A preparation process of Dehua white porcelain sculpture reinforced by natural loofah fiber

Abstract

A preparation process for Dehua white porcelain sculptures reinforced with natural loofah fiber, comprising the following steps: pretreatment of loofah fiber → preparation of white porcelain slurry → preparation of composite slurry → production of initial sculpture → production of finished sculpture. The advantages of the present invention are as follows: 1. Through the composite reinforcement of loofah fiber, a micropore-fiber synergistic toughening mechanism is formed in the white porcelain sculpture, increasing the flexural strength of the white porcelain sculpture to 45-55 MPa and significantly reducing the cracking risk; 2. Utilizing the physical support of loofah fiber to improve the plastic stability of white porcelain slurry; at the same time, the micropore network formed by the carbonization of loofah fiber buffers the thermal stress, increasing the rate of temperature rise during bisque firing to 2 °C / min, shortening the total firing time and reducing energy consumption; 3. By virtue of the lightweight characteristics and micropore structure of loofah fiber, the density of the finished product is reduced to 1.9-2.1 g / cm 3 , reducing the weight of the white porcelain sculpture, lowering the transportation cost and promoting the marketization of large-scale sculptures.

Description

Technical Field

[0001] The invention relates to the field of ceramics, and in particular to a preparation process of a Dehua white porcelain sculpture based on natural loofah fiber reinforcement. Background Art

[0002] Dehua white porcelain is famous for its delicate and warm texture and uniqueness. The preparation process of traditional Dehua white porcelain sculptures uses kaolin as the main raw material, and is made through processes such as mud making, shaping, bisque firing, glazing, and glaze firing. However, the porcelain body in the prior art has the following problems: 1. The body has insufficient toughness and is prone to cracking due to stress concentration during firing or use, and it is especially difficult to achieve complex structural designs such as hollowing out and cantilevering; 2. Pure porcelain mud is easy to collapse when depicting sculpture details, requiring multiple repairs (increasing time by 30%-50%), and bisque firing requires extremely slow heating (1°C / min) to avoid cracking, which leads to high energy consumption and long cycles in the production process of the sculpture, while affecting artistic expression; 3. Traditional white porcelain sculptures have a high density (density of 2.3-2.5g / cm 3 ), such as large sculptures over 1 meter in height, which can weigh hundreds of kilograms. This makes the transportation and installation costs of large sculptures high, and also limits their application in the field of public art.

[0003] In the prior art, although there have been attempts to enhance the performance of ceramics by adding fiber materials, such as glass fiber and carbon fiber, such materials have poor compatibility with white porcelain slurry, and are prone to produce pores or residual impurities after high-temperature firing, affecting the pure texture of white porcelain. Summary of the invention

[0004] The invention provides a preparation process of a Dehua white porcelain sculpture based on natural loofah fiber reinforcement, and its main purpose is to overcome the above-mentioned problems existing in the prior art.

[0005] In order to solve the above technical problems, the present invention adopts the following technical solutions:

[0006] A preparation process of Dehua white porcelain sculpture based on natural loofah fiber reinforcement comprises the following steps:

[0007] S1. Pretreatment of loofah fibers: washing and drying the loofah fibers, cutting the dried loofah fibers into short fibers of suitable length, and finally surface modifying the short fibers;

[0008] S2, preparation of white porcelain slurry: weigh 50-60 parts by weight of kaolin, 20-30 parts by weight of quartz and 10-20 parts by weight of feldspar, and crush, mix and wet-ball-mill the above raw materials to prepare white porcelain slurry;

[0009] S3. Composite Mud Preparation: Weigh the pretreated loofah fiber and white porcelain mud according to the mass ratio of 1-5:95-99 respectively. After mixing the pretreated loofah fiber and white porcelain mud, grind them with a ball mill to obtain composite mud;

[0010] S4. Sculpture Prototype Making: Make the composite mud into a sculpture body, and then dry and bisque-fire the sculpture body to obtain a sculpture prototype;

[0011] S5. Sculpture Finished Product Making: Glaze the sculpture prototype, and then glaze-fire it to obtain a sculpture finished product.

[0012] Furthermore, the step S1 specifically includes the following steps:

[0013] S11. Cleaning and Drying: Immerse the loofah fiber in deionized water and ultrasonically clean it for 30 minutes. After removing impurities, place it in an oven at 60-80 °C and dry it to constant weight;

[0014] S12. Fiber Cutting: Use mechanical shearing to cut the loofah fiber into loofah short fibers with a length of 0.5-2 mm;

[0015] S13. Immerse the cut loofah short fibers in a sodium hydroxide solution with a mass concentration of 5% and treat them for 1 hour, then neutralize them with dilute hydrochloric acid and wash them with water until neutral;

[0016] S14. Pre-oxidation: Calcinate the loofah short fibers at 300-400 °C for 30 minutes in an inert atmosphere to remove the organic matter in the loofah short fibers and form a microporous structure to enhance the mud permeability.

[0017] Furthermore, the pore diameter of the microporous structure in the step S14 is 1-5 μm.

