Plant pattern ceramic partition loading kiln tool and uniform firing method

Abstract

The present application belongs to the technical field of ceramic firing and kiln loading fixture, and particularly relates to a plant pattern ceramic partition loading kiln fixture and uniform firing method. The kiln fixture comprises at least two partition bearing units arranged along the kiln loading space, each partition bearing unit comprising a bearing plate, a supporting element, an adjustable flow component and a positioning component. At least one of the supporting height, the effective flow area and the unit space loading capacity defined by the positioning component of different partition bearing units can be independently set before the start of firing. The method divides the kiln thermal zone by reference firing, classifies and encodes the body according to the ware type and plant pattern parameters, presets the adjustable flow area, the layer distance and the unit space loading capacity in each partition and performs matching loading, and corrects the batch according to the partition temperature difference and the product result after firing, so as to realize uniform firing of plant pattern ceramics in the same kiln. The present application can effectively improve the plant pattern integrity and the consistency of firing in the same kiln.

Description

Technical Field

[0001] This invention relates to the field of ceramic firing and kiln loading technology, specifically to a plant-patterned ceramic zoned kiln loading tool and a method for uniform firing. Background Technology

[0002] Plant-patterned ceramics are ceramic bodies with natural leaves, petals, veins, or other plant-like textures applied to the glaze layer. After firing, the plant outlines and vein patterns are retained on the glaze surface. Compared to ordinary homogeneous glazed ceramics, the areas covered by plant materials experience additional organic matter expulsion, ash migration, localized glaze thickness variations, and differences in radiation absorption. Therefore, they are more sensitive to heating rates, gas flow, maintaining the maximum temperature, and the uniformity of cooling. For example, during the high-temperature firing process of a wood-leaf tenmoku bowl at around 1300℃, the plant material undergoes complex thermochemical processes such as organic matter decomposition and ash melting and bonding with the glaze. The matching of thermal conditions during the kiln loading stage has a significant impact on the firing quality of plant-patterned ceramics.

[0003] In conventional kiln loading, the blanks are usually arranged according to the shape of the vessel and the available space. Temperature and atmosphere differences may exist between the areas near the heating elements, the area near the kiln door, the central area, the edge areas, and different height layers within the same kiln. If the orientation of the plant pattern covering area, the spacing between blanks, and the interlayer flow conditions are inconsistent, blanks in the same batch may exhibit plant pattern erosion, leaf incompleteness, glaze color differences, localized scorch spots, bubbles, or deformation.

[0004] Existing technologies include methods such as refractory ball laying, baffle plates, multi-point temperature measurement, or zoned heating to improve kiln loading uniformity. However, none of these methods address the specific plant material coverage of plant-patterned ceramics by establishing a corresponding relationship between kiln thermal zoning, ceramic loading type, orientation, loading density, and adjustable flow kiln furniture. In particular, existing loading methods primarily focus on improving loading efficiency for ordinary daily-use ceramics, neglecting the unique firing requirements of plant-patterned ceramics due to plant material coverage. Plant-covered areas undergo special thermochemical processes during firing, such as organic matter removal and ash migration, making them far more sensitive to kiln thermal conditions and airflow distribution than ordinary ceramics. Furthermore, while existing technologies employ a qualitative principle of "dense loading at high firing positions and sparse loading at low firing positions," they lack a systematic zoning method based on measured temperature data and quantitative matching rules specific to the characteristics of plant-patterned ceramics. Currently, no technology has been disclosed that incorporates plant-pattern decoration parameters into kiln loading decision rules.

[0005] Therefore, there is a need for a uniform firing method and kiln furniture that is based on the actual thermal field inside the kiln and incorporates the shape parameters and plant decoration parameters of plant-patterned ceramics into the kiln loading decision. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings and deficiencies of existing technologies and to provide a method for partitioned kiln loading and uniform firing of plant-patterned ceramics. By measuring the internal thermal field of the kiln during benchmark firing and dividing it into thermal zones, the shape parameters and plant pattern decoration parameters of the plant-patterned ceramics are incorporated into the kiln loading category code. The effective flow area, interlayer distance, and unit space loading of each zone are independently preset before firing using partitioned firing units. This allows the blanks in different kiln positions to obtain heat flow conditions that are adapted to thermal sensitivity and organic matter discharge requirements. The kiln loading rules are continuously optimized through batch feedback correction, thereby improving the integrity of the plant pattern and the consistency of firing in the same kiln.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A kiln furniture for plant-patterned ceramics with zoned loading includes at least two zoned firing units arranged along the loading space of the kiln. Each zoned firing unit includes a firing plate, a support component, an adjustable flow passage component, and a positioning component. At least one of the support height, effective flow passage area, and unit space loading capacity defined by the positioning component of different zoned firing units can be independently set before firing. By setting at least two zoned firing units arranged along the loading space of the kiln, and enabling at least one of the support height, effective flow passage area, and unit space loading capacity of each unit to be independently preset before firing, differentiated configuration of structural parameters for different thermal zones within the kiln is achieved. This provides a fundamental means to solve the problem of inconsistent firing quality of plant-patterned ceramics caused by thermal differences at different locations within the same kiln from the perspective of kiln furniture structure.

[0008] In some embodiments, the support member is used to form an interlayer space between adjacent heating plates and has at least two selectable support heights; the support member includes a fixed support column and an extension member detachably connected to the fixed support column, and the interlayer distance is changed by selecting the number and / or height of the extension members; the adjustment range of the interlayer distance is 50~300mm. By setting the support member as a combination structure of a fixed support column and a detachable extension member, the interlayer distance can be adjusted as needed within the range of 50~300mm, thereby flexibly changing the height of the interlayer space according to the convective heat transfer requirements of different thermal zones, ensuring sufficient flow of hot air while taking into account the utilization rate of the loading space.

