Wear-resistant domestic ceramic with good light transmission and preparation method of wear-resistant domestic ceramic

Abstract

The invention discloses wear-resistant domestic ceramic with good light transmittance and a preparation method thereof.The wear-resistant domestic ceramic comprises a ceramic body and a glaze layer, and the glaze layer is prepared from, by mass, 10-20 parts of calcined kaolin, 10-15 parts of silica sand, 2-5 parts of titanium dioxide, 0.5-1 part of rare earth oxide, 10-15 parts of zirconite, 5-10 parts of corundum, 2-5 parts of titanium carbide and 1-3 parts of dispersing agent; the rare earth oxide is formed by mixing lanthanum trioxide and cerium dioxide according to the mass ratio of (1: 3)-(1: 5); the ceramic green body is prepared from the following materials in parts by mass: 35 to 45 parts of calcined kaolin, 15 to 25 parts of mullite, 15 to 25 parts of albite, 5 to 15 parts of silica sand, 5 to 15 parts of zirconium silicate, 5 to 10 parts of sodium silicate, 5 to 10 parts of silazite, 5 to 10 parts of calcite, 2 to 5 parts of silicon carbide and 1 to 3 parts of dispersing agent. The wear-resistant domestic ceramic disclosed by the invention is flat and smooth in glaze surface, good in texture, excellent in hardness and bending strength, excellent in wear resistance and good in light transmission.

Description

Technical Field

[0001] This invention relates to the field of ceramic materials technology, and in particular to a wear-resistant daily-use ceramic with good light transmittance and its preparation method. Background Technology

[0002] Daily-use ceramics refer to ceramic products used in daily life, mainly including tableware, cups, vases, and decorations, which possess certain properties such as heat resistance, cold resistance, and acid and alkali resistance. Traditional daily-use ceramics are silicate products made from natural raw materials such as clay, quartz, and feldspar. With the development of modern science and technology, many new daily-use ceramic products have emerged in the past century. These products no longer use or use very little of the traditional ceramic raw materials such as clay, feldspar, and quartz, but instead use other special raw materials, even expanding to non-silicate and non-oxide materials. Furthermore, many new processes have emerged to better meet daily needs.

[0003] Translucent ceramics also belong to the category of daily-use ceramics. When the raw material clay is of good quality and the manufacturing process is relatively thin, it can possess a certain degree of light transmission.

[0004] Food is of paramount importance to the people, and the most commonly used daily ceramic cups, bowls, and plates generally need to be reused. Therefore, the wear resistance of daily ceramics is essential, which places demands on their glaze materials. Some studies have also yielded daily ceramics with better wear resistance. For example, CN112174697A discloses a wear-resistant daily ceramic and its preparation method. Its glaze layer is made from the following raw materials in parts by weight: 30-40 parts zircon sand, 10-15 parts zirconia, 5-10 parts nepheline syenite, 3-6 parts titanium carbide powder, 3-5 parts titanium dioxide, 4-6 parts lutetium oxide, 2-4 parts tungsten powder, 2-4 parts polyvinyl alcohol (5 wt%), 2-4 parts glycerol, and 20-30 parts water.

[0005] Nevertheless, currently used daily-use ceramics still suffer from these problems: poor glaze smoothness; and poor properties such as gloss, hardness, and strength. There remains a need to develop new glaze formulations and new daily-use ceramics. Summary of the Invention

[0006] To address the technical problems existing in the prior art, the present invention provides a wear-resistant daily-use ceramic, comprising a ceramic body and a glaze layer, wherein the material of the glaze layer comprises, by weight, parts of...

[0007] The mixture comprises 10-20 parts calcined kaolin, 10-15 parts silica sand, 2-5 parts titanium dioxide, 0.5-1 parts rare earth oxides, 10-15 parts zircon, 5-10 parts corundum, 2-5 parts titanium carbide, and 1-3 parts dispersant. The rare earth oxides are a mixture of lanthanum trioxide and cerium dioxide in a mass ratio of 1:3 to 1:5.

