CN114804843A - High-strength ultrathin rock plate and preparation method thereof - Google Patents
High-strength ultrathin rock plate and preparation method thereof Download PDFInfo
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Abstract
The invention discloses a high-strength ultrathin rock plate and a preparation method thereof, and relates to the technical field of rock plates. The high-strength ultrathin rock plate comprises a blank layer, wherein the top and the bottom of the blank layer are respectively provided with a zirconia layer; the raw material of the rock slab layer is a rock slab blank, and the content of silicon dioxide in the chemical composition of the rock slab blank is less than 60 percent by mass percent; the thickness of the high-strength ultrathin rock plate is less than or equal to 3 mm. According to the technical scheme, the zirconia layers are respectively arranged at the top and the bottom of the blank layer, and after the blank layer is formed and sintered, the zirconia is uniformly distributed on the upper surface layer and the lower surface layer of the high-strength ultrathin rock plate, so that the later-stage processing cracking phenomenon of the thin rock plate can be greatly reduced.
Description
Technical Field
The invention relates to the technical field of rock plates, in particular to a high-strength ultrathin rock plate and a preparation method thereof.
Background
In recent two years, the rock plate has become a new favorite of each large ceramic enterprise, the thickness range of the rock plate is wider, from 3mm to 20mm, the size is from 900 x 1800mm to 1600 x 3800mm, even 1800 x 9000mm of super-large rock plate appears, the types of the rock plate are various, the ultra-thin rock plate with the thickness less than or equal to 3mm is light, easy to transport and install, can reduce the raw material cost for ceramic enterprises and increase the profit, and the ultra-thin rock plate is widely applied in the fields of furniture panels, electric appliance panels, wall decoration and the like.
Because the rock plate belongs to brittle materials, before the rock plate is used as a household table top and a panel, mechanical processing such as cutting, polishing, drilling, chamfering and the like is required, according to incomplete statistics, 30% -50% of cutting cracks can occur in the conventional mechanical processing of the rock plate product, the cutting cracking rate of the ultrathin rock plate with the thickness of less than or equal to 3mm is higher, the later-stage use of the product is seriously influenced, the production cost is increased, and the easy cracking in processing becomes a bottleneck for limiting the development of the rock plate.
The application number 202010954969.8 discloses a high-strength ceramic rock plate and a preparation method thereof, the high strength of the rock plate is realized by designing different components of a rock plate blank, a ground coat and a surface glaze, but the high matching of the three is needed to achieve the effect, and the purpose of improving the strength of the rock plate is not easily achieved if the raw materials of the blank, the ground coat and the surface glaze fluctuate in the actual production.
The application number is 202010864905.9 Chinese patent application discloses a non-fragile rock plate and a preparation method thereof, the application improves the modulus of rupture and the breaking strength of the rock plate by adding silicon carbide and a reinforcing agent into the raw material of the rock plate, the silicon carbide generates gas through high-temperature reaction, and the gas hole defects are easily generated inside the rock plate and on the glaze surface, so that the modulus of rupture and the breaking strength are reduced, and the purpose of improving the modulus of rupture and the breaking strength of the rock plate is difficult to achieve.
The application No. 202111178761.2 of Chinese patent application teaches a technique for preparing strengthened and toughened rock plates by layered distribution, which adopts layered distribution to prepare a rock plate blank and tetragonal phase zirconia powder to be added into the raw material of the rock plate blank, because the tetragonal phase zirconia expands in volume when changing phase, the tip of a crack is closed, the crack is prevented from expanding and the crack induction energy of the strengthened and toughened rock plate is increased, the application requires that the thickness of the rock plate is 6mm-20mm, and for the ultrathin rock plate with the thickness less than or equal to 3mm, if layered distribution is adopted, each layer is extremely thin, even distribution is difficult to realize when distributing again, therefore, the method for preparing the ultrathin rock plate is not applicable, in addition, although layered and partitioned distribution is adopted, 3-15% of tetragonal zirconia powder is added into the raw material, and the cost is still high.
Disclosure of Invention
Aiming at the problems in the prior art, the invention aims to provide a high-strength ultrathin rock plate which has high strength and high toughness and can effectively avoid the problem of cracking of the thin rock plate in the later processing.
The invention also aims to provide a preparation method of the high-strength ultrathin rock plate, the prepared high-strength ultrathin rock plate has high strength and high toughness, the problem of post-processing cracking of the thin rock plate can be effectively avoided, and meanwhile, the preparation method is simple and low in cost.