[0009] In some embodiments, the adjustable flow-through assembly is disposed on the side, bottom, or interlayer space of the firing plate, and includes a guide plate with multiple flow holes and a shielding member slidably connected to the guide plate; the surface of the guide plate is provided with a groove, and the shielding member is provided with a slider adapted to the groove; the shielding member slides along the groove via the slider and is locked in a preset position by fastening bolts; the shielding member can move relative to the guide plate and be fixed in a preset position before firing begins, so as to change and maintain the effective flow-through area of ​​the partitioned firing unit; the effective flow-through area is the sum of the open areas of the flow holes, and the adjustment range is 10% to 90% of the total flow-through area of ​​the guide plate. By setting the adjustable flow passage component as a structure in which the guide plate and the shielding component slide together, and using the groove-slider connection and fastening bolts to lock, the quantitative displacement and position fixation of the shielding component before firing can be achieved. This allows the effective flow passage area to be continuously adjustable within the range of 10% to 90% of the total flow passage area of ​​the guide plate, and to remain stable during firing. Active adjustment of zoned thermal flow resistance can be achieved without the need for a high-temperature online actuator.

[0010] In some embodiments, the firing plate includes a central firing zone and an edge firing zone surrounding the central firing zone, and the opening ratio of the flow holes in at least one firing zone can be adjusted by a shielding member. By dividing the firing plate into a central firing zone and an edge firing zone, and allowing independent adjustment of the opening ratio of the flow holes in at least one firing zone, differential heat flow control in different regions within the same firing plate plane is achieved, enabling effective compensation of the temperature difference between the central and edge regions through local flow adjustment.

[0011] In some embodiments, the positioning component is disposed on the firing plate and includes a detachable limiting post and a direction indicator; the limiting post is connected to the firing plate by a plug-in fit, the bottom of the limiting post is provided with a plug-in post, and the firing plate is provided with a plug-in hole at a corresponding position; the limiting post forms a placement area adapted to the bottom of the plant-patterned ceramic body; the direction indicator is an arrow-shaped protrusion or groove mark disposed on the surface of the firing plate, used to indicate the opening direction or the predetermined orientation of the plant pattern covering area. By providing a detachable limiting post and a direction indicator, the placement area of ​​the body, the opening direction, and the orientation of the plant pattern covering area can be accurately defined and maintained before firing, avoiding the randomness of manual placement and reducing uneven heating and differences in the appearance of the plant pattern caused by inconsistent body orientation.

[0012] In some embodiments, each of the partitioned firing units is further provided with a temperature recording device mounting base; a detachable partitioned flow divider with an open portion is provided between adjacent partitioned firing units; the partitioned flow divider is a plate-like structure, with the open portion located at the upper or lower part of the flow divider, and the height of the open portion being 20% ​​to 50% of the total height of the flow divider; the partitioned flow divider is made of a refractory material with a service temperature not lower than the highest firing temperature of the plant-patterned ceramic and which does not react with the glaze and plant ash in the firing atmosphere. By limiting the firing plate, support, adjustable flow assembly, and positioning assembly to be made of cordierite-mullite, mullite, or corundum refractory materials with a service temperature not lower than 1300℃, the structural stability and chemical inertness of the kiln furniture in the high-temperature firing environment of the plant-patterned ceramic are ensured, and the adhesion reaction between the kiln furniture and the glaze or plant ash is avoided, thus preventing the product quality from being affected.

[0013] In some embodiments, the firing plate, support, adjustable flow assembly, and positioning assembly are all made of refractory materials with a service temperature not lower than the highest firing temperature of the plant-patterned ceramic and which do not react with the glaze and plant ash in the firing atmosphere. The refractory material is selected from at least one of cordierite-mullite refractory materials, mullite refractory materials, or corundum refractory materials, and has a service temperature not lower than 1300°C. By limiting the firing plate, support, adjustable flow assembly, and positioning assembly to be made of cordierite-mullite, mullite, or corundum refractory materials with a service temperature not lower than 1300°C, the structural stability and chemical inertness of the kiln furniture are ensured in the high-temperature firing environment of the plant-patterned ceramic, preventing the kiln furniture from reacting with the glaze or plant ash and affecting the quality of the product.

[0014] A method for uniform firing of plant-patterned ceramics in a kiln using partitioned kiln furniture includes the following steps: Step S1: Establish kiln position zoning: Set up multiple kiln position measurement points in the loading space of the kiln to be used, and carry out benchmark firing according to the predetermined firing program under the benchmark load conditions to obtain temperature-time data of each kiln position measurement point; divide the loading space into at least two thermal zones according to the temperature deviation of at least two stages in the heating stage, the maximum temperature holding stage and the cooling stage. Step S2: Establish the kiln loading category of the green body: Obtain the shape parameters and plant pattern decoration parameters of the ceramic green body to be fired. The shape parameters include at least two of the following: opening direction, wall thickness, and heating area. The plant pattern decoration parameters include at least two of the following: natural plant material coverage area, coverage area, and plant vein orientation. The plant pattern coverage area is used to characterize the amount of organic matter discharged. Based on this, the green body is classified and a category code is set. Step S3: Set up the zoned firing unit: Set up the zoned firing unit in each thermal zone; preset the effective flow area, interlayer distance and positioning state before firing begins, and maintain the structural state during firing; Step S4, Matching Loading: Match the kiln position for different kiln loading categories according to the thermal zoning deviation; preset the placement area of ​​the billet, the opening direction, the orientation of the plant pattern covering area, the spacing between adjacent billets, and the loading amount per unit space through the positioning component; when the plant pattern covering area is large or the organic matter discharge is high, reduce the loading amount per unit space and increase the flow space; similar billets are arranged in a mirror or staggered manner around the central reference plane of the kiln. Step S5, Firing and Recording: Complete the firing according to the predetermined firing program, record the temperature-time data of different thermal zones, and record the integrity of plant patterns, glaze color difference, scorch marks, bubbles, deformation and cracking according to the type of green body and kiln position; Do not move the guide plate, replace the heightening parts, or change the orientation, spacing or loading of the green body during firing; Step S6, Batch Correction: Compare the temperature data and product results of the same kiln loading category in different thermal zones. If the difference exceeds the preset acceptance range, after shutting down the furnace, cooling, and ensuring safe operation conditions, determine the baffle opening, interlayer distance, unit space loading, or green body orientation for the next batch. After continuous batch verification, a fixed process card is formed. By integrating the six steps of benchmark firing thermal zone, green body plant texture parameter classification and coding, zone kiln furniture parameter preset, matching loading, firing record, and batch correction into a complete closed-loop method, the kiln loading decision for plant texture ceramics is transformed from relying on manual experience to a systematic process method based on measured thermal field data and product result feedback. Each batch can optimize the kiln loading rules based on the previous batch, continuously improving the uniformity of firing plant texture ceramics in the same kiln and the consistency of finished products.

