CN114804843B - High-strength ultrathin rock plate and preparation method thereof - Google Patents

High-strength ultrathin rock plate and preparation method thereof Download PDF

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CN114804843B
CN114804843B CN202210503854.6A CN202210503854A CN114804843B CN 114804843 B CN114804843 B CN 114804843B CN 202210503854 A CN202210503854 A CN 202210503854A CN 114804843 B CN114804843 B CN 114804843B
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rock plate
zirconia
blank
rock
strength
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CN114804843A (en
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赵威
李智鸿
徐登翔
钟保民
古文灿
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Foshan Dongpeng Ceramic Co Ltd
Foshan Dongpeng Ceramic Development Co Ltd
Guangdong Dongpeng Holdings Co Ltd
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Foshan Dongpeng Ceramic Co Ltd
Foshan Dongpeng Ceramic Development Co Ltd
Guangdong Dongpeng Holdings Co Ltd
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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 blank layer is a rock plate blank, and the content of silicon dioxide in the chemical composition of the rock plate blank is less than 60% by mass percent; the thickness of the high-strength ultrathin rock plate is less than or equal to 3mm. According to the technical scheme, the zirconia layers are respectively arranged at the top and the bottom of the blank layer, zirconia is uniformly distributed on the upper surface layer and the lower surface layer of the high-strength ultrathin rock plate after compression molding and sintering, and the later-stage processing cracking phenomenon of the ultrathin rock plate can be greatly reduced.

Description

High-strength ultrathin rock plate and preparation method thereof
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, rock plates have become new pets of large ceramic enterprises, the range of the rock plate thickness is wider from 3mm to 20mm, the size is 900 x 1200 mm to 1600 x 3800mm, even the ultra-large rock plates of 1800 x 9000mm appear, the types of the rock plates are various, the ultra-thin rock plates with the thickness less than or equal to 3mm are light, the transport and the installation are easy, the raw material cost can be reduced for ceramic enterprises, the profit is increased, and the ultra-thin rock plates are widely applied to the fields of furniture panels, electric appliance panels, wall decoration and the like.
Because the rock plate belongs to brittle materials, the rock plate is required to be subjected to mechanical processing such as cutting, polishing, drilling, chamfering and the like before being used as a household table surface and a panel, 30% -50% of cutting cracking can occur when the existing rock plate product is subjected to mechanical processing according to incomplete statistics, the cutting cracking rate of the ultrathin rock plate with the thickness less than or equal to 3mm is higher, the later use of the product is seriously influenced, the production cost is increased, and the processing is easy to crack and becomes a bottleneck for limiting the development of the rock plate.
The Chinese patent application with application number 202010954969.8 discloses a high-strength ceramic rock plate and a preparation method thereof, and the high strength of the rock plate is realized by designing different component compositions of a rock plate blank, a ground glaze and a surface glaze, but the high matching of the rock plate blank, the ground glaze and the surface glaze is required to achieve the effect, and the aim of improving the strength of the rock plate is not easy to achieve if the raw materials of the blank, the ground glaze and the surface glaze fluctuate in actual production.
The Chinese patent application with the application number of 202010864905.9 discloses a rock plate which is not easy to crack and a preparation method thereof, and the application improves the breaking modulus and the breaking strength of the rock plate by adding silicon carbide and a reinforcing agent into the rock plate raw material, and the silicon carbide reacts at high temperature to generate gas, so that the gas hole defects are easy to be generated in the rock plate and on the glaze surface, thereby reducing the breaking modulus and the breaking strength of the rock plate, and the purpose of improving the breaking modulus and the breaking strength of the rock plate is difficult to be achieved.
The chinese patent application No. 202111178761.2 teaches a process for preparing a toughened rock slab by zonal and layered distribution, which adopts a layered and layered distribution to prepare a rock slab body and adds tetragonal zirconia powder to the raw material of the rock slab body, wherein the tetragonal zirconia powder is added into the raw material of the rock slab body, so that the crack tip is closed to prevent crack propagation and increase crack induction energy of the toughened rock slab, the thickness of the rock slab is required to be 6mm-20mm, and for an ultrathin rock slab with the thickness of less than or equal to 3mm, if the layered and layered distribution is adopted, each layer is extremely thin, uniform distribution is difficult to realize during the re-distribution, thus the method is not suitable for preparing the ultrathin rock slab, and in addition, although the layered and zonal distribution is adopted, 3-15% of tetragonal zirconia powder is added into the raw material, and the cost is still higher.
