Lightweight high-strength daily-use ceramic and preparation method thereof

Abstract

This invention belongs to the field of daily-use ceramics technology, specifically disclosing a lightweight and high-strength daily-use ceramic and its preparation method. The daily-use ceramic comprises a porous body layer, an intermediate body layer, and a surface glaze layer, wherein the intermediate body layer and the surface glaze layer sequentially cover the surface of the porous body layer from the inside out. The raw material components of the porous body layer include a base material and a pore-forming agent. The base material, by weight, comprises: 30-35 parts machine-made clay, 40-45 parts quartz, 10-15 parts dolomite, 7-10 parts calcium carbonate, and 3-5 parts zirconium silicate. The pore-forming agent is a high-molecular polymer. The resulting daily-use ceramic, while reducing product weight, simultaneously possesses high mechanical strength and a smooth glaze appearance. Compared to bone china of the same thickness, this daily-use ceramic not only reduces weight by 15-30% but also increases impact strength by more than 30%.

Description

Technical Field

[0001] This invention belongs to the field of daily-use ceramics technology, specifically relating to a lightweight and high-strength daily-use ceramic and its preparation method. Background Technology

[0002] Everyday ceramic tableware is an indispensable utensil in people's daily life. However, compared with tableware made of melamine or other polymer materials on the market, ceramic materials also have their disadvantages, such as low mechanical strength and heavy weight. These factors also affect the user experience.

[0003] To address the aforementioned shortcomings of daily-use ceramics, researchers have been continuously exploring methods to strengthen and toughen ceramics and reduce product weight. Currently, the main method for strengthening and toughening ceramics is to add a certain amount of inorganic fibers or whiskers to the green body formula, while the method for reducing ceramic weight generally involves forming a porous structure to reduce the product's density, thereby achieving the goal of weight reduction.

[0004] For example, invention patent CN111499368A discloses an ultralight daily-use ceramic. This ceramic uses short-cut quartz fibers and mullite fibers as a skeleton, and boron nitride and sepiolite as high-temperature binders. During sintering, adjacent short fibers are bonded together by high-temperature resistant silicon carbide through the binder, forming a lightweight daily-use ceramic with a high porosity and a bird's nest structure with a certain strength. However, this preparation method is only suitable for low-temperature firing at 800-1000℃, making it difficult to guarantee the mechanical strength of the product, and this daily-use ceramic is an unglazed ceramic product.

[0005] Chinese patent application CN104016703A discloses a method for preparing ultralight closed-cell ceramics. This method uses 5-60% oxide or nitride ceramic particles, 0.01-5% foaming agent, and water to prepare granular stable foam, which is then sintered at a high temperature of 1500-2000℃ to produce ultralight closed-cell ceramics with a closed-cell porosity of over 85%. However, the firing temperature of this ceramic product is too high and unsuitable for the firing of daily-use ceramics (generally not exceeding 1400℃).

[0006] Meanwhile, daily-use ceramics also have very high requirements for surface flatness. Porous ceramic blanks prepared using conventional pore-forming methods inevitably contain open pores. If glazing is applied directly, the fired products will inevitably have uneven glaze surfaces, and may even have defects such as pinholes and melt holes. In addition, the conventional thickness of daily-use ceramics is generally 5-6mm, and some are even as thin as 2-3mm. It is difficult to guarantee the strength of porous ceramics made from such thin thicknesses.

[0007] Therefore, there is an urgent need to develop a new type of daily-use ceramic that can simultaneously possess high mechanical strength and good glaze quality while reducing product weight. Summary of the Invention

[0008] The present invention aims to solve at least one of the technical problems existing in the prior art. To this end, the present invention proposes a lightweight and high-strength daily-use ceramic and its preparation method. Compared with traditional daily-use ceramics (such as bone china) of the same thickness, this daily-use ceramic can not only reduce the weight by 15-30%, but also increase the impact strength by more than 30%, while maintaining good glaze quality.