[0015] In some embodiments, in step S1, the plurality of kiln position measurement points are set up according to a three-dimensional grid layout, with each measurement point evenly distributed in the height, horizontal and depth directions of the loading space, and the number of measurement points is not less than 9; at least two of the following are used as the basis for partitioning: the time difference between measurement points reaching the temperature during the heating stage does not exceed 10 min, the actual temperature difference between measurement points during the highest temperature holding stage does not exceed 10℃, and the cooling rate difference between measurement points during the cooling stage does not exceed 5℃ / h; when the temperature deviation directions of different stages are inconsistent, the main partition is established with priority based on the temperature deviation between the heating stage and the highest temperature holding stage; in step S2, the category code is compiled according to the three-level coding rule of "vessel type code - coverage area level code - vein orientation code". By limiting the establishment method of thermal zoning to three-dimensional grid layout, no less than 9 measurement points, and specific zoning judgment thresholds, thermal zoning has clear quantitative standards and repeatable operation procedures, avoiding the arbitrariness of relying on manual visual inspection or experience judgment. At the same time, the three-level coding rule of "vessel type code - coverage area level code - vein orientation code" is used to classify the green body, so that the kiln loading categories of different plant pattern green bodies can be accurately identified, recorded and traced, which improves the standardization and reusability of process management.

[0016] In some embodiments, in step S4, the matching loading is performed according to the following rules: kiln loading categories with higher organic matter discharge are matched to thermal zones with better flowability; green bodies with thicker walls and slower heating are matched to thermal zones with higher temperatures; and green bodies with smaller plant pattern coverage areas are matched to thermal zones with lower temperatures. The adjustment range of the unit space loading amount is 30~80kg of plant pattern ceramic green bodies per cubic meter of loading space; when the plant pattern coverage area accounts for more than 30% of the green body surface area, the unit space loading amount is 30~50kg / m³; when the plant pattern coverage area accounts for no more than 30% of the green body surface area, the unit space loading amount is 50~80kg / m³. In step S6, the preset acceptance range includes: the maximum temperature difference of the same kiln loading category in different thermal zones does not exceed 5℃, the integrity of the plant pattern is not less than 85%, the color difference ΔE does not exceed 3, and the deformation does not exceed 0.5% of the maximum size of the green body. By specifying the matching loading rules as three principles—matching organic matter discharge with zoned flowability, wall thickness with temperature level, and coverage area with temperature margin—and combining the proportion of plant pattern coverage area to classify and limit the loading amount per unit space, the loading decision has a clear quantitative basis and operability. This avoids the appearance of defects in the green body with high organic matter discharge in the kiln position with low flowability, while ensuring the kiln loading efficiency, thus taking into account both firing quality and production economy.

[0017] The beneficial effects of this invention are: First, by using the temperature-time data of each kiln position in the kiln loading space measured in the benchmark firing, and dividing the thermal zones according to the temperature deviations in the heating stage, the highest temperature holding stage, and the cooling stage, the kiln loading decision is transformed from relying on manual experience to quantifiable and reusable rules based on measured thermal field data, thereby improving the scientificity and consistency of kiln loading.

[0018] Secondly, the shape parameters and decorative parameters of plant-patterned ceramics are incorporated into the kiln loading category code. In particular, the plant pattern coverage area is used as a key classification criterion to characterize the amount of organic matter discharged, so that different plant-patterned blanks can be matched to kiln positions that are compatible with their thermal sensitivity and organic matter discharge requirements, thereby reducing the defects caused by differences in kiln position thermal performance.

[0019] Third, the zoned firing unit can independently preset the support height, effective flow area, and unit space loading capacity of each thermal zone before firing begins, and maintain this structural state during firing. It can achieve zoned differentiated heat flow adjustment without relying on high-temperature online actuators, thereby improving the adaptability and operational reliability of the kiln furniture.

[0020] Fourth, by fixing the placement area, opening direction, and orientation of the plant pattern covering area of ​​the green body by positioning components, and by using the same type of green bodies to be arranged in a mirror or staggered manner around the central reference plane of the kiln, the systematic differences in pattern appearance caused by changes in the direction of manual placement and a single heat flow direction are reduced, thereby improving the consistency of products in the same batch.

[0021] Fifth, by recording temperature-time data and product results after firing, and comparing the differences of the same kiln loading category in different thermal zones with the preset acceptance range, a batch feedback correction mechanism is formed. After continuous batch verification, it is solidified into a fixed process card, thereby continuously improving the integrity of plant-patterned ceramics fired in the same kiln and the consistency of finished products. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, obtaining other drawings based on these drawings without creative effort still falls within the scope of the present invention.

[0023] Figure 1 This is a flowchart of the method for uniform firing of plant-patterned ceramics in a kiln with partitioned loading according to the present invention.

[0024] Figure 2 This is a schematic diagram of the thermal zoning of the kiln loading space and the arrangement of the zoning firing units of the present invention.

[0025] Figure 3 This is a schematic diagram of the kiln furniture for partitioned kiln loading according to the present invention.

[0026] Figure 4 This is a schematic diagram of the adjustable flow component of the present invention.

[0027] Figure 5 This is a schematic diagram showing the mirror or staggered arrangement of billets of the same kiln loading category according to the present invention.

[0028] Explanation of reference numerals in the attached drawings: 1-Kiln loading space; 11-First thermal zone; 12-Second thermal zone; 13-Third thermal zone; 2-Sectional firing unit; 21-Firing plate; 211-Central firing zone; 212-Edge firing zone; 22-Supporting component; 221-Fixing support column; 222-Heightening component; 23-Adjustable flow assembly; 231-Guide plate; 232-Flow hole; 233-Blocking component; 2311-Slide groove; 2331-Slider; 2332-Fastening bolt; 24-Positioning component; 241-Limiting post; 2411-Plug-in post; 242-Directional indicator; 2421-Arrow-shaped protrusion; 25-Temperature recorder mounting base; 26-Sectional flow barrier; 261-Open section; 3-Plant-patterned ceramic body; 31-Plant-patterned covered area; 4-Temperature recording element. Detailed Implementation

[0029] To make the technical problems to be solved, the technical solutions, and the beneficial effects of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0030] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the invention. The terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings, are intended to cover non-exclusive inclusion.

[0031] The directional and positional terms used in this invention, such as up, down, front, back, left, right, inside, outside, top, bottom, side, etc., are merely for reference to the accompanying drawings. Therefore, the directional and positional terms used are for illustrating and understanding this invention, and not for limiting the scope of protection of this invention.

[0032] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments: Example 1 like Figures 1 to 3As shown, this embodiment of the invention provides a plant-patterned ceramic partitioned kiln furniture. This embodiment includes at least two partitioned firing units 2 arranged along the kiln loading space 1. The kiln loading space 1 is divided into a first thermal zone 11, a second thermal zone 12, and a third thermal zone 13 according to baseline firing measurements. Each zone is equipped with an independent partitioned firing unit 2. At least one of the following parameters—support height, effective flow area, and unit space loading capacity defined by the positioning component 24—can be independently set before firing begins.

[0033] Each zone firing unit 2 includes a firing plate 21, a support member 22, an adjustable flow assembly 23, and a positioning assembly 24.

[0034] The support member 22 is used to form an interlayer space between adjacent firing plates 21 and has at least two selectable support heights. The support member 22 consists of a fixed support column 221 and an extension member 222 detachably connected to the fixed support column 221. The upper and lower end faces of the fixed support column 221 are respectively provided with positioning bosses, and the corresponding positions of the firing plates 21 are provided with positioning holes adapted to the positioning bosses. The fixed support column 221 is detachably inserted and positioned with the firing plate 21 by inserting the positioning bosses into the positioning holes of the firing plate 21. The heightening element 222 is an annular or cylindrical pad fitted onto the upper end of the fixed support 221. The inner hole of the heightening element 222 is clearance-fitted with the outer wall of the fixed support 221. The lower end face of the heightening element 222 abuts against the upper end face of the fixed support 221 or the upper end face of an adjacent heightening element 222. The upper end face of the heightening element 222 abuts against the lower surface of the upper firing plate 21. Thus, the interlayer distance between adjacent firing plates 21 can be changed by altering the number or height of the heightening elements 222. The adjustment range of the interlayer distance is 50~300mm. In a preferred embodiment, for thermal zones with slower heating, the interlayer distance is 200~300mm; for thermal zones with faster heating, the interlayer distance is 50~150mm.

[0035] The adjustable flow-through assembly 23 is disposed on the side, bottom, or interlayer space of the firing plate 21, and includes a guide plate 231 with multiple flow holes 232 and a shielding member 233 slidably connected to the guide plate 231. In the most preferred embodiment, the adjustable flow-through assembly 23 is disposed on the side of the firing plate 21, so that the operator can manually adjust the position of the shielding member 233 and lock it before firing, and the side is the main channel for the transverse flow of hot air in the compartment, so the adjustment effect is the most direct. The guide plate 231 is detachably connected to the firing plate 21 through a horizontal slot disposed on the side of the firing plate 21; when the adjustable flow-through assembly 23 is disposed on the bottom of the firing plate 21, the guide plate 231 is detachably connected to the firing plate 21 through a slot or bracket disposed on the lower surface of the firing plate 21. When the adjustable flow assembly 23 is installed in the interlayer space, the guide plate 231 is fixed to the airflow channel between adjacent firing plates 21 by an independent bracket or connector. The two ends of the bracket are respectively inserted or snapped into the upper and lower firing plates 21. The guide plate 231 is detachably connected to the bracket, and the shielding member 233 still slides and locks through the slide groove 2311. The surface of the guide plate 231 is provided with the slide groove 2311, and the shielding member 233 is provided with a slider 2331 adapted to the slide groove 2311. After the shielding member 233 slides along the slide groove 2311 to the preset position by the slider 2331, it is locked and fixed by the fastening bolt 2332. The fastening bolt 2332 passes through the bolt hole on the slider 2331 and presses against the surface of the guide plate 231, so that the shielding member 233 is kept in the preset position during firing. The shielding member 233 can move relative to the guide plate 231 and be fixed in a preset position before firing begins, causing some of the flow holes 232 to open or close, thereby changing and maintaining the effective flow area of ​​the partitioned firing unit 2. The effective flow area is the sum of the open areas of the flow holes, and the adjustment range is 10% to 90% of the total flow area of ​​the guide plate. In a preferred embodiment, for thermal zones that reach temperature slowly during the baseline firing, the effective flow area is 70% to 90% of the total flow area of ​​the guide plate; for thermal zones that reach temperature quickly or have strong direct radiation, the effective flow area is 10% to 30% of the total flow area of ​​the guide plate. Unlike firing plates that only have slots, this embodiment achieves active adjustment of the opening ratio of the flow holes through the relative movement of the shielding member 233 and the guide plate 231, and this adjustment is preset before firing and locked during firing, without the need for high-temperature online operation.

[0036] The firing plate 21 includes a central firing zone 211 and an edge firing zone 212 surrounding the central firing zone 211. The central firing zone 211 and the edge firing zone 212 are each provided with an independent set of flow holes 232. At least the opening ratio of the flow holes 232 in the edge firing zone 212 can be individually adjusted by the shielding member 233, thereby realizing differentiated control of heat flow between the central region and the edge region within the same plane of the firing plate 21.

[0037] The positioning component 24 is disposed on the firing plate 21 and includes a detachable limiting post 241 and a direction marker 242. The limiting post 241 is connected to the firing plate 21 by a plug-in engagement. The bottom of the limiting post 241 has a plug-in post 2411, and the firing plate 21 has a corresponding plug-in hole. The installation of the limiting post is completed by inserting the plug-in post 2411 into the plug-in hole. The height of the limiting post 241 is 20~80mm, and the diameter is 5~20mm. The limiting post 241 forms a placement area that fits the bottom of the plant-patterned ceramic body 3. The shape of the placement area can be circular to fit cup-type bodies, rectangular to fit plate-type bodies, or an irregular shape consistent with the bottom shape of the body. The direction marker 242 is an arrow-shaped protrusion 2421 or a groove mark disposed on the surface of the firing plate 21, used to indicate the predetermined orientation of the opening or the plant-patterned covered area 31.

[0038] Each zone-supported firing unit 2 is also equipped with a temperature recording element mounting base 25. The temperature recording element mounting base 25 is located at the upper surface edge of the firing plate 21 or on the side of the firing plate 21, and is fixedly connected to the firing plate 21 by refractory mortar or a plug-in structure, for fixing the temperature recording element 4. A detachable zone-separating baffle 26 with an opening 261 is provided between adjacent zone-supported firing units 2. The zone-separating baffle 26 has a plate-like structure, and the opening 261 is located at the upper or lower part of the baffle. The height of the opening 261 is 20% to 50% of the total height of the baffle. The two sides of the zone-separating baffle 26 are respectively inserted into the vertical slots provided on the side of the firing plate 21 of the adjacent zone-supported firing unit 2 to achieve detachable installation. The function of the zone-separating baffle 26 is to control the degree of heat and air exchange between adjacent thermal zones, so that each zone maintains relatively independent thermal characteristics.

[0039] The firing plate 21, support member 22, adjustable flow assembly 23, positioning assembly 24, and partition flow divider 26 are all made of refractory material whose operating temperature is not lower than the highest firing temperature of plant-textured ceramics and which does not react with glaze and plant ash in the firing atmosphere. The refractory material is selected from at least one of cordierite-mullite refractory material, mullite refractory material, or corundum refractory material, and its operating temperature is not lower than 1300℃.

[0040] The kiln furniture structure of this embodiment has the following functions: the support member 22 adjusts the interlayer distance by changing the height-increasing member 222; the adjustable flow-through component 23 changes the effective flow-through area by moving the blocking member 233; the positioning component 24 defines the placement area and orientation by limiting post 241 and direction marker 242; and the partition flow-blocking member 26 controls the airflow exchange between partitions by the opening 261. All the above adjustments are preset before firing begins, and the structure remains unchanged during firing, requiring no online actuators.

[0041] Example 2 This invention provides a method for uniform firing of plant-patterned ceramics in a kiln with partitioned loading. This method uses the plant-patterned ceramic partitioned loading kiln furniture described in Example 1. Figure 4 As shown, the method includes the following steps: Step S1: Establish kiln site zoning: Multiple kiln site measurement points are set up within the loading space 1 of the kiln to be used, using a three-dimensional grid layout. Each measurement point is evenly distributed along the height, horizontal, and depth directions of the loading space 1, with no fewer than 9 measurement points. Specifically, three temperature measurement layers (upper, middle, and lower) are set up along the height direction of the loading space 1, with a temperature measurement point spaced 200-300mm apart along the horizontal and depth directions in each layer. Each temperature measurement point is equipped with an S-type thermocouple as the temperature recording element 4, with a temperature measurement accuracy of ±1℃, and a test piece with consistent composition, shape, glaze state, and plant material state is placed there.

[0042] The reference load is 60% to 80% of the conventional kiln load to be fired. One or more reference firings are completed according to the firing procedure to be used for production, and temperature-time data are obtained at each kiln location measurement point.

[0043] The loading space 1 is divided into at least two thermal zones based on at least two of the following criteria: the time difference between measurement points reaching the target temperature during the heating phase does not exceed 10 minutes; the actual temperature difference between measurement points during the maximum temperature holding phase does not exceed 10°C; and the temperature drop rate difference between measurement points during the cooling phase does not exceed 5°C / h. For example, the loading space 1 can be divided into a first thermal zone 11, a second thermal zone 12, and a third thermal zone 13. When the time difference between measurement points reaching the target temperature during the heating phase exceeds 10 minutes but the temperature difference during the maximum temperature holding phase does not exceed 10°C, the heating phase data is prioritized as the primary zoning criterion because the heating rate has the most significant impact on the expulsion of organic matter from the plant pattern. When the temperature deviation directions are inconsistent across different phases, the primary zoning is established based on the temperature deviations of the heating phase and the maximum temperature holding phase, which have the greatest impact on the development of the plant pattern.

[0044] After firing, the glaze color, the integrity of the plant pattern outline, the clarity of the main and lateral veins, scorch marks, bubbles, and deformation status of the tested blanks are compared. If the temperature data are similar but the tested blanks show stable differences, the zoning boundaries are corrected by considering the airflow direction, kiln door position, and heating element radiation direction.

[0045] Step S2: Establish the kiln loading category for the ceramic body with plant patterns: Obtain the shape parameters and plant pattern decoration parameters for the ceramic body 3 to be fired. The shape parameters should include at least two of the following: opening direction, wall thickness, and heated area. They may also include the maximum external dimensions and the bottom support shape. The plant pattern decoration parameters should include at least two of the following: the area covered by natural plant material, the coverage area, and the orientation of the plant veins. They may also include the type of natural plant material, the state of the base glaze, and the surface glaze. The plant pattern coverage area is used to characterize the amount of organic matter discharged. The larger the coverage area, the more volatile organic compounds need to be discharged during firing, and the higher the requirements for kiln flow conditions.

[0046] Based on this, the billets are classified and assigned category codes. The category codes are compiled according to a three-level coding rule: "shape code - coverage area level code - vein orientation code". For example, "A-3-R" indicates a type A vessel, a level 3 coverage area (coverage area exceeding 30% of the billet surface area), and a right-side vein orientation. The production records assign category codes to each kiln loading category, ensuring that billets of the same type use the same kiln loading rules.

[0047] Step S3: Setting up the zoned firing units: The zoned firing units 2 described in Example 1 are respectively set in each thermal zone 11, 12, and 13. Before firing begins, the effective flow area, interlayer distance, and positioning state of each zone are preset, and this structural state is maintained during firing. For specific preset methods, please refer to the relevant description in Example 1.

[0048] Step S4, Matching Loading: Based on the thermal zoning deviation, match the kiln position for different kiln loading categories. Matching loading is carried out according to the following rules: matching kiln loading categories with higher organic matter discharge to thermal zones with better flowability, such as zones near the kiln door or vents; matching green bodies with thicker walls and slower heating to thermal zones with higher temperatures, such as zones near heating elements; matching green bodies with smaller areas covered by plant patterns to thermal zones with lower temperatures, such as the central area of ​​the kiln.

[0049] The positioning component 24 presets the placement area of ​​the ceramic body, the opening direction, the orientation of the plant pattern covering area 31, the spacing between adjacent ceramic bodies, and the loading capacity per unit space. When the plant material covering area is large or the organic matter discharge is high, the loading capacity per unit space is reduced and the flow space between adjacent ceramic bodies and between upper and lower layers is increased. The adjustable range of the loading capacity per unit space is 30~80kg of plant pattern ceramic body per cubic meter of loading space. When the plant pattern covering area accounts for more than 30% of the surface area of ​​the ceramic body, the loading capacity per unit space is 30~50kg / m³; when the plant pattern covering area accounts for less than 30% of the surface area of ​​the ceramic body, the loading capacity per unit space is 50~80kg / m³.

[0050] When the opening of the billet is deep, the opening direction should avoid the heat flow dead zone, and a gas exhaust channel should be reserved at the corresponding position of the opening. Billets of the same kiln loading category should be arranged in pairs or groups with the kiln center reference plane as a reference, so that the plant pattern covering area 31 is mirrored or staggered, reducing the systematic influence of a single heat flow direction on the billets in the same batch, such as... Figure 5 As shown. Figure 5 In the middle (a), the plant pattern covering area 31 of the plant pattern ceramic body 3 is arranged in a mirror image. Figure 5 In the middle (b), the plant pattern covering area 31 of the plant pattern ceramic body 3 is arranged in an alternating orientation.

[0051] Step S5, Firing and Recording: After matching and loading, complete the firing according to the predetermined firing program. As an example, the firing program can be as follows: from room temperature to 300℃, taking 100 minutes; from 300℃ to 600℃, taking 120 minutes; from 600℃ to 900℃, taking 120 minutes; from 900℃ to 1000℃, taking 30 minutes and holding at 1000℃ for 60 minutes; from 1000℃ to 1200℃, taking 120 minutes; from 1200℃ to 1260℃, taking 60 minutes and holding at 1260℃ for 40 minutes; after firing, allow the kiln to cool naturally.

[0052] At least one of the following stages—the organic matter concentrated discharge stage (300-600℃), the glaze softening stage (600-1000℃), and the maximum temperature holding stage (1260℃)—temperature-time data for different thermal zones are recorded. During firing, the guide plate 231 is not moved, the heightening component 222 is not replaced, and the orientation, spacing, or loading of the green body is not changed.

[0053] After the kiln is removed, the integrity of the plant pattern, the color difference of the glaze, the scorch marks, the bubbles, the deformation and cracking are recorded according to the type of body and the kiln position, and correlated with the corresponding temperature-time data.

[0054] Step S6, Batch Correction: Compare the temperature data and product results of the same kiln loading category in different thermal zones. The preset acceptance range includes: the maximum temperature difference of the same kiln loading category in different thermal zones does not exceed 5℃, the integrity of the plant texture is not less than 85%, the color difference ΔE does not exceed 3, and the deformation does not exceed 0.5% of the maximum size of the billet. If the difference exceeds the preset acceptance range, after the furnace is shut down, cooled, and safe operating conditions are met, determine the baffle opening, interlayer distance, unit space loading, or billet orientation for the next batch.

[0055] After continuous batch verification, the thermal zone number, kiln furniture opening, interlayer distance, loading quantity, billet orientation, and acceptance scope are formed into a fixed process card. This batch correction mechanism enables the kiln loading rules to be continuously optimized and solidified.

[0056] Example 3 This embodiment is used to illustrate the correspondence between each stage of the firing process in step S5 of embodiment 2 and the firing process of plant-patterned ceramics.

[0057] The temperature rises from room temperature to 300℃ in 100 minutes: This stage is for drying the green body and initial removal of organic matter. Within this temperature range, free water and some bound water in the green body gradually evaporate and are removed; low-boiling-point organic components in the plant material begin to decompose, producing a small amount of volatiles. The heating rate is slow, averaging 3℃ / min, to avoid excessively rapid removal of moisture and volatiles, which could lead to cracking of the green body or displacement of the plant texture.

[0058] The 300℃ to 600℃ stage, lasting 120 minutes, is the stage where organic matter is concentratedly discharged. High-molecular-weight organic compounds such as cellulose, hemicellulose, and pectin in the plant materials undergo pyrolysis within this temperature range, producing a large amount of volatiles. The heating rate is further reduced to an average of 2.5℃ / min to ensure that the organic matter is fully decomposed and discharged in a timely manner, preventing residual carbon from causing black spots on the glaze or blurring of the plant pattern in subsequent high-temperature stages.

[0059] The 600℃ to 900℃ stage, lasting 120 minutes, is the stage of carbonate decomposition and initial melting of the glaze. Carbonate impurities in the body begin to decompose, producing CO2, while low-melting-point components in the glaze begin to soften and melt. The heating rate is maintained at 2.5℃ / min to ensure uniform heat transfer.

[0060] The 900℃ to 1000℃ stage, lasting 30 minutes, followed by a 60-minute hold at 1000℃: This stage marks the beginning of glaze melting. The main flux in the glaze begins to melt, and the glaze gradually becomes molten. The ash from the pyrolysis of the plant materials begins to contact the glaze and undergo an interfacial reaction. The purpose of holding the temperature for 60 minutes is to allow the ash to fully react with the glaze, forming a stable plant-pattern color.

[0061] The 1000℃ to 1200℃ stage, lasting 120 minutes, is the stage where the glaze completely melts and the plant pattern is set. The glaze completely melts into a liquid state, and the plant ash fully integrates with the glaze. The outline and veins of the plant pattern are finally set in this stage. The heating rate is controlled at 1.67℃ / min to avoid excessive glaze flow and deformation of the plant pattern due to rapid heating.

[0062] The temperature range of 1200℃ to 1260℃ is 60 minutes, followed by a 40-minute hold at 1260℃: This stage maintains the highest temperature and stabilizes the color of the plant pattern. At this temperature, the plant ash completes its final chemical bonding with the glaze, resulting in a stable color effect. The 40-minute hold ensures that all parts of the kiln reach a uniform maximum temperature, resulting in consistent color in the plant pattern.

[0063] After the completion of firing, the kiln is allowed to cool naturally along with the kiln body. The cooling rate has a significant impact on the glaze glossiness and the bonding strength between the plant pattern and the glaze layer, and natural cooling can avoid glaze cracking or plant pattern peeling caused by quenching.

[0064] The above temperature procedure follows the verified product process, and zoned kiln loading does not change the sequence of each firing stage.

[0065] Example 4 To verify the feasibility of the endpoints of each numerical range in the present invention, firing verification experiments were carried out under the endpoint condition of each parameter respectively.

[0066] Verification of loading density endpoints: Firing was carried out at loading densities of 30kg / m³ and 80kg / m³ respectively, using the same batch of plant-patterned ceramic green bodies, namely Jizhou leaf temmoku tea bowl green bodies, with mulberry leaves as the plant pattern covering about 35% of the surface area of the green bodies, following the method described in Example 2. The results show that under the condition of 30kg / m³, the average integrity of the plant pattern is 92%, and the average color difference ΔE is 1.8, but the energy consumption per unit product is about 22% higher than that of conventional kiln loading; under the condition of 80kg / m³, the average integrity of the plant pattern is 87%, the average color difference ΔE is 2.5, and the scorch defect rate is about 4%. The products under both endpoint conditions can meet the qualification standards, which proves the rationality of the range of 30~80kg / m³.

[0067] Verification of interlayer distance endpoints: Firing verification was carried out at interlayer distances of 50mm and 300mm respectively. The results show that under the condition of 50mm, the temperature difference between the upper and lower layers of green bodies is about 8~10℃, but by matching different effective flow areas and increasing the flow area of the lower layer to 80%, the temperature difference can be effectively compensated, and finally the integrity of the plant pattern on each layer is ≥87%; under the condition of 300mm, the temperature difference between the upper and lower layers is ≤3℃, but the utilization rate of loading space is about 70% of the conventional level. The products under both endpoint conditions are qualified, which proves the rationality of the range of 50~300mm.

[0068] Verification of effective flow area endpoints: Firing verification was carried out at opening ratios of 10% and 90% of the total flow area of the deflector respectively. The results show that under the 10% opening condition, the temperature reaching time of this zone is extended by about 15% compared with the reference, but by matching this zone with green body types with smaller wall thickness and smaller plant pattern coverage area, the final product integrity reaches 88%; under the 90% opening condition, the heating rate of this zone is accelerated, and by matching this zone with green body types with larger wall thickness and higher organic matter discharge, the final product integrity reaches 91%. The products under both endpoint conditions are qualified, which proves the rationality of the range of 10%~90%.

[0069] The above endpoint value verification experiments show that the endpoints of each numerical range recorded in the present invention can achieve the purpose of the invention, and obtain qualified fired plant-patterned ceramic products.

[0070] Example 5 To verify the overall technical effect of the present invention, plant-patterned ceramic blanks from the same kiln and the same batch were used. The blanks for the wooden leaf Tenmoku teacup had mulberry leaves as the plant pattern, covering an area of ​​about 35% of the blank surface area. Firing comparison experiments were conducted using both conventional kiln loading methods and the method of the present invention.

[0071] Conventional kiln loading method: The vessels are evenly placed in the kiln loading space according to their size, without thermal zoning, and the loading density and orientation are not adjusted according to the plant pattern coverage. The loading density is about 65 kg / m³.

[0072] The method of this invention is as follows: According to the method described in Example 2, the kiln loading space is first divided into three thermal zones by benchmark firing. After classifying the plant-patterned blanks according to "shape code - coverage area level code - vein orientation code", the high coverage area category is matched to the thermal zone with better flowability. The kiln loading density is adjusted to 45 kg / m³. Blanks of the same type are arranged in a mirror image around the central benchmark plane of the kiln. The effective flow area of ​​each zone is preset to 75%, 50% and 30% respectively by the adjustable flow component.

[0073] The results of the comparative experiment are as follows: The above experimental data show that, after adopting the method of the present invention, the integrity of the plant pattern increased from 62%~78% to 88%~94%, the color difference of the glaze in the same batch decreased from ΔE 4.2~6.8 to ΔE 1.5~2.8, the scorch spot / bubble defect rate decreased from 18%~25% to 3%~6%, and the yield of finished products in the same batch increased from about 45%~55% to about 82%~90%. This proves that the present invention has significant technical effects in improving the uniformity of plant pattern ceramics fired in the same kiln and the consistency of finished products.

[0074] The above embodiments are used to illustrate the technical concept of the present invention. The number of kiln position measurement points, the number of thermal zones, the specific opening degree of the guide vanes, the interlayer distance, the unit space loading capacity, and the acceptance range should be determined according to the specific kiln, product category, and benchmark firing results; corresponding adjustments can be made without deviating from the above-mentioned thermal zoning, classification matching, zoning preset, and batch feedback closed loop.

[0075] The above description is merely a preferred embodiment of this application and is not intended to limit the scope of protection of this invention; the scope of protection of this invention is defined by the claims in the claims, and all equivalent changes and modifications made in accordance with this invention are within the scope of protection of this patent.

Claims

1. A plant-patterned ceramic kiln furniture with partitioned loading, characterized in that: It includes at least two partitioned firing units arranged along the loading space of the kiln. Each partitioned firing unit includes a firing plate, a support member, an adjustable flow assembly, and a positioning assembly. At least one of the support height, effective flow area, and unit space loading capacity defined by the positioning assembly of different partitioned firing units can be set independently before firing begins.

2. The plant-patterned ceramic kiln furniture according to claim 1, characterized in that: The support member is used to form an interlayer space between adjacent firing plates and has at least two selectable support heights; the support member includes a fixed support column and an extension member detachably connected to the fixed support column, and the interlayer distance is changed by selecting the number and / or height of the extension members; the adjustment range of the interlayer distance is 50~300mm.

3. The plant-patterned ceramic kiln furniture according to claim 1, characterized in that: The adjustable flow-through assembly is disposed on the side, bottom, or interlayer space of the firing plate, and includes a guide plate with multiple flow holes and a shielding member slidably connected to the guide plate. The surface of the guide plate is provided with a groove, and the shielding member is provided with a slider adapted to the groove. The shielding member slides along the groove via the slider and is locked in a preset position by fastening bolts. The shielding member can move relative to the guide plate and be fixed in a preset position before firing begins, so as to change and maintain the effective flow-through area of ​​the partitioned firing unit. The effective flow-through area is the sum of the open areas of the flow holes, and the adjustment range is 10% to 90% of the total flow-through area of ​​the guide plate.

4. The plant-patterned ceramic kiln furniture according to claim 3, characterized in that: The firing plate includes a central firing zone and an edge firing zone surrounding the central firing zone, and the opening ratio of the flow holes in at least one firing zone can be adjusted by a shielding member.

5. The plant-patterned ceramic kiln furniture according to claim 1, characterized in that: The positioning component is disposed on the firing plate and includes a detachable limiting post and a direction indicator; the limiting post is connected to the firing plate by a plug-in engagement, the bottom of the limiting post is provided with a plug-in post, and the firing plate is provided with a plug-in hole at the corresponding position; the limiting post forms a placement area that fits the bottom of the plant pattern ceramic body; the direction indicator is an arrow-shaped protrusion or groove mark disposed on the surface of the firing plate, used to indicate the opening direction or the predetermined orientation of the plant pattern covering area.

6. The plant-patterned ceramic kiln furniture according to claim 1, characterized in that: Each of the aforementioned zoned firing units is also provided with a temperature recording device mounting base; a detachable zoned flow divider with an open portion is provided between adjacent zoned firing units; the zoned flow divider is a plate-shaped structure, with the open portion located at the upper or lower part of the flow divider, and the height of the open portion being 20% ​​to 50% of the total height of the flow divider; the zoned flow divider is made of refractory material whose operating temperature is not lower than the highest firing temperature of plant-textured ceramics and which does not react with glaze and plant ash in the firing atmosphere.

7. The plant-patterned ceramic kiln furniture according to any one of claims 1 to 5, characterized in that: The firing plate, support, adjustable flow assembly, and positioning assembly are all made of refractory materials whose operating temperature is not lower than the highest firing temperature of plant-textured ceramics and which do not react with glaze and plant ash in the firing atmosphere; the refractory materials are selected from at least one of cordierite-mullite refractory materials, mullite refractory materials, or corundum refractory materials, and the operating temperature is not lower than 1300℃.

8. A method for uniform firing of plant-patterned ceramics in a kiln using partitioned loading, employing the plant-patterned ceramic partitioned loading kiln furniture as described in any one of claims 1 to 7, characterized in that: Includes the following steps: Step S1: Establish kiln position zoning: Set up multiple kiln position measurement points in the loading space of the kiln to be used, and carry out benchmark firing according to the predetermined firing program under the benchmark load conditions to obtain temperature-time data of each kiln position measurement point. The loading space is divided into at least two thermal zones based on the temperature deviation of at least two of the heating phase, the maximum temperature holding phase, and the cooling phase. Step S2: Establish the kiln loading category of the green body: Obtain the shape parameters and plant pattern decoration parameters of the ceramic green body to be fired. The shape parameters include at least two of the following: opening direction, wall thickness, and heating area. The plant pattern decoration parameters include at least two of the following: natural plant material coverage area, coverage area, and plant vein orientation. The plant pattern coverage area is used to characterize the amount of organic matter discharged. Based on this, the green body is classified and a category code is set. Step S3: Set up the zoned firing unit: Set up the zoned firing unit in each thermal zone; preset the effective flow area, interlayer distance and positioning state before firing begins, and maintain the structural state during firing; Step S4, Matching Loading: Match the kiln position for different kiln loading categories based on thermal zoning deviation; preset the green body placement area, opening direction, orientation of the plant pattern covering area, spacing between adjacent green bodies, and loading capacity per unit space through the positioning component; When the plant pattern covers a large area or the amount of organic matter discharged is high, reduce the loading capacity per unit space and increase the circulation space; similar green bodies are arranged in a mirror or staggered manner around the central reference plane of the kiln. Step S5, Firing and Recording: Complete the firing according to the predetermined firing program, record the temperature-time data of different thermal zones, and record the integrity of plant patterns, glaze color difference, scorch marks, bubbles, deformation and cracking according to the type of green body and kiln position; Do not move the guide plate, replace the heightening parts, or change the orientation, spacing or loading of the green body during firing; Step S6, Batch Correction: Compare the temperature data and product results of the same kiln loading category in different thermal zones. If the difference exceeds the preset acceptance range, after shutting down the furnace, cooling, and ensuring safe operation conditions, determine the baffle opening, interlayer distance, unit space loading, or billet orientation for the next batch. After continuous batch verification, a fixed process card is formed.

9. The method for uniform firing of plant-patterned ceramics in a kiln with partitioned loading according to claim 8, characterized in that: In step S1, the multiple kiln position measurement points are set up in a three-dimensional grid layout. Each measurement point is evenly distributed in the height, horizontal and depth directions of the loading space, and the number of measurement points is not less than 9. The partitioning criteria are based on at least two of the following: the time difference between measurement points during the heating phase is no more than 10 min; the actual temperature difference between measurement points during the highest temperature holding phase is no more than 10℃; and the cooling rate difference between measurement points during the cooling phase is no more than 5℃ / h. When the temperature deviation directions of different phases are inconsistent, the main partitioning is established based on the temperature deviation between the heating phase and the highest temperature holding phase. In step S2, the category code is compiled according to the three-level coding rule of "device type code - coverage area level code - vein orientation code".

10. The method for uniform firing of plant-patterned ceramics in a kiln with partitioned loading according to claim 8, characterized in that: In step S4, the matching loading is carried out according to the following rules: kiln loading categories with higher organic matter discharge are matched to thermal zones with better flowability; green bodies with thicker walls and slower heating are matched to thermal zones with higher temperatures; and green bodies with smaller plant pattern coverage areas are matched to thermal zones with lower temperatures. The adjustment range of the unit space loading amount is 30~80kg of plant pattern ceramic green bodies per cubic meter of loading space; when the plant pattern coverage area accounts for more than 30% of the green body surface area, the unit space loading amount is 30~50kg / m³; when the plant pattern coverage area accounts for less than 30% of the green body surface area, the unit space loading amount is 50~80kg / m³. In step S6, the preset acceptance range includes: the maximum temperature difference of the same kiln loading category in different thermal zones does not exceed 5℃, the integrity of the plant pattern is not less than 85%, the color difference ΔE does not exceed 3, and the deformation does not exceed 0.5% of the maximum size of the green body.

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