[0018] Further, in the step S2, the particle size of the prepared white porcelain mud is ≤10 μm.

[0019] Further, the step S3 specifically includes the following steps:

[0020] S31. Weigh the pretreated loofah short fibers and white porcelain mud according to the mass ratio of 1-5:95-99 respectively;

[0021] S32. Uniformly disperse the loofah short fibers in deionized water, and then add a dispersant and stir at high speed to form a suspension. The dosage of the dispersant is 0.5% of the mass of the loofah short fibers;

[0022] S33. Mix the suspension with the white porcelain mud, grind it with a ball mill for at least 2 hours, and the ball-to-material ratio is 2:1 to obtain a composite mud with uniformly distributed loofah short fibers. The water content of the composite mud is 28-32%.

[0023] Furthermore, step S4 specifically includes the following steps:

[0024] S41. Shaping: The composite slurry is made into a carcass by slip casting or manual sculpture method, and the stability of the complex structure of the carcass is enhanced by the supporting effect of loofah short fibers;

[0025] S42. Drying: The carcass is slowly dried for 48 hours in an environment with a humidity of 50 - 60% and a temperature of 25 - 30°C to avoid cracking caused by the shrinkage of loofah short fibers;

[0026] S43. Bisque firing: The temperature of the kiln is raised to 850°C to bisque fire the carcass, and then it is kept warm for 1 hour to carbonize the loofah short fibers to form a microporous network structure, obtaining a preliminary sculpture.

[0027] Furthermore, the bisque firing in step S43 adopts stepped temperature rise bisque firing, and the specific bisque firing steps are as follows:

[0028] S431. The kiln is heated at a heating rate of 1°C / min to 300°C to remove the residual moisture in the carcass;

[0029] S432. The kiln is heated at a heating rate of 2°C / min to 850°C to carbonize the loofah short fibers to form a microporous network.

[0030] Furthermore, in step S5, the thickness of the glaze applied to the preliminary sculpture is 50 - 80 um, and the glaze firing temperature is 1280 - 1320°C.

[0031] From the above description of the invention, compared with the prior art, the present invention has the following advantages:

[0032] 1. Through the composite reinforcement of loofah fibers, a microporous - fiber synergistic toughening mechanism is formed in the white porcelain sculpture, increasing the flexural strength of the white porcelain sculpture to 45 - 55 MPa, significantly reducing the cracking risk (breakage rate < 5%), and expanding the feasibility of complex shapes of white porcelain sculptures.

[0033] 2. Utilizing the physical support effect of loofah fibers, the shaping stability of white porcelain slurry is improved, increasing the one - time forming rate of the fine structure of white porcelain sculptures by 80% and reducing the trimming process by 50%; at the same time, the microporous network formed by the carbonization of loofah fibers buffers the thermal stress, increasing the bisque firing heating rate to 2°C / min, shortening the total firing time by 20% - 25%, and reducing the energy consumption by 0.3 kWH / kg.

[0034] 3. By virtue of the lightweight characteristics and microporous structure of loofah fibers, the density of the finished product is reduced to 1.9 - 2.1 g / cm 3 , the weight is reduced by 15% - 20%, the transportation cost is reduced by 25%, and the marketization of large - scale sculptures is promoted.

[0035] 4. Use loofah fiber, an agricultural waste, to replace part of the kaolin raw material, realizing the recycling of resources. The carbon emissions of a single white porcelain sculpture product are reduced by 18%. The loofah fibers are randomly distributed on the white porcelain sculpture product to form natural "silk texture". After glaze firing, a looming sense of hierarchy is presented, enriching the artistic language of Dehua white porcelain and further enhancing the added value of the product. Specific implementation method

[0036] A preparation process of Dehua white porcelain sculpture reinforced by natural loofah fiber includes the following steps:

[0037] S1. Pretreatment of loofah fiber: Wash and dry the loofah fiber. Cut the dried loofah fiber into short fibers of appropriate length, and finally perform surface modification on the short fibers;

[0038] S2. Preparation of white porcelain slurry: Weigh 50 - 60 parts by weight of kaolin, 20 - 30 parts by weight of quartz, and 10 - 20 parts by weight of feldspar. Crush, mix, and wet ball mill the above raw materials respectively to obtain white porcelain slurry; among them, the particle size of the obtained white porcelain slurry is ≤10um;

[0039] S3. Preparation of composite slurry: Weigh the pretreated loofah fiber and white porcelain slurry according to a mass ratio of 1 - 5:95 - 99. Mix the pretreated loofah fiber and white porcelain slurry and grind them with a ball mill to obtain composite slurry;

[0040] S4. Production of the initial sculpture: Make the composite slurry into a sculpture body, and then dry and bisque-fire the sculpture body to obtain the initial sculpture;

[0041] S5. Production of the finished sculpture: Glaze the initial sculpture, and then glaze-fire it to obtain the finished sculpture.