In order to achieve the purpose, the invention adopts the following technical scheme:
a high-strength ultrathin rock plate comprises a blank layer, wherein the top and the bottom of the blank layer are respectively provided with a zirconia layer;
the raw materials of the rock plate blank layer are rock plate blanks, the raw materials of the rock plate blanks comprise calcined bauxite, high alumina sand, kaolin, super-strong mud and diopside, and the content of silicon dioxide in the chemical composition of the rock plate blanks is less than 60% by mass percent;
the thickness of the high-strength ultrathin rock plate is less than or equal to 3 mm.
Further, the raw materials of the rock plate blank comprise, by mass, 15-25 parts of calcined bauxite, 15-25 parts of high alumina sand, 15-20 parts of kaolin, 10-15 parts of super-strong mud and 18-25 parts of diopside.
Further, the content of silicon dioxide in the chemical composition of the rock plate blank is 50-59% by mass percent.
Furthermore, the zirconia layer is made of zirconia slurry, and the zirconia slurry comprises, by mass, 55-65% of yttrium-stabilized zirconia powder, 0.1-0.4% of a dispersant, and the balance of a solvent.
Furthermore, the yttrium-stabilized zirconia powder consists of 1.3-1.5% of yttrium oxide and 98.5-98.7% of zirconia according to molar percentage.
Further, the zirconia is tetragonal zirconia.
A preparation method of a high-strength ultrathin rock plate is used for preparing the high-strength ultrathin rock plate and comprises the following steps:
(1) respectively preparing a rock plate blank and zirconia slurry;
(2) spraying zirconia slurry at the bottom of the material distribution mould, distributing the rock plate blank, spraying zirconia slurry on the surface of the rock plate blank after the material distribution is finished, preparing an ultrathin rock plate blank through compression molding, and sintering to prepare the high-strength ultrathin rock plate.
Further, the preparation method of the zirconia slurry comprises the following steps: mixing yttrium-stabilized zirconia powder, a dispersing agent and a solvent according to a formula, and grinding for 30-60 min to obtain zirconia slurry.
Further, the operation of the step (2) is as follows: spraying 1-2 layers of zirconia slurry at the bottom of a material distribution die, wherein the thickness of each layer of zirconia slurry is 50-100 microns, distributing a rock plate blank, spraying 1-2 layers of zirconia slurry on the surface of the rock plate blank after material distribution is finished, the thickness of each layer of zirconia slurry is 50-100 microns, performing compression molding after the spraying is finished, preparing an ultrathin rock plate blank, and sintering to prepare the high-strength ultrathin rock plate.
The technical scheme has the following beneficial effects:
the technical scheme adopts the low silicon oxide mineral raw material to prepare SiO 2 The rock plate blank with the content of less than 60% reduces the content of free quartz in the rock plate blank, and further reduces the internal stress generated by quartz crystal transformation during cooling, thereby effectively reducing the proportion of later-stage processing cutting cracking. Meanwhile, when the ultra-thin rock plate is subjected to post-processing and cutting, cracks begin to be caused by surface defects, then the cracks are expanded, and the ultra-thin rock plate is cracked.
Detailed Description
The technical solution of the present invention will be further described with reference to the following embodiments.
A high-strength ultrathin rock plate comprises a blank layer, wherein the top and the bottom of the blank layer are respectively provided with a zirconia layer;
the raw materials of the rock plate blank layer are rock plate blanks, the raw materials of the rock plate blanks comprise calcined bauxite, high alumina sand, kaolin, super-strong mud and diopside, and the content of silicon dioxide in the chemical composition of the rock plate blanks is less than 60% by mass percent;
the thickness of the high-strength ultrathin rock plate is less than or equal to 3 mm.
Because the rock plate belongs to brittle materials, before the rock plate is used as a household table top and a panel, mechanical processing such as cutting, polishing, drilling, chamfering and the like is required, according to incomplete statistics, 30% -50% of cutting cracks can occur when the rock plate product is machined at present, the cutting cracking rate of the ultrathin rock plate with the thickness less than or equal to 3mm is higher, the later-stage use of the product is seriously influenced, the production cost is increased, and the easy cracking during processing becomes a bottleneck limiting the development of the ultrathin rock plate.
