Wear-resistant ceramic glaze water and method for preparing ceramic product

Abstract

The invention discloses wear-resistant ceramic glaze water and a method for preparing a ceramic product, and relates to the technical field of ceramic products. The problems that in the prior art, mixing is not uniform, abrasion resistance is insufficient, adhesive force is poor, and production cost is high are solved. The prepared glaze water can form a compact and uniform glaze layer structure through reasonable proportioning of aluminum oxide, zirconium oxide and nano silicon dioxide, so that a ceramic product shows excellent wear resistance, the wear resistance coefficient of the ceramic product reaches 0.8 or above, and titanium oxide, chromic oxide and boric oxide are added, so that the high-temperature stability of a glaze layer is enhanced, and the service life of the ceramic product is prolonged. According to the invention, the glaze layer is not cracked, does not fall off and does not change color in complex environments such as high temperature, acid-base, impact and the like, the quality and appearance effect of the finished product are remarkably improved by matching with a segmented firing process, the performance of the ceramic product is improved, the stability and operability of production are also ensured, and the production cost is reduced. Wide application prospects are realized.

Description

Technical Field

[0001] The present invention relates to the technical field of ceramic products, and particularly relates to a wear-resistant ceramic glaze and a method for preparing ceramic products. Background Art

[0002] Ceramic products have a wide range of applications in the fields of architecture, industry, and daily necessities. However, traditional ceramic glaze layers are easily affected by friction, impact, high temperature, and acid-base environments, resulting in problems such as glaze layer peeling, cracking, or discoloration, which seriously affect the service life and aesthetic effect of the products. In order to improve the durability and performance of ceramic products, some wear-resistant glaze formulations have been proposed in the prior art. For example, the patent application with the publication number: CN112209620A discloses a crack-resistant ceramic glaze and its preparation method, including the following raw materials in parts by weight: albite 15 parts, potassium feldspar 8 parts, kaolin 3 parts, quartz sand 6 parts, zinc white 4 parts, high-aluminum clay 3 parts, boron carbide 2 parts, niobium pentoxide 3 parts, zinc oxide 2 parts, frit 12 parts, and includes the following steps: S1, obtain raw materials, weigh the above-mentioned raw materials in the formula amount, then thoroughly crush the raw materials through a crushing device, and then pass through a 250-mesh standard sieve to obtain qualified granular raw material A. The ceramic glaze provided by this patent can greatly improve the crack resistance and hardness of the ceramics, meet the market demand for higher hardness and crack resistance, will not generate a large number of bubbles during firing of the glaze surface, has strong anti-fouling ability after polishing of the product, and has a relatively high gloss. At the same time, the raw materials in the glaze are all common raw materials on the market, so the procurement and processing costs can be greatly reduced, and it has good market prospects.

[0003] However, although the above patent shows that the crack resistance and hardness of the ceramics can be greatly improved, during long-term use, especially in an environment with frequent friction, its wear resistance may not be sufficient to meet more stringent usage requirements, and its high-temperature resistance is limited. After long-term use, the gloss of the glaze surface decreases, making it difficult to meet the usage requirements of complex working conditions. Summary of the Invention

[0004] The purpose of the present invention is to provide a wear-resistant ceramic glaze and a method for preparing ceramic products. By optimizing the glaze formulation, the wear resistance of the glaze layer is improved, the high-temperature stability of the glaze layer is enhanced, and its corrosion resistance and impact resistance are also improved. This not only improves the performance of ceramic products but also ensures the stability and operability of production, so as to solve the problems raised in the above background art.

[0005] To achieve the above purpose, the present invention provides the following technical solutions:

[0006] A wear-resistant ceramic glaze, including the following raw materials in parts by weight:

[0007] Silicon dioxide: 35 - 45 parts;

[0008] Aluminum oxide: 20 - 25 parts;

[0009] Zirconia: 6 - 8 parts;

[0010] Titanium oxide: 3 - 4 parts;

[0011] Chromium oxide: 1 - 2 parts;

[0012] Calcium carbonate particles: 3 - 5 parts;

[0013] Boron oxide: 2 - 3 parts;

[0014] Nano - silica: 1 - 3 parts;

[0015] Organic polymer compound: 0.5 - 1 part;

[0016] Deionized water 45 - 60 parts, used to adjust the viscosity of the glaze water.

[0017] Furthermore, accurately weigh the raw materials in parts by weight according to the ratio. Pass the weighed solid raw materials through a 120 - mesh sieve. Add a small amount of deionized water to the nano - silica and treat it with an ultrasonic oscillation device for 30 minutes at a frequency of 40 kHz. Put the sieved solid raw materials into a ball mill for dry mixing. Gradually add the nano - silica dispersion liquid treated by ultrasonic oscillation to the mixed powder until all the solid raw materials are dispersed into fine particles and fully mixed evenly to form the glaze water. Dissolve the organic polymer compound in deionized water at 60°C, stir for 20 minutes and then slowly add it to the glaze water. Use a sand mill to further disperse and mix the glaze water, control the final particle size below 1 μm. Put the glaze water into a vacuum stirrer, stir and defoam to obtain a uniform and stable wear - resistant ceramic glaze water.

