High-strength ceramic rock plate and preparation method thereof

By sintering in a solar sintering furnace and utilizing lattice vibration and optical transition to generate mullite and quartz crystals, the problems of high temperature energy consumption and low strength in the preparation of ceramic rock slabs are solved, and the preparation of high-strength ceramic rock slabs is achieved.

CN120757363APending Publication Date: 2025-10-10WUHAN UNIV OF TECH
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Patent Information

Application Number
CN202510952797.3
Authority / Receiving Office
CN · China
Patent Type
Applications(China)
Current Assignee / Owner
Filing Date
2025-07-10
Publication Date
2025-10-10

AI Technical Summary

Technical Problem

The existing ceramic rock slab preparation process has problems such as high firing temperature, high energy consumption, large carbon emissions and low strength of the ceramic rock slab.

Method used

The sintering is carried out in a solar sintering furnace. The lattice absorbs solar energy to generate lattice vibration, and the high-energy photons in the sunlight are used for optical transitions and electron-phonon scattering, thereby reducing the firing temperature and generating mullite and quartz crystals at a lower temperature. The needle-shaped mullite and quartz form the skeleton of the ceramic rock plate to improve the flexural strength.

Benefits of technology

It significantly reduces the firing temperature of ceramic rock slabs and improves the flexural strength of ceramic rock slabs, and has good application prospects.

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Abstract

The invention discloses a high-strength ceramic rock plate and a preparation method thereof, and belongs to the technical field of ceramic materials. According to the invention, sintering is carried out in a solar sintering furnace body, such that the sintering temperature of the ceramic rock plate can be substantially reduced because crystal lattices absorb solar energy to generate crystal lattice vibration, high-energy photons in sunlight are absorbed by electrons in a ceramic rock plate blank material to generate optical transition, and then electron-phonon scattering is carried out, such that the sintering temperature of the ceramic rock plate can be substantially reduced. Energy is transferred from high-energy electrons to crystal lattices to provide heat energy, so that main crystal phases, namely mullite and quartz crystals, of the ceramic rock plate can be generated at a relatively low temperature; besides, a large amount of needle-rod-shaped mullite in the fired ceramic rock plate is embedded in a glass phase to form a framework in the ceramic rock plate together with quartz, and the framework has good stability and can play a good role in reinforcing and toughening when the rock plate is impacted by external force, so that the breaking strength of the ceramic rock plate is improved. Therefore, the method has a good application prospect.
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Description

Technical Field

[0001] The present invention belongs to the technical field of ceramic materials, and specifically relates to a high-strength ceramic rock plate and a preparation method thereof. Background Art

[0002] Ceramic rock slabs are a new building material, characterized by wear resistance, water resistance, and pollution resistance, making them irreplaceable for floor paving and building wall decoration. However, the firing process in traditional electric furnaces consumes large amounts of fossil energy, resulting in high energy consumption and carbon emissions. Solar energy, as a representative green and clean energy source, offers significant advantages. It is the most widely distributed energy source on Earth and possesses enormous development potential, making it inexhaustible. Therefore, utilizing solar energy to replace traditional fossil energy in the firing of building ceramics is an inevitable trend.

[0003] Currently, when using traditional fossil energy to fire ceramic rock slabs, the firing temperature range is between 1130-1280°C, and the flexural strength of the ceramic rock slabs is between 35-90 MPa. For example, Chinese invention application document CN115849888A discloses a high-strength and high-toughness ceramic rock slab and its preparation method. The high-strength and high-toughness ceramic rock slab is prepared using potassium feldspar, sodium feldspar, and Suzhou clay as the main raw materials. During the preparation process, the raw materials are placed in a roller kiln for sintering at a firing temperature between 1180-1280°C, and the flexural strength is between 50 and 90 MPa. Chinese invention application document CN114436625A discloses an ultra-thin ceramic rock slab and its preparation method. The ceramic rock slab is prepared using clay, ultrafine corundum, potassium feldspar, and sodium feldspar as the main raw materials. During the preparation process, the raw materials are placed in a roller kiln for sintering at a firing temperature between 1180-1220°C, and the flexural strength is between 70 and 95 MPa.

