CN116553919A - Porous ceramic material, product prepared from porous ceramic material and preparation method of porous ceramic material - Google Patents
Porous ceramic material, product prepared from porous ceramic material and preparation method of porous ceramic material Download PDFInfo
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- CN116553919A CN116553919A CN202310567972.8A CN202310567972A CN116553919A CN 116553919 A CN116553919 A CN 116553919A CN 202310567972 A CN202310567972 A CN 202310567972A CN 116553919 A CN116553919 A CN 116553919A
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- 229910010293 ceramic material Inorganic materials 0.000 title claims abstract description 36
- 238000002360 preparation method Methods 0.000 title abstract description 7
- 239000000919 ceramic Substances 0.000 claims abstract description 53
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims abstract description 38
- 239000011325 microbead Substances 0.000 claims abstract description 35
- 239000002994 raw material Substances 0.000 claims abstract description 26
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 21
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 14
- 239000002689 soil Substances 0.000 claims abstract description 14
- 229910021532 Calcite Inorganic materials 0.000 claims abstract description 12
- 239000010433 feldspar Substances 0.000 claims abstract description 12
- 239000000835 fiber Substances 0.000 claims abstract description 12
- 229920000728 polyester Polymers 0.000 claims abstract description 12
- 239000005995 Aluminium silicate Substances 0.000 claims abstract description 11
- 235000012211 aluminium silicate Nutrition 0.000 claims abstract description 11
- 229920003063 hydroxymethyl cellulose Polymers 0.000 claims abstract description 11
- 229940031574 hydroxymethyl cellulose Drugs 0.000 claims abstract description 11
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims abstract description 11
- 239000010453 quartz Substances 0.000 claims abstract description 11
- 238000000034 method Methods 0.000 claims abstract description 10
- 239000002002 slurry Substances 0.000 claims description 22
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 claims description 18
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 9
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 9
- 239000004927 clay Substances 0.000 claims description 9
- 239000002245 particle Substances 0.000 claims description 9
- 239000011701 zinc Substances 0.000 claims description 9
- 229910052725 zinc Inorganic materials 0.000 claims description 9
- 238000007873 sieving Methods 0.000 claims description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 7
- 230000005484 gravity Effects 0.000 claims description 6
- 238000000498 ball milling Methods 0.000 claims description 5
- 238000005245 sintering Methods 0.000 claims description 5
- 238000007605 air drying Methods 0.000 claims description 3
- 238000001035 drying Methods 0.000 claims description 3
- 239000010440 gypsum Substances 0.000 claims description 3
- 229910052602 gypsum Inorganic materials 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 claims description 3
- 238000002156 mixing Methods 0.000 claims description 3
- 239000007921 spray Substances 0.000 claims description 3
- 238000005507 spraying Methods 0.000 claims description 3
- 238000001746 injection moulding Methods 0.000 claims description 2
- 238000010521 absorption reaction Methods 0.000 abstract description 5
- 230000000694 effects Effects 0.000 abstract description 5
- 230000000052 comparative effect Effects 0.000 description 11
- 239000000440 bentonite Substances 0.000 description 5
- 229910000278 bentonite Inorganic materials 0.000 description 5
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 description 5
- 238000011010 flushing procedure Methods 0.000 description 3
- 230000030279 gene silencing Effects 0.000 description 3
- 238000001000 micrograph Methods 0.000 description 3
- 238000000748 compression moulding Methods 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 238000002474 experimental method Methods 0.000 description 1
- 238000010309 melting process Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 238000007569 slipcasting Methods 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/14—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silica
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/06—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances
- C04B38/063—Preparing or treating the raw materials individually or as batches
- C04B38/0635—Compounding ingredients
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- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
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- C04B2235/3231—Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
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- C04B2235/3262—Manganese oxides, manganates, rhenium oxides or oxide-forming salts thereof, e.g. MnO
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Abstract
A porous ceramic material, a porous ceramic product prepared from the porous ceramic material and a preparation method thereof, wherein the porous ceramic material comprises the following raw materials in percentage by weight: 40% -50% of quartz, 10% -25% of kaolin, 15% -25% of black mud, 2% -4% of feldspar, 1% -3% of calcite, 5% -10% of alumina microbeads, 1% -2% of polyester fiber, 1% -5% of expansive soil, 1% -5% of zirconia microbeads and 1% of hydroxymethyl cellulose. The porous ceramic material realizes the preparation of the porous ceramic closestool by using a grouting process, thereby achieving the effects of sound absorption and noise reduction.
Description
Technical Field
The present disclosure relates to a porous ceramic material, products made therefrom, and methods of making
Background
In the ceramic bathroom industry, the use of toilets is very common. The current closestool flushes the water pressure by force, and the in-process of flushing mixes with the air in closestool inner chamber easily and produces resonance to produce the noise, and when the noise reaches 78 decibels, the audio frequency is extremely harsher, has seriously influenced user's use experience.
At present, the toilet products in the domestic and foreign markets mainly reduce noise through a flushing mode and an auxiliary system, and the problem cannot be well solved in the prior art; the porous materials are prepared by compression molding, but the closestool cannot be prepared by compression molding, because the closestool adopts slip casting and internally comprises complex structures such as hollow structures, pipelines and the like.
Disclosure of Invention
The application provides a porous ceramic material, a product prepared from the porous ceramic material and a preparation method, and the porous ceramic material is used for preparing a porous ceramic closestool by using a grouting process, so that the effects of sound absorption and noise reduction are achieved.
In contrast to the prior art, the first aspect of the present application provides a porous ceramic material, comprising, by weight: 40% -50% of quartz, 10% -25% of kaolin, 15% -25% of black mud, 2% -4% of feldspar, 1% -3% of calcite, 5% -10% of alumina microbeads, 1% -2% of polyester fiber, 1% -5% of expansive soil, 1% -5% of zirconia microbeads and 1% of hydroxymethyl cellulose.
In an exemplary embodiment, the porous ceramic material comprises the following raw materials in weight: 50% of quartz, 10% of kaolin, 24% of black mud, 2% of feldspar, 1% of calcite, 5% of alumina microbeads, 1% of polyester fibers, 1% of expansive soil, 5% of zirconia microbeads and 1% of hydroxymethyl cellulose.
In an exemplary embodiment, wherein the expansive soil comprises, by weight: 45% -55% of calcium sulfate, 5% -10% of iron powder, 5% -10% of zinc permanganate and 25% -35% of clay, and preferably comprises: 52.5% of calcium sulfate, 8.8% of iron powder, 9.7% of zinc permanganate and 29% of clay.
In an exemplary embodiment, wherein the alumina microbeads and the zirconia microbeads have a particle size of 200-300 μm.
In a second aspect, the present application provides a porous ceramic product made from a feedstock comprising the porous ceramic material described above.
In an exemplary embodiment, optionally, the porous ceramic product is a toilet product, preferably, the porous ceramic product is a porous acoustic toilet.
In a third aspect, the present application provides a method for preparing the porous ceramic product, which includes the following steps:
s100: preparing porous ceramic slurry;
s200: injection molding the porous ceramic slurry in a gypsum mold to obtain a porous ceramic green body;
s300: demolding the porous ceramic green body and drying;
s400: glazing the dried porous ceramic green body;
s500: and sintering the glazed porous ceramic green body to obtain a porous ceramic material product.
In an exemplary embodiment, step S100 further includes:
s101: preparing the raw materials of the porous ceramic material according to the weight percentage
S102: adding water into the raw materials in the step S101, uniformly mixing, and ball-milling;
s103: sieving to obtain porous ceramic slurry.
In an exemplary embodiment, wherein in step S102, optionally, planetary ball mill is used to ball mill for 1-2 hours, raw materials by weight: the specific gravity of the ball to water is 1:1.5: 0.3.
in an exemplary embodiment, wherein, optionally, in step S103, the specific gravity of the feedstock slurry prior to sieving is greater than 175g/ml, preferably from 175g/ml to 185g/ml, more preferably 185g/100ml; optionally, the viscosity of the feedstock slurry prior to sieving is 70-80s/100ml.
In an exemplary embodiment, wherein, in step S103, the feedstock slurry is optionally screened through a 100 mesh screen, wherein the screened feedstock slurry has a particle size satisfying a 55% -60% ratio of less than 10 μm.
In an exemplary embodiment, wherein in step S300, the porous ceramic green body is dried at 50 ℃ to 60 ℃ for 4 days after being demolded.
In an exemplary embodiment, in step S400, the glazing step includes: spraying glaze by using a spray gun until the thickness of the glaze layer is 0.5-0.8mm, and naturally air-drying.
In an exemplary embodiment, wherein in step S500, the glazed porous ceramic green body is sintered at 1220-1250 ℃ for 1 hour to obtain a porous ceramic product.
Compared with the prior art, the application has the following advantages:
1. according to the porous ceramic material, the porous ceramic closestool is prepared by using a grouting process, so that the effects of sound absorption and noise reduction are achieved.
2. The porous amortization closestool that this application prepared uses the ceramic material that forms intercommunication porous structure, and this porous ceramic material is inside to have a lot of apertures, and the back is gone into to the sound wave, takes place to reflect, reduces sound after the sound wave stack.
3. The porous ceramic closestool is prepared by grouting molding, and the original holes of the microbeads are protected by the expansive soil in the melting process of sintering aid feldspar and calcite; a highly communicated porous ceramic structure is obtained by introducing polyester fibers; the porous ceramic product has good sound absorption performance, and can greatly reduce the noise of the closestool in the using process.
Additional features and advantages of the application will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the application. Other advantages of the present application may be realized and attained by the structure particularly pointed out in the written description and drawings.
Drawings
The accompanying drawings are included to provide an understanding of the technical aspects of the present application, and are incorporated in and constitute a part of this specification, illustrate the technical aspects of the present application and together with the examples of the present application, and not constitute a limitation of the technical aspects of the present application.
FIG. 1 is a cross-sectional microscopic view of a conventional ceramic toilet of the prior art;
FIG. 2 is a cross-sectional micrograph of a porous ceramic toilet of example 3 of the present application;
FIG. 3 is a cross-sectional micrograph of a ceramic toilet of comparative example 1 of the present application;
FIG. 4 is a cross-sectional micrograph of a ceramic toilet of comparative example 3 of the present application.
Detailed Description
The following examples are given for the understanding of the technical solutions of the present invention, the scope of the patent protection of the invention is not limited thereto, and non-inventive dry variants and modifications are made on the basis of the present invention, which all fall within the scope of protection of the invention.
Example 1
The porous ceramic material comprises the following raw materials in parts by weight:
40% quartz, 25% kaolin, 15% black mud, 2% feldspar, 2% calcite, 10% alumina microbeads, 2% polyester fibers, 2% bentonite, 1% zirconia microbeads and 1% hydroxymethyl cellulose;
wherein, the raw materials of the expansive soil by weight are: 52.5% of calcium sulfate, 8.8% of iron powder, 9.7% of zinc permanganate and 29% of clay;
the particle size of the alumina microbeads and zirconia microbeads is 200-300 μm.
Preparation of porous ceramic slurry:
adding water into the porous ceramic material with the composition according to the weight percentage, uniformly mixing, and ball-milling for 1.5 hours by adopting a planetary ball mill, wherein the raw materials are as follows by weight: ball: the specific gravity of water is 1:1.5:0.3;
the specific gravity of the raw material slurry after ball milling is 185g/100ml, and the viscosity is 75s/100ml;
sieving with 100 mesh sieve, wherein the content of the particles with the granularity smaller than 10 μm is 55-60%.
Preparation of a porous silencing closestool:
grouting the porous ceramic slurry under a gypsum mold to obtain a porous ceramic green body;
demoulding the porous ceramic green body and drying at 50 ℃ for 4 days;
spraying glaze by using a spray gun until the thickness of the glaze layer is 0.5-0.8mm, and naturally air-drying;
sintering at 1230 deg.c for 1 hr.
Example 2
The porous ceramic material comprises the following raw materials in parts by weight:
45% quartz, 15% kaolin, 20% black mud, 3% feldspar, 1% calcite, 8% alumina microbeads, 1% polyester fiber, 3% bentonite, 3% zirconia microbeads and 1% hydroxymethyl cellulose;
wherein, the raw materials of the expansive soil by weight are: 52.5% of calcium sulfate, 8.8% of iron powder, 9.7% of zinc permanganate and 29% of clay;
the particle size of the alumina microbeads and zirconia microbeads is 200-300 μm.
The porous ceramic slurry and the porous noise-reducing toilet were prepared in the same manner as in example 1.
Example 3
The porous ceramic material comprises the following raw materials in parts by weight:
50% quartz, 10% kaolin, 24% black mud, 2% feldspar, 1% calcite, 5% alumina microbeads, 1% polyester fiber, 1% bentonite, 5% zirconia microbeads and 1% hydroxymethyl cellulose;
wherein, the raw materials of the expansive soil by weight are: 52.5% of calcium sulfate, 8.8% of iron powder, 9.7% of zinc permanganate and 29% of clay;
the particle size of the alumina microbeads and zirconia microbeads is 200-300 μm.
The porous ceramic slurry and the porous noise-reducing toilet were prepared in the same manner as in example 1.
Comparative example 1.
The ceramic material comprises the following raw materials in parts by weight:
50% quartz, 10% kaolin, 25% black mud, 2% feldspar, 1% calcite, 5% alumina microbeads, 1% polyester fiber, 5% zirconia microbeads and 1% hydroxymethyl cellulose;
wherein the particle size of the alumina microbeads and the zirconia microbeads is 200-300 μm.
The ceramic slurry and toilet bowl were prepared in the same manner as in example 1.
Comparative example 2.
The ceramic material comprises the following raw materials in parts by weight:
50% quartz, 10% kaolin, 24% black mud, 2% feldspar, 1% calcite, 5% alumina, 1% polyester fiber, 1% bentonite, 5% zirconia and 1% hydroxymethyl cellulose;
wherein, the raw materials of the expansive soil by weight are: 52.5% of calcium sulfate, 8.8% of iron powder, 9.7% of zinc permanganate and 29% of clay.
The ceramic slurry and toilet bowl were prepared in the same manner as in example 1.
Comparative example 3.
The ceramic material comprises the following raw materials in parts by weight:
50% quartz, 10% kaolin, 25% black mud, 2% feldspar, 1% calcite, 5% alumina microbeads, 1% bentonite, 5% zirconia microbeads and 1% hydroxymethyl cellulose;
wherein, the raw materials of the expansive soil by weight are: 52.5% of calcium sulfate, 8.8% of iron powder, 9.7% of zinc permanganate and 29% of clay;
the particle size of the alumina microbeads and zirconia microbeads is 200-300 μm.
The ceramic slurry and toilet bowl were prepared in the same manner as in example 1.
Experimental example 1 Sound absorption and reduction Effect
The flushing sound of the general toilet, comparative examples 1 to 3 and porous toilets of examples 1 to 3 was measured using a noise meter SZ 824-4. The results obtained are shown in Table 1 below. Wherein, the ordinary closestool in this experiment is the model of nine-pasture production 11376, does not contain aluminium oxide microballoon, polyester fiber, expansive soil and zirconia microballoon's closestool.
Meanwhile, the sections of the general ceramic toilets, the toilets in example 3 and comparative examples 1 and 3 were observed using a digital microscope. The results are shown in FIGS. 1-4.
As can be seen from table 1, the porous noise reduction toilet of the present application has a superior noise reduction effect compared to the general toilet and the toilet of the comparative example.
As can be seen from fig. 1 to 4 and table 1, the common ceramic toilet has a compact section and no obvious air holes; the porous silencing closestool section air holes are uniformly distributed, and the diameters of the holes are distributed at about 200-300um, so that the porous silencing closestool has a communicated porous structure.
TABLE 1
| Numbering device | Average pore size/um | With or without through holes | decibel/dB |
| Common toilet | Without any means for | Without any means for | 80.2 |
| Comparative example 1 | Without any means for | Without any means for | 80.9 |
| Comparative example 2 | Without any means for | Without any means for | 80.5 |
| Comparative example 3 | 190 | Without any means for | 66.5 |
| Example 1 | 280 | Has the following components | 35.6 |
| Example 2 | 245 | Has the following components | 39.5 |
| Example 3 | 220 | Has the following components | 42.5 |
The present application describes a number of embodiments, but the description is illustrative and not limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the embodiments described herein.
Claims (10)
1. A porous ceramic material comprising, by weight, raw materials: 40% -50% of quartz, 10% -25% of kaolin, 15% -25% of black mud, 2% -4% of feldspar, 1% -3% of calcite, 5% -10% of alumina microbeads, 1% -2% of polyester fiber, 1% -5% of expansive soil, 1% -5% of zirconia microbeads and 1% of hydroxymethyl cellulose.
2. The porous ceramic material of claim 1, comprising, by weight: 50% of quartz, 10% of kaolin, 24% of black mud, 2% of feldspar, 1% of calcite, 5% of alumina microbeads, 1% of polyester fibers, 1% of expansive soil, 5% of zirconia microbeads and 1% of hydroxymethyl cellulose.
3. The porous ceramic material of claim 1 or 2, wherein the expansive soil comprises, by weight: 45% -55% of calcium sulfate, 5% -10% of iron powder, 5% -10% of zinc permanganate and 25% -35% of clay, and preferably comprises: 52.5% of calcium sulfate, 8.8% of iron powder, 9.7% of zinc permanganate and 29% of clay.
4. The porous ceramic material of claim 1 or 2, wherein the alumina microbeads and the zirconia microbeads have a particle size of 200-300 μιη.
5. A porous ceramic product made from a feedstock comprising the porous ceramic material of any one of claims 1-4.
6. The porous ceramic product of claim 5, which is a toilet product, preferably, which is a porous acoustic toilet.
7. A method of preparing the porous ceramic product of claim 5 or 6, the method comprising the steps of:
s100, preparing porous ceramic slurry;
s200, performing injection molding on the porous ceramic slurry in a gypsum mold to obtain a porous ceramic green body;
s300, demolding the porous ceramic green body and drying;
s400, glazing the dried porous ceramic green body;
and S500, sintering the glazed porous ceramic green body to obtain a porous ceramic material product.
8. The method for preparing a porous ceramic product according to claim 7, wherein step S100 further comprises:
s101, preparing the raw materials of the porous ceramic material according to any one of claims 1 to 4 according to weight percentage;
s102, adding water into the raw materials in the step S101, uniformly mixing, and ball-milling;
and S103, sieving to obtain the porous ceramic slurry.
9. The method for producing a porous ceramic product according to claim 8, wherein in step S102, a planetary ball mill is used for ball milling for 1-2 hours, raw materials by weight: ball: the specific gravity of water is 1:1.5:0.3; and/or
In step S103, the specific gravity of the raw material slurry before sieving is greater than 175g/ml, preferably 175g/ml to 185g/ml, more preferably 185g/100ml; the viscosity of the raw material slurry before sieving is 70-80s/100ml; sieving the raw material slurry by a 100-mesh sieve, wherein the granularity of the sieved raw material slurry is 55% -60% of the content of less than 10 μm.
10. The method for producing a porous ceramic product according to claim 7, wherein the porous ceramic green body in step S300 is dried at 50 ℃ to 60 ℃ for 4 days after being demolded; and/or
The glazing step in step S400 includes: spraying glaze by using a spray gun until the thickness of the glaze layer is 0.5-0.8mm, and naturally air-drying; and/or
And (5) sintering the glazed porous ceramic green body in the step (S500) for 1 hour at the temperature of 1220-1250 ℃ to obtain a porous ceramic product.
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