A lightweight Dehua white porcelain sculpture reinforced by foam particles and its preparation process

Abstract

A lightweight Dehua white porcelain sculpture reinforced by foam particles and its preparation process, which relates to the field of ceramics, includes white porcelain slurry and thermoplastic foam particles with a closed-cell structure. The white porcelain slurry is wet-milled from body raw materials and water. The body raw materials include 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. The thermoplastic foam particles are polystyrene or polyurethane particles. In the present invention, a directional microporous structure is formed by the thermoplastic foam particles, so that the density of the finished white porcelain sculpture is reduced to 1.2-1.8 g / cm³, and the weight is reduced by 30-50% compared with the traditional one, greatly reducing the weight of the finished white porcelain sculpture and the transportation and installation costs.

Description

Technical Field

[0001] The present invention relates to the field of ceramics, and more specifically to a lightweight Dehua white porcelain sculpture reinforced by foam particles and its preparation process. Background Art

[0002] Currently, traditional Dehua white porcelain sculptures have the following problems: 1. Heavy weight: The high density of the traditional matrix (usually ≥2.2 g / cm³) makes large-scale sculpture products cumbersome, with high transportation and installation costs, and there are also safety hazards; 2. Prone to cracking: During the firing process, due to the large shrinkage rate of Dehua kaolin (linear shrinkage rate is about 12 - 15%), the stress distribution in the matrix is uneven, and cracks or deformations are likely to occur; 3. High energy consumption and cost: The raw material consumption is large, and the high-temperature firing (1250 - 1300 °C) takes a long time, with low energy efficiency; 4. Contradiction between lightweight and performance: Existing lightweight technologies (such as the foaming agent method) have uncontrollable pore distribution, resulting in a significant decrease in mechanical strength (flexural strength is usually <15 MPa), and cannot meet the structural stability requirements of the sculpture. Based on this, after painstaking research by the applicant, this case came into being. Summary of the Invention

[0003] The present invention provides a lightweight Dehua white porcelain sculpture reinforced by foam particles and its preparation process, and its main purpose is to overcome the above problems existing in existing white porcelain sculptures.

[0004] To solve the above technical problems, the present invention adopts the following technical solutions:

[0005] A lightweight Dehua white porcelain sculpture reinforced by foam particles, comprising white porcelain slurry and thermoplastic foam particles with a closed-cell structure. The white porcelain slurry is wet-ground from matrix raw materials and water. The matrix raw materials include 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. The thermoplastic foam particles are polystyrene or polyurethane particles.

[0006] Furthermore, the present invention also includes 0.5 - 1 part by weight of a dispersant.

[0007] Even further, a lightweight Dehua white porcelain sculpture reinforced by foam particles, comprising white porcelain slurry and thermoplastic foam particles. The white porcelain slurry is mixed from matrix raw materials and water. The matrix 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 slurry is 27%. The volume ratio of the thermoplastic foam particles to the white porcelain slurry is 1:0.3. The weight of the dispersant is 0.7 part.

[0008] Further, 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.

[0009] A preparation method of a lightweight Dehua white porcelain sculpture reinforced by foam particles includes the following steps:

[0010] 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 slurry, where the water content of the white porcelain slurry is 25 - 30%;

[0011] S2. Select thermoplastic foam particles with a closed-cell structure and activate the surface of the thermoplastic foam particles;

[0012] S3. Mix the thermoplastic foam particles and the white porcelain slurry at a volume ratio of 1:0.2 - 0.5, and simultaneously add 0.5 - 1 part by weight of a dispersant, and then stir the thermoplastic foam particles and the white porcelain slurry evenly at a low speed;

[0013] S4. Inject the uniformly mixed thermoplastic foam particles and white porcelain slurry into a sculpture mold, and then place the sculpture mold on a vibrating table for vertical vibration compaction for 5 - 10 minutes to discharge air bubbles. After vibration, let it stand for 2 - 4 hours to demold and obtain a carcass;

[0014] S5. Gradient dehydrate and dry the carcass so that the moisture content of the carcass ≤ 2%;

[0015] S6. Step-firing the dried carcass in a kiln to obtain a bisque-fired carcass;

[0016] S7. Carve the bisque-fired carcass;

[0017] S8. Glaze the surface of the carved bisque-fired carcass, and after the surface glazing is completed, send the carcass into the kiln for secondary firing.

[0018] Further, in the step S1, after obtaining the white porcelain slurry, pass the white porcelain slurry through a 200-mesh sieve to remove impurities, and then let it stand and age for 24 hours.

[0019] Further, in the step S2, immerse the thermoplastic foam particles in a silane coupling agent solution of 1 - 3 parts by weight, 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.

[0020] Further, in the step S3, when the thermoplastic foam particles and the white porcelain slurry are stirred at a low speed, the stirring speed is 100-200 rpm and the stirring time is 10-15 minutes, so that the thermoplastic foam particles and the white porcelain slurry form a uniform suspension slurry; the dispersant is hydroxyethyl cellulose.

[0021] Further, in the step S5, the steps of gradient dehydration drying of the carcass are as follows:

[0022] 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%;

[0023] S52. Place 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 ≤2%, where the temperature in the final drying kiln rises gradually, and the heating rate ≤5°C / h.

[0024] Further, in the step S6, the steps of step-by-step firing of the dried carcass are as follows:

[0025] S61. Low-temperature stage: Raise the temperature in the kiln from room temperature to 300°C, and the firing time is 8h;

[0026] S62. Decomposition stage: Raise the temperature in the kiln from 300°C to 600°C at a heating rate ≤2°C / min, the firing time is 5h, and finally keep the temperature in the kiln at 600°C for 30-60 minutes;

[0027] S63. High-temperature sintering stage: Raise the temperature in the kiln from 800°C to 1100°C, and the firing time is 9h; then raise the temperature in the kiln from 1100°C to 1330°C, the reducing atmosphere is adopted in the kiln, the CO concentration in the kiln is 3-5%, and the firing time is 7-8h; finally, keep the temperature in the kiln at 1330°C, and the firing time is 1h.

[0028] From the above description of the present invention, compared with the prior art, the present invention has the following advantages:

[0029] 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 1.2-1.8 g / cm³, and the weight is reduced by 30-50% compared with the traditional one, greatly reducing the weight of the finished white porcelain sculpture and the transportation and installation costs.

[0030] 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 enable the flexural strength of the finished white porcelain sculpture to be ≥25 Mpa, which is more than 50% better than that of traditional foamed ceramics, the closed cell rate is ≥70%, effectively inhibiting crack propagation, and the cracking rate of the finished white porcelain sculpture is reduced to less than 3%, further optimizing the mechanical properties of the white porcelain sculpture product.

