Antibacterial wear-resistant domestic ceramic and low-temperature sintering process thereof

Abstract

The application relates to the field of functional ceramic synthesis technology and provides an antibacterial wear-resistant daily-use ceramic which is composed of a body and an antibacterial wear-resistant glaze layer and contains the following components in parts by weight: the body contains modified kaolin 35-50 parts, diatomite 8-15 parts, tourmaline 6-12 parts, bentonite 3-6 parts, a low-temperature fluxing agent 4-9 parts and a composite mineral reinforcing agent 5-10 parts; the antibacterial wear-resistant glaze layer contains low-temperature glass powder 40-55 parts, silicon carbide micro powder 5-10 parts, nano titanium oxide 2-5 parts, a silver-zinc composite antibacterial agent 0.3-1.2 parts, talc powder 2-6 parts and a binder 1-3 parts; and the ceramic sintering temperature is 850-980 DEG C. Through specific component proportioning and 850-980 DEG C low-temperature sintering, the energy consumption can be reduced by more than 30%, unexpected energy-saving advantages are achieved; the body and the glaze are synergistically enhanced, the ceramic hardness is high, and the wear resistance is far higher than that of conventional products; the silver-zinc composite antibacterial agent is long-acting and stable, and the antibacterial rate is greater than or equal to 90%; the ceramic has high density, a smooth glaze surface, high body-glaze combination strength, and the finished product rate is remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of functional ceramic synthesis technology, specifically to an antibacterial and wear-resistant daily-use ceramic and its low-temperature sintering process. Background Technology

[0002] Daily-use ceramics are essential products for catering and home use. With the upgrading of health consumption, the demand for high-end daily-use ceramics with antibacterial, wear-resistant and easy-to-clean functions is growing rapidly. At the same time, the industry's requirements for low-temperature energy-saving sintering are increasing.

[0003] Most existing antibacterial and wear-resistant ceramics are fired at high temperatures (above 1250℃), and certain functional effects are achieved by adding antibacterial ions and wear-resistant particles to the glaze.

[0004] However, high-temperature sintering consumes a lot of energy, is costly, and can easily cause glaze discoloration and deactivation of antibacterial agents. Furthermore, it is difficult to achieve both wear resistance and glaze smoothness, resulting in poor body-glaze bonding, easy cracking, and low yield. It is impossible to simultaneously achieve the comprehensive goals of low-temperature firing, high density, strong wear resistance, high antibacterial properties, and high stability. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides an antibacterial and wear-resistant daily-use ceramic and its low-temperature sintering process. This solves the problems of high energy consumption, high cost, easy discoloration of glaze, deactivation of antibacterial agents, difficulty in achieving both wear resistance and glaze smoothness, poor body-glaze bonding, easy cracking, low yield, and inability to simultaneously achieve low-temperature firing, high density, strong wear resistance, high antibacterial properties, and high stability.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an antibacterial and wear-resistant daily-use ceramic, comprising a body and an antibacterial and wear-resistant glaze layer, in parts by weight: The billet body comprises: 35-50 parts modified kaolin, 8-15 parts diatomite, 6-12 parts tourmaline, 3-6 parts bentonite, 4-9 parts low-temperature flux, and 5-10 parts composite mineral reinforcing agent. The antibacterial and wear-resistant glaze layer comprises: 40-55 parts of low-temperature glass powder, 5-10 parts of silicon carbide micro powder, 2-5 parts of nano titanium dioxide, 0.3-1.2 parts of silver-zinc composite antibacterial agent, 2-6 parts of talc powder, and 1-3 parts of binder. The sintering temperature of the ceramic is 850–980℃.

[0007] Preferably, the low-temperature flux is a ternary composite system composed of 2-4 parts spodumene, 1-3 parts zinc borate, and 1-2 parts potassium feldspar, with a melting temperature below 980°C, used to reduce sintering energy consumption and increase the density of the green body.

[0008] Preferably, the composite mineral reinforcing agent is a mixture of mullite micro powder, wollastonite, and alumina micro powder in a mass ratio of 2:1:1, used to improve the flexural strength and surface wear resistance of ceramics.

