

[0065] Test Case

[0066] The slurries prepared in the Examples and Comparative Examples were injected into an SLA-100 ceramic light-curing printer, with the single-layer print dimensions set to 10 mm x 10 mm x 0.1 mm. After printing a single layer, the printed part was removed and cleaned of any uncured slurry. The part was then placed under a high-precision confocal microscope to measure the depth of the cured layer.

[0067] The slurries prepared in the examples and comparative examples were 3D printed, with the print dimensions set to X:30mm×Y:5mm×Z:4mm. After printing, the residual slurry on the surface of the ceramic green body was cleaned, and the green body was then placed in a degreasing and sintering furnace for degreasing and sintering. The degreasing process parameters were: heating from room temperature to 380°C at 0.5°C / min, holding at 380°C for 5 hours, then heating to 600°C at 0.3°C, holding at 600°C for 2 hours, and then cooling to room temperature at 1°C / min. The sintering process parameters were: heating to 1580°C at 2°C / min, holding for 2 hours, and cooling to room temperature at 2°C / min.

[0068] After polishing the sintered specimens, the fracture toughness was measured using a microhardness tester. The specific method was as follows: a 10 kg load was applied to the polished surface of the specimen, and an indentation was made using a conical diamond indenter, causing pre-cracks at the four vertices of the indentation. The fracture toughness value (K) was calculated based on the indentation load P and the indentation crack extension length C. IC ). The calculation formula is: K IC =0.016×(E / H V )^(1 / 2)×(P / (C^(3 / 2))). Here, E is the elastic modulus of the material, in GPa; Hv is the Vickers hardness of the material, in GPa; the crack length C is half the diagonal length of the indentation, in millimeters (mm); and the load P is the force applied to the indenter, in Newtons (N). According to GB / T 6569-2006, the flexural strength of the specimens was tested using a three-point bending test at a loading rate of 0.5 mm / min.

[0069] The test results are as follows Figure 4 shown.

[0070] Comparisons between Comparative Example 1 and Example 1, and Comparative Example 6 and Example 3, show that differences in initiators significantly impact performance. Examples 1 and 3 utilize a combination of long- and short-wavelength initiators, while Comparative Examples 1 and 6 utilize a single initiator. In terms of performance, Example 1 significantly outperforms Comparative Example 1 in terms of cure depth, three-point bend strength, and fracture toughness; Example 3 also significantly outperforms Comparative Example 6 in terms of cure depth, three-point bend strength, and fracture toughness. Short-wavelength initiators (such as 184 and 1173) absorb short-wavelength ultraviolet light (240-280nm), but have shallow light penetration, effectively curing only the surface layer of the material in a short period of time. Long-wavelength initiators (such as TPO and 651) absorb long-wavelength light (320-400nm), allowing deeper light penetration and enabling deep curing of the material. When the two are compounded, the short-wavelength initiator mainly acts on the surface layer, and the long-wavelength initiator simultaneously promotes deep-layer curing, forming "surface-deep synergistic curing", avoiding the problems of "surface over-curing / deep under-curing" or "surface under-curing / deep excessive shrinkage" caused by limited penetration depth, thereby significantly improving the uniformity of curing depth, reducing internal stress concentration, and facilitating the sintering process. Maintaining material stability and density, ultimately obtaining high-strength ceramic parts.

[0071] The difference between Comparative Example 2 and Example 2, and between Comparative Example 3 and Example 3 is whether ceramic composite fibers are added. The curing depth, three-point bending strength and fracture toughness of Comparative Examples 2 and 3, which do not add ceramic composite fibers, are lower than those of the corresponding examples. In the ceramic composite fibers, zirconia fibers can play a bridging role in the process of matrix crack propagation, hindering crack propagation, and silica fibers can improve the refractive index of the material and act as a sintering aid. When sintered at high temperatures, a glass liquid phase is formed to fill the gaps between ceramic particles and promote atomic diffusion between particles, thereby significantly improving the densification of the sintered body. After the two are combined, a good interface is formed with the matrix and the curing depth and mechanical properties are improved. Compared with Example 1, Comparative Example 4 only uses a single zirconia fiber, and Comparative Example 5 only uses silica fibers compared to Example 2. Its performance shows a downward trend compared to the combination of the two fibers. Although single zirconia fiber can hinder crack propagation to a certain extent, it leads to limited light penetration depth and insufficient interface bonding and load transfer effects. Although single silica fiber can improve the refractive index, its own strength and interface bonding ability are lower than those of zirconia fiber. Neither can achieve the significant reinforcement effect of composite fiber. Zirconia and silica fibers work together to improve crack propagation resistance through the bridging effect of zirconia fiber, and can improve the refractive index with the help of silica fiber to promote deep curing. At the same time, good interface bonding is formed to improve the interlayer load transfer efficiency, thereby significantly optimizing the curing depth of the slurry and the bending strength and fracture toughness after sintering.

[0072] In summary, the synergistic combination of long and short wavelength initiators in the present invention combined with zirconia / silica composite fibers significantly improves material performance. It not only improves the curing depth and uniformity to reduce internal stress through the "surface-deep synergistic curing" mechanism, but also utilizes the crack bridging effect of zirconia fiber and the refractive index adjustment and sintering aid effect of silica fiber to enhance interface bonding and load transfer efficiency, significantly improving the curing depth after slurry curing and the bending strength and fracture toughness after sintering, thereby achieving a significant improvement in the comprehensive performance of fiber-reinforced ceramic photocuring slurry and ceramic materials.