[0031] 3. The present invention uses thermoplastic foam particles to replace the matrix raw materials. Compared with traditional finished white porcelain sculptures, the amount of white porcelain slurry used is reduced by 20 - 30%.

[0032] 4. The present invention shortens the matrix forming time by 15% through the vibration compaction process, improving the mold filling efficiency; the segmented drying process compresses the total drying cycle of the matrix from 20 days to 15 days, increasing the production efficiency by 40%.

[0033] 5. The present invention retains the whiteness of Dehua white porcelain ≥90% and light transmittance, supports traditional techniques such as hand carving and glaze decoration, and the artistic expressiveness is consistent with the traditional process. Detailed implementation mode

[0034] A lightweight Dehua white porcelain sculpture based on foam particle reinforcement, comprising white porcelain slurry and thermoplastic foam particles with a closed cell structure. The white porcelain slurry is wet-ground from matrix raw materials and water. The matrix raw materials include 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%, and the volume ratio of the thermoplastic foam particles to the white porcelain slurry is 1:0.2 - 0.5.

[0035] The present invention also includes 0.5 - 1 part by weight of a dispersant, and the dispersant is carboxymethyl cellulose.

[0036] The thermoplastic foam particles are thermoplastic resin particles with a closed cell structure. 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.

[0037] A preparation method of a lightweight Dehua white porcelain sculpture based on foam particle reinforcement, comprising the following steps:

[0038] 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 slurry, where the water content of the white porcelain slurry is 25 - 30%; after obtaining the white porcelain slurry, pass the white porcelain slurry through a 200-mesh sieve to remove impurities, and then let it stand and age for 24 hours to enhance plasticity.

[0039] 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 a silane coupling agent solution of 1-3 parts by weight. The silane coupling agent uses 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 and combines with the hydroxyl groups in the white porcelain slurry to enhance the bonding strength between the ceramic matrix and the particles.

[0040] S3. Mix the thermoplastic foam particles and the white porcelain slurry at a volume ratio of 1:0.2-0.5, and at the same time add 0.5-1 part by weight of a dispersant, and then stir the thermoplastic foam particles and the white porcelain slurry evenly at a low speed; specifically, when the thermoplastic foam particles and the white porcelain slurry are stirred at a low speed, the stirring speed is 100-200 rpm and the stirring time is 10-15 minutes to avoid breaking the thermoplastic foam particles, so that the thermoplastic foam particles and the white porcelain slurry form a uniform suspension slurry; the dispersant is hydroxyethyl cellulose, and the dispersant can ensure that the thermoplastic foam particles are evenly distributed in the white porcelain slurry. At the same time, the dispersant can reduce the viscosity of the white porcelain slurry and improve the mold filling rate.

[0041] S4. Inject the uniformly mixed thermoplastic foam particles and white porcelain slurry into the sculpture mold, and then place the sculpture mold on a vibrating 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 discharge air bubbles and increase the packing density. After vibration, let it stand for 2-4 hours for demolding to obtain the carcass; among them, the thermoplastic foam particles and the white porcelain slurry can optimize the arrangement of the thermoplastic foam particles through vibration compaction, make the thermoplastic foam particles evenly dispersed in the white porcelain slurry, and form a composite structure of "ceramic matrix wrapping thermoplastic foam particles". At the same time, through vibration compaction, the interface between the thermoplastic foam particles and the white porcelain slurry is in close contact, reducing the porosity and preventing the collapse of the carcass structure after firing.

[0042] S5. Gradiently dehydrate and dry the carcass so that the moisture content of the carcass ≤ 2%; the steps for gradient dehydration and drying of the carcass are as follows:

[0043] S51. Place the carcass in a low-humidity drying kiln at a temperature of 40 °C for pre-drying for 24-36 hours to slowly dehydrate the carcass to a moisture content of 15%, preventing the surface of the carcass from hardening too fast and causing internal cracks;

[0044] S52. Place 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 ≤ 2%. The temperature in the final drying kiln rises gradually, and the heating rate ≤ 5 °C / h;

[0045] Gradient dehydration can achieve segmented temperature and humidity control, reduce the shrinkage stress of the carcass, avoid the volume shrinkage difference caused by the rapid evaporation of water in the carcass, and maintain the stability of the carcass microstructure.

[0046] S6. Subject the dried carcass to stepped firing in a kiln to obtain a biscuit-fired carcass. The steps for subjecting the dried carcass to stepped firing are as follows:

[0047] S61. Low-temperature stage: Raise the temperature in the kiln from room temperature to 300 °C, and the firing time is 8 h.

[0048] S62. Decomposition stage: Raise the temperature in the kiln from 300 °C to 600 °C at a heating rate ≤ 2 °C / min, the firing time is 5 h, and finally keep the temperature in the kiln at 600 °C for 30 - 60 minutes.

[0049] S63. High-temperature sintering stage: Raise the temperature in the kiln from 800 °C to 1100 °C, and the firing time is 9 h; then raise the temperature in the kiln from 1100 °C to 1330 °C, use a reducing atmosphere in the kiln, the CO concentration in the kiln is 3 - 5%, and the firing time is 7 - 8 h; finally keep the temperature in the kiln at 1330 °C, and the firing time is 1 h.

[0050] The steps S61 and S62 can cause the thermoplastic foam particles to decompose slowly, forming closed pores with a diameter of 0.3 - 1 mm. After the thermoplastic foam particles decompose, closed pores are left, and the pore walls are wrapped by the ceramic matrix, forming a "honeycomb - ceramic" composite structure. After the thermoplastic foam particles treated with a silane coupling agent decompose, the residual SiO2 forms chemical bonds with the ceramic matrix, enhancing the strength of the pore walls; at the same time, the slow decomposition of the thermoplastic foam particles in the low-temperature decomposition section avoids the rupture of the carcass caused by the sudden release of gas, and the closed pore structure after the decomposition of the thermoplastic foam particles can inhibit the crack propagation path of the carcass.

[0051] S7. Carve the biscuit-fired carcass.

[0052] S8. Glaze the surface of the carved biscuit-fired carcass. After the surface glazing is completed, send the carcass into the kiln for secondary firing, and the temperature in the kiln during secondary firing is 1100 °C. Example 1

[0053] A lightweight Dehua white porcelain sculpture based on foam particle reinforcement, including white porcelain slurry and thermoplastic foam particles with a closed pore structure. The white porcelain slurry is wet-milled from carcass raw materials and water. The carcass raw materials include 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 slurry is 26%, and the volume ratio of the thermoplastic foam particles to the white porcelain slurry is 1:0.2.

