High-strength domestic ceramic based on composite raw materials and low-temperature preparation process thereof

Abstract

The invention relates to a high-strength domestic ceramic based on a composite raw material and a low-temperature preparation process thereof, and belongs to the field of domestic ceramics. Aiming at the problems of insufficient strength, high cost, complex process and the like of the traditional domestic ceramic, the domestic ceramic is prepared by adopting composite raw materials such as Hunan feldspar, Longyan chinastone and the like, controlling the content of specific components and carrying out processes such as two-time wet ball milling, dehydration pugging, green body glazing and low-temperature firing. The ceramic has the advantages of high strength, stable thermal performance, simplified preparation process and low energy consumption, can reduce the damage in the production and use process, reduces the cost, is suitable for various daily use scenes, and improves the market competitiveness of the product.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of daily-use ceramics, and particularly relates to high-strength daily-use ceramics based on composite raw materials and a low-temperature preparation process thereof. BACKGROUND

[0002] Currently, daily-use ceramics face many challenges in production and application. The mechanical strength of traditional daily-use ceramics often cannot meet the actual needs, and breakage often occurs during transportation, handling and daily use, which not only increases the use cost of users, but also affects the market recognition of products. In terms of raw materials, many production enterprises rely on clay with a relatively high price as the main raw material, which leads to high raw material procurement cost, and long-distance transportation of these raw materials further increases the overall production cost. In addition, the traditional daily-use ceramic production process is relatively complex, for example, the green body needs to be subjected to plastic firing treatment before glazing in some processes, which not only prolongs the production cycle, but also makes the energy consumption in the firing process higher, which is neither economical nor in line with the industry development trend of energy saving and consumption reduction. These problems jointly restrict the quality improvement of daily-use ceramic products and the sustainable development of the industry, and therefore, it is of great significance to develop a daily-use ceramic with high strength, low cost and more optimal production process. SUMMARY

[0003] To achieve the above-mentioned purpose, the high-strength daily-use ceramic based on composite raw materials provided by the present application is made of the following raw materials by weight: Hunan feldspar 10-12 parts, Longyan porcelain stone 16-18 parts, Longyan raw ore 15-17 parts, 200-mesh quartz 16-18 parts, aluminum powder 1-3 parts, Xishuangbanna kaolin 6-8 parts, Longyan 60 6-8 parts, 325A 1-3 parts, and cement 325B 20-22 parts. The content of Al2O3 in the daily-use ceramic is 21-23%, the content of SiO2 is 66-68%, the bending strength is greater than or equal to 70 MPa, and the thermal expansion coefficient is 3.0x10 -6 / ℃ - 5.0x10 -6 / ℃.

[0004] Further, the content of Fe2O3 in the daily-use ceramic is 0.1-0.2%, and the content of TiO2 is not more than 0.005%.

[0005] Further, the content of K2O in the daily-use ceramic is 3.0-4.0%, and the content of Na2O is 1.0-1.2%.

[0006] Further, the content of P2O5 in the daily-use ceramic is 0.07-0.09%, and the content of MnO is 0.02-0.03%.

[0007] The application further provides a low-temperature preparation process of the high-strength daily-use ceramic based on composite raw materials. Hunan feldspar, Longyan porcelain stone, Longyan raw ore, 200-mesh quartz, aluminum powder, Xishuangbanna kaolin, and Longyan 60 are mixed according to weight parts, and first wet ball milling is performed, with a ball milling time of 4-6 hours, to obtain first slurry; 325A and cement 325 are added to the first slurry, and second wet ball milling is performed, with a ball milling time of 2-3 hours, to obtain second slurry; The second slurry is dehydrated to a water content of 20-25%, and then is pressed into a green body after being refined; Glaze is applied to the surface of the green body, and the glaze is made of the following raw materials according to weight parts: feldspar 41-43 parts, quartz 16-18 parts, bone stone 12-14 parts, Longyan 9-11 parts, silica ash 6-8 parts, aluminum 2-4 parts, Qin 1-3 parts, zinc 1-3 parts, and anorthite 3-5 parts; the green body after glazing is directly placed in a kiln, and is fired at 1050-1150 DEG C for 2-3 hours, and is naturally cooled to room temperature, to obtain the high-strength daily-use ceramic.

