Production process of high-quality patterned porcelain by using waste ceramic

Abstract

The application relates to the field of ceramics and a preparation process thereof, in particular to a production process for high-quality patterned glaze porcelain by using waste ceramics, wherein the glaze surface comprises, from bottom to top, a bottom glaze, an intermediate glaze and a surface glaze; the high-quality white porcelain particles are used as raw materials in the bottom glaze; due to the large particle size, compact texture and clinker of the white porcelain particles, the flowability difference between the white porcelain particles and other raw materials in the glaze is large, the flowability difference of the glaze occurs during the glazing process, the local flowability of the bottom glaze is insufficient, the flowability difference between the bottom glaze and the intermediate glaze also causes the glaze to crack, break, spread and rebuild during the flow process, and thus the texture with concave-convex texture of the glaze surface is constructed; the filaments in the intermediate glaze contain high molecular substances and zirconium solution; the high molecular substances are decomposed during the glazing process to cause the glaze surface to be concave, and the zirconium solution has large viscosity, thereby causing the strip-shaped concave lines of the glaze surface, and finally forming the glaze surface lines similar to plum blossom skin.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of ceramics and its preparation process, in particular to the production process of high-quality patterned porcelain using waste ceramics. BACKGROUND

[0002] Ceramics is a kind of material made of natural clay and various natural minerals as the main raw material through crushing, mixing, molding and calcining. People call the objects made of clay and fired in a special kiln high-temperature as ceramics. Ceramics is the general term of pottery and porcelain. Modern ceramic production adopts assembly line operation with large output. In the production process, a certain amount of waste ceramics will be produced due to the problem of yield. If the waste ceramics is directly treated as garbage, it will not only waste resources but also increase production cost. If the waste ceramics can be effectively used for new ceramic preparation, it will help to improve production efficiency. In addition, traditional crack glaze ceramics have many small cracks on the glaze surface, which are sparse or dense, thick or thin, long or short, curved or straight. However, the traditional crack glaze does not have a three-dimensional texture. Therefore, the present application is produced. SUMMARY

[0003] An object of the present application is to solve at least the above problems by using the production process of high-quality patterned porcelain using waste ceramics.

[0004] To solve the above technical problems, the technical scheme adopted by the present application is as follows: the production process of high-quality patterned porcelain using waste ceramics, including body and glaze, the glaze from bottom to top includes bottom glaze, intermediate glaze and surface glaze, the raw materials of the body include the following components by weight: 30-40 parts of waste ceramics, 30-40 parts of kaolin, 10-12 parts of feldspar and 4-5 parts of talc.

[0005] Preferably, the raw materials of the bottom glaze include the following components by weight: 10-12 parts of waste white porcelain particles, 20-30 parts of nepheline syenite, 12-15 parts of silicon dioxide, 6-8 parts of calcium carbonate and 2-3 parts of zinc oxide.

[0006] Preferably, the raw materials of the intermediate glaze include the following components by weight: 5-6 parts of long silk, 3-4 parts of CMC glue, 15-18 parts of quartz, 30-40 parts of feldspar and 3-5 parts of borax.

[0007] Preferably, the raw materials of the surface glaze include the following components by weight: 20-25 parts of porcelain clay, 20-25 parts of feldspar, 20-25 parts of quartz stone, 5-8 parts of borate and 12-15 parts of wollastonite.

[0008] According to the above production process of high-quality patterned porcelain using waste ceramics, the following steps are included:

[0009] Step a, forming the body, and baking the formed body;

[0010] Step b, applying a base glaze on the body;

[0011] Step c, applying an intermediate glaze on the base glaze;

[0012] Step d, applying a surface glaze on the intermediate glaze;

[0013] Step e, firing in a kiln.

[0014] Preferably, in the step b, the particle size of the waste white porcelain particles is 0.15-0.2mm.

[0015] Preferably, in the step c, the filaments, CMC glue, quartz, feldspar and borax are mixed and stirred uniformly to prepare the intermediate glaze, and the intermediate glaze is applied on the base glaze by glazing.

[0016] Preferably, in the step c, the length of the filaments is 1-2cm, and the diameter is 0.2-0.3mm, and the structure of the filaments is core-sheath structure, and the filaments include a core layer and a sheath layer covering the outside of the core layer.

[0017] Preferably, in the step c, the preparation process of the filaments is as follows: the polypropylene raw material is prepared into a hollow structure by an extrusion molding process, the filament is soaked in a zirconium solution, and is continuously stirred for 4-5 hours, and then is placed for 10-12 hours, in the process, the zirconium solution is infiltrated into the hollow structure of the filament, then the water content of the zirconium solution is reduced to 10-15% by drying, then the soaked filament is taken out, and is soaked in water-soluble glue for 10-20 minutes, and then is drained after taking out, and finally is dried to obtain the filaments.

[0018] Preferably, in the step c, the raw material of the zirconium solution includes the following components in terms of weight parts: sodium zirconate 10-12 parts, zirconium sulfate 10-12 parts, water 20-30 parts, and water-soluble glue 5-6 parts.

[0019] As can be seen from the above description, the manufacturing process for producing high-quality patterned glaze porcelain from waste ceramics has the following beneficial effects: the high-quality white porcelain particles are used as raw materials in the base glaze, and due to the large particle size, tight texture and clinker of the white porcelain particles, the difference in fluidity between the white porcelain particles and other raw materials in the glaze is large, which leads to a difference in fluidity of the glaze during firing, causing the local fluidity of the base glaze to be insufficient, and the difference in fluidity between the base glaze and the intermediate glaze also causes the glaze to crack, break, spread and rebuild during the flow process, forming local pit textures on the glaze surface, thereby helping to build textures with concave-convex texture on the glaze surface; the filaments in the intermediate glaze contain high molecular substances and zirconium solution, and the high molecular substances decompose during firing to cause the glaze surface to be concave, while the zirconium solution has high viscosity, thereby causing the glaze surface to have strip-shaped concave lines, and finally forming glaze surface lines similar to plum blossom skin. Detailed Implementation

[0020] The present invention will be further described below through specific embodiments.

[0021] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0022] This invention utilizes waste ceramics to produce high-quality patterned glazed porcelain, comprising a body and a glaze. The glaze, from bottom to top, includes a base glaze, an intermediate glaze, and a top glaze. The raw materials for the body, by weight, include the following components: 30-40 parts waste ceramics, 30-40 parts kaolin, 10-12 parts feldspar, and 4-5 parts talc. The inclusion of crushed waste ceramic material in the body improves waste utilization and reduces production costs.

[0023] The base glaze comprises the following components by weight: 10-12 parts waste white porcelain particles, 20-30 parts nepheline orthoclase, 12-15 parts silica, 6-8 parts calcium carbonate, and 2-3 parts zinc oxide. High-quality white porcelain particles are used as the raw material in the base glaze. Due to the large particle size, dense texture, and being a calcined material, the white porcelain particles exhibit a significant difference in fluidity compared to other raw materials in the glaze. This difference in fluidity during firing leads to localized insufficient fluidity in the base glaze. Furthermore, the difference in fluidity between the base glaze and the intermediate glaze causes the glaze to crack, break, disperse, and rebuild during its flow, forming localized pitted textures on the glaze surface, thus contributing to the textured, uneven surface.

[0024] The raw materials for the intermediate glaze, by weight, include the following components: 5-6 parts filaments, 3-4 parts CMC adhesive, 15-18 parts quartz, 30-40 parts feldspar, and 3-5 parts borax. The filaments in the intermediate glaze contain polymers and zirconium solution. During firing, the polymers decompose, causing depressions on the glaze surface. The high viscosity of the zirconium solution creates striped depressions on the glaze surface. The CMC adhesive helps the filaments adhere to the base glaze.

[0025] The raw materials for the glaze, by weight, include the following components: 20-25 parts of porcelain clay, 20-25 parts of feldspar, 20-25 parts of quartz, 5-8 parts of borate, and 12-15 parts of wollastonite.

[0026] The above-described process for producing high-quality patterned glazed porcelain using waste ceramics includes the following steps:

[0027] Step a: Shape the blank and fire it.

[0028] Step b: Apply a base glaze to the body;

[0029] Step c: Apply an intermediate glaze over the base glaze;

[0030] Step d, applying a surface glaze on the intermediate glaze;

[0031] Step e, firing in a kiln. During glazing, the temperature is raised to 1100 degrees Celsius for firing, and the temperature is kept for 5-6 hours. Then the temperature is lowered to 800-900 degrees Celsius, and the temperature is raised again to 1200 degrees Celsius for firing, and the temperature is kept for 5-6 hours. The method of two firing without taking out the furnace is adopted, and the temperature is repeatedly raised and lowered to promote the glaze to break, melt, spread, and reshape, so as to show the state of broken and distorted, and to form complex and variable lines. The lines include point-shaped and strip-shaped lines.

[0032] In step b, the particle size of the waste white porcelain particles is 0.15-0.2 mm.

[0033] In step c, the filaments, CMC glue, quartz, feldspar, and borax are mixed and stirred uniformly in proportion to prepare the intermediate glaze, and the intermediate glaze is applied on the base glaze by the way of glazing.

[0034] In step c, the length of the filaments is 1-2 cm, and the diameter is 0.2-0.3 mm. The structure of the filaments is a skin-core structure, and the filaments include a core layer and a skin layer covering the outside of the core layer.

[0035] In step c, the preparation process of the filament is as follows: the polypropylene raw material is prepared into a hollow structure by an extrusion molding process, the filament is soaked in a zirconium solution, and is stirred for 4-5 hours without interruption, and then is left to stand for 10-12 hours, during which the zirconium solution is infiltrated into the hollow structure of the filament, and then the water content of the zirconium solution is reduced to 10-15% by drying, after which the soaked filament is taken out, and is soaked in water-soluble glue for 10-20 minutes, and then is drained and dried to obtain the filament. The filament is soaked and stirred to fully soak the zirconium solution in the filament, and then is concentrated, soaked in glue, and dried to form a filament with a skin-core structure, the skin layer of the filament is a polymer, which is burned and decomposed during the glazing process, the decomposition of the skin layer mainly occurs at 300-500 degrees Celsius, the decomposition of the skin layer causes the glaze to collapse and form grooves, and the zirconium solution in the core layer has excellent fire resistance, and the zirconium combined with the glaze has high viscosity, so the glaze has poor flowability around the filament, and the grooves are not easily covered, so that the glaze can form irregular intersecting grooves, that is, the pattern of imitation plum skin, and the base glaze is made of high-quality white porcelain particles as raw materials, because the white porcelain particles have large particle sizes and are clinkers, the melting point is high, so the flowability of the white porcelain particles is greatly different from that of other raw materials in the glaze, which causes the flowability of the glaze to be different during the glazing process, and causes the flowability of the base glaze to be insufficient, the flowability of the glaze layers is greatly different, and the glaze is broken, melted, scattered, and reshaped during the glazing process due to the existence of substances with high viscosity such as clinker and zirconium solution, and shows a broken and twisted state, forming a pattern similar to the plum skin, and similar to the pattern on the surface of a Wanton snow cake, and the bottom of the pattern may show yellow or black marks due to incomplete combustion of part of the organic matter or too fast flow of the local glaze.

[0036] In step c, the raw materials of the zirconium solution include the following components in parts by weight: 10-12 parts of sodium zirconate, 10-12 parts of zirconium sulfate, 20-30 parts of water, and 5-6 parts of water-soluble glue.

[0037] The above is only some specific embodiments of the present application, but the design concept of the present application is not limited thereto, and any non-essential modification of the present application using this concept shall be deemed to be an infringement of the protection scope of the present application.

Claims

1. A manufacturing process for producing high-quality patterned glazed porcelain using waste ceramics, characterized in that, Includes the following steps: Step a: Shape the blank and fire it. Step b: Apply a base glaze to the body; Step c: Apply an intermediate glaze over the base glaze; Step d: Apply a top coat of glaze over the intermediate glaze; Step e: Firing in a kiln; In step c, the filament, CMC adhesive, quartz, feldspar, and borax are mixed and stirred evenly in a certain proportion to prepare an intermediate glaze. The intermediate glaze is then applied to the base glaze by a glazing method. In step c, the filament preparation process is as follows: polypropylene raw material is extruded to prepare hollow filaments, the filaments are immersed in zirconium solution and stirred continuously for 4-5 hours, and then left to stand for 10-12 hours. During this process, zirconium solution permeates into the hollow structure of the filaments. Then, the water content of the zirconium solution is reduced to 10-15% by drying. After that, the immersed filaments are taken out, water-soluble adhesive is added and soaked for 10-20 minutes, the filaments are taken out and drained, and finally dried to obtain the filaments. The production of high-quality patterned glazed porcelain using waste ceramics includes a body and a glaze. The glaze, from bottom to top, includes a base glaze, an intermediate glaze, and a top glaze. The raw materials of the body, by weight, include the following components: 30-40 parts waste ceramics, 30-40 parts kaolin, 10-12 parts feldspar, and 4-5 parts talc.

2. The manufacturing process for producing high-quality patterned glazed porcelain using waste ceramics according to claim 1, characterized in that: The raw materials of the base glaze include the following components by weight: 10-12 parts of waste white porcelain particles, 20-30 parts of nepheline orthoclase, 12-15 parts of silicon dioxide, 6-8 parts of calcium carbonate, and 2-3 parts of zinc oxide.

3. The manufacturing process for producing high-quality patterned glazed porcelain using waste ceramics according to claim 1, characterized in that: The raw materials of the intermediate glaze, by weight, include the following components: 5-6 parts filament, 3-4 parts CMC adhesive, 15-18 parts quartz, 30-40 parts feldspar, and 3-5 parts borax.

4. The manufacturing process for producing high-quality patterned glazed porcelain using waste ceramics according to claim 1, characterized in that: The raw materials for the glaze, by weight, include the following components: 20-25 parts of porcelain clay, 20-25 parts of feldspar, 20-25 parts of quartz, 5-8 parts of borate, and 12-15 parts of wollastonite.

5. The manufacturing process for producing high-quality patterned glazed porcelain using waste ceramics according to claim 2, characterized in that: In step b, the particle size of the waste white porcelain particles is 0.15-0.2 mm.

6. The manufacturing process for producing high-quality patterned glazed porcelain using waste ceramics according to claim 1, characterized in that: In step c, the filament has a length of 1-2 cm and a diameter of 0.2-0.3 mm. The filament has a core-sheath structure, consisting of a core layer and a sheath layer covering the outside of the core layer.

7. The manufacturing process for producing high-quality patterned glazed porcelain using waste ceramics according to claim 1, characterized in that: In step c, the raw materials of the zirconium solution, by weight, include the following components: 10-12 parts sodium zirconate, 10-12 parts zirconium sulfate, 20-30 parts water, and 5-6 parts water-soluble adhesive.