[0009] To solve the above-mentioned technical problems, the first aspect of the present invention provides a daily-use ceramic, comprising a porous body layer, an intermediate body layer, and a surface glaze layer, wherein the intermediate body layer and the surface glaze layer sequentially cover the surface of the porous body layer from the inside out; the raw material components of the porous body layer include a base material and a pore-forming agent, wherein the base material comprises, by weight, 30-35 parts of machine-made clay, 40-45 parts of quartz, 10-15 parts of dolomite, 7-10 parts of calcium carbonate, and 3-5 parts of zirconium silicate; the pore-forming agent is a polymer.

[0010] Specifically, this invention uses a polymer as a pore-forming agent. The polymer decomposes at lower temperatures, forming large pores. These pores shrink during high-temperature firing, creating a porous structure in the body and reducing the weight of the ceramic. However, the addition of the polymer significantly affects the plasticity of the body, and the resulting pores are easily filled during firing, potentially negatively impacting the product's strength and glaze quality. To address this, the basic body material of this invention uses machine-made clay as a clay-based raw material to improve the plasticity and strength of the body. Calcium-magnesium alkaline earth metal minerals (dolomite and calcium carbonate) are used as fluxes, and a certain amount of zirconium silicate is added to reduce the high-temperature fluidity of the body, effectively preventing pore filling, ensuring the formation of a porous structure, and reducing the impact on glaze quality. Furthermore, quartz and zirconium silicate enhance the strength of the porous framework structure.

[0011] In some embodiments of the present invention, the pore-forming agent is selected from at least one of polypropylene and polycarbonate.

[0012] Specifically, these polymers can decompose at relatively low temperatures (below 400°C) to form larger pores. These pores become smaller during subsequent high-temperature firing. By adjusting the composition of the base blank, it is beneficial to form a porous structure with suitable pore size.

[0013] In some embodiments of the present invention, the particle size of the pore-forming agent is 40-60 mesh.

[0014] Specifically, selecting a pore-forming agent with this particle size can not only better match the base blank and prevent agglomeration during the mixing process, but also obtain a suitable pore size, preventing the green body strength after molding from being too low due to excessively large particles, and preventing the pores from being completely filled during high-temperature firing due to excessively small particles.

[0015] In some embodiments of the present invention, the mass ratio of the base blank to the pore-forming agent is (96-98):(2-4). By controlling the amount of pore-forming agent added, the mechanical strength of the product can be ensured while reducing its weight.

[0016] In some embodiments of the present invention, the raw material components of the intermediate blank layer include, by weight: 30-35 parts of machine-made mud, 35-45 parts of quartz, 15-25 parts of potassium feldspar, 3-5 parts of alumina, and 2-5 parts of dolomite.

[0017] Specifically, the raw material composition of the intermediate green body layer in this invention is similar to that of the porous green body layer. Meanwhile, potassium feldspar and dolomite are used as fluxes, and a certain amount of alumina is added for reinforcement, thereby reducing the high-temperature viscosity of the intermediate green body layer and making it easier to spread and fill on the surface of the porous green body layer. This results in a smooth and dense intermediate layer, which not only helps reduce glaze defects but also improves the mechanical strength of the product.

[0018] In some embodiments of the present invention, the Al2O3 content in the machine-stacked mud is 37-40 wt%, and the plasticity index is ≥17. Machine-stacked mud is mud material produced by machine-stacking high-alumina washed mud. This mud material has a higher aluminum content and plasticity compared to traditional clay raw materials (such as kaolin).

[0019] In some embodiments of the present invention, the plasticity index of the machine-made sludge is 17-19.

[0020] In some embodiments of the present invention, the chemical composition of the glaze layer, by weight percentage, includes: 50-55% SiO2, 9-11% Al2O3, 4-6% K2O, 4-6% Na2O, 0-0.1% Fe2O3, 0-0.05% TiO2, 7-9% CaO, 1-2% MgO, 7-9% ZnO, 3-4% B2O3, 2-4% SrO, and a loss on ignition of 1.5-2.5%.

