A functional ceramic green body and a method for preparing the same

Abstract

The present application relates to the technical field of ceramic materials, in particular to a functional ceramic blank and a preparation method thereof. The present application overcomes the problem that the ceramic blank is difficult to balance light weight and mechanical properties. The synthetic raw materials of the present application include kaolin, mullite, talc, composite light filler, modified reinforcing agent, interface modifier and functional additive. First, the kaolin, mullite and talc are crushed and treated, and then the remaining components are added in sequence after mixing. After mixing again, deionized water is added for ball milling to obtain the ceramic blank. In the present application, the components synergistically act to not only reduce the density by using light fillers, but also improve the mechanical properties through components such as modified reinforcing agent and interface modifier. The obtained blank has good plasticity and good product performance, and has a good application prospect in the light weight building industry.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of ceramic materials, in particular to a functional ceramic blank and a preparation method thereof. BACKGROUND

[0002] With the development of the building industry towards green and energy-saving, lightweight building materials have become a research hotspot in the field of modern architecture because of their advantages of reducing the self-weight of buildings, reducing transportation energy consumption, and improving construction efficiency. Ceramic materials are widely used in the building industry due to their good durability, fire resistance and decorative properties. However, traditional ceramic materials have high density and cannot meet the needs of lightweight buildings. Therefore, developing ceramic blanks with lightweight characteristics and excellent performance has become a key to promoting the innovative application of ceramic materials in the building industry.

[0003] Currently, to achieve the lightweight of ceramic blanks, existing technologies mainly focus on two aspects. On the one hand, lightweight fillers such as hollow glass microspheres and expanded perlite are added to reduce the density of the blank. On the other hand, processes such as foaming and pore-forming agents are used to introduce pore structures into the ceramic. In addition, some studies attempt to optimize the ratio of traditional ceramic raw materials and use coupling agent modification to improve the overall performance of the blank.

[0004] Although existing technologies have made some progress, there are still many problems. The addition of lightweight fillers can easily lead to a decrease in the interfacial bonding force of the blank, resulting in a significant decrease in the mechanical properties of the material. In the process of introducing pore structures, the size and distribution of the pores are difficult to control accurately, and pore agglomeration or excessively large pore size can easily occur, affecting the strength, waterproofness and other properties of the material. At the same time, existing researches often only focus on the improvement of a single property, and lack of systematic research on the coordinated optimization of lightweight, mechanical properties and functionality, making it difficult to prepare high-performance lightweight ceramic blanks that meet the diversified needs of modern architecture. In summary, the current ceramic blanks have the problem of being unable to balance lightweight and mechanical properties, which affects the use of ceramics in the building industry.

[0005] Therefore, a functional ceramic blank and a preparation method thereof are proposed. SUMMARY

[0006] The purpose of the present application is to design a functional ceramic blank and a preparation method thereof. The synthetic raw materials of the present application include kaolin, mullite, talc, composite lightweight filler, modified reinforcing agent, interfacial modifier and functional additive. First, the kaolin, mullite and talc are crushed and treated, then the remaining components are added in sequence after mixing, and deionized water is added for ball milling after mixing again to obtain a ceramic blank. In the present application, the components work together to reduce the density by using lightweight fillers, and to improve the mechanical properties by using modified reinforcing agents, interfacial modifiers and other components. The obtained blank product has good performance and has good application prospects in the lightweight building industry.

[0007] To achieve the above object, the present application provides the following technical scheme:

[0008] The present application provides a functional ceramic blank, and the ceramic blank comprises the following components in parts by weight:

[0009] Kaolin: 20-30 parts; mullite: 10-20 parts; talc: 35-45 parts; composite lightweight filler: 15-25 parts; modified reinforcing agent: 3-7 parts; interface modifier: 1-5 parts; functional additive: 1-5 parts;

[0010] The modified reinforcing agent comprises nanosilica, carbon fiber, polyvinyl alcohol, glycerol and dibutyl phthalate;

[0011] The interface modifier comprises silane coupling agent KH-550, aluminate coupling agent DL-411 and composite nanoclay;

[0012] The functional additive comprises aerogel powder, expanded perlite and nanometer titanium dioxide.

