A method of sintering ceramic powder

Abstract

The application belongs to the technical field of handicraft preparation, and particularly relates to a ceramic powder sintering process method. The application firstly provides a preparation method of solid ceramic products based on ceramic powder sintering; the application also provides a preparation method of light and thin ceramic products based on ceramic powder sintering. The application aims to explore the possibility of preparing the thickest ceramic process and the thinnest ceramic process (polar and polar) based on the same core process.

Description

Technical Field

[0001] This invention belongs to the field of craft preparation technology, specifically relating to a ceramic powder firing process. Background Technology

[0002] One of the main processes in producing ceramic products is heating the ceramic blank according to a specific thermal regime, causing a physicochemical reaction under high temperature and specific conditions, ultimately resulting in a ceramic product with a fixed volume and specific shape or properties. This production process is called ceramic firing. Common firing methods include single firing and double firing, but in ordinary firing, the ceramic blank is first shaped and then fired at a high temperature. Due to the high temperature during firing, the quality requirements for the blank are also high; otherwise, cracking may occur during firing, leading to substandard ceramic products. Currently, most ceramic products on the market are hollow because solid blanks are extremely prone to cracking or even exploding during firing. Furthermore, due to limitations in technology, it is difficult to find thin, dynamically shaped ceramic products on the market, and even if they exist, they are often expensive.

[0003] In conclusion, it is necessary to propose a new process that differs from traditional ceramic firing methods. Summary of the Invention

[0004] The purpose of this invention is to provide a ceramic powder firing process and ceramic products prepared by this method, which partially solves or alleviates the above-mentioned deficiencies in the prior art. The specific technical solution adopted by this invention is as follows.

[0005] This invention provides a method for preparing solid ceramic products.

[0006] A method for preparing solid ceramic products based on ceramic powder firing includes the following steps: S01: Take raw ceramic materials, fire them into clinker at 600-800℃, and further grind them into powder to obtain ceramic clinker particles with a particle size of less than or equal to 60 mesh; S02: Take ceramic raw materials, add water to prepare a clay body, and make a mold as needed. The mold includes a hollow mold that can load the clinker particles or a solid mold that can support the clinker particles. For example, a hollow mold can be prepared by wheel throwing; or a solid base mold can be prepared by slip casting. A release agent is coated on the mold. S03: Fill the harvested ceramic clinker particles into the hollow mold to make a semi-finished product; or, pile the harvested ceramic clinker particles onto the solid mold to make a semi-finished product. S04: Place the semi-finished product into a kiln for firing at a temperature of 1200-1300℃ (depending on the porcelain-forming temperature of the porcelain clay or pottery clay used), hold for 10-30 minutes, and the entire firing time is 8-10 hours. S05: After firing, remove the mold to obtain the solid ceramic product.

[0007] Furthermore, the ceramic raw materials include porcelain clay, jade clay, or pottery clay.

[0008] Furthermore, the separating agent is aluminum oxide; aluminum oxide is coated on the inner surface of the hollow mold or the outer surface of the solid mold.

[0009] Furthermore, the ceramic clinker particles are compacted when filled into the hollow mold. Optionally, surface finishing may be performed on them.

[0010] Furthermore, when the ceramic clinker particles are piled onto the solid mold, the ceramic clinker is compacted and the outer surface is trimmed (to make it as smooth and flat as possible).

[0011] When the ceramic clinker particles are piled onto the solid mold, they have a certain height, for example, the pile height is above 0.5 cm.

[0012] Another aspect of the present invention provides a method for preparing thin and light ceramic products.