[0004] The above patent documents all use traditional fossil energy and traditional kilns to fire ceramic rock slabs, which have problems such as high firing temperature, high energy consumption, large carbon emissions, and low strength of the ceramic rock slabs. Summary of the Invention

[0005] The purpose of the present invention is to provide a high-strength ceramic rock plate and a preparation method thereof, which is used to solve the problems of high firing temperature, high energy consumption, high carbon emissions and low strength of ceramic rock plates in the existing ceramic rock plate preparation process.

[0006] In a first aspect, the present invention provides a method for preparing a high-strength ceramic rock slab, comprising the following steps: providing a ceramic rock slab blank; subjecting the ceramic rock slab blank to ball milling, spray granulation, homogenization and aging to obtain an intermediate material; subjecting the intermediate material to molding and drying to obtain a blank; placing the blank in a solar sintering furnace for sintering to obtain a high-strength ceramic rock slab; wherein, in terms of mass percentage, the ceramic rock slab blank comprises the following raw materials: 5-10wt% of potassium feldspar, 10-20wt% of sodium feldspar, 55-75wt% of Suzhou kaolin, 1-5wt% of talc, 1-5wt% of wollastonite, and 1-10wt% of quartz.

[0007] In the present invention, the firing temperature of the ceramic rock slab can be significantly reduced by sintering in a solar sintering furnace. This is because the crystal lattice absorbs solar energy to cause lattice vibration, and the high-energy photons in the sunlight are absorbed by the electrons in the ceramic rock slab blank material to cause optical transitions. Subsequently, through electron-phonon scattering, energy is transferred from the high-energy electrons to the crystal lattice to provide thermal energy, so that the main crystal phases of the ceramic rock slab - mullite and quartz crystals - can be generated at a lower temperature; in addition, a large amount of needle-shaped mullite in the fired ceramic rock slab is embedded in the glass phase and together with quartz constitutes the skeleton inside the ceramic rock slab. This skeleton has good stability and can play a better role in strengthening and toughening the rock slab when it is impacted by external force, thereby improving the flexural strength of the ceramic rock slab.

[0008] In some embodiments, the chemical composition of potassium feldspar includes, by mass percentage, 60-75 wt% SiO2, 8-15 wt% K2O3, 10-20 wt% Al2O3, 2-5 wt% Na2O, and 0-5 wt% impurities; the chemical composition of sodium feldspar includes, 60-75 wt% SiO2, 10-20 wt% Al2O3, 10-20 wt% Na2O, and 0-5 wt% impurities.

[0009] In some embodiments, the chemical composition of Suzhou kaolin includes, by mass percentage, 50-60 wt% SiO2 and 40-50 wt% Al2O3; the chemical composition of talc includes 55-65 wt% SiO2, 25-45 wt% MgO, and 0-10 wt% impurities.

[0010] In some embodiments, the chemical composition of wollastonite includes, by weight percentage, 40-60 wt% SiO2, 40-60 wt% CaO, and 0-10 wt% impurities; the chemical composition of quartz includes, by weight percentage, 96-100 wt% SiO2, and 0-4 wt% impurities.

[0011] In some embodiments, in the steps of subjecting the ceramic rock slab blank to ball milling, spray granulation, and homogenization and aging, the ball milling specifically includes: controlling the material ball mass ratio to 1: (1-3), ball milling for 4-8 hours; after the ball milling is completed, passing through a 200-300 mesh sieve.

[0012] In some embodiments, in the steps of subjecting the ceramic rock slab blank to ball milling, spray granulation, and homogenization and aging, the spray granulation specifically includes: adding 1-3 wt% of water and then spray granulating.

[0013] In some embodiments, in the steps of subjecting the ceramic rock slab blank to ball milling, spray granulation, and homogenization and aging, the homogenization and aging specifically include: aging at a temperature of 25-30°C for 40-60 hours.

[0014] In some embodiments, in the steps of molding and drying the intermediate material, the molding process specifically includes: a molding pressure of 30-50 kN; and the drying process specifically includes: drying at a temperature of 80-90° C. for 24-36 hours.

[0015] In some embodiments, in the step of placing the green body in a solar sintering furnace for sintering treatment, the sintering treatment specifically includes: first, keeping the temperature at 250-350°C for 4-6 minutes; then heating to 750-850°C at a heating rate of 40-60°C / min, and keeping it for 3-5 minutes; then continuing to heat at a heating rate of 40-60°C / min, and keeping it for 3-5 minutes after each heating of 40-60°C, until the temperature reaches 1000~1100°C, and keeping it for 8-12 minutes; finally, cooling to room temperature with the furnace.

