Fiber-reinforced ceramic product and preparation method thereof

Abstract

The invention belongs to the field of ceramics, and particularly relates to a fiber-reinforced ceramic product and a preparation method thereof. The fiber-reinforced ceramic product comprises a bonding component, a framework component, a reinforcing component, an auxiliary component and water, wherein the bonding component is prepared from 25 to 90 parts by weight of clay; the skeleton component is prepared from 5 to 50 parts of quartz and 5 to 40 parts of feldspar; the reinforcing component is prepared from the following components in parts by weight: 0.1 to 15 parts of basalt chopped fiber and 0.1 to 15 parts of basalt fiber gridding cloth; the auxiliary agent component is 0.1 to 3 parts of a water reducing agent; and 15 to 60 parts of water. According to the preparation method, grouting, blank pressing, spraying, smearing or dehydration self-leveling forming is adopted, through synergistic reinforcement of the two basalt fibers, the problems that large and special-shaped parts are difficult to manufacture and the brittleness is large are solved, the product is high in strength and good in toughness, the process is flexible and controllable, and the preparation method is suitable for industrial production.

Description

Technical Field

[0001] This invention belongs to the field of ceramics, specifically relating to a fiber-reinforced ceramic product and its preparation method. Background Technology

[0002] Ceramic materials are widely used due to their excellent physical and chemical properties, but their traditional product forms and sizes are fundamentally limited by the forming process. Currently, industrially produced ceramic products mainly fall into two categories: flat products (such as ceramic tiles) and rotary products formed by pottery rotation (such as round cylinders and jars). For large-sized (side length or height exceeding 1 meter), regular square, or complex irregular-shaped three-dimensional components, traditional processes face three major technical bottlenecks that cannot be overcome:

[0003] 1. Collapse upon molding: After losing mold support, large wet blanks, due to insufficient structural strength, cannot resist gravity, resulting in central collapse and edge deformation, making it impossible to achieve the designed shape. There is a common dilemma in the industry: "It's possible to make a 1.5-meter diameter round cylinder, but difficult to make a 1.2-meter side square platform."

[0004] 2. The billet is brittle and difficult to transfer: Even if it is formed, the large dry billet is extremely brittle and is very easy to break due to stress concentration during demolding, handling and kiln loading, making it impossible to transfer the process in large-scale production.

[0005] 3. Firing stress-induced cracking: During the drying shrinkage and firing in the kiln (especially the quartz crystal transformation stage at around 573℃), large green bodies generate huge and uneven thermal stress inside, which can easily cause cracking or deformation of the products during the firing process, resulting in extremely low yield and uncontrollable failure rate.

[0006] To improve the mechanical properties of ceramics, existing technologies have attempted to add reinforcing materials such as glass fiber, carbon fiber, and organic fiber, but all of them have obvious drawbacks: glass fiber has poor heat resistance and is prone to softening and decomposition during ceramic sintering, affecting the stability of the product; carbon fiber is expensive and has poor interfacial compatibility with the ceramic matrix, making it difficult to form a strong bond; organic fiber is prone to carbonization at high temperatures and cannot retain its reinforcing effect in the ceramic sintering environment.

[0007] Basalt fiber, as a natural mineral fiber, possesses advantages such as high temperature resistance, high mechanical strength, good chemical stability, moderate cost, and environmental friendliness. It exhibits good compatibility with the chemical properties of ceramic matrices. However, current technologies have not yet achieved synergistic compatibility between chopped basalt fibers and basalt fiber mesh. Therefore, the ceramic industry urgently needs a technological solution that goes beyond material modification, incorporating systematic innovation in structural design and molding methods to overcome the manufacturing barriers of large, irregularly shaped ceramic components and meet the evolving demands of high-end home furnishings, architectural decoration, and public art for ceramic materials. This invention stems from this need. Summary of the Invention

[0008] To address the problems existing in the prior art, this invention provides a fiber-reinforced ceramic product and its preparation method. The advantage of this invention lies in its systematic solution to the fundamental problem of traditional ceramics' inability to manufacture large, irregularly shaped structural components. This method enables the stable production of large-sized square planar parts, regularly shaped containers, and monolithic sculptures several meters in height. The raw material composition, along with chopped permanent basalt fibers and basalt fiber mesh, synergistically inhibits cracking, raising the yield of large-scale products to a controllable industrial level.

