Environment-friendly ceramic containing bamboo fibers and preparation method thereof

Abstract

The invention relates to the technical field of ceramics, and provides an environment-friendly ceramic containing bamboo fiber and a preparation method thereof, the environment-friendly ceramic containing bamboo fiber comprises the following raw materials by mass: 50-60 parts of kaolin, 18-28 parts of quartz sand, 10-16 parts of feldspar powder, 22-36 parts of modified bamboo charcoal fiber, 0.5-1 part of a binder and 0.2-0.6 part of a dispersant. Wherein the bamboo charcoal fiber is used as a raw material and is environment-friendly and biodegradable; the bamboo charcoal fiber modified by alkali treatment and a sol-gel method has better compatibility with a ceramic matrix and is uniformly dispersed, and the agglomeration phenomenon is reduced, so that the impact resistance and toughness of the ceramic are improved, and the defect of high brittleness of the traditional ceramic is overcome; the honeycomb microporous structure of the bamboo charcoal fiber endows the ceramic with the functions of adsorbing harmful substances, resisting bacteria and deodorizing, so that the ceramic prepared by the invention has excellent antibacterial, deodorizing and mechanical properties, is environment-friendly, and has important application value in the fields of sanitary ware, tableware and the like with high sanitary requirements.

Description

Technical Field

[0001] The present invention relates to the technical field of ceramics, and in particular to an environmentally friendly ceramic containing bamboo fiber and a preparation method thereof. Background Art

[0002] Ceramic tiles, also known as porcelain tiles, are an acid- and alkali-resistant porcelain or stone building and decorative material made from refractory metal oxides and semi-metal oxides through a process of grinding, mixing, pressing, glazing, and firing. Their raw materials are typically a mixture of clay, quartz sand, and other materials. They are widely used in a variety of fields, including architectural decoration, daily necessities, and industrial technology. However, traditional ceramic materials face numerous challenges in their production and use, particularly with increasingly prominent limitations in environmental protection and functionality.

[0003] From a production perspective, the production of traditional ceramics requires a vast amount of natural mineral raw materials, such as clay, feldspar, and quartz. Overexploitation of these non-renewable resources has not only led to a rapid decline in reserves but also severely damaged the ecological environment, triggering a series of geological disasters such as soil erosion and land subsidence. Furthermore, traditional ceramic products are difficult to degrade naturally after disposal, and long-term accumulation can negatively impact the ecological environment.

[0004] In terms of performance, traditional ceramics are hard but brittle, with poor impact resistance. They are easily damaged during transportation and use, resulting in a shortened service life and waste of resources. Furthermore, their smooth surface and lack of special functionality make it difficult to meet the modern society's demand for multifunctional materials. For example, in the fields of sanitary ware and tableware, traditional ceramics lack antibacterial and deodorizing functions, and cannot effectively inhibit bacterial growth and ensure people's healthy lives. Therefore, the development of a new ceramic material with both excellent performance and environmental characteristics has important scientific significance and application value.

[0005] Bamboo fiber, a natural, renewable resource, has recently attracted widespread attention in the composite materials field due to its short growth cycle, biodegradability, and widespread availability. Bamboo fiber includes bamboo pulp fiber and bamboo charcoal fiber. Bamboo charcoal fiber, made from moso bamboo and processed through a specialized process, possesses numerous excellent properties. Its unique honeycomb microporous structure imparts exceptional adsorption capacity, effectively absorbing, decomposing, and deodorizing common indoor harmful substances such as formaldehyde, benzene, toluene, and ammonia, as well as dust. Bamboo charcoal fiber also possesses excellent adsorption and antibacterial properties. Due to its outstanding properties, it is used as a raw material in ceramic flooring, suitable for use in kitchens, bedrooms, and other areas requiring high hygiene standards. However, because bamboo charcoal fiber is an organic carbon material, while ceramic raw materials are mostly inorganic minerals, their chemical properties and surface characteristics differ significantly. Consequently, bamboo charcoal fiber and ceramic raw materials exhibit poor compatibility, making uniform dispersion difficult during mixing and prone to agglomeration. This compromises the uniformity of the ceramic material's internal structure and, in turn, negatively impacts its overall performance. Therefore, addressing these issues is crucial to meet the demands of the ceramics industry. Summary of the Invention

[0006] The present invention provides an environmentally friendly ceramic containing bamboo fiber and a preparation method thereof, which solves the problem of poor compatibility between bamboo charcoal fiber and ceramic raw materials in the related art.