[0009] Preferably, the silver-zinc composite antibacterial agent is composed of 30-50 wt% silver-loaded zeolite and 50-70 wt% nano zinc oxide.

[0010] Preferably, the silicon carbide micro powder has a particle size of 800-1200 mesh and is uniformly distributed in the glaze layer to form a wear-resistant skeleton, so that the glaze surface has a wear resistance of ≥6000 revolutions and a hardness of ≥4H.

[0011] A low-temperature sintering process for antibacterial and wear-resistant daily-use ceramics includes the following steps: Step 1: Weigh the raw materials according to the weight, add water for wet mixing, vacuum knead the clay and age it for 20-28 hours to obtain a uniform and plastic blank. Step 2: Press the blank into a ceramic blank, air dry it, and then fire it at a low temperature of 500-600℃ for 30-60 minutes. Step 3: Mix the glaze raw materials according to the formula, stir at high speed to make glaze slurry, and pass through a 200-300 mesh sieve to remove impurities to obtain antibacterial and wear-resistant glaze slurry; Step 4: Apply a combined glaze of pouring and spraying to the bisque-fired body, controlling the glaze layer thickness to be 0.3–0.8 mm; Step 5: Place the glazed body into the kiln and sinter it at 850-980℃ using a stepped heating method, holding the temperature for 40-80 minutes. Step 6: After sintering, the ceramic is cooled in stages at a rate of ≤2℃ / min above 400℃. After cooling, antibacterial and wear-resistant daily ceramics are obtained.

[0012] Preferably, in step two, the porosity of the sintered green body is controlled at 8% to 15%.

[0013] Preferably, in step three, the stirring speed of the glaze slurry is 800-1200 r / min, and the stirring time is 20-40 min.

[0014] Preferably, the stepped heating process in step five is as follows: Phase 1: Room temperature; Second stage: 350~450℃, keep warm for 30~60min; Third stage: 650~750℃, keep warm for 25~40 minutes; Fourth stage: 850~980℃, keep warm for 40~80 minutes; The heating rate for the four stages is 1.5–3 °C / min.

[0015] Preferably, it also includes a post-processing step for the finished product, as follows: S1: After cooling, the ceramics are sorted by appearance to remove deformed, glaze-shrinked, and chipped products. S2: Polish the bottom surface of qualified ceramics; S3: Use ultraviolet lamps to sterilize and solidify the ceramic surface to enhance the stability of the antibacterial layer; S4: Sampling tests were conducted on the water absorption rate, antibacterial rate, and glaze hardness of the ceramics. S5: After passing the inspection, the product is cleaned, dried, and packaged to obtain the final antibacterial and wear-resistant daily ceramic product.

[0016] This invention provides an antibacterial and wear-resistant daily-use ceramic and its low-temperature sintering process. It has the following beneficial effects: 1. This invention reduces the firing temperature to 850-980℃ through a low-temperature fluxing system and a stepped low-temperature sintering process, which reduces energy consumption by more than 30% compared to traditional high-temperature sintering, significantly shortens the firing cycle, and has unexpected advantages in energy saving, consumption reduction and large-scale production.

[0017] 2. This invention uses the body reinforcement component and the glaze wear-resistant skeleton to synergistically enhance the ceramic glaze surface hardness to 4H to 5H, and the wear resistance rotation can reach up to 9600 revolutions, which is far higher than conventional products, greatly improving the scratch resistance, wear resistance and service life of daily ceramics.

[0018] 3. This invention achieves an antibacterial rate of over 90% against both Escherichia coli and Staphylococcus aureus through the synergistic effect of silver-zinc composite antibacterial agent and nano-titanium oxide. The antibacterial effect is long-lasting and stable, and does not yellow or precipitate at high temperatures, significantly improving the hygiene and safety level of daily-use ceramics.

[0019] 4. This invention significantly improves the bonding strength between the body and glaze through bisque firing pretreatment and composite glazing, resulting in ceramics with high density, low water absorption, no pinholes and no glaze shrinkage, and a yield increase of more than 5%. At the same time, it has excellent thermal stability and is not easy to crack or deform. Attached Figure Description

[0020] Figure 1 This is a process flow diagram of the present invention. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. 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.