[0013] Preferably, the composite lightweight filler comprises hollow glass microbeads and diatomite, and the weight ratio of the hollow glass microbeads to the diatomite is 2-4:1.

[0014] The present application further provides a preparation method of the functional ceramic blank, and the preparation method comprises the following steps:

[0015] S1, talc, kaolin and mullite are subjected to a crushing treatment, and then are put into a high-speed mixer to be mixed at a speed of 600 rpm for 20 min to obtain pretreated raw materials;

[0016] S2, the composite lightweight filler, the modified reinforcing agent, the interface modifier and the functional additive are sequentially added to the pretreated raw materials, and after each addition of the raw materials, the raw materials are mixed at a speed of 600 rpm for 10 min, and after the addition of all the components is completed, the raw materials are stirred for 30 min to obtain mixed materials;

[0017] S3, deionized water is added to the mixed materials, and the weight ratio of the mixed materials to the deionized water is 1:0.3-0.5, and the mixed materials are ball milled in a ball mill for 4 h to obtain the ceramic blank.

[0018] Preferably, the specific process of the crushing treatment is as follows: the talc is put into a crusher to be crushed to a particle size of 2 μm, and then is subjected to vacuum drying; the kaolin is preliminarily crushed in a crusher, and then is put into a ball mill to be ground at a speed of 400 rpm for 1-3 h, is sieved through a 300-mesh sieve, and finally is subjected to vacuum drying; the mullite is put into a grinding machine to be ground, and the discharge particle size is adjusted to 3 μm-5 μm, and then is put into a muffle furnace to be calcined at 800 ℃ for 2 h.

[0019] Preferably, the preparation method of the modified reinforcing agent is as follows: 2-4 parts of nanometer silicon dioxide is added into 30 parts of anhydrous ethanol, and ultrasonic dispersion is carried out for 30 min to obtain a silicon dioxide dispersion liquid; 1-3 parts of carbon fiber is placed in a 5% nitric acid solution, and is soaked in a 60℃ water bath for 50-70 min, and then is washed to neutral with deionized water, and is vacuum dried for 2 h to obtain pretreated carbon fiber; the silicon dioxide dispersion liquid, the pretreated carbon fiber, 1-2 parts of polyvinyl alcohol, 0.5-1.5 parts of glycerol and 0.5 parts of dibutyl phthalate are sequentially added into a high-speed stirrer, and stirring is carried out at a speed of 800 rpm for 30-60 min to obtain the modified reinforcing agent.

[0020] Preferably, the preparation method of the interface modifier is as follows: 1-2 parts of composite nanometer clay is dried at 150℃ for 2-4 h to obtain pretreated composite nanometer clay; 0.5-2.5 parts of silane coupling agent KH-550, 1-3 parts of aluminic ester coupling agent DL-411 and the pretreated composite nanometer clay are added into a reaction kettle, and stirring is carried out at a speed of 300 rpm at 80℃ for 1-3 h to obtain the interface modifier; the composite nanometer clay comprises montmorillonite and sepiolite, and the weight ratio of the montmorillonite to the sepiolite is 2:1-3.

[0021] Preferably, the preparation method of the functional auxiliary agent is as follows: 1-3 parts of aerogel powder is sieved through a 200 mesh screen, and is dried in a vacuum environment for 2 h to obtain pretreated aerogel; 2-4 parts of expanded perlite is soaked in a 3% silane coupling agent KH-550 aqueous solution, and is taken out after being soaked at room temperature for 1-3 h, and is dried at 100℃ for 8 h to obtain modified expanded perlite; the pretreated aerogel, the modified expanded perlite and 1-2 parts of nanometer titanium dioxide are mixed in a mixer at a speed of 150 rpm for 20-40 min to obtain the functional auxiliary agent.

[0022] Preferably, the composition of talc is about 31.6% MgO, about 62.4% SiO2, about 4.5% H2O, and the rest is Al2O3, Fe2O3; the composition of kaolin is about 38.2% Al2O3, about 46.1% SiO2, about 14% H2O, and the rest is impurities; and the composition of mullite is about 70.8% Al2O3, about 27.1% SiO2, and the rest is CaO and other impurities.

[0023] Compared with the prior art, the present application has the following beneficial effects:

[0024] 1. The base skeleton is composed of kaolin, mullite and talc, and the composite lightweight filler composed of hollow glass microspheres and diatomite is uniformly dispersed therein. The hollow glass microspheres greatly reduce the density of the green body by virtue of the hollow structure, and the porous nature of diatomite further reduces the weight; at the same time, the adhesion of kaolin, the high strength of mullite and the lubricity of talc, in cooperation with the lightweight filler, maintain the stability of the green body structure while reducing the density. The ceramic green material is lightened, the density is significantly reduced, and the demand for lightweight building materials is met; at the same time, the mechanical strength is ensured, and the application range of the product in the building field is widened.

[0025] 2. The modified reinforcing agent is composed of nano-silicon dioxide, carbon fiber, polyvinyl alcohol, glycerol and dibutyl phthalate. Nano-silicon dioxide fills the micro-pores to enhance the compactness, carbon fiber provides a high-strength skeleton, and polyvinyl alcohol, glycerol and dibutyl phthalate enhance the plasticity by forming hydrogen bonds and lubrication, and also build a flexible buffer system inside the green body. In the process of temperature change, this system can absorb and buffer thermal stress, reduce internal stress caused by thermal expansion and cold contraction, and avoid the generation and expansion of cracks. This multi-scale synergistic effect effectively improves the mechanical properties of the ceramic green material, optimizes the internal structure and stress distribution of the green body, and significantly improves the thermal stability, meeting the demand for high-performance applications.

[0026] 3. The interface modifier is composed of silane coupling agent KH-550, aluminate coupling agent DL-411 and composite nano-clay. The silane coupling agent reacts with the surface hydroxyl groups to form chemical bonds, the aluminate coupling agent reduces the surface energy and enhances the compatibility, and the composite nano-clay fills the inter-particle gaps. The three work together to build a stable interface layer on the surface of the raw materials, enhance the compatibility and bonding force between the components in the ceramic green material, reduce internal defects of the raw materials, and improve the mechanical properties of the green body.

[0027] 4. The functional additive is composed of aerogel powder, expanded perlite and nano-titanium dioxide. Aerogel powder has extremely low density and high porosity, and expanded perlite also has good lightweight properties after treatment, forming more pore structures in the green body and increasing the air content, thereby further reducing the density of the ceramic green material. They work together with the composite lightweight filler to further enhance the effect of reducing density. The nano-titanium dioxide in the functional additive can refine the ceramic grains and improve the density of the ceramic, thereby enhancing the mechanical properties. BRIEF DESCRIPTION OF DRAWINGS

[0028] Figure 1 The flexural strength and bulk density chart of Example 11 and Comparative Examples 17-21 in the present application. DETAILED DESCRIPTION

[0029] With reference to the accompanying drawings, the technical solutions in the embodiments of the present application will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all the other embodiments obtained by those skilled in the art without creative efforts belong to the scope of the present application.

[0030] The raw materials used in the present application can be obtained from commercially available products.

[0031] Specifically referring to Figure 1 The present application provides a functional ceramic blank and a preparation method thereof, and the technical solutions are as follows.

[0032] Embodiment 1

[0033] 3 parts of nano-silicon dioxide were added into 30 parts of anhydrous ethanol, and ultrasonic dispersion was performed for 30 min to obtain a silicon dioxide dispersion liquid; 2 parts of carbon fibers were placed in a 5% nitric acid solution, and were soaked in a 60℃ water bath for 60 min, and then were washed with deionized water until neutral, and were then vacuum dried for 2 h to obtain pretreated carbon fibers; the silicon dioxide dispersion liquid, the pretreated carbon fibers, 1.5 parts of polyvinyl alcohol, 1 part of glycerol and 0.5 parts of dibutyl phthalate were sequentially added into a high-speed stirrer, and stirring was performed at a speed of 800 rpm for 45 min to obtain a modified reinforcing agent.

[0034] 1.5 parts of composite nano-clay were dried at 150℃ for 3 h to obtain pretreated composite nano-clay; 1.5 parts of silane coupling agent KH-550, 2 parts of aluminate coupling agent DL-411 and the pretreated composite nano-clay were added into a reaction kettle, and stirring and mixing were performed at 80℃ and a stirring speed of 300 rpm for 2 h to obtain an interface modifier; the composite nano-clay comprises montmorillonite and sepiolite, and the weight ratio of the montmorillonite to the sepiolite is 2:2.

[0035] 2 parts of aerogel powder were passed through a 200-mesh screen, and were dried in a vacuum environment for 2 h to obtain pretreated aerogel; 3 parts of expanded perlite were soaked in a 3% silane coupling agent KH-550 aqueous solution, were taken out after soaking at room temperature for 2 h, and were dried at 100℃ for 8 h to obtain modified expanded perlite; the pretreated aerogel, the modified expanded perlite and 1.5 parts of nano-titanium dioxide were mixed in a mixer at a speed of 150 rpm for 30 min to obtain a functional additive.

[0036] The ceramic blank was prepared as follows:

[0037] S1 40 parts of talc, 25 parts of kaolin, 15 parts of mullite were respectively subjected to crushing treatment, then were put into a high-speed mixer and mixed at a speed of 600 rpm for 20 min to obtain pretreated raw materials; the crushing treatment process was as follows: the talc was put into a crusher and crushed to a particle size of 2 μm, and then vacuum dried; the kaolin was preliminarily crushed in a crusher, and then put into a ball mill and ground at 400 rpm for 2 h, and then passed through a 300-mesh sieve, and finally vacuum dried; the mullite was put into a grinding machine and ground, and the discharge particle size was adjusted to 4 μm, and then put into a muffle furnace and calcined at 800 ℃ for 2 h;

[0038] S2 20 parts of composite light filler, 5 parts of modified reinforcing agent, 3 parts of interface modifier and 3 parts of functional additive were sequentially added to the pretreated raw materials, and mixed for 10 min after each addition, and then stirred for 30 min after all the components were added to obtain a mixture; the composite light filler included hollow glass beads and diatomite, and the weight ratio of the hollow glass beads to the diatomite was 3:1;

[0039] S3 Deionized water was added to the mixture, and the weight ratio of the mixture to the deionized water was 1:0.4, and then ball milled in a ball mill for 4 h to obtain a ceramic blank.

[0040] Examples 1-12 refer to the parameter conditions in Example 1, and the specific differences are shown in Table 1.

[0041] Table 1 Parameter conditions of Examples 1-12

[0042]

[0043]

[0044] Comparative Example 1 refers to the parameter conditions in Example 1, and the difference is that kaolin is not added.

[0045] Comparative Example 2 refers to the parameter conditions in Example 1, and the difference is that mullite is not added.

[0046] Comparative Example 3 refers to the parameter conditions in Example 1, and the difference is that talc is not added.

[0047] Comparative Example 4 refers to the parameter conditions in Example 1, and the difference is that only hollow glass beads are added as light fillers.

[0048] Comparative Example 5 refers to the parameter conditions in Example 1, and the difference is that only diatomite is added as a light filler.

[0049] Comparative Example 6 refers to the parameter conditions in Example 1, and the difference is that the composite light filler is not added.

[0050] Comparative Example 7 refers to the parameter conditions in Example 1, except that the kaolin, mullite and talc are not subjected to crushing treatment.

[0051] After the ceramics obtained by firing all the examples and comparative examples are tested.

[0052] All the parameter conditions of Example 1, Example 4, Example 7 and Example 10 are the same.

[0053] Mechanical property and density test of experimental example 1

[0054] The density of Example 1-3 and Comparative Example 1-7 is determined according to GB / T 1966-2024, and the bending resistance of Example 1-3 and Comparative Example 1-7 is tested by using a universal material testing machine, and the results are shown in Table 2.

[0055] Table 2 Mechanical property and density test of Example 1-3 and Comparative Example 1-7

[0056] Example Flexural strength / MPa Bulk density / g / cm 3 ]] Example 1 81 1.49 Example 2 78 1.53 Example 3 76 1.55 Comparative Example 1 62 1.40 Comparative Example 2 67 1.45 Comparative Example 3 64 1.42 Comparative Example 4 74 1.61 Comparative Example 5 72 1.58 Comparative Example 6 68 1.72 Comparative Example 7 70 1.49

[0057] It can be found from Table 2 that the kaolin plays a certain role of viscosity and plasticity in the green body, and the absence of it in Comparative Example 1 leads to poor formability of the green body, reduced bending strength, and reduced overall green density due to the absence of kaolin. The mullite has high strength and high-temperature resistance, and contributes significantly to the mechanical properties of the ceramic. The absence of mullite in Comparative Example 2 leads to a significant decrease in bending strength, and the absence of mullite leads to greater shrinkage of the green body during firing, and the density changes. The talc can improve the processing and sintering properties of the green body, and the absence of talc in Comparative Example 3 leads to poor sintering of the green body, reduced bending strength, and reduced density due to sintering problems. The use of only a single lightweight filler in Comparative Examples 4-5 leads to an increase in the density of the ceramic green body. The main role of the composite lightweight filler is to reduce the density, and the absence of it in Comparative Example 6 leads to an increase in the density of the ceramic, and affects the synergistic effect of other properties, leading to a change in the bending strength. In Comparative Example 7, the kaolin, mullite, and talc are not subjected to crushing treatment, which leads to larger particles of the raw materials, uneven mixing, and a non-dense structure of the green body, thereby reducing the bending strength and changing the density due to particle accumulation problems. In the examples, the kaolin provides viscosity and plasticity, making the green body easy to form, and after mixing with other materials, it helps to form a uniform green body structure, improve the overall density and mechanical properties; the mullite has high strength and high-temperature resistance, and plays a role in reinforcing the skeleton in the green body, and cooperates with other materials to improve the bending strength and high-temperature resistance of the ceramic; the talc improves the processing properties of the green body, making the green body more dense during sintering, and cooperates with kaolin, mullite, and other materials to optimize the sintering properties and mechanical properties of the ceramic. The composite lightweight filler can reduce the density of the ceramic, and interact with other materials, achieve lightweight without significantly reducing the mechanical properties, and possibly have a certain optimization effect on the microstructure of the green body, which helps to improve other properties.

[0058] Comparative Example 8 refers to the parameter conditions in Example 4, the difference being that no nano-silicon dioxide is added to the modified reinforcing agent.

[0059] Comparative Example 9 refers to the parameter conditions in Example 4, the difference being that no carbon fiber is added to the modified reinforcing agent.

[0060] Comparative Example 10 refers to the parameter conditions in Example 4, the difference being that no polyvinyl alcohol is added to the modified reinforcing agent.

[0061] Comparative Example 11 refers to the parameter conditions in Example 4, the difference being that no glycerol is added to the modified reinforcing agent.

[0062] Comparative Example 12 refers to the parameter conditions in Example 4, the difference being that no modified reinforcing agent is added.

[0063] Experimental Example 2: Mechanical property and thermal stability test

[0064] The bending strength of Examples 4-6 and Comparative Examples 8-12 was tested by using a universal material testing machine, and the thermal stability was tested according to the national standard, i.e. the samples were heated to a bottom temperature of 450°C on an electric furnace, and then were poured into 100 ml of cold water at 20°C for instant cooling. The results are shown in Table 3.

[0065] Table 3 Mechanical properties and thermal stability of Examples 4-6 and Comparative Examples 8-12

[0066] Example Flexural strength / MPa Thermal stability Example 4 81 Pass Example 5 77 Pass Example 6 76 Pass Comparative Example 8 68 Pass Comparative Example 9 65 Pass Comparative Example 10 70 Pass Comparative Example 11 71 Pass Comparative Example 12 56 Fail

[0067] As shown in Table 3, the nano-silica has high specific surface area and high activity, and can fill in the pores of the ceramic matrix to increase the density of the material, and can chemically bond or physically adsorb with other components to enhance the interface bonding force, thereby improving the bending strength and thermal stability. In Comparative Example 8, no nano-silica is added, the internal pores of the material increase, the interface bonding is weakened, which leads to a decrease in the bending strength and a deterioration in the thermal stability. The carbon fiber has high strength and high modulus, and can play a role in reinforcing and toughening the ceramic matrix, and can bear part of the load and prevent the crack from expanding. In Comparative Example 9, the carbon fiber is absent, the material is prone to crack and rapidly expand under stress, which leads to a decrease in the bending strength, and the material is also more prone to crack due to insufficient toughness under thermal shock. The polyvinyl alcohol can form a network structure in the ceramic body to increase the plasticity and bonding strength of the body, so that the components are better combined together. In Comparative Example 10, no polyvinyl alcohol is added, the forming performance of the body is deteriorated, the internal structure is not dense enough, and defects are prone to occur during the sintering process, which leads to a decrease in the bending strength and the thermal stability. The presence of glycerol makes the ceramic body more flexible during processing, which is beneficial to the uniform mixing and forming of the components, and can improve the microstructure of the material and reduce stress concentration. In Comparative Example 11, the glycerol is absent, the material is prone to produce micro-cracks due to uneven internal stress during processing, which leads to a decrease in the bending strength, and the thermal stability is also affected. The various components in the modified reinforcing agent synergistically improve the mechanical properties and thermal stability of the ceramic material. In Comparative Example 12, no modified reinforcing agent is added, the material loses the effects of nano-silica filling and reinforcing, carbon fiber toughening, polyvinyl alcohol bonding, and glycerol lubricating and plasticizing, and the performance is significantly decreased, the bending strength is greatly reduced, and the thermal stability is also difficult to meet the requirements.

[0068] Comparative Example 13 refers to the parameters in Example 7, except that no composite nano-clay is added in the interface modifier.

[0069] Comparative Example 14 refers to the parameters in Example 7, except that no silane coupling agent KH-550 is added in the interface modifier.

[0070] Comparative Example 15 refers to the conditions in Example 7, except that no aluminate coupling agent DL-411 was added to the interfacial modifier.

[0071] Comparative Example 16 refers to the conditions in Example 7, except that no interfacial modifier was added.

[0072] Experimental Example 3 Mechanical Property Test

[0073] The flexural strength of Examples 7-9 and Comparative Examples 13-16 was tested using a universal material testing machine, and the results are shown in Table 4.

[0074] Table 4 Mechanical Property Test of Examples 7-9 and Comparative Examples 13-16

[0075] Example Flexural strength / MPa Example 7 81 Example 8 79 Example 9 77 Comparative Example 13 70 Comparative Example 14 71 Comparative Example 15 71 Comparative Example 16 64

[0076] It can be found from Table 4 that the modification effect is incomplete in Comparative Example 13 because the composite nano-clay is not added in the interface modifier. The composite nano-clay can provide special surface properties and structure, and help to enhance the interface bonding force. The lack of it can make the interface bonding slightly weak, and cracks can easily expand when stressed, thereby reducing the bending strength of the ceramic. The silane coupling agent KH-550 can form chemical bonding between different components of the ceramic green body, effectively improving the interface bonding strength. In Comparative Example 14, the coupling agent is not added, and the bonding force between the components of the green body is weakened. When subjected to external force, the interface is prone to damage, thereby reducing the bending strength. The aluminate coupling agent DL-411 also plays an important role in improving the interface performance. It can chemically react with other components to improve the compatibility and bonding force of the interface. In Comparative Example 15, the lack of the coupling agent makes the interface bonding effect worse, and the overall mechanical properties of the material decrease, and the bending strength also decreases. In Comparative Example 16, no interface modifier is added, and the interface bonding between the components of the green body is in a poor state. Different materials cannot work well together, and defects and cracks can easily occur at the interface when subjected to external force, leading to premature damage of the material and a significant reduction in bending strength. In the examples, the materials in the interface modifier work together to effectively improve the performance of the ceramic green body. The silane coupling agent KH-550 and the aluminate coupling agent DL-411 can respectively react with the inorganic components and organic components in the green body, forming a bridge between different materials and enhancing the interface bonding force. The composite nano-clay has a large specific surface area and a special layered structure. It can be adsorbed on the surface of other particles, further improving the microstructure of the interface and improving the uniformity and stability of the interface. The three materials work together to make the different components in the ceramic green body better bonded together to form a tight and uniform overall structure. This good interface bonding state helps to uniformly transmit stress within the material, avoiding stress concentration caused by interface defects, thereby improving the bending strength of the ceramic and enabling the ceramic material to better perform its function.

