Ceramics with high hardness, rough edges and stained glaze surfaces and methods for making the same

Abstract

The present application relates to the field of ceramic and its preparation process, in particular to a kind of ceramic with high hardness, rough edge and stained glaze surface and its preparation method, and the body is provided with pointed decoration, the edge of pointed decoration forms rough edge, and green stain is distributed on glaze surface.In the process of drying body, humidity gradient mainly appears on edge, since pointed decoration protrudes from body, and its edge narrows, more flowing air is contacted by edge part, compared with other parts of body, drying speed is faster, soluble salt precipitate appears, therefore, black-brown scum is distributed on the edge of pointed decoration on body, chalcopyrite and bornite in body combine with sulfur and iron to generate sulphuric iron copper compound when glazing, sulphuric iron copper compound penetrates glaze surface and concentrates, and local part of glaze surface is dyed into green spot;After glazing, the whole glaze surface is milky white matte satin surface, green stain is distributed on it, and black-brown rough edge is formed on the edge of local pointed decoration, which has unique artistic beauty.

Description

Technical Field

[0001] This invention relates to the field of ceramics and their preparation processes, specifically to ceramics with high hardness, rough edges, and stained glaze, and their preparation methods. Background Technology

[0002] Glaze is a colorless or colored vitreous thin layer covering the surface of ceramic products. It is made by grinding mineral raw materials (feldspar, quartz, talc, kaolin, etc.) and other raw materials in a certain proportion (some raw materials can be made into frit first), forming a glaze slurry, which is then applied to the surface of the ceramic body and fired at a certain temperature. Glaze can increase the mechanical strength, thermal stability, and dielectric strength of the product, and also has the characteristics of beautifying the object, facilitating cleaning, and preventing corrosion from dust and dirt. Glaze surfaces can be classified into glossy and satin finishes according to their surface smoothness. Existing glaze surfaces cannot simultaneously achieve the effects of different smoothness levels. In view of this, this case arises. Summary of the Invention

[0003] One object of the present invention is to solve at least the above-mentioned problems by ceramics with high hardness, rough edges and stained glaze, and the preparation method thereof.

[0004] To solve the above technical problems, the present invention adopts the following technical solution: a ceramic with high hardness, rough edges and stained glaze, comprising a body and a glaze covering the surface of the body, wherein the body is provided with pointed decorations, the edges of the pointed decorations form rough edges, and green stained spots are distributed on the glaze.

[0005] Preferably, the pointed decoration is annular, and multiple pointed decorations are arranged longitudinally along the side wall of the blank.

[0006] Preferably, the raw materials of the blank body, by weight, include the following components: 40-50 parts kaolin, 10-12 parts porcelain stone, 6-8 parts bentonite, 8-10 parts pyrophyllite, 15-18 parts silica, 6-9 parts limestone, 5-10 parts slag initiator, 3-4 parts chalcopyrite, and 2-3 parts bornite.

[0007] Preferably, the raw materials of the scum initiator, by weight, include the following components: 10-12 parts ochre, 3-4 parts calcium sulfate, 3-4 parts sodium sulfate, 3-4 parts magnesium sulfate, and 3-4 parts potassium sulfate.

[0008] Preferably, the raw materials for the glaze, by weight, include the following components: 40-45 parts feldspar, 35-36 parts silicon dioxide, 20-22 parts zinc oxide, 10-14 parts calcium carbonate, 6-8 parts kaolin, 3-4 parts bentonite, and 7-8 parts rutile.

[0009] A method for preparing ceramics with high hardness, rough edges, and stained glaze includes the following steps:

[0010] Step a: Prepare ceramic blanks;

[0011] Step b: The billet is formed into a blank;

[0012] Step c: Dry the green body;

[0013] Step d: Apply glaze to the surface of the blank;

[0014] Step e: The glazed body is placed in the kiln for glazing and firing.

[0015] Preferably, in step a, the blank is prepared by clay preparation and clay refining;

[0016] The clay sculpting process includes the following steps:

[0017] Step 1) Pour the raw material into the coarse bucket and stir. Take the upper layer of thin mud slurry and pour it into the fine bucket. Then add water to the coarse bucket and continue to take the upper layer of thin mud slurry and pour it into the fine bucket. Repeat this process 3-5 times and pour out the residue at the bottom of the coarse bucket.

[0018] Step 2) Pour the thin mud slurry obtained in Step 1) back into the coarse bucket, and repeat Step 1) 3-5 times;

[0019] Step 3) Reduce the moisture content of the mud using a filter press.