[0021] In some embodiments of the present invention, the surface glaze used to prepare the surface glaze layer is a frit glaze.

[0022] Specifically, by adjusting the chemical composition of the surface glaze layer to give it a higher initial melting temperature, the premature closure of pores is prevented, thus avoiding defects such as pinholes and melt holes on the glaze surface. At the same time, it is made to have good body-glaze compatibility with the intermediate body layer, thereby improving the mechanical strength of the product.

[0023] In some embodiments of the present invention, the thickness ratio of the porous body layer, the intermediate body layer and the surface glaze layer is (70-80):(10-15):(10-15).

[0024] A second aspect of the present invention provides a method for preparing the above-mentioned daily-use ceramics, comprising the following steps:

[0025] (1) The basic blank is wet-grinded and spray-granulated to obtain basic blank powder; then the basic blank powder is mixed with a pore-forming agent and shaped to obtain a porous blank layer.

[0026] (2) The raw materials for preparing the intermediate green body layer are wet-ground to obtain a slurry; then the porous green body layer is immersed in the slurry and dried to form an intermediate green body layer, thus obtaining a green body.

[0027] (3) The green blank is bisque-fired to obtain a bisque-fired blank;

[0028] (4) After grinding and polishing the bisque, spray the surface glaze to form a surface glaze layer, and then fire the glaze to obtain the daily ceramic.

[0029] In some embodiments of the present invention, in step (1), the particle size distribution of the basic green body powder is as follows: the mass percentage of particles with a particle size of 20 mesh or larger is less than 1%, the mass percentage of particles with a particle size of 20-40 mesh is 35-50%, the mass percentage of particles with a particle size of 40-80 mesh is 45-60%, and the mass percentage of particles with a particle size of less than 80 mesh is less than 5%.

[0030] In some embodiments of the present invention, in step (1), the molding method is isostatic pressing.

[0031] Specifically, because a certain amount of lightweight pore-forming agent is added to the porous preform layer, the pore-forming agent is prone to floating or agglomerating in the slurry, making it impossible to use traditional rolling or high-pressure injection molding. Therefore, this invention employs isostatic pressing and controls specific particle size distribution to ensure the strength of the porous preform layer after molding.

[0032] In some embodiments of the present invention, in step (2), the concentration of the slurry is 37-40 Baume degrees. By controlling the concentration of the slurry, an intermediate preform layer of suitable thickness can be obtained; if the intermediate preform layer is too thick, it is not conducive to the exhaust of gas from the porous preform layer, and if it is too thin, it cannot completely cover the lightweight porous layer.

[0033] In some embodiments of the present invention, steps (1) and (2) further include an iron removal step after wet grinding.

[0034] In some embodiments of the present invention, in step (3), the highest temperature of the bisque firing is 1250-1280°C, and the firing cycle of the bisque firing is 18-20 hours.

[0035] Specifically, the high-temperature slow firing process is beneficial in two ways: firstly, it allows the polymer pore-forming agent to fully decompose and form pores, preventing the incomplete decomposition of the pore-forming agent during glaze firing from affecting the glaze quality; secondly, it facilitates the filling of the porous body layer by the intermediate body layer, forming a closed-cell porous structure and improving the glaze quality.

[0036] In some embodiments of the present invention, in step (4), the highest temperature of the glaze firing is 1130-1160°C, and the firing cycle of the glaze firing is 7-8 hours.

[0037] Specifically, adopting a firing system that combines high-temperature bisque firing with low-temperature glaze firing can effectively reduce the generation of defects such as pinholes and molten holes in the glaze surface, thereby improving the quality of the glaze surface.

