Slip composition for mini sanitary ceramic articles and method for the preparation thereof, mini sanitary ceramic articles

Abstract

The application provides a slurry composition for a mini sanitary ceramic product and a preparation method thereof, and the mini sanitary ceramic product. The slurry composition comprises 11-18 parts of mortar, 3-5 parts of black clay, 10-14 parts of Bondi soil, 10-16 parts of porcelain clay, 2-5 parts of wollastonite, 29-36 parts of kaolin, 2-6 parts of attapulgite, 7-13 parts of ceramic frit, 3-8 parts of diopside, 0.5-2 parts of water reducing agent and 29-39 parts of water in terms of mass. The mini sanitary ceramic product such as a mini toilet made of the slurry composition has low water absorption, small deformation rate, high strength and no bending.

Description

Technical Field

[0001] This application relates to the field of sanitary ceramics, and more particularly to a slurry composition for mini sanitary ceramic articles and a method for preparing the same, which are mini sanitary ceramic articles. Background Technology

[0002] Standard ceramic toilets typically measure 65*34*74cm. These large sizes are inconvenient to carry and make it difficult to clearly see the internal structure, hindering effective customer demonstrations. Therefore, a miniature ceramic toilet (approximately 20cm long, 10cm wide, and 20cm high) has been created by scaling down the toilet's shape and structure. This miniature toilet is lightweight, compact, and its internal structure is clearly visible, allowing it to be easily held and displayed to customers. It plays a crucial role in visual presentation, information delivery, and enhancing the shopping experience, thus contributing to increased sales and improved product competitiveness.

[0003] Existing sanitary ceramic toilets use a slip casting process, but this type of slip has a high water content, low density, low green strength, and large shrinkage. It is easy to deform during sintering, making it difficult to produce the microstructure of miniature toilets.

[0004] Chinese patent CN118184325A discloses a mini sanitary ceramic toilet, which uses organosilicon resin to cross-link and polymerize into a three-dimensional network structure, thereby shaping the ceramic body in situ and improving its strength. However, replacing water with organosilicon resin significantly increases the cost.

[0005] Therefore, it is desirable to provide a slurry composition with improved performance and cost-effectiveness for miniature sanitary ceramic products such as miniature toilets, and a method for preparing the same. Summary of the Invention

[0006] The following is an overview of the subject matter described in detail herein. This overview is not intended to limit the scope of protection of this application.

[0007] In one aspect, this application provides a slurry composition for miniature sanitary ceramic products, comprising, by weight, 11-18 parts of plaster, 3-5 parts of black mud, 10-14 parts of bond clay, 10-16 parts of kaolin, 2-5 parts of wollastonite, 29-36 parts of kaolin, 2-6 parts of attapulgite, 7-13 parts of ceramic frit, 3-8 parts of diopside, 0.5-2 parts of water-reducing agent, and 29-34 parts of water.

[0008] In one exemplary embodiment, the slurry composition comprises, by weight, 13.5-16.5 parts of mortar, 3.5-4.5 parts of black mud, 11-13 parts of bond clay, 11.5-14.5 parts of kaolin, 2.5-3.5 parts of wollastonite, 31-35 parts of kaolin, 3-5 parts of attapulgite, 8.5-11.5 parts of ceramic frit, 4-6 parts of diopside, 0.8-1.2 parts of water-reducing agent, and 30-34 parts of water.

[0009] In an exemplary embodiment, the slurry comprises 57.5 wt.%-63.5 wt.% SiO2, 1.31 wt.%-2.26 wt.% Fe2O3, 30.93 wt.%-36.25 wt.% Al2O3, 1.62 wt.%-2.74 wt.% K2O, and 1.52 wt.%-2.37 wt.% Na2O.

[0010] In an exemplary embodiment, the black mud comprises 56.17 wt.%-61.61 wt.% SiO2, 1.42 wt.%-1.88 wt.% CaO, 2.43 wt.%-3.27 wt.% Fe2O3, 30.2 wt.%-35.1 wt.% Al2O3, 2.3 wt.%-3.6 wt.% K2O, and 0.74 wt.%-1.28 wt.% Na2O.

[0011] In an exemplary embodiment, the bonded clay comprises 64.13 wt.%-71.03 wt.% SiO2, 0.32 wt.%-0.85 wt.% MgO, 1.12 wt.%-1.56 wt.% Fe2O3, 21.6 wt.%-27.5 wt.% Al2O3, 3.7 wt.%-4.6 wt.% K2O, and 1.33 wt.%-2.26 wt.% Na2O.

[0012] In an exemplary embodiment, the kaolin clay comprises 64.51 wt.%-69.76 wt.% SiO2, 1.12 wt.%-1.56 wt.% CaO, 1.36 wt.%-2.15 wt.% Fe2O3, 23.5 wt.%-27.6 wt.% Al2O3, 3.2 wt.%-3.7 wt.% K2O, and 0.56 wt.%-0.98 wt.% Na2O.

[0013] In an exemplary embodiment, the ceramic frit comprises 8.3 wt.%-12.5 wt.% CaO, 58.9 wt.%-67.05 wt.% SiO2, 1.12 wt.%-1.75 wt.% MgO, 0.98 wt.%-1.41 wt.% TiO2, 10.9 wt.%-14.8 wt.% Al2O3, 3.8 wt.%-4.4 wt.% K2O, 1.22 wt.%-1.65 wt.% Na2O, 4.2 wt.%-4.8 wt.% ZnO, and 0.98 wt.%-1.23 wt.% ZrO.

