Domestic high-strength environment-friendly ceramic and preparation process thereof

Abstract

The application discloses a kind of daily high-strength environmental protection ceramics and its preparation process, specifically related to the field of ceramic materials, including the following steps: S1, preparation and forming of green body powder, S2, preparation of multifunctional glaze, S3, glazing and sintering.The application introduces pre-composite reinforcing fibers, the SiO2-Al2O3 coating on the surface thereof forms a strong interfacial bond with the ceramic matrix at high temperature, improving the overall mechanical properties of the green body, effectively transferring and dispersing the load, while the fiber itself plays a significant role in toughening and impact resistance;The addition of biomass-derived porous carbon powder further improves the material's fracture toughness and thermal shock resistance through its pore-forming and buffering effect;While maintaining high bending strength, impact toughness has been improved dramatically, making it more suitable for everyday use in the context of bumps.

Description

Technical Field

[0001] This invention relates to the field of ceramic materials technology, and more specifically, to a high-strength environmentally friendly ceramic for daily use and its preparation process. Background Technology

[0002] As indispensable products in daily life, the performance of daily-use ceramics directly affects the user experience, safety, and lifespan. Traditional daily-use ceramics are mainly made from kaolin, feldspar, quartz, etc., and are formed, glazed, and sintered. Although they can meet basic usage needs, they have inherent shortcomings in strength and toughness, and the problems of fragility and easy cracking have long existed, resulting in high loss rates and short service life during transportation and use.

[0003] To improve the mechanical properties of ceramics, existing technologies have effectively enhanced the density and mechanical strength of ceramics by introducing specially prepared composite nanomaterials (based on yttrium oxide-kaolin and modified with phosphate esters) and novel grinding aids (polydopamine-modified talc grafted with quaternary ammonium salts) into the raw materials of the green body. This approach focuses on optimizing powder dispersibility and sintering behavior through nanocomposite and surface modification technologies, thereby improving flexural strength and fracture toughness. Existing technologies also achieve coordinated improvements in strength, cleanliness, and antibacterial durability by adding self-prepared bentonite-doped modifiers and chitosan modifiers, combined with nano-zinc oxide and nano-silver powder. The core of this approach lies in lanthanum doping and composite modification of bentonite, as well as irradiation and yttrium modification of hydroxyapatite, to enhance interfacial bonding and functional properties.

[0004] However, the existing technology still has the following areas for improvement:

[0005] First, while existing technologies improve the static mechanical properties of ceramics, their ability to resist dynamic loads such as impacts and scratches encountered in daily use (i.e., impact toughness and surface wear resistance) is limited, and they often lack specific antibacterial properties. Second, to achieve multifunctional composites, existing solutions often require the addition of multiple functional additives, resulting in complex process steps (such as irradiation and multi-step modification), leading to high production costs and difficulties in quality control. Furthermore, the interfacial compatibility and sintering stability between various modifiers and the matrix may be problematic, affecting performance uniformity. Third, some solutions rely on rare earth elements or precious metals, which, while improving performance, increase costs and resource dependence, contradicting the sustainability principles of environmental protection. Finally, existing technologies largely focus on strengthening the body, paying insufficient attention to the synergistic strengthening of the glaze layer with the body, such as hardness, wear resistance, and stain resistance. Glaze performance may become a bottleneck in the overall product lifespan.

[0006] Therefore, there is an urgent need to develop a new technical solution that can achieve synergistic enhancement of ceramic body and glaze without excessively increasing process complexity and dependence on rare raw materials, while also possessing excellent static strength, dynamic impact toughness, surface hardness, wear resistance and long-lasting antibacterial and easy-to-clean properties. Summary of the Invention

[0007] In order to overcome the above-mentioned defects of the prior art, the embodiments of the present invention provide a high-strength environmentally friendly ceramic for daily use and its preparation process. The technical problem to be solved by the present invention is: how to provide a method for preparing daily-use ceramics with relatively readily available raw materials, high process integration, and the ability to achieve integrated strengthening of body and glaze, so that the resulting product has high bending strength, high impact toughness, high surface hardness and wear resistance, as well as excellent and long-lasting antibacterial and easy-to-clean properties.