[0054] The present invention further includes 0.5 parts by weight of a dispersant, and the dispersant is hydroxyethyl cellulose.

[0055] 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.

[0056] A preparation method of a lightweight Dehua white porcelain sculpture reinforced by foam particles includes the following steps:

[0057] S1. Wet-mill 60 parts of Dehua kaolin, 20 parts of quartz, 15 parts of feldspar and water to obtain white porcelain slurry, wherein the water content of the white porcelain slurry is 25%; after obtaining the white porcelain slurry, pass the white porcelain slurry through a 200-mesh sieve to remove impurities, and then let it stand and age for 24 hours to enhance plasticity.

[0058] 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 a solution of 1 part by weight of a silane coupling agent, and the silane coupling agent uses 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 a -Si-O- bond on the surface of the thermoplastic foam particles and combines with the hydroxyl groups in the white porcelain slurry to enhance the bonding strength between the ceramic matrix and the particles.

[0059] S3. Mix the thermoplastic foam particles and the white porcelain slurry at a volume ratio of 1:0.2, and at the same time add 0.5 parts by weight of a dispersant, and then stir the thermoplastic foam particles and the white porcelain slurry evenly at a low speed; specifically, when the thermoplastic foam particles and the white porcelain slurry are stirred at a low speed, the stirring speed is 120 rpm and the stirring time is 11 minutes to avoid breaking the thermoplastic foam particles, so that the thermoplastic foam particles and the white porcelain slurry form a uniform suspension slurry; the dispersant is hydroxyethyl cellulose, and the dispersant can ensure that the thermoplastic foam particles are evenly distributed in the white porcelain slurry. At the same time, the dispersant can reduce the viscosity of the white porcelain slurry and improve the mold filling rate.

[0060] S4. Inject the uniformly mixed thermoplastic foam particles and white porcelain slurry into the sculpture mold, and then place the sculpture mold on a vibrating table for vertical vibration compaction at a vibration frequency of 25 Hz and an amplitude of 1 mm for 6 minutes to discharge air bubbles and increase the packing density. After vibration, let it stand for 2.5 hours for demolding to obtain the carcass. Among them, through vibration compaction, the arrangement of thermoplastic foam particles can be optimized, enabling the thermoplastic foam particles to be evenly dispersed in the white porcelain slurry, forming a composite structure of "ceramic matrix wrapping thermoplastic foam particles". At the same time, through vibration compaction, the interface between the thermoplastic foam particles and the white porcelain slurry is in close contact, reducing the porosity and preventing the collapse of the carcass structure after firing.

[0061] S5. Gradient dehydrate and dry the carcass so that the moisture content of the carcass ≤ 2%. The steps for gradient dehydrating and drying the carcass are as follows:

[0062] S51. Place the carcass in a low-humidity drying kiln at a temperature of 40°C for pre-drying for 26 hours to slowly dehydrate the carcass to a moisture content of 15%, preventing the surface of the carcass from hardening too quickly and causing internal cracks.

[0063] S52. Place 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 ≤ 2%. Among them, the temperature in the final drying kiln rises gradually, and the heating rate ≤ 5°C / h.

[0064] Using gradient dehydration can achieve segmented temperature and humidity control, reduce the shrinkage stress of the carcass, avoid the volume shrinkage difference caused by the rapid evaporation of the moisture in the carcass, and maintain the stability of the microscopic structure of the carcass.

[0065] S6. Gradually fire the dried carcass in a kiln to obtain a bisque-fired carcass. The steps for gradually firing the dried carcass are as follows:

[0066] S61. Low-temperature stage: Raise the temperature in the kiln from room temperature to 300°C, and the firing time is 8 h.

[0067] S62. Decomposition stage: Raise the temperature in the kiln from 300°C to 600°C at a heating rate ≤ 2°C / min, the firing time is 5 h, and finally keep the temperature in the kiln at 600°C for 35 minutes.

[0068] S63. High-temperature sintering stage: Raise the temperature in the kiln from 800°C to 1100°C, and the firing time is 9 h. Then raise the temperature in the kiln from 1100°C to 1330°C, use a reducing atmosphere in the kiln, the CO concentration in the kiln is 3%, and the firing time is 7 h. Finally, keep the temperature in the kiln at 1330°C, and the firing time is 1 h.

[0069] Steps S61 and S62 can cause the thermoplastic foam particles to decompose slowly, forming closed pores with a diameter of 0.3 - 1 mm. After the thermoplastic foam particles decompose, closed pores are left, and the pore walls are wrapped by the ceramic matrix, forming a "honeycomb - ceramic" composite structure. After the thermoplastic foam particles treated with silane coupling agent decompose, the residual SiO2 forms chemical bonds with the ceramic matrix, enhancing the strength of the pore walls. At the same time, the low - temperature decomposition section slowly decomposes the thermoplastic foam particles, avoiding the rupture of the matrix caused by the sudden release of gas. The closed - pore structure after the decomposition of the thermoplastic foam particles can inhibit the crack propagation path of the matrix.

[0070] S7. Sculpt the biscuit - fired matrix.

[0071] S8. Glaze the surface of the sculpted biscuit - fired matrix. After the surface glazing is completed, send the matrix into the kiln for secondary firing. The temperature in the kiln during secondary firing is 1100 °C.

[0072] The white porcelain sculpture produced by this embodiment, after testing, has a density of 1.7 g / cm³, a weight reduction of 35%, a flexural strength of 25 MPa, no cracks on the glaze surface, a whiteness of 90% (CIE Lab standard), and the light transmittance is the same as that of traditional white porcelain. Embodiment Two

[0073] A lightweight Dehua white porcelain sculpture based on foam - particle reinforcement, including white porcelain slurry and thermoplastic foam particles with a closed - pore structure. The white porcelain slurry is wet - ground from matrix raw materials and water. The matrix raw materials include 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 slurry is 29%, and the volume ratio of the thermoplastic foam particles to the white porcelain slurry is 1:0.4.

[0074] The present invention also includes 1 part by weight of a dispersant, and the dispersant is hydroxy - methyl cellulose.

[0075] The thermoplastic foam particles are thermoplastic resin particles with a closed - pore structure. 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.