[0009] The present invention provides a fiber-reinforced ceramic product comprising a binder component, a skeleton component, a reinforcing component, an additive component, and water; wherein, by weight: The adhesive component is 25-90 parts of clay; The skeleton components consist of 5-50 parts quartz and 5-40 parts feldspar. The reinforcing component consists of 0.1-15 parts of basalt short-cut fibers and 0.1-15 parts of basalt fiber mesh. The auxiliary agent component is 0.1-3 parts of water-reducing agent; Water is 15-60 parts.

[0010] Preferably, the fiber-reinforced ceramic product comprises the following raw materials in parts by weight: 55 parts clay, 25 parts quartz, 20 parts feldspar, 1.5 parts water-reducing agent, 7 parts chopped basalt fibers, 7 parts basalt fiber mesh, and 35 parts water.

[0011] Preferably, the clay has a particle size of 0.1-2 μm; And / or, the silica content in the quartz is 90-99%, and the particle size of the quartz is 65μm-5mm; And / or, the feldspar has a Mohs hardness of 6-6.5 and a density of 2.6-2.8 g / cm³. 3 ; And / or, the water-reducing agent is sodium lignosulfonate or calcium lignosulfonate; And / or, the basalt chopped fibers have a monofilament diameter of 5.5-25μm and a fiber length of 6-100mm.

[0012] Based on the same technical concept, another aspect of the present invention is to provide a method for preparing fiber-reinforced ceramic products, wherein the preparation method is slip casting, pressing, spraying, troweling, or dehydration self-leveling.

[0013] Preferably, the grouting process includes the following steps: (1) Mix clay, quartz, feldspar, water-reducing agent, basalt short fiber and water to obtain fiber-mixed slurry; (2) Fix the basalt fiber mesh inside the mold and inject the mixed fiber slurry from the bottom of the mold to wrap the basalt fiber mesh and then dehydrate and dry it to form the shape.

[0014] Preferably, the pressing process includes the following steps: (1) Mix clay, quartz, feldspar, water-reducing agent, basalt short fiber and water to obtain fiber-mixed slurry; (2) Press the fiber-mixed slurry into a mud blank, and lay basalt fiber mesh on the surface of the mud blank; (3) After the clay blank is dried, the mixed fiber slurry is then covered onto the basalt fiber mesh cloth and pressed to form a sandwich structure, thus completing the pressing and forming process.

[0015] Preferably, the spray coating process includes the following steps: (1) Mix clay, quartz, feldspar, water-reducing agent, basalt short fiber and water to obtain fiber-mixed slurry; (2) The fiber-mixed slurry is sprayed to obtain the bottom layer mud. (3) Lay basalt fiber mesh on the surface of the bottom mud material, and then continue spraying to complete the spraying and forming.

[0016] Preferably, the coating process includes the following steps: (1) Mix clay, quartz, feldspar, water-reducing agent, basalt short fiber and water to obtain fiber-mixed slurry; (2) The fiber-mixed slurry is applied to the mud by hand to obtain the bottom mud material; (3) Lay basalt fiber mesh on the surface of the bottom mud material, and then continue to apply it by hand to complete the application and shaping.

[0017] Preferably, the dehydration self-leveling molding process includes the following steps: (1) Mix clay, quartz, feldspar, water-reducing agent, basalt short fiber and water to obtain fiber-mixed slurry; (2) The fiber-mixed slurry is poured into a permeable bottom mold, and after dehydration and curing, Wuyan fiber mesh is laid. (3) Then continue to pour the fiber-mixed slurry, and after dehydration, the self-leveling molding is completed.

[0018] It should be noted that when it is necessary to prepare complex ceramic products, such as complex home furnishing products, separate manufacturing and body connection can be adopted; when preparing ultra-large statues, partitioned prefabrication, independent temperature-controlled firing and on-site assembly can be adopted.