[0042] Specifically, the step S1 specifically includes the following steps:

[0043] S11. Cleaning and drying: Immerse the loofah fiber in deionized water and ultrasonically clean it for 30 minutes. After removing impurities, place it in an oven at 60 - 80°C and dry it to constant weight;

[0044] Ultrasonic cleaning can remove the wax and impurities on the surface of the loofah fiber, avoiding the generation of bubbles by volatiles during firing;

[0045] S12. Fiber cutting: Use mechanical shearing to cut the loofah fiber into loofah short fibers with a length of 0.5 - 2mm;

[0046] The loofah short fibers can be evenly dispersed in the white porcelain slurry, avoiding stress concentration caused by over-long entanglement of the loofah fibers and loss of toughening effect due to being too short;

[0047] S13. Immerse the cut loofah short fibers in a sodium hydroxide solution with a mass concentration of 5% for 1 hour, then neutralize with dilute hydrochloric acid and wash with water until neutral.

[0048] The cut loofah short fibers hydrolyze hemicellulose on the fiber surface in the sodium hydroxide solution, exposing the cellulose skeleton to increase the specific surface area; neutralizing with dilute hydrochloric acid can eliminate alkaline residues and prevent fluctuations in the pH value of the subsequent slurry.

[0049] S14. Pre-oxidation: Calcinate the loofah short fibers at 300 - 400 °C for 30 minutes in an inert atmosphere to remove organic matter in the loofah short fibers and form a microporous structure to enhance the permeability of the slurry.

[0050] At 300 - 400 °C, the loofah fibers are partially carbonized to form a stable carbon skeleton. Meanwhile, a microporous structure with a pore size of 1 - 5 μm is formed, which can adsorb white porcelain slurry particles and improve the bonding force. It should be noted that the pre-oxidation temperature needs to be strictly lower than 500 °C to avoid complete carbonization of the loofah fibers and loss of the porous structure.

[0051] The loofah fibers are a porous network structure with polar groups such as hydroxyl groups on their surface; after pre-oxidation, micropores are formed on the surface of the loofah fibers, and after alkali washing with sodium hydroxide solution, a rough interface is formed on its surface, thereby enhancing the mechanical anchoring and chemical bonding with the white porcelain slurry.

[0052] Specifically, the step S3 specifically includes the following steps:

[0053] S31. Weigh the pretreated loofah short fibers and white porcelain slurry according to a mass ratio of 1 - 5:95 - 99 respectively.

[0054] The proportion of the loofah short fibers is 1 - 5%, and an excessive amount will cause a decrease in the fluidity of the white porcelain slurry.

[0055] S32. Uniformly disperse the loofah short fibers in deionized water, then add a dispersant and stir at a high speed to form a suspension. The stirring speed is 2000 rpm, the stirring time is 10 minutes, and the dosage of the dispersant is 0.5% of the mass of the loofah short fibers.

[0056] The dispersant is sodium polyacrylate. The dispersant adsorbs on the surface of the loofah short fibers to form an electrostatic repulsion effect to prevent agglomeration.

[0057] S33. Mix the suspension with the white porcelain slurry and grind it in a ball mill for at least 2 hours with a ball-to-material ratio of 2:1 to obtain a composite slurry with uniformly distributed loofah short fibers. The water content of the composite slurry is 28 - 32%.

[0058] In the composite slurry, the loofah short fibers are evenly embedded in the white porcelain slurry, forming a "fiber-ceramic matrix" interpenetrating structure. It should be noted that the moisture content of the composite slurry is controlled at 28 - 32%. If the moisture content is too low, it will be difficult to form the shape, and if it is too high, it will cause drying cracks.

[0059] The specific steps of step S4 are as follows:

[0060] S41. Shaping: The composite slurry is made into a blank by using slip casting or manual sculpture method, and the stability of the complex structure of the blank is enhanced by the supporting effect of the loofah short fibers;

[0061] By using the supporting effect of the loofah short fibers, blanks with hollowed-out and thin-walled structures can be directly shaped; at the same time, the loofah short fiber network provides a "skeleton effect" to prevent the self-collapse of the composite slurry;

[0062] S42. Drying: The blank is slowly dried for 48 hours in an environment with a humidity of 50 - 60% and a temperature of 25 - 30°C to avoid cracking caused by the shrinkage of the loofah short fibers;

[0063] The shrinkage rate of the loofah short fibers is about 2%, which matches the white porcelain slurry to avoid interfacial peeling;

[0064] S43. Bisque firing: The temperature of the kiln is raised to 850°C to bisque-fire the blank, and then it is kept warm for 1 hour to carbonize the loofah short fibers to form a microporous network structure, obtaining a preliminary sculpture;

[0065] Specifically, the bisque firing in step S43 adopts stepwise temperature rise bisque firing, and the specific bisque firing steps are as follows:

[0066] S431. The kiln is heated at a heating rate of 1°C / min to 300°C to remove the residual moisture in the blank;

[0067] S432. The kiln is heated at a heating rate of 2°C / min to 850°C to carbonize the loofah short fibers to form a microporous network.

