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CN-122010526-A - Fiber reinforced ceramic product and preparation method thereof

CN122010526ACN 122010526 ACN122010526 ACN 122010526ACN-122010526-A

Abstract

The invention belongs to the field of ceramics, and particularly relates to a fiber reinforced ceramic product and a preparation method thereof. The fiber reinforced ceramic product comprises, by weight, 25-90 parts of clay, 5-50 parts of quartz and 5-40 parts of feldspar, 0.1-15 parts of basalt chopped fibers and 0.1-15 parts of basalt fiber mesh cloth, 0.1-3 parts of a water reducer and 15-60 parts of water. The preparation method adopts grouting, green compact, spraying, smearing or dewatering self-leveling molding, solves the problems of large size, special-shaped piece and large brittleness of the traditional ceramic by cooperative reinforcement of two basalt fibers, has high strength and good toughness, and is flexible and controllable in process, thereby being suitable for industrial production.

Inventors

  • JIANG DIAOMIAO
  • Jiang Yanglei
  • JIANG YIYING

Assignees

  • 景德镇市三个石匠工艺品有限公司

Dates

Publication Date
20260512
Application Date
20260202

Claims (9)

  1. 1. The fiber reinforced ceramic product is characterized by comprising a binding component, a framework component, a reinforcing component, an auxiliary component and water, wherein the weight parts of the components are as follows: The adhesive component comprises 25-90 parts of clay; The framework components comprise 5-50 parts of quartz and 5-40 parts of feldspar; The reinforcing component comprises 0.1-15 parts of basalt chopped fiber and 0.1-15 parts of basalt fiber gridding cloth; The auxiliary agent comprises 0.1-3 parts of water reducer; 15-60 parts of water.
  2. 2. The fiber-reinforced ceramic article of claim 1, comprising the raw materials of, by weight, 55 parts of clay, 25 parts of quartz, 20 parts of feldspar, 1.5 parts of a water reducing agent, 7 parts of basalt chopped fibers, 7 parts of basalt fiber mesh cloth, and 35 parts of water.
  3. 3. The fiber reinforced ceramic article of claim 1 or 2, wherein the clay has a particle size of 0.1-2 μm; And/or the silica content in the quartz is 90-99%, and the particle size of the quartz is 65 mu m-5mm; And/or the feldspar has a Mohs hardness of 6-6.5 and a density of 2.6-2.8g/cm 3 ; And/or the water reducing agent is sodium lignin sulfonate or calcium lignin sulfonate; And/or the monofilament diameter of the basalt chopped fiber is 5.5-25 mu m, and the fiber length is 6-100mm.
  4. 4. A method of producing a fiber reinforced ceramic article according to any one of claims 1 to 3, wherein the method of producing is slip casting, green compact forming, spray forming, smear forming or dewatering self-leveling forming.
  5. 5. The method of making a fiber reinforced ceramic article according to claim 4, wherein the slip casting comprises the steps of: (1) Mixing clay, quartz, feldspar, a water reducing agent, basalt chopped fibers and water to obtain mixed fiber slurry; (2) Fixing basalt fiber gridding cloth in a mold, injecting the fiber-mixed slurry from the bottom of the mold, wrapping the basalt fiber gridding cloth, and dehydrating, drying and molding.
  6. 6. The method of making a fiber reinforced ceramic article according to claim 4, wherein the green compact forming comprises the steps of: (1) Mixing clay, quartz, feldspar, a water reducing agent, basalt chopped fibers and water to obtain mixed fiber slurry; (2) Pressing the mixed fiber slurry to form a mud blank, and paving basalt fiber gridding cloth on the surface of the mud blank; (3) And after the mud blank is dried, covering the mixed fiber slurry on the basalt fiber grid cloth to be pressed to form a sandwich structure, and thus, the formation of the pressed blank is completed.
  7. 7. The method of making a fiber reinforced ceramic article according to claim 4, wherein the spray forming comprises the steps of: (1) Mixing clay, quartz, feldspar, a water reducing agent, basalt chopped fibers and water to obtain mixed fiber slurry; (2) Spraying the mixed fiber slurry in a spraying mode to obtain a bottom mud material; (3) And paving basalt fiber mesh cloth on the surface of the bottom mud material, and then continuously spraying the basalt fiber mesh cloth to finish spray forming.
  8. 8. The method of making a fiber reinforced ceramic article according to claim 4, wherein the smear molding comprises the steps of: (1) Mixing clay, quartz, feldspar, a water reducing agent, basalt chopped fibers and water to obtain mixed fiber slurry; (2) Coating the mixed fiber slurry with mud by adopting a manual coating mode to obtain a bottom mud material; (3) And paving basalt fiber mesh cloth on the surface of the bottom mud material, and then continuously manually smearing to finish smearing molding.
  9. 9. The method of making a fiber reinforced ceramic article according to claim 4, wherein the dehydrating self-leveling forming comprises the steps of: (1) Mixing clay, quartz, feldspar, a water reducing agent, basalt chopped fibers and water to obtain mixed fiber slurry; (2) Pouring the mixed fiber slurry into a permeable bottom die, and paving a wushu fiber grid cloth after dehydration and solidification; (3) And then pouring the mixed fiber slurry continuously, and completing the dehydration self-leveling molding after dehydration.

Description

Fiber reinforced ceramic product and preparation method thereof Technical Field The invention belongs to the field of ceramics, and particularly relates to a fiber reinforced ceramic product and a preparation method thereof. Background Ceramic materials are widely used because of their excellent physical and chemical properties, but their conventional product morphology and size are fundamentally limited by the molding process. Currently, the ceramic products produced in industry are mainly focused on two types, namely, a planar product (such as ceramic tiles) and a revolving body product (such as a round cylinder and a tank) formed by revolving blank. For three-dimensional components with large size (side length or height exceeds 1 meter), regular square shape or complex special shape, the traditional process faces three technical bottlenecks which cannot be overcome: 1. And (3) forming, namely collapsing, namely after the die support is lost, the large wet blank cannot resist gravity due to insufficient structural strength, so that the middle part collapses and the edges deform, and the design shape cannot be obtained. The practical dilemma that a round cylinder with the diameter of 1.5 meters can be manufactured and a square table with the side length of 1.2 meters is difficult to manufacture is common in the industry. 2. The blank is crisp and difficult to flow, even if the blank is molded, the large dry blank has extremely high brittleness, and is extremely easy to break due to stress concentration in the processes of demolding, carrying and kiln loading, so that the process flow in large-scale production is impossible. 3. The sintering stress causes cracking, namely, when a large green body is dried and shrunk and sintered in a kiln (particularly at the stage of quartz crystal form conversion at about 573 ℃), huge and uneven thermal stress is generated inside the large green body, so that the product is easily cracked or deformed in the sintering process, and the yield is extremely low and uncontrollable. In order to improve the mechanical properties of ceramics, attempts are made to add reinforcing materials such as glass fibers, carbon fibers and organic fibers in the prior art, but the prior art has obvious defects that the glass fibers are poor in heat resistance and easy to soften and decompose in the ceramic sintering process to influence the stability of products, the carbon fibers are high in cost and poor in interfacial compatibility with a ceramic matrix, firm bonding is difficult to form, and the organic fibers are easy to carbonize at high temperature and cannot keep the reinforcing effect in the ceramic sintering environment. As a natural mineral fiber, the basalt fiber has the advantages of high temperature resistance, high mechanical strength, good chemical stability, moderate cost, environmental protection, no pollution and the like, has good matching property with the chemical property of a ceramic matrix, but the basalt chopped fiber and the basalt fiber mesh cloth are not matched in a cooperative manner in the prior art at present. Therefore, the ceramic industry is in need of a technical scheme which is not limited to material modification, but is systematically innovated from the aspects of structural design and forming methods so as to break through the manufacturing barriers of large-sized and special-shaped ceramic components and meet the brand new requirements of high-end household, building decoration and public art fields on ceramic materials. The invention is derived therefrom. Disclosure of Invention In order to solve the problems in the prior art, the invention provides a fiber reinforced ceramic product and a preparation method thereof. The invention has the advantage of systematically solving the fundamental problem that the traditional ceramic cannot be used for manufacturing large-scale special-shaped structural parts. Through this scheme, can stably prepare square plane spare of jumbo size, regular dysmorphism container and high degree of meters's whole sculpture. The raw material components and the permanent basalt chopped fibers and the basalt fiber mesh cloth cooperate to inhibit cracking, so that the firing yield of the large-scale product is increased to a controllable industrialization level. The invention provides a fiber reinforced ceramic product, which comprises an adhesive component, a framework component, a reinforcing component, an auxiliary component and water, wherein the adhesive component comprises the following components in parts by weight: The adhesive component comprises 25-90 parts of clay; The framework components comprise 5-50 parts of quartz and 5-40 parts of feldspar; The reinforcing component comprises 0.1-15 parts of basalt chopped fiber and 0.1-15 parts of basalt fiber gridding cloth; The auxiliary agent comprises 0.1-3 parts of water reducer; 15-60 parts of water. Preferably, the fiber reinforced ceramic product comprises the following r