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CN106747307B - Heat-insulating ceramic decorative composite board and preparation method thereof - Google Patents

Heat-insulating ceramic decorative composite board and preparation method thereof Download PDF

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Publication number
CN106747307B
CN106747307B CN201611147693.2A CN201611147693A CN106747307B CN 106747307 B CN106747307 B CN 106747307B CN 201611147693 A CN201611147693 A CN 201611147693A CN 106747307 B CN106747307 B CN 106747307B
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ceramic
heat
composite board
blank
decorative composite
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CN106747307A (en
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韩复兴
陈延东
高加林
陈延新
吴长泉
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XINYANG KEMEI NEW MATERIALS CO Ltd
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XINYANG KEMEI NEW MATERIALS CO Ltd
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    • C04B33/00—Clay-wares
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    • C04B33/13—Compounding ingredients
    • C04B33/132—Waste materials; Refuse; Residues
    • C04B33/1321—Waste slurries, e.g. harbour sludge, industrial muds
    • C04B33/1322—Red mud
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B18/00—Layered products essentially comprising ceramics, e.g. refractory products
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Abstract

The invention provides a heat-insulating ceramic decorative composite board, which comprises a foamed ceramic bottom layer and a toughened ceramic surface layer; the foamed ceramic raw material comprises the following components in percentage by mass: 30-60% of yellow river silt, 5-30% of Bayer process red mud, 1-55% of perlite micropowder, 5-10% of alkali gangue, 1-15% of bentonite and 0.2-2.0% of fluorite; 0.1 to 1 percent of green silicon carbide dust collecting powder and 0.1 to 0.5 percent of potassium tripolyphosphate; the heat-insulation ceramic decorative composite board has the advantages of light weight, heat insulation, fire resistance and good mechanical strength, and the heat-insulation ceramic decorative composite board provided by the invention is simple in preparation method and has a good application prospect.

Description

Heat-insulating ceramic decorative composite board and preparation method thereof
Technical Field
The invention relates to the field of building materials, in particular to a heat-insulating ceramic decorative composite board and a preparation method thereof.
Background
Red mud, also known as red mud, is an industrial solid waste discharged after alumina is extracted from bauxite, has a high content of iron oxide, and has an appearance similar to that of red mud, so that the red mud is famous. Generally, 1 ton of alumina is produced on average, and 1.0-2.5 tons of red mud are produced, in recent years, the global annual aluminum yield exceeds 4000 million tons, about 9000 million tons of red mud is discharged behind the yield, and the terrible number is only the red mud discharge amount of one year. If the accumulation of the red mud is calculated over the years, the total amount of the generated red mud is frightening. Only the accumulated red mud in China reaches 3.5 hundred million tons. This means that a large amount of valuable land has to be used to store the waste. Once the red mud is stored in the land, the land is difficult to be reused as cultivated land or construction land. Moreover, red mud contains a large amount of highly corrosive sodium hydroxide, and some of the red mud also contains toxic heavy metals or even radioactive elements, and once the harmful substances permeate into soil or rivers, the red mud causes serious pollution. If the places where the red mud is piled up are leaked due to natural or artificial reasons, the damage caused by the leakage is more serious. In 10.4.2010, in an aluminum plant in Olympic Games (Ajka) in the west city of Hungary, a dam break accident suddenly occurs in an artificial lake storing red mud, and up to 100 million cubic meters of red mud leaks out to affect a plurality of surrounding villages and finally flows into a Danube river. This accident resulted in 10 deaths, 100 injuries and a serious environmental disaster in which 40 square kilometers of land was affected.
Yellow river silt (yellow river silt) is a natural waste, belongs to silicate mineral raw materials, and is an available precious resource. The statistical data show that: the average sand conveying amount of the yellow river in the year is up to 16 hundred million tons, and most of (13 hundred million tons) of the sand conveying amount are accumulated year by year except that a small amount of the sand conveying amount is about 3 hundred million tons of the sand conveying amount enters a river channel or a field, so that the harm is brought to the safety work of the channel and the river channel, the sand of the yellow river is gradually deposited, and the river bed is gradually lifted, and the main reason of causing the disaster of the yellow river is.