[0018] Furthermore, the ball - milling conditions for dry mixing in the ball mill are: rotation speed: 300 rpm; time: 1 hour; medium: zirconia balls; the equipment parameters of the ball mill after adding the nano - silica dispersion liquid are: rotation speed: 1200 rpm; time: 30 minutes; temperature: control the temperature of the liquid medium not to exceed 40°C; the grinding parameters of the sand mill are: rotation speed: 2000 rpm, time: 40 min, temperature: control the liquid medium below 40°C.

[0019] Furthermore, the mass ratio of titanium oxide to zirconia is between 1:1.5 and 1:2, and the particle size of the calcium carbonate particles is between 1 - 5 μm.

[0020] Furthermore, the viscosity range of the glaze water is 300 - 600 mPa·s, the solid content range is 50 - 55%, and the pH value range is 6.5 - 7.5.

[0021] The present invention provides another technical solution, a method for preparing ceramic products, including the following steps:

[0022] S1: Substrate surface treatment: Clean the surface of the ceramic substrate. After cleaning, dry it in a drying oven at 60°C. After drying, perform sandblasting on the surface of the ceramic substrate. Select alumina sand or quartz sand with a particle size of 80 - 120 mesh for uniform sandblasting. After sandblasting, clean and dry it again.

[0023] S2: Coating process: Use an electrostatic spraying device to coat the ceramic substrate twice. During the electrostatic spraying process, evenly coat the prepared wear-resistant ceramic glaze water on the surface of the grounded ceramic substrate. After each coating, place the ceramic substrate in a well-ventilated environment and let it dry naturally for 2 - 4 hours. Among them, the diameter of the spray gun nozzle of the electrostatic spraying device is 0.8 - 1.0 mm, and the air pressure is controlled between 0.2 - 0.4 MPa.

[0024] S3: Firing process: Place the ceramic substrate coated with glaze water into a kiln. The kiln controls the temperature according to a preset heating curve. After firing is completed, let it cool with the kiln to below 500°C, and then cool it naturally to room temperature.

[0025] S4: Finished product inspection: Conduct appearance quality inspection and performance testing on the cooled ceramic products.

[0026] S5: Packaging and storage: Classify and package the qualified ceramic products according to specifications and store them.

[0027] Further, in the S2: Coating process, it also includes fully stirring the wear-resistant ceramic glaze water before coating, rotation speed: 1000 - 1500 rpm; stirring time: 10 - 15 min. After stirring is completed, filter the glaze water using a stainless steel sieve with a mesh size of 800 - 1000 mesh.

[0028] Further, in the S2: Coating process, it also includes taking a small amount of wear-resistant ceramic glaze water and performing a trial coating on a waste ceramic piece to observe the leveling property and adhesion effect of the wear-resistant ceramic glaze water. At the same time, use a thickness gauge to detect the thickness of the trial coating layer, and adjust the flow control valve of the electrostatic spraying device to control the coating thickness within the range of 0.3 - 0.5 mm.

[0029] Further, in the S3, the kiln controls the temperature according to a preset heating curve, specifically including:

[0030] Pre-burning stage: Place the coated ceramic product in the kiln for low-temperature pre-burning, control the kiln temperature within the range of 300 - 400°C, and keep the temperature for 10 - 15 min.

[0031] Heating stage: Starting from the pre-firing temperature, gradually increase the temperature of the kiln to 700 - 800 °C at a heating rate of 5 °C / min, hold for 10 min, then continue to heat up to the final firing temperature of 1150 - 1250 °C and hold for 30 min;

[0032] Cooling stage: After firing is completed, slowly cool the kiln with the furnace to below 500 °C, control the cooling rate of the kiln temperature at 2 °C / min. After the temperature is below 500 °C, open the kiln door and continue to cool naturally to room temperature.