[0014] In one exemplary embodiment, the slurry comprises 60.44 wt.% SiO2, 1.87 wt.% Fe2O3, 33.6 wt.% Al2O3, 2.13 wt.% K2O, and 1.96 wt.% Na2O; and / or, The black mud comprises 59.24 wt.% SiO2, 1.63 wt.% CaO, 2.81 wt.% Fe2O3, 32.4 wt.% Al2O3, 2.95 wt.% K2O, and 0.97 wt.% Na2O; and / or, The bonded clay comprises 67.68 wt.% SiO2, 0.57 wt.% MgO, 1.33 wt.% Fe2O3, 24.5 wt.% Al2O3, 4.15 wt.% K2O, and 1.77 wt.% Na2O; and / or, The kaolin comprises 67.31 wt.% SiO2, 1.34 wt.% CaO, 1.74 wt.% Fe2O3, 25.4 wt.% Al2O3, 3.45 wt.% K2O, and 0.76 wt.% Na2O; and / or, The ceramic frit comprises 10.42 wt.% CaO, 65.04 wt.% SiO2, 1.43 wt.% MgO, 1.19 wt.% TiO2, 12.84 wt.% Al2O3, 4.13 wt.% K2O, 1.44 wt.% Na2O, 4.4 wt.% ZnO, and 1.11 wt.% ZrO.

[0015] In one exemplary embodiment, the slurry comprises 57.5 wt.% SiO2, 2.26 wt.% Fe2O3, 36.25 wt.% Al2O3, 1.62 wt.% K2O, and 2.37 wt.% Na2O; and / or, The black mud comprises 56.17 wt.% SiO2, 1.88 wt.% CaO, 3.27 wt.% Fe2O3, 35.1 wt.% Al2O3, 2.3 wt.% K2O, and 1.28 wt.% Na2O; and / or, The bonded clay comprises 64.13 wt.% SiO2, 0.85 wt.% MgO, 1.56 wt.% Fe2O3, 27.5 wt.% Al2O3, 3.7 wt.% K2O, and 2.26 wt.% Na2O; and / or, The kaolin comprises 64.51 wt.% SiO2, 1.56 wt.% CaO, 2.15 wt.% Fe2O3, 27.6 wt.% Al2O3, 3.2 wt.% K2O, and 0.98 wt.% Na2O; and / or, The ceramic frit comprises 12.5 wt.% CaO, 58.9 wt.% SiO2, 1.75 wt.% MgO, 1.41 wt.% TiO2, 14.8 wt.% Al2O3, 3.8 wt.% K2O, 1.65 wt.% Na2O, 4.2 wt.% ZnO, and 0.98 wt.% ZrO.

[0016] In an exemplary embodiment, the slurry comprises 63.5 wt.% SiO2, 1.31 wt.% Fe2O3, 30.93 wt.% Al2O3, 2.74 wt.% K2O, and 1.52 wt.% Na2O; and / or, The black mud comprises 61.61 wt.% SiO2, 1.42 wt.% CaO, 2.43 wt.% Fe2O3, 30.2 wt.% Al2O3, 3.6 wt.% K2O, and 0.74 wt.% Na2O; and / or, The bonded clay comprises 71.03 wt.% SiO2, 0.32 wt.% MgO, 1.12 wt.% Fe2O3, 21.6 wt.% Al2O3, 4.6 wt.% K2O, and 1.33 wt.% Na2O; and / or, The kaolin comprises 69.76 wt.% SiO2, 1.12 wt.% CaO, 1.36 wt.% Fe2O3, 23.5 wt.% Al2O3, 3.7 wt.% K2O, and 0.56 wt.% Na2O; and / or, The ceramic frit comprises 8.3 wt.% CaO, 67.05 wt.% SiO2, 1.12 wt.% MgO, 0.98 wt.% TiO2, 10.9 wt.% Al2O3, 4.4 wt.% K2O, 1.22 wt.% Na2O, 4.8 wt.% ZnO, and 1.23 wt.% ZrO.

[0017] In one exemplary embodiment, the water-reducing agent is a polycarboxylate-based water-reducing agent.

[0018] On the other hand, this application provides a method for preparing the above-mentioned slurry composition, the method comprising mixing and grinding sludge, black mud, bonded clay, kaolin, wollastonite, kaolin, attapulgite, ceramic frit, and diopside until the proportion of particles with a particle size of <10 μm is 56%-62%, passing the mixture through a 90-110 mesh sieve, and then adding water and a water-reducing agent to obtain the slurry composition.

[0019] On the other hand, this application provides a method for preparing miniature sanitary ceramic articles, the method comprising the following steps: 1) Adjust the specific gravity of the slurry composition according to any one of claims 1-5 or the slurry composition prepared by the method according to claim 6 to be 1.91-1.99; 2) Pour the adjusted slurry composition into the mold, and after molding and demolding, obtain the green body of the miniature sanitary ceramic product; 3) Dry the green body at 50℃-60℃ for 4 days; 4) Spray the glaze until the glaze layer thickness is 0.5-0.8 mm, and allow it to air dry naturally; and 5) The glazed green body is sintered at a temperature of 1170-1190℃ to obtain the mini sanitary ceramic product.