Chinese patent CN102603356A discloses a heat-insulating decorative ceramic plate and a production method thereof, which is made of zeolite, perlite micropowder, tuff, inferior clay, inferior kaolin, calcium carbonate, talc, fluorite, black silicon carbide, bentonite, anhydrous sodium metasilicate, sodium humate, sodium tripolyphosphate and sodium methyl cellulose, and the invention utilizes solid wastes generated in the processes of mining and deep processing of expanded perlite: zeolite, bentonite, tuff, perlite micropowder and the like, under the conditions of 1205-1280 ℃ and the production condition of bare bricks of a ceramic roller kiln, the produced ceramic product has the heat conductivity coefficient of less than 0.1W/(m.k), the water absorption of less than 0.5%, the breaking strength of more than 3.5 MPa, the internal irradiation index of less than 0.3, the external irradiation index of less than 0.6, the fire resistance level of A1 level, the thickness of 30-60 mm and the heat preservation and decoration, and can be widely applied to the heat preservation and decoration of indoor and outdoor places, public places or household rooms.
Chinese patent CN105669173A discloses a heat-insulating decorative ceramic plate produced by comprehensively utilizing perlite wastes and a production method thereof, and the formula of a matrix comprises the following components: 25 to 100 percent of perlite micropowder, 20 to 80 percent of expanded perlite micropowder, 2 to 25 percent of Guangdong black mud, 0 to 10 percent of limestone, 0.1 to 5 percent of fluorite, 0.1 to 2 percent of black silicon carbide, 0.5 to 15 percent of bentonite, 0.1 to 5 percent of sodium metasilicate nonahydrate, 0.1 to 0.5 percent of sodium humate and 0.1 to 1.0 percent of sodium tripolyphosphate. The formula of the glaze material comprises: 50-90% of expanded perlite micropowder, 50-90% of low-temperature frit, 0.1-5% of zinc oxide, 0.1-5% of fluorite, 0-5% of apatite, 0.1-2.0% of sodium tripolyphosphate, 0.5-5% of kaolin and 0.1-0.5% of sodium methyl cellulose. The production method is characterized in that: and (3) firing the blank by a roller kiln at the low temperature of 900-1050 ℃. The water absorption rate is within 0.5 percent and the volume density is less than 500kg/m after the sintering3、The modulus of rupture is more than 3.5 MPa, the thermal conductivity is less than 0.08W/(m.k), and the combustion grade is A-grade heat-insulating decorative ceramic plate.
The existing foamed ceramic composite board mainly takes perlite as a raw material, the perlite serving as a scarce functional mineral material is expensive and scarce in resources, and on the other hand, a large amount of solid wastes such as yellow river silt, red mud and the like cannot be recycled, so that the application and development of the foamed ceramic composite board and the heat-insulating decorative material are restricted.
Disclosure of Invention
In view of the above, the present invention provides a thermal insulation ceramic decorative composite board and a method for manufacturing the same, so as to solve the above problems.
Specifically, the invention adopts the following technical scheme:
the heat-insulating ceramic decorative composite board comprises a foamed ceramic bottom layer and a toughened ceramic surface layer, wherein the foamed ceramic bottom layer comprises the following components in percentage by mass: 30-60% of yellow river sewage silt, 5-30% of Bayer process red mud, 1-55% of perlite micropowder, 5-10% of alkali gangue, 1-15% of bentonite, 0.2-2.0% of fluorite, 0.1-1% of green silicon carbide dust collection powder and 0.1-0.5% of potassium tripolyphosphate.
Based on the above, the green silicon carbide dust collecting powder is powder in a dust collector during silicon carbide grinding material processing, the green silicon carbide content is more than 92%, and the 8000-mesh residual is less than 0.3%.
Based on the above, the raw materials of the toughened ceramic surface layer comprise the following components in percentage by mass: 80-95% of perlite micro powder, 1-10% of wollastonite, 1-10% of bentonite, 1-2% of fluorite, 0.1-0.5% of potassium tripolyphosphate, 0.5-5% of nano zirconium silicate and 0-10% of pigment.
Based on the above, the width of the glass is 300-1200 mm, the length is 300-2400 mm, and the thickness is 16-120 mm.
Based on the above, the thickness of toughening ceramic surface layer is 3-7 mm.
The preparation method of the heat-insulation ceramic decorative composite board comprises the following steps:
ball milling is carried out to mix the raw material of the foamed ceramic bottom layer and the raw material of the toughened ceramic surface layer with water respectively to obtain foamed ceramic slurry and toughened ceramic slurry; respectively sieving and aging the foamed ceramic slurry and the toughened ceramic slurry to prepare foamed ceramic slurry and toughened ceramic slurry;
spray drying and ageing the foamed ceramic slurry and the toughened ceramic slurry respectively to prepare foamed ceramic powder and toughened ceramic powder with the water contents of 9 +/-0.5 percent;
dry pressing to form, namely distributing the toughening ceramic powder, backfilling the foaming ceramic powder to obtain a pre-blank body, and then dry pressing the pre-blank body to obtain a blank body;
and (3) drying, decorating and firing the blank to obtain the heat-insulating ceramic decorative composite board.
Based on the above, the ball milling step comprises: mixing the raw materials of the foamed ceramic bottom layer with water, and performing ball milling processing to prepare foamed ceramic slurry with the fineness of 2.0 +/-0.2% (dry ratio after screening), the flow rate of 40 +/-15 s based on four cups, the specific gravity of 1.50 +/-0.05 and the water content of 46 +/-2%; mixing the raw materials of the toughened ceramic surface layer with water, and carrying out ball milling processing to prepare toughened ceramic slurry with the fineness of 0.5 +/-0.2% (dry ratio after screening), the flow rate of 40 +/-15 s based on four cups, the specific gravity of 1.60 +/-0.05 and the water content of 36 +/-2%; and respectively sieving the foamed ceramic slurry and the toughened ceramic slurry by a sieve of 20-60 meshes, and ageing for more than or equal to 48 hours to prepare the foamed ceramic slurry and the toughened ceramic slurry.
Based on the above, in the dry pressing process, the pre-blank is pressed into the blank with the thickness of 10-60 mm under the pressure of 25-50 MPa, and the filling thickness of the foamed ceramic powder in the blank is 5-10 mm.
Based on the above, in the process of preparing the finished product, the blank body is dried for 80-240 min at 25-220 ℃ so that the moisture content of the blank body is less than 0.5%.
Based on the above, in the process of preparing the finished product, the blank is decorated and then subjected to a firing treatment, and the firing treatment comprises the following steps: dehumidifying and dehumidifying the decorated blank at 180-220 ℃ for 10-15 min; then preheating and drying for 15-20 min at 250-650 ℃; baking and drying the preheated and dried blank at 650-950 ℃ for 20-25 min; carrying out oxidative decomposition on the baked and dried blank at 950-1050 ℃ for 25-30 min; vitrifying and melting the oxidized and decomposed blank at 1050-1120 ℃ for 25-30 min; expanding and foaming the melted blank at 1120-1150 ℃ for 25-30 min; rapidly cooling the foamed blank at 1150-650 ℃ for 5-10 min; and then slowly annealing at 650-250 ℃ for 60-90 min, and finally cooling at 250-50 ℃ for 15-20 min to complete foaming and firing of the bare body without the backing plate, so as to prepare the heat-insulating ceramic decorative composite board.
Through detection, the thermal conductivity coefficient of the heat-insulation ceramic decorative composite board provided by the invention is 0.05-0.1W/(m.k), and the volume density is 200-500 g/cm3The flexural strength is more than 3.0 MPa, the tensile strength perpendicular to the board surface is more than 0.50 MPa, the volume water absorption is less than 0.5%, the combustion grade is A grade, the impact strength of the surface layer is more than 3J, and the Mohs hardness of the surface layer is more than 6.
Compared with the prior art, the heat-insulating ceramic decorative composite board provided by the invention comprises the foamed ceramic bottom layer and the toughened ceramic surface layer, has the double advantages of foamed ceramic and toughened ceramic, is light and heat-insulating, and has higher mechanical strength; meanwhile, the yellow river silt and the Bayer process red mud are used as main materials, and the green silicon carbide dust collecting powder is used as a pore-forming agent, so that the cost is low, and the environment is protected; the fluorite is used as a fluxing agent, has a melting assisting effect at 1050-1120 ℃, is rich in calcium fluoride, has low vitrification liquid phase viscosity, forms a glass closed shell on the outer surface of the ceramic, and reacts with water in the dry alkali at 1120-1180 ℃ to form a refractory oxide ceramic shell, so that the foamed ceramic is protected, and the mechanical strength of the foamed ceramic can also be enhanced; meanwhile, the potassium tripolyphosphate has excellent effects of degumming and water reduction on the dry alkali, the bentonite, the perlite micropowder and the Bayer process red mud, and also has grinding aid and dispersion effects, so that the ball milling efficiency can be greatly improved, and the energy can be saved; in addition, the preparation method of the heat-insulating ceramic decorative composite board provided by the invention is simple and is convenient for industrial application.
Detailed Description
The technical solution of the present invention is further described in detail by the following embodiments.
The following examples were prepared using yellow river silt, bayer process red mud, perlite fines, bentonite and wollastonite as follows:
the fineness of the yellow river sludge sand is more than or equal to 100 meshes, and the yellow river sludge sand comprises the following components in percentage by mass: SiO 2260%～62%，Al2O312%～14%，Fe2O34%～6%，CaO 6%～8%，MgO 1.5%～2.5%，Na2O 1.5%～2.5%，K2O2.0-3.0%, ignition loss 8-9%, and water content less than 5%;
the Bayer process red mud comprises the following components in percentage by mass: SiO 2268%～70%，Al2O312%～14%，Fe2O3＜0.5%，Na2O 0.5%～1.0%，K2O 1.0%～2.0%，Li2O is more than 1.5 percent, CaO is less than 1.5 percent, MgO is less than 2.5 percent, the ignition loss is less than 13 percent, and the whiteness is more than 80 degrees;
the perlite micro powder comprises the following components in percentage by mass: SiO 2272%～74%，Al2O312%～14%，Fe2O3＜0.8%，Na2O 2.0%～3.0%，K2O 2.0%～3.0%，Li2O is more than 1.5 percent, CaO is less than 0.8 percent, MgO is less than 0.2 percent, and the loss on ignition is 5 to 7 percent;
the bentonite comprises the following components in percentage by mass: SiO 2268%～70%，Al2O312%～14%，Fe2O3＜0.5%，Na2O 0.5%～1.0%，K2O1.0%～2.0%，Li2O is more than 1.5 percent, CaO is less than 1.5 percent, MgO is less than 2.5 percent, the ignition loss is less than 13 percent, and the whiteness is more than 80 degrees;
the purity of the wollastonite is more than 92 percent, the whiteness is more than 85 degrees, and the wollastonite is Fe2O3Less than 0.2 percent, less than 0.2 percent of water, less than 0.5 percent of ignition loss and more than or equal to 200 meshes of fineness; k in the potassium tripolyphosphate5P3O10More than or equal to 90 percent; CaF in fluorite2≥65%。
Example 1
The heat-insulating ceramic decorative composite board provided by the embodiment comprises a foamed ceramic bottom layer and a toughened ceramic surface layer;
the raw materials of the foamed ceramic bottom layer comprise the following components in percentage by mass: 58% of yellow river sewage silt, 30% of Bayer process red mud, 4% of alkali waste rock, 1% of perlite micropowder, 6% of Xinyang bentonite, 0.3% of fluorite, 0.5% of green silicon carbide dust collection micropowder and 0.2% of potassium tripolyphosphate.