[0016] In a second aspect, the present invention provides a high-strength ceramic rock plate prepared by any of the above-mentioned preparation methods.

[0017] The beneficial effects of the present invention are as follows: Different from the prior art, the present invention can significantly reduce the firing temperature of ceramic rock slabs by sintering in a solar sintering furnace. This is because the lattice absorbs solar energy and generates lattice vibrations. High-energy photons in sunlight are absorbed by electrons in the ceramic rock slab blank material to generate optical transitions. Subsequently, through electron-phonon scattering, energy is transferred from high-energy electrons to the lattice to provide heat energy. Therefore, the main crystal phases of the ceramic rock slab - mullite and quartz crystals - can be generated at a lower temperature. In addition, a large amount of needle-shaped mullite in the fired ceramic rock slab is embedded in the glass phase and together with quartz forms the internal skeleton of the ceramic rock slab. This skeleton has good stability and can play a good role in strengthening and toughening the rock slab when it is impacted by external forces, thereby improving the flexural strength of the ceramic rock slab. Therefore, it has good application prospects. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a flow chart of the method for preparing high-strength ceramic rock slabs of the present invention; Figure 2 Schematic diagram of the structure of the solar sintering furnace in the present invention; Figure 3 This is a cross-sectional SEM morphology image of the high-strength ceramic rock plate prepared in Example 2 of the present invention; Figure 4 This is the XRD pattern of the high-strength ceramic rock plate prepared in Example 2 of the present invention; in, Figure 2 The reference numerals in the figures have the following meanings: 1: Solar simulator; 11: Xenon lamp; 12: Parabolic concentrator; 2: Sintering furnace, 21: Green body. DETAILED DESCRIPTION

[0019] 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 creative efforts are within the scope of protection of the present invention.

[0020] For experimental methods in the examples where specific conditions are not specified, generally conventional conditions and conditions described in the manual or conditions recommended by the manufacturer were followed. The general equipment, materials, reagents, etc. used were all commercially available unless otherwise specified.

[0021] At present, the existing ceramic rock slab preparation process has problems such as high firing temperature, high energy consumption, large carbon emissions, and low strength of the ceramic rock slab.

[0022] In order to solve the problems of high firing temperature, high energy consumption, large carbon emissions, and low strength of ceramic rock slabs in the existing ceramic rock slab preparation process, the present invention provides a high-strength ceramic rock slab and a preparation method thereof.

[0023] In a first aspect, the present invention provides a method for preparing a high-strength ceramic rock slab, comprising the following steps: providing a ceramic rock slab blank; subjecting the ceramic rock slab blank to ball milling, spray granulation, homogenization and aging to obtain an intermediate material; subjecting the intermediate material to molding and drying to obtain a blank; placing the blank in a solar sintering furnace for sintering to obtain a high-strength ceramic rock slab; wherein, in terms of mass percentage, the ceramic rock slab blank comprises the following raw materials: 5-10wt% of potassium feldspar, 10-20wt% of sodium feldspar, 55-75wt% of Suzhou kaolin, 1-5wt% of talc, 1-5wt% of wollastonite, and 1-10wt% of quartz.

[0024] The preparation method of the high-strength ceramic rock plate provided by the application can significantly reduce the sintering temperature of the ceramic rock plate by sintering in a solar sintering furnace, because the lattice absorbs solar energy to vibrate, high-energy photons in the sunlight are absorbed by electrons in the ceramic rock plate blank material to cause optical transition, and then energy is transferred from high-energy electrons to the lattice through electron-phonon scattering to provide heat energy, so that the main crystal phase of the ceramic rock plate, mullite and quartz crystals, can be generated at a lower temperature; in addition, a large number of needle-like mullite in the sintered ceramic rock plate is embedded in the glass phase to form a framework with quartz in the interior of the ceramic rock plate, and the framework has good stability and can play a good reinforcing and toughening role when the rock plate is impacted by external force, thereby improving the bending strength of the ceramic rock plate.

