Light Dehua white porcelain sculpture based on foam particle reinforcement and preparation process thereof

Abstract

The invention discloses a foam particle reinforcement-based lightweight Dehua white porcelain sculpture and a preparation process thereof, and relates to the field of ceramics, the foam particle reinforcement-based lightweight Dehua white porcelain sculpture comprises white porcelain slurry and thermoplastic foam particles with closed pore structures, the matrix raw materials comprise the following raw materials in parts by weight: 60-70 parts of Dehua kaolin, 20-25 parts of quartz and 10-15 parts of feldspar, the water content of the white porcelain slurry is 25-30%, the volume ratio of the thermoplastic foam particles to the white porcelain slurry is 1: (0.2-0.5), and the thermoplastic foam particles are polystyrene or polyurethane particles. The oriented microporous structure is formed by the thermoplastic foam particles, so that the density of the white porcelain sculpture finished product is reduced to 1.2-1.8 g / cm < 3 >, the weight is reduced by 30-50% compared with the traditional white porcelain sculpture finished product, and the weight and the transportation and installation cost of the white porcelain sculpture finished product are greatly reduced.

Description

Technical Field

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

[0002] At present, the traditional Dehua white porcelain sculptures have the following problems: 1. Heavy weight: The traditional body density is high (usually ≥2.2g / cm³), which makes the finished large sculptures heavy, and the transportation and installation costs are high, and there are safety hazards; 2. Easy to crack: During the firing process, the shrinkage rate of Dehua kaolin is large (linear shrinkage rate is about 12-15%), and the body stress distribution is uneven, which is easy to crack or deform; 3. High energy consumption and cost: The raw material consumption is large, and the high-temperature firing (1250-1300℃) takes a long time, and the energy efficiency is low; 4. The contradiction between lightweight and performance: The existing lightweight technology (such as the foaming agent method) has a significant decrease in mechanical strength (flexural strength is usually <15MPa) due to the uncontrollable pore distribution, which cannot meet the structural stability requirements of the sculpture. Based on this, the applicant has conducted intensive research and thus came up with this case. Summary of the invention

[0003] The invention provides a lightweight Dehua white porcelain sculpture based on foam particle reinforcement and a preparation process thereof, the main purpose of which is to overcome the above-mentioned problems existing in the existing white porcelain sculptures.

[0004] In order to solve the above technical problems, the present invention adopts the following technical solutions: A lightweight Dehua white porcelain sculpture based on foam particle reinforcement comprises white porcelain mud and thermoplastic foam particles with a closed-cell structure. The white porcelain mud is formed by wet grinding of a matrix raw material and water. The matrix raw material comprises the following raw materials in parts by weight: 60-70 parts of Dehua kaolin, 20-25 parts of quartz and 10-15 parts of feldspar. The water content of the white porcelain mud is 25-30%. The volume ratio of the thermoplastic foam particles to the white porcelain mud is 1:0.2-0.5. The thermoplastic foam particles are polystyrene or polyurethane particles.

[0005] Furthermore, the present invention further comprises 0.5-1 parts by weight of a dispersant.

[0006] Furthermore, a lightweight Dehua white porcelain sculpture based on foam particle reinforcement includes white porcelain mud and thermoplastic foam particles. The white porcelain mud is mixed with body raw materials and water. The body raw materials include the following raw materials in parts by weight: 65 parts of Dehua kaolin, 23 parts of quartz and 12 parts of feldspar. The water content of the white porcelain mud is 27%. The volume ratio of the thermoplastic foam particles to the white porcelain mud is 1:0.3, and the weight ratio of the dispersant is 0.7 parts.

[0007] Furthermore, the thermoplastic foam particles are thermoplastic resin particles with a closed-cell structure, and the particle size of the thermoplastic foam particles is 0.5-3 mm and the density is 0.02-0.1 g / cm³.

[0008] A method for preparing a lightweight Dehua white porcelain sculpture based on foam particle reinforcement comprises the following steps: S1, wet-grinding 60-70 parts of Dehua kaolin, 20-25 parts of quartz, 10-15 parts of feldspar and water to obtain white porcelain slurry, wherein the water content of the white porcelain slurry is 25-30%; S2, selecting thermoplastic foam particles with a closed-cell structure, and activating the surfaces of the thermoplastic foam particles; S3, mixing the thermoplastic foam particles and the white porcelain slurry at a volume ratio of 1:0.2-0.5, adding 0.5-1 parts by weight of a dispersant, and then stirring the thermoplastic foam particles and the white porcelain slurry at a low speed until uniform; S4, injecting the evenly mixed thermoplastic foam particles and white porcelain mud into the sculpture mold, and then placing the sculpture mold on a vibration table for vertical vibration compaction for 5-10 minutes to expel bubbles, and standing for 2-4 hours after the vibration is completed to demold and obtain a carcass; S5, performing gradient dehydration and drying on the carcass, so that the moisture content of the carcass is ≤2%; S6, step-firing the dried body in a kiln to obtain a bisque-fired body; S7, carving the bisque-fired body; S8. The surface of the unglazed body after carving is glazed. After the surface glazing is completed, the body is sent into the kiln for secondary firing.

[0009] Furthermore, in the step S1, after obtaining the white porcelain slurry, the white porcelain slurry is sieved through a 200-mesh sieve to remove impurities, and then left to stand for aging for 24 hours.

[0010] Furthermore, in step S2, the thermoplastic foam particles are immersed in 1-3 parts by weight of a silane coupling agent solution, the temperature of the silane coupling agent solution is maintained at 60° C. and stirred for 30 minutes, and the surfaces of the thermoplastic foam particles are dried to form a chemically bonded active surface.

[0011] Furthermore, in step S3, the thermoplastic foam particles and the white porcelain slurry are stirred at a low speed with a stirring speed of 100-200 rpm and a stirring time of 10-15 minutes, so that the thermoplastic foam particles and the white porcelain slurry form a uniform suspension slurry; and the dispersant is hydroxymethyl cellulose.

[0012] Furthermore, in step S5, the step of performing gradient dehydration and drying on the carcass is as follows: S51, place the carcass in a low-humidity drying kiln at a temperature of 40°C for pre-drying for 24-36 hours, so that the carcass is slowly dehydrated to a moisture content of 15%; S52, placing the pre-dried carcass in a final drying kiln with a maximum temperature of 80°C and forced ventilation for final drying for 24 hours, so that the moisture content of the carcass is ≤2%, wherein the temperature in the final drying kiln is gradually increased, and the heating rate is ≤5°C / h.

[0013] Furthermore, in step S6, the step of stepwise firing the dried carcass is as follows: S61, low temperature stage: raise the temperature in the kiln from room temperature to 300℃, and the kiln firing time is 8h; S62, decomposition stage: at a heating rate of ≤2°C / min, the temperature in the kiln is raised from 300°C to 600°C, the kiln firing time is 5h, and finally the kiln is kept at 600°C for 30-60 minutes; S63, high temperature sintering stage: the temperature in the kiln rises from 800℃ to 1100℃, and the kiln firing time is 9h; then the temperature in the kiln rises from 1100℃ to 1330℃, a reducing atmosphere is used in the kiln, the CO concentration in the kiln is 3-5%, and the kiln firing time is 7-8h; finally, the temperature in the kiln is maintained at 1330℃, and the kiln firing time is 1h.

[0014] It can be seen from the above description of the present invention that, compared with the prior art, the present invention has the following advantages: 1. The present invention forms a directional microporous structure through thermoplastic foam particles, so that the density of the finished white porcelain sculpture is reduced to 1.2-1.8g / cm³, and the weight is reduced by 30-50% compared with the traditional one, which greatly reduces the weight of the finished white porcelain sculpture as well as the transportation and installation costs.

[0015] 2. The surface activation treatment of the thermoplastic foam particles and the vibration compaction process of the thermoplastic foam particles and the white porcelain slurry in the mold make the flexural strength of the finished white porcelain sculpture ≥25Mpa, which is more than 50% better than that of traditional foamed ceramics, and the closed cell rate is ≥70%, which effectively inhibits crack propagation. The cracking rate of the finished white porcelain sculpture is reduced to less than 3%, so that the mechanical properties of the white porcelain sculpture products are further optimized.

[0016] 3. The present invention uses thermoplastic foam particles to replace the body raw materials, and compared with the traditional white porcelain sculpture products, the amount of white porcelain mud is reduced by 20-30%.

[0017] 4. The present invention shortens the tire body molding time by 15% and improves the mold filling efficiency through the vibration compaction process; the segmented drying process compresses the total tire body drying cycle from 20 days to 15 days, and the production efficiency is improved by 40%.

[0018] 5. The present invention retains the whiteness ≥ 90% and light transmittance of Dehua white porcelain, supports traditional techniques such as hand carving and glaze decoration, and the artistic expression is consistent with traditional craftsmanship. DETAILED DESCRIPTION

[0019] A lightweight Dehua white porcelain sculpture based on foam particle reinforcement comprises white porcelain mud and thermoplastic foam particles with a closed-cell structure. The white porcelain mud is formed by wet grinding of body raw materials and water. The body raw materials comprise the following raw materials in parts by weight: 60-70 parts of Dehua kaolin, 20-25 parts of quartz and 10-15 parts of feldspar. The water content of the white porcelain mud is 25-30%. The volume ratio of the thermoplastic foam particles to the white porcelain mud is 1:0.2-0.5.

[0020] The present invention further comprises 0.5-1 parts by weight of a dispersant, wherein the dispersant is hydroxymethyl cellulose.

[0021] The thermoplastic foam particles are thermoplastic resin particles with a closed-cell structure, and the particle size of the thermoplastic foam particles is 0.5-3 mm and the density is 0.02-0.1 g / cm³. Specifically, the thermoplastic foam particles are polystyrene or polyurethane particles.

[0022] A method for preparing a lightweight Dehua white porcelain sculpture based on foam particle reinforcement comprises the following steps: S1. Wet-grind 60-70 parts of Dehua kaolin, 20-25 parts of quartz, 10-15 parts of feldspar and water to obtain white porcelain mud, wherein the water content of the white porcelain mud is 25-30%; after obtaining the white porcelain mud, pass the white porcelain mud through a 200-mesh sieve to remove impurities, and then let it stand for 24 hours to enhance plasticity.

[0023] S2. Select thermoplastic foam particles with a closed-cell structure and activate the surface of the thermoplastic foam particles. Specifically, immerse the thermoplastic foam particles in 1-3 parts by weight of a silane coupling agent solution, wherein the silane coupling agent is KH-550 silane coupling agent. The temperature of the silane coupling agent solution is maintained at 60° C. and stirred for 30 minutes. After the surface of the thermoplastic foam particles is dried, a chemically bonded active surface is formed. The silane coupling agent forms -Si-O- bonds on the surface of the thermoplastic foam particles, combines with hydroxyl groups in the white porcelain slurry, and enhances the bonding strength between the ceramic matrix and the particles.

[0024] S3. Thermoplastic foam particles and white porcelain mud are mixed at a volume ratio of 1:0.2-0.5, and 0.5-1 parts by weight of a dispersant is added, and then the thermoplastic foam particles and the white porcelain mud are stirred evenly at a low speed; specifically, the stirring speed of the thermoplastic foam particles and the white porcelain mud is 100-200 rpm and the stirring time is 10-15 minutes when the thermoplastic foam particles and the white porcelain mud are stirred at a low speed to avoid the thermoplastic foam particles from breaking, so that the thermoplastic foam particles and the white porcelain mud form a uniform suspension slurry; the dispersant is hydroxymethyl cellulose, and the dispersant can ensure that the thermoplastic foam particles are evenly distributed in the white porcelain mud, and the dispersant can reduce the viscosity of the white porcelain mud and improve the mold filling rate.

[0025] S4. Inject the evenly mixed thermoplastic foam particles and white porcelain mud into a sculpture mold, and then place the sculpture mold on a vibration table for vertical vibration compaction at a vibration frequency of 20-40 Hz and an amplitude of 1-2 mm for 5-10 minutes to expel bubbles and increase the packing density. After the vibration is completed, let it stand for 2-4 hours to demold and obtain a carcass; wherein, the thermoplastic foam particles and the white porcelain mud can optimize the arrangement of the thermoplastic foam particles through vibration compaction, so that the thermoplastic foam particles are evenly dispersed in the white porcelain mud to form a composite structure of "ceramic matrix wrapped in thermoplastic foam particles". At the same time, the interface of the thermoplastic foam particles and the white porcelain mud is closely contacted through vibration compaction, the porosity is reduced, and the collapse of the carcass structure after firing is prevented.

[0026] S5, performing gradient dehydration and drying on the carcass, so that the moisture content of the carcass is ≤2%; the steps of performing gradient dehydration and drying on the carcass are as follows: S51. Pre-dry the carcass in a low-humidity drying kiln at 40°C for 24-36 hours to slowly dehydrate the carcass to a moisture content of 15% to prevent the carcass surface from hardening too quickly and causing internal cracks. S52, placing the pre-dried carcass in a final drying kiln with a maximum temperature of 80°C and forced ventilation for final drying for 24 hours, so that the moisture content of the carcass is ≤2%, wherein the temperature in the final drying kiln is gradually increased, and the heating rate is ≤5°C / h; The use of gradient dehydration can achieve segmented temperature and humidity control, reduce tire shrinkage stress, avoid volume shrinkage differences caused by rapid evaporation of tire water, and maintain the stability of the tire microstructure.

[0027] S6, step-firing the dried carcass in a kiln to obtain a bisque-fired carcass; the steps of step-firing the dried carcass are as follows: S61, low temperature stage: raise the temperature in the kiln from room temperature to 300℃, and the kiln firing time is 8h; S62, decomposition stage: at a heating rate of ≤2°C / min, the temperature in the kiln is raised from 300°C to 600°C, the kiln firing time is 5h, and finally the kiln is kept at 600°C for 30-60 minutes; S63, high temperature sintering stage: the temperature in the kiln rises from 800℃ to 1100℃, and the kiln firing time is 9h; then the temperature in the kiln rises from 1100℃ to 1330℃, a reducing atmosphere is used in the kiln, the CO concentration in the kiln is 3-5%, and the kiln firing time is 7-8h; finally, the temperature in the kiln is maintained at 1330℃, and the kiln firing time is 1h; The steps S61 and S62 can slowly decompose the thermoplastic foam particles to form closed cells with a diameter of 0.3-1 mm. After the thermoplastic foam particles are decomposed, closed cells are left, and the cell walls are wrapped by a ceramic matrix to form a "honeycomb-ceramic" composite structure. After the thermoplastic foam particles treated with a silane coupling agent are decomposed, the residual SiO2 forms a chemical bond with the ceramic matrix to enhance the strength of the cell walls; at the same time, the low-temperature decomposition section slowly decomposes the thermoplastic foam particles to avoid sudden release of gas leading to rupture of the matrix. The closed-cell structure after the decomposition of the thermoplastic foam particles can inhibit the crack propagation path of the matrix.

[0028] S7, carving the bisque-fired body; S8. The surface of the unglazed body after carving is glazed. After the surface glazing is completed, the body is sent into the kiln for secondary firing. The temperature in the kiln during the secondary firing is 1100°C. Embodiment 1

[0029] A lightweight Dehua white porcelain sculpture based on foam particle reinforcement comprises white porcelain mud and thermoplastic foam particles with a closed-cell structure. The white porcelain mud is made by wet grinding a carcass raw material and water. The carcass raw material comprises the following raw materials in parts by weight: 60 parts of Dehua kaolin, 20 parts of quartz and 15 parts of feldspar. The water content of the white porcelain mud is 26%. The volume ratio of the thermoplastic foam particles to the white porcelain mud is 1:0.2.

[0030] The present invention further comprises 0.5 parts by weight of a dispersant, wherein the dispersant is hydroxymethyl cellulose.

[0031] The thermoplastic foam particles are thermoplastic resin particles with a closed-cell structure, and the particle size of the thermoplastic foam particles is 0.8 mm and the density is 0.04 g / cm³. Specifically, the thermoplastic foam particles are polyurethane particles.

[0032] A method for preparing a lightweight Dehua white porcelain sculpture based on foam particle reinforcement comprises the following steps: S1. Wet-grind 60 parts of Dehua kaolin, 20 parts of quartz, 15 parts of feldspar and water to obtain white porcelain mud, wherein the water content of the white porcelain mud is 25%; after obtaining the white porcelain mud, pass the white porcelain mud through a 200-mesh sieve to remove impurities, and then let it stand for 24 hours to enhance plasticity.

[0033] S2. Select thermoplastic foam particles with a closed-cell structure and activate the surface of the thermoplastic foam particles. Specifically, immerse the thermoplastic foam particles in 1 part by weight of a silane coupling agent solution, wherein the silane coupling agent is KH-550 silane coupling agent. Keep the temperature of the silane coupling agent solution at 60°C and stir for 30 minutes. After the surface of the thermoplastic foam particles is dried, a chemically bonded active surface is formed. The silane coupling agent forms -Si-O- bonds on the surface of the thermoplastic foam particles, combines with hydroxyl groups in the white porcelain slurry, and enhances the bonding strength between the ceramic matrix and the particles.

[0034] S3. The thermoplastic foam particles and the white porcelain mud are mixed in a volume ratio of 1:0.2, and 0.5 parts by weight of a dispersant is added at the same time, and then the thermoplastic foam particles and the white porcelain mud are stirred evenly at a low speed; specifically, the stirring speed of the thermoplastic foam particles and the white porcelain mud is 120 rpm and the stirring time is 11 minutes when the thermoplastic foam particles and the white porcelain mud are stirred at a low speed to avoid the thermoplastic foam particles from breaking, so that the thermoplastic foam particles and the white porcelain mud form a uniform suspended slurry; the dispersant is hydroxymethyl cellulose, and the dispersant can ensure that the thermoplastic foam particles are evenly distributed in the white porcelain mud, and the dispersant can reduce the viscosity of the white porcelain mud and improve the mold filling rate.

[0035] S4. Inject the evenly mixed thermoplastic foam particles and white porcelain mud into a sculpture mold, and then place the sculpture mold on a vibration table for vertical vibration compaction at a vibration frequency of 25 Hz and an amplitude of 1 mm for 6 minutes to expel bubbles and increase the packing density. After the vibration is completed, let it stand for 2.5 hours to demold and obtain a carcass; wherein, the thermoplastic foam particles and the white porcelain mud can optimize the arrangement of the thermoplastic foam particles through vibration compaction, so that the thermoplastic foam particles are evenly dispersed in the white porcelain mud to form a composite structure of "ceramic matrix wrapping thermoplastic foam particles". At the same time, the interface of the thermoplastic foam particles and the white porcelain mud is closely contacted through vibration compaction, the porosity is reduced, and the collapse of the carcass structure after firing is prevented.

[0036] S5, performing gradient dehydration and drying on the carcass, so that the moisture content of the carcass is ≤2%; the steps of performing gradient dehydration and drying on the carcass are as follows: S51. Place the carcass in a low-humidity drying kiln at a temperature of 40°C for pre-drying for 26 hours, so that the carcass is slowly dehydrated to a moisture content of 15% to prevent the carcass surface from hardening too quickly and causing internal cracks; S52, placing the pre-dried carcass in a final drying kiln with a maximum temperature of 80°C and forced ventilation for final drying for 24 hours, so that the moisture content of the carcass is ≤2%, wherein the temperature in the final drying kiln is gradually increased, and the heating rate is ≤5°C / h; The use of gradient dehydration can achieve segmented temperature and humidity control, reduce tire shrinkage stress, avoid volume shrinkage differences caused by rapid evaporation of tire water, and maintain the stability of the tire microstructure.

[0037] S6, step-firing the dried carcass in a kiln to obtain a bisque-fired carcass; the steps of step-firing the dried carcass are as follows: S61, low temperature stage: raise the temperature in the kiln from room temperature to 300℃, and the kiln firing time is 8h; S62, decomposition stage: at a heating rate of ≤2°C / min, the temperature in the kiln is raised from 300°C to 600°C, the kiln firing time is 5h, and finally the kiln is kept at 600°C for 35 minutes; S63, high temperature sintering stage: the temperature in the kiln rises from 800℃ to 1100℃, and the kiln firing time is 9h; then the temperature in the kiln rises from 1100℃ to 1330℃, a reducing atmosphere is used in the kiln, the CO concentration in the kiln is 3%, and the kiln firing time is 7h; finally, the temperature in the kiln is maintained at 1330℃, and the kiln firing time is 1h; The steps S61 and S62 can slowly decompose the thermoplastic foam particles to form closed cells with a diameter of 0.3-1 mm. After the thermoplastic foam particles are decomposed, closed cells are left, and the cell walls are wrapped by a ceramic matrix to form a "honeycomb-ceramic" composite structure. After the thermoplastic foam particles treated with a silane coupling agent are decomposed, the residual SiO2 forms a chemical bond with the ceramic matrix to enhance the strength of the cell walls; at the same time, the low-temperature decomposition section slowly decomposes the thermoplastic foam particles to avoid sudden release of gas leading to rupture of the matrix. The closed-cell structure after the decomposition of the thermoplastic foam particles can inhibit the crack propagation path of the matrix.

[0038] S7, carving the bisque-fired body; S8. The surface of the unglazed body after carving is glazed. After the surface glazing is completed, the body is sent into the kiln for secondary firing. The temperature in the kiln during the secondary firing is 1100°C.

[0039] The white porcelain sculpture produced by this embodiment has been tested to have a density of 1.7 g / cm³, a weight reduction of 35%, a flexural strength of 25 MPa, no cracks on the glaze, a whiteness of 90% (CIE Lab standard), and light transmittance consistent with that of traditional white porcelain. Embodiment 2

[0040] A lightweight Dehua white porcelain sculpture based on foam particle reinforcement comprises white porcelain mud and thermoplastic foam particles with a closed-cell structure. The white porcelain mud is made by wet grinding a matrix raw material and water. The matrix raw material comprises the following raw materials in parts by weight: 70 parts of Dehua kaolin, 25 parts of quartz and 10 parts of feldspar. The water content of the white porcelain mud is 29%. The volume ratio of the thermoplastic foam particles to the white porcelain mud is 1:0.4.

[0041] The present invention further comprises 1 part by weight of a dispersant, wherein the dispersant is hydroxymethyl cellulose.

[0042] The thermoplastic foam particles are thermoplastic resin particles with a closed-cell structure, and the particle size of the thermoplastic foam particles is 2 mm and the density is 0.08 g / cm³. Specifically, the thermoplastic foam particles are polyurethane particles.

[0043] A method for preparing a lightweight Dehua white porcelain sculpture based on foam particle reinforcement comprises the following steps: S1. Wet-grind 70 parts of Dehua kaolin, 25 parts of quartz, 10 parts of feldspar and water to obtain white porcelain mud, wherein the water content of the white porcelain mud is 29%; after obtaining the white porcelain mud, pass the white porcelain mud through a 200-mesh sieve to remove impurities, and then let it stand for 24 hours to enhance plasticity.

[0044] S2. Select thermoplastic foam particles with a closed-cell structure and activate the surface of the thermoplastic foam particles; specifically, immerse the thermoplastic foam particles in 3 parts by weight of a silane coupling agent solution, wherein the silane coupling agent is KH-550 silane coupling agent, and maintain the temperature of the silane coupling agent solution at 60° C. and stir for 30 minutes. After the surface of the thermoplastic foam particles is dried, a chemically bonded active surface is formed; the silane coupling agent forms -Si-O- bonds on the surface of the thermoplastic foam particles, combines with hydroxyl groups in the white porcelain slurry, and enhances the bonding strength between the ceramic matrix and the particles.

[0045] S3. The thermoplastic foam particles and the white porcelain mud are mixed in a volume ratio of 1:0.4, and 1 part by weight of a dispersant is added, and then the thermoplastic foam particles and the white porcelain mud are stirred evenly at a low speed; specifically, the stirring speed of the thermoplastic foam particles and the white porcelain mud is 180 rpm and the stirring time is 15 minutes when the thermoplastic foam particles and the white porcelain mud are stirred at a low speed to avoid the thermoplastic foam particles from breaking, so that the thermoplastic foam particles and the white porcelain mud form a uniform suspended slurry; the dispersant is hydroxymethyl cellulose, and the dispersant can ensure that the thermoplastic foam particles are evenly distributed in the white porcelain mud, and the dispersant can reduce the viscosity of the white porcelain mud and improve the mold filling rate.

[0046] S4. Inject the evenly mixed thermoplastic foam particles and white porcelain mud into a sculpture mold, and then place the sculpture mold on a vibration table for vertical vibration compaction with a vibration frequency of 40 Hz and an amplitude of 2 mm for 10 minutes to expel bubbles and increase the packing density. After the vibration is completed, let it stand for 3.5 hours to demold and obtain a carcass; wherein, the thermoplastic foam particles and the white porcelain mud can optimize the arrangement of the thermoplastic foam particles through vibration compaction, so that the thermoplastic foam particles are evenly dispersed in the white porcelain mud to form a composite structure of "ceramic matrix wrapping thermoplastic foam particles". At the same time, the interface of the thermoplastic foam particles and the white porcelain mud is closely contacted through vibration compaction, the porosity is reduced, and the collapse of the carcass structure after firing is prevented.

[0047] S5, performing gradient dehydration and drying on the carcass, so that the moisture content of the carcass is ≤2%; the steps of performing gradient dehydration and drying on the carcass are as follows: S51, pre-dry the carcass in a low-humidity drying kiln at a temperature of 40°C for 35 hours, so that the carcass is slowly dehydrated to a moisture content of 15%, to prevent the carcass surface from hardening too quickly and causing internal cracks; S52, placing the pre-dried carcass in a final drying kiln with a maximum temperature of 80°C and forced ventilation for final drying for 24 hours, so that the moisture content of the carcass is ≤2%, wherein the temperature in the final drying kiln is gradually increased, and the heating rate is ≤5°C / h; The use of gradient dehydration can achieve segmented temperature and humidity control, reduce tire shrinkage stress, avoid volume shrinkage differences caused by rapid evaporation of tire water, and maintain the stability of the tire microstructure.

[0048] S6, step-firing the dried carcass in a kiln to obtain a bisque-fired carcass; the steps of step-firing the dried carcass are as follows: S61, low temperature stage: raise the temperature in the kiln from room temperature to 300℃, and the kiln firing time is 8h; S62, decomposition stage: at a heating rate of ≤2°C / min, the temperature in the kiln is raised from 300°C to 600°C, the kiln firing time is 5h, and finally the kiln is kept at 600°C for 60 minutes; S63, high temperature sintering stage: the temperature in the kiln rises from 800℃ to 1100℃, and the kiln firing time is 9h; then the temperature in the kiln rises from 1100℃ to 1330℃, a reducing atmosphere is used in the kiln, the CO concentration in the kiln is 3-5%, and the kiln firing time is 8h; finally, the temperature in the kiln is maintained at 1330℃, and the kiln firing time is 1h; The steps S61 and S62 can slowly decompose the thermoplastic foam particles to form closed cells with a diameter of 0.3-1 mm. After the thermoplastic foam particles are decomposed, closed cells are left, and the cell walls are wrapped by a ceramic matrix to form a "honeycomb-ceramic" composite structure. After the thermoplastic foam particles treated with a silane coupling agent are decomposed, the residual SiO2 forms a chemical bond with the ceramic matrix to enhance the strength of the cell walls; at the same time, the low-temperature decomposition section slowly decomposes the thermoplastic foam particles to avoid sudden release of gas leading to rupture of the matrix. The closed-cell structure after the decomposition of the thermoplastic foam particles can inhibit the crack propagation path of the matrix.

[0049] S7, carving the bisque-fired body; S8. The surface of the unglazed body after carving is glazed. After the surface glazing is completed, the body is sent into the kiln for secondary firing. The temperature in the kiln during the secondary firing is 1100°C.

[0050] The white porcelain sculpture produced by this embodiment has been tested to have a density of 1.6 g / cm³, a weight reduction of 38%, a flexural strength of 26 MPa, no cracks on the glaze, a whiteness of 91% (CIE Lab standard), and light transmittance consistent with that of traditional white porcelain. Embodiment 3

[0051] A lightweight Dehua white porcelain sculpture based on foam particle reinforcement comprises white porcelain mud and thermoplastic foam particles with a closed-cell structure. The white porcelain mud is made by wet grinding a carcass raw material and water. The carcass raw material comprises the following raw materials in parts by weight: 65 parts of Dehua kaolin, 23 parts of quartz and 12 parts of feldspar. The water content of the white porcelain mud is 27%. The volume ratio of the thermoplastic foam particles to the white porcelain mud is 1:0.3.

[0052] The present invention further comprises 0.7 parts by weight of a dispersant, wherein the dispersant is hydroxymethyl cellulose.

[0053] The thermoplastic foam particles are thermoplastic resin particles with a closed-cell structure, and the particle size of the thermoplastic foam particles is 1 mm and the density is 0.06 g / cm³. Specifically, the thermoplastic foam particles are polyurethane particles.

[0054] A method for preparing a lightweight Dehua white porcelain sculpture based on foam particle reinforcement comprises the following steps: S1. Wet-grind 65 parts of Dehua kaolin, 23 parts of quartz, 12 parts of feldspar and water to obtain white porcelain mud, wherein the water content of the white porcelain mud is 27%; after obtaining the white porcelain mud, pass the white porcelain mud through a 200-mesh sieve to remove impurities, and then let it stand for 24 hours to enhance plasticity.

[0055] S2. Select thermoplastic foam particles with a closed-cell structure and activate the surface of the thermoplastic foam particles; specifically, immerse the thermoplastic foam particles in 2 parts by weight of a silane coupling agent solution, wherein the silane coupling agent is KH-550 silane coupling agent, and maintain the temperature of the silane coupling agent solution at 60° C. and stir for 30 minutes. After the surface of the thermoplastic foam particles is dried, a chemically bonded active surface is formed; the silane coupling agent forms -Si-O- bonds on the surface of the thermoplastic foam particles, combines with hydroxyl groups in the white porcelain slurry, and enhances the bonding strength between the ceramic matrix and the particles.

[0056] S3. The thermoplastic foam particles and the white porcelain mud are mixed in a volume ratio of 1:03, and 0.7 parts by weight of a dispersant is added at the same time, and then the thermoplastic foam particles and the white porcelain mud are stirred evenly at a low speed; specifically, the stirring speed of the thermoplastic foam particles and the white porcelain mud is 150 rpm and the stirring time is 14 minutes when the thermoplastic foam particles and the white porcelain mud are stirred at a low speed to avoid the thermoplastic foam particles from breaking, so that the thermoplastic foam particles and the white porcelain mud form a uniform suspended slurry; the dispersant is hydroxymethyl cellulose, and the dispersant can ensure that the thermoplastic foam particles are evenly distributed in the white porcelain mud, and the dispersant can reduce the viscosity of the white porcelain mud and improve the mold filling rate.

[0057] S4. Inject the evenly mixed thermoplastic foam particles and white porcelain mud into a sculpture mold, and then place the sculpture mold on a vibration table for vertical vibration compaction with a vibration frequency of 30 Hz and an amplitude of 1.5 mm for 8 minutes to expel bubbles and increase the packing density. After the vibration is completed, let it stand for 3 hours to demold and obtain a carcass; wherein, the thermoplastic foam particles and the white porcelain mud can optimize the arrangement of the thermoplastic foam particles through vibration compaction, so that the thermoplastic foam particles are evenly dispersed in the white porcelain mud to form a composite structure of "ceramic matrix wrapping thermoplastic foam particles". At the same time, the interface of the thermoplastic foam particles and the white porcelain mud is closely contacted through vibration compaction, the porosity is reduced, and the collapse of the carcass structure after firing is prevented.

[0058] S5, performing gradient dehydration and drying on the carcass, so that the moisture content of the carcass is ≤2%; the steps of performing gradient dehydration and drying on the carcass are as follows: S51, pre-dry the carcass in a low-humidity drying kiln at a temperature of 40°C for 30 hours, so that the carcass is slowly dehydrated to a moisture content of 15%, to prevent the carcass surface from hardening too quickly and causing internal cracks; S52, placing the pre-dried carcass in a final drying kiln with a maximum temperature of 80°C and forced ventilation for final drying for 24 hours, so that the moisture content of the carcass is ≤2%, wherein the temperature in the final drying kiln is gradually increased, and the heating rate is ≤5°C / h; The use of gradient dehydration can achieve segmented temperature and humidity control, reduce tire shrinkage stress, avoid volume shrinkage differences caused by rapid evaporation of tire water, and maintain the stability of the tire microstructure.

[0059] S6, step-firing the dried carcass in a kiln to obtain a bisque-fired carcass; the steps of step-firing the dried carcass are as follows: S61, low temperature stage: raise the temperature in the kiln from room temperature to 300℃, and the kiln firing time is 8h; S62, decomposition stage: at a heating rate of ≤2°C / min, the temperature in the kiln is raised from 300°C to 600°C, the kiln firing time is 5h, and finally the kiln is kept at 600°C for 45 minutes; S63, high temperature sintering stage: the temperature in the kiln rises from 800℃ to 1100℃, and the kiln firing time is 9h; then the temperature in the kiln rises from 1100℃ to 1330℃, a reducing atmosphere is used in the kiln, the CO concentration in the kiln is 3-5%, and the kiln firing time is 7.5h; finally, the temperature in the kiln is maintained at 1330℃, and the kiln firing time is 1h; The steps S61 and S62 can slowly decompose the thermoplastic foam particles to form closed cells with a diameter of 0.3-1 mm. After the thermoplastic foam particles are decomposed, closed cells are left, and the cell walls are wrapped by a ceramic matrix to form a "honeycomb-ceramic" composite structure. After the thermoplastic foam particles treated with a silane coupling agent are decomposed, the residual SiO2 forms a chemical bond with the ceramic matrix to enhance the strength of the cell walls; at the same time, the low-temperature decomposition section slowly decomposes the thermoplastic foam particles to avoid sudden release of gas leading to rupture of the matrix. The closed-cell structure after the decomposition of the thermoplastic foam particles can inhibit the crack propagation path of the matrix.

[0060] S7, carving the bisque-fired body; S8. The surface of the unglazed body after carving is glazed. After the surface glazing is completed, the body is sent into the kiln for secondary firing. The temperature in the kiln during the secondary firing is 1100°C.

[0061] The white porcelain sculpture produced by this embodiment has been tested to have a density of 1.4 g / cm³, a weight reduction of 40%, a flexural strength of 28 MPa, no cracks on the glaze, a whiteness of 92% (CIE Lab standard), and light transmittance consistent with that of traditional white porcelain. Embodiment 4

[0062] A lightweight Dehua white porcelain sculpture based on foam particle reinforcement comprises white porcelain mud and thermoplastic foam particles with a closed-cell structure. The white porcelain mud is made by wet grinding a carcass raw material and water. The carcass raw material comprises the following raw materials in parts by weight: 60 parts of Dehua kaolin, 20 parts of quartz and 15 parts of feldspar. The water content of the white porcelain mud is 26%. The volume ratio of the thermoplastic foam particles to the white porcelain mud is 1:0.2.

[0063] The present invention further comprises 0.5 parts by weight of a dispersant, wherein the dispersant is hydroxymethyl cellulose.

[0064] The thermoplastic foam particles are thermoplastic resin particles with a closed-cell structure, and the particle size of the thermoplastic foam particles is 0.8 mm and the density is 0.04 g / cm³. Specifically, the thermoplastic foam particles are polystyrene particles.

[0065] A method for preparing a lightweight Dehua white porcelain sculpture based on foam particle reinforcement comprises the following steps: S1. Wet-grind 60 parts of Dehua kaolin, 20 parts of quartz, 15 parts of feldspar and water to obtain white porcelain mud, wherein the water content of the white porcelain mud is 25%; after obtaining the white porcelain mud, pass the white porcelain mud through a 200-mesh sieve to remove impurities, and then let it stand for 24 hours to enhance plasticity.

[0066] S2. Select thermoplastic foam particles with a closed-cell structure and activate the surface of the thermoplastic foam particles. Specifically, immerse the thermoplastic foam particles in 1 part by weight of a silane coupling agent solution, wherein the silane coupling agent is KH-550 silane coupling agent. Keep the temperature of the silane coupling agent solution at 60°C and stir for 30 minutes. After the surface of the thermoplastic foam particles is dried, a chemically bonded active surface is formed. The silane coupling agent forms -Si-O- bonds on the surface of the thermoplastic foam particles, combines with hydroxyl groups in the white porcelain slurry, and enhances the bonding strength between the ceramic matrix and the particles.

[0067] S3. The thermoplastic foam particles and the white porcelain mud are mixed in a volume ratio of 1:0.2, and 0.5 parts by weight of a dispersant is added at the same time, and then the thermoplastic foam particles and the white porcelain mud are stirred evenly at a low speed; specifically, the stirring speed of the thermoplastic foam particles and the white porcelain mud is 120 rpm and the stirring time is 11 minutes when the thermoplastic foam particles and the white porcelain mud are stirred at a low speed to avoid the thermoplastic foam particles from breaking, so that the thermoplastic foam particles and the white porcelain mud form a uniform suspended slurry; the dispersant is hydroxymethyl cellulose, and the dispersant can ensure that the thermoplastic foam particles are evenly distributed in the white porcelain mud, and the dispersant can reduce the viscosity of the white porcelain mud and improve the mold filling rate.

[0068] S4. Inject the evenly mixed thermoplastic foam particles and white porcelain mud into a sculpture mold, and then place the sculpture mold on a vibration table for vertical vibration compaction at a vibration frequency of 25 Hz and an amplitude of 1 mm for 6 minutes to expel bubbles and increase the packing density. After the vibration is completed, let it stand for 2.5 hours to demold and obtain a carcass; wherein, the thermoplastic foam particles and the white porcelain mud can optimize the arrangement of the thermoplastic foam particles through vibration compaction, so that the thermoplastic foam particles are evenly dispersed in the white porcelain mud to form a composite structure of "ceramic matrix wrapping thermoplastic foam particles". At the same time, the interface of the thermoplastic foam particles and the white porcelain mud is closely contacted through vibration compaction, the porosity is reduced, and the collapse of the carcass structure after firing is prevented.

[0069] S5, performing gradient dehydration and drying on the carcass, so that the moisture content of the carcass is ≤2%; the steps of performing gradient dehydration and drying on the carcass are as follows: S51. Place the carcass in a low-humidity drying kiln at a temperature of 40°C for pre-drying for 26 hours, so that the carcass is slowly dehydrated to a moisture content of 15% to prevent the carcass surface from hardening too quickly and causing internal cracks; S52, placing the pre-dried carcass in a final drying kiln with a maximum temperature of 80°C and forced ventilation for final drying for 24 hours, so that the moisture content of the carcass is ≤2%, wherein the temperature in the final drying kiln is gradually increased, and the heating rate is ≤5°C / h; The use of gradient dehydration can achieve segmented temperature and humidity control, reduce tire shrinkage stress, avoid volume shrinkage differences caused by rapid evaporation of tire water, and maintain the stability of the tire microstructure.

[0070] S6, step-firing the dried carcass in a kiln to obtain a bisque-fired carcass; the steps of step-firing the dried carcass are as follows: S61, low temperature stage: raise the temperature in the kiln from room temperature to 300℃, and the kiln firing time is 8h; S62, decomposition stage: at a heating rate of ≤2°C / min, the temperature in the kiln is raised from 300°C to 600°C, the kiln firing time is 5h, and finally the kiln is kept at 600°C for 35 minutes; S63, high temperature sintering stage: the temperature in the kiln rises from 800℃ to 1100℃, and the kiln firing time is 9h; then the temperature in the kiln rises from 1100℃ to 1330℃, a reducing atmosphere is used in the kiln, the CO concentration in the kiln is 3%, and the kiln firing time is 7h; finally, the temperature in the kiln is maintained at 1330℃, and the kiln firing time is 1h; The steps S61 and S62 can slowly decompose the thermoplastic foam particles to form closed cells with a diameter of 0.3-1 mm. After the thermoplastic foam particles are decomposed, closed cells are left, and the cell walls are wrapped by a ceramic matrix to form a "honeycomb-ceramic" composite structure. After the thermoplastic foam particles treated with a silane coupling agent are decomposed, the residual SiO2 forms a chemical bond with the ceramic matrix to enhance the strength of the cell walls; at the same time, the low-temperature decomposition section slowly decomposes the thermoplastic foam particles to avoid sudden release of gas leading to rupture of the matrix. The closed-cell structure after the decomposition of the thermoplastic foam particles can inhibit the crack propagation path of the matrix.

[0071] S7, carving the bisque-fired body; S8. The surface of the unglazed body after carving is glazed. After the surface glazing is completed, the body is sent into the kiln for secondary firing. The temperature in the kiln during the secondary firing is 1100°C.

[0072] The white porcelain sculpture produced by this embodiment is tested to have a density of 1.72 g / cm³, a weight reduction of 34.8%, a flexural strength of 25 MPa, no cracks on the glaze, a whiteness of 90% (CIE Lab standard), and light transmittance consistent with that of traditional white porcelain. Embodiment 5

[0073] A lightweight Dehua white porcelain sculpture based on foam particle reinforcement comprises white porcelain mud and thermoplastic foam particles with a closed-cell structure. The white porcelain mud is made by wet grinding a matrix raw material and water. The matrix raw material comprises the following raw materials in parts by weight: 70 parts of Dehua kaolin, 25 parts of quartz and 10 parts of feldspar. The water content of the white porcelain mud is 29%. The volume ratio of the thermoplastic foam particles to the white porcelain mud is 1:0.4.

[0074] The present invention further comprises 1 part by weight of a dispersant, wherein the dispersant is hydroxymethyl cellulose.

[0075] The thermoplastic foam particles are thermoplastic resin particles with a closed-cell structure, and the particle size of the thermoplastic foam particles is 2 mm and the density is 0.08 g / cm³. Specifically, the thermoplastic foam particles are polystyrene particles.

[0076] A method for preparing a lightweight Dehua white porcelain sculpture based on foam particle reinforcement comprises the following steps: S1. Wet-grind 70 parts of Dehua kaolin, 25 parts of quartz, 10 parts of feldspar and water to obtain white porcelain mud, wherein the water content of the white porcelain mud is 29%; after obtaining the white porcelain mud, pass the white porcelain mud through a 200-mesh sieve to remove impurities, and then let it stand for 24 hours to enhance plasticity.

[0077] S2. Select thermoplastic foam particles with a closed-cell structure and activate the surface of the thermoplastic foam particles; specifically, immerse the thermoplastic foam particles in 3 parts by weight of a silane coupling agent solution, wherein the silane coupling agent is KH-550 silane coupling agent, and maintain the temperature of the silane coupling agent solution at 60° C. and stir for 30 minutes. After the surface of the thermoplastic foam particles is dried, a chemically bonded active surface is formed; the silane coupling agent forms -Si-O- bonds on the surface of the thermoplastic foam particles, combines with hydroxyl groups in the white porcelain slurry, and enhances the bonding strength between the ceramic matrix and the particles.

[0078] S3. The thermoplastic foam particles and the white porcelain mud are mixed in a volume ratio of 1:0.4, and 1 part by weight of a dispersant is added, and then the thermoplastic foam particles and the white porcelain mud are stirred evenly at a low speed; specifically, the stirring speed of the thermoplastic foam particles and the white porcelain mud is 180 rpm and the stirring time is 15 minutes when the thermoplastic foam particles and the white porcelain mud are stirred at a low speed to avoid the thermoplastic foam particles from breaking, so that the thermoplastic foam particles and the white porcelain mud form a uniform suspended slurry; the dispersant is hydroxymethyl cellulose, and the dispersant can ensure that the thermoplastic foam particles are evenly distributed in the white porcelain mud, and the dispersant can reduce the viscosity of the white porcelain mud and improve the mold filling rate.

[0079] S4. Inject the evenly mixed thermoplastic foam particles and white porcelain mud into a sculpture mold, and then place the sculpture mold on a vibration table for vertical vibration compaction with a vibration frequency of 40 Hz and an amplitude of 2 mm for 10 minutes to expel bubbles and increase the packing density. After the vibration is completed, let it stand for 3.5 hours to demold and obtain a carcass; wherein, the thermoplastic foam particles and the white porcelain mud can optimize the arrangement of the thermoplastic foam particles through vibration compaction, so that the thermoplastic foam particles are evenly dispersed in the white porcelain mud to form a composite structure of "ceramic matrix wrapping thermoplastic foam particles". At the same time, the interface of the thermoplastic foam particles and the white porcelain mud is closely contacted through vibration compaction, the porosity is reduced, and the collapse of the carcass structure after firing is prevented.

[0080] S5, performing gradient dehydration and drying on the carcass, so that the moisture content of the carcass is ≤2%; the steps of performing gradient dehydration and drying on the carcass are as follows: S51, pre-dry the carcass in a low-humidity drying kiln at a temperature of 40°C for 35 hours, so that the carcass is slowly dehydrated to a moisture content of 15%, to prevent the carcass surface from hardening too quickly and causing internal cracks; S52, placing the pre-dried carcass in a final drying kiln with a maximum temperature of 80°C and forced ventilation for final drying for 24 hours, so that the moisture content of the carcass is ≤2%, wherein the temperature in the final drying kiln is gradually increased, and the heating rate is ≤5°C / h; The use of gradient dehydration can achieve segmented temperature and humidity control, reduce tire shrinkage stress, avoid volume shrinkage differences caused by rapid evaporation of tire water, and maintain the stability of the tire microstructure.

[0081] S6, step-firing the dried carcass in a kiln to obtain a bisque-fired carcass; the steps of step-firing the dried carcass are as follows: S61, low temperature stage: raise the temperature in the kiln from room temperature to 300℃, and the kiln firing time is 8h; S62, decomposition stage: at a heating rate of ≤2°C / min, the temperature in the kiln is raised from 300°C to 600°C, the kiln firing time is 5h, and finally the kiln is kept at 600°C for 60 minutes; S63, high temperature sintering stage: the temperature in the kiln rises from 800℃ to 1100℃, and the kiln firing time is 9h; then the temperature in the kiln rises from 1100℃ to 1330℃, a reducing atmosphere is used in the kiln, the CO concentration in the kiln is 3-5%, and the kiln firing time is 8h; finally, the temperature in the kiln is maintained at 1330℃, and the kiln firing time is 1h; The steps S61 and S62 can slowly decompose the thermoplastic foam particles to form closed cells with a diameter of 0.3-1 mm. After the thermoplastic foam particles are decomposed, closed cells are left, and the cell walls are wrapped by a ceramic matrix to form a "honeycomb-ceramic" composite structure. After the thermoplastic foam particles treated with a silane coupling agent are decomposed, the residual SiO2 forms a chemical bond with the ceramic matrix to enhance the strength of the cell walls; at the same time, the low-temperature decomposition section slowly decomposes the thermoplastic foam particles to avoid sudden release of gas leading to rupture of the matrix. The closed-cell structure after the decomposition of the thermoplastic foam particles can inhibit the crack propagation path of the matrix.

[0082] S7, carving the bisque-fired body; S8. The surface of the unglazed body after carving is glazed. After the surface glazing is completed, the body is sent into the kiln for secondary firing. The temperature in the kiln during the secondary firing is 1100°C.

[0083] The white porcelain sculpture produced by this embodiment is tested to have a density of 1.62 g / cm³, a weight reduction of 37.8%, a flexural strength of 26 MPa, no cracks on the glaze, a whiteness of 91% (CIE Lab standard), and light transmittance consistent with that of traditional white porcelain. Embodiment 6

[0084] A lightweight Dehua white porcelain sculpture based on foam particle reinforcement comprises white porcelain mud and thermoplastic foam particles with a closed-cell structure. The white porcelain mud is made by wet grinding a carcass raw material and water. The carcass raw material comprises the following raw materials in parts by weight: 65 parts of Dehua kaolin, 23 parts of quartz and 12 parts of feldspar. The water content of the white porcelain mud is 27%. The volume ratio of the thermoplastic foam particles to the white porcelain mud is 1:0.3.

[0085] The present invention further comprises 0.7 parts by weight of a dispersant, wherein the dispersant is hydroxymethyl cellulose.

[0086] The thermoplastic foam particles are thermoplastic resin particles with a closed-cell structure, and the particle size of the thermoplastic foam particles is 1 mm and the density is 0.06 g / cm³. Specifically, the thermoplastic foam particles are polystyrene particles.

[0087] A method for preparing a lightweight Dehua white porcelain sculpture based on foam particle reinforcement comprises the following steps: S1. Wet-grind 65 parts of Dehua kaolin, 23 parts of quartz, 12 parts of feldspar and water to obtain white porcelain mud, wherein the water content of the white porcelain mud is 27%; after obtaining the white porcelain mud, pass the white porcelain mud through a 200-mesh sieve to remove impurities, and then let it stand for 24 hours to enhance plasticity.

[0088] S2. Select thermoplastic foam particles with a closed-cell structure and activate the surface of the thermoplastic foam particles; specifically, immerse the thermoplastic foam particles in 2 parts by weight of a silane coupling agent solution, wherein the silane coupling agent is KH-550 silane coupling agent, and maintain the temperature of the silane coupling agent solution at 60° C. and stir for 30 minutes. After the surface of the thermoplastic foam particles is dried, a chemically bonded active surface is formed; the silane coupling agent forms -Si-O- bonds on the surface of the thermoplastic foam particles, combines with hydroxyl groups in the white porcelain slurry, and enhances the bonding strength between the ceramic matrix and the particles.

[0089] S3. The thermoplastic foam particles and the white porcelain mud are mixed in a volume ratio of 1:03, and 0.7 parts by weight of a dispersant is added at the same time, and then the thermoplastic foam particles and the white porcelain mud are stirred evenly at a low speed; specifically, the stirring speed of the thermoplastic foam particles and the white porcelain mud is 150 rpm and the stirring time is 14 minutes when the thermoplastic foam particles and the white porcelain mud are stirred at a low speed to avoid the thermoplastic foam particles from breaking, so that the thermoplastic foam particles and the white porcelain mud form a uniform suspended slurry; the dispersant is hydroxymethyl cellulose, and the dispersant can ensure that the thermoplastic foam particles are evenly distributed in the white porcelain mud, and the dispersant can reduce the viscosity of the white porcelain mud and improve the mold filling rate.

[0090] S4. Inject the evenly mixed thermoplastic foam particles and white porcelain mud into a sculpture mold, and then place the sculpture mold on a vibration table for vertical vibration compaction with a vibration frequency of 30 Hz and an amplitude of 1.5 mm for 8 minutes to expel bubbles and increase the packing density. After the vibration is completed, let it stand for 3 hours to demold and obtain a carcass; wherein, the thermoplastic foam particles and the white porcelain mud can optimize the arrangement of the thermoplastic foam particles through vibration compaction, so that the thermoplastic foam particles are evenly dispersed in the white porcelain mud to form a composite structure of "ceramic matrix wrapping thermoplastic foam particles". At the same time, the interface of the thermoplastic foam particles and the white porcelain mud is closely contacted through vibration compaction, the porosity is reduced, and the collapse of the carcass structure after firing is prevented.

[0091] S5, performing gradient dehydration and drying on the carcass, so that the moisture content of the carcass is ≤2%; the steps of performing gradient dehydration and drying on the carcass are as follows: S51, pre-dry the carcass in a low-humidity drying kiln at a temperature of 40°C for 30 hours, so that the carcass is slowly dehydrated to a moisture content of 15%, to prevent the carcass surface from hardening too quickly and causing internal cracks; S52, placing the pre-dried carcass in a final drying kiln with a maximum temperature of 80°C and forced ventilation for final drying for 24 hours, so that the moisture content of the carcass is ≤2%, wherein the temperature in the final drying kiln is gradually increased, and the heating rate is ≤5°C / h; The use of gradient dehydration can achieve segmented temperature and humidity control, reduce tire shrinkage stress, avoid volume shrinkage differences caused by rapid evaporation of tire water, and maintain the stability of the tire microstructure.

[0092] S6, step-firing the dried carcass in a kiln to obtain a bisque-fired carcass; the steps of step-firing the dried carcass are as follows: S61, low temperature stage: raise the temperature in the kiln from room temperature to 300℃, and the kiln firing time is 8h; S62, decomposition stage: at a heating rate of ≤2°C / min, the temperature in the kiln is raised from 300°C to 600°C, the kiln firing time is 5h, and finally the kiln is kept at 600°C for 45 minutes; S63, high temperature sintering stage: the temperature in the kiln rises from 800℃ to 1100℃, and the kiln firing time is 9h; then the temperature in the kiln rises from 1100℃ to 1330℃, a reducing atmosphere is used in the kiln, the CO concentration in the kiln is 3-5%, and the kiln firing time is 7.5h; finally, the temperature in the kiln is maintained at 1330℃, and the kiln firing time is 1h; The steps S61 and S62 can slowly decompose the thermoplastic foam particles to form closed cells with a diameter of 0.3-1 mm. After the thermoplastic foam particles are decomposed, closed cells are left, and the cell walls are wrapped by a ceramic matrix to form a "honeycomb-ceramic" composite structure. After the thermoplastic foam particles treated with a silane coupling agent are decomposed, the residual SiO2 forms a chemical bond with the ceramic matrix to enhance the strength of the cell walls; at the same time, the low-temperature decomposition section slowly decomposes the thermoplastic foam particles to avoid sudden release of gas leading to rupture of the matrix. The closed-cell structure after the decomposition of the thermoplastic foam particles can inhibit the crack propagation path of the matrix.

[0093] S7, carving the bisque-fired body; S8. The surface of the unglazed body after carving is glazed. After the surface glazing is completed, the body is sent into the kiln for secondary firing. The temperature in the kiln during the secondary firing is 1100°C.

[0094] The white porcelain sculpture produced by this embodiment is tested to have a density of 1.42 g / cm³, a weight reduction of 38.2%, a flexural strength of 28 MPa, no cracks on the glaze, a whiteness of 92% (CIE Lab standard), and light transmittance consistent with that of traditional white porcelain.

[0095] The above is only a specific implementation of the present invention, but the design concept of the present invention is not limited thereto. Any non-substantial changes to the present invention using this concept shall be deemed as an infringement of the protection scope of the present invention.

Claims

1. A lightweight Dehua white porcelain sculpture based on foam particle reinforcement, characterized in that: The invention comprises white porcelain mud and thermoplastic foam particles with a closed-cell structure. The white porcelain mud is formed by wet grinding of body raw materials and water. The body raw materials comprise the following raw materials in parts by weight: 60-70 parts of Dehua kaolin, 20-25 parts of quartz and 10-15 parts of feldspar. The water content of the white porcelain mud is 25-30%. The volume ratio of the thermoplastic foam particles to the white porcelain mud is 1:0.2-0.

5. The thermoplastic foam particles are polystyrene or polyurethane particles.

2. A lightweight Dehua white porcelain sculpture based on foam particle reinforcement as claimed in claim 1, characterized in that: It also includes 0.5-1 parts by weight of a dispersant.

3. A lightweight Dehua white porcelain sculpture based on foam particle reinforcement as claimed in claim 2, characterized in that: It includes white porcelain mud and thermoplastic foam particles. The white porcelain mud is mixed with body raw materials and water. The body raw materials include the following raw materials in parts by weight: 65 parts of Dehua kaolin, 23 parts of quartz and 12 parts of feldspar. The water content of the white porcelain mud is 27%. The volume ratio of the thermoplastic foam particles to the white porcelain mud is 1:0.

3. The weight portion of the dispersant is 0.7 parts.

4. A lightweight Dehua white porcelain sculpture based on foam particle reinforcement as claimed in claim 1, characterized in that: The thermoplastic foam particles are thermoplastic resin particles with a closed-cell structure, and the particle size of the thermoplastic foam particles is 0.5-3 mm and the density is 0.02-0.1 g / cm³.

5. A method for preparing a lightweight Dehua white porcelain sculpture based on foam particle reinforcement, characterized in that: The following steps are involved: S1, wet-grinding 60-70 parts of Dehua kaolin, 20-25 parts of quartz, 10-15 parts of feldspar and water to obtain white porcelain slurry, wherein the water content of the white porcelain slurry is 25-30%; S2, selecting thermoplastic foam particles with a closed-cell structure, and activating the surfaces of the thermoplastic foam particles; S3, mixing the thermoplastic foam particles and the white porcelain slurry at a volume ratio of 1:0.2-0.5, adding 0.5-1 parts by weight of a dispersant, and then stirring the thermoplastic foam particles and the white porcelain slurry at a low speed until uniform; S4, injecting the evenly mixed thermoplastic foam particles and white porcelain mud into the sculpture mold, and then placing the sculpture mold on a vibration table for vertical vibration compaction for 5-10 minutes to expel bubbles, and standing for 2-4 hours after the vibration is completed to demold and obtain a carcass; S5, performing gradient dehydration and drying on the carcass, so that the moisture content of the carcass is ≤2%; S6, step-firing the dried body in a kiln to obtain a bisque-fired body; S7, carving the bisque-fired body; S8. The surface of the unglazed body after carving is glazed. After the surface glazing is completed, the body is sent into the kiln for secondary firing.

6. A method for preparing a lightweight Dehua white porcelain sculpture based on foam particle reinforcement as claimed in claim 5, characterized in that: In the step S1, after obtaining the white porcelain slurry, the white porcelain slurry is passed through a 200-mesh sieve to remove impurities, and then left to stand for aging for 24 hours.

7. The method for preparing a lightweight Dehua white porcelain sculpture based on foam particle reinforcement as claimed in claim 5, characterized in that: In the step S2, the thermoplastic foam particles are immersed in 1-3 parts by weight of a silane coupling agent solution, the temperature of the silane coupling agent solution is maintained at 60° C. and stirred for 30 minutes, and the surfaces of the thermoplastic foam particles are dried to form a chemically bonded active surface.

8. The method for preparing a lightweight Dehua white porcelain sculpture based on foam particle reinforcement as claimed in claim 5, characterized in that: In the step S3, the thermoplastic foam particles and the white porcelain slurry are stirred at a low speed with a stirring speed of 100-200 rpm and a stirring time of 10-15 minutes, so that the thermoplastic foam particles and the white porcelain slurry form a uniform suspension slurry; and the dispersant is hydroxymethyl cellulose.

9. The method for preparing a lightweight Dehua white porcelain sculpture based on foam particle reinforcement as claimed in claim 5, characterized in that: In step S5, the steps of gradient dehydration and drying the carcass are as follows: S51, place the carcass in a low-humidity drying kiln at a temperature of 40°C for pre-drying for 24-36 hours, so that the carcass is slowly dehydrated to a moisture content of 15%; S52, placing the pre-dried carcass in a final drying kiln with a maximum temperature of 80°C and forced ventilation for final drying for 24 hours, so that the moisture content of the carcass is ≤2%, wherein the temperature in the final drying kiln is gradually increased, and the heating rate is ≤5°C / h.

10. The method for preparing a lightweight Dehua white porcelain sculpture based on foam particle reinforcement as claimed in claim 5, characterized in that: In step S6, the steps of step-firing the dried carcass are as follows: S61, low temperature stage: raise the temperature in the kiln from room temperature to 300℃, and the kiln firing time is 8h; S62, decomposition stage: at a heating rate of ≤2°C / min, the temperature in the kiln is raised from 300°C to 600°C, the kiln firing time is 5h, and finally the kiln is kept at 600°C for 30-60 minutes; S63, high temperature sintering stage: the temperature in the kiln rises from 800℃ to 1100℃, and the kiln firing time is 9h; then the temperature in the kiln rises from 1100℃ to 1330℃, a reducing atmosphere is used in the kiln, the CO concentration in the kiln is 3-5%, and the kiln firing time is 7-8h; finally, the temperature in the kiln is maintained at 1330℃, and the kiln firing time is 1h.