[0073] The above embodiments are exemplary and intended to illustrate the technical concepts and features of the present invention so that those skilled in the art can understand the present invention and implement it accordingly. They are not intended to limit the scope of protection of the present invention. Any equivalent changes or modifications made in accordance with the spirit of the present invention are intended to be included within the scope of protection of the present invention.

Claims

1. A fiber-reinforced ceramic light-curing slurry, characterized in that: Including ceramic powder, ceramic composite fiber, light-curing resin, photoinitiator, coloring oxide, dispersant, plasticizer; The ceramic powder is one or more of zirconia, alumina, zirconia-toughened alumina, and alumina-toughened zirconia; The ceramic composite fiber is a composite fiber of zirconium oxide fiber and silicon oxide fiber, accounting for 1.5%-4.0% of the mass of the ceramic powder, wherein the mass ratio of zirconium oxide to silicon oxide is 1-2; and the ceramic composite fiber is subjected to silane coupling surface treatment before being prepared into a slurry; The photocurable resin includes a photosensitive resin monomer and a prepolymer; the photosensitive resin monomer is a mixture of hexanediol diacrylate, isodecyl acrylate, trimethylolpropane triacrylate, and pentaerythritol tetraacrylate, accounting for 75% to 85% of the mass of the photocurable resin; the prepolymer is one or more of epoxy acrylate resin, polyurethane acrylate resin, and bisphenol A epoxy acrylate resin, accounting for 15% to 25% of the mass of the photocurable resin; The photoinitiator includes a short-wavelength initiator and a long-wavelength initiator, wherein the short-wavelength initiator is an ultraviolet light initiator with an absorption wavelength in the range of 240-280 nm, and the long-wavelength initiator is an ultraviolet light initiator with an absorption wavelength in the range of 320-400 nm. The mass ratio of the short-wavelength initiator to the long-wavelength initiator is 0.5-2, and the total amount of the photoinitiator accounts for 1.2%-2.2% of the mass of the photocurable resin; The short wavelength initiator is selected from 1-hydroxycyclohexyl phenyl ketone and 2-hydroxy-2-methyl-1-phenyl acetone; the long wavelength initiator is selected from benzoin diethyl ether, phenyl bis(2,4,6-trimethylbenzoyl)phosphine oxide and 2,4,6-trimethylbenzoyl-diphenylphosphine oxide.

2. The fiber-reinforced ceramic light-curing slurry according to claim 1, characterized in that: The composite fiber has a length of 5-20 μm and a diameter of 1-4 μm.

3. The fiber-reinforced ceramic light-curing slurry according to claim 1, characterized in that: The coloring oxide is one or more of iron oxide, cobalt oxide, cerium oxide, niobium oxide, and erbium oxide, accounting for 0.8%-1.5% of the mass of the ceramic powder.

4. The fiber-reinforced ceramic light-curing slurry according to claim 3, characterized in that: The dispersant is one or more of BYK110, BYK218, BYK111, and KOS110, accounting for 1%-3% of the mass of the ceramic powder.

5. The fiber-reinforced ceramic light-curing slurry according to claim 4, characterized in that: The plasticizer is one or more of polyethylene glycol 200, polyethylene glycol 400, polypropylene glycol 400, dibutyl phthalate, and dioctyl phthalate, accounting for 20%-25% of the mass of the light-curable resin.

6. The fiber-reinforced ceramic light-curing slurry according to claim 5, characterized in that: The composition further comprises a leveling agent, which is one or more of TEGO450 and TEGOPREN5847, accounting for 8%-15% of the mass of the photocurable resin; and a defoaming agent, which is Foamex N, accounting for 5%-10% of the mass of the photocurable resin.

7. The method for preparing the fiber-reinforced ceramic photocuring slurry according to any one of claims 1 to 6, characterized in that: The following steps are involved: Step (1): using a silane coupling agent to modify the surface of the ceramic composite fiber; Step (2): uniformly mixing the surface-modified ceramic composite fiber with other materials according to the formula amount and performing degassing treatment to obtain the fiber-reinforced ceramic photocuring slurry.

8. The method for preparing the fiber-reinforced ceramic light-curing slurry according to claim 7, characterized in that: The following steps are involved: Step (1): adding the ceramic composite fiber to an ethanol solution containing 2-4 wt% of a silane coupling agent γ-methacryloxypropyltrimethoxysilane, ultrasonically dispersing the solution for 20-40 minutes, filtering the solution, drying the solution at 55-70°C for 3-6 hours, and then heat treating the solution at 170-190°C for 0.5-2 hours; Step (2) adding the surface-modified ceramic composite fiber together with the photocurable resin, photoinitiator, dispersant, plasticizer and optional coloring oxide, leveling agent and defoaming agent into a mixing container, vacuum degassing and mixing at a speed of 500-2000 rpm for 5-12 minutes, then adding ceramic powder, transferring to a planetary ball mill, ball milling and mixing at a speed of 100-300 rpm for 5-12 hours, and finally vacuum degassing again for 10-30 minutes to obtain the fiber-reinforced ceramic photocurable slurry.

9. A reinforced ceramic material, characterized in that: The fiber-reinforced ceramic photocurable slurry according to any one of claims 1 to 6 is prepared by 3D printing photocuring molding, degreasing, and sintering.

Citation Information

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