[0019] The beneficial effects of this invention are as follows: This invention provides five forming methods: grouting, pressing, spraying, troweling, and dehydration self-leveling. These methods can be flexibly selected according to the size (from small components to super-large sculptures) and shape (from regular parts to complex irregular parts), solving the pain point that traditional processes are difficult to use to produce large and irregular ceramic products. For super-large or complex structural products, they can be made through separate manufacturing, green body connection or partition prefabrication, and on-site assembly, further expanding the application scenarios of ceramic products. Secondly, basalt chopped fibers and basalt fiber mesh form a synergistic reinforcement system. The chopped fibers can be uniformly dispersed in the ceramic matrix, inhibiting the generation and propagation of microcracks, while the basalt fiber mesh forms a continuous reinforcing skeleton, improving the overall flexural strength and impact toughness of the product, effectively overcoming the defects of traditional ceramics being brittle. Finally, the chemical composition of basalt fibers has good compatibility with the ceramic matrix (clay, quartz, feldspar system), and can form a strong interface bond with the matrix during sintering, avoiding problems such as fiber shedding and delamination, ensuring the structural stability and performance consistency of the product during long-term use. Moreover, basalt fibers have excellent high-temperature resistance and can withstand the high-temperature environment of ceramic sintering without softening, decomposition, or carbonization. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be described in detail below. Obviously, the described embodiments are merely some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0021] Example 1 This embodiment provides a grouting molding process, including the following steps: (1) Raw material pretreatment: Take 25 kg of clay (particle size 0.1-1 μm), put it in a 60℃ constant temperature oven and dry for 4 h to remove free moisture from the raw material; take 5 kg of quartz (silica content 90%, particle size 65 μm-200 μm) and 5 kg of feldspar (Mohs hardness 6, density 2.6 g / cm³) 3 The raw materials are sieved through a 200-mesh standard sieve to remove large particles and lumps. Drying the clay prevents air bubbles from forming in the slurry due to uneven moisture content, and sieving the raw materials ensures uniform particle size, improving the dispersibility of the subsequent slurry and the density of the finished product.

[0022] (2) Preparation of mixed fiber slurry: Pretreated clay, quartz, and feldspar were sequentially added to the grinding jar of a planetary ball mill. 0.1 kg of water-reducing agent (sodium lignosulfonate), 0.1 kg of basalt chopped fibers (monofilament diameter 25 μm, fiber length 30 mm), and 15 kg of water were added. After sealing the grinding jar, the ball mill speed was set to 300 r / min, and the milling time was 2 h. After milling, the grinding balls were removed by filtration to obtain a uniform and fine mixed fiber slurry. The ball milling process allows for thorough mixing of the raw materials. The water-reducing agent reduces the viscosity of the slurry and improves its fluidity. The basalt chopped fibers are uniformly dispersed in the slurry during the ball milling process, providing uniform reinforcement for the finished product.

[0023] (3) Mold pretreatment: Select a plaster mold that matches the shape of the target product, wipe the inner wall of the mold with a clean cloth to remove dust and impurities, and then evenly apply a layer of silicone oil release agent to the inner wall of the mold. The coating thickness should be controlled at 0.05 mm. Place it in a ventilated place to dry for 1 hour. The release agent can reduce the adhesion between the blank and the inner wall of the mold, avoid damage to the blank during demolding, and ensure the integrity of the product shape.

[0024] (4) Fixing the basalt fiber mesh: Take 1 kg of basalt fiber mesh and cut it into the corresponding shape according to the inner cavity size of the mold. Use a high-temperature resistant inorganic adhesive to apply the adhesive at 5 cm intervals along the edge of the mesh and fix it in the preset position inside the mold, ensuring that the mesh is flat, wrinkle-free, and without displacement. Fixing the mesh ensures that it maintains the preset position during the grouting process, so that the subsequent grout can evenly wrap the mesh and form a stable reinforced structure.

[0025] (5) Grouting operation: Pour the fiber-mixed slurry into the grouting funnel and slowly inject it from the grouting port at the bottom of the mold. The grouting speed should be controlled at 5L / min until the slurry completely covers the basalt fiber mesh and the inner cavity of the mold is filled with slurry. After closing the grouting port, let it stand for 2 hours. Slow grouting can avoid the slurry impacting the mesh and causing displacement, and at the same time reduce the generation of air bubbles in the slurry; the standing process can allow the slurry to fully fill the gaps in the mold and improve the density of the blank. It should be noted that the material should also be discharged from the bottom.