Disclosure of Invention
Aiming at the problems of the background technology, 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 post-processing cracking of a Bao Yan plate.
The invention further 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 Bao Yan plate can be effectively avoided, and meanwhile, the preparation method is simple and the cost is low.
To achieve the purpose, the invention adopts the following technical scheme:
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 materials of the blank layer are rock plate blank materials, wherein the raw materials of the rock plate blank 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 blank is less than 60% by mass percent;
the thickness of the high-strength ultrathin rock plate is less than or equal to 3mm.
Further, the raw materials of the rock plate blank comprise 15-25 parts of calcined bauxite, 15-25 parts of high alumina sand, 15-20 parts of kaolin, 10-15 parts of super mud and 18-25 parts of diopside according to parts by weight.
Further, the content of silicon dioxide in the chemical composition of the rock plate blank is 50-59% by mass percent.
Further, the zirconia layer is prepared from zirconia slurry, and the zirconia slurry comprises 55-65% of yttrium-stabilized zirconia powder, 0.1-0.4% of dispersing agent and the balance of solvent according to mass percent.
Further, the yttrium-stabilized zirconia powder consists of 1.3-1.5% of yttrium oxide and 98.5-98.7% of zirconium oxide by mole percent.
Further, the zirconia is tetragonal phase zirconia.
The preparation method of the high-strength ultrathin rock plate is used for preparing the high-strength ultrathin rock plate and comprises the following steps of:
(1) Respectively preparing a rock plate blank and zirconia slurry;
(2) And (3) spraying zirconia slurry at the bottom of the distributing mould, distributing rock plate blank, spraying zirconia slurry on the surface of the rock plate blank after distributing, performing compression molding to obtain an ultrathin rock plate blank, and sintering to obtain 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 on the bottom of a distributing die, wherein the thickness of each layer of sprayed 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 distributing, and after spraying, performing compression molding to obtain an ultrathin rock plate blank and sintering to obtain the high-strength ultrathin rock plate.
The technical scheme has the following beneficial effects:
the technical proposal adopts the low silicon oxide mineral raw material to prepare SiO 2 The rock plate blank with the content less than 60 percent reduces the content of free quartz in the rock plate blank, thereby reducing the internal stress generated by quartz crystal form conversion during cooling, and further effectively reducing the proportion of post-processing cutting cracking. Meanwhile, when the ultrathin rock plate is cut after being machined, cracks start from surface defects, the cracks are induced, then the cracks are expanded, and the ultrathin rock plate is cracked, the technical scheme is characterized in that zirconia layers are respectively arranged at the top and the bottom of a blank layer, zirconia is uniformly distributed in the upper surface layer and the lower surface layer of the high-strength ultrathin rock plate after being sintered, and the zirconia phase change reinforcement and small-grain dispersion reinforcement are utilized, so that the phenomenon of the thin rock plate after-machining cracking can be greatly reduced, and because the technical scheme is only that the zirconia layers are arranged at the top and the bottom of the blank layer, the zirconia layers are not needed to be arranged in a rock plate blankThe zirconia is added, the zirconia consumption of the method is very small, the cost is low, the method is acceptable to enterprises, and the method can realize large-scale production.
Detailed Description
The technical scheme of the invention is further described below with reference to the specific embodiments.
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 materials of the blank layer are rock plate blank materials, wherein the raw materials of the rock plate blank 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 blank is less than 60% by mass percent;
the thickness of the high-strength ultrathin rock plate is less than or equal to 3mm.
As the rock plate belongs to a brittle material, the rock plate is required to be subjected to mechanical processing such as cutting, polishing, drilling, chamfering and the like before being used as a household table surface and a panel, 30% -50% cutting cracking can occur when the existing rock plate product is subjected to mechanical processing according to incomplete statistics, the cutting cracking rate of the ultrathin rock plate with the thickness less than or equal to 3mm is higher, the later use of the product is seriously influenced, the production cost is increased, and the processing is easy to crack and becomes a bottleneck for limiting the development of the ultrathin rock plate.