[0013] A method for preparing thin ceramic products based on ceramic powder firing includes the following steps: S01: Take raw ceramic materials, fire them into clinker at 600-800℃, and further grind them into powder to obtain ceramic clinker particles with a particle size of less than or equal to 60 mesh; S02: Thoroughly mix water-soluble viscous powder with water to obtain a viscous excipient; S03: Mix the viscous additives and the ceramic clinker particles evenly in a mass ratio of 2:1 to 2:1.5 to obtain viscous ceramic raw materials; S04: Take an elastic sheet-like carrier and coat the adhesive ceramic material onto one side surface of the sheet-like carrier. The coated adhesive ceramic material needs to completely cover the sheet-like carrier and the weight of the coating does not exceed 5 times the weight of the sheet-like carrier itself. S05: A sheet-like carrier coated with a viscous ceramic raw material, which is dried to make its surface non-sticky and has foldable hardness; S06: The dried sheet carrier is placed in a kiln for firing at a temperature of 1200-1300℃ (depending on the porcelain-forming temperature of the clay or earthenware used), and held at that temperature for 10-30 minutes. The total firing time is 8-10 hours. After firing, the thin ceramic product is obtained.

[0014] This invention provides a new material, namely a mixture of ceramic clinker and adhesive additives. By mixing the ceramic clinker and adhesive additives in a specific ratio, thin and flexible ceramic products can be prepared.

[0015] Understandably, the elastic sheet-like carrier will burn off during the firing process. When raw material is coated onto an elastic carrier, shrinkage and deformation will occur after firing; this invention discovers that using cooked material can effectively solve this problem.

[0016] Furthermore, the ceramic raw materials include porcelain clay, jade clay, or pottery clay.

[0017] Furthermore, the elastic sheet carrier is a fiber cloth, including polyurethane fiber, polyether ester elastic fiber, nylon or Lycra.

[0018] Furthermore, the water-soluble viscous powder includes polyvinyl alcohol powder, carboxymethyl cellulose powder, or glutinous rice flour.

[0019] Furthermore, the sheet-like carrier coated with the adhesive ceramic raw material is shaped as needed before firing; this includes laying it on a predetermined mold before drying, or folding it into a predetermined shape after drying.

[0020] Beneficial technical effects: This invention proposes a method for preparing solid and thin ceramics based on a ceramic powder sintering process. The invention aims to explore the possibility of preparing the thickest and thinnest ceramics (e.g., polarity) using the same core process. Specifically, the process method of this invention has the following advantages: (1) It reduces the drying process of traditional ceramic blank making, alleviates problems such as blank cracking, and simplifies the entire production process.

[0021] (2) After firing, the ceramic surface will have a special texture due to the shrinkage of the clay powder, resulting in richer visual effects and higher artistic value.

[0022] (3) By using simple methods and readily available materials, expensive thin ceramic products were made. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or parts are generally identified by similar reference numerals. The elements or parts in the drawings are not necessarily drawn to scale. Obviously, the drawings described below are some embodiments of the present invention, and those skilled in the art can obtain other drawings based on these drawings without any creative effort.

[0024] Figure 1 This is a process flow diagram for preparing solid ceramic products according to the present invention; Figure 2 This is a process flow diagram for preparing thin and light ceramic products according to the present invention; Figure 3 This is a process diagram of preparing solid ceramics according to one embodiment of the present invention (A is the mold for preparing the blank by throwing, B is the filling of clinker powder; C is the solid ceramic product obtained by demolding). Figure 4 This is a ceramic product prepared as a comparative example in one embodiment of the present invention; Figure 5 A ceramic article prepared as another comparative example in one embodiment of the present invention; Figure 6 The diagram shows the process of preparing thin ceramics in one embodiment of the present invention (A is laying fiber cloth on the mold, B is brushing ceramic raw materials onto the fiber cloth, and C is the finished product obtained by firing). Figure 7 This is a diagram of a thin ceramic product prepared in one embodiment of the present invention; Figure 8 This is a diagram of a thin ceramic product prepared in another embodiment of the present invention; Figure 9 This is a diagram of a solid ceramic product prepared in another embodiment of the present invention; Figure 10 This is a diagram of a solid ceramic product prepared in another embodiment of the present invention. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0026] In this document, "and / or" includes any and all combinations of one or more of the listed related items.

[0027] In this article, "multiple" means two or more, that is, it includes two, three, four, five, etc.