[0020] In another aspect, this application provides a miniature sanitary ceramic article prepared by the above method.

[0021] In one exemplary embodiment, the mini sanitary ceramic product is a mini toilet.

[0022] This application introduces a polycarboxylate superplasticizer, which uses the cross-linking effect of molecular chains to connect ceramic particles, thereby reducing water consumption and achieving a miniature green body reinforcement effect.

[0023] This application improves the strength of miniature preforms by introducing a specific inorganic reinforcing agent, attapulgite, whose unique fibrous rod-like structure enhances the strength of the preforms.

[0024] This application reduces the coefficient of thermal expansion of the product by adding diopside, which maintains low expansion at high temperatures, thereby reducing deformation and obtaining mini sanitary ceramic products with low deformation.

[0025] This application lowers the sintering temperature by introducing ceramic frit. Because the ceramic frit has a high content of silicon oxide and aluminum oxide, the miniature sanitary ceramic products produced have high hardness and strength. Furthermore, the ceramic frit has a high calcium oxide content; CaO reacts with SiO2 to form crystals such as wollastonite (CaSiO3) or diopside (CaMgSi2O6), which have low coefficients of thermal expansion. In this application, the ceramic frit is prepared by sintering ceramic oxides containing calcium oxide, aluminum oxide, silicon oxide, etc., at a temperature of approximately 1250-1260°C.

[0026] Miniature sanitary ceramic products, such as miniature toilets, made from the slurry composition of this application not only have low water absorption, low deformation, high strength, but also no bending.

[0027] Other features and advantages of this application will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the application. Other advantages of this application may be realized and obtained by means of the embodiments described in the description and drawings. Attached Figure Description

[0028] Figure 1 A photograph of the mini toilet prepared according to Embodiment 1 of this application is shown. Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of this application clearer, the embodiments of this application are described in detail below. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be arbitrarily combined with each other.

[0030] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein in the specification of this application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0031] Unless otherwise stated or in case of conflict, the terms or phrases used in this application shall have the following meanings: In this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" and "second" may explicitly or implicitly include at least one of those features.

[0032] In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise expressly and specifically limited.

[0033] In this application, "one or more" refers to any one, two, or more of the listed items. "Multiple" refers to any two or more of the listed items.

[0034] Unless otherwise specified, all percentage concentrations mentioned in this application refer to the final concentration. The final concentration refers to the proportion of the added component in the system after the addition of that component.

[0035] In this application, terms such as "further," "even more," "particularly," "for example," "like," "example," and "exemplary" are used for descriptive purposes to indicate a connection in the coverage of different technical solutions presented earlier and later, but should not be construed as limiting the preceding technical solution or restricting the scope of protection herein. Unless otherwise specified herein, A (e.g., B) indicates that B is a non-limiting example of A, and it can be understood that A is not limited to B.

[0036] In this application, "optionally," "optionally," and "optional" mean that something is optional, that is, it is selected from either "present" or "absent." If multiple "options" appear in a technical solution, unless otherwise specified and there are no contradictions or mutual constraints, each "option" is independent. In this application, descriptions such as "optionally contains" and "optionally includes" indicate "contains or does not contain." "Optional component X" indicates whether component X exists or does not exist, or whether component X is contained or not.

[0037] When a numerical range is disclosed in this application, the range is considered continuous and includes the minimum and maximum values ​​of the range, as well as every value between the minimum and maximum values. Furthermore, when the range refers to an integer, it includes every integer between the minimum and maximum values ​​of the range. Additionally, when multiple ranges are provided to describe a feature or characteristic, the ranges may be merged. In other words, unless otherwise specified, all ranges disclosed in this application should be understood to include any and all subranges to which they are included.

[0038] In this application, the technical features described in an open-ended manner include both closed technical solutions consisting of the listed features and open technical solutions that include the listed features.

[0039] The terms "comprising" and "having," and any variations thereof, used in the embodiments of this application, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to the steps or units listed, but may optionally include steps or units not listed, or may optionally include other steps or components inherent to such processes, methods, products, or devices.

[0040] In this application, the reference to "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a mutually exclusive, independent, or alternative embodiment. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described in this application can be combined with other embodiments.

[0041] Existing sanitary ceramic toilets are manufactured using a slip-casting process, but the slip has a high water content, low density, low green strength, and significant shrinkage, making it prone to deformation during sintering. Due to variations in the pipes, deformation, and internal microstructure of miniature toilets, this method would be insufficient for their production.

[0042] Unless otherwise specified, all materials used in the following examples and comparative examples are commercially available.

[0043] This application provides a method for preparing miniature sanitary ceramic articles, comprising the following steps: 1) Weigh out the lime mud, black mud, Bondi clay, kaolin, wollastonite, kaolin, attapulgite, ceramic frit, and diopside, mix and grind them until the proportion of particles with a particle size of <10um is 56%-62%, pass them through a 90-110 mesh sieve, and then add water and water-reducing agent to obtain the slurry composition. 2) Add water to adjust the specific gravity of the slurry composition to 1.91-1.99; 3) Pour the adjusted slurry composition into the mold of the mini toilet, and after molding and demolding, obtain the green body of the mini toilet; 4) Dry the green body at 50℃-60℃ for 4 days; 5) Spray the glaze until the glaze layer thickness is 0.5-0.8 mm, and let it air dry naturally; 6) The glazed green body is sintered at a temperature of 1170-1190℃ to obtain sanitary ceramic products.