SiO in conventional rock plate blank 2 The content (in mass%) is generally around 70%, and during firing, a large amount of free SiO is present in the rock plate 2 In the cooling stage, at 573 ℃, the quartz crystal form is converted with 0.82% of volume change; the transformation of quartz crystal forms is accompanied by 2.8 percent of volume change at 180-270 ℃, and the volume change in the cooling process can lead the internal stress of the rock plate to be generated, so that the cutting cracking is easy to occur in the later processing. Therefore, the technical proposal adopts the low silicon oxide mineral raw materials, and prepares SiO by adopting the raw materials of calcined bauxite, high alumina sand, kaolin, super mud and diopside 2 The rock plate blank (before firing) with the content less than 60 percent reduces the content of free quartz in the rock plate blank, thereby reducing the internal stress generated by quartz crystal form conversion during cooling, effectively avoiding the post-processing cracking of the ultrathin rock plate and reducing the cost of the ultra-thin rock plateAnd the proportion of the later processing cutting cracking of the ultrathin rock plate is effectively reduced. Meanwhile, when the ultrathin rock plate is machined and cut after being cut, cracks start from surface defects, the cracks are induced, then the cracks are expanded, the ultrathin rock plate is cracked, the zirconia layers are respectively arranged at the top and the bottom of the blank layer, after being sintered, zirconia is uniformly distributed in the upper surface layer and the lower surface layer of the high-strength ultrathin rock plate, the phenomenon of post-machining cracking of the ultrathin rock plate can be greatly reduced by using zirconia phase change strengthening and small-grain dispersion strengthening, and moreover, as the zirconia layers are only arranged at the top and the bottom of the blank layer, no zirconia is required to be added in the rock plate material in the method, the zirconia consumption is extremely small, the cost is low, and the method is acceptable for enterprises and can realize large-scale production.
Specifically, this technical scheme high strength ultra-thin rock plate is thickness is less than or equal to 3 mm's ultra-thin rock plate, to thickness is less than or equal to 3 mm's ultra-thin rock plate, 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 zirconia layer respectively at the top and the bottom of body layer, after compression molding, the sintering, obtains zirconia layer respectively in the upper and lower surface layer of high strength ultra-thin rock plate, can reduce thin rock plate post-processing cracking phenomenon by a wide margin.
Further illustrating, the raw materials of the rock plate blank comprise 15-25 parts of calcined bauxite, 15-25 parts of high alumina sand, 15-20 parts of kaolin, 10-15 parts of super mud and 18-25 parts of diopside according to parts by weight.
Illustratively, the chemical compositions of calcined bauxite, kaolin, super mud and diopside, in mass percent, are shown in table 1 below:
TABLE 1 chemical composition of raw materials in rock plate blank (%)
Figure BDA0003636494930000051
Figure BDA0003636494930000061
As can be seen from Table 1, the rock plate blank material in the technical proposal adopts calcined bauxite, high alumina sand, kaolin, super mud, diopside and other SiO 2 Mineral raw materials with low content are used as raw materials, and SiO in each raw material is used as a raw material 2 The content is lower than 60 percent, and the SiO in the rock plate blank is realized by adopting the formula 2 The content is controlled to be 50-59%, so that the content of free quartz is reduced, and the internal stress generated by quartz crystal form conversion during cooling is further reduced, thereby reducing the cutting cracking of the rock plate in the later processing.
Further, bauxite and high alumina sand are calcined in the raw materials of the rock plate blank to improve the alumina content in the raw materials, reduce the silica content, increase the mullite crystal content in the ultra-thin rock plate after sintering and improve the strength of the rock plate; the kaolin is added into the formula, so that the forming performance of the rock plate can be improved, and the silicon oxide content in a formula system can be further reduced; the super-strong mud can reduce the firing temperature of the rock plate, and meanwhile, due to SiO in the super-strong mud 2 The mass percentage of the cement is 54.43 percent, the firing temperature of the rock plate is reduced by using the super-strong mud, and SiO in the rock plate blank can be avoided 2 The content exceeds 60%; diopside can reduce the firing temperature and improve the performance of ultrathin rock plates, but excessive diopside can increase the silicon oxide content in a formula system, so that 18-25 parts by mass of kaolin is required to be controlled.
