阅读说明：本技术 一种以低品位钾长石为原料的微晶面多孔保温陶瓷复合材料及其制备方法 (Microcrystalline surface porous heat-insulating ceramic composite material taking low-grade potassium feldspar as raw material and preparation method thereof ) 是由 刘鹏 王琦琦 刘作冬 于永生 于 2019-10-24 设计创作，主要内容包括：本发明公开了一种以低品位钾长石为主要原料的微晶面多孔保温陶瓷复合材料及其制备方法；所述的复合材料包括多孔保温陶瓷基体和微晶面层,基体以低品位钾长石为主要原料,面层主要材料包括珍珠岩、氧化铝、氧化镁和二氧化硅,采用二次布料,一次高温发泡法制备,发泡剂为碳化硅。基体层导热系数为0.060~0.097 W/(m·K),具有保温隔热功能,面层具有装饰效果。本发明成本低廉,节能环保；微晶面层极大程度地提高了复合材料的力学性能,同时能够有效地抑制发泡过程中气泡的融合溢出,改善发泡效果,降低发泡剂用量；复合材料一次高温发泡烧成,工艺简单,制备成本低；用于建筑领域可实现保温隔热和装饰一体化。(The invention discloses a microcrystalline surface porous heat-insulating ceramic composite material taking low-grade potassium feldspar as a main raw material and a preparation method thereof, wherein the composite material comprises a porous heat-insulating ceramic matrix and a microcrystalline surface layer, the matrix takes the low-grade potassium feldspar as the main raw material, the surface layer mainly comprises perlite, alumina, magnesia and silicon dioxide, the composite material is prepared by adopting secondary cloth and a one-step high-temperature foaming method, a foaming agent is silicon carbide, the matrix layer has a heat conductivity coefficient of 0.060 ~ 0.097.097W/(m.K), and has the heat-insulating function and a decorative effect.)

1. The microcrystalline surface porous heat-insulating ceramic composite material taking low-grade potassium feldspar as a raw material is characterized in that: the composite material comprises a substrate and a surface layer, wherein the substrate takes low-grade potassium feldspar as a raw material, a silicon carbide powder foaming agent is added, and porous heat-insulating ceramic is prepared by a high-temperature foaming method; the main raw materials of the surface layer comprise perlite, alumina, magnesia and silica, and are prepared by high-temperature sintering.

2. The preparation method of the microcrystalline surface porous heat-insulating ceramic composite material taking the low-grade potassium feldspar as the raw material as claimed in claim 1, characterized by comprising the following steps:

step 1), preparing a porous ceramic matrix raw material: weighing low-grade potassium feldspar raw materials with set mass, adding silicon carbide powder with set mass, and performing ball milling uniformly;

step 2), preparing a microcrystalline glass surface layer raw material: weighing perlite, aluminum oxide, magnesium oxide and silicon dioxide with set mass, melting at high temperature, quenching into vitreous body particles by water, then ball-milling in deionized water, and drying to obtain glass powder;

step 3), preparing a microcrystalline porous heat-insulating ceramic composite material blank: respectively wetting the raw material powder obtained in the step 1) and the step 2) with water, and uniformly stirring; firstly, filling the wetted matrix material into a die, prepressing to a set depth, and then filling the wetted surface layer raw material; performing compression molding under set pressure, demolding, and drying to obtain a blank;

step 4), firing the microcrystalline porous heat-insulating ceramic composite material: placing the blank prepared in the step 3) into a programmed heating furnace to sinter according to a set temperature system, and cooling along with the furnace;

step 5), post-treatment of the microcrystalline porous heat-insulating ceramic composite material: cutting the sample obtained in the step 4), and polishing on a polishing machine to obtain the microcrystalline porous heat-insulating ceramic composite material taking the low-grade potassium feldspar as a main raw material.