[0038] In some embodiments of the present invention, in step (4), the grinding and polishing is performed by a spiral vibratory grinding machine to ensure the flatness and smoothness of the bisque-fired blank.

[0039] Compared with the prior art, the above-described technical solution of the present invention has at least the following technical effects or advantages:

[0040] (1) The daily-use ceramic of the present invention includes a porous body layer, an intermediate body layer, and a surface glaze layer, wherein: the porous body layer uses a polymer as a pore-forming agent, utilizing the decomposition of the polymer at low temperature to form large pores, and the pore size decreases during high-temperature firing to form a porous structure, thereby reducing the weight of the product. At the same time, the porous body layer uses specific components of organic clay, calcium magnesium alkaline earth metal minerals, zirconium silicate, and quartz as the base material, ensuring the formation of the porous structure, reducing the impact of pores on the glaze quality, and improving the mechanical strength of the product.

[0041] (2) This invention optimizes and rationally blends the raw material components of each layer of daily-use ceramics, while controlling the particle size and particle size distribution. Combined with a high-temperature bisque firing and low-temperature glaze firing process, the resulting daily-use ceramics achieve both high mechanical strength and excellent glaze quality while reducing product weight. Compared to traditional bone china of the same thickness, this daily-use ceramics not only reduces weight by 15-30% but also increases impact strength by more than 30%. Attached Figure Description

[0042] Figure 1 This is a schematic diagram of the cross-sectional structure of the daily-use ceramic of the present invention. Detailed Implementation

[0043] The present invention will now be described in detail with reference to embodiments to facilitate understanding of the invention by those skilled in the art. It is particularly important to note that the embodiments are merely illustrative of the invention and should not be construed as limiting the scope of protection of the invention. Non-essential improvements and adjustments made to the invention by those skilled in the art based on the above description should still fall within the scope of protection of the invention. Furthermore, all raw materials mentioned below, unless otherwise specified, are commercially available products; all process steps or preparation methods not mentioned in detail are process steps or preparation methods known to those skilled in the art.

[0044] like Figure 1 As shown, the daily-use ceramic of the present invention includes a porous body layer 100, an intermediate body layer 200 and a surface glaze layer 300, wherein: the intermediate body layer 200 and the surface glaze layer 300 cover the surface of the porous body layer 100 from the inside to the outside, that is, the intermediate body layer 200 completely covers the outer surface of the porous body 100, and the surface glaze layer 300 completely covers the outer surface of the intermediate body layer 200.

[0045] Example 1

[0046] A type of daily-use ceramic (bowl) includes a porous body layer, an intermediate body layer, and a surface glaze layer. The thickness ratio of the porous body layer, the intermediate body layer, and the surface glaze layer is 75:15:10. The total thickness of the product is 4mm, and the size is 4.5 inches.

[0047] The raw material components of the porous preform layer include a base preform and a pore-forming agent with a mass ratio of 98:2. The pore-forming agent is polypropylene with a particle size of 50 mesh.

[0048] The basic blank material, by weight, includes: 30 parts machine-made mud, 45 parts quartz, 10 parts dolomite, 10 parts calcium carbonate, and 5 parts zirconium silicate.

[0049] The raw material components of the intermediate blank layer include, by weight: 30 parts machine-made mud, 45 parts quartz, 17 parts potassium feldspar, 3 parts alumina, and 5 parts dolomite.

[0050] The Al2O3 content in the machine-made mud is 38 wt%, and the plasticity index is 17.

[0051] The chemical composition of the glaze layer, by weight percentage, includes: 55% SiO2, 9% Al2O3, 6% K2O, 4% Na2O, 0.05% Fe2O3, 0.05% TiO2, 8% CaO, 1% MgO, 8% ZnO, 4% B2O3, 3% SrO, with a loss on ignition of 1.9%.