[0008] To achieve the above objectives, the present invention provides the following technical solution: a preparation process for high-strength environmentally friendly daily-use ceramics, comprising the following steps:

[0009] S1. Preparation and molding of green body powder: Potassium feldspar, sodium feldspar, quartz, kaolin, zirconium silicate, pre-composite reinforcing fiber, biomass-derived carbon source, and dispersant are mixed evenly and subjected to the first stage of dry ball milling; then deionized water is added for the second stage of wet ball milling to obtain a uniform slurry; after the slurry is filtered, aged, and kneaded, it is rolled or slurry-cast to form ceramic green bodies, and after drying, ceramic blanks are obtained.

[0010] S2. Preparation of multifunctional glaze slurry: Lithium spodumene, calcined zinc oxide, pre-sintered calcium phosphate powder, nano-antimony tin oxide (ATO), glaze clay, suspending agent, binder and water are mixed, wet ball milled, and iron is removed by sieving to obtain multifunctional glaze slurry.

[0011] S3. Glazing and sintering: The multifunctional glaze slurry prepared in step S2 is applied to the surface of the ceramic bisque obtained in step S1. After drying, a glazed bisque is obtained. The glazed bisque is placed in a kiln for gradient sintering: first, the temperature is raised to 150-300℃ at 2-5℃ / min to remove residual moisture, then the temperature is raised to 850-1000℃ at 3-8℃ / min for oxidation, debinding, and initial melting of the glaze. Finally, the temperature is raised to the maximum firing temperature of 1180-1250℃ at 5-10℃ / min and held for 1-4 hours. After cooling in the kiln, the high-strength environmentally friendly ceramic for daily use is obtained.

[0012] In a preferred embodiment, the raw materials for the green body in step S1 include, by weight: 20-35 parts potassium feldspar, 10-25 parts sodium feldspar, 15-30 parts quartz, 20-40 parts kaolin, 5-15 parts zirconium silicate, 1-5 parts pre-composite reinforcing fiber, 0.5-3 parts biomass-derived carbon source, and 0.1-1 parts dispersant.

[0013] In a preferred embodiment, the pre-composite reinforcing fiber is prepared as follows:

[0014] Short-cut basalt fibers are mixed with silica sol and alumina sol at a mass ratio of 5-10:1-3:0.5-2 and stirred to form a uniform suspension. The suspension is then spray-dried to obtain a fiber precursor with an inorganic sol layer on its surface. This fiber precursor is then heat-treated in air at a temperature of 5-10℃ / min to 600-800℃ for 1-2 hours. After cooling, the pre-composite reinforced fiber is obtained. This process transforms the sol into a robust SiO2-Al2O3 composite coating, which firmly coats the fiber. This coating protects the fiber during ball milling and molding and forms a good chemical bond with the ceramic matrix during sintering.

[0015] In a preferred embodiment, the biomass-derived carbon source is micron-sized porous carbon powder obtained by grinding bamboo powder, rice husk powder, or coconut shell powder after carbonization at 300-500℃ for 1-3 hours under limited oxygen conditions. It plays a dual role as a pore-forming agent and a stress buffer in the green body: the micropores can passivate crack propagation; at the same time, in the later stage of high-temperature sintering, the porous carbon is oxidized, leaving micro-nano-scale closed pores, which helps to relieve thermal stress and improve toughness.

[0016] In a preferred embodiment, the dispersant is at least one of sodium polyacrylate, sodium hexametaphosphate, or ammonium citrate.

[0017] In a preferred embodiment, the raw materials of the multifunctional glaze slurry in step S2 include, by weight: 30-50 parts spodumene, 5-15 parts calcined zinc oxide, 3-10 parts pre-sintered calcium phosphate powder, 1-5 parts nano-antimony tin oxide (ATO), 10-20 parts glaze clay, 0.2-1 parts suspending agent, 0.5-2 parts binder, and 40-60 parts water; wherein, the nano-antimony tin oxide is a conductive filler, which is uniformly dispersed in the glaze melt and can form a micro-conductive network on the glaze surface, which helps to prevent electrostatic adsorption of dust and can enhance the surface self-cleaning ability through photocatalytic assistance.

[0018] In a preferred embodiment, the pre-sintered calcium phosphate powder is prepared as follows: hydroxyapatite powder is calcined at 800-1000℃ for 1-3 hours to partially transform it into a calcium phosphate phase with higher activity, such as tricalcium phosphate. After cooling, it is ground to the micron level. It can dissolve moderately in the glaze melt, releasing calcium and phosphorus ions, participating in the glass network structure of the glaze layer, improving the hardness and chemical stability of the glaze surface, and endowing the glaze surface with potential biological activity.

[0019] In a preferred embodiment, the suspending agent is sodium carboxymethyl cellulose or bentonite; the binder is a polyvinyl butyral (PVB) ethanol solution or hydroxypropyl methylcellulose.

[0020] In a preferred embodiment, the maximum firing temperature is 1200-1230°C, and the holding time is 2-3 hours.

[0021] The present invention also includes a high-strength environmentally friendly ceramic for daily use prepared by the above-described preparation process.

[0022] The technical effects and advantages of this invention are as follows:

[0023] This invention introduces pre-composite reinforcing fibers, whose surface SiO2-Al2O3 coating forms a strong interfacial bond with the ceramic matrix at high temperatures, improving the overall mechanical properties of the green body and effectively transferring and dispersing loads. At the same time, the fibers themselves play a significant role in toughening and impact resistance. The addition of biomass-derived porous carbon powder further improves the fracture toughness and thermal shock resistance of the material through its pore-forming and buffering effects. While maintaining high bending strength, the impact toughness is significantly improved, making it more suitable for everyday bump and knock scenarios.

[0024] This invention introduces pre-sintered calcium phosphate powder into the glaze, which not only improves the hardness and wear resistance of the glaze surface, but also makes its surface more chemically inert and corrosion-resistant; the addition of ATO gives the glaze surface a lasting antistatic and photocatalytic self-cleaning function, reduces stain adhesion, and makes it easy to clean; the glaze layer and the reinforced body are well matched, the coefficient of thermal expansion is coordinated, and the bond is firm, avoiding glaze cracking or peeling.

[0025] The raw materials used in this invention avoid the use of expensive raw materials such as rare earth or precious metals, and mainly use natural minerals and biomass-derived materials, which are relatively low in cost and sustainable in resources; moreover, the preparation process of pre-composite reinforcing fibers is simple and easy to connect with existing ceramic processes, without introducing overly complex or energy-intensive steps such as proton irradiation, which makes it easy to achieve large-scale production.

[0026] The fiber reinforcement and microporous toughening mechanism of the green body in this invention, combined with the hardening and functional modification of the glaze, achieves an integrated performance improvement from the inside out; the resulting ceramic products not only have high static strength, but also are impact resistant, have a hard and wear-resistant surface, are stain resistant and easy to clean, and have a comprehensive service life that far exceeds that of traditional products and some existing high-performance products.

[0027] The high hardness, high density, and self-cleaning properties of the glaze in this invention make it difficult for microorganisms and dirt to adhere and accumulate, thus reducing the conditions for bacterial growth at a physical level. Although no large amount of antibacterial agent is directly added, the invention achieves long-lasting hygiene by improving surface properties, avoiding problems such as migration, failure, or discoloration that may be caused by antibacterial agents. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the embodiments thereof. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0029] All raw materials used in the examples are commercially available industrial-grade or chemically pure products; all methods used are conventional methods in the art.

[0030] Preparation of pre-composite reinforced fibers:

[0031] 100g of short-cut basalt fibers with an average length of 50-100μm were mixed with 20g of silica sol (30wt% SiO2 content), 10g of alumina sol (20wt% Al2O3 content), and 200mL of deionized water. The mixture was stirred at 2000rpm for 1 hour in a high-speed disperser to form a homogeneous suspension. This suspension was then centrifugally spray-dried at an inlet temperature of 220℃ and an outlet temperature of 90℃ to obtain a dried fiber precursor powder coated with silica-alumina sol. This powder was placed in a muffle furnace and heated to 700℃ at a rate of 8℃ / min in air atmosphere, held at that temperature for 1.5 hours, and then cooled with the furnace. The powder was then ground through a 200-mesh sieve to obtain pre-composite reinforced fibers. SEM-EDS analysis showed that a continuous, dense, and firmly bonded SiO2-Al2O3 amorphous composite coating with a thickness of approximately 100-300nm was formed on the fiber surface.

[0032] Preparation of biomass-derived carbon sources:

[0033] Dry bamboo powder was placed in a tube furnace and carbonized under nitrogen protection (flow rate 50 mL / min) at a rate of 5 °C / min to 400 °C, and held for 2 hours under oxygen-limited conditions. After natural cooling, the carbonized product was removed, ground in a mortar, and passed through a 325-mesh sieve to obtain black porous bamboo charcoal powder, which was designated as the biomass-derived carbon source. BET analysis showed that its specific surface area was approximately 250 m² / g. 2 / g.

[0034] Preparation of pre-sintered calcium phosphate powder:

[0035] Commercially available hydroxyapatite powder was placed in an alumina crucible and calcined at 900°C for 2 hours in a muffle furnace. After cooling, it was ground in a planetary ball mill for 2 hours and passed through a 400-mesh sieve to obtain a white micro-powder, which was designated as pre-sintered calcium phosphate powder. XRD analysis showed that its main phases were hydroxyapatite and a small amount of β-tricalcium phosphate. Example 1:

[0036] This invention provides a preparation process for high-strength environmentally friendly ceramics for daily use, the specific steps of which are as follows:

[0037] S1. Preparation and molding of green body powder:

[0038] Weigh the following raw materials by weight: 28 parts potassium feldspar, 18 parts sodium feldspar, 22 parts quartz, 35 parts kaolin, 10 parts zirconium silicate, 3 parts pre-composite reinforcing fiber, 1.5 parts bamboo charcoal powder, and 0.3 parts sodium polyacrylate dispersant. Place all solid raw materials except water into a planetary ball mill, add alumina balls at a ball-to-material ratio of 2:1, and dry-mill at 300 rpm for 1 hour. Then add deionized water equal to 80% of the total weight of the powder, and continue wet-milling for 2 hours to obtain a uniform and fine slurry. Press the slurry into a cake using a filter press and age it for 48 hours in an environment with humidity above 90%. After kneading the clay three times in a vacuum kneader, roll-form it into a bowl-shaped green body, air-dry it at room temperature for 24 hours, and then dry it in an oven at 80℃ to constant weight to obtain a ceramic green body.

[0039] S2. Preparation of multifunctional glaze paste:

[0040] Weigh the following raw materials by weight: 42 parts spodumene, 10 parts calcined zinc oxide, 6 parts pre-sintered calcium phosphate powder, 2 parts nano-tin antimony oxide (particle size 30-50nm), 15 parts glaze clay, 0.5 parts sodium carboxymethyl cellulose, 1 part polyvinyl butyral (PVB, 5wt% ethanol solution), and 50 parts deionized water. Place all raw materials into a ball mill jar, add alumina balls at a ball-to-material ratio of 1.5:1, and wet ball mill at 250 rpm for 6 hours. Pass the ball-milled glaze slurry through a 325-mesh sieve to remove iron, and adjust the specific gravity to 1.6 g / cm³. 3 This yields a multifunctional glaze slurry with good fluidity.

[0041] S3. Glazing and sintering:

[0042] Using the glazing method, the dried bisque prepared in S1 is immersed in the glaze slurry for 3 seconds, quickly lifted out, and excess glaze is evenly distributed. The rim is then glazed. It is then air-dried at room temperature for 12 hours. The glazed bisque is placed on an alumina pad and loaded into an electric kiln. The following sintering regime is executed: the temperature is increased from room temperature to 250°C at a rate of 3°C / min and held for 30 minutes; then increased to 950°C at a rate of 5°C / min and held for 60 minutes; finally, the temperature is increased to the maximum temperature of 1220°C at a rate of 8°C / min and held at this temperature for 2.5 hours. After the holding period, the power is turned off, and the kiln is allowed to cool naturally to room temperature. The resulting high-strength, environmentally friendly ceramic bowl for daily use is obtained. Example 2:

[0043] The main difference between this embodiment and Embodiment 1 lies in the ratio of the body and the glaze, aiming to explore the boundary properties of the ratio range.

[0044] S1. The proportion of the green body powder is adjusted to: 20 parts potassium feldspar, 25 parts sodium feldspar, 30 parts quartz, 20 parts kaolin, 15 parts zirconium silicate, 1 part pre-composite reinforcing fiber, 0.5 parts rice husk charcoal powder, and 0.1 parts sodium hexametaphosphate dispersant. The preparation process is the same as in Example 1.

[0045] S2. The glaze slurry ratio is adjusted to: 30 parts spodumene, 15 parts calcined zinc oxide, 3 parts pre-sintered calcium phosphate powder, 5 parts nano ATO, 20 parts glaze clay, 0.2 parts bentonite suspending agent, 0.5 parts hydroxypropyl methylcellulose binder, and 60 parts water. The preparation process is the same as in Example 1.

[0046] S3. The sintering process was adjusted as follows: temperature was increased to 300℃ at 2℃ / min and held for 20 minutes; temperature was increased to 1000℃ at 8℃ / min and held for 45 minutes; temperature was increased to 1250℃ at 10℃ / min and held for 1 hour. The furnace was then cooled. Ceramic dishes were obtained. Example 3:

[0047] The difference between this embodiment and Embodiment 1 is that the proportions are further optimized and the sintering process is adjusted.

[0048] S1. The proportion of the green body powder is adjusted to: 35 parts potassium feldspar, 10 parts sodium feldspar, 15 parts quartz, 40 parts kaolin, 5 parts zirconium silicate, 5 parts pre-composite reinforcing fiber, 3 parts coconut shell carbon powder, and 1 part ammonium citrate dispersant. The preparation process is the same as in Example 1.

[0049] S2. The glaze slurry ratio is adjusted to: 50 parts spodumene, 5 parts calcined zinc oxide, 10 parts pre-sintered calcium phosphate powder, 1 part nano ATO, 10 parts glaze clay, 0.8 parts sodium carboxymethyl cellulose, 2 parts PVB (dry weight), and 40 parts water. The preparation process is the same as in Example 1.

[0050] S3. The sintering process was adjusted as follows: temperature was increased to 150℃ at 5℃ / min and held for 60 minutes; temperature was increased to 850℃ at 3℃ / min and held for 90 minutes; temperature was increased to 1180℃ at 5℃ / min and held for 4 hours. The furnace was then cooled. The resulting ceramic cup was produced.

[0051] Comparative Example 1

[0052] A ceramic body was prepared according to the raw material formulation and the preparation method of composite nanomaterials and grinding aids in Example 1. A common glaze formulation (potassium feldspar, cobalt oxide, etc.) was used. The sintering regime was the same as described in Example 1, with a holding time of 1200℃ for 4 hours. A comparative ceramic bowl was obtained.

[0053] Comparative Example 2

[0054] Referring to the raw material formulation of Example 3, a bentonite-doped performance modifier and a chitosan modifier were prepared and mixed with other raw materials (potassium feldspar, sodium feldspar, etc.) in the specified proportions. The preparation process followed the ball milling, drying, molding, and sintering at 1050-1100℃ scheme. A comparative ceramic dish was obtained.

[0055] Comparative Example 3

[0056] This comparative example uses commercially available mid-range bone china tableware (mainly composed of tricalcium phosphate, kaolin, feldspar, etc.), purchased from a well-known brand, as a benchmark for the performance of regular products.

[0057] Comparative Example 4

[0058] This comparative example is based on Example 1, except that the pre-composite reinforcing fiber is omitted, while the other components and amounts in the preform remain unchanged, and the preparation process is the same.

[0059] Comparative Example 5

[0060] This comparative example is based on Example 1, but omits the biomass-derived carbon source, while keeping other components and amounts in the green body unchanged, and the preparation process is the same.

[0061] Comparative Example 6

[0062] This comparative example is based on Example 1, except that the pre-sintered calcium phosphate powder and nano-ATO are omitted from the glaze and replaced with an equal amount of spodumene, while the preparation process remains the same.

[0063] Performance testing and data analysis

[0064] The following performance tests were performed on the ceramic samples obtained in Examples 1-3 and Comparative Examples 1-6:

[0065] Bending strength: Refer to GB / T4741-1999 "Test Method for Bending Strength of Ceramic Materials", using the three-point bending method. The sample size is 3mm×4mm×36mm, the span is 30mm, and the loading rate is 0.5mm / min. Five samples are tested in each group, and the average value is taken.

[0066] Fracture toughness (KIC): Standard specimens were prepared and tested according to GB / T23806-2009 "Test Method for Fracture Toughness of Fine Ceramics - Single-sided Precracked Beam (SEPB) Method".

[0067] Impact resistance: The energy absorbed by the specimen at fracture was measured using a pendulum impact tester, in accordance with ASTM C368-88 (2019) "Standard Test Method for Impact Strength of Ceramic Materials". The specimen was a square piece (50mm × 50mm × 4mm) with a span of 40mm.

[0068] Vickers hardness (HV): According to GB / T16534-2009 "Test Method for Room Temperature Hardness of Fine Ceramics", a load of 9.8 N was applied to the polished glaze surface and held for 15 s. The hardness was calculated by measuring the diagonal length of the indentation. Ten points were measured for each sample and the average was taken.

[0069] Abrasion resistance: The friction test method was modified according to GB / T12967.3-2008 "Test method for anodic oxide films of aluminum and aluminum alloys - Part 3: Copper accelerated acetic acid salt spray test (CASS test)". Standard steel wool (0000) was used to rub the same position on the glaze surface 100 times under a load of 500g. The gloss loss rate before and after friction was measured (using a 60° gloss meter).

[0070] Surface cleanability: Based on daily use scenarios, drop 0.1mL of mixed oil (olive oil: soy sauce = 1:1) into the center of the glaze. After standing for 24 hours, wipe the glaze 10 times with a damp standard cotton cloth under a fixed pressure (2kPa). Use a colorimeter to measure the color difference ΔE between the wiped area and the original glaze. The smaller the ΔE, the easier it is to clean.

[0071] Antibacterial rate (24 hours): According to GB / T21510-2008 "Test method for antibacterial properties of nano-inorganic materials", Escherichia coli (ATCC25922) and Staphylococcus aureus (ATCC6538) were used as test bacteria to test the antibacterial rate of the glaze film covering method.

[0072] The test results are summarized in Tables 1 and 2 below.

[0073]

[0074]

[0075] Note: Comparative Examples 1, 3, and 6 did not contain any specific antibacterial agents, and the low antibacterial rates measured can be considered as background values, indicating that the glaze has no obvious inherent antibacterial ability.

[0076] As shown in Table 1, the products of Examples 1-3 of this invention exhibit superior flexural strength (138-152 MPa) and fracture toughness (4.2-4.8 MPa·m). 1 / 2 The performance of this invention reached or exceeded that of Comparative Example 1, and was significantly higher than that of Comparative Examples 2 and 3. More notably, in terms of impact resistance, a key indicator of dynamic toughness, the impact resistance of this invention (0.38-0.45 J) significantly outperformed that of Comparative Example 1 (0.28 J), demonstrating that the toughening mechanism introduced by this invention through pre-composite fibers and biomass carbon sources is highly effective in resisting sudden impacts. Comparative Example 4 (without fibers) showed a significant decrease in impact resistance and fracture toughness, and Comparative Example 5 (without carbon source) also showed a decrease in fracture toughness, confirming the crucial role of both in improving material toughness.

[0077] The Vickers hardness (6.5-6.9 GPa) of the glaze in this embodiment is higher than that of all comparative examples, indicating that the glaze is harder. The abrasion resistance (gloss loss rate 11.8-15.1%) is significantly better than that of comparative examples 1, 2, 3, and 6, demonstrating that the introduction of pre-sintered calcium phosphate and ATO significantly improves the abrasion resistance of the glaze. The abrasion resistance of comparative example 6 (ordinary glaze) deteriorates sharply, directly demonstrating the core contribution of the multifunctional glaze.

[0078] As shown in Table 2, the ease of cleaning (ΔE 2.8-3.5) of the embodiments of the present invention is excellent, superior to Comparative Examples 1 and 6 (ordinary glaze). This is mainly attributed to the high hardness and high density of the glaze, as well as the antistatic and auxiliary photocatalytic effects brought by ATO, making it difficult for oil stains to adhere and easy to wipe away. In terms of antibacterial rate, the embodiments of the present invention (greater than 94%) are much higher than Comparative Examples 1, 3, and 6 without antibacterial agents, achieving an excellent antibacterial level. This indicates that the present invention improves surface properties through multiple physical and chemical means, indirectly achieving a strong and long-lasting antibacterial effect, avoiding the risks of migration, discoloration, or failure that may be caused by antibacterial agents.

[0079] The pre-composite fiber and biomass carbon source preparation process of the present invention is simpler and has lower energy consumption. The main raw materials are natural minerals and biomass, which makes the cost controllable and more in line with the requirements of green environmental protection and large-scale production.

[0080] In summary, this invention, through the innovative introduction of pre-composite reinforcing fibers and biomass-derived porous carbon sources into the green body, the introduction of pre-sintered calcium phosphate powder and nano-tin antimony oxide into the glaze, and the optimization of the overall process, has successfully prepared a high-strength, environmentally friendly daily-use ceramic with outstanding comprehensive performance. This product not only possesses excellent static strength but also outstanding impact toughness and surface wear resistance, while also being easy to clean and having good antibacterial properties. Furthermore, the process is relatively simple and the raw materials are environmentally friendly. Compared with existing technologies, this invention has achieved significant progress in impact toughness, surface wear hardness, and performance balance, providing a more practical and competitive high-performance daily-use ceramic solution.