[0033] Further, the step S4: finished product inspection specifically includes:

[0034] Appearance quality inspection: Conduct surface inspection, glossiness detection and color detection on the fired ceramic products;

[0035] Dimensional accuracy inspection: Detect the length, width, height and thickness of the ceramic products. The test requirement is that the dimensional error ≤ ±0.1 mm. Randomly sample the thickness of the coated glaze layer using a coating thickness gauge to ensure that the glaze layer thickness is controlled within the range of 0.3 - 0.5 mm;

[0036] Wear resistance test: Conduct wear resistance detection on the glaze layer, calculate the wear resistance coefficient according to the friction loss amount. The test requirement is that the wear resistance coefficient ≥ 0.8. Conduct scratch resistance performance test on the glaze layer to detect the hardness of the glaze layer. The test requirement is that the glaze layer hardness grade ≥ 6;

[0037] Impact resistance test: Place the ceramic products on the impact test bench, freely drop a hammer from a standard height to impact and test the impact resistance of the glaze layer to ensure that the glaze layer has no peeling or cracks, and detect the adhesion of the glaze layer to evaluate the bonding force between the glaze layer and the substrate. The test requirement is that the adhesion ≥ 4;

[0038] High-temperature stability test: Place the ceramic products in a high-temperature test chamber, gradually heat to 800 - 1000 °C, hold for 30 minutes, then quickly cool to room temperature, observe whether the glaze layer has cracking, color change and peeling phenomena, and repeat the thermal shock cycle test until the sample is damaged to ensure that the thermal shock resistance of the glaze layer meets the design standard;

[0039] Chemical resistance test: Immerse the surface of the ceramic products in acid and alkali solutions for 24 hours respectively, observe whether the glaze layer has corrosion, peeling or color change, evaluate the corrosion resistance grade of the glaze layer according to the test results to ensure compliance with the industrial standard of chemical corrosion resistance;

[0040] Comprehensive performance evaluation: Conduct statistical analysis on the test results to ensure that all performance indicators meet the test requirements, select products with excellent performance as standard samples for archiving, mark the unqualified ceramic products, classify and recycle them and carry out rework.

[0041] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0042] By reasonably proportioning alumina, zirconia and nano-silica, the prepared glaze water can form a dense and uniform glaze layer structure, enabling the ceramic products to exhibit excellent wear resistance, with a wear resistance coefficient reaching above 0.8. Adding titanium oxide, chromium oxide and boron oxide not only enhances the high-temperature stability of the glaze layer, but also improves its corrosion resistance and impact resistance, ensuring that the glaze layer does not crack, peel off or change color in complex environments such as high temperature, acid-base and impact. Moreover, methods such as ultrasonic dispersion, ball milling mixing and electrostatic spraying are adopted to effectively avoid problems such as uneven glaze water and coating defects. Combining with the segmented firing process, the quality and appearance effect of the finished products are significantly improved. It not only improves the performance of ceramic products, but also ensures the stability and operability of production, and has broad application prospects. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] Figure 1 It is a flowchart of the method for preparing ceramic products of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0044] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0045] In order to solve the technical problems of uneven mixing, insufficient wear resistance, poor adhesion and high production cost existing in the prior art, the following technical solutions are provided in this embodiment:

[0046] A wear-resistant ceramic glaze water, comprising the following raw materials in parts by weight:

[0047] Silica: 35 - 45 parts, providing the glaze water matrix and maintaining hardness and wear resistance;

[0048] Alumina: 20 - 25 parts, enhancing hardness and crack resistance;

[0049] Zirconia: 6 - 8 parts, providing wear resistance and thermal shock resistance;

[0050] Titanium oxide: 3 - 4 parts, optimizing the optical properties (high gloss and whiteness) and high-temperature resistance of the ceramic;

[0051] Chromium oxide: 1 - 2 parts, as a hardening agent, improving surface hardness and scratch resistance, and enhancing high-temperature performance at the same time;

[0052] Calcium carbonate particles: 3 - 5 parts, enhancing the compactness of the glaze surface, improving impact resistance, wear resistance and compactness;

[0053] Boron oxide: 2 - 3 parts, maintaining good melting fluidity and gloss effect;

[0054] Nano - silica: 1 - 3 parts, toughening effect, enhancing crack resistance and impact resistance;

[0055] Organic polymer compound: 0.5 - 1 part, including polyvinyl alcohol, sodium carboxymethyl cellulose, sodium polyacrylate, polyurethane, polyacrylamide, etc., improving the fluidity and adhesion performance of the glaze water;

[0056] Deionized water 45 - 60 parts, used to adjust the viscosity of the glaze water for easy spraying or brushing operation;

[0057] In this embodiment, the mass ratio of titanium oxide to zirconium oxide is between 1:1.5 and 1:2, which can optimize the optical properties and high - temperature resistance of the ceramic surface. The particle size of calcium carbonate is between 1 - 5μm, which helps to improve the wear resistance and impact resistance of the ceramic surface. The viscosity range of the glaze water is 300 - 600 mPa·s, the solid content range is 50 - 55%, and the pH value range is 6.5 - 7.5.