[0068] Specifically, in step S5, the thickness of the glaze applied to the preliminary sculpture is 50 - 80 um, and the glaze firing temperature is 1280 - 1320°C. It should be noted that the glaze firing temperature is raised to 1280 - 1320°C at a heating rate of 5°C / min. At a temperature of 1280 - 1320°C, the glaze layer melts and covers the micropores, making the surface smoothness of the sculpture finished product the same as that of traditional white porcelain, and the light transmittance ≥ 90%. Example 1

[0069] A preparation process of Dehua white porcelain sculpture reinforced by natural loofah fibers includes the following steps:

[0070] S1. Pretreatment of loofah fiber: Clean and dry the loofah fiber, cut the dried loofah fiber into short fibers of appropriate length, and finally perform surface modification on the short fibers;

[0071] S2. Preparation of white porcelain slurry: Weigh 50 parts by weight of kaolin, 20 parts by weight of quartz, and 12 parts by weight of feldspar. Crush, mix, and wet ball mill the above raw materials to obtain white porcelain slurry; among them, the particle size of the obtained white porcelain slurry is ≤10um;

[0072] S3. Preparation of composite slurry: Weigh the pretreated loofah fiber and white porcelain slurry according to a mass ratio of 2:98, mix the pretreated loofah fiber and white porcelain slurry, and grind them with a ball mill to obtain composite slurry;

[0073] S4. Production of rough sculpture: Make the composite slurry into a sculpture body, and then dry and biscuit-fire the sculpture body to obtain a rough sculpture;

[0074] S5. Production of finished sculpture: Glaze the rough sculpture, and then glaze-fire it to obtain a finished sculpture.

[0075] Specifically, step S1 specifically includes the following steps:

[0076] S11. Cleaning and drying: Immerse the loofah fiber in deionized water and ultrasonically clean it for 30 minutes. After removing impurities, place it in an oven at 60°C and dry it to constant weight;

[0077] Ultrasonic cleaning can remove the wax and impurities on the surface of the loofah fiber, and avoid the generation of bubbles by volatiles during firing;

[0078] S12. Fiber cutting: Use mechanical shearing to cut the loofah fiber into loofah short fibers with a length of 0.5;

[0079] The loofah short fibers can be evenly dispersed in the white porcelain slurry, avoiding stress concentration caused by overlong entanglement of the loofah fibers and loss of toughening effect due to being too short;

[0080] S13. Immerse the cut loofah short fibers in a sodium hydroxide solution with a mass concentration of 5% and treat them for 1 hour, then neutralize with dilute hydrochloric acid and wash with water until neutral;

[0081] The cut loofah short fibers hydrolyze the hemicellulose on the fiber surface in the sodium hydroxide solution, exposing the cellulose skeleton to increase the specific surface area; neutralizing with dilute hydrochloric acid can eliminate alkaline residues and prevent fluctuations in the pH value of the subsequent slurry;

[0082] S14. Pre-oxidation: Calcinate the loofah short fibers at 300°C for 30 minutes in an inert atmosphere to remove the organic matter in the loofah short fibers and form a microporous structure to enhance the permeability of the slurry;

[0083] At 300 °C, the loofah fiber is partially carbonized to form a stable carbon skeleton, and at the same time, a microporous structure with a pore size of 1-5 μm is formed, which can adsorb white porcelain slurry particles and improve the bonding force. It should be noted that the pre-oxidation temperature needs to be strictly lower than 500 °C to avoid complete carbonization of the loofah fiber and loss of the porous structure;

[0084] The loofah fiber has a porous network structure, and its surface contains polar groups such as hydroxyl groups; after pre-oxidation, micropores are formed on the surface of the loofah fiber, and after alkali washing with sodium hydroxide solution, a rough interface is formed on its surface, thereby enhancing the mechanical anchoring and chemical bonding with the white porcelain slurry.

[0085] Specifically, step S3 specifically includes the following steps:

[0086] S31. Weigh the pretreated loofah short fibers and white porcelain slurry according to a mass ratio of 2:98 respectively;

[0087] The proportion of the loofah short fibers is 2%. Excessive amount will cause a decrease in the fluidity of the white porcelain slurry;

[0088] S32. Uniformly disperse the loofah short fibers in deionized water, and then add a dispersant and stir at high speed to form a suspension. The stirring speed is 2000 rpm, the stirring time is 10 minutes, and the dosage of the dispersant is 0.5% of the mass of the loofah short fibers;

[0089] The dispersant is sodium polyacrylate. The dispersant is adsorbed on the surface of the loofah short fibers to form an electrostatic repulsion effect to prevent agglomeration;

[0090] S33. Mix the suspension with the white porcelain slurry and grind it in a ball mill for at least 2 hours. The ball-to-material ratio is 2:1 to obtain a composite slurry with uniformly distributed loofah short fibers. The water content of the composite slurry is 28%;

[0091] In the composite slurry, the loofah short fibers are uniformly embedded in the white porcelain slurry to form a "fiber-ceramic matrix" interpenetrating structure. It should be noted that the water content of the composite slurry is controlled at 28%. Too low water content will cause difficulties in forming, and too high water content will cause drying cracks.