[0007] The technical solutions of the present invention are as follows: The invention provides an environmentally friendly ceramic containing bamboo fiber, which comprises the following raw materials in parts by weight: 50-60 parts of kaolin, 18-28 parts of quartz sand, 10-16 parts of feldspar powder, 22-36 parts of modified bamboo charcoal fiber, 0.5-1 part of a binder and 0.2-0.6 part of a dispersant.

[0008] As a further technical solution, the binder is one of sodium carboxymethyl cellulose, polyvinyl alcohol and lignin sulfonate.

[0009] As a further technical solution, the dispersant is one of sodium hexametaphosphate, sodium tripolyphosphate and sodium polyacrylate.

[0010] The kaolin of the present invention provides plasticity to the ceramics, the quartz sand increases the hardness and wear resistance, and the feldspar plays a fluxing role and reduces the firing temperature.

[0011] As a further technical solution, the modified bamboo charcoal fiber is prepared by the following steps: Step S1, mixing bamboo charcoal fibers with a sodium hydroxide solution (mass fraction 20%), placing the mixture in an ultrasonic generator, treating for 30-60 minutes, filtering and separating, washing with deionized water until neutral, and vacuum drying to obtain alkali-treated bamboo charcoal fibers; Step S2: mixing the alkali-treated bamboo charcoal fiber with the precursor solution, stirring evenly at room temperature, standing for 24 hours, then placing it in a 50-60° C. water bath and stirring for 2 hours, standing for another 48 hours, filtering and separating, and vacuum drying to obtain modified bamboo charcoal fiber.

[0012] As a further technical solution, in step S1, the ratio of bamboo charcoal fiber to sodium hydroxide solution is 1 g:20 mL.

[0013] As a further technical solution, the precursor solution in step S2 is prepared by mixing ethyl orthosilicate, deionized water and anhydrous ethanol in a volume ratio of 1:4:15.

[0014] As a further technical solution, in step S2, the ratio of the amount of alkali-treated bamboo charcoal fiber to the precursor solution is 1 g:15 mL.

[0015] The present invention first performs an alkali treatment on bamboo charcoal fibers using a sodium hydroxide solution. The alkali solution can increase the active specific surface area of the bamboo charcoal fibers, enhance the reaction activity, fully expose a large number of highly reactive hydroxyl groups, and improve the reaction activity of the bamboo fibers. Then, a sol-gel method is used to prepare an inorganic / biomass hybrid material using ethyl laurate as an inorganic precursor. By using this method, the compatibility of the bamboo charcoal fibers with ceramic raw materials is greatly enhanced, making them easier to disperse, reducing agglomeration, and fully exerting the performance of the bamboo charcoal fibers, thereby greatly improving the antibacterial properties, mechanical properties, and environmental protection of the ceramics.

[0016] The present invention also proposes a method for preparing environmentally friendly ceramics containing bamboo fiber, comprising the following steps: Step A1: kaolin, quartz sand, and feldspar powder are mixed, deionized water is added, and ball milling is performed to obtain a ceramic-based slurry; Step A2: slowly adding the modified bamboo charcoal fiber to the ceramic-based slurry prepared in step A1, adding a binder and a dispersant, and continuing ball milling to ensure that the fiber is evenly dispersed to obtain a ceramic slurry; Step A3: injecting the ceramic slurry prepared in step A2 into a mold, maintaining the pressure at 0.05-0.1 MPa for 10-20 minutes to allow the slurry to fill the mold cavity, and then allowing it to stand and solidify before demolding to obtain a green body; Step A4: placing the green body obtained in step A3 into a drying oven for drying to obtain a dried green body; Step A5: Place the dried green body obtained in step A4 into a high-temperature kiln for firing. After firing, cool the green body to room temperature to obtain an environmentally friendly ceramic containing bamboo fiber.