[0022] Example: As one aspect of the present invention, please refer to the appendix. Figure 1This invention provides an antibacterial and wear-resistant daily-use ceramic, comprising a body and an antibacterial and wear-resistant glaze layer, in parts by weight: The billet body comprises: 35-50 parts modified kaolin, 8-15 parts diatomite, 6-12 parts tourmaline, 3-6 parts bentonite, 4-9 parts low-temperature flux, and 5-10 parts composite mineral reinforcing agent. The antibacterial and wear-resistant glaze layer comprises: 40-55 parts of low-temperature glass powder, 5-10 parts of silicon carbide micro powder, 2-5 parts of nano titanium dioxide, 0.3-1.2 parts of silver-zinc composite antibacterial agent, 2-6 parts of talc powder, and 1-3 parts of binder. The sintering temperature of ceramics is 850–980℃; The low-temperature flux is a ternary composite system consisting of 2-4 parts spodumene, 1-3 parts zinc borate, and 1-2 parts potassium feldspar, with a melting temperature below 980℃, used to reduce sintering energy consumption and improve the density of the green body. The mineral reinforcing agent is a mixture of mullite powder, wollastonite, and alumina powder in a mass ratio of 2:1:1, used to improve the flexural strength and surface wear resistance of ceramics. The silver-zinc composite antibacterial agent is composed of 30-50 wt% silver-loaded zeolite and 50-70 wt% nano zinc oxide; The silicon carbide micro powder has a particle size of 800-1200 mesh and is evenly distributed in the glaze layer to form a wear-resistant skeleton, making the glaze surface wear-resistant for ≥6000 revolutions and hardness ≥4H.

[0023] As another aspect of the present invention, the low-temperature sintering process of the above-mentioned antibacterial and wear-resistant daily-use ceramics is as follows: Step 1: Weigh the components of the green body according to their corresponding weight parts, mix the solid raw materials, add water and mix them, send them into a vacuum plowing machine to plow and age for 24 hours to obtain a plastic green body. Step 2: The raw material is formed into a ceramic blank by hydraulic press, naturally air-dried, and then sent into the kiln for bisque firing at 500-600℃, followed by heat preservation and cooling. Step 3: Weigh the raw materials according to the glaze ratio, add water and stir at high speed to make glaze slurry. The stirring speed of the glaze slurry is 800-1200 r / min and the stirring time is 20-40 min. Pass it through a 200-mesh sieve to remove impurities and obtain a uniform antibacterial and wear-resistant glaze slurry. Step 4: Apply glaze to the bisque-fired body using the methods of glazing as a base and spraying glaze for finishing, controlling the glaze layer thickness to be between 0.3 and 0.8 mm; Step 5: Place the glazed ceramic body into the kiln and sinter it at a low temperature using a stepped heating regime, with a maximum temperature of 850–980℃. The stepped heating regime is as follows: Phase 1: Room temperature; Second stage: 350~450℃, keep warm for 30~60min; Third stage: 650~750℃, keep warm for 25~40 minutes; Fourth stage: 850~980℃, keep warm for 40~80 minutes; The heating rate for the four stages is 1.5–3 °C / min; Step 6: After sintering, perform segmented slow cooling and remove the product after cooling to room temperature; Step 7: Sorting, polishing, UV curing, performance testing and packaging of the finished products to obtain the final product.

[0024] To better illustrate the implementation scheme of the antibacterial and wear-resistant daily-use ceramics of the present invention and their low-temperature sintering process, the following examples are provided:

[0025] Example 1 An antibacterial and wear-resistant daily-use ceramic and its low-temperature sintering process: Green body composition: 35 parts modified kaolin, 8 parts diatomite, 6 parts tourmaline, 3 parts bentonite, 4 parts low-temperature flux, and 5 parts composite mineral reinforcing agent.

[0026] Glaze composition: 40 parts low-temperature glass powder, 5 parts silicon carbide micro powder, 2 parts nano titanium dioxide, 0.3 parts silver-zinc composite antibacterial agent, 2 parts talc powder, and 1 part binder.