[0008] The materials of the ceramic green body, in parts by weight, include:

[0009] Calcined kaolin 35-45 parts, mullite 15-25 parts, albite 15-25 parts, silica sand 5-15 parts, zirconium silicate 5-15 parts, sodium silicate 5-10 parts, borosilicate aluminum calcium stone 5-10 parts, calcite 5-10 parts, silicon carbide 2-5 parts, dispersant 1-3 parts.

[0010] The glaze layer of this invention is primarily composed of calcined kaolin, zircon, and silica sand. Kaolin is a common clay mineral found in nature, possessing excellent plasticity and refractoriness; zircon exhibits low thermal expansion, high thermal conductivity, and strong chemical stability; silica sand has high refractoriness, enhancing the strength and wear resistance of ceramics. The glaze layer also contains a small amount of rare earth oxides. The addition of rare earth oxides allows for synergistic effects with other components, promoting a dense and fine glaze surface and further improving the wear resistance and mechanical strength of the ceramics.

[0011] The ceramic body of this invention is mainly made of kaolin, mullite, and albite. Mullite powder is an aluminosilicate with high temperature resistance, low thermal conductivity, and low coefficient of thermal expansion. Albite is a common feldspar mineral. Before firing, feldspar can act as a lean raw material, reducing drying shrinkage and deformation of the body, improving drying performance, and shortening drying time.

[0012] Furthermore, the dispersant is at least one of sodium tripolyphosphate, sodium pyrophosphate, sodium dodecyl sulfonate, and carboxymethyl cellulose.

[0013] Furthermore, the mesh size of each component in the glaze layer material and the ceramic body material is 325 to 6000 mesh.

[0014] This invention also provides a method for preparing the above-mentioned wear-resistant daily-use ceramics, comprising the following steps:

[0015] S1. Weigh each raw material by mass and mix them separately to obtain the glaze layer material and the ceramic body material;

[0016] S2. Add water to the ceramic body material and ball mill it to pass through the first screen to obtain clay. Shape the clay to obtain a rough blank, then air dry it naturally and then trim the blank. Finally, bisque fire it to obtain the ceramic body.

[0017] S3. Add water to the glaze layer material and ball mill it to pass it through the second sieve to obtain glaze. Use the glaze to glaze the ceramic body, and then fire the glaze to obtain wear-resistant daily ceramics.

[0018] Furthermore, the ball-to-material ratio in the ball mill is 1:1.5 to 2.5.

[0019] Furthermore, the ball mill rotation speed is 200-300 rpm.

[0020] Furthermore, the first sieve has a mesh size of 80-120.

[0021] The second sieve is 100-150 mesh.

[0022] Furthermore, the solid content of the mud is 40% to 60%;

[0023] The solid content of the glaze is 45% to 55%.

[0024] Furthermore, the bisque firing is maintained at 900–950°C for 6–10 hours.

[0025] Furthermore, the glaze is fired at 650–700°C for 1.5–2 hours; then the temperature is raised to 850–950°C and held for 2–3 hours; finally, the temperature is raised to 1050–1250°C and sintered for 3–5 hours.

[0026] Compared with the prior art, the present invention has the following beneficial effects:

[0027] The wear-resistant daily-use ceramic of the present invention has a suitable raw material ratio for the glaze layer, resulting in a glaze layer with excellent density and mechanical strength. Furthermore, the addition of small amounts of lanthanum trioxide and cerium dioxide to the glaze layer, along with the adjustment of the lanthanum trioxide to cerium dioxide ratio, improves the toughness and wear resistance of the glaze layer. Overall, the wear-resistant daily-use ceramic of the present invention has a smooth and even glaze surface with good texture, excellent hardness and flexural strength, superior wear resistance, and good light transmittance. Detailed Implementation

[0028] The endpoints and any values ​​of the ranges disclosed in this invention are not limited to the precise ranges or values, and these ranges or values ​​should be understood to include values ​​close to these ranges or values. For numerical ranges, the endpoint values ​​of the various ranges, the endpoint values ​​of the various ranges and individual point values, and individual point values ​​can be combined with each other to obtain one or more new numerical ranges, which should be considered as specifically disclosed in this invention.

