A manufacturing method of Longquan celadon decorative plate

Abstract

The application relates to a manufacturing method of Longquan celadon decorative plates, wherein the blank body raw material is composed of Longquan soil 50-70%, Malai soil 10-30%, quartz 5-25% and bentonite 2-6% by weight percentage, and sodium oleate 0.01-0.05% and PVA 0.01-0.05% are additionally added; the glaze raw material is composed of purple gold soil 6-12%, quartz 8-15%, potassium feldspar 35-55%, calcite 10-15%, calcined talc 5-14%, calcined kaolin 8-15% and iron oxide 0.5-2% by weight percentage, and sodium tripolyphosphate 0.1-0.2% is additionally added; the Longquan celadon decorative plate is obtained after blank glaze preparation, blank body shaping, drying, body burning, glazing and firing processes; the Longquan celadon decorative plate prepared by the application has simple process, low cost and excellent quality, and therefore has wide market prospect.

Description

Technical Field

[0001] This invention relates to the field of traditional ceramic manufacturing technology, and in particular to a method for manufacturing a Longquan celadon decorative panel. Background Technology

[0002] Longquan celadon, a gem of traditional Chinese ceramics, is world-renowned for its warm, jade-like glaze and exquisite craftsmanship. In recent years, with the increasing demand for home decoration, Longquan celadon decorative panels have gradually become a new favorite in the ceramics industry due to their unique decorative effects and broad application prospects.

[0003] Currently, Longquan celadon production largely follows traditional porcelain-making techniques. Research on body and glaze formulations relies heavily on experience, with limited systematic scientific research. Systematic scientific studies on body and glaze formulations, forming processes, and firing methods for celadon decorative panels are lacking. For example, most Longquan celadon glazes are feldspar glazes, possessing a high coefficient of expansion. Combined with the typically thick glaze layer, this results in a significant difference in expansion coefficients between the glaze and the body. During firing, the stress between the glaze and body causes the body to bend and deform, leading to a high deformation rate in the fired celadon decorative panels. Furthermore, the high difference in expansion coefficients also causes crazing on the glaze surface. Existing body and glaze formulations are incompatible with high-temperature reduction firing techniques, resulting in color differences and pinholes on the glaze surface. In particular, the celadon decorative panel process borrows from traditional porcelain panel making methods, namely hand-rolling and forming. The primary problem with this forming technique is its poor compatibility with local Longquan glazes, leading to numerous technical difficulties such as poor flatness, significant color differences, dense pinholes, and glaze cracking in the celadon decorative panels. In addition, the manual rolling method is inefficient and cannot meet the actual needs of mass production and large-scale production. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a manufacturing method for Longquan celadon decorative panels that is simple in process, low in cost, and of high quality.

[0005] The technical solution of this invention is: a method for manufacturing a Longquan celadon decorative panel, characterized in that: The raw materials for the green body are composed of the following formula by weight percentage: Longquan clay 50-70%, Malaysian clay 10-30%, quartz 5-25%, bentonite 2-6%, with sodium oleate 0.01-0.05% and PVA 0.01-0.05% added externally; The glaze raw materials are composed of the following formula by weight percentage: 6-12% purple clay, 8-15% quartz, 35-55% potassium feldspar, 10-15% calcite, 5-14% calcined talc, 8-15% calcined kaolin, 0.5-2% iron oxide, and 0.1-0.2% sodium tripolyphosphate. Longquan celadon decorative plates are obtained through the processes of raw material and glaze preparation, body forming, drying, bisque firing, glazing, and firing.

[0006] In the billet preparation process, Longquan clay, Malaysian clay, quartz, and bentonite are weighed and mixed according to the billet raw material formula. The mixture is then loaded into a ball mill with a material:ball:water ratio of 1:2:1 to 1.2 and ball-milled for 16 hours. Sodium oleate and PVA are weighed according to the billet raw material formula and placed in 200ml of 80℃ water. After being thoroughly stirred, the mixture is poured into the ball mill and ball-milled for another 2 hours. After ball milling, the slurry is aged for 24 hours and then passed through a 100-mesh sieve. Finally, it is dewatered and kneaded to produce mud.