[0052] The above-mentioned method for preparing daily-use ceramics (bowls) includes the following steps:

[0053] (1) Grind the basic blank material, remove iron by sieving, and spray granulate to obtain basic blank powder; then mix the basic blank powder with a pore-forming agent and use isostatic pressing to form a porous blank layer; wherein: the particle size distribution of the basic blank powder is: the mass percentage of particles with a particle size of 20 mesh or above is 0.5%, the mass percentage of particles with a particle size of 20-40 mesh is 45%, the mass percentage of particles with a particle size of 40-60 mesh is 50%, and the mass percentage of particles with a particle size of 60-80 mesh or below is 4.5%.

[0054] (2) Wet grinding of each raw material for preparing intermediate green body layer, iron removal by sieving, and preparation of slurry (concentration of 39 Baume degrees); then immersion of the porous green body layer obtained in step (1) in slurry, drying to form intermediate green body layer, and preparation of green body.

[0055] (3) The green blank obtained in step (2) is bisque fired to obtain a bisque fired blank; wherein: the maximum temperature of bisque firing is 1260℃ and the firing cycle is 19 hours.

[0056] (4) The bisque obtained in step (3) is wet-polished using a spiral vibratory grinder. After drying, a surface glaze is sprayed to form a surface glaze layer. The glaze is then fired. The maximum firing temperature is 1150℃ and the firing cycle is 7 hours. This produces the daily ceramic (bowl) of this embodiment.

[0057] Example 2

[0058] A type of daily-use ceramic (bowl) includes a porous body layer, an intermediate body layer, and a surface glaze layer. The thickness ratio of the porous body layer, the intermediate body layer, and the surface glaze layer is 70:15:15. The total thickness of the product is 4mm, and the size is 4.5 inches.

[0059] The raw material components of the porous preform layer include a base preform and a pore-forming agent with a mass ratio of 96:4. The pore-forming agent is polycarbonate with a particle size of 40 mesh.

[0060] The basic blank material, by weight, includes: 35 parts machine-made mud, 40 parts quartz, 15 parts dolomite, 7 parts calcium carbonate, and 3 parts zirconium silicate.

[0061] The raw material components of the intermediate blank layer include, by weight: 35 parts machine-made mud, 40 parts quartz, 20 parts potassium feldspar, 3 parts alumina, and 2 parts dolomite.

[0062] The Al2O3 content in the machine-made mud was 39 wt%, and the plasticity index was 18.

[0063] The chemical composition of the glaze layer, by weight percentage, includes: 50% SiO2, 11% Al2O3, 6% K2O, 5% Na2O, 0.1% Fe2O3, 0.02% TiO2, 7% CaO, 2% MgO, 9% ZnO, 4% B2O3, 4% SrO, with a loss on ignition of 1.88%.

[0064] The above-mentioned method for preparing daily-use ceramics (bowls) includes the following steps:

[0065] (1) Grind the basic blank material, remove iron by sieving, and spray granulate to obtain basic blank powder; then mix the basic blank powder with a pore-forming agent and use isostatic pressing to form a porous blank layer; wherein: the particle size distribution of the basic blank powder is: the mass percentage of particles with a particle size of 20 mesh or above is 0.3%, the mass percentage of particles with a particle size of 20-40 mesh is 45%, the mass percentage of particles with a particle size of 40-80 mesh is 52%, and the mass percentage of particles with a particle size of less than 80 mesh is less than 2.7%.

[0066] (2) Wet grinding of each raw material for preparing intermediate green body layer, iron removal by sieving, and preparation of slurry (concentration of 38 Baume degrees); then the porous green body layer obtained in step (1) is immersed in slurry, dried to form intermediate green body layer, and green body is obtained.

[0067] (3) The green blank obtained in step (2) is bisque fired to obtain a bisque fired blank; wherein: the maximum temperature of bisque firing is 1270℃ and the firing cycle is 18 hours.