[0026] (6) Dehydration and drying: Transfer the mold filled with slurry to a constant temperature and humidity drying oven, set the temperature to 40℃ and the relative humidity to 60%, and dry for 12 hours. During this period, observe the condition of the green body every 3 hours. If micro-cracks are found on the surface, adjust the humidity to 70% in time. Constant temperature and humidity drying can control the rate of moisture evaporation, avoid the green body from generating internal stress due to excessive drying, thereby preventing cracking and ensuring the stability of the green body structure.

[0027] (7) Demolding and sintering: When the moisture content of the green body drops below 5%, gently tap the side wall of the mold to separate the green body from the mold, and slowly remove the green body; place the green body into the electric kiln, heat it to 1250℃ for about 12 hours and then hold it at that temperature, then turn off the kiln fire, and cool it to room temperature for about 24 hours to obtain fiber-reinforced ceramic products. Gradient heating sintering can improve the density and crystallinity of the ceramic matrix, enhance the interfacial bonding force between the fiber and the matrix, and further optimize the mechanical properties and structural stability of the products.

[0028] Example 2 This embodiment provides a process for pressing and forming a preform, including the following steps: (1) Raw material pretreatment: Weigh 30 kg of clay (particle size 0.1-1 μm) and dry it in an oven at 55℃ for 3.5 h; weigh 10 kg of quartz (silica content 92%, particle size 100 μm-300 μm) and 10 kg of feldspar (Mohs hardness 6, density 2.6 g / cm³) 3 The clay is passed through a 180-mesh sieve to remove impurities and large particles. Drying the clay reduces the moisture content of the slurry, making it easier to press and shape later; screening the raw materials ensures that the particles are uniform and avoids large particles affecting the pressing effect of the green body.

[0029] (2) Preparation of fiber-reinforced slurry: Pretreated clay, quartz, and feldspar were placed in a high-speed mixer, and 0.5 kg of water-reducing agent (calcium lignosulfonate), 1 kg of basalt chopped fibers (monofilament diameter 20 μm, fiber length 40 mm), and 25 kg of water were added. The mixture was stirred at 800 r / min for 1.5 h to obtain a uniform fiber-reinforced slurry. High-speed stirring allows the raw materials to mix quickly, the water-reducing agent improves the fluidity of the slurry, and the basalt chopped fibers are evenly dispersed, laying the foundation for the reinforcing effect.

[0030] (3) Initial pressing of the clay blank: Pour the fiber-mixed slurry into the lower mold cavity of the hydraulic press, control the slurry thickness at 20mm, set the pressing pressure to 15MPa, and hold the pressure for 3min. After pressing, a preliminary clay blank is obtained. Pressing removes some water from the slurry, forming a clay blank with a certain strength, which provides support for the subsequent laying of the mesh cloth.

[0031] (4) Laying the mesh: When there are no obvious water stains on the surface of the mud blank (moisture content of about 15%), take out the mud blank and lay 1 kg of basalt fiber mesh on the upper surface of the mud blank. Gently press the mesh with a scraper to make the mesh adhere tightly to the surface of the mud blank without gaps. Ensure that the mesh is in full contact with the bottom mud blank to provide a stable intermediate layer for the subsequent covering slurry to form a sandwich structure and ensure the reinforcement effect.

[0032] (5) Clay blank drying: Place the clay blank with the mesh cloth laid on it on the drying rack and let it dry naturally at room temperature (25℃) and under ventilation for 8 hours to reduce the moisture content of the clay blank to below 10%. Natural drying can prevent the clay blank from cracking due to rapid dehydration and ensure that the clay blank maintains its structural integrity before secondary pressing.

[0033] (6) Secondary pressing: The dried clay blank is placed back into the lower mold cavity of the hydraulic press. Fiber-mixed slurry is evenly spread on the upper surface of the mesh cloth, with the slurry thickness controlled at 20 mm. The pressing pressure is set to 20 MPa, and the holding time is 4 min, forming a sandwich structure of "clay blank-mesh cloth-clay blank". Secondary pressing allows the upper and lower layers of clay blank to be tightly bonded to the mesh cloth, expelling air from the sandwich and improving the overall density and structural integrity of the blank.