3. The preparation method of the microcrystalline surface porous heat-insulating ceramic composite material taking the low-grade potassium feldspar as the raw material as claimed in claim 2 is characterized by comprising the following steps of: k in the low-grade potassium feldspar raw material powder used in the step 1)₂The content of O is about 9 percent, the particle diameter of the potassium feldspar raw material powder is 1 ~ 15 mu m, and the SiC is pureThe degree is more than or equal to 98.5 percent, and the addition amount of SiC is 0.6 ~ 1.2.2 wt.%.

4. The method for preparing the microcrystalline porous heat-insulating ceramic composite material by using the low-grade potassium feldspar as the raw material according to the claim 2, wherein the dosage of the perlite in the step 2) is 35 ~ 55 wt.%, the dosage of the alumina is 25.08 ~ 28.13.13 wt.%, the dosage of the magnesia is 15.77 ~ 16.29 wt.%, and the dosage of the silicon dioxide is 7.31 ~ 22.58.58 wt.%.

5. The method for preparing the microcrystalline porous heat-insulating ceramic composite material by using the low-grade potassium feldspar as the raw material according to the claim 2 is characterized in that when the composite material blank in the step 3) is prepared, the base material and the surface layer material need to be wetted by water, the base material is firstly put into a die, is pre-pressed for 3 mm downwards, then is added with the surface layer material, and is finally subjected to compression molding, wherein the molding pressure is 10 ~ 15 MPa.

6. The method for preparing the microcrystalline porous heat-insulating ceramic composite material from the low-grade potassium feldspar according to claim 2, wherein the sintering temperature schedule in the step 4) is that the temperature is increased to 300 ℃ at the temperature rising rate of 5 ~ 25 ℃/min, the temperature is kept for 30 min at the temperature, then the temperature is increased to 1190 ~ 1270 ℃ at the temperature rising rate of 5 ~ 25 ℃/min, the temperature is kept for 20 ~ 60 min at the temperature, then the heating is stopped, and the microcrystalline porous heat-insulating ceramic composite material is cooled to the room temperature along with the furnace.

7. The preparation method of the microcrystalline surface porous heat-insulating ceramic composite material taking the low-grade potassium feldspar as the raw material as claimed in claim 2 is characterized by comprising the following steps of: the prepared microcrystalline surface porous heat-insulating ceramic composite material is formed by one-step firing, the surface layer is a microcrystalline glass surface layer, and the matrix is a porous heat-insulating ceramic layer.

Technical Field

The invention relates to the technical field of building heat-insulating and decorating materials, in particular to a microcrystalline porous heat-insulating ceramic composite material taking low-grade potassium feldspar as a raw material and a preparation method thereof.

Background

The popularization and the use of the building heat-insulation material can reduce the heat exchange between the indoor and the outdoor of the building, effectively reduce the energy consumption in the using process of the building and be an effective means for realizing the energy conservation of the building. The building thermal insulation material has various types, and can be generally divided into an organic thermal insulation material, an inorganic thermal insulation material and a composite thermal insulation material, and the porous thermal insulation ceramic belongs to one of the inorganic thermal insulation materials. The porous heat-insulating ceramic has abundant pore structures inside and low heat conductivity coefficient; the preparation process is fired at high temperature, so that the fire resistance, durability and weather resistance are excellent; the preparation raw materials mainly comprise industrial solid wastes, particularly mine tailings and waste ores, and the comprehensive utilization of mineral resources can be realized. Therefore, porous heat-insulating ceramic materials are receiving increasing attention.

The high-temperature foaming method is one of the most common methods for preparing the porous ceramic, and has the advantages of simple process, good foaming effect and the like.

Chinese patent CN106747307A provides a heat-insulating ceramic decorative composite board and a preparation method thereof. The heat-insulating ceramic decorative composite board comprises a foamed ceramic bottom layer and a toughened ceramic surface layer, wherein the bottom layer is mainly made of red mud and yellow river silt which are wastes extracted from bauxite, the surface layer is mainly made of perlite micro powder, wollastonite, bentonite and the like, a high-temperature foaming method is adopted in the preparation method, and a foaming agent is silicon carbide.