SiO in conventional rock slab stock 2 Content (by mass)Percent by weight) is typically around 70%, during firing, there is a significant amount of free SiO in the rock plate 2 In the temperature reduction stage, the quartz crystal form is transformed at 573 ℃ along with 0.82% volume change; 180-270 ℃, the conversion of quartz crystal forms is accompanied with 2.8% volume change, and the volume change in the cooling process can cause internal stress in the rock plate, which is easy to cause cutting cracking in later processing. Therefore, according to the technical scheme, the SiO is prepared by adopting the low-silicon-oxide mineral raw material and adopting the calcined bauxite, the high-alumina sand, the kaolin, the super-strong mud and the diopside 2 The content of the rock plate blank (before firing) with the content of less than 60% reduces the content of free quartz in the rock plate blank, further reduces the internal stress generated by quartz crystal transformation during cooling, and can effectively avoid the later-stage processing cracking of the ultrathin rock plate, thereby effectively reducing the proportion of the later-stage processing cutting cracking of the ultrathin rock plate. Meanwhile, when the ultra-thin rock plate is subjected to post-processing cutting, cracks start from surface defects, are induced, then are expanded, and are cracked, zirconia layers are respectively arranged at the top and the bottom of a blank layer in the technical scheme, zirconia is uniformly distributed in the upper surface layer and the lower surface layer of the high-strength ultra-thin rock plate after firing, and the later-stage processing cracking phenomenon of the ultra-thin rock plate can be greatly reduced by utilizing the phase change strengthening and the small crystal grain dispersion strengthening of the zirconia.
Particularly, this technical scheme high strength ultra-thin rock plate is the ultra-thin rock plate that thickness is less than or equal to 3mm, and to the ultra-thin rock plate that thickness is less than or equal to 3mm, if adopt the layering cloth, every layer thickness is extremely thin, is difficult to realize even cloth when the cloth, consequently, this technical scheme is through being equipped with the zirconia layer respectively at the top and the bottom on body layer, and the briquetting, the back of firing obtain the zirconia layer respectively in the upper and lower superficial layer of high strength ultra-thin rock plate, can reduce thin rock plate post processing fracture phenomenon by a wide margin.
Further, the raw materials of the rock plate blank comprise, by mass, 15-25 parts of calcined bauxite, 15-25 parts of high alumina sand, 15-20 parts of kaolin, 10-15 parts of super-strong mud and 18-25 parts of diopside.
It is worth noting that the chemical compositions of the calcined bauxite, the high alumina sand, the kaolin, the ultra-strong mud and the diopside are shown in the following table 1 in percentage by mass:
TABLE 1 chemical composition of raw materials in rock plate blank (%)
As can be seen from Table 1, in the technical scheme, the rock plate blank adopts SiO such as calcined bauxite, high alumina sand, kaolin, super-strong mud, diopside and the like 2 The mineral raw materials with low content are used as raw materials, and SiO in each raw material 2 The contents of the SiO and the SiO in the rock plate blank are all lower than 60 percent by adopting the formula 2 The content is controlled to be 50-59%, the content of free quartz is reduced, and the internal stress generated by quartz crystal transformation during cooling is reduced, so that the cutting cracking of the rock plate during later processing is reduced.
Further, the purpose of calcining bauxite and high-alumina sand in the raw materials of the rock plate blank is to improve the content of alumina in the raw materials, reduce the content of silicon oxide, increase the content of mullite crystals in the fired ultrathin rock plate and improve the strength of the rock plate; by adding kaolin into the formula, the forming performance of the rock plate can be improved, and the content of silicon oxide in a formula system can be further reduced; the ultra-strong mud can reduce the firing temperature of the rock plate, and meanwhile, SiO in the ultra-strong mud 2 The weight percentage of the rock plate is 54.43 percent, the ultra-strong mud is used for reducing the firing temperature of the rock plate, and SiO in the rock plate blank can be avoided 2 The content is more than 60 percent; diopside can reduce the firing temperature and improve the performance of the ultrathin rock plate, but excessive diopside can increase the content of silicon oxide in a formula system, so that the mass part of kaolin needs to be controlled to be 18-25 parts.
Specifically, the high-alumina sand is prepared from bauxite raw materials through high-temperature roasting, crushing, screening, Raymond, iron removal and other machining processes, and has the advantages of high aluminum content, low iron content, high hardness, small thermal expansion coefficient, high refractoriness, stable thermochemical property and the like.
Further, the content of silicon dioxide in the chemical composition of the rock plate blank is 50-59% by mass percent.
The raw material of the zirconia layer is zirconia slurry, and the zirconia slurry comprises 55-65% of yttrium-stabilized zirconia powder, 0.1-0.4% of a dispersant and the balance of a solvent by mass percent.
Particularly, the yttrium-stabilized zirconia powder, the dispersing agent and the solvent are mixed to prepare zirconia slurry with the solid content of 55-65%, a spray gun is convenient to use for spraying and the spraying amount is convenient to control, if the content of the yttrium-stabilized zirconia powder in the zirconia slurry is too much, the fluidity of the zirconia slurry is poor, a nozzle of the spray gun is easy to block in the spraying process, and if the content of the yttrium-stabilized zirconia powder in the zirconia slurry is too little, too much solvent can be introduced, and the performance of a formed blank body can be influenced.
Preferably, the solvent in the zirconia slurry is water and the dispersant is an aqueous dispersant, such as TEGO 750.
Further, the yttrium-stabilized zirconia powder is composed of 1.3-1.5% of yttrium oxide and 98.5-98.7% of zirconia in terms of molar percentage.
Illustratively, the zirconia is tetragonal zirconia.
In particular, tetragonal zirconia (t-ZrO) exists due to a phase transition strengthening mechanism of zirconia when subjected to an external impact force 2 ) And cubic phase zirconium oxide (c-ZrO) 2 ) Will convert to monoclinic phase zirconia (m-ZrO) 2 ) The technical scheme is that zirconia powder is added into zirconia slurry, and the principle of the phase change volume increase of zirconia is utilized to improve the high-strength ultrathin rock plateWhen the rock is stressed (or impacted), the crack can be induced to prevent the formation of the through crack on the surface of the high-strength ultrathin rock plate, and further the purpose of reducing the cutting crack proportion of the high-strength ultrathin rock plate is achieved. Meanwhile, 1.3-1.5% of yttrium oxide is added into the yttrium-stabilized zirconia powder, so that the problem that the zirconia is transformed into monoclinic-phase zirconia due to phase change in a sintering area at a low temperature of 100-400 ℃ is solved, and the high-strength ultrathin rock plate is prevented from cracking during later processing.
It is worth mentioning that zirconia is generally classified as tetragonal phase zirconia (t-ZrO) 2 ) Monoclinic phase zirconium oxide (m-ZrO) 2 ) And cubic phase zirconium oxide (c-ZrO) 2 ) Wherein, monoclinic phase zirconia (m-ZrO) 2 ) No phase change and volume expansion under stress, and the effect of closing the crack tip, even though the cubic phase of zirconium oxide (c-ZrO) 2 ) When stressed, the zirconium oxide partially converted into monoclinic phase (m-ZrO) 2 ) But cubic phase zirconia (c-ZrO) 2 ) The phase change and the volume change are small, the crack tips appearing in mechanical cutting are difficult to be closed, and the technical scheme selects tetragonal phase zirconium oxide (t-ZrO) 2 ) Is due to tetragonal zirconia (t-ZrO) 2 ) The phase change is generated under the stress to be converted into monoclinic zirconia (m-ZrO) 2 ) During the process, the volume expansion of 7-10% is accompanied, the volume change is large, the tip of a crack generated during mechanical cutting can be closed, the crack induction energy is improved, and therefore cracking of the high-strength ultrathin rock plate is effectively avoided.
A preparation method of a high-strength ultrathin rock plate is used for preparing the high-strength ultrathin rock plate and comprises the following steps:
(1) respectively preparing a rock plate blank and zirconia slurry;
(2) spraying zirconia slurry at the bottom of the material distribution mould, distributing the rock plate blank, spraying zirconia slurry on the surface of the rock plate blank after the material distribution is finished, preparing an ultrathin rock plate blank through compression molding, and sintering to prepare the high-strength ultrathin rock plate.
It is worth explaining that, according to the technical scheme, zirconia slurry is sprayed on the bottom of the material distribution die before material distribution, after material distribution is completed, zirconia slurry is uniformly sprayed on the upper layer of the rock plate blank, after compression molding and firing, the high-strength ultrathin rock plate is obtained, zirconia is uniformly distributed in the upper surface layer and the lower surface layer of the high-strength ultrathin rock plate, and the later-stage processing cracking phenomenon of the thin rock plate can be greatly reduced by utilizing zirconia phase change strengthening and small crystal grain dispersion strengthening.