[0034] (7) Subsequent drying and sintering: The green body after secondary pressing is placed in a constant temperature drying oven and dried at 60°C for 6 hours until the moisture content drops below 5%; then it is transferred to a sintering furnace, heated to 1300°C for about 24 hours and held at that temperature, then the kiln is turned off and cooled to room temperature for about 36 hours to obtain fiber-reinforced ceramic products. Subsequent drying further removes moisture from the green body to prevent cracking of the products due to moisture evaporation during sintering; the sintering process optimizes the ceramic matrix structure, enhances the bonding force between the fibers and the matrix, and improves the mechanical properties of the products.

[0035] Example 3 This embodiment provides a spray coating process, including the following steps: (1) Raw material pretreatment: Take 35 kg of clay (particle size 0.1-1 μm) and dry it in an oven at 50℃ for 3 h; take 15 kg of quartz (silica content 91%, particle size 100 μm-300 μm) and 15 kg of feldspar (Mohs hardness 6, density 2.6 g / cm³) 3 The clay is passed through a 160-mesh sieve to remove impurities. Drying the clay improves the fluidity of the spray coating, and sieving the raw materials ensures uniform particle size and avoids clogging of the spraying equipment.

[0036] (2) Preparation of mixed fiber slurry: The pretreated clay, quartz, and feldspar were put into a mixing tank, along with 1 kg of water-reducing agent (calcium lignosulfonate), 2 kg of basalt short-cut fibers (monofilament diameter 20 μm, fiber length 40 mm), and 40 kg of water. The mixing tank was turned on and stirred at 600 r / min for 2 h. After stirring, the slurry was filtered through a 100-mesh screen to remove undispersed lumps. Stirring ensures that the raw materials are fully mixed, and the filtration step ensures that the slurry is fine and free of impurities, avoiding affecting the spraying effect and ensuring that the short-cut fibers are evenly dispersed.

[0037] (3) Spraying equipment debugging: A high-pressure airless sprayer is selected. The fiber-mixed slurry filtered through the screen is poured into the sprayer's hopper. The spraying pressure is adjusted to 0.8 MPa, the spraying distance is controlled at 30 cm, and the nozzle diameter is selected as 1.5 mm. A test spray is performed on waste board in advance to observe the slurry atomization effect and ensure that the spraying is uniform and without drips. Debugging the equipment can ensure a stable spraying process and uniform slurry atomization, avoiding uneven thickness of the bottom layer mud due to improper pressure or distance.

[0038] (4) Spraying the base layer of slurry: Fix the target substrate (such as the ceramic blank base or the inner surface of the mold) on the spraying workbench, turn on the spraying machine, and spray the fiber-mixed slurry evenly along the surface of the substrate. The spraying thickness is controlled at 10mm. After spraying, let it stand for 1 hour to form the base layer of slurry, which provides a flat support surface for the subsequent laying of the mesh cloth. Letting it stand allows the base layer of slurry to initially solidify, avoiding deformation caused by subsequent operations.

[0039] (5) Basalt fiber mesh laying: Take 2 kg of basalt fiber mesh and cut it to the corresponding size according to the area of ​​the base mud. Lay the mesh flat on the surface of the base mud and gently roll it with a roller to make the mesh tightly adhere to the base mud and remove air from the contact surface. Ensure that the mesh is firmly bonded to the base mud to avoid the mesh shifting or bubbling during subsequent spraying and to ensure the stability of the reinforced structure.

[0040] (6) Surface slurry spraying: Adjust the spraying machine pressure to 0.9MPa and continue to spray the fiber-mixed slurry evenly on the surface of the mesh fabric. The spraying thickness is controlled at 10mm to ensure that the mesh fabric is completely covered by the slurry with no exposed parts. After spraying, let it stand for 2 hours. The surface slurry wraps around the mesh fabric to form a complete reinforcement system. Letting it stand allows the upper and lower layers of slurry to fully integrate with the mesh fabric, improving the overall integrity of the blank.