Chinese patent CN 108840568A provides a light heat-insulating ceramic decorative board and a preparation method thereof. The light heat-insulating ceramic decorative board comprises a base body and a metal glaze layer, wherein the main raw materials of the base body are perlite micro powder and expanded perlite micro powder, the metal glaze layer mainly comprises perlite tail ash, low-temperature fusion block powder, aluminum silver powder, sodium carboxymethylcellulose and the like, and the preparation method adopts secondary firing.

The Chinese patent CN 107651966A discloses a decorative light heat-insulating ceramic tile and a preparation method thereof, the decorative light heat-insulating ceramic tile comprises a composite body layer, a ground glaze layer, a fancy glaze decorative layer and a glaze-polished layer from bottom to top, wherein the composite body layer is made of a common ceramic blank, and the preparation method comprises the steps of preparing the composite body layer, drying at 150 ~ 180 ℃, then carrying out secondary glazing, and firing at 1180 ~ 1230 ℃.

Chinese patent CN 105985020 a discloses a foamed glass-ceramic and a preparation method of the foamed glass-ceramic. The patent takes steelmaking hot slag as a main raw material, firstly foam glass is prepared, and then the foam glass is subjected to heat treatment to obtain the foam glass ceramics. The invention has the advantages of directly utilizing the sensible heat of the hot slag and saving energy consumption.

The invention patent CN 104150964A discloses a manufacturing method and a product of a microcrystalline glass ceramic composite board, and the utility model patent CN203976648U discloses a microcrystalline glass ceramic composite board. They are all made by compounding microcrystalline glass on the surface of ceramic tile.

Similar to the patents, the common characteristics are that the foamed ceramics or the composite material with the glaze decoration layer is prepared by different raw materials through a high-temperature foaming method and a low-temperature foaming method and is used for building heat preservation and insulation decoration; or the microcrystalline glass is compounded on the surface of the ceramic tile for architectural decoration.

The foamed ceramic has good heat insulation, fire resistance, durability and weather resistance, but has generally low mechanical properties, is independently used as a heat insulation material, and needs to be externally provided with a decorative layer for the second time; the glaze layer has rich decorative effect, is a good choice for compounding with the foamed ceramic, but the surface strength and hardness of the conventional glaze layer compounded with the foamed ceramic are generally low, and the glaze layer is easy to damage under the action of external force.

The microcrystalline glass material has higher hardness and breaking strength, and also has a decorative effect, so that the performance of a foamed ceramic matrix and a decorative surface layer can be improved simultaneously by compounding the microcrystalline surface and the foamed ceramic, the requirements of heat preservation, heat insulation and decoration integration are met, and the problem of research is needed urgently.

Disclosure of Invention

In order to realize the efficient utilization of non-metallic minerals and effectively solve the problem of environmental pollution caused by stacking mineral tailings, the invention provides a porous heat-insulating ceramic composite material with a microcrystalline decorative surface, which is prepared by taking low-grade potassium feldspar as a main raw material and adopting a high-temperature foaming process.

The purpose of the invention is realized as follows:

a microcrystalline surface porous heat-insulating ceramic composite material taking low-grade potassium feldspar as a raw material comprises a matrix and a surface layer, wherein the matrix takes the low-grade potassium feldspar as the raw material, silicon carbide powder as a foaming agent, and porous heat-insulating ceramic is prepared by a high-temperature foaming method; the main raw materials of the surface layer comprise perlite, alumina, magnesia and silicon dioxide, and the surface layer is prepared by high-temperature sintering, and the base layer and the surface layer are formed by one-step sintering;

the preparation method of the microcrystalline surface porous heat-insulating ceramic composite material by taking the low-grade potassium feldspar as the raw material comprises the following steps:

step 1), preparing a porous ceramic matrix raw material: weighing low-grade potassium feldspar raw materials with set mass, adding silicon carbide powder with set mass, and performing ball milling uniformly;