[0068] (4) The bisque obtained in step (3) is wet-polished using a spiral vibratory grinder. After drying, it is sprayed with a surface glaze to form a surface glaze layer. The glaze is then fired. The maximum firing temperature is 1160℃ and the firing cycle is 7 hours. This produces the daily ceramic (bowl) of this embodiment.

[0069] Example 3

[0070] A type of daily-use ceramic (bowl) includes a porous body layer, an intermediate body layer, and a surface glaze layer. The thickness ratio of the porous body layer, the intermediate body layer, and the surface glaze layer is 75:15:10. The total thickness of the product is 4mm, and the size is 4.5 inches.

[0071] The porous preform layer consists of a base preform and a pore-forming agent with a mass ratio of 97:3. The pore-forming agent is polypropylene with a particle size of 60 mesh.

[0072] The basic blank material, by weight, includes: 32 parts machine-made mud, 43 parts quartz, 13 parts dolomite, 8 parts calcium carbonate, and 4 parts zirconium silicate.

[0073] The raw material components of the intermediate blank layer include, by weight: 33 parts machine-made mud, 40 parts quartz, 20 parts potassium feldspar, 4 parts alumina, and 3 parts dolomite.

[0074] The content of Al2O3 in the machine-made mud is 40wt%, and the plasticity index is 19.

[0075] The chemical composition of the glaze layer, by weight percentage, includes: 54% SiO2, 11% Al2O3, 5% K2O, 5% Na2O, 0.05% Fe2O3, 0.05% TiO2, 8% CaO, 1% MgO, 8% ZnO, 3% B2O3, 3% SrO, with a loss on ignition of 1.9%.

[0076] The above-mentioned method for preparing daily-use ceramics (bowls) includes the following steps:

[0077] (1) Grind the basic blank, remove iron by sieving, and spray granulate to obtain basic blank powder; then mix the basic blank powder with a pore-forming agent and use isostatic pressing to form a porous blank layer; wherein: the particle size distribution of the basic blank powder is: the mass percentage of particles with a particle size of 20 mesh or above is 0.5%, the mass percentage of particles with a particle size of 20-40 mesh is 50%, the mass percentage of particles with a particle size of 40-80 mesh is 46%, and the mass percentage of particles with a particle size of less than 80 mesh is 3.5%.

[0078] (2) Wet grinding of each raw material for preparing intermediate green body layer, iron removal by sieving, and preparation of slurry (concentration of 37 Baume degrees); then the porous green body layer obtained in step (1) is immersed in slurry, dried to form intermediate green body layer, and green body is obtained.

[0079] (3) The green blank obtained in step (2) is bisque fired to obtain a bisque fired blank; wherein: the maximum temperature of bisque firing is 1250℃ and the firing cycle is 19 hours.

[0080] (4) The bisque obtained in step (3) is wet-polished using a spiral vibratory grinder. After drying, it is sprayed with a surface glaze to form a surface glaze layer. The glaze is then fired. The maximum firing temperature is 1130℃ and the firing cycle is 8 hours. This produces the daily ceramic (bowl) of this embodiment.

[0081] Comparative Example 1

[0082] The difference between Comparative Example 1 and Example 1 lies in the different raw material composition of the base blank. Comparative Example 1 uses an equal amount of kaolin (alumina content of 30wt%, plasticity index of 12) to replace the machine-made mud in Example 1.

[0083] Comparative Example 2

[0084] The difference between Comparative Example 2 and Example 1 lies in the different raw material composition of the base blank. The raw material composition of the base blank of Comparative Example 2, by weight, includes: 30 parts of machine-made mud, 45 parts of quartz, 20 parts of potassium feldspar, and 5 parts of zirconium silicate.

[0085] Comparative Example 3

[0086] The difference between Comparative Example 3 and Example 1 is that the pore-forming agent is different. Comparative Example 3 uses silicon carbide of equal particle size and amount to replace polypropylene in Example 1.