[0028] As used in this specification, the term "about" typically means + / -5% of the value, more typically + / -4% of the value, more typically + / -3% of the value, more typically + / -2% of the value, even more typically + / -1% of the value, and even more typically + / -0.5% of the value.

[0029] In this specification, certain embodiments may be disclosed in a range-bound format. It should be understood that this "range-bound" description is merely for convenience and brevity and should not be construed as a rigid limitation on the disclosed range. Therefore, the description of a range should be considered as having specifically disclosed all possible subranges and the individual numerical values ​​within that range. For example, a description of the range 1-6 should be considered as having specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6, etc., and the individual numbers within that range, such as 1, 2, 3, 4, 5, and 6. This rule applies regardless of the breadth of the range.

[0030] Definition of the noun: In this invention, "raw material" and "cooked material" are relative concepts. "Raw material" refers to unprocessed ceramic raw materials; "cooked material" refers to the material obtained by firing the "raw material" according to a certain process.

[0031] The "separating agent" mentioned in this invention refers to a substance that separates the clinker particles from the mold, and its function is to make the fired ceramics better separate from the mold.

[0032] The “lightweight ceramic” described in this invention is a relative concept, which has a light and thin appearance similar to paper; or its shape has an appearance similar to folded paper.

[0033] Example 1 This embodiment provides an overview of a ceramic powder firing process.

[0034] For example, this embodiment provides an example of preparing a solid ceramic product based on ceramic powder firing, as detailed below.

[0035] S01: Take ceramic raw materials, fire them into clinker at 600-800℃ (for example, fire them for 4-12 hours in this temperature range), and further grind them into powder to obtain ceramic clinker particles with a particle size of less than or equal to 60 mesh. S02: Take ceramic raw materials, add water to prepare clay blanks, and make molds as needed. The molds include hollow molds that can load the clinker particles or solid molds that can support the clinker particles; apply a release agent to the inner surface of the hollow mold or the outer surface of the solid mold. S03: Fill the harvested ceramic clinker particles into the hollow mold to make a semi-finished product; or, pile the harvested ceramic clinker particles onto the solid mold to make a semi-finished product. S04: The semi-finished product is placed in a kiln for firing at a temperature of 1200-1300℃ for 10-30 minutes, and the entire firing time is 8-10 hours. S05: After firing, remove the mold to obtain the solid ceramic product.

[0036] See process flow diagram Figure 1 .

[0037] For example, this embodiment provides a preparation example of a thin ceramic product based on ceramic powder firing, as detailed below.

[0038] S01: Take raw ceramic materials, fire them into clinker at 600-800℃, and further grind them into powder to obtain ceramic clinker particles with a particle size of less than or equal to 60 mesh; S02: Thoroughly mix water-soluble viscous powder with water to obtain a viscous excipient; S03: Mix the viscous additives and the ceramic clinker particles evenly in a mass ratio of 2:1 to 2:1.5 to obtain viscous ceramic raw materials; S04: Take an elastic sheet-like carrier and coat the adhesive ceramic material onto one side surface of the sheet-like carrier. The coated adhesive ceramic material needs to completely cover the sheet-like carrier and the weight of the coating does not exceed 5 times the weight of the sheet-like carrier itself. S05: A sheet-like carrier coated with a viscous ceramic raw material, which is dried to make its surface non-sticky and has foldable hardness; S06: The dried sheet carrier is placed in a kiln for firing at a temperature of 1200-1300℃ for 10-30 minutes, with a total firing time of 8-10 hours; after firing, the thin ceramic product is obtained.

[0039] Before firing, the sheet-like carrier coated with the adhesive ceramic raw material is shaped as needed; this includes laying it on a predetermined mold before drying, or folding it into a predetermined shape after drying.

[0040] See process flow diagram Figure 2 .

[0041] Example 2 This embodiment provides a specific example of a ceramic powder firing process.

[0042] S01: Preparation of clinker: Jade clay (e.g., jade clay from Jingdezhen) is fired at 800℃ for 4-8 hours. After ensuring that the clinker is produced, it is ground into powder using a ball mill or a manual grinding bowl, and then passed through a 60-mesh sieve to obtain jade clay clinker particles with a particle size of less than or equal to 60 mesh.