[0076] A preparation method of a lightweight Dehua white porcelain sculpture based on foam - particle reinforcement, including the following steps:

[0077] S1. Wet - grind 70 parts of Dehua kaolin, 25 parts of quartz, 10 parts of feldspar and water to obtain white porcelain slurry, where the water content of the white porcelain slurry is 29%. After obtaining the white porcelain slurry, pass the white porcelain slurry through a 200 - mesh sieve to remove impurities, and then let it stand and age for 24 hours to enhance plasticity.

[0078] 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 a silane coupling agent solution of 3 parts by weight. The silane coupling agent uses 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 a -Si-O- bond on the surface of the thermoplastic foam particles, which combines with the hydroxyl groups in the white porcelain slurry to enhance the bonding strength between the ceramic matrix and the particles.

[0079] S3. Mix the thermoplastic foam particles and the white porcelain slurry according to a volume ratio of 1:0.4, and at the same time add 1 part by weight of a dispersant, and then stir the thermoplastic foam particles and the white porcelain slurry evenly at a low speed; specifically, when the thermoplastic foam particles and the white porcelain slurry are stirred at a low speed, the stirring speed is 180 rpm and the stirring time is 15 minutes to avoid breaking the thermoplastic foam particles, so that the thermoplastic foam particles and the white porcelain slurry 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 slurry. At the same time, the dispersant can reduce the viscosity of the white porcelain slurry and improve the mold filling rate.

[0080] S4. Inject the uniformly mixed thermoplastic foam particles and white porcelain slurry into the sculpture mold, and then place the sculpture mold on a vibrating table for vertical vibration compaction at a vibration frequency of 40 Hz and an amplitude of 2 mm for 10 minutes to discharge air bubbles and increase the packing density. After vibration, let it stand for 3.5 hours for demolding to obtain a carcass; among them, the thermoplastic foam particles and the white porcelain slurry can optimize the arrangement of the thermoplastic foam particles through vibration compaction, make the thermoplastic foam particles evenly dispersed in the white porcelain slurry, and form a composite structure of "ceramic matrix wrapping thermoplastic foam particles". At the same time, through vibration compaction, the interface between the thermoplastic foam particles and the white porcelain slurry is in close contact, reducing the porosity and preventing the collapse of the carcass structure after firing.

[0081] S5. Gradient dehydrate and dry the carcass so that the moisture content of the carcass ≤ 2%; the steps for gradient dehydrating and drying the carcass are as follows:

[0082] S51. Place the carcass in a low-humidity drying kiln at a temperature of 40 °C for pre-drying for 35 hours to slowly dehydrate the carcass to a moisture content of 15%, preventing the surface of the carcass from hardening too quickly and causing internal cracks;

[0083] S52. Place 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 ≤ 2%. The temperature in the final drying kiln rises gradually, and the heating rate ≤ 5 °C / h;

[0084] Gradient dehydration can achieve segmented temperature and humidity control, reduce the shrinkage stress of the carcass, avoid the volume shrinkage difference caused by the rapid evaporation of water in the carcass, and maintain the stability of the microscopic structure of the carcass.

[0085] S6. Fire the dried carcass in a kiln step by step to obtain a bisque-fired carcass. The steps for firing the dried carcass step by step are as follows:

[0086] S61. Low-temperature stage: Raise the temperature in the kiln from room temperature to 300 °C, and the firing time is 8 h.

[0087] S62. Decomposition stage: Raise the temperature in the kiln from 300 °C to 600 °C at a heating rate ≤ 2 °C / min, the firing time is 5 h, and finally keep the temperature in the kiln at 600 °C for 60 minutes.

[0088] S63. High-temperature sintering stage: Raise the temperature in the kiln from 800 °C to 1100 °C, and the firing time is 9 h; then raise the temperature in the kiln from 1100 °C to 1330 °C, use a reducing atmosphere in the kiln, the CO concentration in the kiln is 3 - 5%, and the firing time is 8 h; finally keep the temperature in the kiln at 1330 °C, and the firing time is 1 h.

[0089] The steps S61 and S62 can cause the thermoplastic foam particles to decompose slowly, forming closed pores with a diameter of 0.3 - 1 mm. After the thermoplastic foam particles decompose, closed pores are left, and the pore walls are wrapped by a ceramic matrix, forming a "honeycomb-ceramic" composite structure. After the thermoplastic foam particles treated with a silane coupling agent decompose, the residual SiO2 forms a chemical bond with the ceramic matrix, enhancing the strength of the pore walls; at the same time, the slow decomposition of the thermoplastic foam particles in the low-temperature decomposition section avoids the rupture of the carcass caused by the sudden release of gas, and the closed pore structure after the decomposition of the thermoplastic foam particles can inhibit the crack propagation path of the carcass.

[0090] S7. Carve the bisque-fired carcass.

[0091] S8. Glaze the surface of the carved bisque-fired carcass. After the surface glazing is completed, send the carcass into the kiln for secondary firing. The temperature in the kiln during secondary firing is 1100 °C.

[0092] The white porcelain sculpture produced by this embodiment, after testing, has a density of 1.6 g / cm³, a weight reduction of 38%, a flexural strength of 26 MPa, no cracks on the glaze surface, a whiteness of 91% (CIE Lab standard), and the light transmittance is the same as that of traditional white porcelain. Example Three

[0093] A lightweight Dehua white porcelain sculpture reinforced with foam particles, comprising white porcelain slurry and thermoplastic foam particles with a closed-cell structure. The white porcelain slurry is wet-ground from the 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 slurry is 27%. The volume ratio of the thermoplastic foam particles to the white porcelain slurry is 1:0.3.

[0094] The present invention further includes 0.7 parts by weight of a dispersant, and the dispersant is hydroxyethyl cellulose.

[0095] The thermoplastic foam particles are thermoplastic resin particles with a closed-cell structure. 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.

[0096] A preparation method of a lightweight Dehua white porcelain sculpture reinforced with foam particles, comprising the following steps:

[0097] S1. Wet-grind 65 parts of Dehua kaolin, 23 parts of quartz, 12 parts of feldspar, and water to obtain white porcelain slurry, wherein the water content of the white porcelain slurry is 27%. After obtaining the white porcelain slurry, pass the white porcelain slurry through a 200-mesh sieve to remove impurities, and then let it stand and age for 24 hours to enhance plasticity.

[0098] 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 a solution of 2 parts by weight of a silane coupling agent. The silane coupling agent used 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 and combines with the hydroxyl groups in the white porcelain slurry to enhance the bonding strength between the ceramic matrix and the particles.