[0077] Comparative Example 17 refers to the parameter conditions in Example 10, except that aerogel powder is not added in the functional additive.

[0078] Comparative Example 18 refers to the parameter conditions in Example 10, except that expanded perlite is not added in the functional additive.

[0079] Comparative Example 19 refers to the parameter conditions in Example 10, except that nano-titanium dioxide is not added in the functional additive.

[0080] Comparative Example 20 refers to the parameter conditions in Example 10, except that no functional additive is added.

[0081] Comparative Example 21 refers to the parameter conditions in Example 10, except that no composite lightweight filler is added.

[0082] Comparative Example 22 follows the same parameters and conditions as in Example 10, except that in S2, the composite lightweight filler, the modifier, the interface modifier, and the functional additive are added together and stirred for 30 minutes, while the subsequent steps remain unchanged.

[0083] Experiment Example 4: Mechanical Properties and Density Testing

[0084] Mechanical properties and density were tested for Examples 10-12 and Comparative Examples 17-22 according to Experimental Example 1. The results are shown in Table 5. The flexural strength and bulk density of Examples 11 and Comparative Examples 17-21 are as follows: Figure 1 As shown.

[0085] Table 5 Mechanical properties and density tests of Examples 10-12 and Comparative Examples 17-22

[0086]

[0087]

[0088] From Table 5 and Figure 1It can be found that the absence of aerogel powder in Comparative Example 17 leads to insufficient optimization of the pore structure of the material, an increase in internal defects under stress, and a decrease in the bending strength. Aerogel powder has a filling effect, and its absence causes a slight increase in the bulk density of the material. The absence of expanded perlite in Comparative Example 18 weakens the lightweight properties of the material, leading to an increase in density, and the support effect of expanded perlite on the internal structure of the material disappears, resulting in a decrease in the bending strength. The absence of nano-titanium dioxide in Comparative Example 19 leads to a decrease in the bonding force in the material, thereby reducing the bending strength, and has a relatively small effect on the density. The absence of functional additives in Comparative Example 20 makes it impossible to achieve multiple functions, and the comprehensive performance of the material decreases significantly, resulting in a substantial decrease in the bending strength, and the density increases significantly due to the absence of components that help reduce the density. Composite lightweight fillers play an important role in reducing the density and improving the mechanical properties of the material. The absence of composite lightweight fillers in Comparative Example 21 makes the material heavier, with a substantial increase in density, and the rationality of the structure of the material is destroyed, resulting in a significant decrease in the bending strength. The simultaneous addition of various materials in Comparative Example 22 leads to agglomeration, especially for materials with small particle sizes or special properties, which are difficult to disperse uniformly in the entire system in a short period of time. This leads to uneven distribution of the materials in the matrix, resulting in large differences in local performance, thereby affecting the overall mechanical properties. Aerogel powder, expanded perlite, nano-titanium dioxide, and composite lightweight fillers cooperate with each other. Aerogel powder optimizes the pore structure, expanded perlite provides lightweight support, nano-titanium dioxide enhances the interface bonding, and composite lightweight fillers work together to make the material have low density and good mechanical properties. They improve the overall performance of the material by improving the microstructure of the material and enhancing the bonding force between components, thereby achieving a good balance between low density and high bending strength.