[0043] S02: Use refractory gypsum or ordinary clay or porcelain clay to make a clay body, throw it into shape to make a mold, the mold is a hollow mold, and then coat the inner surface of the mold with alumina.

[0044] S03: The clinker granules prepared in S01 are filled into the hollow mold, compacted, and made into a green body. The green body is then placed in a kiln for firing. The firing temperature range is 1240℃, the holding time is 20 minutes, and the total firing time is 8 hours.

[0045] S04: Remove the mold from the fired ceramic product to obtain a solid, columnar ceramic item. See the process images for this embodiment. Figure 3 .

[0046] As a comparison, this embodiment also provides a method for preparing a ceramic product in S02 without coating the inner surface of the mold with alumina, see [link to example]. Figure 4 As can be seen in the image, the inner surface of the mold was not coated with alumina, and the clinker powder adhered to the mold.

[0047] As a comparison, this embodiment also provides an example of preparing solid ceramics directly from raw materials in S01, see... Figure 5 The specific process is as follows.

[0048] S01: Prepare the filling material: jade clay (e.g., jade clay from Jingdezhen), grind it into powder using a ball mill or manual grinding bowl, pass it through a 60-mesh sieve, and harvest jade clay clinker particles with a particle size of less than or equal to 60 mesh.

[0049] S02: Use ordinary clay or porcelain clay to make a clay body, and then throw it into shape to make a mold. The mold is a hollow mold.

[0050] S03: The raw material pellets prepared in S01 are filled into the hollow mold, compacted, and made into a green body. The green body is then placed in a kiln for firing. The firing temperature range is 1200℃-1250℃, the holding time is 20 minutes, and the total firing time is 8 hours.

[0051] S04: Remove the mold from the outside of the fired ceramic product to obtain a solid ceramic product.

[0052] The results of this embodiment show that when solid ceramics are prepared using raw materials, the ceramics will crack significantly after firing.

[0053] Example 3 This embodiment provides a specific example of another ceramic powder firing process.

[0054] S01: Preparation of Clinker: The ceramic raw materials are fired at 800℃ for 4-12 hours. After ensuring that the raw materials are properly fired into clinker, they are ground into powder using a ball mill or a manual grinding bowl. The powder is then passed through a 60-mesh sieve to obtain clinker particles with a particle size of 60 mesh or less. Ceramic raw materials include porcelain clay, clay, and jade clay.

[0055] S02: Preparation of auxiliary material: Heat and mix glutinous rice powder and water at a mass ratio of 1:1 to prepare a viscous auxiliary material (paste). Pour the paste onto a glass plate and use a scraper to press it firmly to ensure that the large powder particles are fully and evenly mixed with the water.

[0056] S03: Mix the prepared viscous auxiliary material and clinker in a mass ratio of 2:1 to 2:1.5 (using a stirring tool) to obtain viscous ceramic raw material.

[0057] S04: A mold is made using ordinary clay or porcelain clay; in this embodiment, the mold is hemispherical. A fiber cloth is laid flat on the mold. A scraper is used to apply the adhesive ceramic material onto the fiber cloth, ensuring even coating and a thin layer. For example, the applied adhesive ceramic material should completely cover the fiber cloth, and the weight of the coating should not exceed five times the weight of the fiber cloth itself to ensure lightness and thinness; multiple applications in small amounts are acceptable. After coating, the adhesive ceramic material is placed in a ventilated area to air dry or sun dry until the surface no longer sticks together, resulting in a fiber cloth coated with the adhesive ceramic material.

[0058] S05: Remove the fiber cloth coated with adhesive ceramic raw material from the hemispherical mold and place it in the kiln for firing. The firing temperature range is 1240℃, the holding time is 20 minutes, and the total firing time is 8 hours.