[0044] The following example, a miniature toilet made of sanitary ceramics, illustrates the manufacturing process of sanitary ceramic products.

[0045] Example 1 1) Mix 15 parts by weight of mortar, 4 parts by weight of black mud, 12 parts by weight of bond clay, 13 parts by weight of porcelain clay, 3 parts by weight of wollastonite, 33 parts by weight of kaolinite, 4 parts by weight of attapulgite, 10 parts by weight of ceramic frit, and 5 parts by weight of diopside and grind them until the proportion of particles with a particle size <10µm is 56%. After passing through a 100-mesh sieve, add 32 parts by weight of water and 1 part by weight of water-reducing agent to obtain a slurry composition. 2) Add water to adjust the specific gravity of the slurry composition to 1.95; 3) Pour the adjusted slurry composition into the mold of the mini toilet, and after molding and demolding, obtain the green body of the mini toilet; 4) Dry the green body at 55℃ for 4 days; 5) Spray the glaze until the glaze layer thickness is 0.65 mm, and let it air dry naturally; 6) The glazed green body is sintered at 1180°C to obtain a miniature toilet.

[0046] The mortar used in this embodiment has the following composition: 60.44 wt.% SiO2, 1.87 wt.% Fe2O3, 33.6 wt.% Al2O3, 2.13 wt.% K2O and 1.96 wt.% Na2O.

[0047] The black mud used in this embodiment has the following composition: 59.24 wt.% SiO2, 1.63 wt.% CaO, 2.81 wt.% Fe2O3, 32.4 wt.% Al2O3, 2.95 wt.% K2O and 0.97 wt.% Na2O.

[0048] The Bondi clay used in this embodiment has the following composition: 67.68 wt.% SiO2, 0.57 wt.% MgO, 1.33 wt.% Fe2O3, 24.5 wt.% Al2O3, 4.15 wt.% K2O and 1.77 wt.% Na2O.

[0049] The porcelain clay used in this embodiment has the following composition: 67.31 wt.% SiO2, 1.34 wt.% CaO, 1.74 wt.% Fe2O3, 25.4 wt.% Al2O3, 3.45 wt.% K2O and 0.76 wt.% Na2O.

[0050] The ceramic frit used in this embodiment has the following composition: 10.42 wt.% CaO, 65.04 wt.% SiO2, 1.43 wt.% MgO, 1.19 wt.% TiO2, 12.84 wt.% Al2O3, 4.13 wt.% K2O, 1.44 wt.% Na2O, 4.4 wt.% ZnO, and 1.11 wt.% ZrO.

[0051] The water-reducing agent used in this embodiment is a polycarboxylate-based water-reducing agent, purchased from Shanxi Feike New Materials Co., Ltd., model HLX.

[0052] Figure 1 A photograph of the mini toilet prepared according to Embodiment 1 of this application is shown.

[0053] Example 2 1) Mix and grind 11 parts by weight of lime, 5 parts by weight of black mud, 14 parts by weight of bond clay, 10 parts by weight of kaolin, 2.3 parts by weight of wollastonite, 36 parts by weight of kaolin, 6 parts by weight of attapulgite, 7 parts by weight of ceramic frit and 8 parts by weight of diopside until the proportion of particles with a particle size <10µm is 62%. After passing through a 100-mesh sieve, add 34 parts by weight of water and 0.7 parts by weight of water-reducing agent to obtain a slurry composition. 2) Add water to adjust the specific gravity of the slurry composition to 1.91; 3) Pour the adjusted slurry composition into the mold of the mini toilet, and after molding and demolding, obtain the green body of the mini toilet; 4) Dry the green body at 50℃ for 4 days; 5) Spray the glaze until the glaze layer thickness is 0.50 mm, and let it air dry naturally; 6) The glazed green body is sintered at 1170°C to obtain a miniature toilet.

[0054] The water-reducing agent used in this embodiment is a polycarboxylate-based water-reducing agent, purchased from Shanxi Feike New Materials Co., Ltd., model HLX.

[0055] The mortar used in this embodiment has the following composition: 57.5 wt.% SiO2, 2.26 wt.% Fe2O3, 36.25 wt.% Al2O3, 1.62 wt.% K2O, and 2.37 wt.% Na2O.

[0056] The black mud used in this embodiment has the following composition: 56.17 wt.% SiO2, 1.88 wt.% CaO, 3.27 wt.% Fe2O3, 35.1 wt.% Al2O3, 2.3 wt.% K2O and 1.28 wt.% Na2O.

[0057] The Bondi clay used in this embodiment has the following composition: 64.13 wt.% SiO2, 0.85 wt.% MgO, 1.56 wt.% Fe2O3, 27.5 wt.% Al2O3, 3.7 wt.% K2O, and 2.26 wt.% Na2O.

[0058] The porcelain clay used in this embodiment has the following composition: 64.51 wt.% SiO2, 1.56 wt.% CaO, 2.15 wt.% Fe2O3, 27.6 wt.% Al2O3, 3.2 wt.% K2O and 0.98 wt.% Na2O.

[0059] The ceramic frit used in this embodiment has the following composition: 12.5 wt.% CaO, 58.9 wt.% SiO2, 1.75 wt.% MgO, 1.41 wt.% TiO2, 14.8 wt.% Al2O3, 3.8 wt.% K2O, 1.65 wt.% Na2O, 4.2 wt.% ZnO, and 0.98 wt.% ZrO. Example 3 1) Mix 18 parts by weight of mortar, 3 parts by weight of black mud, 10 parts by weight of bond clay, 16 parts by weight of kaolin, 4.5 parts by weight of wollastonite, 29 parts by weight of kaolin, 2 parts by weight of attapulgite, 13 parts by weight of ceramic frit, and 3 parts by weight of diopside and grind them until the proportion of particles with a particle size <10µm is 58%. After passing through a 100-mesh sieve, add 30 parts by weight of water and 1.5 parts by weight of water-reducing agent to obtain a slurry composition. 2) Add water to adjust the specific gravity of the slurry composition to 1.99; 3) Pour the adjusted slurry composition into the mold of the mini toilet, and after molding and demolding, obtain the green body of the mini toilet; 4) Dry the green body at 60℃ for 4 days; 5) Spray the glaze until the glaze layer thickness is 0.65 mm, and let it air dry naturally; 6) The glazed green body is sintered at 1190°C to obtain a miniature toilet.

[0060] The water-reducing agent used in this embodiment is a polycarboxylate-based water-reducing agent, purchased from Shanxi Feike New Materials Co., Ltd., model HLX.

[0061] The mortar used in this embodiment has the following composition: 63.5 wt.% SiO2, 1.31 wt.% Fe2O3, 30.93 wt.% Al2O3, 2.74 wt.% K2O, and 1.52 wt.% Na2O; and / or, The black mud used in this embodiment has the following composition: 61.61 wt.% SiO2, 1.42 wt.% CaO, 2.43 wt.% Fe2O3, 30.2 wt.% Al2O3, 3.6 wt.% K2O and 0.74 wt.% Na2O.

[0062] The Bondi clay used in this embodiment has the following composition: 71.03 wt.% SiO2, 0.32 wt.% MgO, 1.12 wt.% Fe2O3, 21.6 wt.% Al2O3, 4.6 wt.% K2O and 1.33 wt.% Na2O.

[0063] The porcelain clay used in this embodiment has the following composition: 69.76 wt.% SiO2, 1.12 wt.% CaO, 1.36 wt.% Fe2O3, 23.5 wt.% Al2O3, 3.7 wt.% K2O and 0.56 wt.% Na2O.

[0064] The ceramic frit used in this embodiment has the following composition: 8.3 wt.% CaO, 67.05 wt.% SiO2, 1.12 wt.% MgO, 0.98 wt.% TiO2, 10.9 wt.% Al2O3, 4.4 wt.% K2O, 1.22 wt.% Na2O, 4.8 wt.% ZnO, and 1.23 wt.% ZrO.

[0065] Comparative Example 1: The preparation process of this comparative example is similar to that of Example 1, but instead of using a polycarboxylate superplasticizer, a water glass superplasticizer is used. Specifically, it includes: 1) Mix 15 parts by weight of mortar, 4 parts by weight of black mud, 12 parts by weight of Bondi clay, 13 parts by weight of porcelain clay, 3 parts by weight of wollastonite, 33 parts by weight of kaolinite, 4 parts by weight of attapulgite, 10 parts by weight of ceramic frit, and 5 parts by weight of diopside and grind them until the proportion of particles with a particle size <10µm is 56%. After passing through a 100-mesh sieve, add 39 parts by weight of water and 1 part by weight of water-reducing agent to obtain a slurry composition. 2) Add water to adjust the specific gravity of the slurry composition to 1.99; 3) Pour the adjusted slurry composition into the mold of the mini toilet, and after molding and demolding, obtain the green body of the mini toilet; 4) Dry the green body at 55℃ for 4 days; 5) Spray the glaze until the glaze layer thickness is 0.65 mm, and let it air dry naturally; 6) The glazed green body is sintered at 1180°C to obtain a miniature toilet.

[0066] Comparative Example 2: The preparation process for this comparative example is similar to that of Example 1, but without the addition of attapulgite. Specifically, it includes: 1) Mix 16 parts by weight of mortar, 4 parts by weight of black mud, 13 parts by weight of Bondi clay, 14 parts by weight of porcelain clay, 3 parts by weight of wollastonite, 34 parts by weight of kaolinite, 10 parts by weight of ceramic frit, and 5 parts by weight of diopside and grind them until the proportion of particles with a particle size <10µm is 56%. After passing through a 100-mesh sieve, add 32 parts by weight of water and 1 part by weight of water-reducing agent to obtain a slurry composition. 2) Add water to adjust the specific gravity of the slurry composition to 1.99; 3) Pour the adjusted slurry composition into the mold of the mini toilet, and after molding and demolding, obtain the green body of the mini toilet; 4) Dry the green body at 55℃ for 4 days; 5) Spray the glaze until the glaze layer thickness is 0.65 mm, and let it air dry naturally; 6) The glazed green body is sintered at 1180°C to obtain a miniature toilet.

[0067] Comparative Example 3: The preparation process for this comparative example is similar to that of Example 1, but without the addition of ceramic frit. Specifically, it includes: 1) Mix 17 parts by weight of mortar, 5 parts by weight of black mud, 13 parts by weight of Bondi clay, 15 parts by weight of kaolin, 4 parts by weight of wollastonite, 36 parts by weight of kaolin, 4 parts by weight of attapulgite and 5 parts by weight of diopside and grind until the proportion of particles with a particle size <10µm is 56%. After passing through a 100-mesh sieve, add 32 parts by weight of water and 1 part by weight of water-reducing agent to obtain a slurry composition. 2) Add water to adjust the specific gravity of the slurry composition to 1.99; 3) Pour the adjusted slurry composition into the mold of the mini toilet, and after molding and demolding, obtain the green body of the mini toilet; 4) Dry the green body at 55℃ for 4 days; 5) Spray the glaze until the glaze layer thickness is 0.65 mm, and let it air dry naturally; 6) The glazed green body is sintered at 1180°C to obtain a miniature toilet.

[0068] Comparative Example 4: The preparation process for this comparative example is similar to that of Example 1, but without the addition of diopside. Specifically, it includes: 1) Mix 16 parts by weight of mortar, 5 parts by weight of black mud, 13 parts by weight of Bondi clay, 14 parts by weight of porcelain clay, 3 parts by weight of wollastonite, 34 parts by weight of kaolinite, 4 parts by weight of attapulgite and 10 parts by weight of ceramic frit and grind them until the proportion of particles with a particle size <10µm is 56%. After passing through a 100-mesh sieve, add 32 parts by weight of water and 1 part by weight of water-reducing agent to obtain a slurry composition. 2) Add water to adjust the specific gravity of the slurry composition to 1.99; 3) Pour the adjusted slurry composition into the mold of the mini toilet, and after molding and demolding, obtain the green body of the mini toilet; 4) Dry the green body at 55℃ for 4 days; 5) Spray the glaze until the glaze layer thickness is 0.65 mm, and let it air dry naturally; 6) The glazed green body is sintered at 1180°C to obtain a miniature toilet.

[0069] Comparative Example 5: The preparation process for this comparative example is similar to that of Example 1, but without the addition of attapulgite and ceramic frit. Specifically, it includes: 1) Mix 18 parts by weight of mortar, 5 parts by weight of black mud, 14 parts by weight of Bondi clay, 16 parts by weight of kaolin, 4 parts by weight of wollastonite, 36 parts by weight of kaolin and 7 parts by weight of diopside and grind until the proportion of particles with a particle size <10µm is 56%. After passing through a 100-mesh sieve, add 32 parts by weight of water and 1 part by weight of water-reducing agent to obtain a slurry composition. 2) Add water to adjust the specific gravity of the slurry composition to 1.99; 3) Pour the adjusted slurry composition into the mold of the mini toilet, and after molding and demolding, obtain the green body of the mini toilet; 4) Dry the green body at 55℃ for 4 days; 5) Spray the glaze until the glaze layer thickness is 0.65 mm, and let it air dry naturally; 6) The glazed green body is sintered at 1180°C to obtain a miniature toilet.

[0070] Comparative Example 6: The preparation process for this comparative example is similar to that of Example 1, but without the addition of attapulgite and diopside. Specifically, it includes: 1) Mix 18 parts by weight of mortar, 5 parts by weight of black mud, 14 parts by weight of Bondi clay, 16 parts by weight of porcelain clay, 4 parts by weight of wollastonite, 36 parts by weight of kaolin and 7 parts by weight of ceramic frit and grind them until the proportion of particles with a particle size <10µm is 56%. After passing through a 100-mesh sieve, add 32 parts by weight of water and 1 part by weight of water-reducing agent to obtain a slurry composition. 2) Add water to adjust the specific gravity of the slurry composition to 1.99; 3) Pour the adjusted slurry composition into the mold of the mini toilet, and after molding and demolding, obtain the green body of the mini toilet; 4) Dry the green body at 55℃ for 4 days; 5) Spray the glaze until the glaze layer thickness is 0.65 mm, and let it air dry naturally; 6) The glazed green body is sintered at 1180°C to obtain a miniature toilet.

[0071] Comparative Example 7: The preparation process for this comparative example is similar to that of Example 1, but without the addition of ceramic frit and diopside. Specifically, it includes: 1) Mix 18 parts by weight of mortar, 5 parts by weight of black mud, 14 parts by weight of Bondi clay, 16 parts by weight of porcelain clay, 5 parts by weight of wollastonite, 36 parts by weight of kaolinite and 6 parts by weight of attapulgite and grind them until the proportion of particles with a particle size <10µm is 56%. After passing through a 100-mesh sieve, add 32 parts by weight of water and 1 part by weight of water-reducing agent to obtain a slurry composition. 2) Add water to adjust the specific gravity of the slurry composition to 1.99; 3) Pour the adjusted slurry composition into the mold of the mini toilet, and after molding and demolding, obtain the green body of the mini toilet; 4) Dry the green body at 55℃ for 4 days; 5) Spray the glaze until the glaze layer thickness is 0.65 mm, and let it air dry naturally; 6) The glazed green body is sintered at 1180°C to obtain a miniature toilet.

[0072] The performance of the mini toilets prepared in Examples 1-3 and Comparative Examples 1-7 was tested. The test results are shown in Table 1 below.

[0073] Water absorption testing can be conducted according to standard GB6952-2015.