[0025] In some embodiments, the chemical composition of the potassium feldspar includes, in mass percentage: SiO260-75wt%, K2O 8-15wt%, Al2O310-20wt%, Na2O 2-5wt%, impurities 0-5wt%; the chemical composition of the sodium feldspar includes: SiO260-75wt%, Al2O310-20wt%, Na2O 10-20wt%, impurities 0-5wt%.

[0026] In the application, the inventors have found that by selecting potassium feldspar and sodium feldspar with specific component contents, the strength of the ceramic rock plate prepared can be significantly improved in cooperation with other raw material components.

[0027] In some embodiments, the chemical composition of the Suzhou kaolin includes, in mass percentage: SiO250-60wt%, Al2O340-50wt%; the chemical composition of the talc includes: SiO255-65wt%, MgO 25-45wt%, impurities 0-10wt%.

[0028] In the application, the inventors have found that by selecting Suzhou kaolin and talc with specific component contents, the strength of the ceramic rock plate prepared can be significantly improved in cooperation with other raw material components.

[0029] In some embodiments, the chemical composition of the wollastonite includes, in mass percentage: SiO240-60wt%, CaO 40-60wt%, impurities 0-10wt%; the chemical composition of the quartz includes: SiO296-100wt%, impurities 0-4wt%.

[0030] In the application, the inventors have found that by selecting wollastonite and quartz with specific component contents, the strength of the ceramic rock plate prepared can be significantly improved in cooperation with other raw material components.

[0031] In some embodiments, in the steps of subjecting the ceramic rock slab blank to ball milling, spray granulation, and homogenization and aging, the ball milling treatment specifically includes: controlling the material ball mass ratio to 1: (1-3), preferably 1:2; ball milling for 4-8 hours, preferably 6 hours; after the ball milling is completed, passing through a 200-300 mesh sieve, preferably a 250 mesh sieve.

[0032] In the present invention, by ball milling and screening the blank, the specific surface area of ​​the material can be increased, which is convenient for subsequent processing and improves the performance of the material.

[0033] In some embodiments, in the steps of subjecting the ceramic rock slab blank to ball milling, spray granulation, and homogenization and aging, the spray granulation specifically includes: adding 1-3 wt% (preferably 2 wt%) of water and then performing spray granulation.

[0034] In the present invention, the amount of water added is controlled within a specific range, thereby facilitating better granulation of the material.

[0035] In some embodiments, in the steps of subjecting the ceramic rock slab blank to ball milling, spray granulation, and homogenization aging, the homogenization aging specifically includes: aging at a temperature of 25-30°C (preferably 28°C) for 40-60h, preferably 48h.

[0036] In the present invention, by controlling the temperature of homogenization and aging within a specific range, not only the uniformity and plasticity of the raw materials are improved, but also the chemical and physical properties of the raw materials are optimized, thereby providing a guarantee for the production of high-quality ceramic rock slabs.

[0037] In some embodiments, in the steps of molding and drying the intermediate material, the molding process specifically includes: a molding pressure of 30-50 kN, preferably 40 kN; the drying process specifically includes: drying at a temperature of 80-90°C (preferably 85°C) for 24-36 hours, preferably 30 hours.

[0038] In the present invention, a green body with better performance can be obtained by controlling the molding pressure, the temperature and the time of the drying process within a specific range.

[0039] In some embodiments, in the step of placing the green body in a solar sintering furnace for sintering treatment, the sintering treatment specifically includes: first, keeping the temperature at 250-350°C for 4-6 minutes; then heating to 750-850°C at a heating rate of 40-60°C / min, and keeping it for 3-5 minutes; then continuing to heat at a heating rate of 40-60°C / min, and keeping it for 3-5 minutes after each heating of 40-60°C, until the temperature reaches 1000~1100°C, and keeping it for 8-12 minutes; finally, cooling to room temperature with the furnace.

[0040] In some preferred embodiments, in the step of placing the green body in a solar sintering furnace for sintering treatment, the sintering treatment specifically includes: first, keeping the temperature at 300°C for 5 minutes; then heating to 800°C at a heating rate of 50°C / min and keeping it for 4 minutes; then continuing to heat at a heating rate of 50°C / min, and keeping it for 4 minutes after each 50°C increase, until the temperature reaches 1100°C, and keeping it for 10 minutes; finally, cooling to room temperature with the furnace.

[0041] In the present invention, ceramic rock plates with higher strength and better performance can be obtained by gradually increasing the temperature and calcining in a solar sintering furnace.

[0042] In a second aspect, the present invention provides a high-strength ceramic rock plate prepared by any of the above-mentioned preparation methods.

[0043] The high-strength ceramic rock plate provided by the present invention has high flexural strength.

[0044] Some specific embodiments are listed below. It should be noted that the embodiments described below are exemplary and are only used to explain the present invention, and should not be understood as limiting the present invention.

[0045] See also Figure 1 , which is a flow chart of the preparation method of the high-strength ceramic rock slab of the present invention. Specifically, the preparation method includes the following steps: providing a ceramic rock slab blank; subjecting the ceramic rock slab blank to ball milling, spray granulation, and homogenization and aging to obtain an intermediate material; forming and drying the intermediate material to obtain a green body; and sintering the green body in a solar sintering furnace to obtain a high-strength ceramic rock slab.

[0046] Please continue reading Figure 2 , which is a structural schematic diagram of the solar sintering furnace body in the present invention, the solar sintering furnace body includes a solar simulator 1 and a sintering furnace body 2 arranged side by side, a xenon lamp 11 is provided in the solar simulator 1, a parabolic concentrator 12 is provided at one end of the xenon lamp 11, and a blank 21 is placed in the sintering furnace body 2; the working principle of the solar sintering furnace body is as follows: the light emitted by the xenon lamp 11 in the solar simulator 1 enters the sintering furnace body 2 through the parabolic concentrator 12, and the blank 21 is fired.

[0047] In the present invention, the chemical composition of potassium feldspar includes, by mass percentage, 67.13wt% of SiO2, 10.43wt% of K2O, 17.84wt% of Al2O3, 3.93wt% of Na2O, and 0.67wt% of impurities; the chemical composition of sodium feldspar includes 67.04wt% of SiO2, 18.81wt% of Al2O3, 12.58wt% of Na2O, and 1.57wt% of impurities; the chemical composition of Suzhou kaolin includes 53.96wt% of SiO2 and 46.04wt% of Al2O3; the chemical composition of talc includes 60.76wt% of SiO2, 31.98wt% of MgO, and 7.26wt% of impurities; the chemical composition of wollastonite includes 47.92wt% of SiO2, 43.57wt% of CaO, and 8.51wt% of impurities; and the chemical composition of quartz includes 98.56wt% of SiO2 and 1.44wt% of impurities.

[0048] Example 1 A method for preparing a high-strength ceramic rock plate comprises the following steps: S1. Provide a ceramic rock slab blank, which comprises the following raw materials, calculated by mass percentage: 5wt% potassium feldspar, 20wt% sodium feldspar, 68wt% Suzhou kaolin, 2wt% talc, 1wt% wollastonite, and 4wt% quartz; S2. The ceramic rock slab blank in step S1 is placed in a ball mill, with a material-ball mass ratio of 1:2, and ball milled for 6 hours. After the ball milling, the mixture is sieved through a 250-mesh sieve to obtain a mixed material. 2 wt% of water is added to the mixed material, and then spray granulated. The granulated material is sealed and stored in a container, and aged at 28° C. for 48 hours to obtain an intermediate material. S3, pouring the intermediate material in step S2 into a mold and pressing it under a pressure of 40 kN, and then drying it in a constant temperature drying oven at 85° C. for 30 hours to obtain a green body; S4. Place the green body in a solar sintering furnace for sintering treatment. Specifically, first keep the temperature at 300℃ for 5 minutes; then heat it to 800℃ at a heating rate of 50℃ / min and keep it for 4 minutes; then continue to heat it at a heating rate of 50℃ / min, and keep it for 4 minutes after each 50℃ increase, until it reaches 1100℃ and keep it for 10 minutes; finally cool it to room temperature with the furnace to obtain a high-strength ceramic rock plate.

[0049] Example 2 A method for preparing a high-strength ceramic rock plate comprises the following steps: S1. Provide a ceramic rock slab blank, which comprises the following raw materials, calculated by mass percentage: 8wt% potassium feldspar, 17wt% sodium feldspar, 68wt% Suzhou kaolin, 2wt% talc, 1wt% wollastonite, and 4wt% quartz; S2. The ceramic rock slab blank in step S1 is placed in a ball mill, with a material-ball mass ratio of 1:2, and ball milled for 6 hours. After the ball milling, the mixture is sieved through a 250-mesh sieve to obtain a mixed material. 2 wt% of water is added to the mixed material, and then spray granulated. The granulated material is sealed and stored in a container, and aged at 28° C. for 48 hours to obtain an intermediate material. S3, pouring the intermediate material in step S2 into a mold and pressing it under a pressure of 40 kN, and then drying it in a constant temperature drying oven at 85° C. for 30 hours to obtain a green body; S4. Place the green body in a solar sintering furnace for sintering treatment. Specifically, first keep the temperature at 300℃ for 5 minutes; then heat it to 800℃ at a heating rate of 50℃ / min and keep it for 4 minutes; then continue to heat it at a heating rate of 50℃ / min, and keep it for 4 minutes after each 50℃ increase, until it reaches 1100℃ and keep it for 10 minutes; finally cool it to room temperature with the furnace to obtain a high-strength ceramic rock plate.

[0050] Example 3 A method for preparing a high-strength ceramic rock plate comprises the following steps: S1. Provide a ceramic rock slab blank, which comprises the following raw materials, calculated by mass percentage: 10 wt % of potassium feldspar, 15 wt % of sodium feldspar, 68 wt % of Suzhou kaolin, 2 wt % of talc, 1 wt % of wollastonite, and 4 wt % of quartz. S2. The ceramic rock slab blank in step S1 is placed in a ball mill, with a material-ball mass ratio of 1:2, and ball milled for 6 hours. After the ball milling, the mixture is sieved through a 250-mesh sieve to obtain a mixed material. 2 wt% of water is added to the mixed material, and then spray granulated. The granulated material is sealed and stored in a container, and aged at 28° C. for 48 hours to obtain an intermediate material. S3, pouring the intermediate material in step S2 into a mold and pressing it under a pressure of 40 kN, and then drying it in a constant temperature drying oven at 85° C. for 30 hours to obtain a green body; S4. Place the green body in a solar sintering furnace for sintering treatment. Specifically, first keep the temperature at 300℃ for 5 minutes; then heat it to 800℃ at a heating rate of 50℃ / min and keep it for 4 minutes; then continue to heat it at a heating rate of 50℃ / min, and keep it for 4 minutes after each 50℃ increase, until it reaches 1100℃ and keep it for 10 minutes; finally cool it to room temperature with the furnace to obtain a high-strength ceramic rock plate.

[0051] Comparative Example 1 In this comparative example, the preparation method of the ceramic rock slab is basically the same as that in Example 2, except that, in step S4, conventional firing in an electric furnace is adopted, the firing temperature is 1180°C, and the firing time is 12.75h.

[0052] Comparative Example 2 In this comparative example, the preparation method of the ceramic rock slab is basically the same as that in Example 2, except that in step S4, the temperature is directly increased from 300°C to 1100°C at a heating rate of 50°C / min and kept warm for 0.17h.

[0053] Performance Testing The high strength ceramic rock plate prepared in Example 2 was subjected to cross-sectional SEM and XRD tests, and the results were as follows: Figure 3 and 4 shown.

[0054] from Figure 3 and 4 It can be seen that the main crystal phases of the ceramic rock slab are mullite and quartz crystals, which significantly improve the flexural strength of the ceramic rock slab.

[0055] The ceramic rock slabs prepared in Examples 1-3 and Comparative Examples 1-2 were tested using the three-point bending method and static weighing. The test results are shown in Table 1.

[0056] Table 1 Performance test results

[0057] It can be seen from Table 1 that compared with the comparative example, the ceramic rock slab obtained by adopting a specific firing process in the present invention has a higher flexural strength, between 95-100 MPa; the firing cycle is 50-70 min, and the water absorption rate is 0.10-0.20%, reaching the T / CBCSA 40-2021 "Ceramic Rock Slab" standard, and therefore has good application prospects.

[0058] It should be noted that the above embodiments all belong to the same inventive concept, and the description of each embodiment has its own focus. For any details not described in individual embodiments, reference may be made to the description in other embodiments.

[0059] The above-described embodiments merely illustrate the implementation methods of the present invention. While the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent. It should be noted that a person skilled in the art would be able to make various modifications and improvements without departing from the spirit of the present invention, all of which fall within the scope of protection of the present invention. Therefore, the scope of protection of the patent for this invention shall be determined by the appended claims.

Claims

1. A method for preparing a high-strength ceramic rock plate, characterized in that: The steps include: Provide ceramic rock slab blanks; The ceramic rock slab blank is subjected to ball milling, spray granulation, homogenization and aging to obtain an intermediate material; The intermediate material is subjected to molding and drying to obtain a green body; The green body is placed in a solar sintering furnace for sintering to obtain a high-strength ceramic rock plate; Among them, the ceramic rock slab blank includes the following raw materials, in terms of mass percentage: 5-10wt% of potassium feldspar, 10-20wt% of sodium feldspar, 55-75wt% of Suzhou kaolin, 1-5wt% of talc, 1-5wt% of wollastonite, and 1-10wt% of quartz.

2. The method for preparing a high-strength ceramic rock plate according to claim 1, characterized in that: The chemical composition of the potassium feldspar includes, in percentage by mass: SiO2 60-75wt%, K2O 8-15wt%, Al2O3 10-20wt%, Na2O 2-5wt%, and impurities 0-5wt%; The chemical composition of the albite includes: SiO2 60-75wt%, Al2O3 10-20wt%, Na2O 10-20wt%, and impurities 0-5wt%.

3. The method for preparing a high-strength ceramic rock plate according to claim 1, wherein: In terms of mass percentage, the chemical composition of the Suzhou kaolin includes: SiO2 50-60wt%, Al2O3 40-50wt%; The chemical composition of the talc includes: SiO2 55-65wt%, MgO 25-45wt%, and impurities 0-10wt%.

4. The method for preparing a high-strength ceramic rock plate according to claim 1, wherein: The chemical composition of the wollastonite includes, in percentage by mass: SiO2 40-60wt%, CaO 40-60wt%, and impurities 0-10wt%; The chemical composition of the quartz includes: SiO2 96-100wt%, impurities 0-4wt%.

5. The method for preparing a high-strength ceramic rock plate according to claim 1, characterized in that: In the steps of subjecting the ceramic rock slab blank to ball milling, spray granulation, and homogenization and aging, the ball milling treatment specifically includes: controlling the material ball mass ratio to be 1: (1-3), ball milling for 4-8 hours; after the ball milling is completed, passing through a 200-300 mesh sieve.

6. The method for preparing a high-strength ceramic rock plate according to claim 1, characterized in that: In the steps of subjecting the ceramic rock slab blank to ball milling, spray granulation, and homogenization and aging, the spray granulation specifically includes: adding 1-3 wt% of water and then spray granulating.

7. The method for preparing a high-strength ceramic rock plate according to claim 1, characterized in that: In the steps of subjecting the ceramic rock slab blank to ball milling, spray granulation, and homogenization and aging, the homogenization and aging specifically include: aging at a temperature of 25-30° C. for 40-60 hours.

8. The method for preparing a high-strength ceramic rock plate according to claim 1, characterized in that: In the step of molding and drying the intermediate material, the molding process specifically includes: a molding pressure of 30-50 kN; The drying process specifically includes: drying at a temperature of 80-90° C. for 24-36 hours.

9. The method for preparing a high-strength ceramic rock plate according to claim 1, characterized in that: In the step of placing the green body in a solar sintering furnace for sintering, the sintering treatment specifically includes: first, keeping the temperature at 250-350°C for 4-6 minutes; then heating to 750-850°C at a heating rate of 40-60°C / min, and keeping the temperature for 3-5 minutes; then continuing to heat at a heating rate of 40-60°C / min, and keeping the temperature for 3-5 minutes after each 40-60°C increase, until the temperature reaches 1000-1100°C, and keeping the temperature for 8-12 minutes; finally, cooling to room temperature with the furnace.

10. A high-strength ceramic rock plate, characterized in that: The method is prepared according to any one of claims 1 to 9.

Citation Information

Patent Citations

  • Ultrathin ceramic rock plate and preparation method thereof

    CN114436625A

  • High-strength and high-toughness ceramic rock plate and preparation method thereof

    CN115849888A