[0059] The process diagram for preparing the ceramic product in this embodiment and several other ceramic products prepared by the same method are shown below. Figure 6 and Figure 7 This yields ceramic products that resemble paper in shape.

[0060] Example 4 This embodiment provides a specific example of another ceramic powder firing process.

[0061] S01: Preparation of Clinker: The ceramic raw materials are fired at 800℃ for 4-12 hours. After ensuring that the raw materials are properly fired into clinker, they are ground into powder using a ball mill or a manual grinding bowl. The powder is then passed through a 60-mesh sieve to obtain clinker particles with a particle size of 60 mesh or less. Ceramic raw materials include porcelain clay, clay, and jade clay.

[0062] S02: Preparation of auxiliary material: Heat and mix glutinous rice powder and water at a mass ratio of 1:1 to prepare a viscous auxiliary material (paste). Pour the paste onto a glass plate and use a scraper to press it firmly to ensure that the large powder particles are fully and evenly mixed with the water.

[0063] S03: Mix the prepared viscous auxiliary material and clinker in a mass ratio of 2:1 to 2:1.5 (using a stirring tool) to obtain viscous ceramic raw material.

[0064] S04: Take a fiber cloth and use a scraper to apply the adhesive ceramic material onto it. During the application process, ensure the adhesive ceramic material is evenly coated and that the coating is as thin as possible. The coated adhesive ceramic material should completely cover the fiber cloth, and the weight of the coating should not exceed five times the weight of the fiber cloth itself to ensure lightness and thinness; multiple applications in small amounts are acceptable. After coating, place it in a ventilated area to air dry or sun dry until the adhesive ceramic material on the surface no longer sticks together, thus obtaining the fiber cloth coated with the adhesive ceramic material.

[0065] S05: Fold the fiber cloth coated with adhesive ceramic raw material into the predetermined shape according to the design requirements.

[0066] S06: Place the folded fabric into the predetermined shape into the kiln for firing. The firing temperature range is 1200℃-1300℃, the holding time is 20 minutes, and the total firing time is 8 hours.

[0067] The ceramic products prepared in this embodiment are shown below. Figure 8 This yields ceramic products in the shape of paper cranes, resembling folded paper.

[0068] Example 5 This embodiment provides a specific example of another ceramic powder firing process, and the ceramic products prepared in this embodiment can be used for decoration.

[0069] S01: Preparation of clinker: Select porcelain clay and fire it at 800℃ for 4-8 hours. After ensuring that the clinker is produced, grind it into powder using a ball mill or manual grinding bowl, and pass it through a 60-mesh sieve to obtain jade clinker particles with a particle size of less than or equal to 60 mesh.

[0070] S02: A base is made by casting a green body using jade clay (e.g., jade clay from Jingdezhen) and gypsum.

[0071] S03: Place the clinker granules prepared in S01 on a sieve and shake it to evenly sprinkle the clinker granules onto the surface of the billet. When the accumulation thickness reaches a predetermined range, for example, in this embodiment, the accumulation thickness range is set to 0.5cm-1cm, and use a brush for minor finishing.

[0072] S04: Place the powdered green body into the kiln for firing. The firing temperature range is 1200℃-1300℃, the holding time is 20 minutes, and the total firing time is 8 hours.

[0073] The ceramic products prepared in this embodiment are shown below. Figure 9 The fired ceramic products are solid ceramics with a textured surface.

[0074] Example 6 This embodiment provides a specific example of another ceramic powder firing process, and the ceramic products prepared in this embodiment can be used for decoration.

[0075] S01: Preparation of clinker: Select jade clay and fire it at 800℃ for 4-8 hours. After ensuring that the clinker is produced, grind it into powder using a ball mill or manual grinding bowl, and pass it through a 60-mesh sieve to obtain jade clay clinker particles with a particle size of less than or equal to 60 mesh.

[0076] S02: Use plaster or ordinary clay or porcelain clay to make a clay body, and then shape it into a mold as needed. The mold is a hollow mold, and then the inner surface of the mold is coated with aluminum oxide.