[0008] The high-strength daily-use ceramic based on composite raw materials and the low-temperature preparation process thereof have the following beneficial effects: The high-strength daily-use ceramic based on composite raw materials has the following advantages: the scientific raw material ratio effectively enhances the mechanical properties of the product, reduces the damage in the process of circulation and use, reasonably selects the raw material components, reduces the comprehensive cost of raw materials, is beneficial to improving the market competitiveness of the product, and optimizes the raw material composition to improve the thermal properties of the product, so that the product can adapt to more diverse use scenarios and expand the application range of the product. BRIEF DESCRIPTION OF DRAWINGS

[0009] Figure 1 is a flowchart of the low-temperature preparation process of the high-strength daily-use ceramic based on composite raw materials in an embodiment of the application.

[0010] The implementation, functional features and advantages of the application will be further described with reference to the embodiments and the accompanying drawings. DETAILED DESCRIPTION

[0011] In order to make the purpose, technical scheme and advantages of the application more clear, the application will be further described in detail below with reference to the drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the application and not to limit the application.

[0012] A high-strength daily-use ceramic based on composite raw materials is made of the following raw materials according to weight parts: Hunan feldspar 10-12 parts, Longyan porcelain stone 16-18 parts, Longyan raw ore 15-17 parts, 200 mesh quartz 16-18 parts, aluminum powder 1-3 parts, Xishuangfeng kaolin 6-8 parts, Longyan 60 6-8 parts, 325A 1-3 parts, cement 325B 20-22 parts; The content of Al2O3 in the daily-use ceramic is 21-23%, the content of SiO2 is 66-68%, the bending strength is greater than or equal to 70 MPa, and the thermal expansion coefficient is 3.0*10 -6 / ℃-5.0*10 -6 / ℃.

[0013] Specifically, in the raw material ratio of the high-strength daily-use ceramic based on composite raw materials, each component cooperates to build a body structure with high strength and stable thermal performance. Hunan feldspar, as a flux, contains K2O, Na2O and other components that promote the formation of glass phase during firing, reducing the firing temperature of the body and enhancing the bonding force between different particles, providing good density for the overall structure; Longyan porcelain stone and Longyan raw ore, as local advantage raw materials, are rich in quartz and aluminosilicate minerals, not only providing sufficient SiO2 and Al2O3 for the body, but also reducing transportation costs through local sourcing, meeting the economic demand for raw material optimization. 200 mesh quartz, as a barren raw material, forms a rigid skeleton in the body with its uniform particle size, effectively improving the body's resistance to deformation and reducing shrinkage during firing, laying a structural foundation for high strength; the introduction of aluminum powder increases the content of Al2O3 in the body, which reacts with SiO2 to form mullite crystals during firing. Mullite has high hardness and strength, greatly enhancing the body's bending resistance, enabling the final product to achieve a high level of bending strength. Xibianfu na kaolin, as a clay raw material, has good plasticity, ensuring the stability of the body forming process and avoiding defects such as cracking during forming. Meanwhile, the kaolin contained in it decomposes into mullite at high temperatures, further supplementing the reinforcing phase; Longyan 60 Ji, as another local mineral raw material, adjusts the ratio of SiO2 and Al2O3 in the body by cooperating with other aluminosilicate components, ensuring that they are stable within the range of 66-68% and 21-23% respectively. This ratio range balances the content of glass phase, mullite phase and quartz phase, forming a mutually supporting structure system. 325A and machine 325B, as functional additives, help optimize the sintering activity of the body and promote the close bonding between particles. Machine 325B improves the dispersibility and forming performance of the raw materials, reducing the air pores and defects in the body and further improving the structural density. It is this multi-component synergy that forms a stable structure in the body, with quartz as the skeleton, mullite as the reinforcing phase and glass phase as the binding phase, ensuring that the bending strength meets high standards and that the thermal expansion characteristics of each phase are reasonably controlled. Excessive standard may cause local gray or dark spots, damaging the visual aesthetics of the product.

[0014] The present application realizes the above content control by selecting low-impurity raw material components: the used Hunan feldspar, Longyan porcelain stone and Xiangxi high-kaolin are screened and pretreated, and the Fe2O3 and TiO2 impurities contained therein are less, and then the adsorption and regulation of trace impurities in the raw materials by 325A and other additives are combined, so that the content of Fe2O3 in the final product is stably controlled in the range of 0.1-0.2%, and the content of TiO2 is not more than 0.005%. This control range can not only avoid the color defects caused by impurities, ensure the cleanliness and consistency of the appearance of daily-use ceramics, but also provide a good substrate for subsequent glaze decoration - especially when using reduction flame high-temperature color glaze, low-impurity content can reduce the interference of mixed colors, ensure the stability and purity of red-wrapped and yellow-wrapped glazes, meet the quality requirements of daily-use ceramics for "fashion" and "aesthetics", and meet the goal of "improving product performance" in raw material research.

[0015] In one embodiment, the content of K2O in the daily-use ceramic is 3.0-4.0%, and the content of Na2O is 1.0-1.2%.

[0016] In this embodiment, the content of K2O and Na2O in the daily-use ceramic is limited to 3.0-4.0% and 1.0-1.2%, which is derived from the synergistic matching of raw material components and the precise matching of performance requirements. Among the used raw materials, Hunan feldspar serves as an important source of alkali metal oxides, and the K2O and Na2O contained therein play a key role in the firing process - they can reduce the melting temperature of the body, promote the formation and uniform distribution of the glass phase, and the glass phase as the medium connecting the skeletal phase (quartz, mullite) can enhance the bonding strength between particles and improve the densification of the body.

[0017] From the performance point of view, the K2O and Na2O in this content range can effectively adjust the thermal expansion characteristics of the body. The document mentions that by adjusting the proportion of raw materials, the thermal expansion coefficient of the ceramic product can be made more reasonable, and the thermal shock resistance can be enhanced, and K2O and Na2O as an important component of the glass phase, the content directly affects the thermal expansion behavior of the glass phase, and balances with the thermal expansion characteristics of the crystal phase such as quartz and mullite, and finally makes the overall thermal expansion coefficient stable at 3.0×10⁻ 6 -5.0×10⁻ 6 / ℃, ensuring that the product is not easy to crack when the temperature changes sharply, and adapting to high-temperature kitchen utensils and other application scenarios.

[0018] At the same time, the alkali metal oxide content in the range helps to support the low-temperature preparation process. The document mentions that optimizing the process can save firing costs and reduce energy consumption, and a reasonable ratio of K2O and Na2O can reduce the firing temperature of the body, which is suitable for the simplified process of "green glaze", and the sintering can be completed at a low temperature of 1050-1150°C, which not only ensures the strength of the product, but also realizes energy saving and consumption reduction, which is consistent with the goals of "cost optimization" and "process simplification" in raw material research.

[0019] In one embodiment, the content of P2O5 in the daily-use ceramic is 0.07-0.09%, and the content of MnO is 0.02-0.03%.

[0020] In this embodiment, the content of P2O5 in the daily-use ceramic is limited to 0.07-0.09%, and the content of MnO is limited to 0.02-0.03%. This control is based on the precise adjustment of raw material components and the coordinated adaptation of product functional requirements. From the source of raw materials, these trace components are mainly brought in by the use of Longyan porcelain stone, Longyan raw ore and other natural minerals. Through the selection and optimization of raw materials, the contents of the two are stable in the above range.

[0021] P2O5, as a trace fluxing component, can form a low-melting-point glass phase with other oxides in the body during firing, promoting the close combination between particles, and helping to improve the bonding strength between glaze and body, avoiding glaze falling off during use. This is consistent with the research direction of "optimizing raw material formula to reduce waste rate" in the document. MnO, as a coloring auxiliary component, can synergize with metal oxides in the glaze (such as the components required for wrapped red and wrapped yellow mentioned in the document) under reducing flame firing environment, to assist in stabilizing the presentation of glaze color and reducing color deviation caused by component fluctuations, which has an important supporting role in the development of stable reducing flame high-temperature color glaze technology, ensuring the stability and consistency of daily-use ceramics in terms of decoration.

[0022] At the same time, the control of this content range avoids the negative effects of excessive amounts: excessive P2O5 may cause a decrease in body strength, and excessive MnO may cause the product to appear mottled, affecting the appearance quality. Therefore, this limitation not only plays a positive role in trace components, but also guarantees the mechanical properties and appearance effect of the product, which is consistent with the company's goal of "improving product quality and expressiveness" in ceramic raw material research.

[0023] Referring to Table 1, the component ratio of a preferred embodiment of the present application is shown. Table 1 Referring to the Figure 1A flowchart of a low-temperature preparation process of high-strength daily-use ceramic based on composite raw materials is provided, and the process is used to prepare the high-strength daily-use ceramic based on composite raw materials, which comprises the following steps: S1, mixing Hunan feldspar, Longyan porcelain stone, Longyan raw ore, 200 mesh quartz, aluminum powder, Xishuangbanna kaolin, and Longyan 60 according to weight parts, and performing first wet ball milling for 4-6 hours to obtain first slurry; S2, adding 325A and machine 325 to the first slurry, and performing second wet ball milling for 2-3 hours to obtain second slurry; S3, dehydrating the second slurry to a water content of 20-25%, and then pressing the dehydrated slurry into a green body after refining; S4, applying glaze on the surface of the green body, wherein the glaze is made of the following raw materials according to weight parts: feldspar 41-43 parts, quartz 16-18 parts, bone stone 12-14 parts, Longyan 9-11 parts, silica ash 6-8 parts, aluminum 2-4 parts, qin 1-3 parts, zinc 1-3 parts, and anorthite 3-5 parts; and placing the green body after glazing directly in a kiln, and firing at 1050-1150°C for 2-3 hours, and naturally cooling to room temperature to obtain high-strength daily-use ceramic.

[0024] The first wet ball milling of S1 is 4-6 hours of ball milling for the main raw materials such as Hunan feldspar and Longyan porcelain stone, and the purpose is to finely grind and uniformly mix the raw material particles by wet grinding. The document mentions "accurate grasp of the characteristics of the raw materials" as the basis for process optimization, this step can break the agglomeration state of the raw material particles, and the fluxing components in feldspar, silicate and aluminate in porcelain stone and raw ore are effectively dispersed, which lays a uniform material foundation for the reaction of each component during subsequent sintering, and the refined particles can improve the density of the body, which is consistent with the goal of "strengthening mechanical properties".

[0025] The second wet ball milling of 2-3 hours after adding 325A and machine 325 in S2 is a further optimization of the raw material system. The document clearly distinguishes "first time dosing" and "second time dosing" in the mud formula, and the second ball milling can ensure that the functional components such as 325A and machine 325 are fully integrated with the previous slurry, avoiding performance fluctuations caused by local aggregation of additives. The wet environment can reduce the frictional heat between particles, protect the original properties of the raw materials, and improve the flowability and stability of the slurry, providing good conditions for subsequent forming, which is consistent with the research direction of "optimizing raw material formula to reduce waste rate".

[0026] The dehydration of S3 and the pressing green body step are key links according to the forming performance of the raw material. The document mentions that the improved forming performance of the raw material is better, and the water content is controlled at 20-25%, which can ensure that the mud has enough plasticity, is convenient for pressing forming, and can avoid the high water content from causing the green body to crack. The mud process can remove bubbles in the mud, make the particles more closely arranged, improve the green body strength, and provide support for the subsequent "green body direct glazing" - without the need for traditional processes to be first fired at 800 DEG C, directly meeting the structural stability requirements when glazing, embodying the advantages of "process simplification".