[0092] Step S4 specifically includes the following steps:

[0093] S41. Shaping: Use slip casting or manual sculpture to form the composite slurry into a carcass, and utilize the supporting effect of the loofah short fibers to enhance the stability of the complex structure of the carcass;

[0094] Utilizing the supporting effect of the loofah short fibers, a carcass with a hollowed-out or thin-walled structure can be directly shaped; at the same time, the loofah short fiber network provides a "skeleton effect" to prevent the self-collapse of the composite slurry due to its own weight;

[0095] S42. Drying: Slowly dry the carcass for 48 hours in an environment with a humidity of 50% and a temperature of 25°C to avoid cracking caused by the shrinkage of loofah short fibers;

[0096] The shrinkage rate of the loofah short fibers is about 2%, which matches the white porcelain slurry to avoid interface peeling;

[0097] S43. Bisque firing: Raise the temperature of the kiln to 850°C to bisque-fire the carcass, and then keep it warm for 1 hour to carbonize the loofah short fibers to form a microporous network structure, obtaining a preliminary sculpture;

[0098] Specifically, the bisque firing in step S43 adopts stepped temperature rise bisque firing, and the specific bisque firing steps are as follows:

[0099] S431. The kiln is heated to 300°C at a heating rate of 1°C / min to remove the residual moisture in the carcass;

[0100] S432. The kiln is heated to 850°C at a heating rate of 2°C / min to carbonize the loofah short fibers to form a microporous network.

[0101] Specifically, in step S5, the thickness of the glaze applied to the preliminary sculpture is 60 um, and the glaze firing temperature is 1280°C. It should be noted that the glaze firing temperature is raised to 1280°C at a heating rate of 5°C / min. At a temperature of 1280°C, the glaze layer melts and covers the micropores, making the surface smoothness of the sculpture finished product consistent with that of traditional white porcelain, and the light transmittance ≥ 90%.

[0102] After comparison, the white porcelain sculptures prepared by the present invention and those prepared by the traditional method are as follows:

[0103] Example Two

[0104] A preparation process of Dehua white porcelain sculpture reinforced by natural loofah fiber includes the following steps:

[0105] S1. Pretreatment of loofah fiber: Wash and dry the loofah fiber, cut the dried loofah fiber into short fibers of appropriate length, and finally perform surface modification on the short fibers;

[0106] S2. Preparation of white porcelain slurry: Weigh 55 parts by weight of kaolin, 25 parts by weight of quartz, and 15 parts by weight of feldspar, and respectively crush, mix, and wet ball mill the above raw materials to obtain white porcelain slurry; among them, the particle size of the obtained white porcelain slurry ≤ 10 um;

[0107] S3. Preparation of composite slurry: Weigh the pretreated loofah fiber and white porcelain slurry according to a mass ratio of 3:97, mix the pretreated loofah fiber and white porcelain slurry, and grind them with a ball mill to obtain a composite slurry;

[0108] S4. Sculpture rough product production: Make a sculpture matrix from the composite slurry, and then dry and bisque-fire the sculpture matrix to obtain a sculpture rough product;

[0109] S5. Sculpture finished product production: Glaze the sculpture rough product, and then glaze-fire it to obtain a sculpture finished product.

[0110] Specifically, the step S1 specifically includes the following steps:

[0111] S11. Cleaning and drying: Immerse the loofah fiber in deionized water and ultrasonically clean it for 30 minutes. After removing impurities, place it in an oven at 70°C and dry it to constant weight;

[0112] Ultrasonic cleaning can remove the wax and impurities on the surface of the loofah fiber, avoiding the generation of bubbles by volatiles during firing;

[0113] S12. Fiber cutting: Cut the loofah fiber into loofah short fibers with a length of 1 mm by mechanical shearing method;

[0114] The loofah short fibers can be evenly dispersed in the white porcelain slurry, avoiding stress concentration caused by over-long entanglement of the loofah fibers and loss of toughening effect due to over-short fibers;

[0115] S13. Immerse the cut loofah short fibers in a sodium hydroxide solution with a mass concentration of 5% and treat them for 1 hour, then neutralize them with dilute hydrochloric acid and wash them to neutral;

[0116] The cut loofah short fibers hydrolyze the hemicellulose on the fiber surface in the sodium hydroxide solution, exposing the cellulose skeleton to increase the specific surface area; neutralizing with dilute hydrochloric acid can eliminate alkaline residues and prevent fluctuations in the pH value of the subsequent slurry;

[0117] S14. Pre-oxidation: Calcinate the loofah short fibers at 350°C for 30 minutes in an inert atmosphere to remove the organic matter in the loofah short fibers and form a microporous structure to enhance the slurry permeability;

[0118] At 350°C, the loofah fiber is partially carbonized to form a stable carbon skeleton. At the same time, a microporous structure with a pore size of 1-5 μm can adsorb white porcelain slurry particles, improving the bonding force. It should be noted that the pre-oxidation temperature needs to be strictly lower than 500°C to avoid complete carbonization of the loofah fiber and loss of the porous structure;

[0119] The loofah fiber is a porous network structure with polar groups such as hydroxyl groups on its surface; after pre-oxidation, micropores are formed on the surface of the loofah fiber, and after alkali washing with sodium hydroxide solution, a rough interface is formed on its surface, thereby enhancing the mechanical anchoring and chemical bonding with the white porcelain slurry.