Particularly, this technical scheme high strength ultra-thin rock plate is the ultra-thin rock plate that thickness is less than or equal to 3mm, and to the ultra-thin rock plate that thickness is less than or equal to 3mm, if adopt the layering cloth, every layer thickness is extremely thin, is difficult to realize even cloth when the cloth, consequently, this technical scheme is through spraying zirconia thick liquids respectively at the bottom and the top of rock plate blank, and after compression moulding, the firing, obtain the zirconia layer in the upper and lower superficial layer of high strength ultra-thin rock plate respectively, can reduce thin rock plate later stage processing fracture phenomenon by a wide margin.
Specifically, after the ultra-thin rock plate blank is prepared by press forming in the step (2), a glaze spraying process and an ink jet printing process are carried out on the surface of the ultra-thin rock plate blank, and after sintering, the high-strength ultra-thin rock plate is obtained.
Further, the zirconia slurry is prepared by the following method: mixing yttrium-stabilized zirconia powder, a dispersing agent and a solvent according to a formula, and grinding for 30-60 min to obtain zirconia slurry.
To explain further, the operation of step (2) is as follows: spraying 1-2 layers of zirconia slurry at the bottom of a material distribution die, wherein the thickness of each layer of zirconia slurry is 50-100 microns, distributing a rock plate blank, spraying 1-2 layers of zirconia slurry on the surface of the rock plate blank after material distribution is finished, the thickness of each layer of zirconia slurry is 50-100 microns, performing compression molding after the spraying is finished, preparing an ultrathin rock plate blank, and sintering to prepare the high-strength ultrathin rock plate.
It is worth pointing out that the technical scheme adopts the spray gun to spray, the thickness of each layer of spraying is 50-100 microns, 1-2 layers of zirconia slurry are respectively sprayed on the bottom and the top of the rock plate blank, zirconia can be uniformly distributed in the upper surface layer and the lower surface layer of the ultrathin rock plate under the condition of minimum usage of silica, and the phenomenon of later-stage processing cracking of the ultrathin rock plate is greatly reduced by utilizing zirconia phase change strengthening and small crystal grain dispersion strengthening.
Specifically, the strength and toughness of the prepared high-strength ultrathin rock plate are improved better along with the increase of the spraying thickness, the effect of reducing the post-processing cracking of the thin rock plate is better, but the generation cost is greatly increased along with the increase of the spraying thickness; if the spraying thickness is thinner, the effect of reducing the post-processing cracking phenomenon of the thin rock plate is not good, so that the thickness of each layer of the sprayed zirconia slurry in the technical scheme is 50-100 micrometers.
The technical scheme of the invention is further illustrated by combining specific examples and comparative examples.
Examples 1 to 5
A preparation method of a high-strength ultrathin rock plate comprises the following steps:
(1) preparing a rock plate blank and zirconia slurry, wherein the rock plate blank comprises, by mass, 15-25 parts of calcined bauxite, 15-25 parts of high alumina sand, 15-20 parts of kaolin, 10-15 parts of super-strong mud and 18-25 parts of diopside, and the content of silicon dioxide in the chemical components of the rock plate blank is 50-59%; the zirconia slurry comprises 60 percent of yttrium-stabilized zirconia powder, 0.2 percent of dispersant and the balance of solvent (water), wherein the yttrium-stabilized zirconia powder consists of 1.4 percent of yttrium oxide and the balance of tetragonal zirconia;
the preparation method of the zirconia slurry comprises the following steps: mixing yttrium-stabilized zirconia powder, a dispersing agent and a solvent (water) according to a formula, and grinding for 45min to obtain zirconia slurry;
(2) spraying 1 layer of zirconia slurry (the spraying thickness is 100 microns) at the bottom of the material distribution mould, distributing the rock plate blank, spraying 1 layer of zirconia slurry (the spraying thickness is 100 microns) on the surface of the rock plate blank after the material distribution is finished, and performing compression molding to obtain an ultrathin rock plate blank;
(3) and (3) after glaze spraying and ink-jet printing are carried out on the surface of the ultrathin rock plate blank, sintering to obtain the high-strength ultrathin rock plate, wherein the thickness of the high-strength ultrathin rock plate is 3 mm.