[0007] The moisture content of the mud is 15-20%.

[0008] In the glaze preparation process, the raw materials are weighed and mixed according to the glaze formula, and the mixture is loaded into a ball mill with a material:ball:water ratio of 1:2:1 to 1.2 and milled for 10 to 20 hours. After milling, the fineness of the slurry is less than 0.04% residue on a 10,000-mesh sieve.

[0009] In the forming process, the clay is placed into the hopper of a screw extruder, and different sizes of Longquan celadon decorative blanks are extruded by adjusting the shape of the die.

[0010] The glaze thickness in the glazing process is 1.5 to 2.5 mm.

[0011] The temperature of the bisque firing process is 700-800℃, and the holding time is 20 minutes.

[0012] The firing process includes five stages: drying, oxidation, strong reduction, weak reduction, and cooling. Specifically: in the drying stage, the temperature is raised to 580-600℃ in 2-3 hours; in the oxidation stage, the temperature is raised to 980℃ in an oxidizing atmosphere in 3-4 hours and held for 10 minutes; in the strong reduction stage, the temperature is raised to 1120-1140℃ in a strong reducing atmosphere in 1.5-2 hours; in the weak reduction stage, the temperature is raised to 1280-1310℃ in a weak reducing atmosphere in 2.5-3.5 hours; and in the cooling stage, the temperature is naturally cooled to room temperature.

[0013] The surface flatness of the Longquan celadon decorative panel is: maximum deviation ≤ ±0.5%; strength: average modulus of rupture ≥ 53 N / mm². 2 Thermal stability: It does not crack after three cycles from 180℃ to 20℃.

[0014] To improve the forming efficiency of Longquan celadon decorative panels, this invention employs an extrusion molding method. To adapt to the requirements of extrusion molding and the expansion coefficient of Longquan celadon glaze, the body formulation was adjusted. Firstly, to ensure the expansion coefficients of the body and glaze are compatible, the body expansion coefficient needs to be increased, which involves introducing Longquan clay with high potassium and sodium content as the main raw material. However, the high feldspar and quartz content in Longquan clay results in low body plasticity. Therefore, this invention introduces sodium oleate and PVA as additives to improve body plasticity while reducing drying shrinkage and increasing body strength. Sodium oleate molecules possess hydrophilic groups (carboxyl groups) and hydrophobic groups (hydrocarbon chains), allowing them to adsorb onto the surface of clay particles. The mutual repulsion between the hydrophilic and hydrophobic groups reduces interparticle friction, making the clay particles slide more easily, thereby improving the body's plasticity. After drying, the PVA solution can form a thin and uniform film that covers the surface of ceramic particles, enhancing the bonding force between particles and increasing the density and strength of the green body. This makes the green body less prone to cracking or deformation during the forming and drying process, thus solving the problem of low yield in the current production of Longquan celadon decorative panels.

[0015] The Longquan celadon decorative plate formula involved in this invention breaks through the limitation of using local Longquan raw materials. The body and glaze formulas both use common mineral and chemical raw materials, resulting in products with uniform color and a jade-like texture, good thermal stability, and wide adaptability. The body formula involves the introduction of sodium oleate and PVA, which increases the plasticity of the body and is compatible with the expansion coefficient of the glaze. This allows for better flatness during extrusion molding, making it less prone to cracking or deformation, improving the product yield, and increasing the profit margin. Therefore, it has broad market prospects. Detailed Implementation

[0016] To further illustrate the present invention, the technical means and effects adopted to achieve the intended purpose of the invention, the present invention will be described in detail below with reference to preferred embodiments: The chemical compositions of the mineral raw materials used in this invention—quartz, potassium feldspar, calcined talc, calcite, purple clay, calcined kaolin, iron oxide, Malaysian clay, Longquan clay, and bentonite—are as follows:

[0017] Example 1 A method for manufacturing a Longquan celadon decorative panel, wherein the raw materials for the body are composed of the following formula by weight percentage: 50% Longquan clay, 23% Malaysian clay, 25% quartz, 2% bentonite, with an external coating of 0.01% sodium oleate and 0.01% PVA; The glaze raw materials are composed of the following formula by weight percentage: 6% purple clay, 8% quartz, 55% potassium feldspar, 10% calcite, 5.5% calcined talc, 15% calcined kaolin, 0.5% iron oxide, plus 0.1% sodium tripolyphosphate; Longquan celadon decorative plates are obtained through the processes of raw material and glaze preparation, body forming, drying, bisque firing, glazing, and firing.

[0018] In the billet preparation process, Longquan clay, Malaysian clay, quartz, and bentonite are weighed and mixed according to the billet raw material formula, and the mixture is loaded into a ball mill with a material:ball:water ratio of 1:2:1 and ball milled for 16 hours. Sodium oleate and PVA are weighed according to the billet raw material formula, placed in 200ml of 80℃ water, stirred thoroughly, and then poured into the ball mill for further ball milling for 2 hours. After ball milling, the slurry is aged for 24 hours and then passed through a 100-mesh sieve. After dehydration and kneading, it is made into mud.

[0019] The moisture content of the mud is 18%.

[0020] In the glaze preparation process, the raw materials are weighed and mixed according to the glaze formula, and then loaded into a ball mill with a material:ball:water ratio of 1:2:1 and ball milled for 10 hours. After ball milling, the fineness of the slurry is less than 0.04% residue on a 10,000-mesh sieve.

[0021] In the forming process, the clay is placed into the hopper of a screw extruder, and different sizes of Longquan celadon decorative blanks are extruded by adjusting the shape of the die.

[0022] The glaze thickness in the glazing process is 1.5 mm.

[0023] The firing process is carried out at a temperature of 700℃ for 20 minutes.

[0024] The firing process includes five stages: drying, oxidation, strong reduction, weak reduction, and cooling. Specifically: in the drying stage, the temperature is raised to 580°C in 2 hours; in the oxidation stage, the temperature is raised to 980°C in an oxidizing atmosphere in 3 hours and held for 10 minutes; in the strong reduction stage, the temperature is raised to 1120°C in a strong reducing atmosphere in 1.8 hours; in the weak reduction stage, the temperature is raised to 1300°C in a weak reducing atmosphere in 2.5 hours; and in the cooling stage, the temperature is naturally cooled to room temperature.

[0025] The surface flatness of the product obtained in this embodiment is ≤ ±0.5% (maximum deviation); strength is 53.7 N / mm² (mean modulus of rupture). 2 Thermal stability: It does not crack after three cycles from 180℃ to 20℃.

[0026] Example 2 A method for manufacturing a Longquan celadon decorative panel, wherein the raw materials for the body are composed of the following formula by weight percentage: 59% Longquan clay, 30% Malaysian clay, 6% quartz, 5% bentonite, with an outer layer of 0.02% sodium oleate and 0.02% PVA; The glaze raw materials are composed of the following formula by weight percentage: 12% purple clay, 15% quartz, 35% potassium feldspar, 15% calcite, 10% calcined talc, 12% calcined kaolin, 1% iron oxide, plus 0.15% sodium tripolyphosphate; Longquan celadon decorative plates are obtained through the processes of raw material and glaze preparation, body forming, drying, bisque firing, glazing, and firing.

[0027] In the billet preparation process, Longquan clay, Malaysian clay, quartz, and bentonite are weighed and mixed according to the billet raw material formula. The mixture is then loaded into a ball mill with a material:ball:water ratio of 1:2:1.1 and ball milled for 16 hours. Sodium oleate and PVA are weighed according to the billet raw material formula and placed in 200ml of 80℃ water. After being thoroughly stirred, the mixture is poured into the ball mill and ball milled for another 2 hours. After ball milling, the slurry is aged for 24 hours and then passed through a 100-mesh sieve. Finally, it is dewatered and kneaded to produce mud.

[0028] The moisture content of the mud is 15%.

[0029] In the glaze preparation process, the raw materials are weighed and mixed according to the glaze formula, and the mixture is loaded into a ball mill with a material:ball:water ratio of 1:2:1.1 and ball-milled for 15 hours. After ball milling, the fineness of the slurry is less than 0.04% residue on a 10,000-mesh sieve.

[0030] In the forming process, the clay is placed into the hopper of a screw extruder, and different sizes of Longquan celadon decorative blanks are extruded by adjusting the shape of the die.

[0031] The glaze thickness in the glazing process is 2mm.

[0032] The firing process is carried out at a temperature of 750°C for 20 minutes.

[0033] The firing process includes five stages: drying, oxidation, strong reduction, weak reduction, and cooling. Specifically: in the drying stage, the temperature is raised to 590°C in 2.5 hours; in the oxidation stage, the temperature is raised to 980°C in an oxidizing atmosphere in 3.5 hours and held for 10 minutes; in the strong reduction stage, the temperature is raised to 1130°C in a strong reducing atmosphere in 2 hours; in the weak reduction stage, the temperature is raised to 1280°C in a weak reducing atmosphere in 3 hours; and in the cooling stage, the temperature is naturally cooled to room temperature.

[0034] The surface flatness of the product obtained in this embodiment is ≤ ±0.5% (maximum deviation); strength is 53.9 N / mm² (mean modulus of rupture). 2 Thermal stability: It does not crack after three cycles from 180℃ to 20℃.

[0035] Example 3 A method for manufacturing a Longquan celadon decorative panel, wherein the raw materials for the body are composed of the following formula by weight percentage: 70% Longquan clay, 10% Malaysian clay, 16% quartz, 4% bentonite, with an external coating of 0.05% sodium oleate and 0.05% PVA; The glaze raw materials are composed of the following formula by weight percentage: 9% purple clay, 11% quartz, 45% potassium feldspar, 12% calcite, 13% calcined talc, 8% calcined kaolin, 2% iron oxide, plus 0.2% sodium tripolyphosphate; Longquan celadon decorative plates are obtained through the processes of raw material and glaze preparation, body forming, drying, bisque firing, glazing, and firing.

[0036] In the billet preparation process, Longquan clay, Malaysian clay, quartz, and bentonite are weighed and mixed according to the billet raw material formula. The mixture is then loaded into a ball mill with a material:ball:water ratio of 1:2:1.2 and ball-milled for 16 hours. Sodium oleate and PVA are weighed according to the billet raw material formula and placed in 200ml of 80℃ water. After being thoroughly stirred, the mixture is poured into the ball mill and ball-milled for another 2 hours. After ball milling, the slurry is aged for 24 hours and then passed through a 100-mesh sieve. Finally, it is dewatered and kneaded to produce mud.

[0037] The moisture content of the mud is 20%.

[0038] In the glaze preparation process, the raw materials are weighed and mixed according to the glaze formula, and the mixture is loaded into a ball mill with a material:ball:water ratio of 1:2:1.2 and ball-milled for 20 hours. After ball milling, the fineness of the slurry is less than 0.04% residue on a 10,000-mesh sieve.

[0039] In the forming process, the clay is placed into the hopper of a screw extruder, and different sizes of Longquan celadon decorative blanks are extruded by adjusting the shape of the die.

[0040] The glaze thickness in the glazing process is 2.5 mm.

[0041] The firing process is carried out at a temperature of 800℃ for 20 minutes.

[0042] The firing process includes five stages: drying, oxidation, strong reduction, weak reduction, and cooling. Specifically: in the drying stage, the temperature is raised to 600°C in 3 hours; in the oxidation stage, the temperature is raised to 980°C in an oxidizing atmosphere in 4 hours and held for 10 minutes; in the strong reduction stage, the temperature is raised to 1140°C in a strong reducing atmosphere in 1.5 hours; in the weak reduction stage, the temperature is raised to 1310°C in a weak reducing atmosphere in 3.5 hours; and in the cooling stage, the temperature is naturally cooled to room temperature.

[0043] The surface flatness of the product obtained in this embodiment is ≤ ±0.5% (maximum deviation); strength is 54.3 N / mm² (mean modulus of rupture). 2 Thermal stability: It does not crack after three cycles from 180℃ to 20℃.

Claims

1. A method for manufacturing a Longquan celadon decorative panel, characterized in that: The raw materials for the green body are composed of the following formula by weight percentage: Longquan clay 50-70%, Malaysian clay 10-30%, quartz 5-25%, bentonite 2-6%, with sodium oleate 0.01-0.05% and PVA 0.01-0.05% added externally; The glaze raw materials are composed of the following formula by weight percentage: 6-12% purple clay, 8-15% quartz, 35-55% potassium feldspar, 10-15% calcite, 5-14% calcined talc, 8-15% calcined kaolin, 0.5-2% iron oxide, and 0.1-0.2% sodium tripolyphosphate. Longquan celadon decorative plates are obtained through the processes of raw material and glaze preparation, body forming, drying, bisque firing, glazing, and firing.

2. The manufacturing method according to claim 1, characterized in that: In the preparation process of the body material and glaze, Longquan clay, Malaysian clay, quartz, and bentonite are weighed and mixed according to the raw material formula of the body, and the mixture is loaded into the ball mill with a material:ball:water ratio of 1:2:1 to 1.2 and ball milled for 16 hours. Sodium oleate and PVA are weighed according to the raw material formula of the body and placed in 200ml of 80℃ water. After being stirred evenly, the mixture is poured into the ball mill and ball milled for another 2 hours. After ball milling, the slurry is aged for 24 hours and then passed through a 100-mesh sieve. After dehydration and kneading, it is made into clay.

3. The manufacturing method according to claim 2, characterized in that: The moisture content of the mud is 15-20%.

4. The manufacturing method according to claim 1, characterized in that: In the glaze preparation process, the raw materials are weighed and mixed according to the glaze formula, and the mixture is loaded into a ball mill with a material:ball:water ratio of 1:2:1 to 1.2 and milled for 10 to 20 hours. After milling, the fineness of the slurry is less than 0.04% residue on a 10,000-mesh sieve.

5. The manufacturing method according to claim 2, characterized in that: In the forming process, the clay is placed into the hopper of a screw extruder, and different sizes of Longquan celadon decorative blanks are extruded by adjusting the shape of the die.

6. The manufacturing method according to claim 1, characterized in that: The glaze thickness in the glazing process is 1.5 to 2.5 mm.

7. The manufacturing method according to claim 1, characterized in that: The temperature of the bisque firing process is 700-800℃, and the holding time is 20 minutes.

8. The manufacturing method according to claim 1, characterized in that: The firing process includes five stages: drying, oxidation, strong reduction, weak reduction, and cooling. Specifically: in the drying stage, the temperature is raised to 580-600℃ in 2-3 hours; in the oxidation stage, the temperature is raised to 980℃ in an oxidizing atmosphere in 3-4 hours and held for 10 minutes; in the strong reduction stage, the temperature is raised to 1120-1140℃ in a strong reducing atmosphere in 1.5-2 hours; in the weak reduction stage, the temperature is raised to 1280-1310℃ in a weak reducing atmosphere in 2.5-3.5 hours; and in the cooling stage, the temperature is naturally cooled to room temperature.

9. The manufacturing method according to claim 1, characterized in that: The surface flatness of the Longquan celadon decorative panel is: maximum deviation ≤ ±0.5%; strength: average modulus of rupture ≥ 53 N / mm². 2 Thermal stability: It does not crack after three cycles from 180℃ to 20℃.

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