[0041] (7) Drying and sintering: The spray-coated green body is placed in a drying oven and dried at 55°C for 10 hours until the moisture content drops below 5%; then it is placed in a sintering furnace and heated to 1350°C for about 48 hours and held at that temperature. The furnace is then turned off and cooled to room temperature for about 48 hours to obtain fiber-reinforced ceramic products. Drying removes moisture from the green body, and sintering improves the density and mechanical properties of the product, ensuring a stable bond between the fiber and the ceramic matrix.

[0042] Example 4 This embodiment provides a coating process, including the following steps: (1) Raw material pretreatment: Weigh 60 kg of clay (particle size 0.1-1 μm) and dry it in an oven at 60℃ for 4 h; weigh 20 kg of quartz (silica content 91%, particle size 100 μm-300 μm) and 20 kg of feldspar (Mohs hardness 6, density 2.6 g / cm³) 3The clay is passed through an 180-mesh sieve to remove impurities and large clumps. Drying the clay makes the slurry less sticky during subsequent application, improving ease of operation; sieving the raw materials ensures uniform particle size, resulting in a smooth surface after application.

[0043] (2) Preparation of mixed fiber slurry: Pretreated clay, quartz, and feldspar were placed in a mixing tank, along with 1 kg of water-reducing agent (calcium lignosulfonate), 5 kg of basalt chopped fibers (monofilament diameter 20 μm, fiber length 40 mm), and 50 kg of water. The mixture was stirred for 1.8 h at 500 r / min using an electric mixer. During the stirring process, the tank wall was scraped with a scraper every 20 min to ensure no residue of raw materials, resulting in a uniform mixed fiber slurry. Thorough stirring ensured that all raw materials were evenly mixed and the chopped fibers were evenly dispersed. The water-reducing agent improved the smoothness of the slurry during application, preventing wrinkling and breakage during application.

[0044] (3) Base treatment: Select a flat mold or support substrate, sand the surface of the substrate with sandpaper to remove burrs and dust, and then wipe the surface with a damp cloth to keep the substrate surface slightly moist (moisture content of about 8%). Sanding the substrate can ensure a flat surface, and a slightly moist surface can improve the adhesion between the bottom mud and the substrate, and prevent the blank from falling off.

[0045] (4) Applying the base layer of mud: Using a stainless steel trowel, apply the mixed fiber slurry manually to the surface of the substrate. The thickness of the slurry should be controlled at 8mm. During the application process, apply force evenly in the same direction to ensure that the surface of the mud is flat, free of bubbles and depressions. This forms the base support structure, providing a stable foundation for the subsequent laying of the mesh cloth. Even application ensures that the thickness of the base layer of mud is consistent and avoids uneven stress during subsequent drying.

[0046] (5) Basalt fiber mesh laying: When the surface of the bottom layer of mud has initially set (no obvious indentation when pressed with a finger, moisture content of about 12%), take 5 kg of basalt fiber mesh and lay it flat on the surface of the bottom layer of mud. Gently press the mesh with a trowel to embed it into the mud, ensuring that the mesh is tightly bonded to the bottom layer of mud without curling or hollow areas. This allows the mesh to form a preliminary bond with the bottom layer of mud, providing a reinforcing skeleton for the surface coating and ensuring that the reinforcing effect is evenly distributed.

[0047] (6) Surface slurry application: Continue to apply the mixed fiber slurry to the surface of the mesh cloth by hand. The thickness of the slurry should be controlled at 8 mm. Press the slurry repeatedly in a crisscross pattern to ensure that the slurry completely fills the pores of the mesh cloth and the surface is smooth. The surface slurry wraps around the mesh cloth to form a complete reinforcement system. The crisscross pressing can improve the density of the blank and avoid the formation of pores.

[0048] (7) Drying and sintering: Place the coated green body in a well-ventilated and dry place, and dry at room temperature (25℃) for 15 hours, avoiding direct sunlight during this period; after the moisture content drops below 5%, place it in a sintering furnace, heat it to 1280℃ for about 30 hours, hold it at that temperature, then turn off the furnace and cool it to room temperature for about 60 hours to obtain fiber-reinforced ceramic products. Slow drying can prevent cracking of the green body, and the sintering process optimizes the ceramic matrix structure, improving the mechanical properties and service life of the products.