[0027] Preparation process: aging for 24 hours, bisque firing at 500℃ for 40 minutes, glazing thickness of 0.3 mm, step sintering to 850℃ for 40 minutes, slow cooling in stages, post-processing, polishing, testing and packaging.

[0028] Example 2 An antibacterial and wear-resistant daily-use ceramic and its low-temperature sintering process: Green body composition: 42 parts modified kaolin, 12 parts diatomite, 9 parts tourmaline, 4 parts bentonite, 6 parts low-temperature flux, and 7 parts composite mineral reinforcing agent.

[0029] Glaze composition: 48 parts low-temperature glass powder, 7 parts silicon carbide micro powder, 3.5 parts nano titanium dioxide, 0.7 parts silver-zinc composite antibacterial agent, 4 parts talc powder, and 2 parts binder.

[0030] Preparation process: aging for 24 hours, bisque firing at 550℃ for 45 minutes, glazing thickness of 0.5 mm, step sintering to 920℃ for 60 minutes, slow cooling in stages, post-processing, polishing, testing and packaging.

[0031] Example 3 An antibacterial and wear-resistant daily-use ceramic and its low-temperature sintering process: Green body composition: 50 parts modified kaolin, 15 parts diatomite, 12 parts tourmaline, 6 parts bentonite, 9 parts low-temperature flux, and 10 parts composite mineral reinforcing agent.

[0032] Glaze composition: 55 parts low-temperature glass powder, 10 parts silicon carbide micro powder, 5 parts nano titanium oxide, 1.2 parts silver-zinc composite antibacterial agent, 6 parts talc powder, and 3 parts binder.

[0033] Preparation process: aging for 24 hours, bisque firing at 600℃ for 60 minutes, glazing thickness of 0.8 mm, step sintering to 980℃ for 80 minutes, slow cooling in stages, post-processing, polishing, testing and packaging.

[0034] The performance of Examples 1-3 and commercially available conventional high-temperature antibacterial and wear-resistant ceramics (comparative examples) was tested, and the results are shown in Table 1 below: Table 1. Comparison of Antibacterial and Wear-Resistant Properties of Daily-Use Ceramics:

[0035] The results show that the antibacterial and wear-resistant daily ceramics of the present invention adopt a low-temperature sintering process, which can significantly reduce the firing temperature and production energy consumption. At the same time, the glaze has higher hardness and better wear resistance, the antibacterial effect is long-lasting and stable, the water absorption rate is lower, and the yield is higher. The overall performance is significantly better than the existing high-temperature sintered antibacterial ceramics, and it is suitable for the large-scale and green production of various daily ceramics.

[0036] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An antibacterial and wear-resistant daily-use ceramic, characterized in that, Composed of a body and an antibacterial and wear-resistant glaze layer; by weight: The raw material composition of the billet is as follows: 35-50 parts modified kaolin, 8-15 parts diatomite, 6-12 parts tourmaline, 3-6 parts bentonite, 4-9 parts low-temperature flux, and 5-10 parts composite mineral reinforcing agent. The raw material components of the antibacterial and wear-resistant glaze layer are: 40-55 parts of low-temperature glass powder, 5-10 parts of silicon carbide micro powder, 2-5 parts of nano titanium dioxide, 0.3-1.2 parts of silver-zinc composite antibacterial agent, 2-6 parts of talc powder, and 1-3 parts of binder. The low-temperature flux is a ternary composite system composed of 2-4 parts of spodumene, 1-3 parts of zinc borate, and 1-2 parts of potassium feldspar, with a melting temperature below 980℃. The composite mineral reinforcing agent is a mixture of mullite powder, wollastonite, and alumina powder in a mass ratio of 2:1:

1. The low-temperature sintering preparation process of the antibacterial and wear-resistant daily-use ceramics includes the following steps: Step 1: Weigh the raw materials according to the weight, add water for wet mixing, vacuum knead the clay and age it for 20-28 hours to obtain a uniform and plastic blank. Step 2: Press the blank into a ceramic blank, air dry it, and then fire it at a low temperature of 500~600℃ for 30~60 minutes. Step 3: Weigh the raw materials according to the ratio of antibacterial and wear-resistant glaze materials, add water and stir at high speed to make glaze slurry, and pass it through a 200-300 mesh sieve to remove impurities to obtain antibacterial and wear-resistant glaze slurry; Step 4: Apply a combined glaze of pouring and spraying to the bisque-fired body, controlling the glaze layer thickness to be 0.3~0.8mm; Step 5: Place the glazed body into the kiln and sinter it at 850~980℃ using a stepped heating method, holding the temperature for 40~80 minutes. Step 6: After sintering, the ceramic is cooled in stages at a rate of ≤2℃ / min above 400℃. After cooling, antibacterial and wear-resistant daily ceramic is obtained. The stepped heating system is as follows: Phase 1: Room temperature; Second stage: 350~450℃, keep warm for 30~60 minutes; Third stage: 650~750℃, keep warm for 25~40 minutes; Fourth stage: 850~980℃, keep warm for 40~80 minutes; The heating rate for the four stages is 1.5~3℃ / min.

2. The antibacterial and wear-resistant daily-use ceramic according to claim 1, characterized in that, The silver-zinc composite antibacterial agent is composed of 30-50 wt% silver-loaded zeolite and 50-70 wt% nano zinc oxide.

3. The antibacterial and wear-resistant daily-use ceramic according to claim 2, characterized in that, The silicon carbide micro powder has a particle size of 800~1200 mesh and is uniformly distributed in the glaze layer to form a wear-resistant skeleton. The resulting glaze surface has a wear resistance of ≥6000 revolutions and a hardness of ≥4H.

4. A low-temperature sintering process for preparing antibacterial and wear-resistant daily-use ceramics, used to prepare the antibacterial and wear-resistant daily-use ceramics according to any one of claims 1 to 3, characterized in that, Includes the following steps: Step 1: Weigh the raw materials according to the weight, add water for wet mixing, vacuum knead the clay and age it for 20-28 hours to obtain a uniform and plastic blank. Step 2: Press the blank into a ceramic blank, air dry it, and then fire it at a low temperature of 500~600℃ for 30~60 minutes. Step 3: Weigh the raw materials according to the ratio of antibacterial and wear-resistant glaze materials, add water and stir at high speed to make glaze slurry, and pass it through a 200-300 mesh sieve to remove impurities to obtain antibacterial and wear-resistant glaze slurry; Step 4: Apply a combined glaze of pouring and spraying to the bisque-fired body, controlling the glaze layer thickness to be 0.3~0.8mm; Step 5: Place the glazed body into the kiln and sinter it at 850~980℃ using a stepped heating method, holding the temperature for 40~80 minutes. Step Six: After sintering, the ceramic is slowly cooled in stages, with a cooling rate of ≤2℃ / min above 400℃. After cooling, antibacterial and wear-resistant daily-use ceramics are obtained. The stepped heating system is as follows: Phase 1: Room temperature; Second stage: 350~450℃, keep warm for 30~60 minutes; Third stage: 650~750℃, keep warm for 25~40 minutes; Fourth stage: 850~980℃, hold for 40~80 minutes. The heating rate for the four stages is 1.5~3℃ / min.

5. The low-temperature sintering preparation process of antibacterial and wear-resistant daily-use ceramics according to claim 4, characterized in that, In step two, the porosity of the bisque-fired green body is controlled at 8% to 15%.

6. The low-temperature sintering preparation process of antibacterial and wear-resistant daily-use ceramics according to claim 4, characterized in that, In step three, the stirring speed of the glaze slurry is 800~1200 r / min, and the stirring time is 20~40 min.

7. The low-temperature sintering preparation process of antibacterial and wear-resistant daily-use ceramics according to claim 4, characterized in that, It also includes post-processing steps for the finished product, as follows: S1: After cooling, the ceramics are sorted by appearance to remove deformed, glaze-shrinked, and chipped products. S2: Polish the bottom surface of qualified ceramics; S3: Use ultraviolet lamps to sterilize and solidify the ceramic surface to enhance the stability of the antibacterial layer; S4: Sampling tests were conducted on the water absorption rate, antibacterial rate, and glaze hardness of the ceramics. S5: After passing the inspection, the product is cleaned, dried, and packaged to obtain the final antibacterial and wear-resistant daily ceramic product.

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