[0120] Specifically, the step S3 specifically includes the following steps:

[0121] S31. Weigh the pretreated loofah short fibers and white porcelain slurry at a mass ratio of 3:97 respectively;

[0122] The proportion of the loofah short fibers is 3%. Excessive amount will cause the fluidity of the white porcelain slurry to decrease;

[0123] S32. Uniformly disperse the loofah short fibers in deionized water, and then add a dispersant and stir at high speed to form a suspension. The stirring speed is 2000 rpm, the stirring time is 10 minutes, and the dosage of the dispersant is 0.5% of the mass of the loofah short fibers;

[0124] The dispersant is sodium polyacrylate. The dispersant is adsorbed on the surface of the loofah short fibers to form an electrostatic repulsion effect to prevent agglomeration;

[0125] S33. Mix the suspension with the white porcelain slurry and grind it in a ball mill for at least 2 hours with a ball-to-material ratio of 2:1 to obtain a composite slurry with uniformly distributed loofah short fibers. The water content of the composite slurry is 30%;

[0126] In the composite slurry, the loofah short fibers are uniformly embedded in the white porcelain slurry to form a "fiber-ceramic matrix" interpenetrating structure. It should be noted that the water content of the composite slurry is controlled at 28 - 32%. Too low water content will cause difficulty in forming, and too high water content will cause drying cracks.

[0127] The specific steps of step S4 are as follows:

[0128] S41. Shaping: Use slip casting or manual sculpture method to make the composite slurry into a carcass, and utilize the supporting effect of the loofah short fibers to enhance the stability of the complex structure of the carcass;

[0129] Utilizing the supporting effect of the loofah short fibers, the carcass with hollowed-out and thin-walled structures can be directly shaped; at the same time, the loofah short fiber network provides a "skeleton effect" to prevent the self-collapse of the composite slurry;

[0130] S42. Drying: Slowly dry the carcass in an environment with a humidity of 5% and a temperature of 28°C for 48 hours to avoid cracking caused by the shrinkage of the loofah short fibers;

[0131] The shrinkage rate of the loofah short fibers is about 2%, which matches the white porcelain slurry to avoid interfacial peeling;

[0132] S43. Bisque firing: Raise the temperature of the kiln to 850°C to bisque fire the carcass, and then keep it warm for 1 hour to carbonize the loofah short fibers to form a microporous network structure to obtain a preliminary sculpture;

[0133] Specifically, the bisque firing in step S43 adopts stepwise temperature rise bisque firing. The specific bisque firing steps are as follows:

[0134] S431. The kiln is heated at a rate of 1 °C / min to 300 °C to remove the residual moisture in the matrix.

[0135] S432. The kiln is heated at a rate of 2 °C / min to 850 °C to carbonize the loofah short fibers and form a microporous network.

[0136] Specifically, in the step S5, the thickness of the glaze applied to the initial sculpture is 60 μm, and the temperature of the glaze firing is 1300 °C. It should be noted that the temperature of the glaze firing is increased to 1300 °C at a rate of 5 °C / min. At a temperature of 1300 °C, the glaze layer melts and covers the micropores, making the surface smoothness of the finished sculpture consistent with that of traditional white porcelain, and the light transmittance ≥ 90%.

[0137] After comparison, the white porcelain sculptures prepared by the present invention and those prepared by the traditional method are as follows:

[0138]

[0139] Example 3

[0140] A preparation process of Dehua white porcelain sculpture reinforced by natural loofah fiber includes the following steps:

[0141] S1. Pretreatment of loofah fiber: The loofah fiber is cleaned and dried, the dried loofah fiber is cut into short fibers of suitable length, and finally the short fibers are surface-modified.

[0142] S2. Preparation of white porcelain slurry: Weigh 60 parts by weight of kaolin, 30 parts by weight of quartz, and 20 parts by weight of feldspar. The above raw materials are respectively crushed, mixed, and wet ball-milled to prepare white porcelain slurry; among them, the particle size of the prepared white porcelain slurry ≤ 10 μm.

[0143] S3. Preparation of composite slurry: Weigh the pretreated loofah fiber and white porcelain slurry according to a mass ratio of 4:96. After mixing the pretreated loofah fiber and white porcelain slurry, they are ground by a ball mill to obtain composite slurry.

[0144] S4. Fabrication of initial sculpture: The composite slurry is made into a sculpture matrix, and then the sculpture matrix is dried and bisque-fired to obtain an initial sculpture.

[0145] S5. Fabrication of finished sculpture: The initial sculpture is glazed, and after glazing, it is glaze-fired to obtain a finished sculpture.