[0077] S03: Place the clinker particles and glass powder prepared in S01 on a sieve, shake to evenly sprinkle the clinker particles and glass powder onto the surface of the billet, and when the accumulation thickness reaches a predetermined range, for example, in this embodiment the accumulation thickness range is set to 0.5cm-1cm, use a brush for minor finishing.

[0078] S04: Place the powdered green body into the kiln for firing. The firing temperature range is 1200℃-1300℃, the holding time is 20 minutes, and the total firing time is 8 hours.

[0079] S05: After firing, gently lift the finished product to separate it from the mold.

[0080] The ceramic product prepared in this embodiment is placed on a tile, and together with the tile, it constitutes a work of art. Figure 10 .

[0081] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0082] The embodiments of the present invention have been described above with reference to the accompanying drawings. However, the present invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of the present invention without departing from the spirit and scope of the claims. All of these forms are within the protection scope of the present invention.

Claims

1. A method for preparing solid ceramic products based on ceramic powder firing, characterized in that, Includes the following steps: S01: Take raw ceramic materials, fire them into clinker at 600-800℃, and further grind them into powder to obtain ceramic clinker particles with a particle size of less than or equal to 60 mesh; the ceramic raw materials include porcelain clay, jade clay or pottery clay; S02: Take ceramic raw materials, add water to prepare clay blanks, and make molds as needed. The molds include hollow molds that can hold the clinker particles or solid molds that can support the clinker particles; coat the molds with a release agent. S03: Fill the harvested ceramic clinker particles into the hollow mold to make a semi-finished product; or, pile the harvested ceramic clinker particles onto the solid mold to make a semi-finished product. S04: The semi-finished product is placed in a kiln for firing at a temperature of 1200-1300℃ for 10-30 minutes, and the entire firing time is 8-10 hours. S05: After firing, remove the mold to obtain the solid ceramic product.

2. The preparation method according to claim 1, characterized in that, The separating agent is aluminum oxide; aluminum oxide is coated on the inner surface of the hollow mold or the outer surface of the solid mold.

3. The preparation method according to claim 1, characterized in that, When the ceramic clinker particles are filled into the hollow mold, the ceramic clinker particles are compacted.

4. The preparation method according to claim 1, characterized in that, When the ceramic clinker particles are piled onto the solid mold, the ceramic clinker is compacted and the outer surface is trimmed.

5. A method for preparing thin and light ceramic products based on ceramic powder firing, characterized in that, Includes the following steps: S01: Take raw ceramic materials, fire them into clinker at 600-800℃, and further grind them into powder to obtain ceramic clinker particles with a particle size of less than or equal to 60 mesh; the ceramic raw materials include porcelain clay, jade clay or pottery clay; S02: Thoroughly mix water-soluble viscous powder with water to obtain a viscous excipient; S03: Mix the viscous additives and the ceramic clinker particles evenly in a mass ratio of 2:1 to 2:1.5 to obtain viscous ceramic raw materials; S04: Take an elastic sheet carrier and coat the adhesive ceramic raw material onto one side surface of the sheet carrier. The coated adhesive ceramic raw material needs to completely cover the sheet carrier and the weight of the coating does not exceed 5 times the weight of the sheet carrier itself. The elastic sheet carrier is a fiber cloth, including polyurethane fiber, polyether ester elastic fiber or nylon. S05: A sheet-like carrier coated with a viscous ceramic raw material, which is dried to make its surface non-sticky and have foldable hardness; S06: The dried sheet carrier is placed in a kiln for firing at a temperature of 1200-1300℃ for 10-30 minutes, with a total firing time of 8-10 hours; after firing, the thin ceramic product is obtained.

6. The preparation method according to claim 5, characterized in that, The water-soluble viscous powder includes polyvinyl alcohol powder, carboxymethyl cellulose powder, or glutinous rice flour.

7. The preparation method according to claim 5, characterized in that, Before firing, the sheet-like carrier coated with adhesive ceramic raw material is shaped as needed, including laying it on a predetermined mold before drying, or folding it into a predetermined shape after drying.

Images