[0099] S3. Mix the thermoplastic foam particles and the white porcelain slurry according to a volume ratio of 1:0.3, and at the same time add 0.7 parts by weight of a dispersant. Then, stir the thermoplastic foam particles and the white porcelain slurry evenly at a low speed. Specifically, when stirring the thermoplastic foam particles and the white porcelain slurry at a low speed, the stirring speed is 150 rpm and the stirring time is 14 minutes to avoid breaking the thermoplastic foam particles, so that the thermoplastic foam particles and the white porcelain slurry form a uniform suspension slurry. The dispersant is hydroxyethyl cellulose, and the dispersant can ensure that the thermoplastic foam particles are evenly distributed in the white porcelain slurry. At the same time, the dispersant can reduce the viscosity of the white porcelain slurry and improve the mold filling rate.

[0100] S4. Inject the uniformly mixed thermoplastic foam particles and white porcelain slurry into the sculpture mold, and then place the sculpture mold on a vibrating table for vertical vibration compaction at a vibration frequency of 30 Hz and an amplitude of 1.5 mm for 8 minutes to discharge air bubbles and increase the packing density. After vibration, let it stand for 3 hours for demolding to obtain the carcass. Among them, through vibration compaction, the arrangement of thermoplastic foam particles can be optimized, and the thermoplastic foam particles can be evenly dispersed in the white porcelain slurry to form a composite structure of "ceramic matrix wrapping thermoplastic foam particles". At the same time, through vibration compaction, the interface between the thermoplastic foam particles and the white porcelain slurry is in close contact, reducing the porosity and preventing the collapse of the carcass structure after firing.

[0101] S5. Gradient dehydrate and dry the carcass so that the moisture content of the carcass ≤ 2%. The steps for gradient dehydrating and drying the carcass are as follows:

[0102] S51. Place the carcass in a low-humidity drying kiln at a temperature of 40°C for pre-drying for 30 hours to slowly dehydrate the carcass to a moisture content of 15%, preventing the surface of the carcass from hardening too quickly and causing internal cracks.

[0103] S52. Place 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 ≤ 2%. Among them, the temperature in the final drying kiln rises gradually, and the heating rate ≤ 5°C / h.

[0104] Gradient dehydration can achieve segmented temperature and humidity control, reduce the shrinkage stress of the carcass, avoid the volume shrinkage difference caused by the rapid evaporation of the moisture in the carcass, and maintain the stability of the microstructure of the carcass.

[0105] S6. Fire the dried carcass in a kiln in a stepwise manner to obtain a bisque-fired carcass. The steps for firing the dried carcass in a stepwise manner are as follows:

[0106] S61. Low-temperature stage: Raise the temperature in the kiln from room temperature to 300°C, and the firing time is 8 h.

[0107] S62. Decomposition stage: Raise the temperature in the kiln from 300°C to 600°C at a heating rate ≤ 2°C / min, the firing time is 5 h, and finally keep the temperature in the kiln at 600°C for 45 minutes.

[0108] S63. High-temperature sintering stage: Raise the temperature in the kiln from 800°C to 1100°C, and the firing time is 9 h. Then raise the temperature in the kiln from 1100°C to 1330°C. A reducing atmosphere is used in the kiln, and the CO concentration in the kiln is 3 - 5%. The firing time is 7.5 h. Finally, keep the temperature in the kiln at 1330°C, and the firing time is 1 h.

[0109] Steps S61 and S62 can cause the thermoplastic foam particles to decompose slowly, forming closed pores with a diameter of 0.3 - 1 mm. After the thermoplastic foam particles decompose, closed pores are left, and the pore walls are wrapped by the ceramic matrix, forming a "honeycomb - ceramic" composite structure. After the thermoplastic foam particles treated with silane coupling agent decompose, the remaining SiO2 forms chemical bonds with the ceramic matrix, enhancing the strength of the pore walls. At the same time, the low - temperature decomposition section decomposes the thermoplastic foam particles slowly, avoiding the rupture of the matrix caused by the sudden release of gas. The closed - pore structure after the decomposition of the thermoplastic foam particles can inhibit the crack propagation path of the matrix.

[0110] S7. Sculpt the biscuit - fired matrix.

[0111] S8. Glaze the surface of the sculpted biscuit - fired matrix. After the surface glazing is completed, send the matrix into the kiln for secondary firing. The temperature in the kiln during secondary firing is 1100 °C.

[0112] The white porcelain sculpture produced by this embodiment, after testing, has a density of 1.4 g / cm³, a weight reduction of 40%, a flexural strength of 28 MPa, no cracks on the glaze surface, a whiteness of 92% (CIE Lab standard), and the light transmittance is the same as that of traditional white porcelain. Embodiment 4

[0113] A lightweight Dehua white porcelain sculpture based on foam - particle reinforcement, comprising white porcelain slurry and thermoplastic foam particles with a closed - pore structure. The white porcelain slurry is wet - ground from matrix raw materials and water. The matrix raw materials include 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 slurry is 26%, and the volume ratio of the thermoplastic foam particles to the white porcelain slurry is 1:0.2.

[0114] The present invention also includes 0.5 part by weight of a dispersant, and the dispersant is hydroxymethyl cellulose.

[0115] The thermoplastic foam particles are thermoplastic resin particles with a closed - pore structure. 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.

[0116] A preparation method of a lightweight Dehua white porcelain sculpture based on foam - particle reinforcement, comprising the following steps:

[0117] S1. Wet - grind 60 parts of Dehua kaolin, 20 parts of quartz, 15 parts of feldspar and water to obtain white porcelain slurry, where the water content of the white porcelain slurry is 25%. After obtaining the white porcelain slurry, pass the white porcelain slurry through a 200 - mesh sieve to remove impurities, and then let it stand and age for 24 hours to enhance plasticity.

[0118] 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 a silane coupling agent solution of 1 part by weight. The silane coupling agent uses 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, which combines with the hydroxyl groups in the white porcelain slurry to enhance the bonding strength between the ceramic matrix and the particles.

[0119] S3. Mix the thermoplastic foam particles and the white porcelain slurry at a volume ratio of 1:0.2, and simultaneously add 0.5 part by weight of a dispersant, and then stir the thermoplastic foam particles and the white porcelain slurry evenly at a low speed; specifically, when the thermoplastic foam particles and the white porcelain slurry are stirred at a low speed, the stirring speed is 120 rpm and the stirring time is 11 minutes to avoid breaking the thermoplastic foam particles, so that the thermoplastic foam particles and the white porcelain slurry 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 slurry. At the same time, the dispersant can reduce the viscosity of the white porcelain slurry and improve the mold filling rate.