[0087] Comparative Example 4

[0088] The difference between Comparative Example 4 and Example 1 lies in the different raw material composition of the intermediate blank. Comparative Example 4 uses an equal amount of albite to replace the dolomite in Example 1.

[0089] Comparative Example 5

[0090] The difference between Comparative Example 5 and Example 1 lies in the particle size distribution of the basic green body powder. The particle size distribution of the basic green body powder of Comparative Example 5 is as follows: the mass percentage of particles with a particle size of 20 mesh or larger is 0.5%, the mass percentage of particles with a particle size of 20-40 mesh is 80%, the mass percentage of particles with a particle size of 40-60 mesh is 15%, and the mass percentage of particles with a particle size of 60-80 mesh or smaller is 4.5%.

[0091] Comparative Example 6

[0092] The difference between Comparative Example 6 and Example 1 lies in the firing process. Comparative Example 6 adopts a one-time firing process without spruce firing, and the highest firing temperature is 1250°C, with a firing cycle of 18 hours.

[0093] Comparative Example 7

[0094] Comparative Example 7 is a traditional bone china ceramic for daily use, consisting of a body layer and a glaze layer. The thickness ratio of the body layer to the glaze layer is 90:10, the total thickness of the product is 4 mm, and the size is 4.5 inches.

[0095] The raw material components of the green body layer, by weight, include: 35 parts kaolin, 24 parts quartz, 36 parts bone char, and 5 parts bentonite.

[0096] The chemical composition of the glaze layer, by weight percentage, includes: 55% SiO2, 9% Al2O3, 6% K2O, 4% Na2O, 0.05% Fe2O3, 0.05% TiO2, 8% CaO, 1% MgO, 8% ZnO, 4% B2O3, 3% SrO, with a loss on ignition of 1.9%.

[0097] The above-mentioned method for preparing daily-use ceramics (bowls) includes the following steps:

[0098] (1) Grind the raw materials of the green body layer, remove iron by screening and spray granulation to obtain the basic green body powder, and use isostatic pressing to obtain the green body layer.

[0099] (2) The blank layer obtained in step (1) is bisque fired to obtain a bisque fired blank; wherein: the maximum temperature of bisque firing is 1260℃ and the firing cycle is 19 hours.

[0100] (3) The bisque obtained in step (2) is wet-polished using a spiral vibratory grinder. After drying, it is sprayed with a surface glaze to form a surface glaze layer. The glaze is then fired at a maximum temperature of 1150℃ and the firing cycle is 7 hours to obtain the daily ceramic (bowl) of this comparative example.

[0101] Performance testing

[0102] The daily-use ceramic samples (bowls) prepared in Examples 1-3 and Comparative Examples 1-7 were subjected to weight and mechanical property tests, and the forming condition of the porous body layer was recorded. The glaze quality of the products was observed. Among them, the impact strength was tested according to the T / CCIA0008-2021 standard, and the test results are shown in Table 1.

[0103] Table 1:

[0104]

[0105]

[0106] As shown in Table 1, the daily-use ceramics prepared in Examples 1-3, compared with the traditional daily-use bone china of the same size (4.5 inches) and thickness (4 mm) in Comparative Example 7, not only have a weight reduction of 15-30%, but also an impact strength increase of more than 30%, and the glaze quality is good.

[0107] Compared to Example 1, Comparative Examples 1 and 5, respectively, failed to form a porous green body layer due to the use of conventional clay and particle gradation in the base blanks.

[0108] Compared to Example 1, Comparative Examples 2 and 6, respectively, were able to completely fill the pores generated by the decomposition of the pore-forming agent due to the use of traditional potassium feldspar as a flux in the base billet and the use of a single firing process. Therefore, the total weight of the product was not reduced.

[0109] Compared to Example 1, Comparative Example 3, by using high-temperature dispersed pore-forming agent silicon carbide instead of polypropylene, although it also had a better pore-forming effect, caused a series of glaze problems, such as blackening, pinholes and melt holes, and its impact resistance also decreased.