Specifically, the raw material composition of the rock plate blanks in examples 1-5 are shown in table 2 below:
table 2 raw material composition (in parts by mass) of the rock-plate blank in examples 1 to 5
Specifically, in each example of table 2, the calculation formula of the silica content (%) in the rock plate blank is as follows:
SiO in rock slab stock 2 Content is (A) 1 Is multiplied by A 1 SiO 2 2 Content + A 2 Is multiplied by A 2 SiO 2 2 Content + A 3 Is multiplied by A 3 SiO 2 2 Content + A 4 Is multiplied by A 4 SiO 2 2 Content + A 5 Is multiplied by A 5 SiO 2 2 Content)/total parts by mass of this example;
wherein A is 1 For calcining bauxite, A 2 Is high alumina sand, A 3 Is kaolin, A 4 Is super-strong mud, A 5 Is diopside.
Example 6
A preparation method of a high-strength ultrathin rock plate comprises the following steps:
(1) preparing a rock plate blank and zirconia slurry, wherein the raw materials of the rock plate blank comprise 21 parts of calcined bauxite, 20 parts of high alumina sand, 18 parts of kaolin, 13 parts of super-strong mud and 22 parts of diopside by mass percent, and the content of silicon dioxide in the rock plate blank is 52.39 percent by mass percent; the zirconia slurry comprises 60% of yttrium-stabilized zirconia powder, 0.2% of a dispersant and the balance of a solvent (water), wherein the yttrium-stabilized zirconia powder consists of 1.4% of yttrium oxide and 98.6% of tetragonal zirconia;
the preparation method of the zirconia slurry comprises the following steps: mixing yttrium-stabilized zirconia powder, a dispersing agent and a solvent (water) according to a formula, and grinding for 45min to obtain zirconia slurry;
(2) spraying 2 layers of zirconia slurry (the thickness of each layer of zirconia slurry is 100 microns) at the bottom of the material distribution mould, distributing the rock plate blank, spraying 2 layers of zirconia slurry (the thickness of each layer of zirconia slurry is 100 microns) on the surface of the rock plate blank after material distribution, and performing compression molding to obtain an ultrathin rock plate blank;
(3) and (3) after glaze spraying and ink-jet printing are carried out on the surface of the ultrathin rock plate blank, sintering to obtain the high-strength ultrathin rock plate, wherein the thickness of the high-strength ultrathin rock plate is 3 mm.
Comparative example 1
A preparation method of a high-strength ultrathin rock plate comprises the following steps:
(1) preparing a rock plate blank, wherein the raw materials of the rock plate blank comprise, by mass, 21 parts of black mud, 5 parts of kaolin, 18 parts of porcelain sand, 10 parts of aluminum powder, 11 parts of wollastonite, 10 parts of feldspar, 18 parts of sand powder, 0.3 part of sodium hexametaphosphate, 0.5 part of sodium humate, 0.5 part of water glass (900 ℃), and 0.5 part of sodium carboxymethylcellulose; the green body layer comprises the following raw materials in percentage by mass: 66.4% silica, 22.5% alumina, 4.2% potassium oxide, 1.0% sodium oxide, 3.8% calcium oxide, 0.8% magnesium oxide, 0.3% iron oxide, 1% loss on ignition;
(2) distributing the rock plate blank on a distribution die, and performing compression molding to obtain an ultrathin rock plate blank;
(3) and (3) after glaze spraying and ink-jet printing are carried out on the surface of the ultrathin rock plate blank, sintering to obtain the high-strength ultrathin rock plate, wherein the thickness of the high-strength ultrathin rock plate is 3 mm.
Comparative example 2
A preparation method of a high-strength ultrathin rock plate comprises the following steps:
(1) preparing a rock plate blank and zirconia slurry, wherein the rock plate blank comprises, by mass, 21 parts of black mud, 5 parts of kaolin, 18 parts of porcelain sand, 10 parts of aluminum powder, 11 parts of wollastonite, 10 parts of feldspar, 18 parts of sand powder, 0.3 part of sodium hexametaphosphate, 0.5 part of sodium humate, 0.5 part of water glass (900 ℃), and 0.5 part of sodium carboxymethylcellulose; the green body layer comprises the following raw materials in percentage by mass: 66.4% silica, 22.5% alumina, 4.2% potassium oxide, 1.0% sodium oxide, 3.8% calcium oxide, 0.8% magnesium oxide, 0.3% iron oxide, 1% loss on ignition;
the zirconia slurry comprises 60 percent of yttrium-stabilized zirconia powder, 0.2 percent of dispersant and the balance of solvent (water), wherein the yttrium-stabilized zirconia powder consists of 1.4 percent of yttrium oxide and the balance of tetragonal zirconia; the preparation method of the zirconia slurry comprises the following steps: mixing yttrium-stabilized zirconia powder, a dispersing agent and a solvent (water) according to a formula, and grinding for 45min to obtain zirconia slurry;
(2) spraying 1 layer of zirconia slurry (the spraying thickness is 100 microns) at the bottom of the material distribution mould, distributing the rock plate blank, spraying 1 layer of zirconia slurry (the spraying thickness is 100 microns) on the surface of the rock plate blank after the material distribution is finished, and performing compression molding to obtain an ultrathin rock plate blank;
(3) and (3) after glaze spraying and ink-jet printing are carried out on the surface of the ultrathin rock plate blank, sintering to obtain the high-strength ultrathin rock plate, wherein the thickness of the high-strength ultrathin rock plate is 3 mm.