[0049] Example 5 This embodiment provides a dehydration self-leveling molding process, including the following steps: (1) Raw material pretreatment: Take 70 kg of clay (particle size 0.1-1 μm) and dry it in an oven at 58℃ for 3.8 h; take 25 kg of quartz (silica content 91%, particle size 100 μm-300 μm) and 25 kg of feldspar (Mohs hardness 6, density 2.6 g / cm³) 3 The clay is passed through a 170-mesh sieve to remove impurities and large particles. Drying the clay helps adjust the moisture content of the slurry, which is beneficial for self-leveling and dehydration. Screening the raw materials ensures uniform particle size, improves the fluidity of the slurry and the flatness of the green body.

[0050] (2) Preparation of mixed fiber slurry: The pretreated clay, quartz, and feldspar were put into a vertical mixer, along with 1 kg of water-reducing agent (calcium lignosulfonate), 8 kg of basalt short-cut fibers (monofilament diameter 20 μm, fiber length 40 mm), and 60 kg of water. The mixer speed was set to 700 r / min, and the mixture was stirred for 2.2 h. After stirring, the mixture was allowed to stand for 30 min to allow air bubbles in the slurry to rise and dissipate naturally. Thorough stirring ensured uniform mixing of the raw materials and stable dispersion of the short-cut fibers. Allowing the mixture to stand and degas prevented the formation of pores in the green body and improved density.

[0051] (3) Preparation of permeable bottom mold: Select a porous ceramic permeable bottom mold with a porosity controlled at 30%. Soak it in clean water for 2 hours in advance to remove impurities inside the bottom mold. Then drain the surface water and place it on a horizontal workbench to ensure that the bottom mold is flat and not tilted. The permeable bottom mold can quickly drain the water in the slurry. Soaking the bottom mold can prevent the bottom mold from absorbing too much water from the slurry, which would cause local drying to be too fast. Placing it horizontally ensures that the thickness of the green body is uniform.

[0052] (4) Initial pouring and dehydration curing: The fiber-mixed slurry is slowly poured into the permeable bottom mold, with the pouring thickness controlled at 15mm. After pouring, a layer of breathable non-woven fabric is covered on the surface of the slurry and placed in a vacuum dehydrator. The vacuum degree is set to 0.08MPa and the dehydration time is 1h until the slurry is initially cured (hard to the touch and not flowing). Vacuum dehydration can accelerate the removal of water and increase the curing speed of the green body; the breathable non-woven fabric can prevent the surface of the slurry from cracking due to excessive dehydration, and the initially cured green body provides support for the subsequent laying of the mesh fabric.

[0053] (5) Basalt fiber mesh laying: Take 10kg of basalt fiber mesh, cut it to a size that fits the inner cavity of the bottom mold, lay it flat on the surface of the initially cured slurry, and press it gently with a pressure plate to make the mesh adhere tightly to the slurry surface without gaps. Ensure that the mesh is firmly bonded to the bottom blank, providing a reinforcing skeleton for subsequent secondary pouring and ensuring uniform reinforcement effect.

[0054] (6) Secondary casting and dewatering: Continue to cast the fiber-reinforced slurry into the bottom mold, controlling the casting thickness to 15mm, ensuring that the mesh fabric is completely covered by the slurry. Cover it again with breathable nonwoven fabric, place it in a vacuum dewatering machine, maintain a vacuum of 0.08MPa, and dewater for 2 hours until the green body is completely solidified. The secondary casting forms a complete sandwich reinforcement structure, and vacuum dewatering further removes moisture from the green body, improving the density and structural stability of the green body.

[0055] (7) Demolding and sintering: After the green body is completely solidified, gently pry the edge of the green body to separate it from the bottom mold and remove the green body; place the green body in a drying oven and dry it at 65°C for 8 hours. After the moisture content drops to below 5%, transfer it to a sintering furnace and heat it to 1275°C for about 28 hours, then keep it at that temperature. After that, turn off the kiln fire and cool it to room temperature for about 46 hours to obtain fiber-reinforced ceramic products. After demolding, drying removes residual moisture, and sintering optimizes the properties of the ceramic matrix, enhances the interfacial bonding force between the fiber and the matrix, and ensures that the mechanical properties of the product meet the standards.