Specifically, the high alumina sand is prepared from bauxite raw material by 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 performance and the like.
Further illustratively, the rock laminate blank has a silica content of 50 to 59% by mass.
Further illustrating that the zirconia layer is made of zirconia slurry, the zirconia slurry comprises 55-65% of yttrium-stabilized zirconia powder, 0.1-0.4% of dispersing agent and the balance of solvent according to mass percent.
Specifically, according to the technical scheme, yttrium-stabilized zirconia powder, a dispersing agent and a solvent are mixed to prepare the zirconia slurry with the solid content of 55-65%, a spray gun is convenient to use for spraying and the spraying amount is controlled, if the content of yttrium-stabilized zirconia powder in the zirconia slurry is too high, the fluidity of the zirconia slurry is poor, the nozzle of the spray gun is easy to block in the spraying process, and if the content of yttrium-stabilized zirconia powder in the zirconia slurry is too low, too much solvent is introduced, and the performance of a blank body after molding is affected.
Preferably, the solvent in the zirconia slurry is water and the dispersant is an aqueous dispersant, such as TEGO750.
Further illustratively, the yttrium-stabilized zirconia powder is comprised of 1.3 to 1.5% yttria and 98.5 to 98.7% zirconia, calculated as mole percent.
Further illustratively, the zirconia is tetragonal phase zirconia.
Specifically, since zirconia has a phase change strengthening mechanism, tetragonal zirconia (t-ZrO 2 ) And cubic phase zirconia (c-ZrO 2 ) Will be converted into monoclinic phase zirconia (m-ZrO 2 ) The zirconia powder is added into the zirconia slurry, and the principle of the zirconia phase change volume increase is utilized to improve crack induction energy when the high-strength ultrathin rock plate is stressed (or impacted), prevent the formation of penetrating cracks on the surface of the high-strength ultrathin rock plate and further achieve the purpose of reducing the 'cutting crack' proportion of the high-strength ultrathin rock plate. Meanwhile, as 1.3 to 1.5 percent of yttrium oxide is added in the yttrium-stabilized zirconia powder, the phase change of the zirconium oxide in a sintering area at a low temperature of between 100 and 400 ℃ can be avoided, and the zirconium oxide is converted into monoclinic phase zirconium oxide, so that the problem of cracking in the later processing of a high-strength ultrathin rock plate is solved.
It is noted that zirconia is generally classified into tetragonal zirconia (t-ZrO 2 ) Monoclinic phase zirconia (m-ZrO 2 ) And cubic phase zirconia (c-ZrO 2 ) Wherein the monoclinic phase zirconia (m-ZrO 2 ) The phase change can not occur when the stress is applied, the volume expansion can not occur, and the effect of closing the crack tip can not occurAlthough cubic phase zirconia (c-ZrO 2 ) There will also be partial transformation into monoclinic zirconia (m-ZrO 2 ) But cubic phase zirconia (c-ZrO 2 ) The phase change of the ceramic material is small, the crack tip generated during mechanical cutting is difficult to be closed, and the technical proposal adopts tetragonal zirconia (t-ZrO) 2 ) Because of tetragonal zirconia (t-ZrO 2 ) Phase transition to monoclinic zirconia (m-ZrO) 2 ) When the mechanical cutting device is used, the volume expansion is carried out by 7% -10%, the volume change is large, the crack tips generated during mechanical cutting can be closed, the crack induction energy is improved, and therefore the cracking of the high-strength ultrathin rock plate is effectively avoided.
The preparation method of the high-strength ultrathin rock plate is used for preparing the high-strength ultrathin rock plate and comprises the following steps of:
(1) Respectively preparing a rock plate blank and zirconia slurry;
(2) And (3) spraying zirconia slurry at the bottom of the distributing mould, distributing rock plate blank, spraying zirconia slurry on the surface of the rock plate blank after distributing, performing compression molding to obtain an ultrathin rock plate blank, and sintering to obtain the high-strength ultrathin rock plate.
The zirconia slurry is sprayed at the bottom of the distributing mould before distributing, the zirconia slurry is uniformly sprayed at the upper layer of the rock plate blank after distributing, the high-strength ultrathin rock plate is obtained after compression molding and sintering, the zirconia is uniformly distributed in the upper surface layer and the lower surface layer of the high-strength ultrathin rock plate, and the zirconia phase change reinforcement and the small crystal grain dispersion reinforcement are utilized, so that the later processing cracking phenomenon of the thin rock plate can be greatly reduced.
Specifically, the ultrathin rock plate with high strength is an ultrathin rock plate with the thickness less than or equal to 3mm, if layered distribution is adopted for the ultrathin rock plate with the thickness less than or equal to 3mm, each layer of thickness is extremely thin, and even distribution is difficult to realize during distribution.
Specifically, after the ultra-thin rock plate blank body is manufactured by compression molding in the step (2), a glaze spraying process and an ink jet printing process are further required to be performed on the surface of the ultra-thin rock plate blank body, and after firing, the high-strength ultra-thin rock plate is obtained.
Further illustratively, the zirconia slurry is prepared 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.
Further illustratively, the operation of step (2) is as follows: spraying 1-2 layers of zirconia slurry on the bottom of a distributing die, wherein the thickness of each layer of sprayed 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 distributing, and after spraying, performing compression molding to obtain an ultrathin rock plate blank and sintering to obtain the high-strength ultrathin rock plate.
It is worth pointing out that, this technical scheme adopts the spray gun to spray, and the thickness of each layer spraying is 50 ~ 100 microns, through spraying 1 ~ 2 layers of zirconia thick liquids respectively in the bottom and the top of rock board blank, can make the even distribution zirconia in the upper and lower surface layer of ultra-thin rock board under the circumstances that the silica quantity is minimum, utilizes zirconia phase transition reinforcement and small grain dispersion strengthening, reduces ultra-thin rock board later stage processing cracking's phenomenon by a wide margin.
Specifically, as the spraying thickness is increased, the strength and toughness of the prepared high-strength ultrathin rock plate are better, the effect of reducing the post-processing cracking of the Bao Yan plate is better, but as the spraying thickness is increased, the generation cost is greatly increased; if the spraying thickness is thinner, the effect of reducing the later processing cracking phenomenon of the thin rock plate is poor, so that the thickness of each layer of sprayed zirconia slurry in the technical scheme is 50-100 microns.
The technical scheme of the invention is further described below by combining specific examples and comparative examples.
Examples 1 to 5
The preparation method of the 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 15-25 parts of calcined bauxite, 15-25 parts of high alumina sand, 15-20 parts of kaolin, 10-15 parts of super mud and 18-25 parts of diopside according to mass percent, and the content of silicon dioxide in the chemical components of the rock plate blank is 50-59%; the zirconia slurry comprises 60% of yttrium-stabilized zirconia powder, 0.2% of dispersant and the balance of solvent (water), wherein the yttrium-stabilized zirconia powder consists of 1.4% of yttrium oxide and the balance of tetragonal phase zirconium oxide;
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 45 minutes to obtain zirconia slurry;
(2) Spraying 1 layer of zirconia slurry (the sprayed thickness is 100 microns) on the bottom of a distributing die, distributing a rock plate blank, spraying 1 layer of zirconia slurry (the sprayed 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 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 3mm.
Specifically, the raw material compositions of the rock plate blanks in examples 1 to 5 are shown in the following Table 2:
table 2 raw material composition (in parts by mass) of the rock plate blank in examples 1 to 5
Figure BDA0003636494930000101
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 plate blank 2 Content= (a) 1 Is multiplied by A in parts by mass 1 SiO of (B) 2 Content +A 2 Is multiplied by A in parts by mass 2 SiO of (B) 2 Content +A 3 Is multiplied by A in parts by mass 3 SiO of (B) 2 Content +A 4 Is multiplied by A in parts by mass 4 SiO of (B) 2 Content +A 5 Is multiplied by A in parts by mass 5 SiO of (B) 2 Content)/total parts by weight of this example;
wherein A is 1 For calcining bauxite, A 2 Is high alumina sand, A 3 Is kaolin A 4 Is super mud A 5 Is diopside.