[0089] Although embodiments of the present application have been shown and described, it is to be understood that various modifications, substitutions, replacements and changes can be made to these embodiments without departing from the principles and spirit of the present application, and the scope of the present application is defined by the appended claims and their equivalents.

Claims

1. A functional ceramic green body, characterized by: The ceramic blank comprises the following components in parts by weight: Kaolin: 20-30 parts; Mullite: 10-20 parts; Talc: 35-45 parts; composite lightweight filler: 15-25 parts; modified reinforcing agent: 3-7 parts; interface modifier: 1-5 parts; functional additive: 1-5 parts; The modified reinforcing agent comprises nanosilica, carbon fiber, polyvinyl alcohol, glycerol and dibutyl phthalate; the modified reinforcing agent is that 2-4 parts of the nanosilica is added into 30 parts of anhydrous ethanol, ultrasonic dispersion is carried out for 30 min to obtain a silica dispersion liquid; 1-3 parts of the carbon fiber is placed in a 5% concentration nitric acid solution, soaked in a 60℃ water bath for 50 min-70 min, washed to neutral with deionized water after taking out, and then vacuum dried for 2 h to obtain pretreated carbon fiber; The silica dispersion liquid, the pretreated carbon fiber, 1-2 parts of the polyvinyl alcohol, 0.5-1.5 parts of the glycerol and 0.5 parts of the dibutyl phthalate are sequentially added into a high-speed blender, stirred at a speed of 800 rpm for 30 min-60 min to obtain a mixture; The interface modifier comprises silane coupling agent KH-550, aluminate coupling agent DL-411 and composite nanoclay; the interface modifier is that 1-2 parts of the composite nanoclay is dried at 150℃ for 2 h-4 h to obtain pretreated composite nanoclay; 0.5-2.5 parts of the silane coupling agent KH-550, 1-3 parts of the aluminate coupling agent DL-411 and the pretreated composite nanoclay are added into a reaction kettle, stirred and mixed at a speed of 300 rpm at 80℃ for 1 h-3 h to obtain a mixture; the composite nanoclay comprises montmorillonite and sepiolite, and the weight ratio of the montmorillonite to the sepiolite is 2:1-3; The functional additive comprises aerogel powder, expanded perlite and nanometer titanium dioxide; the functional additive is that 1-3 parts of the aerogel powder is sieved through a 200 mesh screen, dried in a vacuum environment for 2 h to obtain pretreated aerogel; 2-4 parts of the expanded perlite is soaked in a 3% concentration silane coupling agent KH-550 aqueous solution, taken out after soaking at room temperature for 1 h-3 h, and dried at 100℃ for 8 h to obtain modified expanded perlite; the pretreated aerogel, the modified expanded perlite and 1-2 parts of the nanometer titanium dioxide are mixed in a mixer at a speed of 150 rpm for 20 min-40 min to obtain a mixture; The composite lightweight filler comprises hollow glass microspheres and diatomite, and the weight ratio of the hollow glass microspheres to the diatomite is 2-4:

1.

2. A method of producing a functional ceramic green body, characterized by: The ceramic blank is prepared by the following steps: S1: the talc, kaolin and mullite are respectively subjected to crushing treatment, then put into a high-speed mixer, mixed at a speed of 600 rpm for 20 min to obtain pretreated raw materials; S2adding composite light filler, modified reinforcing agent, interface modifier and functional additive in the pretreated raw material in turn, mixing 10 min after adding raw material each time, stirring 30 min after adding all components, obtaining mixture material; S3adding deionized water to the mixture material, the weight ratio of the mixture material and the deionized water is 1:0.3-0.5, ball milling in a ball mill for 4 h, obtaining the ceramic blank.

3. A method of producing a functional ceramic green body according to claim 2, characterized in that: The specific process of the crushing treatment is: putting the talc into a crusher for crushing, and then vacuum drying; the kaolin is preliminarily crushed in the crusher, and then put into a ball mill for grinding for 1 h-3 h, and then vacuum drying after sieving; the mullite is put into a grinding machine for grinding, and the discharge particle size is adjusted to 3 μm-5 μm, and then calcined in a muffle furnace.

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