[0056] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A fiber-reinforced ceramic product, characterized in that, Includes adhesive components, skeleton components, reinforcing components, auxiliary components, and water; wherein, by weight: The adhesive component is 25-90 parts of clay; The skeleton components consist of 5-50 parts quartz and 5-40 parts feldspar. The reinforcing component consists of 0.1-15 parts of basalt short-cut fibers and 0.1-15 parts of basalt fiber mesh. The auxiliary agent component is 0.1-3 parts of water-reducing agent; Water is 15-60 parts.

2. The fiber-reinforced ceramic article according to claim 1, characterized in that, The raw materials include the following parts by weight: 55 parts clay, 25 parts quartz, 20 parts feldspar, 1.5 parts water-reducing agent, 7 parts chopped basalt fiber, 7 parts basalt fiber mesh, and 35 parts water.

3. The fiber-reinforced ceramic article according to claim 1 or 2, characterized in that, The clay has a particle size of 0.1-2 μm; And / or, the silica content in the quartz is 90-99%, and the particle size of the quartz is 65μm-5mm; And / or, the feldspar has a Mohs hardness of 6-6.5 and a density of 2.6-2.8 g / cm³. 3 ; And / or, the water-reducing agent is sodium lignosulfonate or calcium lignosulfonate; And / or, the basalt chopped fibers have a monofilament diameter of 5.5-25μm and a fiber length of 6-100mm.

4. A method for preparing the fiber-reinforced ceramic article according to any one of claims 1-3, characterized in that, The preparation method is grouting, pressing, spraying, troweling, or dehydration self-leveling.

5. The method for preparing the fiber-reinforced ceramic product according to claim 4, characterized in that, The grouting process includes the following steps: (1) Mix clay, quartz, feldspar, water-reducing agent, basalt short fiber and water to obtain fiber-mixed slurry; (2) Fix the basalt fiber mesh inside the mold and inject the mixed fiber slurry from the bottom of the mold to wrap the basalt fiber mesh and then dehydrate and dry it to form the shape.

6. The method for preparing the fiber-reinforced ceramic article according to claim 4, characterized in that, The pressing and forming process includes the following steps: (1) Mix clay, quartz, feldspar, water-reducing agent, basalt short fiber and water to obtain fiber-mixed slurry; (2) Press the fiber-mixed slurry into a mud blank, and lay basalt fiber mesh on the surface of the mud blank; (3) After the clay blank is dried, the mixed fiber slurry is then covered onto the basalt fiber mesh cloth and pressed to form a sandwich structure, thus completing the pressing and forming process.

7. The method for preparing the fiber-reinforced ceramic product according to claim 4, characterized in that, The spray coating process includes the following steps: (1) Mix clay, quartz, feldspar, water-reducing agent, basalt short fiber and water to obtain fiber-mixed slurry; (2) The fiber-mixed slurry is sprayed to obtain the bottom layer mud. (3) Lay basalt fiber mesh on the surface of the bottom mud material, and then continue spraying to complete the spraying and forming.

8. The method for preparing the fiber-reinforced ceramic article according to claim 4, characterized in that, The coating process includes the following steps: (1) Mix clay, quartz, feldspar, water-reducing agent, basalt short fiber and water to obtain fiber-mixed slurry; (2) The fiber-mixed slurry is applied to the mud by hand to obtain the bottom mud material; (3) Lay basalt fiber mesh on the surface of the bottom mud material, and then continue to apply it by hand to complete the application and shaping.

9. The method for preparing the fiber-reinforced ceramic article according to claim 4, characterized in that, The dehydration self-leveling molding process includes the following steps: (1) Mix clay, quartz, feldspar, water-reducing agent, basalt short fiber and water to obtain fiber-mixed slurry; (2) The fiber-mixed slurry is poured into a permeable bottom mold, and after dehydration and curing, Wuyan fiber mesh is laid. (3) Then continue to pour the fiber-mixed slurry, and after dehydration, the self-leveling molding is completed.