Example 6
The preparation method of the 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 according to the mass parts, and the content of silicon dioxide in the rock plate blank is 52.39 percent according to the mass percent; the zirconia slurry comprises 60% of yttrium-stabilized zirconia powder, 0.2% of dispersant and the balance of solvent (water), wherein the yttrium-stabilized zirconia powder consists of 1.4% of yttrium oxide and 98.6% of tetragonal phase zirconium oxide;
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 45 minutes to obtain zirconia slurry;
(2) Spraying 2 layers of zirconia slurry (the thickness of each layer of spraying is 100 microns) on the bottom of a distributing die, distributing a rock plate blank, spraying 2 layers of zirconia slurry (the thickness of each layer of spraying 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 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 3mm.
Comparative example 1
The preparation method of the high-strength ultrathin rock plate comprises the following steps:
(1) Preparing a rock plate blank, 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 sodium silicate (900 ℃) and 0.5 part of hydroxymethyl cellulose sodium; 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 material on a distributing die, and performing compression molding to obtain an ultrathin rock plate blank;
(3) And (3) after glaze spraying and ink-jet printing 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 3mm.
Comparative example 2
The preparation method of the 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, 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 sodium silicate (900 ℃) and 0.5 part of sodium hydroxymethyl cellulose; 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% of yttrium-stabilized zirconia powder, 0.2% of dispersant and the balance of solvent (water), wherein the yttrium-stabilized zirconia powder consists of 1.4% of yttrium oxide and the balance of tetragonal phase zirconium oxide; 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 45 minutes to obtain zirconia slurry;
(2) Spraying 1 layer of zirconia slurry (the sprayed thickness is 100 microns) on the bottom of a distributing die, distributing a rock plate blank, spraying 1 layer of zirconia slurry (the sprayed 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 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 3mm.
Comparative example 3
The preparation method of the 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 mud and 22 parts of diopside in parts by mass, and the content of silicon dioxide in the rock plate blank is 52.39 percent in percentage by mass;
(2) Distributing the rock plate blank material on a distributing die, and performing compression molding to obtain an ultrathin rock plate blank;
(3) And (3) after glaze spraying and ink-jet printing 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 3mm.
Comparative example 4
The preparation method of the 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 in parts by mass, and the content of silicon dioxide in the rock plate blank is 52.39 percent in percentage by mass; the zirconia slurry comprises 60% of yttrium-stabilized zirconia powder, 0.2% of dispersant and the balance of solvent (water), wherein the yttrium-stabilized zirconia powder consists of 1.4% of yttrium oxide and the balance of tetragonal phase zirconium oxide;
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 45 minutes to obtain zirconia slurry;
(2) Distributing a rock plate blank at the bottom of a distributing die, spraying 1 layer of zirconia slurry (the sprayed thickness is 100 micrometers) 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 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 3mm.
Specifically, the high-strength ultrathin rock plates produced in examples 1 to 6 and comparative examples 1 to 4 were examined for strength and fracture toughness, respectively, according to the method for examination of strength and fracture toughness in ceramic rock plates (T/GDTC 002-2021), and the examination results are shown in Table 2 below.
TABLE 2 Performance test results
Figure BDA0003636494930000141
As shown in Table 2, from the detectable results of examples 1 to 6, the high-strength ultrathin rock plates prepared in examples 1 to 6 have high strength, high fracture toughness values, strength of 65 to 70MPa and fracture toughness of 1.34 to 1.45MPa/m 2 The problem that cracking occurs in the later processing of the high-strength ultrathin rock plates can be effectively prevented and avoided. From the results of the tests in example 2 and example 3, it is understood that SiO was contained in the rock plate blank 2 The content of the ultra-thin rock plate is increased by a small margin, so that the fracture toughness of the prepared ultra-thin rock plate is reduced; from the results of the tests in example 4 and example 5, it is understood that SiO was contained in the rock plate blank 2 The content of the ultra-thin rock plates is reduced by a small extent, so that the fracture toughness of the ultra-thin rock plates is increased; from the test results of example 6, it was found that the strength and fracture toughness of the ultrathin rock plate can be effectively improved by spraying 2 layers of zirconia slurry on the bottom and top of the rock plate blank.