[0017] As a further technical solution, the ball milling time in step A1 is 4-6 hours, and the particle size D50 of the particles is ≤5 μm.

[0018] As a further technical solution, the ball milling time in step A2 is 1-2 hours.

[0019] As a further technical solution, the standing time in step A3 is 3-4 hours.

[0020] As a further technical solution, the drying temperature in step A4 is 60-70° C. and the drying time is 12-24 hours.

[0021] As a further technical solution, the firing conditions in step A5 are to increase the temperature to 1050-1150°C at 5°C / min and keep the temperature for 2-3 hours.

[0022] The working principle and beneficial effects of the present invention are: 1. The present invention uses bamboo charcoal fiber as raw material. Bamboo fiber has a short growth cycle and is biodegradable, which reduces dependence on non-renewable mineral resources and conforms to the concept of sustainable development. 2. The bamboo charcoal fiber modified by alkali treatment and sol-gel method has better compatibility with the ceramic matrix, is evenly dispersed, and reduces agglomeration, thereby improving the impact resistance and toughness of the ceramic and compensating for the brittleness of traditional ceramics. 3. The honeycomb microporous structure of bamboo charcoal fiber gives ceramics the functions of absorbing harmful substances (such as formaldehyde, benzene, etc.), antibacterial and deodorizing; Therefore, the ceramics prepared by the present invention have excellent antibacterial, deodorizing and mechanical properties, are environmentally friendly, and have important application value in fields with high hygiene requirements such as sanitary ware and tableware. DETAILED DESCRIPTION

[0023] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of the present invention.

[0024] Example 1 Preparation of modified bamboo charcoal fiber: Step S1, 50 g of bamboo charcoal fiber was mixed with 1000 mL of sodium hydroxide solution (mass fraction 20%), and then placed in an ultrasonic generator for treatment for 30 minutes, filtered and separated, washed with deionized water until neutral, and vacuum dried to obtain alkali-treated bamboo charcoal fiber; Step S2: 50 g of alkali-treated bamboo charcoal fiber was mixed with 750 mL of a precursor solution (prepared by mixing 37.5 mL of ethyl orthosilicate, 150 mL of deionized water, and 562.5 mL of anhydrous ethanol), stirred evenly at room temperature, allowed to stand for 24 h, and then placed in a 50° C. water bath and stirred for 2 h. After standing for another 48 h, the mixture was filtered and separated, and vacuum dried to obtain modified bamboo charcoal fiber.

[0025] Example 2 Preparation of modified bamboo charcoal fiber: Step S1, 50 g of bamboo charcoal fiber was mixed with 1000 mL of sodium hydroxide solution (mass fraction 20%), and then placed in an ultrasonic generator for 60 min. The mixture was filtered and separated, washed with deionized water until neutral, and vacuum dried to obtain alkali-treated bamboo charcoal fiber; Step S2: 50 g of alkali-treated bamboo charcoal fiber was mixed with 750 mL of a precursor solution (prepared by mixing 37.5 mL of ethyl orthosilicate, 150 mL of deionized water, and 562.5 mL of anhydrous ethanol), stirred evenly at room temperature, allowed to stand for 24 h, and then placed in a 60° C. water bath and stirred for 2 h. After standing for another 48 h, the mixture was filtered and separated, and vacuum dried to obtain modified bamboo charcoal fiber.