The toughened ceramic surface layer comprises the following raw materials in percentage by mass: 92% of perlite micro powder, 2% of wollastonite, 3% of bentonite, 1% of fluorite, 0.2% of potassium tripolyphosphate and 1.8% of zirconium silicate.
The method comprises the following specific steps:
ball milling is carried out, wherein raw material water of the foamed ceramic bottom layer is mixed according to the mass ratio of 1: 0.75, mixing, performing ball milling processing to prepare foamed ceramic slurry with the fineness of 2.0 +/-0.2 percent (dry ratio after screening), the flow rate of 40 +/-15 seconds based on four cups, the specific gravity of 1.50 +/-0.05 and the water content of 46 +/-2 percent, and passing the foamed ceramic slurry through three screens of 20 meshes, 40 meshes and 60 meshes for ageing for 48 hours to prepare foamed ceramic slurry; the raw materials of the toughening ceramic surface layer and water are respectively mixed according to the mass ratio of 1: 0.75 percent of the mixture is mixed and ball-milled to prepare toughened ceramic slurry with the fineness of 0.5 plus or minus 0.2 percent (the dry ratio of the rest of the sieve), the flow rate of 40 plus or minus 15 seconds based on four cups, the specific gravity of 1.60 plus or minus 0.05 and the water content of 36 plus or minus 2 percent; sieving the toughened ceramic slurry by using three sieves of 20 meshes, 40 meshes and 60 meshes, and ageing for 48 hours to prepare toughened ceramic slurry;
spray drying is respectively carried out on the foamed ceramic slurry and the toughened ceramic slurry to prepare foamed ceramic powder and toughened ceramic powder with the water contents of 9 +/-0.5%, and the foamed ceramic powder and the toughened ceramic powder are aged for 48 hours;
dry pressing and molding, namely distributing the foamed ceramic powder, backfilling the toughened ceramic powder to obtain a pre-blank body, and dry pressing the pre-blank body into a blank body under the molding pressure of 35 MPa, wherein the thickness of the blank body is 17 mm, the width of the blank body is 400mm, the length of the blank body is 650mm, and the thickness of a filler of the toughened ceramic powder in the blank body is 6.5 mm;
the blank prepared by the finished product is dried for 120 min at the temperature of less than or equal to 220 ℃, and the moisture content of the dried blank is less than or equal to 0.5%; printing the dried green body into an Italian wood grain stone effect by a four-color roller, distributing dry particle fritted glaze by a dry particle machine, spraying a fixing agent, and decorating; and carrying out firing treatment on the decorated blank, wherein the firing treatment comprises the following steps: dehumidifying and dehumidifying the decorated blank at the temperature of 180-220 ℃ for 10 min; then preheating and drying for 15min at the temperature of 250-650 ℃; then baking and drying for 20min at the temperature of 650-950 ℃; carrying out oxidative decomposition on the baked and dried blank at 950-1050 ℃ for 25 min; then carrying out vitrification melting for 25 min at 1050-1120 ℃; expanding and foaming the melted blank at 1120-1150 ℃ for 25 min; rapidly cooling the foamed blank at 1150-650 ℃ for 5 min; then slowly annealing for 60 min at 650-250 ℃; and finally cooling at 250-50 ℃ for 15min to finish foaming and firing of the bare body without the backing plate to obtain the heat-insulating ceramic decorative composite board.
Through detection, the heat-insulating ceramic decorative composite board provided by the embodiment has the thickness of 35 mm, the width of 650mm, the length of 1150 mm and the volume density of 180kg/m3The thermal conductivity coefficient is 0.058W/(m.k), the flexural strength is 5.8 MPa, the tensile strength perpendicular to the plate surface is 2.50 MPa, the volume water absorption is 0.47 percent, and the combustion grade is AAnd the impact strength of the surface layer is 3J, and the Mohs hardness of the surface layer is 6. Therefore, the heat-insulating ceramic decorative composite board has the advantages of light weight, heat insulation, fire resistance and good mechanical strength, and has a wide application prospect.
Example 2
The difference between the heat-insulating ceramic decorative composite board provided by the embodiment and the embodiment 1 is that:
the foamed ceramic raw material comprises the following components in percentage by mass: 40% of yellow river sewage silt, 25% of red mud, 5% of alkali waste rock, 20% of perlite micro powder, 9% of Xinyang bentonite, 0.3% of fluorite, 0.5% of green silicon carbide dust collection micro powder and 0.2% of potassium tripolyphosphate;
the toughening ceramic raw material comprises the following components in percentage by mass: 85% of perlite micro powder, 6% of wollastonite, 3% of bentonite, 0.8% of fluorite, 0.2% of potassium tripolyphosphate and 5% of zirconium silicate;
the dry pressing step comprises: distributing the foamed ceramic powder, backfilling the toughened ceramic powder to obtain a pre-blank body, and dry-pressing the pre-blank body into a blank body, wherein the forming pressure is 45 MPa, the thickness of the blank body is 25 mm, the width is 400mm, the length is 650mm, and the filler thickness of the toughened ceramic powder in the blank body is 6.5 mm;
in the step of preparing the finished product, the decorated blank is subjected to firing treatment, and the firing treatment comprises the following steps: dehumidifying and dehumidifying the decorated blank at the temperature of 180-220 ℃ for 15 min; then preheating and drying for 20min at the temperature of 250-650 ℃; then baking and drying for 25 min at the temperature of 650-950 ℃; oxidizing and decomposing the baked and dried blank at 950-1050 ℃ for 30 min; then carrying out vitrification melting for 30 min at 1050-1120 ℃; expanding and foaming the melted blank at 1120-1150 ℃ for 30 min; rapidly cooling the foamed blank at 1150-650 ℃ for 10 min; then slowly annealing for 90min at 650-250 ℃; and finally cooling at 250-50 ℃ for 20min to finish foaming and firing of the bare body without the backing plate to obtain the heat-insulating ceramic decorative composite board.
Through detection, the heat-insulating ceramic decorative composite board has the thickness of 51 mm, the width of 800 mm, the length of 1300mm and the volume density of 247 kg/m3Coefficient of thermal conductivity0.057W/(m.k), the flexural strength is 4.65 MPa, the tensile strength perpendicular to the board surface is 2.50 MPa, the volume water absorption is 0.43 percent, the combustion grade is A grade, the impact strength of the surface layer is 10J, and the Mohs hardness of the surface layer is 6. Therefore, the heat-insulating ceramic decorative composite board has the advantages of light weight, heat insulation, fire resistance and good mechanical strength, and has wide application prospect.
Example 3
The difference between the heat-insulating ceramic decorative composite board provided by the embodiment and the embodiment 1 is that:
the foamed ceramic raw material comprises the following components in percentage by mass: 35% of yellow river sewage silt, 15% of red mud, 5% of alkali waste rock, 30% of perlite micro powder, 4% of Xinyang bentonite, 0.3% of fluorite, 0.5% of green silicon carbide dust collection micro powder and 0.2% of potassium tripolyphosphate;
the toughening ceramic raw material comprises the following components in percentage by mass: 95% of perlite micro powder, 1% of wollastonite, 2% of bentonite, 0.8% of fluorite, 0.2% of potassium tripolyphosphate and 1% of zirconium silicate;
through detection, the thickness of the heat-insulating ceramic decorative composite board is 45 mm, the width is 720 mm, the length is 1170mm, and the volume density is 280 kg/m3The thermal conductivity coefficient is 0.081W/(m.k), the flexural strength is 8.87 MPa, the tensile strength perpendicular to the plate surface is 3.74 MPa, the volume water absorption is 0.46%, the combustion grade is A grade, the impact strength of the surface layer is 10J, and the Mohs hardness of the surface layer is 6. Therefore, the heat-insulating ceramic decorative composite board has the advantages of light weight, heat insulation, fire resistance and good mechanical strength, and has wide application prospect.
Example 4
The difference between the heat-insulating ceramic decorative composite board provided by the embodiment and the embodiment 1 is that:
the foamed ceramic raw material comprises the following components in percentage by mass: 30% of yellow river sewage silt, 10% of red mud, 5% of alkali waste rock, 52% of perlite micro powder, 7% of Xinyang bentonite, 0.3% of fluorite, 0.5% of green silicon carbide dust collection micro powder and 0.2% of potassium tripolyphosphate;
in the step of preparing the finished product, the decorated blank is subjected to firing treatment, and the firing treatment comprises the following steps: dehumidifying and dehumidifying the decorated blank at the temperature of 180-220 ℃ for 15 min; then preheating and drying for 20min at the temperature of 250-650 ℃; then baking and drying for 25 min at the temperature of 650-950 ℃; oxidizing and decomposing the baked and dried blank at 950-1050 ℃ for 30 min; then carrying out vitrification melting for 25 min at 1050-1120 ℃; expanding and foaming the melted blank at 1120-1150 ℃ for 25 min; rapidly cooling the foamed blank at 1150-650 ℃ for 5 min; then slowly annealing for 80 min at 650-250 ℃; and finally cooling at 250-50 ℃ for 20min to finish foaming and firing of the bare body without the backing plate to obtain the heat-insulating ceramic decorative composite board.
Through detection, the thickness of the heat-insulating ceramic decorative composite board is 41 mm, the width is 660 mm, the length is 1070mm, and the volume density is 310kg/m3The thermal conductivity coefficient is 0.085W/(m.k), the flexural strength is 12.34 MPa, the tensile strength perpendicular to the plate surface is 5.74 MPa, the volume water absorption is 0.11%, the combustion grade is A grade, the impact strength of the surface layer is 10J, and the Mohs hardness of the surface layer is 6. Therefore, the heat-insulating ceramic decorative composite board has the advantages of light weight, heat insulation, fire resistance and good mechanical strength, and has wide application prospect.
Finally, it should be noted that: the above examples are only intended to illustrate the technical solution of the present invention and not to limit it; although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art will understand that: modifications to the specific embodiments of the invention or equivalent substitutions for parts of the technical features may be made; without departing from the spirit of the present invention, it is intended to cover all aspects of the invention as defined by the appended claims.

Claims (9)

1. The heat-insulation ceramic decorative composite board is characterized by comprising a foamed ceramic bottom layer and a toughened ceramic surface layer, wherein the foamed ceramic bottom layer comprises the following components in percentage by mass: 30-60% of yellow river sewage silt, 5-30% of Bayer process red mud, 1-55% of perlite micropowder, 5-10% of alkali gangue, 1-15% of bentonite, 0.2-2.0% of fluorite, 0.1-1% of green silicon carbide dust collection powder and 0.1-0.5% of potassium tripolyphosphate; the Bayer process red mud comprises the following components in percentage by mass: siO268%～70%，Al2O312%～14%，Fe2O3＜0.5%，Na2O 0.5%～1.0%，K2O 1.0%～2.0%，Li2O is more than 1.5 percent, CaO is less than 1.5 percent, and MgO is less than 2.5 percent; the toughened ceramic surface layer comprises the following raw materials in percentage by mass: 80-95% of perlite micro powder, 1-10% of wollastonite, 1-10% of bentonite, 1-2% of fluorite, 0.1-0.5% of potassium tripolyphosphate, 0.5-5% of nano zirconium silicate and 0-10% of pigment.
2. The heat-insulating ceramic decorative composite board according to claim 1, wherein the green silicon carbide dust collecting powder is powder in a dust collector during silicon carbide grinding material processing, the content of the green silicon carbide is more than 92%, and the residue of a 8000-mesh sieve is less than 0.3%.
3. The heat-insulating ceramic decorative composite board according to claim 1, wherein the width of the heat-insulating ceramic decorative composite board is 300-1200 mm, the length of the heat-insulating ceramic decorative composite board is 300-2400 mm, and the thickness of the heat-insulating ceramic decorative composite board is 16-120 mm.
4. The heat-insulating ceramic decorative composite board according to claim 1, wherein the thickness of the toughened ceramic surface layer is 3-7 mm.
5. The preparation method of the heat-insulating ceramic decorative composite board according to any one of claims 1 to 4, comprising the following steps:
ball milling is carried out to mix the raw material of the foamed ceramic bottom layer and the raw material of the toughened ceramic surface layer with water respectively to obtain foamed ceramic slurry and toughened ceramic slurry; respectively sieving and aging the foamed ceramic slurry and the toughened ceramic slurry to prepare foamed ceramic slurry and toughened ceramic slurry;
spray drying and ageing the foamed ceramic slurry and the toughened ceramic slurry respectively to prepare foamed ceramic powder and toughened ceramic powder with the water contents of 9 +/-0.5 percent;
dry pressing to form, namely distributing the toughening ceramic powder, backfilling the foaming ceramic powder to obtain a pre-blank body, and then dry pressing the pre-blank body to obtain a blank body;
and (3) drying, decorating and firing the blank to obtain the heat-insulating ceramic decorative composite board.
6. The method for preparing the heat-insulating ceramic decorative composite board according to claim 5, wherein the step of ball milling comprises the following steps: mixing the raw materials of the foamed ceramic bottom layer with water, and performing ball milling processing to prepare foamed ceramic slurry with the fineness of 2.0 +/-0.2%, the flow rate of 40 +/-15 s based on four cups, the specific gravity of 1.50 +/-0.05 and the water content of 46 +/-2%; mixing the raw materials of the toughened ceramic surface layer with water, and carrying out ball milling processing to prepare toughened ceramic slurry with the fineness of 0.5 +/-0.2%, the flow rate of 40 +/-15 s based on four cups, the specific gravity of 1.60 +/-0.05 and the water content of 36 +/-2%; and respectively sieving the foamed ceramic slurry and the toughened ceramic slurry by a sieve of 20-60 meshes, and ageing for more than or equal to 48 hours to prepare the foamed ceramic slurry and the toughened ceramic slurry.
7. The preparation method of the heat-preservation ceramic decorative composite board according to claim 6, wherein in the dry pressing process, the pre-blank is pressed into the blank with the thickness of 10-60 mm under the pressure of 25-50 MPa, and the filling thickness of the foamed ceramic powder in the blank is 5-10 mm.
8. The preparation method of the heat-preservation ceramic decorative composite board as claimed in claim 5, wherein in the preparation process of the finished product, the blank body is dried at 25-220 ℃ for 80-240 min, so that the moisture content of the blank body is less than 0.5%.
9. The method for preparing the heat-preservation ceramic decorative composite board as claimed in claim 5, wherein in the process of preparing the finished product, the blank is decorated and then subjected to a firing treatment, and the firing treatment comprises the following steps: dehumidifying and dehumidifying the decorated blank at 180-220 ℃ for 10-15 min; then preheating and drying for 15-20 min at 250-650 ℃; baking and drying the preheated and dried blank at 650-950 ℃ for 20-25 min; carrying out oxidative decomposition on the baked and dried blank at 950-1050 ℃ for 25-30 min; vitrifying and melting the oxidized and decomposed blank at 1050-1120 ℃ for 25-30 min; expanding and foaming the melted blank at 1120-1150 ℃ for 25-30 min; rapidly cooling the foamed blank at 1150-650 ℃ for 5-10 min; and then slowly annealing at 650-250 ℃ for 60-90 min, and finally cooling at 250-50 ℃ for 15-20 min to complete foaming and firing of the bare body without the backing plate, so as to prepare the heat-insulating ceramic decorative composite board.
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