阅读说明：本技术 一种高性能自清洁卫生陶瓷及其制备方法 (High-performance self-cleaning sanitary ceramic and preparation method thereof ) 是由 李润润 李月明 闫朝一 沈宗洋 于 2021-09-11 设计创作，主要内容包括：本发明公开了一种高性能自清洁卫生陶瓷及其制备方法,由陶瓷坯体以及包覆于陶瓷坯体表面的基底涂层、和基底涂层表面的面涂层构成；所述陶瓷坯体的原料组成为高岭土25～70wt％、长石20～40wt％、石英0～35wt％、电解质0～3wt％；所述基底涂层的原料组成为钾长石10～30wt％、石英20～50wt％、星子高岭土5～20wt％、方解石10～25wt％、白云石1～5wt％、锂辉石0～10wt％、硅酸锆7～20wt％、氧化锌0～10wt％；所述面涂层的组成为浓度为0.02～0.2mol/L的聚苯乙烯浆料65～100wt％、粘结剂0～35wt％。本发明通过配方设计和复合涂层的使用,实现了卫生陶瓷的超疏水自清洁性能；制备方法原料便宜、环保、工艺简单,便于推广和大规模使用,对于工业上有着极大的价值。(The invention discloses a high-performance self-cleaning sanitary ceramic and a preparation method thereof, which consists of a ceramic body, a substrate coating coated on the surface of the ceramic body and a surface coating on the surface of the substrate coating; the ceramic blank comprises the following raw materials of 25-70 wt% of kaolin, 20-40 wt% of feldspar, 0-35 wt% of quartz and 0-3 wt% of electrolyte; the base coating comprises the following raw materials of 10-30 wt% of potash feldspar, 20-50 wt% of quartz, 5-20 wt% of star kaolin, 10-25 wt% of calcite, 1-5 wt% of dolomite, 0-10 wt% of spodumene, 7-20 wt% of zirconium silicate and 0-10 wt% of zinc oxide; the top coating comprises 65-100 wt% of polystyrene slurry with the concentration of 0.02-0.2 mol/L and 0-35 wt% of binder. According to the invention, through the formula design and the use of the composite coating, the super-hydrophobic self-cleaning performance of the sanitary ceramic is realized; the preparation method has the advantages of cheap raw materials, environmental protection, simple process, convenient popularization and large-scale use, and has great value in industry.)

1. A high-performance self-cleaning sanitary ceramic is characterized in that: the ceramic coating consists of a ceramic body, a substrate coating coated on the surface of the ceramic body and a surface coating on the surface of the substrate coating; the ceramic blank comprises the following raw materials of 25-70 wt% of kaolin, 20-40 wt% of feldspar, 0-35 wt% of quartz and 0-3 wt% of electrolyte; the base coating comprises the following raw materials of 10-30 wt% of potash feldspar, 20-50 wt% of quartz, 5-20 wt% of star kaolin, 10-25 wt% of calcite, 1-5 wt% of dolomite, 0-10 wt% of spodumene, 7-20 wt% of zirconium silicate and 0-10 wt% of zinc oxide; the top coating comprises 65-100 wt% of polystyrene slurry with the concentration of 0.02-0.2 mol/L and 0-35 wt% of a binder, wherein the binder is one or a combination of PVA, PVB, an aluminum phosphate binder and polymethylsiloxane.

2. The method for preparing the high-performance self-cleaning sanitary ceramic as claimed in claim 1, which is characterized by comprising the following steps:

(1) preparation of sanitary ceramic body

Uniformly mixing the raw materials of the ceramic body according to a ratio, performing ball milling, sieving, ageing, stirring, refining, grouting, drying and biscuit firing treatment, and cooling to obtain a sanitary ceramic body;

(2) preparation of base coat slurry

Uniformly mixing the raw materials of the substrate coating according to a ratio, and performing ball milling and sieving to obtain uniform substrate coating slurry;

(3) preparation of the base coating

Uniformly spraying the base coating slurry on a sanitary ceramic blank, drying to form a spraying layer, and sintering to obtain a ceramic blank coated with a base coating;

(4) preparation of polystyrene slurry

Mixing a styrene monomer and potassium hydroxide or sodium hydroxide with the concentration of 0.01-0.15 mol/L in a volume ratio of 1: 1, performing ultrasonic dispersion and standing treatment, taking upper-layer styrene, and adding a potassium persulfate solution with the concentration of 0.005-0.01 mol/L and a sodium dodecyl sulfate or cetyl trimethyl ammonium bromide solution with the concentration of 0.001-0.005 mol/L to form a mixed solution; wherein, the volume ratio of the styrene monomer to the potassium persulfate solution to the sodium dodecyl sulfate or cetyl trimethyl ammonium bromide solution is 1: 0.1-6; placing the mixed solution in a water bath at the temperature of 60-90 ℃, heating and stirring for 10-30 h, centrifugally cleaning for 5-15 times, and adding water to prepare polystyrene slurry with the concentration of 0.02-0.2 mol/L;

(5) preparation of topcoat slurry

Uniformly mixing the polystyrene slurry and the binder according to the proportion to obtain a surface coating slurry;

(6) preparation of the topcoat

And uniformly spraying the surface coating slurry on the ceramic blank coated with the substrate coating by adopting a spraying method, and drying to obtain the super-hydrophobic self-cleaning sanitary ceramic.

3. The method for preparing the high-performance self-cleaning sanitary ceramic as claimed in claim 2, wherein: the bisque firing temperature in the step (1) is 850-950 ℃.

4. The method for preparing the high-performance self-cleaning sanitary ceramic as claimed in claim 2, wherein: the thickness of the spraying layer in the step (3) is 0.3-1.2 mm, and the sintering temperature is 1150-1250 ℃.

5. The method for preparing the high-performance self-cleaning sanitary ceramic as claimed in claim 2, wherein: the spraying method in the step (6) is as follows: the air pressure of spraying is 0.2-2 MPa, the diameter of a nozzle is 1-3 mm, and the distance between the nozzle and a base coating is 6-15 cm.

6. The method for preparing the high-performance self-cleaning sanitary ceramic as claimed in claim 2, wherein: and (3) drying at 100-200 ℃ for 5-10 min in the step (6).

Technical Field

The invention relates to the technical field of building ceramic materials, in particular to super-hydrophobic self-cleaning sanitary ceramic and a preparation method thereof.

Background

With the continuous progress and development of society, the supply of fresh water is always in a continuously high demand no matter daily household or industrial activity, however, the shortage of water resources has become one of the problems to be solved urgently in the world increasingly. Today, approximately 40 hundred million people face severe water shortage conditions. To solve the problem of water shortage, there are two methods, one is to add fresh water, such as can be obtained by sea water desalination, treatment and from the air; the other is water saving. It is statistical that toilet flushing accounts for 20% of the total domestic water in a domestic life, and approximately 1400 billion liters of fresh water are used to flush toilets worldwide. And about 26 million people in 70 million worldwide cannot obtain basic public health services because of water shortage. Therefore, there has been an increasing interest in reducing the amount of water used to flush toilets. In the daily use of sanitary ware, residues, scales, urine scale and the like are easily accumulated on the wall of the sanitary ware, so that a large amount of water resources are mainly used for flushing the sanitary ware. If a low viscosity, low surface energy superhydrophobic, self-cleaning sanitary fixture could be prepared, the residue accumulated on the walls would be well rinsed clean. Self-cleaning means that pollutants, water drops and dust can automatically fall off or be degraded under the action of external force such as gravity, rainwater, wind power and the like, and the key of self-cleaning is to realize the super-hydrophobicity of the material.

At present, although many reports are made on super-hydrophobic materials, no report on high-performance super-hydrophobic self-cleaning sanitary ceramics based on polystyrene is found.

Disclosure of Invention

The invention aims to overcome the defects of the prior art and provide the super-hydrophobic self-cleaning sanitary ceramic, and the super-hydrophobic self-cleaning performance of the sanitary ceramic is realized through formula design and use of a composite coating. The invention also aims to provide a preparation method of the sanitary ceramic with the super-hydrophobic self-cleaning property.

The purpose of the invention is realized by the following technical scheme:

the invention provides a high-performance self-cleaning sanitary ceramic which is composed of a ceramic body, a substrate coating coated on the surface of the ceramic body and a surface coating on the surface of the substrate coating; the ceramic blank comprises the following raw materials of 25-70 wt% of kaolin, 20-40 wt% of feldspar, 0-35 wt% of quartz and 0-3 wt% of electrolyte; the base coating comprises the following raw materials of 10-30 wt% of potash feldspar, 20-50 wt% of quartz, 5-20 wt% of star kaolin, 10-25 wt% of calcite, 1-5 wt% of dolomite, 0-10 wt% of spodumene, 7-20 wt% of zirconium silicate and 0-10 wt% of zinc oxide; the top coating comprises 65-100 wt% of polystyrene slurry with the concentration of 0.02-0.2 mol/L and 0-35 wt% of a binder, wherein the binder is one or a combination of PVA, PVB, an aluminum phosphate binder and polymethylsiloxane.

The other purpose of the invention is realized by the following technical scheme:

the preparation method of the high-performance self-cleaning sanitary ceramic provided by the invention is characterized by comprising the following steps of:

(1) preparation of sanitary ceramic body

Uniformly mixing the raw materials of the ceramic body according to a ratio, performing ball milling, sieving, ageing, stirring, refining, grouting, drying and biscuit firing treatment, and cooling to obtain a sanitary ceramic body;

(2) preparation of base coat slurry

Uniformly mixing the raw materials of the substrate coating according to a ratio, and performing ball milling and sieving to obtain uniform substrate coating slurry;

(3) preparation of the base coating

Uniformly spraying the base coating slurry on a sanitary ceramic blank, drying to form a spraying layer, and sintering to obtain a ceramic blank coated with a base coating;

(4) preparation of polystyrene slurry

Mixing a styrene monomer and potassium hydroxide or sodium hydroxide with the concentration of 0.01-0.15 mol/L in a volume ratio of 1: 1, performing ultrasonic dispersion and standing treatment, taking upper-layer styrene, and adding a potassium persulfate solution with the concentration of 0.005-0.01 mol/L and a sodium dodecyl sulfate or cetyl trimethyl ammonium bromide solution with the concentration of 0.001-0.005 mol/L to form a mixed solution; wherein, the volume ratio of the styrene monomer to the potassium persulfate solution to the sodium dodecyl sulfate or cetyl trimethyl ammonium bromide solution is 1: 0.1-6; placing the mixed solution in a water bath at the temperature of 60-90 ℃, heating and stirring for 10-30 h, centrifugally cleaning for 5-15 times, and adding water to prepare polystyrene slurry with the concentration of 0.02-0.2 mol/L;

(5) preparation of topcoat slurry

Uniformly mixing the polystyrene slurry and the binder according to the proportion to obtain a surface coating slurry;

(6) preparation of the topcoat

And uniformly spraying the surface coating slurry on the ceramic blank coated with the substrate coating by adopting a spraying method, and drying to obtain the super-hydrophobic self-cleaning sanitary ceramic.

Further, the bisque firing temperature in the step (1) of the preparation method is 850-950 ℃. The thickness of the spraying layer in the step (3) is 0.3-1.2 mm, and the sintering temperature is 1150-1250 ℃. The spraying method in the step (6) is as follows: the pressure intensity of sprayed air is 0.2-2 MPa, the diameter of a nozzle is 1-3 mm, and the distance between the nozzle and a base coating is 6-15 cm; the drying temperature is 100-200 ℃, and the drying time is 5-10 min.

The invention has the following beneficial effects:

(1) the invention uses polystyrene slurry and adhesive to form a surface coating, and prepares a composite coating with super-hydrophobic self-cleaning with a substrate coating, and the building sanitary ceramic with super-high hydrophobicity, self-cleaning and good mechanical property is formed by coating the surface of the building sanitary ceramic body, thereby providing a feasible method for preparing the high-performance super-hydrophobic self-cleaning material.

(2) The invention adopts the emulsion-in-water method to prepare the polystyrene slurry for the first time, and the method is simple and easy to realize. The super-hydrophobic self-cleaning building sanitary ceramic prepared by the invention has a contact angle of more than 155 degrees, and the highest tolerance temperature is more than 245 ℃; compared with other methods adopted at present, the method has the advantages of cheap raw materials, environmental protection, simple preparation, popularization and large-scale use, and has great value in industry.

The present invention will be described in further detail with reference to examples.

Detailed Description

The embodiment of the invention provides high-performance self-cleaning sanitary ceramic which is composed of a ceramic body, a substrate coating coated on the surface of the ceramic body and a surface coating on the surface of the substrate coating.

The ceramic blank comprises 25-70 wt% of kaolin, 20-40 wt% of feldspar, 0-35 wt% of quartz and 0-3 wt% of electrolyte; the base coating comprises the following raw materials of 10-30 wt% of potash feldspar, 20-50 wt% of quartz, 5-20 wt% of star kaolin, 10-25 wt% of calcite, 1-5 wt% of dolomite, 0-10 wt% of spodumene, 7-20 wt% of zirconium silicate and 0-10 wt% of zinc oxide; the top coating comprises 65-100 wt% of polystyrene slurry with the concentration of 0.02-0.2 mol/L and 0-35 wt% of a binder, wherein the binder is one or a combination of PVA, PVB, an aluminum phosphate binder and polymethylsiloxane.

TABLE 1 raw Material composition of ceramic body/base coat, topcoat in the examples of the invention

The preparation method of the high-performance self-cleaning sanitary ceramic comprises the following steps:

(1) preparation of sanitary ceramic body

Uniformly mixing the raw materials of the ceramic body according to the proportion shown in the table 1, carrying out ball milling, sieving, ageing, stirring, refining, grouting and drying treatment, carrying out biscuit firing at the temperature of 850-950 ℃, and cooling to obtain a sanitary ceramic body;

(2) preparation of base coat slurry

Uniformly mixing the raw materials of the base coating according to the proportion shown in the table 1, and performing ball milling and sieving to obtain uniform base coating slurry;

(3) preparation of the base coating

Uniformly spraying the base coating slurry on a sanitary ceramic blank, drying to form a spraying layer with the thickness of 0.3-1.2 mm, sintering at the temperature of 1150-1250 ℃, and preserving heat for 2 hours at the highest temperature to obtain a ceramic blank coated with the base coating;

(4) preparation of polystyrene slurry

Mixing 100ml of styrene monomer and 100ml of potassium hydroxide or sodium hydroxide with the concentration of 0.01-0.15 mol/L, carrying out ultrasonic treatment for 5min, standing for 10min, taking upper-layer styrene, and adding 600ml of potassium persulfate solution with the concentration of 0.005-0.01 mol/L and 600ml of sodium dodecyl sulfate or hexadecyl trimethyl ammonium bromide solution with the concentration of 0.001-0.005 mol/L to form a mixed solution; placing the mixed solution in a water bath at the temperature of 60-90 ℃, heating and stirring for 10-30 h, centrifugally cleaning for 5-15 times, and adding water to prepare polystyrene slurry with the concentration of 0.02-0.2 mol/L;

(5) preparation of topcoat slurry

Uniformly mixing the polystyrene slurry and the binder according to the proportion shown in Table 1 to obtain a surface coating slurry;

(6) preparation of the topcoat

Uniformly spraying the surface coating slurry on a ceramic blank coated with a substrate coating by adopting a spraying method, wherein the spraying air pressure is 0.2-2 MPa, the diameter of a nozzle is 1-3 mm, and the distance between the nozzle and the substrate coating is 6-15 cm; and then, drying the ceramic at the temperature of 100-200 ℃ for 5-10 min to obtain the super-hydrophobic self-cleaning sanitary ceramic.

TABLE 2 Process parameters of the preparation method of the high performance self-cleaning sanitary ceramic of the embodiment of the present invention

The performance indexes of the self-cleaning sanitary ceramic prepared by the embodiment of the invention are shown in Table 3.

TABLE 3 Performance index of the self-cleaning sanitary ceramic prepared by the embodiment of the present invention