[0058] In this embodiment, according to the above parameters, the key performance indicators of the glaze water are tested. If the viscosity of the glaze water does not meet the requirements, it can be filtered and adjusted again. The viscosity of the glaze water is adjusted by adding deionized water. If the solid content is less than 50%: appropriately add the pre - mixed powder material (according to the original formula ratio), and then carry out low - speed stirring and dispersion to ensure uniformity; if the solid content is higher than 55%: continue to slowly add deionized water while stirring to avoid local over - dilution. If the pH value is less than 6.5: add a small amount of sodium hydroxide (NaOH) solution or ammonia water, add drop - by - drop and stir continuously while detecting to avoid over - adjustment; if the pH value is higher than 7.5: add a small amount of citric acid solution (mass fraction is 1 - 2%), add drop - by - drop and detect.

[0059] In this embodiment, the physical properties of the glaze water are detected. The glaze water is coated on the surface of a smooth ceramic chip, and the leveling property is observed to see if it is uniform without brush marks or sagging. If the leveling property is poor: appropriately add an organic polymer compound to improve fluidity and uniformity. If any performance deviates from the target range, such as insufficient wear resistance: increase the proportion of zirconium oxide or add more nano - scale silica; insufficient gloss: adjust the ratio of titanium oxide to zirconium oxide to 1:1.8 or appropriately increase the content of boron oxide; insufficient adhesion: increase the organic polymer compound (such as polyethylene glycol).

[0060] In this embodiment, the raw materials in parts by weight are accurately weighed. The weighed solid raw materials are passed through a 120-mesh sieve to remove impurities with too large particles and ensure the uniformity of the raw material particles. A small amount of deionized water is added to the nano-silica, and it is treated with an ultrasonic oscillation device for 30 minutes at a frequency of 40 kHz to ensure uniform dispersion and avoid agglomeration. The sieved solid raw materials are put into a ball mill for dry mixing. The nano-silica dispersion liquid treated by ultrasonic oscillation is gradually added to the mixed powder until all the solid raw materials are dispersed into fine particles and fully mixed evenly to form glaze water. An organic polymer compound such as polyethylene glycol or hydroxypropyl methylcellulose is dissolved in deionized water at 60°C. After stirring for 20 minutes, it is slowly added to the glaze water. A sand mill is used to further disperse and mix the glaze water, and the final particle size is controlled to be below 1 μm. The glaze water is put into a vacuum stirrer for stirring and defoaming to obtain uniform and stable wear-resistant ceramic glaze water.

[0061] In this embodiment, the ball milling conditions for the dry mixing in the ball mill are: rotation speed: 300 rpm; time: 1 hour; medium: zirconia balls; the equipment parameters of the ball mill after adding the nano-silica dispersion liquid are: rotation speed: 1200 rpm; time: 30 minutes; temperature: control the temperature of the liquid medium not to exceed 40°C; the grinding parameters of the sand mill are: rotation speed: 2000 rpm, time: 40 min, temperature: control the liquid medium below 40°C.

[0062] In this embodiment, by precisely proportioning raw materials such as silica, alumina, and zirconia, the wear resistance, hardness, and crack resistance of the ceramic are significantly improved. At the same time, the optical properties and high-temperature resistance are optimized. The addition of calcium carbonate and nano-silica enhances the denseness and impact resistance, while the organic polymer compound improves the fluidity and adhesiveness. Moreover, the preparation process of the glaze water ensures the uniformity and stability of the glaze water, making it suitable for various ceramic products and providing an aesthetically pleasing and durable high-performance surface treatment solution.

[0063] In this embodiment, in order to optimize the raw material ratio of the experiment to improve the performance and quality of a certain product, by comparing the raw material ratios of different embodiments and comparative examples, the optimal combination of each component is determined, so as to achieve the best product performance. In Example 1, Example 2, and Example 3, the proportions of the main components such as silica, alumina, and zirconia are adjusted respectively, while keeping the other components basically stable. Comparative Example 1 and Comparative Example 2 provide two different reference formulas, as shown in Table 1:

[0064] Table 1 Experimental raw material ratio

[0065]

[0066] Preparation process parameters: Ball mill parameters: In the example, the ball milling speed is 300 rpm and the time is 1 hour; in the comparative example, the mixing parameters were not strictly controlled, resulting in uneven mixing. Sand mill parameters: In the example, the speed is controlled at 2000 rpm, the time is 40 minutes, and the temperature does not exceed 40°C; in the comparative example, the temperature was not controlled, causing the viscosity of the glaze water to malfunction. Electrostatic spraying parameters: The spraying thickness is 0.3 - 0.5 mm, and the air pressure is 0.3 MPa; in the comparative example, the spraying thickness is too thick or too thin, resulting in an uneven glaze layer.

[0067] In this example, through the analysis of the raw material ratios and preparation process parameters of Example 1, Example 2, Example 3, Comparative Example 1, and Comparative Example 2, it can be seen that inappropriate raw material ratios and unprecisely controlled preparation process parameters will lead to a decline in product performance. By finely adjusting the raw material ratios and controlling the preparation process parameters, wear-resistant ceramic glaze water with excellent performance can be prepared. Example 2 achieved a good balance in the contents of alumina and zirconia, and at the same time, the content of the organic polymer compound was also appropriate, making the glaze water perform well in terms of wear resistance, hardness, crack resistance, and fluidity.

[0068] To better demonstrate the performance of the wear-resistant ceramic glaze water, please refer to Figure 1 , the present invention provides a method for preparing a ceramic article, comprising the following steps:

[0069] S1: Substrate surface treatment: Clean the surface of the ceramic substrate, removing stains, grease, and dust. After washing, dry it in a drying oven at 60°C to ensure no moisture remains. After drying, perform sandblasting on the surface of the ceramic substrate. Select alumina sand or quartz sand with a particle size of 80 - 120 mesh for uniform sandblasting to increase the surface roughness and improve the adhesion performance of the glaze water. After sandblasting, wash and dry again;

[0070] S2: Coating process: Use an electrostatic spraying device to coat the ceramic substrate twice. During the electrostatic spraying process, evenly coat the prepared wear-resistant ceramic glaze water on the surface of the grounded ceramic substrate to enhance the adhesion of the glaze water and avoid performance instability caused by being too thick or too thin. After each coating, place the ceramic substrate in a well-ventilated environment and let it air dry naturally for 2 - 4 hours to ensure that the surface of the glaze layer is evenly dry and no moisture remains. Among them, the diameter of the spray gun nozzle of the electrostatic spraying device is 0.8 - 1.0 mm, and the air pressure is controlled between 0.2 - 0.4 MPa to ensure that the glaze water is evenly sprayed and adheres to the substrate surface;

[0071] S3: Firing Process: Place the ceramic substrate coated with glaze into a kiln. The kiln controls the temperature according to a preset heating curve: starting temperature: room temperature; heating rate: 5°C / min; firing temperature: 1150 - 1250°C; holding time: 30 minutes. After firing, let it cool in the kiln to below 500°C and then cool naturally to room temperature to avoid thermal stress caused by rapid cooling leading to cracking or peeling of the glaze layer.

[0072] S4: Final Product Inspection: Conduct appearance quality inspection and performance testing on the cooled ceramic products.

[0073] S5: Packaging and Storage: Classify and package the qualified ceramic products according to specifications and store them, avoiding damage caused by surface friction. The storage environment should be dry and well-ventilated, avoiding high humidity and direct sunlight to prevent damage to the glaze performance.

[0074] In this embodiment, by optimizing the preparation and coating process of the ceramic glaze, not only is a comprehensive improvement in the physical, optical, and mechanical properties of the glaze achieved, but also the key parameters in the process are controlled, such as the particle size distribution, coating thickness, and firing temperature curve of the glaze. It is applicable to the manufacture of high-gloss, high-temperature-resistant, and high-wear-resistant ceramic products and has broad application potential in the fields of architectural ceramics, daily-use ceramics, and industrial ceramics.

[0075] In this embodiment, in the S2: Coating Process, it also includes, before coating, fully stirring the wear-resistant ceramic glaze at a rotation speed of 1000 - 1500 rpm for a stirring time of 10 - 15 minutes to ensure uniform distribution of the glaze components. After stirring, filter the glaze through an 800 - 1000 mesh stainless steel sieve to remove any possible coagulated particles, ensuring the fluidity and uniformity of the glaze. Take a small amount of the wear-resistant ceramic glaze and apply it on a waste ceramic piece for trial coating to observe the leveling property and adhesion effect of the wear-resistant ceramic glaze. At the same time, use a thickness gauge to detect the thickness of the trial coating layer and adjust the flow control valve of the electrostatic spraying device to control the coating thickness within the range of 0.3 - 0.5 mm.

[0076] In this embodiment, in the coating process, by fully stirring and filtering the wear-resistant ceramic glaze, the uniform distribution and fluidity of the glaze components are ensured, effectively avoiding the interference of coagulated particles. The trial coating and thickness detection steps precisely control the coating thickness, optimize the electrostatic spraying parameters, improve the leveling property and adhesion effect of the glaze, ensure the consistency and stability of the glaze layer quality, and provide a good foundation for the subsequent firing process, thus significantly improving the overall performance and appearance quality of the ceramic products.

[0077] In this embodiment, in the S3, the kiln controls the temperature according to a preset heating curve, specifically including:

[0078] Pre - firing stage: Place the coated ceramic products in a kiln for low - temperature pre - firing. Control the kiln temperature within the range of 300 - 400 °C and keep the temperature for 10 - 15 minutes.

[0079] Heating - up stage: Starting from the pre - firing temperature, gradually increase the kiln temperature to 700 - 800 °C at a heating rate of 5 °C / min and keep the temperature for 10 minutes to gradually solidify the glaze layer and form a good bond with the substrate surface. Then continue to heat up to the final firing temperature of 1150 - 1250 °C and keep the temperature for 30 minutes to ensure that the glaze layer is completely melted and exhibits ideal gloss and wear - resistant properties.

[0080] Cooling - down stage: After firing, slowly cool the kiln with the furnace to below 500 °C. Control the cooling rate of the kiln temperature at 2 °C / min to avoid glaze layer cracking caused by rapid cooling. After the temperature is below 500 °C, open the kiln door and continue to cool naturally to room temperature.

[0081] In this embodiment, pre - firing helps to remove residual volatile substances in the glaze water, avoiding the generation of bubbles or cracks during high - temperature firing. Setting a staged heating - up and cooling - down process effectively avoids the phenomena of glaze layer cracking and peeling off during high - temperature or rapid cooling processes, improving the high - temperature stability and thermal shock resistance of the ceramic products. From surface activation to glaze coating and then to staged firing, the entire technological process fully considers the coupling of materials, processes, and equipment, achieving high densification and uniformity of the glaze layer, while improving the glaze surface decoration effect and wear - resistant properties.

[0082] In this embodiment, S4: finished product inspection specifically includes:

[0083] Appearance quality inspection: Conduct surface inspection, glossiness detection, and color detection on the fired ceramic products, including judging whether there are defects such as cracks, bubbles, glaze layer peeling off, and uneven sintering. Measure the glossiness of the glaze layer surface to ensure that the glossiness value meets the design standard. Detect the glaze surface color and compare it with the standard sample to ensure that the color difference ΔE ≤ 0.5.

[0084] Dimensional accuracy inspection: Detect the length, width, height, and thickness of the ceramic products. The test requirement is that the dimensional error ≤ ±0.1 mm. Randomly inspect the thickness of the coated glaze layer using a coating thickness gauge to ensure that the glaze layer thickness is controlled within the range of 0.3 - 0.5 mm.

[0085] Wear - resistant performance test: Conduct wear - resistance detection on the glaze layer, calculate the wear - resistant coefficient according to the friction loss amount. The test requirement is that the wear - resistant coefficient ≥ 0.8. Conduct anti - scratch performance test on the glaze layer to detect the glaze layer hardness. The test requirement is that the glaze layer hardness grade ≥ 6.

[0086] Impact resistance test: Place the ceramic product on an impact test bench and use a free-falling hammer at a standard height to impact the glaze layer to test its impact resistance. Ensure that the glaze layer has no peeling or cracks, and detect the adhesion of the glaze layer to evaluate the bonding strength between the glaze layer and the substrate. The test requirement is that the adhesion ≥ grade 4;

[0087] High-temperature stability test: Place the ceramic product in a high-temperature test chamber, gradually heat it to 800 - 1000 °C, keep it warm for 30 minutes, and then quickly cool it to room temperature. Observe whether the glaze layer shows cracking, discoloration, or peeling, and repeat the thermal shock cycle test until the sample is damaged. Ensure that the thermal shock resistance of the glaze layer meets the design standard;

[0088] Chemical resistance test: Immerse the surface of the ceramic product in acid and alkali solutions (such as 10% HCl and 10% NaOH solutions) for 24 hours respectively. Observe whether the glaze layer shows corrosion, peeling, or color change, and evaluate the corrosion resistance grade of the glaze layer according to the test results. Ensure that it meets the industrial standard of chemical corrosion resistance;

[0089] Comprehensive performance evaluation: Conduct statistical analysis on the test results to ensure that all performance indicators meet the test requirements. Select products with excellent performance as standard samples for archiving, mark the unqualified ceramic products, classify and recycle them, and carry out rework.

[0090] In this embodiment, by introducing scientific detection methods and precision instrument equipment, comprehensively detect the appearance, dimensions, wear resistance, impact resistance, high-temperature stability, and chemical resistance of ceramic products. It can not only ensure the high quality of ceramic products, but also further optimize the production process parameters, provide data support for batch production, significantly improve the reliability and service life of products, and meet the high requirements of the high-end market for the comprehensive performance of ceramic products.

[0091] In this embodiment, in order to verify the effect of the wear-resistant ceramic glaze water of the present invention on improving the performance of the ceramic substrate during coating and firing processes, conduct finished product detection and performance testing on the glaze water made from each example and comparative example in Table 1. The comparison results in terms of coating effect, firing quality, and final ceramic performance are shown in Table 2:

[0092] Table 2 Results of finished product detection and performance testing

[0093]

[0094]

[0095] In this embodiment, it can be seen from Table 2 that embodiments 1-3 are significantly better than the comparative examples in multiple key performance indicators. The particle size distribution of the glaze water in the embodiment is uniform, the mixing is sufficient, the coating thickness is reasonably controlled, and the surface glossiness is higher than the standard requirements; the comparative example has an uneven surface or low glossiness due to insufficient control of mixing and coating process parameters; the content of aluminum oxide and zirconium oxide in the embodiment is reasonably matched to form a dense wear-resistant glaze layer; the comparative example has a low zirconium oxide ratio or insufficient adhesion, resulting in substandard wear resistance; the embodiment effectively avoids cracking of the glaze layer through a segmented firing process (pre-firing, heating, and cooling control); the comparative example does not set pre-firing, the heating rate is too fast, and the glaze layer is easy to crack and fall off; the addition of chromium oxide and boron oxide in the embodiment enhances the corrosion resistance of the glaze layer; the comparative example shows poor acid and alkali resistance due to the low content of chromium oxide or boron oxide; through the above experimental data, the superiority of the technical solution of the embodiment can be clearly seen. After the glaze water formula and preparation process are optimized, the optical, mechanical and durability of ceramic products can be greatly improved, and the problem of easy generation of particles and uneven coating in the comparative example glaze water is solved. In addition, the wear resistance, adhesion and thermal shock stability of the glaze layer of the embodiment all meet the high-quality standards and are significantly better than the control example. This shows that the wear-resistant ceramic glaze of the present invention can maintain the density and stability of the glaze layer under high-temperature firing and harsh use conditions.

[0096] In this embodiment, the preparation cost of the glaze in the embodiment is low, while the coating thickness and uniformity are guaranteed. During the firing process, the glaze layer does not crack or peel off, which further verifies that the present invention achieves a comprehensive improvement in ceramic performance while reducing production costs. In particular, the excellent performance of the embodiment in terms of wear resistance, adhesion and thermal shock stability makes it suitable for the production needs of high-end building ceramics and industrial ceramics. It can be seen that the wear-resistant ceramic glaze of the present invention not only has good process adaptability, but also can significantly improve the quality and performance of ceramic products, and has a wide range of application value and promotion potential in actual production.

[0097] Further, considering the comprehensive performance of all performance indicators of Examples 1-3, Example 2 is the best example. Example 2 meets or exceeds the standard requirements in most performance indicators, and performs better than Example 1 in adhesion level. Although Example 1 performs slightly better in some performance indicators, its adhesion level is low, which affects its overall performance. Therefore, Example 2 is the best choice in terms of comprehensive performance, especially in terms of wear resistance coefficient, glaze layer hardness and adhesion level.

[0098] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical scheme and inventive concept of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. A wear-resistant ceramic glaze, characterized in that: The invention comprises the following raw materials in parts by weight: Silicon dioxide: 35-45 parts; Alumina: 20-25 parts; Zirconia: 6-8 parts; Titanium oxide: 3-4 parts; Chromium oxide: 1-2 parts; Calcium carbonate particles: 3-5 parts; Boron oxide: 2-3 parts; Nano silicon dioxide: 1-3 parts; Organic polymer compound: 0.5-1 part; 45-60 parts of deionized water is used to adjust the viscosity of the glaze.

2. The wear-resistant ceramic glaze according to claim 1, characterized in that: The raw materials in parts by weight are accurately weighed according to the proportion, the weighed solid raw materials are sieved through a 120-mesh sieve, a small amount of deionized water is added to the nano-silicon dioxide, and the mixture is treated with an ultrasonic oscillation device for 30 minutes, the sieved solid raw materials are placed in a ball mill for dry mixing, and the nano-silicon dioxide dispersion treated with ultrasonic oscillation is gradually added to the mixed powder until all the solid raw materials are dispersed into fine particles and fully mixed to form glaze water, the organic polymer compound is dissolved in deionized water at 60°C, and the mixture is slowly added into the glaze water after stirring for 20 minutes, and the glaze water is further dispersed and mixed using a sand mill, and the glaze water is placed in a vacuum agitator, and stirred for degassing to obtain a uniform and stable wear-resistant ceramic glaze water.

3. The wear-resistant ceramic glaze according to claim 2, characterized in that: The ball mill dry mixing conditions are: rotation speed: 300 rpm; time: 1 hour; medium: zirconia balls; after adding the nano-silicon dioxide dispersion, the equipment parameters of the ball mill are: rotation speed: 1200 rpm; Time: 30 minutes Temperature: the temperature of the liquid medium is controlled not to exceed 40°C; the grinding parameters of the sand mill are: speed: 2000 rpm, time: 40 min, temperature: the liquid medium is controlled below 40°C.

4. The wear-resistant ceramic glaze according to claim 3, characterized in that: The mass ratio of titanium oxide to zirconium oxide is between 1:1.5 and 1:2, and the particle size of calcium carbonate particles is between 1-5 μm.