[0020] Preferably, the clay refining process includes the following steps: performing a coarse clay refining, then adding the scum initiator to the clay slurry obtained from the pottery clay and mixing, and performing two fine clay refining processes.

[0021] Preferably, in step c, the billet is dried by a dryer, which includes a shell, a top cover, a turntable, an internal ventilation pipe, a heating pipe, and a connecting pipe. The shell has a heating chamber, with an exhaust port at the top connecting to the outside and a bypass port connecting to the top of the heating pipe, and a return air port at the bottom connecting to the bottom of the heating pipe. The top cover is detachably mounted on the top of the shell. The turntable is rotatably mounted at the bottom of the heating chamber. The internal ventilation pipe is fixed below the top cover and has an internal air outlet at the bottom. The heating pipe is mounted on the side wall of the shell, and its bottom is connected to the internal ventilation pipe via a connecting pipe. The heating pipe contains a circulating fan and a heater, and its top has an exhaust port connecting to the outside.

[0022] Preferably, in step c, the billet is placed in the heating chamber of the dryer, the top cover is closed, the inner ventilation pipe extends into the interior of the billet, the circulating fan, heater and turntable inside the heating pipe are started, hot air enters the heating chamber and connecting pipe from the bottom of the heating pipe, and then the hot air flows upward from the space between the outer wall of the billet and the heating chamber and flows back to the heating pipe through the bypass port. At the same time, the hot air enters the inner ventilation pipe through the connecting pipe and is discharged from the inner air outlet. The hot air flows upward from the space between the inner ventilation pipe and the inner wall of the billet and flows back to the heating pipe through the bypass port, thereby drying the inside and outside of the billet.

[0023] As described above, the ceramic with high hardness, rough edges, and stained glaze provided by this invention and its preparation method have the following beneficial effects: During the drying process of the body, the humidity gradient mainly appears at the edges. Because the pointed decoration protrudes from the body and its edges are narrower, the edge area comes into contact with more flowing air, resulting in a faster drying speed and higher drying rate compared to other parts of the body. Therefore, soluble salt precipitates appear at the edges, resulting in blackish-brown scum distributed on the edges of the pointed decoration on the body, which is to say, it has a blackish-brown rough edge effect. When chalcopyrite and bornite in the body combine with sulfur and iron during glaze firing, they form pyrite-copper compounds. The pyrite-copper compounds penetrate the glaze surface and accumulate, staining the glaze surface locally with green spots. After glaze firing, the overall glaze surface is a milky white matte satin surface with green stains distributed on it, while the edges of the pointed decorations in some areas form blackish-brown rough edges, which have a unique artistic beauty. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of a dryer for ceramics with high hardness, rough edges, and stained glaze. Detailed Implementation

[0025] The present invention will be further described below through specific embodiments.

[0026] 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.

[0027] like Figure 1 As shown, the present invention relates to a ceramic with high hardness, rough edges, and a glaze with green stains. The ceramic comprises a body 100 and a glaze covering the surface of the body 100. The body 100 has pointed decorations 101 with rough edges, and the glaze surface is covered with green stains. After firing, the overall glaze surface is a milky white matte satin finish with green stains, while the edges of the pointed decorations 101 in certain areas form dark brown rough edges, creating a unique artistic aesthetic.

[0028] The pointed decorations 101 are in the shape of rings, and multiple pointed decorations 101 are arranged longitudinally along the side wall of the body 100. After firing, multiple rough, dark brown ring decorations are formed on the ceramic surface, which not only enhances the artistic beauty but also improves the feel and friction.

[0029] The raw materials of the body 100, by weight, include the following components: 40-50 parts kaolin, 10-12 parts porcelain stone, 6-8 parts bentonite, 8-10 parts pyrophyllite, 15-18 parts silica, 6-9 parts limestone, 5-10 parts slag initiator, 3-4 parts chalcopyrite, and 2-3 parts bornite. During glaze firing, the chalcopyrite and bornite in the body 100 combine with sulfur and iron to form copper pyrite-iron oxides. These copper pyrite-iron oxides penetrate and accumulate on the glaze surface, locally staining the glaze surface with green spots. The chalcopyrite and bornite particles are relatively large, 0.2-0.3 mm, and these larger particles react more readily with the glaze surface during firing to form green spots.

[0030] The raw materials for the scum initiator, by weight, include the following components: 10-12 parts ochre, 3-4 parts calcium sulfate, 3-4 parts sodium sulfate, 3-4 parts magnesium sulfate, and 3-4 parts potassium sulfate. Ochre contains a large amount of soluble salts, and together with soluble salts such as calcium sulfate, sodium sulfate, magnesium sulfate, and potassium sulfate, the scum initiator is rich in soluble salt substances. During the drying process of the body 100, the humidity gradient mainly appears at the edges. Since the pointed decoration 101 protrudes from the body 100 and its edges are narrower, the edge area comes into contact with more flowing air. Compared with other parts of the body 100, the drying speed is faster and the drying rate is higher. Therefore, soluble salt precipitates appear at the edges. These precipitates appear during the drying process but are not easily observed by the naked eye. They melt during the firing process and become more vitrified than other parts of the body 100. They react with the glaze, thus presenting a localized rough edge effect, i.e., inducing a rough edge effect. Ochre also contains ferric oxide, which induces black or brown spots on the body 100, making the slag appear dark brown. Therefore, the edges of the pointed decoration 101 on the body 100 are distributed with dark brown slag, i.e., they have a dark brown rough edge effect.

[0031] The raw materials for the glaze, by weight, include the following components: feldspar 40-45 parts, silica 35-36 parts, zinc oxide 20-22 parts, calcium carbonate 10-14 parts, kaolin 6-8 parts, bentonite 3-4 parts, and rutile 7-8 parts. After firing, the glaze is milky white. After reacting with the body, it exhibits localized green stains and dark brown rough edges. Due to its high silica content, the glaze has high hardness and good wear resistance.

[0032] Preferred embodiment 1: The raw materials of the billet 100, by weight, include the following components: 40 parts kaolin, 10 parts porcelain stone, 6 parts bentonite, 8 parts pyrophyllite, 15 parts silica, 6 parts limestone, 5 parts slag initiator, 3 parts chalcopyrite, and 2 parts bornite.

[0033] The raw materials for the scum initiator, by weight, include the following components: 10 parts ochre, 3 parts calcium sulfate, 3 parts sodium sulfate, 3 parts magnesium sulfate, and 3 parts potassium sulfate.

[0034] The raw materials for the glaze, by weight, include the following components: 405 parts feldspar, 35 parts silicon dioxide, 20 parts zinc oxide, 10 parts calcium carbonate, 6 parts kaolin, 3 parts bentonite, and 7 parts light rutile.

[0035] Preferred embodiment 2: The raw materials of the blank body 100, by weight, include the following components: 50 parts kaolin, 12 parts porcelain stone, 8 parts bentonite, 10 parts pyrophyllite, 18 parts silica, 9 parts limestone, 10 parts slag initiator, 4 parts chalcopyrite, and 3 parts bornite.

[0036] The raw materials for the scum initiator, by weight, include the following components: 12 parts ochre, 4 parts calcium sulfate, 4 parts sodium sulfate, 4 parts magnesium sulfate, and 4 parts potassium sulfate.

[0037] The raw materials for the glaze, by weight, include the following components: 45 parts feldspar, 36 parts silicon dioxide, 22 parts zinc oxide, 14 parts calcium carbonate, 8 parts kaolin, 4 parts bentonite, and 8 parts light rutile.

[0038] Preferred embodiment 3: The raw materials of the blank body 100, by weight, include the following components: 42 parts kaolin, 11 parts porcelain stone, 7 parts bentonite, 9 parts pyrophyllite, 16 parts silica, 7 parts limestone, 7 parts slag initiator, 3.5 parts chalcopyrite, and 2.5 parts bornite.

[0039] The raw materials for the scum initiator, by weight, include the following components: 11 parts ochre, 3.5 parts calcium sulfate, 3.5 parts sodium sulfate, 3.5 parts magnesium sulfate, and 3.5 parts potassium sulfate.

[0040] The raw materials for the glaze, by weight, include the following components: 42 parts feldspar, 35.5 parts silicon dioxide, 21 parts zinc oxide, 12 parts calcium carbonate, 7 parts kaolin, 3.5 parts bentonite, and 7.5 parts rutile.

[0041] A method for preparing ceramics with high hardness, rough edges, and stained glaze includes the following steps:

[0042] Step a: Prepare ceramic blanks;

[0043] Step b: The billet is formed into a blank body of 100;

[0044] Step c: Dry the green body 100;

[0045] Step d: Apply glaze to the surface of the blank 100;

[0046] Step e: 100g of the glazed body is placed in the kiln for glazing and firing.

[0047] In step a, the blank 100 is prepared by clay preparation and clay refining;

[0048] The clay-making process includes the following steps:

[0049] Step 1: Pour 100g of raw material into the coarse bucket and stir. Take the upper layer of thin mud slurry and pour it into the fine bucket. Then add water to the coarse bucket and continue to take the upper layer of thin mud slurry and pour it into the fine bucket. Repeat this process 3-5 times and pour out the residue at the bottom of the coarse bucket.

[0050] Step 2: Pour the thin mud slurry obtained in Step 1 back into the coarse bucket, and repeat Step 13-5 times;

[0051] Step 3: Reduce the moisture content of the slurry using a filter press. Repeated washing in coarse and fine barrels effectively removes impurities; however, during this process, most of the soluble salts in the slurry also dissolve in the water and are removed.

[0052] The clay preparation process includes the following steps: a coarse clay preparation, followed by mixing a scum initiator with the clay slurry obtained from the clay preparation, and then two fine clay preparations. The scum initiator contains a large amount of soluble salts. Since these substances are largely removed during the clay preparation process, they are specifically added during the clay preparation process. During the drying process of the clay body 100, these soluble salts accumulate at the pointed edges of the clay body 100, resulting in scum formation at the pointed edges after firing, thus creating a localized rough surface effect, i.e., a rough edge. In traditional clay preparation processes, soluble salts are mostly washed away during the ceramic production process, resulting in a very low soluble salt content in the clay. This makes it difficult for soluble salts to precipitate, thus inducing scum. However, this invention specifically adds a scum initiator during the clay preparation stage to increase the soluble salt content in the clay. This balances the need for washing and cleaning with the requirement for a high soluble salt content. While the formation of sediment on the body 100 and scum after firing might be considered defects in traditional ceramic firing, this invention innovatively transforms these defects into a unique artistic expression. After firing, the glaze has an overall satin finish with green spots, while the edges of the pointed decorative elements 101 have a rough, dark brown border, creating a unique artistic aesthetic.

[0053] like Figure 1In step c, the billet 100 is dried by a dryer, which includes a shell 1, a top cover 2, a turntable 3, an internal ventilation pipe 4, a heating pipe 5, and a connecting pipe 6. The shell 1 is provided with a heating chamber. The top of the heating chamber is provided with an exhaust port 7 that connects to the outside and a bypass port 8 that connects to the top of the heating pipe 5. The bottom is provided with a return air port 9 that connects to the bottom of the heating pipe 5. The top cover 2 is detachably placed on the top of the shell 1. The turntable 3 is rotatably placed at the bottom of the heating chamber. The internal ventilation pipe 4 is fixed below the top cover 2. The bottom of the internal ventilation pipe 4 is provided with an internal air outlet 10. The heating pipe 5 is placed on the side wall of the shell 1. The bottom of the heating pipe 5 is connected to the internal ventilation pipe 4 through the connecting pipe 6. The heating pipe 5 is provided with a circulating fan 11 and a heater 12. The top of the heating pipe 5 is provided with an air inlet 13 that connects to the outside.

[0054] In step c, the billet 100 is placed in the heating chamber of the dryer, the top cover 2 is closed, the inner ventilation pipe 4 extends into the interior of the billet 100, and the circulating fan 11, heater 12 and turntable 3 in the heating pipe 5 are started. Hot air enters the heating chamber and connecting pipe 6 from the bottom of the heating pipe 5. Then, the hot air flows upward from the space between the outer wall of the billet 100 and the heating chamber and flows back to the heating pipe 5 through the bypass port 8. At the same time, the hot air enters the inner ventilation pipe 4 through the connecting pipe 6 and is discharged from the inner air outlet 10. The hot air flows upward through the space between the inner ventilation pipe 4 and the inner wall of the billet 100 and flows back to the heating pipe 5 through the bypass port 8, thereby drying the inside and outside of the billet 100. The heating chamber is equipped with humidity and temperature sensors to control the appropriate drying temperature and humidity, ensuring drying efficiency and preventing cracking. The exhaust vent 7, bypass vent 8, and intake vent 13 are all equipped with electrically controlled valves. In the initial drying stage, the exhaust vent 7 and intake vent 13 are closed to heat the heating chamber to the appropriate temperature and humidity. During continuous drying, when the humidity in the heating chamber rises to 20-30% above the specified humidity, the exhaust vent 7 is opened to expel the humid air, while the intake vent 13 is opened to introduce external dry air into the heating chamber. Once the humidity drops to the specified level, the exhaust vent 7 and intake vent 13 are closed again for cyclic heating. For most of the time, the heating chamber is in a cyclic heating state, intermittently expelling humid air and introducing dry air, thereby accelerating the drying speed of the blank 100 and promoting rapid airflow at the edge of the pointed decoration 101. Therefore, this specially structured dryer can effectively increase the drying speed, thereby promoting the precipitation of soluble salts and forming scum at the edge. Simultaneously, the blank 100 rotates while undergoing internal and external drying, making it less prone to cracking.

