High-strength light and thin ceramic tile and preparation method thereof

Abstract

The invention relates to a high-strength light and thin ceramic tile and a preparation method thereof, and belongs to the technical field of building ceramic preparation. The high-strength light and thin ceramic tile is mainly prepared from the following components in parts by weight: 20 to 25 parts of kaolin, 8 to 10 parts of clay, 10 to 12 parts of potassium feldspar, 20 to 22 parts of albite, 12 to 15 parts of spodumene, 1.2 to 1.5 parts of a toughening agent, 8.5 to 12.8 parts of an accelerant and 3.5 to 7 parts of a reinforcing agent. The ceramic tile prepared in the invention has good mechanical properties and high strength while ensuring lightness and thinness.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of building ceramic preparation and relates to a high-strength light and thin ceramic tile and a preparation method thereof. BACKGROUND

[0002] The ceramic tile is a kind of acid and alkali resistant ceramic or stone building or decoration material formed through the processes of grinding, mixing, pressing, glazing and sintering of refractory metal oxides and semi-metal oxides. The raw materials are mainly clay and quartz sand. The ceramic tile is widely used as an important building decoration material due to its high strength, high hardness, high temperature resistance and corrosion resistance.

[0003] The light and thin ceramic tile not only has the advantages of the half ceramic tile, but also is much thinner than the traditional ceramic tile. The heat transfer is fast and uniform during the sintering process, thereby reducing the sintering temperature and the holding time and achieving good energy-saving performance. However, the thickness of the light and thin ceramic tile is required to be thin, and the green body is prone to crack and deformation during the transportation process, thereby increasing the influence of the sintering speed and the uniformity of the kiln temperature on the quality of the ceramic tile. It is more difficult to consider the strength of the light and thin ceramic tile in addition to the brittleness of the traditional ceramic tile.

[0004] Therefore, the successful preparation of the light and thin ceramic tile needs to be controlled from the aspects of raw material selection and proportioning, forming process, sintering system and kiln optimization. SUMMARY

[0005] The main purpose of the application is to provide a high-strength light and thin ceramic tile and a preparation method thereof.

[0006] The application adopts the following technical scheme to achieve the above purpose. A high-strength light and thin ceramic tile is prepared mainly from the following components: 20-25 parts by weight of kaolin, 8-10 parts by weight of clay, 10-12 parts by weight of potassium feldspar, 20-22 parts by weight of sodium feldspar, 12-15 parts by weight of spodumene, 1.2-1.5 parts by weight of a toughening agent, 8.5-12.8 parts by weight of a promoter and 3.5-7 parts by weight of a reinforcing agent.

[0007] Preferably, the toughening agent is polyvinyl alcohol.

[0008] Preferably, the promoter contains 8-12 parts by weight of modified talc powder and 0.5-0.8 parts by weight of aluminum metaphosphate.

[0009] Further preferably, the preparation method of the modified talc powder is as follows. Mixing talc powder 10-20 parts by weight, molybdenum disulfide 2-2.5 parts by weight, white carbon black 4-5 parts by weight, isopropyl di-stearoyl aluminum acid ester 1-1.5 parts by weight, then place in 120℃ condition, keep grinding for 30min, cool down, then continue grinding for 15-20min at room temperature, the modified talc powder is obtained.

[0010] Preferably, the reinforcing agent contains silicon nitride 0.5-1 parts by weight, hydroxypropyl starch ether 2-3 parts by weight, cerium dioxide 1-3 parts by weight.

[0011] The application provides a preparation method of the high-strength ceramic tile, mainly comprising the following steps: The preparation method mainly comprises the following steps: Step 1, ball milling: weigh kaolin, clay, potassium feldspar, sodium feldspar, spodumene, accelerator and reinforcing agent, mix to obtain a mixture; the mixture, balls and water are placed in a ball mill in a ratio of 1:2:0.5 for wet grinding, and then a toughening agent is added for continuous grinding to obtain a slurry for standby; Step 2, iron removal: the slurry after ball milling is discharged, passed through a vibrating screen, removed by an iron removal machine, and aged for 12-15h to obtain a mud slurry for standby; Step 3, powder preparation: the mud slurry is dried by a spray drying tower to obtain a powder with a water content of 5-7%, and the powder is aged for 20h for standby; Step 4, shaping: the powder after aging is pressed into a green body by a high-pressure press under a pressure of 750-800kg / cm 2 ; Step 5, drying: the green body is dried in a drying kiln until the water content is less than or equal to 1%; Step 6, glazing: the glaze obtained above is sprayed on the dried green body at a glazing amount of 180-220g / cm 2 to form a glaze layer; Step 7, firing: the green body with the glaze layer is fired according to the set program to obtain a high-strength thin ceramic tile with a thickness of 3-5mm.

[0012] Preferably, the particle size distribution of the slurry obtained in step 1 is 1.5%-2% of the amount of 300 mesh sieve residue.

[0013] Preferably, the preparation method of the glaze in step 6 is as follows: 10-15 parts by weight of quartz, 2-3 parts by weight of sepiolite, 3-4 parts by weight of borax, 1-1.5 parts by weight of magnesium stearate are kept at 100-120 DEG C and ground for 20-30 min; after cooling to room temperature, 3-5 parts by weight of peroxyacetic acid, 3-4 parts by weight of kaolin and 5-6 parts by weight of bentonite are added and ground for 10-20 min; an equal weight of sodium chloride solution with a mass fraction of 5-7% is added, and after being mixed uniformly, heated to 200-300 DEG C, kept for 10-15 min, and cooled to room temperature, 20-25 parts by weight of potassium feldspar, 15-18 parts by weight of sodium feldspar, 8-10 parts by weight of modified talc powder, 3-5 parts by weight of strontium carbonate and 8-10 parts by weight of colorant are added and ground to 1.3-1.5% residue on a 300-mesh sieve, and the glaze is obtained.

[0014] Preferably, the firing procedure in step 7 is as follows: heated to 800 DEG C at a rate of 20 DEG C / min, kept for 30 min; heated to 1200 DEG C at a rate of 10 DEG C / min, kept for 1 h; cooled to 800 DEG C at a rate of 20 DEG C / min, kept for 1 h; heated to 1050 DEG C at a rate of 20 DEG C / min again, kept for 1.5 h, and after natural cooling, the high-strength light and thin ceramic tile is obtained.

[0015] The application provides the high-strength light and thin ceramic tile prepared from the above raw materials and preparation method.

[0016] The application has the following beneficial effects: In the application, the formula of the ceramic tile body is selected, the content of alumina is reduced, the sintering effect is avoided from being affected by the high content of alumina, the modified talc powder is added in the formula, the toughness and strength of the body are increased, the cracking and body breaking caused by the thickness reduction are reduced, the density and sintering activity of the body are improved, the deformation of the body caused in the firing process is avoided; in addition, the formula of the glaze is improved in the application, the hardness and wear resistance of the glaze surface are improved, and the solid glaze layer is formed. DETAILED DESCRIPTION

[0017] The application is further illustrated in combination with specific embodiments, and it should be understood that the embodiments are only used for illustrating the application and are not used for limiting the scope of the application. After reading the application, the modification of various equivalent forms of the application by those skilled in the art falls within the scope protected by the claims of the application. In the following embodiments, the colorant is a substance for adding color to the glaze, such as metal oxide, metal salt, inorganic pigment and artificial synthetic colorant, etc.

[0018] Embodiment 1 Preparation of modified talc powder: mix talc powder 10 kg, molybdenum disulfide 2.5 kg, white carbon black 4 kg, isopropyl distearyl oxyl aluminate 1.5 kg, and then place in a 120°C environment for 30 minutes of heat grinding, and then cool to room temperature and continue to grind for 20 minutes at room temperature to obtain the modified talc powder.

[0019] Preparation of glaze: mix quartz 10 kg, sepiolite 3 kg, borax 3 kg, and magnesium stearate 1.5 kg, and then grind for 20 minutes at 120°C; then cool to room temperature, add peroxoacetic acid 1.5 kg, kaolin 3 kg, and bentonite 5 kg, and continue to grind for 20 minutes, add an equal weight of 5% sodium chloride solution, mix well, heat to 300°C, and then heat for 10 minutes, cool to room temperature, and then add potassium feldspar 20 kg, sodium feldspar 15 kg, modified talc powder 10 kg, strontium carbonate 3 kg, and colorant 10 kg, and grind to 1.3% residue on a 300 mesh sieve to obtain the glaze.

[0020] Preparation of high-strength and thin ceramic tile: Step 1, ball milling: accurately weigh and mix kaolin 20 kg, clay 10 kg, potassium feldspar 10 kg, sodium feldspar 22 kg, spodumene 12 kg, modified talc powder 12 kg, silicon nitride 0.5 kg, hydroxypropyl starch ether 3 kg, aluminum metaphosphate 0.8 kg, and cerium dioxide 3 kg to obtain the mixed material; place the material, balls, and water in a ball mill in a ratio of 1:2:0.5 for wet grinding for 30 minutes, then add polyvinyl alcohol 1.2 kg, and continue to grind to a fineness of 1.5%-2% residue on a 300 mesh sieve to obtain the slurry for use; Step 2, iron removal: drain the slurry after ball milling, pass through a vibrating screen, remove iron with an iron removal machine, and then age for 15 hours to obtain the mud slurry for use; Step 3, powder preparation: dry the mud slurry through a spray drying tower to obtain a powder with a water content of 5%-7%, and then age the powder for 20 hours for use; Step 4, shaping: press the aged powder through a high-pressure press at a pressure of 750 kg / cm 2 to obtain the green tile; Step 5, drying: dry the green tile in a drying kiln until the water content is ≤1%; Step 6, glazing: spray the glaze obtained in the above step on the dried green tile to form a glaze layer; Step 7, firing: the green body with glaze layer is fired according to the following procedure: heating at a rate of 20℃ / min to 800℃, keeping for 30min; then heating at a rate of 10℃ / min to 1200℃, keeping for 1h; then cooling at a rate of 20℃ / min to 800℃, keeping for 1h; then heating at a rate of 20℃ / min to 1050℃, keeping for 1.5h, and then naturally cooling to obtain high-strength light thin ceramic tiles with a thickness of 3-5mm.

[0021] Example 2 Preparation of modified talc powder: 20kg of talc powder, 2kg of molybdenum disulfide, 5kg of white carbon black, and 1kg of isopropyl distearyl oxyl aluminate are mixed, then placed in a 120℃ environment for 30min of heat and grinding, and then cooled to room temperature and continue to grind for 15min to obtain the modified talc powder.

[0022] Preparation of glaze: 15kg of quartz, 2kg of sepiolite, 4kg of borax, and 1kg of magnesium stearate are heat-grinded at 100℃ for 30min; then cooled to room temperature, 1kg of peroxoacetic acid, 4kg of kaolin, and 6kg of bentonite are added and continue to grind for 15min, then 7% sodium chloride solution with equal weight is added, mixed uniformly, heated to 200℃, kept for 15min, cooled to room temperature, then 25kg of potassium feldspar, 18kg of sodium feldspar, 8kg of modified talc powder, 5kg of strontium carbonate, and 8kg of colorant are added, and grinded to 1.5% residue on a 300 mesh sieve to obtain the glaze.

[0023] Preparation of high-strength light thin ceramic tiles: Step 1, ball milling: the raw materials are accurately weighed according to the weight ratio of 25kg of kaolin, 8kg of clay, 12kg of potassium feldspar, 20kg of sodium feldspar, 15kg of spodumene, 8kg of modified talc powder, 1kg of silicon nitride, 2kg of hydroxypropyl starch ether, 0.5kg of aluminum metaphosphate, and 1kg of cerium dioxide to obtain the mixture; the mixture is placed in a ball mill for wet grinding according to the ratio of 1:2:0.5 of material:ball:water, and grinded for 30min, then 1.5kg of polyvinyl alcohol is added and continue to grind until the fineness is 1.5%-2% residue on a 300 mesh sieve to obtain the slurry for standby; Step 2, iron removal: the slurry after ball milling is discharged, passed through a vibrating screen, removed by an iron removal machine, and aged for 12h to obtain the mud slurry for standby; Step 3, powder preparation: the mud slurry is dried by a spray drying tower to obtain the powder with a water content of 5-7%, and the powder is aged for 20h for standby; Step 4, forming: the powder after aging is pressed into a green body by a high-pressure press under a pressure of 800kg / cm 2 ; Step 5, drying: the green body is placed in a drying kiln for drying until the water content is ≤1%; Step 6, glazing: the glaze obtained above is sprayed on the dried brick body to form a glaze layer; Step 7, firing: the brick body with the glaze layer is fired according to the following procedure: heating at a rate of 20℃ / min to 800℃, keeping for 30min; then heating at a rate of 10℃ / min to 1200℃, keeping for 1h; then cooling at a rate of 20℃ / min to 800℃, keeping for 1h; then heating at a rate of 20℃ / min to 1050℃, keeping for 1.5h, and then naturally cooling to obtain high-strength thin ceramic tiles with a thickness of 3-5mm.

[0024] Example 3 Preparation of modified talc powder: 15kg of talc powder, 2kg of molybdenum disulfide, 4.5kg of white carbon black, and 1.3kg of isopropyl distearyl oxyl aluminate are mixed and then placed in a 120℃ environment for 30min of heat grinding. After cooling, the mixture is ground for another 20min at room temperature to obtain the modified talc powder.

[0025] Preparation of glaze: 13kg of quartz, 2.5kg of sepiolite, 3.5kg of borax, and 1kg of magnesium stearate are heat ground at 120℃ for 25min. After cooling to room temperature, 1.3kg of peroxoacetic acid, 3.5kg of kaolin, and 5.5kg of bentonite are added and ground for another 15min. An equal weight of a 6% sodium chloride solution is added, and the mixture is uniformly mixed and heated to 300℃ for 13min. After cooling to room temperature, 23kg of potassium feldspar, 17kg of sodium feldspar, 9kg of modified talc powder, 4kg of strontium carbonate, and 9kg of colorant are added and ground to a 300-mesh sieve residue of 1.4% to obtain the glaze.

[0026] Preparation of high-strength thin ceramic tiles: Step 1, ball milling: the raw materials are accurately weighed according to the weight ratio of 23kg of kaolin, 9kg of clay, 11kg of potassium feldspar, 21kg of sodium feldspar, 13kg of spodumene, 10kg of modified talc powder, 0.8kg of silicon nitride, 2.5kg of hydroxypropyl starch ether, 0.7kg of aluminum metaphosphate, and 2kg of cerium dioxide to obtain a mixture. The mixture is placed in a ball mill for wet grinding according to the ratio of 1:2:0.5 of material:ball:water for 30min. Then, 1.3kg of polyvinyl alcohol is added and the grinding is continued until the fineness is 1.5%-2% of a 300-mesh sieve residue to obtain a slurry for standby use; Step 2, iron removal: the slurry after ball milling is discharged and passed through a vibrating screen. The iron is removed by an iron removal machine, and the mud slurry is aged for 13h for standby use; Step 3, powder preparation: the mud slurry is dried by a spray drying tower to obtain a powder with a water content of 5-7%. The powder is aged for 20h for standby use; Step 4, shaping: the powder after aging is subjected to high-pressure pressing in a high-pressure press at 800kg / cm 2under pressure to form a green brick; Step 5, drying: the green brick is placed in a drying kiln for drying until the moisture content is ≤1%; Step 6, glazing: the glaze obtained above is sprayed on the dried green brick to form a glaze layer; Step 7, firing: the green brick with the glaze layer is fired according to the following procedure: heating at a rate of 20℃ / min to 800℃, holding for 30min; then heating at a rate of 10℃ / min to 1200℃, holding for 1h; then cooling at a rate of 20℃ / min to 800℃, holding for 1h; then heating at a rate of 20℃ / min to 1050℃, holding for 1.5h, and then naturally cooling to obtain high-strength thin ceramic tiles with a thickness of 3-5mm.

[0027] Comparative Example 1 Glaze preparation: 13kg of quartz, 2.5kg of sepiolite, 3.5kg of borax, and 1kg of magnesium stearate are ground at 120℃ for 25min; then, after cooling to room temperature, 1.4kg of peroxyacetic acid, 3.5kg of kaolin, and 5.5kg of bentonite are added and ground for another 15min; then, an equal weight of a 6% sodium chloride solution is added, and the mixture is uniformly mixed and heated to 300℃ for 13min; then, after cooling to room temperature, 23kg of potassium feldspar, 17kg of sodium feldspar, 4kg of strontium carbonate, and 9kg of colorant are added and ground to a residue of 1.4% on a 300-mesh sieve to obtain the glaze.

[0028] Preparation of high-strength thin ceramic tiles: Step 1, ball milling: the raw materials are accurately weighed according to the weight ratio of 23kg of kaolin, 9kg of clay, 11kg of potassium feldspar, 21kg of sodium feldspar, 13kg of spodumene, 0.8kg of silicon nitride, 2.5kg of hydroxypropyl starch ether, 0.7kg of aluminum metaphosphate, and 2kg of cerium dioxide, and then mixed to obtain a mixture; the mixture is placed in a ball mill for wet grinding according to the ratio of 1:2:0.5 (material: ball: water) for 30min, then 1.2kg of polyvinyl alcohol is added, and the grinding is continued until the fineness is 1.5%-2% on a 300-mesh sieve to obtain a slurry for standby use; Step 2, iron removal: the slurry after ball milling is discharged, passed through a vibrating screen, removed by an iron removal machine, and aged for 13h to obtain a mud slurry for standby use; Step 3, powder preparation: the mud slurry is dried by a spray drying tower to obtain a powder with a moisture content of 5-7%, and the powder is aged for 20h for standby use; Step 4, shaping: the powder after aging is subjected to high-pressure pressing in a high-pressure press at 750kg / cm 2 under pressure to form a green brick; Step 5, drying: the green brick is placed in a drying kiln for drying until the moisture content is ≤1%; Step 6, glazing: the glaze obtained above is sprayed on the dried green tile to form a glaze layer; Step 7, firing: the green tile with the glaze layer is fired according to the following procedure: heating at a rate of 20℃ / min to 800℃, keeping for 30min; then heating at a rate of 10℃ / min to 1200℃, keeping for 1h; then cooling at a rate of 20℃ / min to 800℃, keeping for 1h; then heating at a rate of 20℃ / min to 1050℃, keeping for 1.5h, and then naturally cooling to obtain high-strength light thin ceramic tiles with a thickness of 3-5mm.

[0029] Comparative Example 2 Preparation of modified talc powder: 15kg of talc powder, 2kg of molybdenum disulfide and 1.3kg of isopropyl distearyl oxyl aluminate are mixed, then placed in a 120℃ environment for 30min of heat grinding, and then cooled to room temperature and continue to grind for 20min to obtain the modified talc powder.

[0030] Preparation of glaze: 13kg of quartz, 2.5kg of sepiolite, 3.5kg of borax, 1kg of magnesium stearate, 3.5kg of kaolin and 5.5kg of bentonite are mixed and ground for 25min; then an equal weight of 6% sodium chloride solution is added, mixed uniformly, heated to 300℃, kept for 13min, cooled to room temperature, then 23kg of potassium feldspar, 17kg of sodium feldspar, 9kg of modified talc powder, 4kg of strontium carbonate and 9kg of colorant are added, and ground to 1.4% residue on a 300 mesh sieve to obtain the glaze.

[0031] Preparation of high-strength light thin ceramic tiles: Step 1, ball milling: the raw materials are accurately weighed according to the weight ratio of 23kg of kaolin, 9kg of clay, 11kg of potassium feldspar, 21kg of sodium feldspar, 13kg of spodumene, 10kg of modified talc powder, 0.8kg of silicon nitride, 2.5kg of hydroxypropyl starch ether, 0.7kg of aluminum metaphosphate and 2kg of cerium dioxide, and mixed to obtain a mixture; the mixture is placed in a ball mill for wet grinding according to the ratio of 1:2:0.5 of material:ball:water, and ground for 30min, then 1.2kg of polyvinyl alcohol is added, and the grinding is continued until the fineness is 1.5%-2% residue on a 300 mesh sieve to obtain a slurry for standby; Step 2, iron removal: the slurry after ball milling is discharged, passed through a vibrating screen, removed by an iron removal machine, and aged for 13h to obtain a slurry for standby; Step 3, powder preparation: the slurry is dried by a spray drying tower to obtain a powder with a water content of 5-7%, and the powder is aged for 20h for standby; Step 4, shaping: the powder after aging is pressed into a green tile by a high-pressure press under a pressure of 750kg / cm 2 ​Step 5, drying: the green brick is placed in a drying kiln for drying until the moisture content is less than or equal to 1%; Step 6, glazing: the glaze obtained above is sprayed on the dried green brick to form a glaze layer; Step 7, firing: the green brick with the glaze layer is fired according to the following procedure: heating at a rate of 20℃ / min to 800℃, holding for 30min; then heating at a rate of 10℃ / min to 1200℃, holding for 1h; then cooling at a rate of 20℃ / min to 800℃, holding for 1h; then heating at a rate of 20℃ / min to 1050℃, holding for 1.5h, and then naturally cooling to obtain high-strength thin ceramic tiles with a thickness of 3-5mm.

[0032] Comparative Example 3 Preparation of modified talc powder: 15kg of talc powder, 2kg of molybdenum disulfide, 4.5kg of white carbon black, and 1.3kg of isopropyl distearyl oxyl aluminate are mixed, then placed in a 120℃ environment for 30min of heat and grinding, and then cooled to room temperature and continue to grind for 20min to obtain the modified talc powder.

[0033] Preparation of glaze: 13kg of quartz, 2.5kg of sepiolite, and 1kg of magnesium stearate are heat-ground at 120℃ for 25min; then cooled to room temperature, 1.4kg of peroxoacetic acid and 3.5kg of kaolin are added and continue to grind for 15min, then add an equal weight of 6% sodium chloride solution, mix well, heat to 300℃, hold for 13min, cool to room temperature, then add 23kg of potassium feldspar, 17kg of sodium feldspar, 9kg of modified talc powder, and 9kg of colorant, grind to 1.4% residue on a 300 mesh sieve to obtain the glaze.

[0034] Preparation of high-strength thin ceramic tiles: Step 1, ball milling: the raw materials are accurately weighed according to the weight ratio of 23kg of kaolin, 9kg of clay, 11kg of potassium feldspar, 21kg of sodium feldspar, 13kg of spodumene, 10kg of modified talc powder, and 2.5kg of hydroxypropyl starch ether to obtain a mixture; the mixture is placed in a ball mill for wet grinding according to the ratio of material: ball: water = 1:2:0.5, and ground for 30min, then 1.2kg of polyvinyl alcohol is added and continue to grind to a fineness of 1.5%-2% residue on a 300 mesh sieve to obtain a slurry for standby; Step 2, iron removal: the slurry after ball milling is discharged, passed through a vibrating screen, removed by an iron removal machine, and aged for 13h to obtain a slurry for standby; Step 3, powder preparation: the slurry is dried by a spray drying tower to obtain a powder with a moisture content of 5-7%, and the powder is aged for 20h for standby; Step 4, shaping: the powder after aging is pressed into a green brick by a high-pressure press at a pressure of 750kg / cm 2 pressure. Step 5, drying: the green brick is placed in a drying kiln for drying until the moisture content is less than or equal to 1%; Step 6, glazing: the glaze obtained above is sprayed on the dried green brick to form a glaze layer; Step 7, firing: the green brick with the glaze layer is fired according to the following procedure: heating at a rate of 20℃ / min to 1050℃, holding for 1h; then heating at a rate of 10℃ / min to 1200℃, holding for 1h, and naturally cooling to obtain high-strength light and thin ceramic tiles with a thickness of 3-5mm.

[0035] Performance test The ceramic tiles obtained in Examples 1-3 and Comparative Examples 1-3 are subjected to corresponding performance tests, and the results are shown in Tables 1 and 2.

[0036] As can be seen from the results in Tables 1 and 2, the ceramic tiles prepared in the present application are light and thin, have high wear resistance, and good stain resistance.

[0037] Table 1 Performance test results of different ceramic tiles As can be seen from the results in Table 2, the ceramic tiles prepared in the present application have high hardness, high density, and high bending strength, and have good performance.

[0038] Table 2 Strength performance test results of different ceramic tiles As can be seen from the results in Tables 1 and 2, the ceramic tiles prepared in the present application are light and thin while still having good mechanical properties, high hardness, and high bending strength. The ceramic tile green body raw materials and glaze prepared in Comparative Example 1 do not contain modified talc powder, and the ceramic tiles have poor wear resistance, hardness, and bending strength. In Comparative Example 2, the modified talc powder is prepared by a method different from that in the present application, and the glaze does not use modified talc powder, and the performance of the ceramic tiles is better than that in Comparative Example 1 but still worse than that in the present application. In Comparative Example 3, the green body raw materials and glaze composition and firing procedure are different from those in the present application, and the mechanical properties of the ceramic tiles are similar to those in Comparative Example 2 but worse than those in the present application.

Claims

1. A high-strength, lightweight ceramic tile, characterized in that, It is mainly prepared from the following components: 20-25 parts by weight of kaolin, 8-10 parts by weight of clay, 10-12 parts by weight of potassium feldspar, 20-22 parts by weight of sodium feldspar, 12-15 parts by weight of spodumene, 1.2-1.5 parts by weight of toughening agent, 8.5-12.8 parts by weight of accelerator, and 3.5-7 parts by weight of reinforcing agent.

2. The high-strength, lightweight ceramic tile as described in claim 1, characterized in that, The toughening agent is polyvinyl alcohol.

3. The high-strength, lightweight ceramic tile as described in claim 1, characterized in that, The accelerator contains 8-12 parts by weight of modified talc and 0.5-0.8 parts by weight of aluminum metaphosphate.

4. The high-strength, lightweight ceramic tile as described in claim 3, characterized in that, The modified talc powder is prepared by: Mix 10-20 parts by weight of talc, 2-2.5 parts by weight of molybdenum disulfide, 4-5 parts by weight of silica, and 1-1.5 parts by weight of isopropyl distearate aluminate, and then grind at 120°C for 30 minutes. After cooling to room temperature, continue grinding for 15-20 minutes to obtain modified talc.

5. The high-strength, lightweight ceramic tile as described in claim 1, characterized in that, The reinforcing agent contains 0.5-1 parts by weight of silicon nitride, 2-3 parts by weight of hydroxypropyl starch ether, and 1-3 parts by weight of cerium dioxide.

6. A method for preparing a high-strength, lightweight ceramic tile as described in any one of claims 1-5, characterized in that, The main steps include: Step 1, ball milling: Weigh kaolin, clay, potassium feldspar, sodium feldspar, spodumene, accelerator, and reinforcing agent and mix them to obtain a mixture; place it in a ball mill for wet grinding according to the ratio of material:ball:water = 1:2:0.5, then add toughening agent and continue grinding to obtain a slurry for later use; Step 2, iron removal: drain the slurry after ball milling, pass it through a vibrating screen, remove iron through an iron removal machine, and age it for 12-15 hours to obtain mud slurry for later use; Step 3, Powdering: The mud is dried in a spray drying tower to produce powder with a moisture content of 5-7%, and the powder is aged for 20 hours for later use. Step 4, Molding: The above-mentioned aged powder is pressed using a high-pressure press at 750-800 kg / cm³. 2 Brick blanks are formed under pressure; Step 5, Drying: Place the brick blanks in a drying kiln for drying until the moisture content is ≤1%; Step 6, Glazing: Apply the glaze obtained above at a ratio of 180-220 g / cm³. 2 The glaze is sprayed onto the dried brick blank to form a glaze layer; Step 7, firing: The glazed brick blanks are fired according to the set program to obtain high-strength, lightweight ceramic tiles with a thickness of 3-5mm.

7. The preparation method according to claim 6, characterized in that, The particle size distribution of the slurry obtained in step 1 is 1.5%-2% residue on a 300-mesh sieve.

8. The preparation method according to claim 6, characterized in that, The preparation method of the glaze in step 6 is as follows: 10-15 parts by weight of quartz, 2-3 parts by weight of sepiolite, 3-4 parts by weight of borax, and 1-1.5 parts by weight of magnesium stearate are ground at 100-120℃ for 20-30 minutes; after cooling to room temperature, 3-5 parts by weight of peracetic acid, 3-4 parts by weight of kaolin, and 5-6 parts by weight of bentonite are added and the grinding continues for 10-20 minutes. An equal weight of sodium chloride solution with a mass fraction of 5-7% is added, and the mixture is mixed evenly. The mixture is then heated to 200-300℃ and held for 10-15 minutes. After cooling to room temperature, 20-25 parts by weight of potassium feldspar, 15-18 parts by weight of sodium feldspar, 8-10 parts by weight of modified talc, 3-5 parts by weight of strontium carbonate, and 8-10 parts by weight of colorant are added. The mixture is ground until the residue on a 300-mesh sieve is 1.3-1.5%, thus obtaining the glaze.

9. The preparation method according to claim 6, characterized in that, The firing process in step 7 is as follows: heat up to 800℃ at a rate of 20℃ / min and hold for 30min; then heat up to 1200℃ at a rate of 10℃ / min and hold for 1h; then cool down to 800℃ at a rate of 20℃ / min and hold for 1h; then heat up to 1050℃ again at a rate of 20℃ / min and hold for 1.5h. After natural cooling, high-strength, lightweight ceramic tiles are obtained.

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