[0074] The method for testing the deformation rate may include: making mini toilet samples of 100mm×100mm×5mm from the examples and comparative examples, and measuring the deformation value A after sintering, where the deformation rate = A / 100×100%.

[0075] The method for testing the flexural strength of dry blanks may include: making cylindrical specimens of sanitary ceramics of the examples and comparative examples into ∅50 mm × 120 mm, and testing their flexural strength on a universal testing machine.

[0076] The criteria for judging whether sanitary ceramics are qualified can be as follows: if they are bent, the sanitary ceramics are unqualified; otherwise, they are qualified.

[0077] Table 1 As can be seen from the results in Table 1, the mini toilets prepared in the various embodiments of this application not only have low water absorption, low deformation, and high strength, but also exhibit no bending. This indicates that this application reduces water consumption and achieves a body strengthening effect by introducing a polycarboxylate-based water-reducing agent and utilizing the cross-linking effect of molecular chains to connect ceramic particles. In contrast, Comparative Example 1, due to the use of water glass, a conventional water-reducing agent in the art, has an excessively high water absorption rate.

[0078] This application improves the strength of the green body by adding a specific inorganic reinforcing agent, attapulgite, whose unique fibrous rod structure enhances its strength.

[0079] This application reduces overall volume change by adding diopside, utilizing the negative expansion of diopside at high temperatures to partially offset the positive expansion of the matrix. Table 1 shows that adding diopside significantly reduces the coefficient of thermal expansion of the samples, thus reducing deformation and resulting in a low-deformation mini-toilet. In contrast, the deformation rates of Comparative Examples 4, 6, and 7 (without diopside) are significantly increased.

[0080] This application lowers the sintering temperature by introducing calcined ceramic frit. Because the frit has a high content of silicon dioxide and aluminum oxide, the resulting sanitary ceramic products have high hardness and strength. The ceramic frit used in this application also has a high calcium oxide content; CaO can react with SiO2 to form crystals with low coefficients of thermal expansion, such as wollastonite (CaSiO3) or diopside (CaMgSi2O6), which further contributes to obtaining mini toilets with low deformation. As shown in Table 1, Comparative Example 7, without the addition of ceramic frit and diopside, exhibits the highest deformation rate.

[0081] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. A slurry composition for use in miniature sanitary ceramic products, characterized in that, By weight, the slurry composition comprises 11-18 parts of mortar, 3-5 parts of black mud, 10-14 parts of bond clay, 10-16 parts of kaolin, 2-5 parts of wollastonite, 29-36 parts of kaolin, 2-6 parts of attapulgite, 7-13 parts of ceramic frit, 3-8 parts of diopside, 0.5-2 parts of water-reducing agent, and 29-34 parts of water.

2. The slurry composition according to claim 1, characterized in that, By weight, the slurry composition comprises 13.5-16.5 parts of mortar, 3.5-4.5 parts of black mud, 11-13 parts of bond clay, 11.5-14.5 parts of kaolin, 2.5-3.5 parts of wollastonite, 31-35 parts of kaolin, 3-5 parts of attapulgite, 8.5-11.5 parts of ceramic frit, 4-6 parts of diopside, 0.8-1.2 parts of water-reducing agent, and 30-34 parts of water.

3. The slurry composition according to claim 1 or 2, characterized in that, The sludge comprises 57.5 wt.%-63.5 wt.% SiO2, 1.31 wt.%-2.26 wt.% Fe2O3, 30.93 wt.%-36.25 wt.% Al2O3, 1.62 wt.%-2.74 wt.% K2O, and 1.52 wt.%-2.37 wt.% Na2O; and / or, The black mud comprises 56.17 wt.%-61.61 wt.% SiO2, 1.42 wt.%-1.88 wt.% CaO, 2.43 wt.%-3.27 wt.% Fe2O3, 30.2 wt.%-35.1 wt.% Al2O3, 2.3 wt.%-3.6 wt.% K2O, and 0.74 wt.%-1.28 wt.% Na2O; and / or, The bonded clay comprises 64.13 wt.%-71.03 wt.% SiO2, 0.32 wt.%-0.85 wt.% MgO, 1.12 wt.%-1.56 wt.% Fe2O3, 21.6 wt.%-27.5 wt.% Al2O3, 3.7 wt.%-4.6 wt.% K2O, and 1.33 wt.%-2.26 wt.% Na2O; and / or, The kaolin comprises 64.51 wt.%-69.76 wt.% SiO2, 1.12 wt.%-1.56 wt.% CaO, 1.36 wt.%-2.15 wt.% Fe2O3, 23.5 wt.%-27.6 wt.% Al2O3, 3.2 wt.%-3.7 wt.% K2O, and 0.56 wt.%-0.98 wt.% Na2O; and / or, The ceramic frit comprises 8.3 wt.%-12.5 wt.% CaO, 58.9 wt.%-67.05 wt.% SiO2, 1.12 wt.%-1.75 wt.% MgO, 0.98 wt.%-1.41 wt.% TiO2, 10.9 wt.%-14.8 wt.% Al2O3, 3.8 wt.%-4.4 wt.% K2O, 1.22 wt.%-1.65 wt.% Na2O, 4.2 wt.%-4.8 wt.% ZnO, and 0.98 wt.%-1.23 wt.% ZrO; and / or, The water-reducing agent is a polycarboxylate-based water-reducing agent.

4. The slurry composition according to claim 3, characterized in that, The sludge comprises 60.44 wt.% SiO2, 1.87 wt.% Fe2O3, 33.6 wt.% Al2O3, 2.13 wt.% K2O, and 1.96 wt.% Na2O; and / or, The black mud comprises 59.24 wt.% SiO2, 1.63 wt.% CaO, 2.81 wt.% Fe2O3, 32.4 wt.% Al2O3, 2.95 wt.% K2O, and 0.97 wt.% Na2O; and / or, The bonded clay comprises 67.68 wt.% SiO2, 0.57 wt.% MgO, 1.33 wt.% Fe2O3, 24.5 wt.% Al2O3, 4.15 wt.% K2O, and 1.77 wt.% Na2O; and / or, The kaolin comprises 67.31 wt.% SiO2, 1.34 wt.% CaO, 1.74 wt.% Fe2O3, 25.4 wt.% Al2O3, 3.45 wt.% K2O, and 0.76 wt.% Na2O; and / or, The ceramic frit comprises 10.42 wt.% CaO, 65.04 wt.% SiO2, 1.43 wt.% MgO, 1.19 wt.% TiO2, 12.84 wt.% Al2O3, 4.13 wt.% K2O, 1.44 wt.% Na2O, 4.4 wt.% ZnO, and 1.11 wt.% ZrO.

5. The slurry composition according to claim 3, characterized in that, The sludge comprises 57.5 wt.% SiO2, 2.26 wt.% Fe2O3, 36.25 wt.% Al2O3, 1.62 wt.% K2O, and 2.37 wt.% Na2O; and / or, The black mud comprises 56.17 wt.% SiO2, 1.88 wt.% CaO, 3.27 wt.% Fe2O3, 35.1 wt.% Al2O3, 2.3 wt.% K2O, and 1.28 wt.% Na2O; and / or, The bonded clay comprises 64.13 wt.% SiO2, 0.85 wt.% MgO, 1.56 wt.% Fe2O3, 27.5 wt.% Al2O3, 3.7 wt.% K2O, and 2.26 wt.% Na2O; and / or, The kaolin comprises 64.51 wt.% SiO2, 1.56 wt.% CaO, 2.15 wt.% Fe2O3, 27.6 wt.% Al2O3, 3.2 wt.% K2O, and 0.98 wt.% Na2O; and / or, The ceramic frit comprises 12.5 wt.% CaO, 58.9 wt.% SiO2, 1.75 wt.% MgO, 1.41 wt.% TiO2, 14.8 wt.% Al2O3, 3.8 wt.% K2O, 1.65 wt.% Na2O, 4.2 wt.% ZnO, and 0.98 wt.% ZrO.

6. The slurry composition according to claim 3, characterized in that, The sludge comprises 63.5 wt.% SiO2, 1.31 wt.% Fe2O3, 30.93 wt.% Al2O3, 2.74 wt.% K2O, and 1.52 wt.% Na2O; and / or, The black mud comprises 61.61 wt.% SiO2, 1.42 wt.% CaO, 2.43 wt.% Fe2O3, 30.2 wt.% Al2O3, 3.6 wt.% K2O, and 0.74 wt.% Na2O; and / or, The bonded clay comprises 71.03 wt.% SiO2, 0.32 wt.% MgO, 1.12 wt.% Fe2O3, 21.6 wt.% Al2O3, 4.6 wt.% K2O, and 1.33 wt.% Na2O; and / or, The kaolin comprises 69.76 wt.% SiO2, 1.12 wt.% CaO, 1.36 wt.% Fe2O3, 23.5 wt.% Al2O3, 3.7 wt.% K2O, and 0.56 wt.% Na2O; and / or, The ceramic frit comprises 8.3 wt.% CaO, 67.05 wt.% SiO2, 1.12 wt.% MgO, 0.98 wt.% TiO2, 10.9 wt.% Al2O3, 4.4 wt.% K2O, 1.22 wt.% Na2O, 4.8 wt.% ZnO, and 1.23 wt.% ZrO.

7. A method for preparing the slurry composition according to any one of claims 1-6, characterized in that, The method includes mixing and grinding slurry, black mud, bonded clay, porcelain clay, wollastonite, kaolin, attapulgite, ceramic frit, and diopside until the proportion of particles with a particle size <10µm is 56%-62%, passing it through a 90-110 mesh sieve, and then adding water and a water-reducing agent to obtain the slurry composition.

8. A method for preparing miniature sanitary ceramic products, characterized in that, The method includes the following steps: 1) Adjust the specific gravity of the slurry composition according to any one of claims 1-6 or the slurry composition prepared by the method according to claim 7 to be 1.91-1.99; 2) Pour the adjusted slurry composition into the mold, and after molding and demolding, obtain the green body of the miniature sanitary ceramic product; 3) Dry the green body at 50℃-60℃ for 4 days; 4) Spray the glaze until the glaze layer thickness is 0.5-0.8 mm, and let it air dry naturally; 5) The glazed green body is sintered at a temperature of 1170-1190℃ to obtain the sanitary ceramic product.

9. A miniature sanitary ceramic product, characterized in that, The mini sanitary ceramic product is prepared by the method of claim 8.

10. The miniature sanitary ceramic product according to claim 9, characterized in that, The mini sanitary ceramic product is a mini toilet.

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