[0120] S4. Inject the uniformly mixed thermoplastic foam particles and white porcelain slurry into the sculpture mold, and then place the sculpture mold on a vibrating table for vertical vibration compaction at a vibration frequency of 25 Hz and an amplitude of 1 mm for 6 minutes to discharge air bubbles and increase the packing density. After vibration, let it stand for 2.5 hours for demolding to obtain a carcass; among them, the thermoplastic foam particles and the white porcelain slurry can optimize the arrangement of the thermoplastic foam particles through vibration compaction, make the thermoplastic foam particles evenly dispersed in the white porcelain slurry, and form a composite structure of "ceramic matrix wrapping thermoplastic foam particles". At the same time, through vibration compaction, the interfaces of the thermoplastic foam particles and the white porcelain slurry are in close contact, reducing the porosity and preventing the collapse of the carcass structure after firing.

[0121] S5. Gradient dehydrate and dry the carcass so that the moisture content of the carcass ≤ 2%; the steps for gradient dehydrating and drying the carcass are as follows:

[0122] S51. Place the carcass in a low-humidity drying kiln at a temperature of 40 °C for pre-drying for 26 hours to slowly dehydrate the carcass to a moisture content of 15%, preventing the surface of the carcass from hardening too quickly and causing internal cracks;

[0123] S52. Place 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 ≤ 2%. Among them, the temperature in the final drying kiln rises gradually, and the heating rate ≤ 5 °C / h;

[0124] Gradient dehydration can achieve segmented temperature and humidity control, reduce the shrinkage stress of the carcass, avoid the volume shrinkage difference caused by the rapid evaporation of water in the carcass, and maintain the stability of the microscopic structure of the carcass.

[0125] S6. Subject the dried carcass to stepped firing in a kiln to obtain a bisque-fired carcass. The steps for subjecting the dried carcass to stepped firing are as follows:

[0126] S61. Low-temperature stage: Raise the temperature in the kiln from room temperature to 300 °C, and the firing time is 8 h.

[0127] S62. Decomposition stage: Raise the temperature in the kiln from 300 °C to 600 °C at a heating rate ≤ 2 °C / min, the firing time is 5 h, and finally keep the temperature in the kiln at 600 °C for 35 minutes.

[0128] S63. High-temperature sintering stage: Raise the temperature in the kiln from 800 °C to 1100 °C, and the firing time is 9 h; then raise the temperature in the kiln from 1100 °C to 1330 °C, use a reducing atmosphere in the kiln, the CO concentration in the kiln is 3%, and the firing time is 7 h; finally keep the temperature in the kiln at 1330 °C, and the firing time is 1 h.

[0129] Steps S61 and S62 can cause the thermoplastic foam particles to decompose slowly, forming closed pores with a diameter of 0.3 - 1 mm. After the thermoplastic foam particles decompose, closed pores are left, and the pore walls are wrapped by the ceramic matrix, forming a "honeycomb-ceramic" composite structure. After the thermoplastic foam particles treated with a silane coupling agent decompose, the residual SiO2 forms chemical bonds with the ceramic matrix, enhancing the pore wall strength; at the same time, the slow decomposition of the thermoplastic foam particles in the low-temperature decomposition section avoids the rupture of the carcass caused by the sudden release of gas, and the closed pore structure after the decomposition of the thermoplastic foam particles can inhibit the crack propagation path of the carcass.

[0130] S7. Carve the bisque-fired carcass.

[0131] S8. Apply glaze to the surface of the carved bisque-fired carcass. After the surface glazing is completed, send the carcass into the kiln for secondary firing. The temperature in the kiln during secondary firing is 1100 °C.

[0132] The white porcelain sculpture produced by this embodiment, after testing, has a density of 1.72 g / cm³, a weight reduction of 34.8%, a flexural strength of 25 MPa, no cracks on the glaze surface, a whiteness of 90% (CIE Lab standard), and the light transmittance is the same as that of traditional white porcelain. Example Five

[0133] A lightweight Dehua white porcelain sculpture reinforced by foam particles, comprising white porcelain slurry and thermoplastic foam particles with a closed-cell structure. The white porcelain slurry is wet-ground from the body raw materials and water. The body raw materials include 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 slurry is 29%, and the volume ratio of the thermoplastic foam particles to the white porcelain slurry is 1:0.4.

[0134] The present invention also includes 1 part by weight of a dispersant, and the dispersant is hydroxymethyl cellulose.

[0135] 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.

[0136] A preparation method of a lightweight Dehua white porcelain sculpture reinforced by foam particles, comprising the following steps:

[0137] S1. Wet-grind 70 parts of Dehua kaolin, 25 parts of quartz, 10 parts of feldspar and water to obtain white porcelain slurry, wherein the water content of the white porcelain slurry is 29%; after obtaining the white porcelain slurry, pass the white porcelain slurry through a 200-mesh sieve to remove impurities, and then stand and age for 24 hours to enhance plasticity.

[0138] 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 a 3-part-by-weight silane coupling agent solution, and the silane coupling agent uses 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 and combines with the hydroxyl groups in the white porcelain slurry to enhance the bonding strength between the ceramic matrix and the particles.

[0139] S3. Mix the thermoplastic foam particles and the white porcelain slurry at a volume ratio of 1:0.4, and simultaneously add 1 part by weight of a dispersant, and then stir the thermoplastic foam particles and the white porcelain slurry evenly at a low speed; specifically, when the thermoplastic foam particles and the white porcelain slurry are stirred at a low speed, the stirring speed is 180 rpm and the stirring time is 15 minutes to avoid breaking the thermoplastic foam particles, so that the thermoplastic foam particles and the white porcelain slurry 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 slurry. At the same time, the dispersant can reduce the viscosity of the white porcelain slurry and improve the mold filling rate.

[0140] S4. Inject the uniformly mixed thermoplastic foam particles and white porcelain slurry into the sculpture mold, and then place the sculpture mold on a vibrating table for vertical vibration compaction at a vibration frequency of 40 Hz and an amplitude of 2 mm for 10 minutes to discharge air bubbles and increase the packing density. After vibration, let it stand for 3.5 hours and then demold to obtain the carcass. Among them, through vibration compaction, the arrangement of thermoplastic foam particles can be optimized, and the thermoplastic foam particles can be evenly dispersed in the white porcelain slurry to form a composite structure of "ceramic matrix wrapping thermoplastic foam particles". At the same time, through vibration compaction, the interface between the thermoplastic foam particles and the white porcelain slurry is in close contact, reducing the porosity and preventing the collapse of the carcass structure after firing.

[0141] S5. Gradually dehydrate and dry the carcass so that the moisture content of the carcass ≤ 2%. The steps for gradually dehydrating and drying the carcass are as follows:

[0142] S51. Place the carcass in a low-humidity drying kiln at a temperature of 40°C for pre-drying for 35 hours to slowly dehydrate the carcass to a moisture content of 15%, preventing the surface of the carcass from hardening too quickly and causing internal cracks.

[0143] S52. Place 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 ≤ 2%. Among them, the temperature in the final drying kiln rises gradually, and the heating rate ≤ 5°C / h.

[0144] Gradient dehydration can achieve segmented temperature and humidity control, reduce the shrinkage stress of the carcass, avoid volume shrinkage differences caused by rapid evaporation of the moisture in the carcass, and maintain the stability of the microscopic structure of the carcass.

[0145] S6. Fire the dried carcass step by step in a kiln to obtain a bisque-fired carcass. The steps for firing the dried carcass step by step are as follows:

[0146] S61. Low-temperature stage: Raise the temperature in the kiln from room temperature to 300°C, and the firing time is 8 hours.

[0147] S62. Decomposition stage: Raise the temperature in the kiln from 300°C to 600°C at a heating rate ≤ 2°C / min, the firing time is 5 hours, and finally keep the temperature in the kiln at 600°C for 60 minutes.

[0148] S63. High-temperature sintering stage: Raise the temperature in the kiln from 800°C to 1100°C, and the firing time is 9 hours; then raise the temperature in the kiln from 1100°C to 1330°C. A reducing atmosphere is adopted in the kiln, and the CO concentration in the kiln is 3 - 5%, and the firing time is 8 hours; finally, keep the temperature in the kiln at 1330°C, and the firing time is 1 hour.

[0149] Steps S61 and S62 can cause the thermoplastic foam particles to decompose slowly, forming closed pores with a diameter of 0.3 - 1 mm. After the thermoplastic foam particles decompose, closed pores are left, and the pore walls are wrapped by the ceramic matrix, forming a "honeycomb - ceramic" composite structure. After the thermoplastic foam particles treated with silane coupling agent decompose, the remaining SiO2 forms chemical bonds with the ceramic matrix, enhancing the strength of the pore walls. At the same time, the low - temperature decomposition section decomposes the thermoplastic foam particles slowly, avoiding the rupture of the matrix caused by the sudden release of gas. The closed - pore structure after the decomposition of the thermoplastic foam particles can inhibit the crack propagation path of the matrix.

[0150] S7. Sculpt the biscuit - fired matrix.

[0151] S8. Glaze the surface of the biscuit - fired matrix after sculpting. After the surface glazing is completed, send the matrix into the kiln for secondary firing. The temperature in the kiln during secondary firing is 1100 °C.

[0152] The white porcelain sculpture produced by this embodiment, after testing, has a density of 1.62 g / cm³, a weight reduction of 37.8%, a flexural strength of 26 MPa, no cracks on the glaze surface, a whiteness of 91% (CIE Lab standard), and the light transmittance is the same as that of traditional white porcelain. Example Six

[0153] A lightweight Dehua white porcelain sculpture based on foam - particle reinforcement, including white porcelain slurry and thermoplastic foam particles with a closed - pore structure. The white porcelain slurry is wet - ground from matrix raw materials and water. The matrix 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 slurry is 27%, and the volume ratio of the thermoplastic foam particles to the white porcelain slurry is 1:0.3.

[0154] The present invention also includes 0.7 part by weight of a dispersant, and the dispersant is hydroxy - methyl cellulose.

[0155] The thermoplastic foam particles are thermoplastic resin particles with a closed - pore structure. 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.

[0156] A preparation method of a lightweight Dehua white porcelain sculpture based on foam - particle reinforcement includes the following steps:

[0157] S1. Wet - grind 65 parts of Dehua kaolin, 23 parts of quartz, 12 parts of feldspar and water to obtain white porcelain slurry, where the water content of the white porcelain slurry is 27%. After obtaining the white porcelain slurry, pass the white porcelain slurry through a 200 - mesh sieve to remove impurities, and then let it stand and age for 24 hours to enhance plasticity.

[0158] 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 a silane coupling agent solution of 2 parts by weight. The silane coupling agent uses 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 a -Si-O- bond on the surface of the thermoplastic foam particles, which combines with the hydroxyl groups in the white porcelain slurry to enhance the bonding strength between the ceramic matrix and the particles.

[0159] S3. Mix the thermoplastic foam particles and the white porcelain slurry at a volume ratio of 1:03, and at the same time add 0.7 parts by weight of a dispersant, and then stir the thermoplastic foam particles and the white porcelain slurry evenly at a low speed. Specifically, when the thermoplastic foam particles and the white porcelain slurry are stirred at a low speed, the stirring speed is 150 rpm and the stirring time is 14 minutes to avoid breaking the thermoplastic foam particles, so that the thermoplastic foam particles and the white porcelain slurry form a uniform suspension slurry. The dispersant is hydroxyethyl cellulose. The dispersant can ensure that the thermoplastic foam particles are evenly distributed in the white porcelain slurry. At the same time, the dispersant can reduce the viscosity of the white porcelain slurry and improve the mold filling rate.

[0160] S4. Inject the uniformly mixed thermoplastic foam particles and white porcelain slurry into the sculpture mold, and then place the sculpture mold on a vibrating table for vertical vibration compaction at a vibration frequency of 30 Hz and an amplitude of 1.5 mm for 8 minutes to discharge air bubbles and increase the packing density. After vibration, let it stand for 3 hours for demolding to obtain a carcass. Among them, the thermoplastic foam particles and the white porcelain slurry can optimize the arrangement of the thermoplastic foam particles through vibration compaction, make the thermoplastic foam particles evenly dispersed in the white porcelain slurry, and form a composite structure of "ceramic matrix wrapped with thermoplastic foam particles". At the same time, through vibration compaction, the interface between the thermoplastic foam particles and the white porcelain slurry is in close contact, reducing the porosity and preventing the collapse of the carcass structure after firing.

[0161] S5. Gradiently dehydrate and dry the carcass so that the moisture content of the carcass ≤ 2%. The steps for gradient dehydration and drying of the carcass are as follows:

[0162] S51. Place the carcass in a low-humidity drying kiln at a temperature of 40 °C for pre-drying for 30 hours to slowly dehydrate the carcass to a moisture content of 15%, preventing the surface of the carcass from hardening too fast and causing internal cracks.

[0163] S52. Place 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 ≤ 2%. Among them, the temperature in the final drying kiln rises gradually, and the heating rate ≤ 5 °C / h.

[0164] Gradient dehydration can achieve segmented temperature and humidity control, reduce the shrinkage stress of the carcass, avoid volume shrinkage differences caused by rapid evaporation of water in the carcass, and maintain the stability of the microscopic structure of the carcass.

[0165] S6. Fire the dried carcass step by step in a kiln to obtain a bisque-fired carcass. The steps for step-by-step firing of the dried carcass are as follows:

[0166] S61. Low-temperature stage: Raise the temperature in the kiln from room temperature to 300 °C, and the firing time is 8 h.

[0167] S62. Decomposition stage: Raise the temperature in the kiln from 300 °C to 600 °C at a heating rate ≤ 2 °C / min, the firing time is 5 h, and finally keep the temperature in the kiln at 600 °C for 45 minutes.

[0168] S63. High-temperature sintering stage: Raise the temperature in the kiln from 800 °C to 1100 °C, and the firing time is 9 h; then raise the temperature in the kiln from 1100 °C to 1330 °C, a reducing atmosphere is adopted in the kiln, the CO concentration in the kiln is 3 - 5%, and the firing time is 7.5 h; finally keep the temperature in the kiln at 1330 °C, and the firing time is 1 h.

[0169] Steps S61 and S62 can cause the thermoplastic foam particles to decompose slowly, forming closed pores with a diameter of 0.3 - 1 mm. After the thermoplastic foam particles decompose, closed pores are left, and the pore walls are wrapped by the ceramic matrix, forming a "honeycomb-ceramic" composite structure. After the thermoplastic foam particles treated with silane coupling agent decompose, the residual SiO2 forms chemical bonds with the ceramic matrix, enhancing the strength of the pore walls; at the same time, the slow decomposition of the thermoplastic foam particles in the low-temperature decomposition section avoids the rupture of the carcass caused by sudden gas release, and the closed pore structure after the decomposition of the thermoplastic foam particles can inhibit the crack propagation path of the carcass.

[0170] S7. Carve the bisque-fired carcass.

[0171] S8. Glaze the surface of the carved bisque-fired carcass. After the surface glazing is completed, send the carcass into the kiln for secondary firing. The temperature in the kiln during secondary firing is 1100 °C.

[0172] The white porcelain sculpture produced by this embodiment, after testing, has a density of 1.42 g / cm³, a weight reduction of 38.2%, a flexural strength of 28 MPa, no cracks on the glaze surface, a whiteness of 92% (CIE Lab standard), and the light transmittance is the same as that of traditional white porcelain.

[0173] The above is only the specific embodiment of the present invention, but the design concept of the present invention is not limited to this. Any non-substantive modification made to the present invention using this concept shall fall within the scope of infringement of the protection scope of the present invention.

Claims

1. A lightweight Dehua white porcelain sculpture enhanced by foam particles, characterized in that: It includes white porcelain slurry and thermoplastic foam particles with a closed-cell structure. The white porcelain slurry is wet-ground from the body raw materials and water. The body raw materials include 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. The thermoplastic foam particles are polystyrene or polyurethane particles; The preparation method of the lightweight Dehua white porcelain sculpture reinforced by foam particles includes 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 slurry, where the water content of the white porcelain slurry is 25 - 30%; S2. Select thermoplastic foam particles with a closed-cell structure and activate the surface of the thermoplastic foam particles; S3. Mix the thermoplastic foam particles and the white porcelain slurry according to a volume ratio of 1:0.2 - 0.5, and simultaneously add 0.5 - 1 part by weight of a dispersant, and then stir the thermoplastic foam particles and the white porcelain slurry evenly at a low speed; S4. Inject the uniformly mixed thermoplastic foam particles and white porcelain slurry into a sculpture mold, and then place the sculpture mold on a vibrating table for vertical vibration compaction for 5 - 10 minutes to discharge air bubbles. After vibration, let it stand for 2 - 4 hours to demold to obtain a body; S5. Gradient dehydrate and dry the body so that the moisture content of the body ≤ 2%; S6. Step-firing the dried body in a kiln to obtain a bisque body; S7. Carve the bisque body; S8. Glaze the surface of the carved bisque body. After surface glazing, send the body into the kiln for secondary firing; In the step S2, immerse the thermoplastic foam particles in a silane coupling agent solution of 1 - 3 parts by weight, 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; In the step S6, the steps of step-firing the dried body are as follows: S61. Low-temperature stage: Raise the temperature in the kiln from room temperature to 300°C, and the firing time is 8h; S62. Decomposition stage: Raise the temperature in the kiln from 300°C to 600°C at a heating rate ≤ 2°C / min, the firing time is 5h, and finally keep the temperature in the kiln at 600°C for 30 - 60 minutes; S63. High-temperature sintering stage: Raise the temperature in the kiln from 800°C to 1100°C, and the firing time is 9h; then raise the temperature in the kiln from 1100°C to 1330°C. A reducing atmosphere is adopted in the kiln, and the CO concentration in the kiln is 3 - 5%. The firing time is 7 - 8h; finally, keep the temperature in the kiln at 1330°C, and the firing time is 1h.

2. The lightweight Dehua white porcelain sculpture reinforced by foam particles as claimed in claim 1, wherein: It includes white porcelain slurry and thermoplastic foam particles. The white porcelain slurry is wet-milled from the 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 slurry is 27%. The volume ratio of the thermoplastic foam particles to the white porcelain slurry is 1:0.3, and the weight of the dispersant is 0.7 parts.

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

4. The lightweight Dehua white porcelain sculpture enhanced by foam particles as described in claim 1, wherein: 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 age for 24 hours.

5. A lightweight Dehua white porcelain sculpture enhanced by foam particles as claimed in claim 1, wherein: In the step S3, when the thermoplastic foam particles and the white porcelain slurry are stirred at a low speed, the stirring speed is 100 - 200 rpm and the stirring time is 10 - 15 minutes, so that the thermoplastic foam particles and the white porcelain slurry form a uniform suspension slurry; the dispersant is hydroxymethyl cellulose.

6. The lightweight Dehua white porcelain sculpture enhanced by foam particles as claimed in claim 1, wherein: In the step S5, the steps for gradient dehydration drying of the body are as follows: S51: Place the body in a low-humidity drying kiln at a temperature of 40°C for pre-drying for 24 - 36 hours, so that the body is slowly dehydrated to a moisture content of 15%. S52: Place the pre-dried body 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 body ≤ 2%. Among them, the temperature in the final drying kiln is gradually increased, and the heating rate ≤ 5°C / h.