Comparative example 3
A preparation method of a high-strength ultrathin rock plate comprises the following steps:
(1) preparing a rock plate blank, wherein the raw materials of the rock plate blank comprise 21 parts of calcined bauxite, 20 parts of high alumina sand, 18 parts of kaolin, 13 parts of super-strong mud and 22 parts of diopside by mass percent, and the content of silicon dioxide in the rock plate blank is 52.39 percent by mass percent;
(2) distributing the rock plate blank on a distribution die, and performing compression molding to obtain an ultrathin rock plate blank;
(3) and (3) after glaze spraying and ink-jet printing are carried out on the surface of the ultrathin rock plate blank, sintering to obtain the high-strength ultrathin rock plate, wherein the thickness of the high-strength ultrathin rock plate is 3 mm.
Comparative example 4
A preparation method of a high-strength ultrathin rock plate comprises the following steps:
(1) preparing a rock plate blank and zirconia slurry, wherein the raw materials of the rock plate blank comprise 21 parts of calcined bauxite, 20 parts of high alumina sand, 18 parts of kaolin, 13 parts of super-strong mud and 22 parts of diopside by mass percent, and the content of silicon dioxide in the rock plate blank is 52.39 percent by mass percent; the zirconia slurry comprises 60 percent of yttrium-stabilized zirconia powder, 0.2 percent of dispersant and the balance of solvent (water), wherein the yttrium-stabilized zirconia powder consists of 1.4 percent of yttrium oxide and the balance of tetragonal zirconia;
the preparation method of the zirconia slurry comprises the following steps: mixing yttrium-stabilized zirconia powder, a dispersing agent and a solvent (water) according to a formula, and grinding for 45min to obtain zirconia slurry;
(2) distributing the rock plate blank at the bottom of the distributing mold, spraying 1 layer of zirconia slurry (the spraying thickness is 100 microns) on the surface of the rock plate blank after distributing, and performing compression molding to obtain an ultrathin rock plate blank;
(3) and (3) after glaze spraying and ink-jet printing are carried out on the surface of the ultrathin rock plate blank, sintering to obtain the high-strength ultrathin rock plate, wherein the thickness of the high-strength ultrathin rock plate is 3 mm.
Specifically, according to the method for testing the strength and fracture toughness in the ceramic slate (T/GDTC 002-2021), the strength and fracture toughness of the high-strength ultrathin slates prepared in examples 1-6 and comparative examples 1-4 were tested, and the test results are shown in the following Table 2.
TABLE 2 Performance test results
As shown in Table 2, it is understood from the results of the tests performed in examples 1 to 6 that the high-strength ultrathin rock slabs prepared in examples 1 to 6 have high strength and high fracture toughness, the strength is 65 to 70MPa, and the fracture toughness is 1.34 to 1.45MPa/m 2 The problem of cracking in the later processing of the high-strength ultrathin rock plate can be effectively prevented and avoided. From the results of the measurements of examples 2 and 3, it was found that SiO was contained in the rock laminate blank 2 The content of (A) is increased in a small range, so that the fracture toughness of the prepared ultrathin rock plate is reduced to some extent; from the results of the measurements in examples 4 and 5, it was found that SiO was contained in the rock laminate blank 2 Of small magnitudeThe fracture toughness of the prepared ultrathin rock plate is increased; from the test results of example 6, it was found that spraying 2 layers of zirconia slurry on the bottom and top of the rock slab blank, respectively, can effectively improve the strength and fracture toughness of the ultra-thin rock slab.