[0055] The above are merely some specific embodiments of the present invention, but the design concept of the present invention is not limited thereto. Any non-substantial modifications made to the present invention using this concept shall be considered as infringing upon the protection scope of the present invention.

Claims

1. A ceramic with high hardness, rough edges, and a mottled glaze, characterized by: The product comprises a body and a glaze covering the surface of the body. The body is decorated with pointed ornaments, the edges of which are roughened. The glaze is covered with green dye spots. The raw materials for the body, by weight, include the following components: 40-50 parts kaolin, 10-12 parts porcelain stone, 6-8 parts bentonite, 8-10 parts pyrophyllite, 15-18 parts silica, 6-9 parts limestone, 5-10 parts slag initiator, 3-4 parts chalcopyrite, and bornite. 2-3 parts, the raw materials of the scum initiator, by weight, include the following components: 10-12 parts ochre, 3-4 parts calcium sulfate, 3-4 parts sodium sulfate, 3-4 parts magnesium sulfate, and 3-4 parts potassium sulfate. The raw materials of the glaze, by weight, consist of the following components: 40-45 parts feldspar, 35-36 parts silicon dioxide, 20-22 parts zinc oxide, 10-14 parts calcium carbonate, 6-8 parts kaolin, 3-4 parts bentonite, and 7-8 parts light rutile.

2. The ceramic with high hardness, rough edges, and stained glaze according to claim 1, characterized in that: The pointed decoration is ring-shaped, and multiple pointed decorations are arranged longitudinally along the side wall of the blank.

3. The method for preparing ceramics with high hardness, rough edges, and stained glaze according to any one of claims 1-2, characterized in that, Includes the following steps: Step a: Prepare ceramic blanks; Step b: The billet is formed into a blank; Step c: Dry the green body; Step d: Apply glaze to the surface of the blank; Step e: The glazed body is placed in the kiln for glazing and firing.

4. The method for preparing ceramics with high hardness, rough edges, and stained glaze according to claim 3, characterized in that: In step a, the blank is prepared by washing and kneading the clay; The mud-washing process includes the following steps: Step 1) Pour the raw material into the coarse bucket and stir. Take the upper layer of thin mud slurry and pour it into the fine bucket. Then add water to the coarse bucket and continue to take the upper layer of thin mud slurry and pour it into the fine bucket. Repeat this process 3-5 times and pour out the residue at the bottom of the coarse bucket. Step 2) Pour the thin mud slurry obtained in Step 1) back into the coarse bucket, and repeat Step 1) 3-5 times; Step 3) Reduce the water content of the mud using a filter press.

5. The method for preparing ceramics with high hardness, rough edges, and stained glaze according to claim 4, characterized in that: The mud refining process includes the following steps: performing a coarse mud refining, then adding the scum initiator to the mud slurry obtained after mud washing and mixing, and performing two fine mud refining processes.

6. The method for preparing ceramics with high hardness, rough edges, and stained glaze according to claim 3, characterized in that: In step c, the billet is dried by a dryer, which includes a shell, a top cover, a turntable, an internal ventilation pipe, a heating pipe, and a connecting pipe. The shell has a heating chamber, with an exhaust port at the top connecting to the outside and a bypass port connecting to the top of the heating pipe, and a return air port at the bottom connecting to the bottom of the heating pipe. The top cover is detachably placed on the top of the shell. The turntable is rotatably placed at the bottom of the heating chamber. The internal ventilation pipe is fixed below the top cover and has an internal air outlet at the bottom. The heating pipe is placed on the side wall of the shell, and its bottom is connected to the internal ventilation pipe through a connecting pipe. The heating pipe contains a circulating fan and a heater, and its top has an exhaust port connecting to the outside.

7. The method for preparing ceramics with high hardness, rough edges, and stained glaze according to claim 6, characterized in that: In step c, the billet is placed in the heating chamber of the dryer, the top cover is closed, the inner ventilation pipe extends into the interior of the billet, the circulating fan, heater and turntable inside the heating pipe are started, hot air enters the heating chamber and connecting pipe from the bottom of the heating pipe, and then the hot air flows upward from the space between the outer wall of the billet and the heating chamber and flows back to the heating pipe through the bypass port. At the same time, the hot air enters the inner ventilation pipe through the connecting pipe and is discharged from the inner air outlet. The hot air flows upward from the space between the inner ventilation pipe and the inner wall of the billet and flows back to the heating pipe through the bypass port, thereby drying the inside and outside of the billet.

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