step 2), preparing a microcrystalline glass surface layer raw material: weighing perlite, aluminum oxide, magnesium oxide and silicon dioxide with set mass, melting at high temperature, quenching in water to prepare glass particles, then ball-milling in deionized water, and drying to obtain glass powder;

step 3), preparing a microcrystalline porous heat-insulating ceramic composite material blank: respectively wetting the raw material powder obtained in the step 1) and the step 2) with water, and uniformly stirring; firstly, filling the wetted matrix material into a die, prepressing to a set depth, and then filling the wetted surface layer raw material; performing compression molding under set pressure, demolding, and drying to obtain a blank;

step 4), firing the microcrystalline porous heat-insulating ceramic composite material: placing the blank prepared in the step 3) into a programmed heating furnace to sinter according to a set temperature system, and cooling along with the furnace;

step 5), post-treatment of the microcrystalline porous heat-insulating ceramic composite material: cutting the sample obtained in the step 4), and polishing on a polishing machine to obtain the microcrystalline surface porous heat-insulating ceramic composite material taking the low-grade potassium feldspar as a main raw material.

K in the low-grade potassium feldspar raw material powder used in the step 1)₂The content of O is about 9 percent, the particle size of the potassium feldspar raw material powder is about 1 ~ 15 mu m, the purity of SiC is more than or equal to 98.5 percent, and the addition amount of the SiC is 0.6 ~ 1.2.2 wt.%;

in the step 2), the dosage of perlite is 35 ~ 55 wt.%, the dosage of alumina is 25.08 ~ 28.13.13 wt.%, the dosage of magnesia is 15.77 ~ 16.29 wt.%, and the dosage of silica is 7.31 ~ 22.58.58 wt.%;

when the composite material blank in the step 3) is prepared, the base body and the surface layer raw materials need to be moistened by adding water, the base body raw materials are firstly put into a die, are pre-pressed for 3 mm downwards, then are added with the surface layer raw materials, and are finally molded by compression, wherein the molding pressure is 10 ~ 15 MPa;

in the step 4), the sintering temperature schedule is that the temperature is increased to 300 ℃ at the heating rate of 5 ~ 25 ℃/min, the temperature is kept for 30 min at the temperature, then the temperature is increased to 1190 ~ 1270 ℃ at the heating rate of 5 ~ 25 ℃/min, the temperature is kept for 20 ~ 60 min at the temperature, then the heating is stopped, and the furnace is cooled to the room temperature;

the prepared microcrystalline surface porous heat-insulating ceramic composite material is formed by one-step firing, the surface layer is a microcrystalline glass surface layer, and the matrix is a porous heat-insulating ceramic layer.

Has the positive and beneficial effects that: the method takes the low-grade potassium feldspar as a main raw material, has low firing temperature and low cost, and provides a solution for comprehensive utilization of potassium feldspar tailings; the surface layer of the composite material is microcrystalline glass, so that the composite material has higher hardness and breaking strength, and has a decorative effect while improving and protecting the substrate layer. The porous heat-preservation and heat-insulation ceramic is prepared by a high-temperature foaming method and one-time firing only by adding the silicon carbide foaming agent, the preparation process is simple in flow, short in period and simple in equipment, and the production cost can be effectively reduced; the microcrystalline glass surface layer greatly improves the mechanical property of the material, can effectively inhibit the fusion of bubbles from overflowing in the foaming process, improves the foaming effect and reduces the dosage of the foaming agent. The microcrystalline porous heat-preservation ceramic composite material provided by the invention has the functions of heat preservation and heat insulation and the decorative effect, can be used for building heat preservation and heat insulation decoration, and meets the requirements of heat preservation, heat insulation and decoration integration.

Drawings

FIG. 1 is a particle size diagram of a low-grade potassium feldspar raw material powder used in the invention;

FIG. 2 is a photograph of the micro-crystalline porous insulating ceramic prepared by the present invention.

Detailed Description

The invention is further described with reference to the following drawings and specific embodiments: