Ceramic fabric and preparation method thereof

Abstract

The invention provides a ceramic fabric and a preparation method thereof, and relates to the field of materials. The ceramic fabric comprises a ceramic chip and a base fabric, wherein the ceramic chip is adhered to the surface of the base fabric through glue. The preparation method comprises the following steps: S1, preparing slurry, brushing the slurry on the surface of a gypsum board, repeatedly brushing for three layers until the thickness of a mud blank is 0.3-0.4 mm, and drying in the shade for 10 minutes to obtain the mud blank with the water content of 10-20% on the gypsum surface; s2, cutting the mud blank to obtain a mud sheet matrix, and completely drying the mud sheet matrix; s3, glaze is sprayed to the surface of the mud piece matrix dried in the shade to form a glaze layer until the mud piece matrix is completely dried in the shade; s4, putting the mud sheet blank treated in the step S3 into a kiln for firing, and cooling to obtain a ceramic sheet; s5, respectively coating one surface of the ceramic chip and one surface of the base fabric with glue, then covering the surface of the base fabric with the ceramic chip, and carrying out weight-bearing drying in the shade; s6, after the ceramic chips and the base fabric are firmly combined, the ceramic chips on the base fabric are crushed, and the ceramic fabric is obtained. And the ceramic chips are used as decorative surfaces, so that the diversity of the fabric is expanded.

Description

Technical Field

[0001] The present invention relates to the field of materials, and in particular to a ceramic fabric and a preparation method thereof. Background Art

[0002] Ceramic fabrics are a composite material that combines ceramic properties with textile technology. Currently, ceramic fabrics include ceramic fiber-based fabrics, ceramic coated fabrics, ceramic composite yarns, etc. Ceramic fiber-based fabrics refer to ceramic raw materials made into fibers through melt spinning, and then woven into fabrics; ceramic coated fabrics refer to ceramic nanoparticles (such as zirconium oxide, titanium oxide) or ceramic sols coated on the surface of the fabric, which are then cured at high temperature to form a dense coating; ceramic composite yarns refer to ceramic fibers blended with organic fibers such as polyester and aramid to form composite yarns that are both rigid and flexible, which are then woven into fabrics.

[0003] At present, there is no related fabric on the market that combines ceramic pieces with fabrics and uses ceramic pieces as decoration. Summary of the Invention

[0004] The purpose of the present invention is to provide a ceramic fabric which uses ceramic sheets as decorative surfaces, thereby broadening the diversity of fabrics.

[0005] Another object of the present invention is to provide a method for preparing ceramic fabrics, wherein thin ceramic sheets are pasted on a base fabric. The ceramic fabrics can be used as soft-package decorations for clothing, screens, walls, etc.

[0006] The present invention solves the technical problem by adopting the following technical solutions.

[0007] On the one hand, an embodiment of the present invention provides a ceramic fabric, including a ceramic sheet and a base fabric, wherein the ceramic sheet is adhered to the surface of the base fabric by glue.

[0008] In some embodiments of the present invention, the raw material of the base fabric is any one of synthetic leather, animal leather, plant fiber, and synthetic fiber.

[0009] In some embodiments of the present invention, the glue is one or two of leather glue, ceramic glue, and cloth glue.

[0010] In another aspect, an embodiment of the present invention provides a method for preparing a ceramic fabric, comprising the following steps:

[0011] S1, prepare mud, brush the mud on the surface of the gypsum board, and dry it until the moisture content is 10-20% to obtain a mud blank; specifically, brush it three times repeatedly until the thickness of the mud blank reaches 0.3-0.4 mm, and dry it in the shade for ten minutes to obtain a mud blank with a moisture content of 10-20% on the gypsum surface;

[0012] S2, cutting the clay to obtain the clay sheet body, and drying it in the shade;

[0013] S3, spraying glaze on the surface of the clay body after air drying to form a glaze layer, and air drying until completely dry;

[0014] S4, placing the clay sheet body processed in step S3 in a kiln for firing and cooling to obtain a ceramic sheet;

[0015] S5, respectively coating glue on one surface of the ceramic sheet and one surface of the base fabric, then covering the ceramic sheet on the surface of the base fabric, and drying in the shade under load, wherein the drying time under load is 24-30 hours;

[0016] S6, after the ceramic sheet is firmly bonded to the base fabric, the ceramic sheet on the base fabric is crushed to obtain the ceramic fabric.

[0017] In some embodiments of the present invention, in step S1, the method for preparing the mud is: the purchased original mud (mud produced by Delta) is mixed evenly with water in a ratio of original mud: water = 9:1 by volume.

[0018] In some embodiments of the present invention, in step S2, the thickness of the mud sheet body is 0.3-0.4 mm.

[0019] In some embodiments of the present invention, in step S3, the thickness of the glaze layer is 0.1-0.15 mm.

[0020] In some embodiments of the present invention, in step S4, the firing includes: controlling the temperature in the kiln from room temperature, continuously firing, gradually heating up to 1250-1300°C, stopping after reaching the highest temperature, and then waiting for cooling to room temperature for 6-12 hours.

[0021] In some embodiments of the present invention, in step S5, ceramic glue is coated on the surface of the ceramic sheet, and leather glue is coated on the surface of the base fabric; the raw material of the base fabric is animal leather or synthetic leather.

[0022] It should be noted that leather glue is only used when the base fabric is animal leather or leather synthetic products. For other fabrics (such as cotton, linen, chemical fiber, etc.), the glue used is Feifanli's 780 fabric glue or Zhanlida's E7000 glue.

[0023] In some embodiments of the present invention, in step S5, the weight-bearing shade drying is: placing a heavy object on the ceramic sheet to apply pressure to the ceramic sheet for 24-30 hours.

[0024] In some embodiments of the present invention, in step S6, the length and width of the crushed ceramic pieces are between 0.3-0.6 cm.

[0025] Compared with the prior art, the embodiments of the present invention have at least the following advantages or beneficial effects:

[0026] The ceramic fabric and its preparation method provided by the present invention utilize a base fabric as a carrier. Thin ceramic sheets are adhered to the base fabric with glue and then air-dried under a load, ensuring the sheets are firmly adhered to the base fabric. The ceramic sheets can be used as decorative surfaces, allowing for the design of ceramic decals in various colors and patterns to create diverse artistic styles. Furthermore, by crushing the ceramic sheets, the ceramic fabric becomes more flexible, meeting the flexibility requirements for garment processing.

[0027] The ceramic fabric provided by the present invention broadens the types, application fields and decorative styles of fabrics, overturns the boundary between ceramics and fabrics, and can be used as both ceramic products and fashion products. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments. It should be understood that the following drawings only illustrate certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other relevant drawings can be obtained based on these drawings without paying any creative work.

[0029] Figure 1 This is a process flow chart for preparing ceramic fabrics according to an embodiment of the present invention;

[0030] Figure 2 The actual ceramic fabric prepared in Example 1 of the present invention Figure 1 ;

[0031] Figure 3 The actual ceramic fabric prepared in Example 1 of the present invention Figure 2 ;

[0032] Figure 4 The actual ceramic fabric prepared in Example 1 of the present invention Figure 3 . DETAILED DESCRIPTION

[0033] To make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention are described clearly and completely below. Where specific conditions are not specified in the embodiments, conventional conditions or conditions recommended by the manufacturer are used. Where the manufacturer of the reagents or instruments is not specified, all are conventional products that can be purchased commercially.

[0034] It should be noted that, in the absence of conflict, the embodiments and features of the embodiments of the present invention can be combined with each other. The present invention will be described in detail below with reference to specific embodiments.

[0035] An embodiment of the present invention provides a ceramic fabric, comprising a ceramic sheet and a base fabric, wherein the ceramic sheet is adhered to the surface of the base fabric by glue.

[0036] The raw material of the base fabric is one of synthetic leather, animal leather, plant fiber, and synthetic fiber. More preferably, the base fabric is animal leather or cotton cloth. It should be noted that in the embodiment of the present invention, the base fabric can be a natural fiber fabric, plant fiber such as cotton, linen, bamboo fiber, etc., animal fiber, such as fabrics made of sheep wool, cashmere, mohair, mulberry silk, tussah silk; animal leather fabrics such as cowhide and sheepskin; it can also be a chemical fiber fabric, such as viscose fiber, strong fiber, polyester, nylon, acrylic fiber, spandex, etc. As for the weaving method of the fabric, it can be a woven fabric of the above-mentioned fibers, or a knitted fabric, or a non-woven fabric, or a multi-layer composite fabric, etc.

[0037] The glue can be one or more of leather glue, ceramic glue, and fabric glue. Preferred are Intercom's leather glue (1618B) and Huayongzhen's 3612 strong ceramic repair glue. It should be noted that leather glue is only used when the base fabric is animal leather or leather-based synthetic products. For other fabrics (such as cotton, linen, and chemical fibers), Feifanli's 780 fabric glue or Zhanlida's E7000 glue can be used.

[0038] The method for preparing the ceramic fabric comprises the following steps:

[0039] S1. Prepare the mud: Mix purchased high-white mud (mud produced by Delta) with water in a ratio of 9:1 to obtain the mud. Apply the mud to the surface of the gypsum board three times until the thickness reaches 0.3-0.4 mm. Then, dry it in the air (moisture content is 10-20%) to obtain the mud blank.

[0040] The gypsum board is precisely 2cm thick, allowing for rapid evaporation and reuse. It is 7cm wide and 20cm long, suitable for making three 6.5cm x 6.5cm squares. The post-firing shrinkage is 10%, resulting in a tile thickness of approximately 0.3mm and a size of approximately 6cm x 6cm.

[0041] S2, cutting the clay to obtain a clay sheet body, and drying in the shade; the thickness of the clay sheet body is 0.3-0.4 mm;

[0042] S3, spraying glaze onto the surface of the air-dried clay body to form a glaze layer, and air-drying. The thickness of the glaze layer is 0.1-0.15 mm. If the glaze layer is too thick, the clay sheet will break during the air-drying and firing process. A matte transparent glaze is selected as it is less likely to cause the ceramic sheet to break.

[0043] S4, placing the clay sheet body processed in step S3 in a kiln for firing, cooling, and obtaining a ceramic sheet. When it is necessary to set a pattern on the ceramic sheet, decals can be made on the ceramic sheet, and then placed in a kiln for firing to obtain a decal ceramic sheet. Wherein, the firing includes: controlling the temperature in the kiln to start from room temperature and continue firing, gradually heating up to 1250-1300℃, stopping when the highest temperature is reached, and then waiting for 6-12 hours to cool down to room temperature. Wherein, if the firing is carried out in winter, the firing time is about 5 hours, the heat dissipation and cooling is about 6 hours, and the actual cooling time is based on the temperature dropping to room temperature; if the firing is carried out in summer, the firing time is about 4 hours, the heat dissipation and cooling is about 12 hours, and the actual cooling time is based on the temperature dropping to room temperature.

[0044] S5, respectively apply glue on one surface of the ceramic sheet or decal ceramic sheet and one surface of the base fabric, that is, apply ceramic glue on the surface of the ceramic sheet, and apply leather glue or cloth glue on the surface of the base fabric; then cover the ceramic sheet on the surface of the base fabric, and dry it in the shade with a weight: place a heavy object on the ceramic sheet and apply pressure to the ceramic sheet for 24-30 hours.

[0045] S6, after the ceramic sheet is firmly bonded to the base fabric, the ceramic sheet on the base fabric is crushed, and the length and width of the crushed ceramic sheet fragments are between 0.3-0.6 cm, thus obtaining the ceramic fabric.

[0046] It should be noted that, in order to provide more patterns and colors, customized ceramic decals of different colors and patterns can be affixed to the surface of the ceramic piece after glaze spraying and firing.

[0047] The decal production process is as follows: A3-sized ceramic decal paper is customized, cut into 6.5cm long and wide pieces, and soaked in warm water at 20°C for 5 minutes to separate the film on the decal surface from the paper.

[0048] On the fired white 6cm×6cm porcelain tile, stick a 6.5cm long and wide decal film. Use a plastic scraper to scrape off the bubbles in the decal film layer and the porcelain tile to ensure that all the patterns can be fired on the porcelain tile.

[0049] Put the tile with the pattern on it into the kiln, heat it up from room temperature to 680℃, stop heating, cool it down to room temperature, and take it out. This way the pattern can be firmly printed on the ceramic surface.

[0050] The process of making the ceramic fabric provided by the embodiment of the present invention into ready-made clothes is as follows: the ceramic fabric is cut into a suitable clothing pattern. If it is a square or regular pattern, during the production process of pasting ceramic tiles, a 1-2 cm fabric base margin will be left on the edge of the ceramic fabric for machine sewing. For other irregular edges, the fabric base can be cut cleanly, holes are punched in the ceramic fabric, and then the irregular edges are sewn together with other interfaces by hand.

[0051] The fabric can be sized to the desired size by gluing ceramic sheets of equal area together. The fabric can then be cut into corresponding shapes based on the pattern. The pieces can then be joined together using leather drilled holes and cotton thread, stitched together using the same stitching technique used for leather sewing. This ceramic fabric can be made into clothing or into furniture installations, such as screens and ceramic wall coverings. It can also be used to make bags, soft packaging for furniture decoration, and as detachable decorative products in the clothing industry, such as detachable collars and cuffs.

[0052] Existing technology can only fire ceramics very thinly. If the thickness is less than 0.3 mm, it is difficult to fire into a fixed shape. This is because the thin body is easily affected by air pressure in gas and electric kilns, causing the ceramic pieces to crack. Furthermore, the cracked ceramic pieces are difficult to preserve. The present invention adjusts the ratio of mud to water, studies the number of times the mud is applied to the gypsum board (three times), controls the precise thickness, and applies a quantitative amount of glaze. Only then can such thin mud sheets be fired into a fixed-size square in the kiln, making them strong and resistant to cracking.

[0053] The features and performance of the present invention are further described in detail below with reference to the embodiments.

[0054] Example 1

[0055] The ceramic fabric of this embodiment was prepared as follows.

[0056] S1, prepare mud: Mix purchased high-white mud (mud produced by Delta) with water in a volume ratio of 9:1 to obtain mud. Brush the mud on the surface of the gypsum board three times and then dry it (water content is 20%) to obtain a mud blank.

[0057] The gypsum board is 2cm thick, allowing for rapid evaporation and reuse. It is 7cm wide and 20cm long, suitable for making three 6.5cm x 6.5cm squares. The post-firing shrinkage is 10%, resulting in a tile thickness of approximately 0.3mm and a size of approximately 6cm x 6cm.

[0058] S2, use a knife with mud stains to cut the clay blank. The mud stains on the blade make it easier for the clay sheet to be quickly demoulded to obtain a clay sheet body, which is then dried in the shade. The thickness of the clay sheet body is 0.3-0.4mm.

[0059] S3, spraying glaze onto the surface of the clay body after air drying to form a glaze layer, and air drying; the thickness of the glaze layer is 0.1mm-0.15mm, and the glaze surface is matte transparent glaze.

[0060] In step S4, the clay sheet body treated in step S3 is placed in a kiln for firing and cooling to obtain a ceramic sheet. The firing process includes controlling the temperature in the kiln from room temperature and gradually increasing it to 1300°C, stopping the firing at the highest temperature, and then allowing the temperature to cool to room temperature for 6-12 hours. A decal is then applied to the ceramic sheet, which is then placed in the kiln for firing again to obtain a decaled ceramic sheet.

[0061] S5: Apply ceramic glue to the bottom surface of the decal ceramic sheet, and apply leather glue (intercom leather glue 1618B) to the surface of the base fabric (vegetable tanned leather); then cover the ceramic sheet on the surface of the base fabric to allow the ceramic glue and leather glue to combine, and then dry in the shade under a load: place a heavy object on the ceramic sheet and apply pressure to the ceramic sheet. The pressure on the ceramic sheet is 3kg / cm 2 , the pressure application time is 24h.

[0062] S6, after the decal ceramic sheet is firmly bonded to the base fabric, the ceramic sheet on the base fabric is crushed by manual rolling, and the length and width of the crushed ceramic fragments are approximately 0.3-0.6 cm, respectively, to obtain the ceramic fabric.

[0063] Example 2

[0064] S1. Prepare the slurry by mixing purchased high-white slurry (produced by Delta) with water in a volume ratio of 9:1 to obtain the slurry. Apply the slurry to the surface of the gypsum board three times and then air dry it (moisture content is 200%) to obtain the slurry.

[0065] The thickness of the gypsum board is 2cm, which facilitates the rapid evaporation of moisture in the gypsum board and allows for rapid reuse. The width is 7cm and the length is 20cm, which is suitable for making three 6×6cm square mud pieces.

[0066] S2, use a knife with mud stains to cut the clay blank. The mud stains on the blade make it easier for the clay sheet to be quickly demoulded to obtain a clay sheet body, which is then dried in the shade. The thickness of the clay sheet body is 0.3-0.4mm.

[0067] S3, spraying glaze onto the surface of the air-dried clay body to form a glaze layer, and air-drying the glaze layer; the thickness of the glaze layer is 0.1mm-0.15mm, and the glaze surface is matte transparent glaze.

[0068] In step S4, the clay sheet body treated in step S3 is placed in a kiln for firing and cooling to obtain a ceramic sheet. The firing process includes controlling the temperature in the kiln from room temperature, gradually increasing the temperature to 1250°C, stopping the firing at the highest temperature, and then allowing the temperature to cool to room temperature for 6-12 hours. A decal is then applied to the ceramic sheet, which is then placed in the kiln for firing again to obtain a decaled ceramic sheet.

[0069] S5, apply ceramic glue on the bottom surface of the decal ceramic sheet, and apply 780 fabric glue on the surface of the base fabric (cotton); then cover the ceramic sheet on the surface of the base fabric to make the ceramic glue and leather glue combine, and then dry it in the shade under load (24 hours): place a heavy object on the ceramic sheet and apply pressure to the ceramic sheet, the pressure on the ceramic sheet is 2kg / cm 2 , the pressure application time is 30h.

[0070] S6, after the decal ceramic sheet is firmly bonded to the base fabric, the ceramic sheet on the base fabric is crushed by manual rolling, and the length and width of the crushed ceramic sheet are between 0.3-0.6 cm, thus obtaining the ceramic fabric.

[0071] Example 3

[0072] S1, prepare mud: Mix purchased high-white mud (mud produced by Delta) with water in a volume ratio of 9:1 to obtain mud. Brush the mud on the surface of the gypsum board three times and then dry it (water content is 20%) to obtain a mud blank.

[0073] The gypsum board is 2cm thick, allowing for rapid evaporation and reuse. It is 7cm wide and 20cm long, suitable for making three 6.5cm x 6.5cm squares. The post-firing shrinkage is 10%, resulting in a tile thickness of approximately 0.3mm and a size of approximately 6cm x 6cm.

[0074] S2, use a knife with mud stains to cut the clay blank. The mud stains on the blade make it easier for the clay sheet to be quickly demoulded to obtain a clay sheet body, which is then dried in the shade. The thickness of the clay sheet body is 0.3-0.4mm.

[0075] S3, spraying glaze onto the surface of the air-dried clay body to form a glaze layer, and air-drying the glaze layer; the thickness of the glaze layer is 0.1mm-0.15mm, and the glaze surface is matte transparent glaze.

[0076] In step S4, the clay sheet body treated in step S3 is placed in a kiln for firing and cooling to obtain a ceramic sheet. The firing process includes controlling the temperature in the kiln from room temperature and gradually increasing it to 1300°C, stopping the firing at the highest temperature, and then allowing the temperature to cool to room temperature for 6-12 hours. A decal is then applied to the ceramic sheet, which is then placed in the kiln for firing again to obtain a decaled ceramic sheet.

[0077] S5, apply ceramic glue on the bottom surface of the decal ceramic sheet, and apply E7000 glue on the surface of the base fabric (polyurethane fabric); then cover the ceramic sheet on the surface of the base fabric to allow the ceramic glue to combine with the leather glue, and then dry it in the shade under a load: place a heavy object on the ceramic sheet and apply pressure to the ceramic sheet. The pressure on the ceramic sheet is 2kg / cm 2 , the pressure application time is 24h.

[0078] S6, after the decal ceramic sheet is firmly bonded to the base fabric, the ceramic sheet on the base fabric is crushed by manual rolling. The length and width of the crushed ceramic sheet are respectively about 0.5 cm, thus obtaining the ceramic fabric.

[0079] In summary, the ceramic fabric and preparation method provided by the embodiments of the present invention use a base fabric as a carrier, adhere thin ceramic sheets to the base fabric with glue, and dry them in the shade under a load, so that the ceramic sheets are firmly adhered to the base fabric. The ceramic sheets can be used as decorative surfaces, and different colors, patterns, etc. can be designed on the ceramic sheets to present different artistic styles. In addition, by crushing the ceramic sheets, the ceramic fabric is made more flexible, meeting the flexibility requirements for processing into clothing. This broadens the types of fabrics, application fields, and decorative styles. It subverts the boundary between ceramics and fabrics, and can be used to make both ceramic products and fashion products.

[0080] The embodiments described above are some, but not all, of the embodiments of the present invention. The detailed description of the embodiments of the present invention is not intended to limit the scope of the invention as claimed, but rather merely represents selected embodiments of the present invention. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without inventive effort are also within the scope of protection of the present invention.

Claims

1. A ceramic fabric, characterized in that: It comprises a ceramic sheet and a base fabric, wherein the ceramic sheet is adhered to the surface of the base fabric by glue.

2. The ceramic fabric according to claim 1, characterized in that: The raw material of the base fabric is one of synthetic leather, animal leather, plant fiber, animal fiber and synthetic fiber.

3. The ceramic fabric according to claim 1, characterized in that: The glue is one or two of leather glue, ceramic glue and cloth glue.

4. A method for preparing the ceramic fabric according to any one of claims 1 to 3, characterized in that: The following steps are involved: S1, preparing mud, brushing the mud on the surface of the gypsum board, and drying it to a moisture content of 10-20% to obtain a mud blank; S2, cutting the clay to obtain the clay sheet body, and drying it in the shade; S3, spraying glaze on the surface of the clay body after air drying to form a glaze layer, and air drying until completely dry; S4, placing the clay sheet body processed in step S3 in a kiln for firing, cooling, and obtaining a ceramic sheet; or applying a decal on the ceramic sheet, and then placing the clay sheet in a kiln for firing, to obtain a decal ceramic sheet; S5, coating glue on one surface of the ceramic sheet or the decal ceramic sheet and one surface of the base fabric, respectively, then covering the ceramic sheet on the surface of the base fabric, and drying in the shade under a load; S6, after the ceramic sheet is firmly bonded to the base fabric, the ceramic sheet on the base fabric is crushed to obtain the ceramic fabric.

5. The method for preparing a ceramic fabric according to claim 4, wherein: In step S2, the thickness of the mud sheet body is 0.3-0.4 mm.

6. The method for preparing a ceramic fabric according to claim 4, wherein: In step S3, the thickness of the glaze layer is 0.1-0.15 mm.

7. The method for preparing a ceramic fabric according to claim 4, wherein: In step S4, the firing includes: controlling the temperature in the kiln to continuously fire from room temperature, gradually raising the temperature to 1250-1300°C, stopping the firing when the highest temperature is reached, and then cooling the temperature to room temperature for 6-12 hours.

8. The method for preparing a ceramic fabric according to claim 4, wherein: In the step S5, ceramic glue is coated on the surface of the ceramic sheet, and leather glue is coated on the surface of the base fabric; the raw material of the base fabric is animal leather or synthetic leather.

9. The method for preparing a ceramic fabric according to claim 4, wherein: In step S5, the weight-bearing shade drying is: placing a heavy object on the ceramic sheet and applying pressure to the ceramic sheet for 24-30 hours.

10. The method for preparing a ceramic fabric according to claim 6, wherein: In step S6, the length and width of the crushed ceramic pieces are between 0.3-0.6 cm.

Images