[0110] Compared to Example 1, Comparative Example 4 uses low-temperature flux sodium feldspar instead of dolomite in the intermediate body layer, resulting in excessively low high-temperature viscosity. This causes the gas generated in the body layer to overflow into the glaze layer, resulting in a large number of pinholes on the glaze surface.

[0111] For those skilled in the art, several simple deductions or substitutions can be made without departing from the inventive concept, without requiring creative effort. Therefore, any simple improvements made to this invention by those skilled in the art based on the disclosure of this invention should be within the scope of protection of this invention. The above embodiments are preferred embodiments of this invention, and all processes similar to this invention and equivalent changes should fall within the scope of protection of this invention.

Claims

1. A type of daily-use ceramic, characterized in that, It comprises a porous body layer, an intermediate body layer, and a top glaze layer, wherein the intermediate body layer and the top glaze layer sequentially cover the surface of the porous body layer from the inside out; the raw material components of the porous body layer include a base material and a pore-forming agent, wherein the base material is composed of the following components by weight: 30-35 parts of machine-made clay, 40-45 parts of quartz, 10-15 parts of dolomite, 7-10 parts of calcium carbonate, and 3-5 parts of zirconium silicate; the pore-forming agent is a high molecular polymer. The pore-forming agent is selected from at least one of polypropylene and polycarbonate; The intermediate blank layer is composed of the following raw material components by weight: 30-35 parts machine-made mud, 35-45 parts quartz, 15-25 parts potassium feldspar, 3-5 parts alumina, and 2-5 parts dolomite. The content of Al2O3 in the sludge is 37-40 wt%, and the plasticity index is ≥17; The daily-use ceramics are prepared using a method comprising the following steps: (1) The basic blank is wet-ground and spray-granulated to obtain basic blank powder; then the basic blank powder is mixed with a pore-forming agent and shaped to obtain a porous blank layer; The particle size distribution of the basic preform powder is as follows: less than 1% by mass of particles larger than 20 mesh, 35-50% by mass of particles between 20-40 mesh, 45-60% by mass of particles between 40-80 mesh, and less than 5% by mass of particles smaller than 80 mesh. (2) The raw materials for preparing the intermediate green body layer are wet-ground to obtain a slurry; then the porous green body layer is immersed in the slurry and dried to form an intermediate green body layer, thus obtaining a green body; (3) The green blank is bisque-fired to obtain a bisque-fired blank; the maximum temperature of the bisque-fired blank is 1250-1280℃, and the firing cycle of the bisque-fired blank is 18-20 hours. (4) After grinding and polishing the bisque, spray the surface glaze to form a surface glaze layer and fire it; the maximum temperature of the glaze firing is 1130-1160℃ and the firing cycle of the glaze firing is 7-8 hours; the daily ceramic is obtained.

2. The daily-use ceramics according to claim 1, characterized in that, The particle size of the pore-forming agent is 40-60 mesh.

3. The daily-use ceramics according to claim 1, characterized in that, The mass ratio of the base blank to the pore-forming agent is (96-98):(2-4).

4. The daily-use ceramics according to claim 1, characterized in that, The chemical composition of the surface glaze layer, by weight percentage, includes: 50-55% SiO2, 9-11% Al2O3, 4-6% K2O, 4-6% Na2O, 0-0.1% Fe2O3, 0-0.05% TiO2, 7-9% CaO, 1-2% MgO, 7-9% ZnO, 3-4% B2O3, 2-4% SrO, and a loss on ignition of 1.5-2.5%.

5. The daily-use ceramics according to claim 1, characterized in that, The thickness ratio of the porous body layer, the intermediate body layer and the surface glaze layer is (70-80):(10-15):(10-15).

6. The daily-use ceramics according to claim 1, characterized in that, In step (2), the concentration of the slurry is 37-40 Baume degrees.

Images