[0029] The technical solutions of the present invention will be clearly and completely described below with reference to specific embodiments. 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 skilled in the art without creative effort are within the scope of protection of the present invention.

[0030] Description of some of the raw materials used in the embodiments of this invention:

[0031] Calcined kaolin, 6000 mesh; silica sand, 1000 mesh; titanium dioxide, 2000 mesh; lanthanum trioxide, 1000 mesh; cerium dioxide, 1000 mesh; zircon, 2000 mesh; corundum, 2000 mesh; titanium carbide, 1000 mesh; mullite, 1000 mesh; albite, 1000 mesh; zirconium silicate, 500 mesh; sodium silicate, 500 mesh; calcium silicate, 500 mesh; calcite, 600 mesh; silicon carbide, 1000 mesh; these mineral raw materials are all commonly used and can be purchased directly from the market.

[0032] Carboxymethyl cellulose, purchased from Shandong Duoju Chemical Co., Ltd.

[0033] All other raw materials not mentioned are common materials in the art. These will not be elaborated upon in the specific embodiments.

[0034] Example 1

[0035] A method for preparing a wear-resistant daily-use ceramic with good light transmittance, the steps of which are as follows, in parts by weight:

[0036] Step 1: Preparation of ceramic body: 40 parts calcined kaolin, 20 parts mullite, 20 parts albite, 10 parts silica sand, 15 parts zirconium silicate, 10 parts sodium silicate, 10 parts calcium silicate, 10 parts calcite, 3 parts silicon carbide, 2 parts carboxymethyl cellulose, and water are placed in a fine ball mill. The ball-to-material ratio is controlled at 1:2, and the mixture is ball-milled at 250 rpm. The mixture is then passed through a 100-mesh sieve to obtain a clay material with a solid content of 55%. The clay material is shaped to obtain a rough body, then naturally air-dried and trimmed. Finally, it is bisque-fired at 950℃ for 8 hours to obtain the ceramic body.

[0037] Step 2, Preparation of glaze: 20 parts calcined kaolin, 10 parts silica sand, 5 parts titanium dioxide, 1 part rare earth oxide (lanthanum trioxide to cerium dioxide mass ratio 1:3), 15 parts zircon, 10 parts corundum, 5 parts titanium carbide, and 1 part carboxymethyl cellulose are mixed by ball milling at 300 rpm with a ball-to-material ratio of 1:2 and then passed through a 150-mesh sieve to obtain a glaze with a solid content of 45%.

[0038] Step 3, glazing: The ceramic body from Step 1 is glazed with the glaze from Step 2, then heated from room temperature to 650°C at a rate of 2°C and fired for 2 hours. Then, the temperature is raised to 900°C at a rate of 5°C and held for 2.5 hours. Finally, the temperature is raised to 1250°C at a rate of 6°C and sintered for 4 hours. Finally, the wear-resistant daily ceramic is obtained by cooling in the furnace.

[0039] Example 2

[0040] A method for preparing a wear-resistant daily-use ceramic with good light transmittance, the steps of which are as follows, in parts by weight:

[0041] Step 1: Preparation of ceramic body: 40 parts calcined kaolin, 20 parts mullite, 20 parts albite, 10 parts silica sand, 15 parts zirconium silicate, 10 parts sodium silicate, 10 parts calcium silicate, 10 parts calcite, 3 parts silicon carbide, 2 parts carboxymethyl cellulose, and water are placed in a fine ball mill. The ball-to-material ratio is controlled at 1:2, and the mixture is ball-milled at 250 rpm. The mixture is then passed through a 100-mesh sieve to obtain a clay material with a solid content of 55%. The clay material is shaped to obtain a rough body, then naturally air-dried and trimmed. Finally, it is bisque-fired at 950℃ for 8 hours to obtain the ceramic body.