As can be seen from the results of the performance test of comparative example 1, the conventional SiO was used 2 High-strength ultrathin rock plate prepared from rock plate blank with 66.4% content, wherein the strength is only 45MPa, and the fracture toughness is 1.10MPa/m 2 The later stage is easy to crack in the processing process; as can be seen from the detection results of comparative example 2, the preparation method can remarkably improve the preparation of the rock plate blank by adopting the same rock plate blank formula of comparative example 1, spraying 1 layer of zirconia slurry on the bottom of the distribution die before distribution, and spraying 1 layer of zirconia slurry on the surface of the rock plate blank after distributionThe strength and fracture toughness of the ultrathin rock plates; from the detection result of comparative example 3, compared with example 1, if only the rock plate blank in the technical scheme is used, the zirconia slurry is not sprayed in the preparation process, and the strength and fracture toughness of the prepared high-strength ultrathin rock plate are greatly reduced; from the test results of comparative example 4, it is understood that if zirconia slurry is sprayed only on top of the rock plate blank, the strength and fracture toughness of the prepared high-strength ultrathin rock plate are reduced.
The technical principle of the present invention is described above in connection with the specific embodiments. The description is made for the purpose of illustrating the general principles of the invention and should not be taken in any way as limiting the scope of the invention. Other embodiments of the invention will be apparent to those skilled in the art from consideration of this specification without undue burden.

Claims (8)

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, and the thickness of the high-strength ultrathin rock plate is less than or equal to 3mm; respectively spraying zirconia slurry on the bottom and the top of a rock plate blank, and respectively obtaining zirconia layers in the upper surface layer and the lower surface layer of the high-strength ultrathin rock plate after compression molding and sintering;
the raw materials of the blank layer are rock plate blanks, and the raw materials of the rock plate blanks comprise 15-25 parts of calcined bauxite, 15-25 parts of high alumina sand, 15-20 parts of kaolin, 10-15 parts of super mud and 18-25 parts of diopside according to parts by weight;
the chemical compositions of the calcined bauxite, the high alumina sand, the kaolin, the super mud and the diopside are as follows in percentage by mass:
recipe name AL 2 O 3 SiO 2 CaO MgO Fe 2 O 3 TiO 2 K 2 O Na 2 O Loss on ignition Calcined bauxite 52.58 42.03 0.37 0.42 1.44 1.74 0.25 0.31 0.86 High alumina sand 29.65 53.74 0.05 0.34 2.69 0.26 3.82 0.64 8.81 Kaolin clay 32.14 52.83 0.06 0.29 1.31 0.13 2.49 0.49 10.26 Super-strong mud 23.19 54.43 0.05 0.26 1.27 0.4 5.92 3.86 10.62 Diopside stone 2.35 59.47 19.2 10.49 0.27 0.14 0.31 0.38 7.39
The content of silicon dioxide in the chemical composition of the rock plate blank is less than 60 percent by mass percent.
2. The high strength ultra-thin rock laminate according to claim 1, characterized in that the content of silica in the chemical composition of the rock laminate blank is 50-59% in mass percent.
3. The high-strength ultrathin rock plate according to claim 1, wherein the zirconia layer is prepared from a zirconia slurry, and the zirconia slurry comprises, by mass, 55-65% of yttrium-stabilized zirconia powder, 0.1-0.4% of a dispersing agent and the balance of a solvent.
4. A high strength ultra-thin rock laminate according to claim 3, wherein said yttrium stabilized zirconia powder consists of 1.3 to 1.5% yttria and 98.5 to 98.7% zirconia, calculated as mole percent.
5. The high strength ultra-thin rock laminate according to claim 4, wherein the zirconia is tetragonal phase zirconia.
6. A method for preparing a high strength ultra-thin rock plate, characterized by comprising the steps of:
(1) Respectively preparing a rock plate blank and zirconia slurry;
(2) And (3) spraying zirconia slurry at the bottom of the distributing mould, distributing rock plate blank, spraying zirconia slurry on the surface of the rock plate blank after distributing, performing compression molding to obtain an ultrathin rock plate blank, and sintering to obtain the high-strength ultrathin rock plate.
7. The method for preparing a high-strength ultra-thin rock plate according to claim 6, wherein the method for preparing 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.
8. The method for manufacturing a high-strength ultra-thin rock laminate according to claim 6, wherein the operation of the step (2) is as follows: spraying 1-2 layers of zirconia slurry on the bottom of a distributing die, wherein the thickness of each layer of sprayed 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 distributing, and after spraying, performing compression molding to obtain an ultrathin rock plate blank and sintering to obtain the high-strength ultrathin rock plate.
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