As can be seen from the results of the performance test of comparative example 1, the conventional SiO was used 2 The high-strength ultrathin rock plate prepared from the rock plate blank with the content of 66.4 percent has the strength of only 45MPa and the fracture toughness of 1.10MPa/m 2 Cracking easily in the later period of processing; according to the detection result of the comparative example 2, by adopting the rock plate blank formula which is the same as that of the comparative example 1, 1 layer of zirconia slurry is sprayed on the bottom of the material distribution mould before material distribution, and 1 layer of zirconia slurry is sprayed on the surface of the rock plate blank after material distribution, so that the strength and the fracture toughness of the prepared ultrathin rock plate can be obviously improved; from the test results of comparative example 3, it can be seen that, compared to example 1, if only the rock plate blank in the present technical solution is used, and zirconia slurry is not sprayed during the preparation process, the strength and fracture toughness of the high-strength ultrathin rock plate prepared are greatly reduced; from the test results of comparative example 4, it was found that the strength and fracture toughness of the high-strength ultra-thin rock plate prepared by spraying the zirconia slurry only on the top of the rock plate blank were reduced.
The technical principle of the present invention is described above in connection with specific embodiments. The description is made for the purpose of illustrating the principles of the invention and should not be construed in any way as limiting the scope of the invention. Based on the explanations herein, those skilled in the art will be able to conceive of other embodiments of the present invention without inventive effort, which would fall within the scope of the present invention.
Claims (9)
1. The high-strength ultrathin rock plate is characterized by comprising a blank layer, wherein the top and the bottom of the blank layer are respectively provided with a zirconia layer;
the raw materials of the rock plate blank layer are rock plate blanks, and the raw materials of the rock plate blanks comprise calcined bauxite, high-alumina sand, kaolin, super-strong mud and diopside in parts by weight;
the content of silicon dioxide in the chemical composition of the rock plate blank is less than 60 percent by mass percent;
the thickness of the high-strength ultrathin rock plate is less than or equal to 3 mm.
2. The high-strength ultrathin rock plate as claimed in claim 1, characterized in that the raw materials of the rock plate blank comprise, by mass, 15-25 parts of calcined bauxite, 15-25 parts of high alumina sand, 15-20 parts of kaolin, 10-15 parts of ultra-strong mud and 18-25 parts of diopside.
3. The high-strength ultra-thin rock plate as claimed in claim 2, wherein the chemical composition of the rock plate blank contains 50-59% by mass of silica.
4. The high-strength ultrathin rock plate according to claim 1, characterized in that the zirconia layer is made of zirconia slurry, and the zirconia slurry comprises 55-65% by mass of yttrium stabilized zirconia powder, 0.1-0.4% by mass of a dispersant, and the balance of a solvent.
5. The high strength ultra-thin rock panel of claim 4, wherein said yttrium stabilized zirconia powder consists of, in mole percent, 1.3-1.5% yttrium oxide and 98.5-98.7% zirconium oxide.
6. The high strength ultra-thin rock panel of claim 5, wherein said zirconia is tetragonal zirconia.
7. A preparation method of a high-strength ultrathin rock plate, which is used for preparing the high-strength ultrathin rock plate as claimed in any one of claims 1 to 6, and comprises the following steps:
(1) respectively preparing a rock plate blank and zirconia slurry;
(2) spraying zirconia slurry at the bottom of the material distribution mould, distributing the rock plate blank, spraying zirconia slurry on the surface of the rock plate blank after the material distribution is finished, preparing an ultrathin rock plate blank through compression molding, and sintering to prepare the high-strength ultrathin rock plate.
8. The method of manufacturing a high-strength ultra-thin rock plate according to claim 7, wherein the zirconia slurry is manufactured as follows: mixing yttrium-stabilized zirconia powder, a dispersing agent and a solvent according to a formula, and grinding for 30-60 min to obtain zirconia slurry.
9. The method for preparing a high-strength ultra-thin rock plate according to claim 7, wherein the step (2) is performed as follows: spraying 1-2 layers of zirconia slurry at the bottom of a material distribution die, wherein the thickness of each layer of zirconia slurry is 50-100 microns, distributing a rock plate blank, spraying 1-2 layers of zirconia slurry on the surface of the rock plate blank after material distribution is finished, the thickness of each layer of zirconia slurry is 50-100 microns, performing compression molding after the spraying is finished, preparing an ultrathin rock plate blank, and sintering to prepare the high-strength ultrathin rock plate.
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