[0027] The glazing and firing process of S4 is the core of realizing "low temperature energy saving" and "performance guarantee". The document clearly compares the disadvantages of the traditional process "body plastic firing 800 DEG C after glazing", and this process directly glazes the green body, cooperates with the firing temperature of 1050-1150 DEG C, saves the plastic firing link, and significantly reduces the energy consumption (the document mentions that the energy consumption is reduced by 30%). The components such as feldspar and quartz in the glaze formula form a matching thermal expansion characteristic with the silicate in the body, avoiding the glaze cracking; at the same time, the components such as zinc and calcite assist in improving the gloss and stability of the glaze, which is in line with the development of stable reducing flame high temperature color glaze technology, ensuring that the glaze color is uniform and stable under low temperature firing. The firing time of 2-3 hours can ensure that the body is fully sintered (form the mullite phase and glass phase structure required for high strength), shorten the production cycle, and improve the efficiency, and finally realize the coordination of "high strength" and "low cost".

[0028] The above only describes the preferred embodiments of the present application, and does not limit the patent scope of the present application, and any equivalent structure or equivalent process transformation using the content of the specification and drawings, or direct or indirect application in other related technical fields, are also included in the patent protection scope of the present application.

Claims

1. A high-strength daily-use ceramic based on composite raw materials, characterized in that: Made from the following raw materials in parts by weight: 10-12 parts of Hunan feldspar, 16-18 parts of Longyan porcelain stone, 15-17 parts of Longyan raw ore, 16-18 parts of 200 mesh quartz, 1-3 parts of aluminum powder, 6-8 parts of Xishuangfu Nakaolin, 6-8 parts of Longyan 60ji, 1-3 parts of 325A, and 20-22 parts of machine-made 325B; The daily-use ceramic has an Al2O3 content of 21-23%, a SiO2 content of 66-68%, a flexural strength of ≥70 MPa, and a thermal expansion coefficient of 3.0×10 -6 / ℃ - 5.0×10 -6 / ℃.

2. The high-strength daily-use ceramic based on composite raw materials according to claim 1, characterized in that: The content of Fe2O3 in the daily-use ceramic is 0.1-0.2%, and the content of TiO2 does not exceed 0.005%.

3. The high-strength daily-use ceramic based on composite raw materials according to claim 1, characterized in that: The content of K2O in the daily-use ceramic is 3.0-4.0%, and the content of Na2O is 1.0-1.2%.

4. The high-strength daily-use ceramic based on composite raw materials according to claim 1, characterized in that: The content of P2O5 in the daily-use ceramic is 0.07-0.09%, and the content of MnO is 0.02-0.03%.

5. A low-temperature preparation process for high-strength daily-use ceramics based on composite raw materials, for preparing the high-strength daily-use ceramics based on composite raw materials according to any one of claims 1 to 4, characterized in that: The following steps are involved: Hunan feldspar, Longyan porcelain stone, Longyan ore, 200 mesh quartz, aluminum powder, Xishuangfu kaolin, and Longyan 60-year-old are mixed according to weight, and the mixture is wet-milled for a first time for 4-6 hours to obtain a first slurry; Add 325A and mechanical 325 to the first slurry and perform a second wet ball milling for 2-3 hours to obtain a second slurry; Dehydrate the second slurry to a moisture content of 20-25%, knead the slurry and press it into a green body; A glaze is applied on the surface of a green body, wherein the glaze is made of the following raw materials in parts by weight: 41-43 parts of feldspar, 16-18 parts of quartz, 12-14 parts of bone stone, 9-11 parts of longyan, 6-8 parts of silica fume, 2-4 parts of aluminum, 1-3 parts of titanium, 1-3 parts of zinc, and 3-5 parts of calcite; the glazed green body is directly placed in a kiln, fired at 1050-1150° C. for 2-3 hours, and naturally cooled to room temperature to obtain high-strength daily-use ceramics.

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