[0042] Step 2, Preparation of glaze: 20 parts calcined kaolin, 10 parts silica sand, 5 parts titanium dioxide, 1 part rare earth oxide (lanthanum trioxide to cerium dioxide mass ratio 1:4), 15 parts zircon, 10 parts corundum, 5 parts titanium carbide, and 1 part carboxymethyl cellulose are mixed by ball milling at 300 rpm with a ball-to-material ratio of 1:2 and then passed through a 150-mesh sieve to obtain a glaze with a solid content of 45%.

[0043] Step 3, glazing: The ceramic body from Step 1 is glazed with the glaze from Step 2, then heated from room temperature to 650°C at a rate of 2°C and fired for 2 hours. Then, the temperature is raised to 900°C at a rate of 5°C and held for 2.5 hours. Finally, the temperature is raised to 1250°C at a rate of 6°C and sintered for 4 hours. Finally, the wear-resistant daily ceramic is obtained by cooling in the furnace.

[0044] Example 3

[0045] A method for preparing a wear-resistant daily-use ceramic with good light transmittance, the steps of which are as follows, in parts by weight:

[0046] Step 1: Preparation of ceramic body: 40 parts calcined kaolin, 20 parts mullite, 20 parts albite, 10 parts silica sand, 15 parts zirconium silicate, 10 parts sodium silicate, 10 parts calcium silicate, 10 parts calcite, 3 parts silicon carbide, 2 parts carboxymethyl cellulose, and water are placed in a fine ball mill. The ball-to-material ratio is controlled at 1:2, and the mixture is ball-milled at 250 rpm. The mixture is then passed through a 100-mesh sieve to obtain a clay material with a solid content of 55%. The clay material is shaped to obtain a rough body, then naturally air-dried and trimmed. Finally, it is bisque-fired at 950℃ for 8 hours to obtain the ceramic body.

[0047] Step 2, Preparation of glaze: 20 parts calcined kaolin, 10 parts silica sand, 5 parts titanium dioxide, 1 part rare earth oxide (lanthanum trioxide to cerium dioxide mass ratio 1:5), 15 parts zircon, 10 parts corundum, 5 parts titanium carbide, and 1 part carboxymethyl cellulose are mixed by ball milling at 300 rpm with a ball-to-material ratio of 1:2 and then passed through a 150-mesh sieve to obtain a glaze with a solid content of 45%.

[0048] Step 3, glazing: The ceramic body from Step 1 is glazed with the glaze from Step 2, then heated from room temperature to 650°C at a rate of 2°C and fired for 2 hours. Then, the temperature is raised to 900°C at a rate of 5°C and held for 2.5 hours. Finally, the temperature is raised to 1250°C at a rate of 6°C and sintered for 4 hours. Finally, the wear-resistant daily ceramic is obtained by cooling in the furnace.

[0049] Comparative Example 1

[0050] The difference from Example 1 is that the rare earth oxide is lanthanum trioxide.

[0051] Comparative Example 2

[0052] The difference from Example 1 is that the rare earth oxide is cerium dioxide.

[0053] Comparative Example 3

[0054] The difference from Example 1 is that it does not contain rare earth oxides.

[0055] Test case

[0056] The appearance of the daily-use ceramics in the embodiments and comparative examples of the present invention was evaluated. The results showed that they all had a smooth, fine, and delicate glaze surface with a glossy texture. This indicates that the raw materials for the glaze layer and the raw materials for the body of the ceramic material of the present invention are well-proportioned and have good overall performance.