[0026] Example 3 A method for preparing environmentally friendly ceramics containing bamboo fiber comprises the following steps: Step A1: 50 g of kaolin, 18 g of quartz sand, and 10 g of feldspar powder were mixed, deionized water was added, and the mixture was ball-milled for 4 h until the particle size D50 was ≤ 5 μm to obtain a ceramic-based slurry; Step A2: Slowly add 22 g of the modified bamboo charcoal fiber prepared in Example 1 to the ceramic-based slurry prepared in Step A1, and simultaneously add 0.5 g of a binder and 0.2 g of a dispersant. Continue ball milling for 1 h to ensure uniform dispersion of the fibers, thereby obtaining a ceramic slurry. Step A3: injecting the ceramic slurry prepared in step A2 into a mold, maintaining the pressure at 0.05 MPa for 10 minutes to allow the slurry to fill the mold cavity, and then allowing it to stand for 3 hours. After solidification, demolding is performed to obtain a green body; Step A4: placing the green body obtained in step A3 in a drying oven at 60° C. for 12 hours to obtain a dried green body; Step A5: Place the dried green body obtained in step A4 into a high-temperature kiln, heat it to 1050°C at a rate of 5°C / min, and keep it warm for 2 hours for firing. After firing, cool it to room temperature in the kiln to obtain environmentally friendly ceramics containing bamboo fiber.

[0027] Example 4 A method for preparing environmentally friendly ceramics containing bamboo fiber comprises the following steps: Step A1: 55 g of kaolin, 23 g of quartz sand, and 13 g of feldspar powder were mixed, deionized water was added, and the mixture was ball-milled for 5 h. The particle size D50 of the particles was ≤ 5 μm to obtain a ceramic-based slurry; Step A2: Slowly add 28 g of the modified bamboo charcoal fiber prepared in Example 1 to the ceramic-based slurry prepared in Step A1, and simultaneously add 0.7 g of a binder and 0.4 g of a dispersant. Continue ball milling for 72 h to ensure uniform dispersion of the fibers, thereby obtaining a ceramic slurry. Step A3: injecting the ceramic slurry prepared in step A2 into a mold, maintaining the pressure at 0.08 MPa for 15 minutes to allow the slurry to fill the mold cavity, and then allowing it to stand for 4 hours. After solidification, demolding is performed to obtain a green body; Step A4: placing the green body obtained in step A3 in a drying oven at 70° C. for 724 hours to obtain a dried green body; Step A5: Place the dried green body obtained in step A4 into a high-temperature kiln, heat it to 1100°C at 5°C / min, and keep it warm for 3 hours for firing. After firing, cool it to room temperature with the kiln to obtain environmentally friendly ceramics containing bamboo fiber.

[0028] Example 5 A method for preparing environmentally friendly ceramics containing bamboo fiber comprises the following steps: Step A1: 60 g of kaolin, 28 g of quartz sand, and 16 g of feldspar powder were mixed, deionized water was added, and the mixture was ball-milled for 6 h. The particle size D50 of the particles was ≤ 5 μm to obtain a ceramic-based slurry; Step A2: 36 g of the modified bamboo charcoal fiber prepared in Example 1 was slowly added to the ceramic-based slurry prepared in Step A1, and 1 g of a binder and 0.6 g of a dispersant were added. The ball milling was continued for 2 h to ensure that the fibers were evenly dispersed, thereby obtaining a ceramic slurry. Step A3: injecting the ceramic slurry prepared in step A2 into a mold, maintaining the pressure at 0.1 MPa for 20 minutes to allow the slurry to fill the mold cavity, and then allowing it to stand for 4 hours. After solidification, demolding is performed to obtain a green body; Step A4: placing the green body obtained in step A3 in a drying oven at 70° C. for 24 hours to obtain a dried green body; Step A5: Place the dried green body obtained in step A4 into a high-temperature kiln, heat it to 1150°C at a rate of 5°C / min, and keep it warm for 3 hours for firing. After firing, cool it to room temperature with the kiln to obtain environmentally friendly ceramics containing bamboo fiber.