[0146] Specifically, the step S1 specifically includes the following steps:

[0147] S11. Cleaning and drying: The loofah fiber is soaked in deionized water and ultrasonically cleaned for 30 minutes. After removing impurities, it is placed in an 80 °C oven and dried to constant weight.

[0148] Ultrasonic cleaning can remove the wax and impurities on the surface of loofah fiber, avoiding the generation of bubbles by volatiles during firing;

[0149] S12. Fiber cutting: Cut the loofah fiber into loofah short fibers with a length of 2 mm by mechanical shearing method;

[0150] The loofah short fibers can be evenly dispersed in the white porcelain slurry, avoiding stress concentration caused by overlong entanglement of loofah fibers and losing the toughening effect due to being too short;

[0151] S13. Immerse the cut loofah short fibers in a sodium hydroxide solution with a mass concentration of 5% for 1 hour, then neutralize with dilute hydrochloric acid and wash with water until neutral;

[0152] The cut loofah short fibers hydrolyze the hemicellulose on the fiber surface in the sodium hydroxide solution, exposing the cellulose skeleton to increase the specific surface area; neutralizing with dilute hydrochloric acid can eliminate alkaline residues and prevent fluctuations in the pH value of the subsequent slurry;

[0153] S14. Pre-oxidation: Calcinate the loofah short fibers at 400 °C for 30 minutes in an inert atmosphere to remove the organic matter in the loofah short fibers and form a microporous structure to enhance the slurry permeability;

[0154] At 400 °C, the loofah fiber is partially carbonized to form a stable carbon skeleton. At the same time, a microporous structure with a pore size of 1 - 5 μm can adsorb white porcelain slurry particles to enhance the bonding force. It should be noted that the pre-oxidation temperature needs to be strictly lower than 500 °C to avoid complete carbonization of the loofah fiber and loss of the porous structure;

[0155] The loofah fiber is a porous network structure, and its surface contains polar groups such as hydroxyl groups; after pre-oxidation, micropores are formed on the surface of the loofah fiber, and after alkali washing with sodium hydroxide solution, a rough interface is formed on its surface, thereby enhancing the mechanical anchoring and chemical bonding with the white porcelain slurry.

[0156] Specifically, the step S3 specifically includes the following steps:

[0157] S31. Weigh the pretreated loofah short fibers and white porcelain slurry according to a mass ratio of 4:96 respectively;

[0158] The proportion of the loofah short fibers is 4%. Excess will cause a decrease in the fluidity of the white porcelain slurry;

[0159] S32. Uniformly disperse the loofah short fibers in deionized water, then add a dispersant and stir at a high speed to form a suspension, where the stirring speed is 2000 rpm and the stirring time is 10 minutes, and the dosage of the dispersant is 0.5% of the mass of the loofah short fibers;

[0160] The dispersant is sodium polyacrylate, and the dispersant is adsorbed on the surface of the loofah fiber to form an electrostatic repulsion effect to prevent agglomeration;

[0161] S33. Mix the suspension with the white porcelain slurry and grind it in a ball mill for at least 2 hours with a ball-to-material ratio of 2:1 to obtain a composite slurry with uniformly distributed loofah short fibers. The water content of the composite slurry is 31%;

[0162] In the composite slurry, the loofah short fibers are uniformly embedded in the white porcelain slurry to form a "fiber-ceramic matrix" interpenetrating structure. It should be noted that the water content of the composite slurry is controlled at 31%. If the water content is too low, it will be difficult to form, and if the water content is too high, it will cause drying cracks.

[0163] The specific steps of step S4 are as follows:

[0164] S41. Shaping: Use slip casting or manual sculpture to make the composite slurry into a carcass, and utilize the supporting effect of the loofah short fibers to enhance the stability of the complex structure of the carcass;

[0165] Utilizing the supporting effect of the loofah short fibers, a carcass with a hollow or thin-walled structure can be directly shaped. At the same time, the loofah short fiber network provides a "skeleton effect" to prevent the self-collapse of the composite slurry due to its own weight;

[0166] S42. Drying: Slowly dry the carcass in an environment with a humidity of 60% and a temperature of 30°C for 48 hours to avoid cracking caused by the shrinkage of the loofah short fibers;

[0167] The shrinkage rate of the loofah short fibers is about 2%, which matches the white porcelain slurry to avoid interfacial peeling;

[0168] S43. Bisque firing: Raise the temperature of the kiln to 850°C to bisque-fire the carcass, and then keep it warm for 1 hour to carbonize the loofah short fibers to form a microporous network structure to obtain a preliminary sculpture;

[0169] Specifically, the bisque firing in step S43 adopts stepwise temperature-raising bisque firing, and the specific bisque firing steps are as follows:

[0170] S431. The kiln is heated to 300°C at a heating rate of 1°C / min to remove the residual moisture in the carcass;

[0171] S432. The kiln is heated to 850°C at a heating rate of 2°C / min to carbonize the loofah short fibers to form a microporous network.