[0057] Thermal stability is an important indicator of daily-use fine ceramics, characterizing their ability to resist drastic temperature changes. Referring to GB / T 3298-2022 "Test Method for Thermal Shock Resistance of Daily-Use Ceramic Ware", the daily-use ceramics prepared in the embodiments and comparative examples of this invention were heated to 120, 140, 160, 180, and 200℃, respectively, held at that temperature for 30 minutes, and then rapidly immersed in 20℃ water for rapid cooling. Thermal stability was determined by the presence or absence of cracks in the products. Five samples were set for each group. The thermal stability results are shown in Table 1. No cracks were observed in the embodiments and comparative examples at 120℃~20℃ and 140℃~20℃, and are therefore omitted from Table 1.

[0058] Table 1 Thermal stability test results

[0059]

[0060]

[0061] As can be seen from the test results in Table 1, the glaze material without lanthanum trioxide and cerium dioxide in Comparative Example 3, after multiple thermal stability tests at 200℃ to 20℃, all samples developed cracks. Comparative Examples 1 and 2 show that adding lanthanum trioxide or cerium dioxide can improve the thermal stability of the ceramics. The results from Comparative Examples 1 to 3 demonstrate that adding lanthanum trioxide and cerium dioxide, and adjusting their ratio, can further enhance the thermal stability of the ceramics.

[0062] The water absorption rate of ceramic samples from the examples and comparative examples was tested using the boiling method in GB / T 3810.3-2016 "Test Methods for Ceramic Tiles Part 3: Determination of Water Absorption, Apparent Porosity, Apparent Relative Density and Bulk Density". Each group was tested 5 times. The results are shown in Table 2.

[0063] Table 2 Results of water absorption rate test

[0064] Water absorption (%) Example 1 0.3 Example 2 0.2 Example 3 0.3 Comparative Example 1 0.4 Comparative Example 2 0.5 Comparative Example 3 0.7

[0065] As can be seen from the test results in Table 2, the daily-use ceramics of Examples 1 to 3 of the present invention all have low water absorption rates. This may be because the addition of lanthanum trioxide and cerium dioxide improves the density of the glaze layer, thereby reducing the water absorption of the daily-use ceramics.

[0066] Referring to GB / T 3810.7-2016 "Test Methods for Ceramic Tiles - Part 7: Determination of Abrasion Resistance of Glazed Tiles", the abrasion resistance grades for ceramic tiles range from 1 to 5, with 5 being the best and 1 the worst. The abrasion resistance test results for the examples and comparative examples are shown in Table 3.

[0067] Table 3 Abrasion resistance test results

[0068] Abrasion resistance level Example 1 4 Example 2 5 Example 3 4 Comparative Example 1 3 Comparative Example 2 3 Comparative Example 3 3

[0069] As can be seen from the test results in Table 3, Examples 1 to 3 of the present invention all have good wear resistance, and the wear resistance level is above level 4.

[0070] Daily-use ceramics are often used to hold food or water at high temperatures. The thermal conductivity of the embodiments and comparative examples of this invention was also tested using a flat plate thermal conductivity meter. The results are shown in Table 4. The lower the thermal conductivity, the slower the heat conduction and the slower the temperature transfer.

[0071] Table 4 Thermal conductivity test results

[0072] Thermal conductivity (W / m-k) Example 1 24 Example 2 22 Example 3 25 Comparative Example 1 27 Comparative Example 2 28 Comparative Example 3 29

[0073] The test results in Table 4 show that the addition of lanthanum trioxide and cerium dioxide can also reduce the thermal conductivity of ceramic materials. This indicates that although the addition of lanthanum trioxide and cerium dioxide promotes the formation of a denser structure on the glaze surface, it also creates more thermal conductivity channels within the glaze, thus reducing the thermal conductivity.

[0074] The flexural strength of the examples and comparative examples was also tested, and the results are shown in Table 5.