5. The wear-resistant ceramic glaze according to claim 4, characterized in that: The viscosity of the glaze water ranges from 300 to 600 mPa·s, the solid content ranges from 50 to 55%, and the pH value ranges from 6.5 to 7.

5.

6. A method for preparing ceramic products, using the wear-resistant ceramic glaze according to claim 5, characterized in that: The following steps are involved: S1: Substrate surface treatment: The surface of the ceramic substrate is cleaned and dried in a drying furnace at 60°C. After drying, the surface of the ceramic substrate is sandblasted and then cleaned and dried again after sandblasting. S2: coating process: the ceramic substrate is coated twice using an electrostatic spray device. During the electrostatic spraying process, the prepared wear-resistant ceramic glaze is evenly coated on the surface of the grounded ceramic substrate. After each coating, the ceramic substrate is placed in a well-ventilated environment and dried naturally for 2-4 hours. The nozzle diameter of the spray gun of the electrostatic spray device is 0.8-1.0 mm, and the air pressure is controlled between 0.2-0.4 MPa. S3: Firing process: The glazed ceramic substrate is placed in a kiln, and the kiln controls the temperature according to a preset heating curve; after firing, the kiln cools down to below 500°C, and then naturally cools down to room temperature; S4: Finished product inspection: Perform appearance quality inspection and performance test on the cooled ceramic products; S5: Packaging and storage: The qualified ceramic products are classified, packaged and stored according to specifications.

7. A method for preparing a ceramic product according to claim 6, characterized in that: The coating process S2 also includes fully stirring the wear-resistant ceramic glaze water before coating, with a rotation speed of 1000-1500rpm and a stirring time of 10-15min. After the stirring is completed, the glaze water is filtered using a stainless steel screen of 800-1000 mesh.

8. A method for preparing a ceramic product according to claim 7, characterized in that: The S2: coating process also includes taking a small amount of wear-resistant ceramic glaze water for trial coating on the discarded ceramic sheet before coating to observe the leveling and adhesion effect of the wear-resistant ceramic glaze water; at the same time, using a thickness measuring instrument to detect the thickness of the trial coating layer, adjusting the flow control valve of the electrostatic spraying device, and controlling the coating thickness within the range of 0.3-0.5mm.

9. A method for preparing a ceramic product according to claim 8, characterized in that: The kiln in S3 controls the temperature according to a preset heating curve, specifically including: Pre-firing stage: Place the coated ceramic products in a kiln for low-temperature pre-firing, control the kiln temperature within the range of 300-400°C, and keep warm for 10-15 minutes; Heating stage: starting from the pre-firing temperature, gradually increase the kiln temperature to 700-800℃ at a heating rate of 5℃ / min, keep warm for 10min, continue to heat up to the final firing temperature of 1150-1250℃, keep warm for 30min; Cooling stage: After firing is completed, the temperature is slowly lowered to below 500°C with the furnace, and the kiln temperature cooling rate is controlled at 2°C / min. When the temperature is lower than 500°C, open the kiln door and continue to cool naturally to room temperature.

10. A method for preparing a ceramic product according to claim 9, characterized in that: S4: Finished product testing, specifically includes: Appearance quality inspection: Surface inspection, glossiness inspection and color inspection of fired ceramic products; Dimensional accuracy detection: The length, width, height and thickness of ceramic products are tested. The test requirement is that the dimensional error is ≤±0.1mm. The thickness of the glaze layer is randomly inspected using a coating thickness gauge to ensure that the glaze layer thickness is controlled within the range of 0.3-0.5mm; Wear resistance test: test the wear resistance of the glaze layer, calculate the wear resistance coefficient according to the friction loss, and the test requirement is that the wear resistance coefficient is ≥ 0.8; test the anti-scratch performance of the glaze layer, test the hardness of the glaze layer, and the test requirement is that the hardness grade of the glaze layer is ≥ 6; Impact resistance test: Place the ceramic product on an impact test bench and use a standard height free-falling hammer to test the impact resistance of the glaze layer. Also test the adhesion of the glaze layer and evaluate the bonding strength between the glaze layer and the substrate. The test requirement is adhesion ≥ Level 4. High temperature stability test: Place the ceramic product in a high temperature test chamber, gradually heat it to 800-1000℃, keep it warm for 30 minutes, then quickly cool it to room temperature, observe whether the glaze layer cracks, changes color, or falls off, and repeat the thermal shock cycle test until the sample is damaged; Chemical resistance test: Use acid and alkali solutions to soak the surface of ceramic products for 24 hours respectively, and evaluate the corrosion resistance of the glaze layer based on the test results; Comprehensive performance evaluation: Conduct statistical analysis on the test results to ensure that all performance indicators meet the test requirements, select products with excellent performance as standard samples for archiving, mark unqualified ceramic products, classify them for recycling and rework.

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