[0172] Specifically, in step S5, the thickness of the glaze applied to the initial sculpture is 70 um, and the temperature of the glaze firing is 1320 °C. It should be noted that the temperature of the glaze firing is raised to 1320 °C at a heating rate of 5 °C / min. At a temperature of 1320 °C, the glaze layer melts and covers the micropores, making the surface smoothness of the finished sculpture consistent with that of traditional white porcelain, and the light transmittance ≥ 90%.

[0173] After comparison, the white porcelain sculptures prepared by the present invention and those prepared by the traditional method are as follows:

[0174]

[0175] The above is only the specific implementation manner of the present invention, but the design concept of the present invention is not limited thereto. Any non-substantive modification of the present invention using this concept shall fall within the scope of infringement of the protection scope of the present invention.

Claims

1. A preparation process of Dehua white porcelain sculpture reinforced by natural loofah fiber, characterized in that: It includes the following steps: S1. Pretreatment of loofah fiber: Clean and dry the loofah fiber, cut the dried loofah fiber into short fibers of suitable length, and finally perform surface modification on the short fibers; S2. Preparation of white porcelain slurry: Weigh 50 - 60 parts by weight of kaolin, 20 - 30 parts by weight of quartz, and 10 - 20 parts by weight of feldspar. Crush, mix, and wet ball mill kaolin, quartz, and feldspar respectively to obtain white porcelain slurry; S3. Preparation of composite slurry: Weigh the pretreated loofah fiber and white porcelain slurry according to a mass ratio of 1 - 5:95 - 99. Mix the pretreated loofah fiber and white porcelain slurry and grind them with a ball mill to obtain composite slurry; S4. Making of the initial sculpture: Make the composite slurry into a sculpture body, and then dry and bisque-fire the sculpture body to obtain the initial sculpture; S5. Making of the finished sculpture: Glaze the initial sculpture, and then glaze-fire it to obtain the finished sculpture; The specific steps of step S1 include the following steps: S11. Cleaning and drying: Immerse the loofah fiber in deionized water and ultrasonically clean it for 30 minutes. After removing impurities, place it in an oven at 60 - 80 °C and dry it to constant weight; S12. Fiber cutting: Cut the loofah fiber into loofah short fibers with a length of 0.5 - 2 mm by mechanical shearing method; S13. Immerse the cut loofah short fibers in a sodium hydroxide solution with a mass concentration of 5% and treat for 1 hour, then neutralize with dilute hydrochloric acid and wash to neutral; S14. Pre-oxidation: Calcinate the loofah short fibers at 300 - 400 °C for 30 minutes in an inert atmosphere to remove the organic matter in the loofah short fibers and form a microporous structure to enhance the permeability of the slurry; The bisque-fire adopts stepwise temperature rise bisque-fire, and the specific bisque-fire steps are as follows: S431. The kiln is heated to 300 °C at a heating rate of 1 °C / min to remove the residual moisture in the body; S432. The kiln is heated to 850 °C at a heating rate of 2 °C / min to carbonize the loofah short fibers to form a microporous network; In step S5, the thickness of glazing the initial sculpture is 50 - 80 μm, and the temperature of glaze-fire is 1280 - 1320 °C.

2. The preparation process of Dehua white porcelain sculpture reinforced by natural loofah fiber as described in claim 1, wherein: In step S14, the pore diameter of the microporous structure is 1 - 5 μm.

3. The preparation process of a Dehua white porcelain sculpture reinforced by natural loofah fiber as claimed in claim 1, characterized in that: In step S2, the particle size of the obtained white porcelain slurry is ≤10 μm.

4. The preparation process of a Dehua white porcelain sculpture reinforced by natural loofah fiber as described in claim 1, characterized in that: The specific steps of step S3 include the following steps: S31. Weigh the pretreated loofah short fibers and white porcelain slurry according to a mass ratio of 1 - 5:95 - 99; S32. Uniformly disperse the loofah short fibers in deionized water, then add a dispersant and stir at high speed to form a suspension. The dosage of the dispersant is 0.5% of the mass of the loofah short fibers; S33. Mix the suspension with the white porcelain slurry, grind it with a ball mill for at least 2 hours, and the ball-to-material ratio is 2:1 to obtain a composite slurry with uniformly distributed loofah short fibers. The water content of the composite slurry is 28 - 32%.

5. The preparation process of Dehua white porcelain sculpture reinforced by natural loofah fiber as claimed in claim 1, wherein: The specific steps of step S4 include the following steps: S41. Shaping: Make the composite slurry into a body by slip casting or manual sculpture method, and utilize the supporting effect of the loofah short fibers to enhance the stability of the complex structure of the body; S42. Drying: Slowly dry the carcass for 48 hours in an environment with a humidity of 50 - 60% and a temperature of 25 - 30°C to avoid cracking caused by the shrinkage of loofah short fibers; S43. Bisque firing: Raise the temperature of the kiln to 850°C to bisque-fire the carcass, and then keep it warm for 1 hour to carbonize the loofah short fibers to form a microporous network structure, obtaining a preliminary sculpture.

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