[0075] Flexural strength (MPa) Example 1 15.2 Example 2 16.3 Example 3 15.5 Comparative Example 3 13.4

[0076] In addition, because the glaze layer of this invention also contains materials with good light transmittance such as titanium dioxide, and the glaze layer is also relatively dense, the daily ceramics of this invention also have relatively good light transmittance.

[0077] In summary, the glaze material ratio of the wear-resistant daily-use ceramic of the present invention is appropriate, resulting in a glaze layer with excellent density and mechanical strength. Furthermore, the addition of small amounts of lanthanum trioxide and cerium dioxide to the glaze layer, along with the adjustment of the lanthanum trioxide to cerium dioxide ratio, improves the toughness and wear resistance of the glaze layer. Overall, the wear-resistant daily-use ceramic of the present invention has a smooth and even glaze surface with good texture, excellent hardness and flexural strength, superior wear resistance, and good light transmittance.

[0078] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. 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 wear-resistant daily-use ceramic, comprising a ceramic body and a glaze layer, characterized in that, The material of the glaze layer includes, by weight, parts thereof. The mixture comprises 10-20 parts calcined kaolin, 10-15 parts silica sand, 2-5 parts titanium dioxide, 0.5-1 parts rare earth oxides, 10-15 parts zircon, 5-10 parts corundum, 2-5 parts titanium carbide, and 1-3 parts dispersant. The rare earth oxides are a mixture of lanthanum trioxide and cerium dioxide in a mass ratio of 1:3 to 1:

5. The materials of the ceramic green body, in parts by weight, include: Calcined kaolin 35-45 parts, mullite 15-25 parts, albite 15-25 parts, silica sand 5-15 parts, zirconium silicate 5-15 parts, sodium silicate 5-10 parts, borosilicate aluminum calcium stone 5-10 parts, calcite 5-10 parts, silicon carbide 2-5 parts, dispersant 1-3 parts.

2. The wear-resistant daily-use ceramic according to claim 1, characterized in that, The dispersant is at least one of sodium tripolyphosphate, sodium pyrophosphate, sodium dodecyl sulfonate, and carboxymethyl cellulose.

3. The wear-resistant daily-use ceramic according to claim 1, characterized in that, The mesh size of each component in the glaze layer material and the ceramic body material is 325 to 6000 mesh.

4. A method for preparing wear-resistant daily-use ceramics as described in claim 1, characterized in that, Includes the following steps, S1. Weigh each raw material by mass and mix them separately to obtain the glaze layer material and the ceramic body material; S2. Add water to the ceramic body material and ball mill it to pass through the first screen to obtain clay. Shape the clay to obtain a rough blank, then air dry it naturally and then trim the blank. Finally, bisque fire it to obtain the ceramic body. S3. Add water to the glaze layer material and ball mill it to pass it through the second sieve to obtain glaze. Use the glaze to glaze the ceramic body, and then fire the glaze to obtain wear-resistant daily ceramics.

5. The method for preparing wear-resistant daily-use ceramics according to claim 4, characterized in that, The ball-to-material ratio in the ball mill is 1:1.5 to 2.

5.

6. The method for preparing wear-resistant daily-use ceramics according to claim 4, characterized in that, The ball milling speed is 200-300 rpm.

7. The method for preparing wear-resistant daily-use ceramics according to claim 4, characterized in that, The first sieve is 80-120 mesh; The second sieve is 100-150 mesh.

8. The method for preparing wear-resistant daily-use ceramics according to claim 4, characterized in that, The solid content of the mud is 40% to 60%; The solid content of the glaze is 45% to 55%.

9. The method for preparing wear-resistant daily-use ceramics according to claim 4, characterized in that, The bisque firing is carried out at 900-950℃ for 6-10 hours.

10. The method for preparing wear-resistant daily-use ceramics according to claim 4, characterized in that, The glaze is fired at 650–700°C for 1.5–2 hours; then the temperature is raised to 850–950°C and held for 2–3 hours; finally, the temperature is raised to 1050–1250°C and sintered for 3–5 hours.

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