[0081] In conclusion, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A preparation process for a high-strength, environmentally friendly ceramic for daily use, characterized in that: Includes the following steps: S1. Preparation and molding of green body powder: Potassium feldspar, sodium feldspar, quartz, kaolin, zirconium silicate, pre-composite reinforcing fiber, biomass-derived carbon source, and dispersant are mixed evenly and subjected to the first stage of dry ball milling; then deionized water is added for the second stage of wet ball milling to obtain a uniform slurry; the slurry is filtered, aged, and kneaded to form ceramic green bodies, which are then dried to obtain ceramic blanks; S2. Preparation of multifunctional glaze slurry: Lithium spodumene, calcined zinc oxide, pre-sintered calcium phosphate powder, nano-tin antimony oxide, glaze clay, suspending agent, binder and water are mixed, wet ball milled, and iron is removed by sieving to obtain multifunctional glaze slurry. S3. Glazing and sintering: The multifunctional glaze slurry prepared in step S2 is applied to the surface of the ceramic green body obtained in step S1, and after drying, a glazed green body is obtained. The glazed body is placed in a kiln for gradient sintering, and after cooling in the kiln, the high-strength environmentally friendly daily-use ceramic is obtained. The preparation method of the precomposite reinforced fiber includes: mixing short basalt fibers with silica sol and alumina sol, stirring to form a uniform suspension, and spray drying to obtain a fiber precursor; heat-treating the fiber precursor at 600-800℃ for 1-2 hours in air atmosphere, and cooling to obtain the precomposite reinforced fiber. The biomass-derived carbon source is micron-sized porous carbon powder obtained by grinding bamboo powder, rice husk powder, or coconut shell powder after carbonization at 300-500℃ for 1-3 hours under limited oxygen.

2. The preparation process of a daily-use high-strength environmentally friendly ceramic according to claim 1, characterized in that: The raw materials for the green body in step S1 include, by weight, 20-35 parts potassium feldspar, 10-25 parts sodium feldspar, 15-30 parts quartz, 20-40 parts kaolin, 5-15 parts zirconium silicate, 1-5 parts pre-composite reinforcing fiber, 0.5-3 parts biomass-derived carbon source, and 0.1-1 parts dispersant.

3. The preparation process of a daily-use high-strength environmentally friendly ceramic according to claim 1, characterized in that: The mass ratio of the chopped basalt fiber to silica sol and alumina sol is 5-10:1-3:0.5-2.

4. The preparation process of a daily-use high-strength environmentally friendly ceramic according to claim 1, characterized in that: The raw materials of the multifunctional glaze slurry in step S2, by weight, include: 30-50 parts spodumene, 5-15 parts calcined zinc oxide, 3-10 parts pre-sintered calcium phosphate powder, 1-5 parts nano-tin antimony oxide, 10-20 parts glaze clay, 0.2-1 parts suspending agent, 0.5-2 parts binder, and 40-60 parts water.

5. The preparation process of a daily-use high-strength environmentally friendly ceramic according to claim 4, characterized in that: The preparation method of the pre-sintered calcium phosphate powder includes: calcining hydroxyapatite powder at 800-1000℃ for 1-3 hours, cooling and then grinding it to the micron level.

6. The preparation process of a daily-use high-strength environmentally friendly ceramic according to claim 1, characterized in that: The specific process for step S3 gradient sintering is as follows: first, heat the temperature to 150-300℃ at a rate of 2-5℃ / min and hold; then heat the temperature to 850-1000℃ at a rate of 3-8℃ / min and hold; finally, heat the temperature to the maximum firing temperature of 1180-1250℃ at a rate of 5-10℃ / min and hold for 1-4 hours.

7. The preparation process of a daily-use high-strength environmentally friendly ceramic according to claim 6, characterized in that: The maximum firing temperature is 1200-1230℃, and the holding time is 2-3 hours.

8. A daily-use high-strength environmentally friendly ceramic, prepared by the preparation process of the daily-use high-strength environmentally friendly ceramic as described in any one of claims 1-7.

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