Ceramic material as well as preparation method and application thereof

Abstract

The invention relates to the technical field of ceramic materials, in particular to a ceramic material and a preparation method and application thereof. The invention provides a ceramic material, which is prepared from the following raw materials in percentage by mass: 5 to 30 percent of ball clay, 5 to 25 percent of purple grit mud, 10 to 35 percent of mullite, 15 to 40 percent of cordierite and 3 to 10 percent of pore forming agent. The ceramic material has the characteristics of good heat storage property, impact resistance and light weight. The pizza stone plate can be comparable with a high-grade pizza stone plate made of natural volcanic materials.

Description

Technical Field

[0001] The present invention relates to the technical field of ceramic materials, and in particular to a ceramic material, a preparation method and an application thereof. Background Art

[0002] A pizza stone is a specialized tool used for baking pizzas, typically made from refractory materials such as ceramic, clay, or stone. It evenly absorbs and conducts heat, simulating the effects of a traditional stone kiln oven, resulting in a crispy bottom while preventing burning. Consequently, pizza stones have quickly gained popularity since their introduction. While domestically produced pizza stones offer good value and practicality, they also have some drawbacks, such as poor heat storage, impact resistance, and a heavy, high-density material, making them incomparable to high-end pizza stones made from natural volcanic materials abroad. Summary of the Invention

[0003] In view of this, the object of the present invention is to provide a ceramic material and a preparation method and application thereof. The ceramic material has the characteristics of good heat storage, impact resistance and light weight.

[0004] In order to achieve the above-mentioned object of the invention, the present invention provides the following technical solutions:

[0005] The invention provides a ceramic material, which comprises the following raw materials, calculated by mass percentage: 5-30% of ball clay, 5-25% of purple sand mud, 10-35% of mullite, 15-40% of cordierite and 3-10% of a pore-forming agent.

[0006] Preferably, the raw materials for preparation further comprise, by mass percentage, 0-20% of clay, 0-10% of quartz, 0-10% of red mountain stone powder, 0-10% of talc and 0-10% of alumina;

[0007] The amounts of the clay, quartz, Hongshan stone powder, talc and alumina are not all 0 at the same time.

[0008] Preferably, the fineness of the ball clay, purple sand mud and talc is independently less than 200 mesh.

[0009] Preferably, the fineness of the quartz is 60-200 mesh.

[0010] Preferably, the fineness of the mullite and cordierite is independently 20-100 mesh.

[0011] Preferably, the fineness of the clay is less than 100 mesh;

[0012] The fineness of the Hongshan stone powder is 40-200 mesh;

[0013] The fineness of the aluminum oxide is less than 200 meshes.

[0014] Preferably, the fineness of the pore-forming agent is 40-100 mesh;

[0015] The pore-forming agent includes one or more of corn flour, starch and walnut shell powder.

[0016] The present invention also provides a method for preparing the ceramic material described in the above technical solution, comprising the following steps:

[0017] Ball clay, purple sand mud, mullite, cordierite, a pore-forming agent and water are mixed, subjected to aging treatment, and then molded and sintered in sequence to obtain the ceramic material.

[0018] Preferably, the aging treatment time is 12 to 48 hours;

[0019] The molding pressure is 50 to 150 bar, and the holding time is 0.3 to 5 seconds;

[0020] The sintering temperature is 1050-1250° C., and the holding time is 2-5 hours.

[0021] The present invention also provides the application of the ceramic material described in the above technical solution or the ceramic material prepared by the preparation method described in the above technical solution in the field of pizza stone plates.

[0022] The present invention provides a ceramic material comprising the following raw materials, calculated by mass percentage: 5-30% ball clay, 5-25% purple sand clay, 10-35% mullite, 15-40% cordierite, and 3-10% pore-forming agent. The density of the ceramic material of the present invention is less than 1.5 g / cm 3 , heat storage coefficient>10.0W / (m 2 K), thermal shock resistance >450°C, comparable to high-end pizza stones made from natural volcanic materials. Testing has shown that the ceramic material has a flexural strength >10 MPa, withstands >10 thermal shocks at 450°C, and has a shrinkage rate <1%. By controlling the types and amounts of the components and synergizing them, the present invention achieves excellent heat storage, impact resistance, and lightweight properties. DETAILED DESCRIPTION

[0023] The invention provides a ceramic material, which comprises the following raw materials, calculated by mass percentage: 5-30% of ball clay, 5-25% of purple sand mud, 10-35% of mullite, 15-40% of cordierite and 3-10% of a pore-forming agent.

[0024] The raw materials for preparing the ceramic material of the present invention include 5-30% ball clay, more preferably 5-25% by mass. In an embodiment of the present invention, the ball clay in the ceramic material may be 5%, 10% or 25% by mass.

[0025] In the present invention, the fineness of the ball soil is preferably less than 200 mesh. In the present invention, the mass percentage of aluminum oxide in the ball soil is 37-38%; and the plasticity index is preferably ≥35.

[0026] In the present invention, the ball clay can provide plasticity, enhance strength, and optimize sintering behavior in the ceramic material.

[0027] The raw materials for preparing the ceramic material of the present invention include 5-25% of purple sand clay in terms of mass percentage. In an embodiment of the present invention, the mass percentage of purple sand clay in the ceramic material can be 5% or 25%.

[0028] In the present invention, the fineness of the purple sand clay is preferably less than 200 mesh.

[0029] In the present invention, the purple clay can provide excellent plasticity, air permeability and heat resistance in the ceramic material, and improve the heat storage capacity of the ceramic material.

[0030] The raw materials for preparing the ceramic material of the present invention include 10-35% mullite by mass, more preferably 10-20%. In an embodiment of the present invention, the mass percentage of mullite in the ceramic material can be 10% or 20%.

[0031] In the present invention, the fineness of the mullite is preferably 20-100 mesh.

[0032] In the present invention, due to its unique crystal structure and chemical stability, mullite can improve the heat resistance and fire resistance of ceramic materials and enhance the strength of ceramic materials; at the same time, the combination with cordierite can further improve the product's resistance to cold and heat shock.

[0033] The raw materials for preparing the ceramic material of the present invention include 15-40% cordierite by mass, more preferably 25-40%. In an embodiment of the present invention, the mass percentage of cordierite in the ceramic material can be 15%, 25% or 40%.

[0034] In the present invention, the fineness of the cordierite is preferably 20-100 mesh.

[0035] The raw materials for preparing the ceramic material of the present invention include 3-10% of pore-forming agent by weight, more preferably 5-10%. In an embodiment of the present invention, the weight percentage of the pore-forming agent in the ceramic material can be 5% or 10%.

[0036] In the present invention, the pore-forming agent preferably includes one or more of corn flour, starch and walnut shell powder, and more preferably includes corn flour, starch or walnut shell powder; when the pore-forming agent is two or more of the above-mentioned specific selections, the present invention has no special limitation on the ratio of the above-mentioned specific substances, and they can be mixed in any ratio.

[0037] In the present invention, the pore-forming agent is easy to obtain, has low cost, contains few impurities, and is easy to mix evenly with other components, thereby further reducing the density of the ceramic material and achieving the purpose of light weight.

[0038] The raw materials for preparing the ceramic material of the present invention preferably further include 0-20% clay in terms of mass percentage. In an embodiment of the present invention, the mass percentage of clay in the ceramic material can be 0% or 10%.

[0039] In the present invention, the fineness of the clay is preferably less than 100 mesh.

[0040] In the present invention, the clay can provide the basic plasticity, forming performance and air permeability of the ceramic material, promote the densification of the ceramic material, and also cooperate with the ball clay to adjust the forming properties such as plasticity and forming moisture control (too high forming moisture can easily lead to defects during firing).

[0041] In terms of mass percentage, the raw materials for preparing the ceramic material of the present invention also preferably include 0-10% quartz, more preferably 5-10%. In an embodiment of the present invention, the mass percentage of quartz in the ceramic material can be 0%, 5% or 10%.

[0042] In the present invention, the fineness of the quartz is preferably 60-200 mesh.

[0043] In the present invention, the quartz can increase the skeleton strength of the ceramic material.

[0044] The raw materials for preparing the ceramic material of the present invention preferably further include 0-10% of Hongshan stone powder in terms of mass percentage. In an embodiment of the present invention, the mass percentage of Hongshan stone powder in the ceramic material can be 0%.

[0045] In the present invention, the fineness of the Hongshan stone powder is preferably 40-200 mesh.

[0046] In the present invention, the Hongshan stone powder has the functions of increasing the iron content (color adjustment) and promoting dissolution in the ceramic material.

[0047] The raw materials for preparing the ceramic material of the present invention preferably further include 0-10% talc, more preferably 5-10%, by mass percentage. In an embodiment of the present invention, the mass percentage of talc in the ceramic material can be 5% or 10%.

[0048] In the present invention, the fineness of the talc is preferably less than 200 mesh.

[0049] In the present invention, the addition of talc can reduce the sintering temperature and regulate the expansion and thermal shock resistance of the ceramic material. The synergistic regulation of talc, clay, quartz and ball clay can further improve the strength of the product.

[0050] The raw materials for preparing the ceramic material of the present invention preferably further include 0-10% aluminum oxide, more preferably 5-10%, by weight. In an embodiment of the present invention, the aluminum oxide in the ceramic material may be 0%, 5%, or 10% by weight.

[0051] In the present invention, the fineness of the alumina is preferably less than 200 mesh.

[0052] In the present invention, the alumina exhibits a high melting point, high strength, excellent chemical stability, and diverse crystal structures. Its application in ceramic materials can improve the refractory properties, wear resistance, and brittleness of the ceramic materials. Alumina also combines with talc to form a cordierite phase, further controlling the thermal expansion coefficient and improving product strength.

[0053] The present invention also provides a method for preparing the ceramic material described in the above technical solution, comprising the following steps:

[0054] Ball clay, purple sand mud, mullite, cordierite, a pore-forming agent and water are mixed, subjected to aging treatment, and then molded and sintered in sequence to obtain the ceramic material.

[0055] In the present invention, the mixing is preferably performed by first mixing the ball clay, purple clay, mullite, cordierite, and pore-forming agent, followed by the addition of water. The present invention does not impose any particular restrictions on the amount of water used. In the present invention, the first mixing is preferably performed by ball milling. The present invention does not impose any particular restrictions on the ball milling process; a process well known to those skilled in the art can be employed to ensure uniform mixing. In an embodiment of the present invention, the ball milling time can be 1 hour.

[0056] In the present invention, the aging treatment time is preferably 12 to 48 hours, the humidity is preferably 65 to 80%, and the temperature is preferably 15 to 25° C. In an embodiment of the present invention, the aging treatment time can be 12 hours or 48 hours, the humidity can be 75%, and the temperature can be 20° C.

[0057] In the present invention, the molding pressure is preferably 50 to 150 bar, more preferably 50 to 100 bar; the molding holding time is preferably 0.3 to 5.0 seconds, more preferably 0.5 to 1.2 seconds. In an embodiment of the present invention, the molding pressure can be 50 bar or 100 bar; and the molding holding time can be 0.6 seconds.

[0058] In the present invention, after the molding is completed, drying is preferably further included. The present invention does not have any particular limitation on the drying process, and can be carried out using a process well known to those skilled in the art and ensuring sufficient drying. In an embodiment of the present invention, the drying temperature can be 180° C. and the drying time can be 2 hours or 4 hours.

[0059] In the present invention, the sintering temperature is preferably 1050-1250°C, more preferably 1050-1200°C; the holding time is preferably 2-5 hours. In embodiments of the present invention, the sintering temperature can be 1050°C, 1150°C, or 1200°C; and the sintering time can be 2 hours, 2.5 hours, or 3 hours. In the present invention, the sintering is preferably performed in an oxidizing atmosphere, which is not particularly limited in the present invention.

[0060] In the present invention, controlling the molding and sintering parameters within the above ranges and combining them with the components of the ceramic material can further produce a high-strength product.

[0061] After the sintering is completed, the present invention preferably further includes cooling. The present invention does not have any special limitation on the cooling process, and the cooling process can be carried out using a process well known to those skilled in the art.

[0062] The present invention also provides the use of the ceramic material described in the above technical solution or the ceramic material prepared by the preparation method described in the above technical solution in the field of pizza stone. The present invention does not have any particular limitation on the method of the application, and the method can be performed using methods well known to those skilled in the art.

[0063] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions of the present invention. Obviously, the embodiments described are only some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0064] Example 1

[0065] 10 parts by weight of ball clay (fineness <200 mesh, mass percentage of alumina of 37-38%, plasticity index ≥35), 25 parts by weight of purple clay (fineness <200 mesh), 5 parts by weight of quartz (fineness of 60-200 mesh), 25 parts by weight of cordierite (fineness of 20-100 mesh), 20 parts by weight of mullite (fineness of 20-100 mesh), 5 parts by weight of talc (fineness <200 mesh) and 10 parts by weight of corn flour are mixed and ball-milled for 1 hour, 8 parts by weight of water are added, and the mixture is aged for 48 hours (aging humidity is 75% and temperature is 20°C), and then formed under 50 bar (holding time is 0.6s), dried at 180°C for 2 hours, sintered at 1150°C in an oxidizing atmosphere for 2.5 hours, and cooled to obtain a ceramic material.

[0066] Example 2

[0067] 25 parts by weight of ball clay (fineness <200 mesh, mass percentage of aluminum oxide of 37-38%, plasticity index ≥35), 25 parts by weight of purple clay (fineness <200 mesh), 10 parts by weight of quartz (fineness 60-200 mesh), 15 parts by weight of cordierite (fineness 20-100 mesh), 20 parts by weight of mullite (fineness 20-100 mesh), 10 parts by weight of talc (fineness <200 mesh), 10 parts by weight of aluminum oxide (fineness <200 mesh) and 5 parts by weight of starch are mixed and ball-milled for 1 hour, and then 10 parts by weight of water are added. After aging for 12 hours (aging humidity is 75% and temperature is 20°C), it is formed under 100 bar (holding time is 0.6s), dried at 180°C for 2 hours, sintered at 1200°C in an oxidizing atmosphere for 2 hours, and cooled to obtain a ceramic material.

[0068] Example 3

[0069] 5 parts by weight of ball clay (fineness <200 mesh, mass percentage of aluminum oxide of 37-38%, plasticity index ≥35), 5 parts by weight of purple sand mud (fineness <200 mesh), 20 parts by weight of pottery clay (fineness <100 mesh), 40 parts by weight of cordierite (fineness 20-100 mesh), 10 parts by weight of mullite (fineness 20-100 mesh), 10 parts by weight of talc (fineness <200 mesh), 5 parts by weight of aluminum oxide (fineness <200 mesh) and 5 parts by weight of walnut powder are mixed and ball-milled for 1 hour, 6.5 parts by weight of water are added, and the mixture is aged for 12 hours (aging humidity is 75% and temperature is 20°C), and then formed under 100 bar (holding time is 0.6s), dried at 180°C for 4 hours, sintered at 1050°C in an oxidizing atmosphere for 3 hours, and cooled to obtain a ceramic material.

[0070] Test Case

[0071] The density of the ceramic materials described in Examples 1 to 3 was tested according to the standard GB / T2997-2000 for bulk density and apparent porosity of dense shaped refractory products.

[0072] The heat storage coefficients of the ceramic materials described in Examples 1 to 3 were tested using a heat flow meter method by measuring the thermal diffusivity and specific heat capacity respectively, and the product of the two is the heat storage coefficient;

[0073] According to the standard of GBT 5593-2015 Structural ceramic materials for electronic components, the thermal shock resistance temperature of the ceramic materials described in Examples 1 to 3 was tested;

[0074] The flexural strength of the ceramic materials described in Examples 1 to 3 was tested according to the standard GB / T 3001-2007 Test method for flexural strength of refractory products at room temperature;

[0075] According to the standard of GBT 5593-2015 for structural ceramic materials of electronic components, the ceramic materials described in Examples 1 to 3 were tested for the number of thermal shocks at 450°C.

[0076] According to the standard of QBT 1548-2015, the shrinkage rate of the ceramic materials described in Examples 1 to 3 was tested;

[0077] The test results are shown in Table 1:

[0078] Table 1 Performance parameters of the ceramic materials described in Examples 1 to 3

[0079]

[0080] The above description is merely a preferred embodiment of the present invention and does not constitute any limitation thereto. It should be noted that those skilled in the art may make various improvements and modifications without departing from the principles of the present invention, and such improvements and modifications shall also be considered within the scope of protection of the present invention.

Claims

1. A ceramic material, characterized in that: The preparation material comprises the following raw materials in percentage by mass: 5-30% ball clay, 5-25% purple sand mud, 10-35% mullite, 15-40% cordierite and 3-10% pore-forming agent.

2. The ceramic material according to claim 1, wherein According to the percentage by mass, the raw materials for preparation further include 0-20% of clay, 0-10% of quartz, 0-10% of red mountain stone powder, 0-10% of talc and 0-10% of aluminum oxide; The amounts of the clay, quartz, Hongshan stone powder, talc and alumina are not all 0 at the same time.

3. The ceramic material according to claim 2, wherein The fineness of the ball clay, purple sand mud and talc is independently less than 200 meshes.

4. The ceramic material according to claim 2, wherein The fineness of the quartz is 60-200 meshes.

5. The ceramic material according to claim 1 or 2, characterized in that The fineness of the mullite and cordierite is independently 20-100 mesh.

6. The ceramic material according to claim 2, wherein The fineness of the clay is less than 100 mesh; The fineness of the Hongshan stone powder is 40-200 mesh; The fineness of the aluminum oxide is less than 200 meshes.

7. The ceramic material according to claim 1, wherein The fineness of the pore-forming agent is 40 to 100 mesh; The pore-forming agent includes one or more of corn flour, starch and walnut shell powder.

8. The method for preparing the ceramic material according to any one of claims 1 to 7, characterized in that: The following steps are involved: Ball clay, purple sand mud, mullite, cordierite, a pore-forming agent and water are mixed, subjected to aging treatment, and then molded and sintered in sequence to obtain the ceramic material.

9. The preparation method according to claim 8, wherein The aging treatment time is 12 to 48 hours; The molding pressure is 50 to 150 bar, and the holding time is 0.3 to 5 seconds; The sintering temperature is 1050-1250° C., and the holding time is 2-5 hours.

10. Use of the ceramic material according to any one of claims 1 to 7 or the ceramic material prepared by the preparation method according to claim 8 or 9 in the field of pizza stone.

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