[0029] Comparative Example 1 Ordinary bamboo charcoal fibers of the same mass were used to replace the modified bamboo charcoal fibers in Example 5, and the remaining steps were the same as in Example 5.

[0030] Comparative Example 2 A commercially available ceramic sheet was used.

[0031] The performance tests of Examples 3-5 and Comparative Examples 1-2 were carried out, and the results are shown in the following table:

[0032] As can be seen from the above table, the ceramics prepared in the embodiments of the present invention have higher antibacterial and mechanical properties than those in the comparative examples, and therefore have important application value in fields with high hygiene requirements such as sanitary ware and tableware.

[0033] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. An environmentally friendly ceramic containing bamboo fiber, characterized in that: The invention comprises the following raw materials in parts by weight: 50-60 parts of kaolin, 18-28 parts of quartz sand, 10-16 parts of feldspar powder, 22-36 parts of modified bamboo charcoal fiber, 0.5-1 part of binder and 0.2-0.6 part of dispersant.

2. The environmentally friendly ceramic containing bamboo fiber according to claim 1, characterized in that: The modified bamboo charcoal fiber is prepared by the following steps: Step S1, mixing bamboo charcoal fibers with sodium hydroxide solution, placing the mixed fibers in an ultrasonic generator, treating the mixed fibers, filtering and separating the mixed fibers, washing the mixed fibers to neutrality, and vacuum drying the mixed fibers to obtain alkali-treated bamboo charcoal fibers; Step S2: mixing the alkali-treated bamboo charcoal fiber with the precursor solution, stirring evenly at room temperature, letting it stand, and then placing it in a water bath at 50-60° C. and stirring for 2 h. After letting it stand again, filtering and separating, and vacuum drying to obtain modified bamboo charcoal fiber.

3. The environmentally friendly ceramic containing bamboo fiber according to claim 2, characterized in that: In step S1, the usage ratio of bamboo charcoal fiber to sodium hydroxide solution is 1 g:20 mL.

4. The environmentally friendly ceramic containing bamboo fiber according to claim 2, characterized in that: In step S2, the precursor solution is prepared by mixing ethyl orthosilicate, deionized water, and anhydrous ethanol in a volume ratio of 1:4:

15.

5. The environmentally friendly ceramic containing bamboo fiber according to claim 2, characterized in that: In step S2, the ratio of the alkali-treated bamboo charcoal fiber to the precursor solution is 1 g:15 mL.

6. The environmentally friendly ceramic containing bamboo fiber according to claim 1, characterized in that: The binder is one of sodium carboxymethyl cellulose, polyvinyl alcohol and lignin sulfonate.

7. The environmentally friendly ceramic containing bamboo fiber according to claim 1, characterized in that: The dispersant is one of sodium hexametaphosphate, sodium tripolyphosphate and sodium polyacrylate.

8. The method for preparing an environmentally friendly ceramic containing bamboo fiber according to any one of claims 1 to 7, characterized in that: The following steps are involved: Step A1: kaolin, quartz sand, and feldspar powder are mixed, deionized water is added, and ball milling is performed to obtain a ceramic-based slurry; Step A2: slowly adding the modified bamboo charcoal fiber to the ceramic-based slurry prepared in step A1, adding a binder and a dispersant, and continuing ball milling to obtain a ceramic slurry; Step A3: injecting the ceramic slurry prepared in step A2 into a mold, maintaining the pressure at 0.05-0.1 MPa for 10-20 minutes to allow the slurry to fill the mold cavity, and then allowing it to stand and solidify before demolding to obtain a green body; Step A4: placing the green body obtained in step A3 into a drying oven for drying to obtain a dried green body; Step A5: Place the dried green body obtained in step A4 into a high-temperature kiln for firing. After firing, cool the green body to room temperature to obtain an environmentally friendly ceramic containing bamboo fiber.

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