CN101870588B - 一种制备空心陶瓷微珠的方法与装置 - Google Patents

一种制备空心陶瓷微珠的方法与装置 Download PDF

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CN101870588B
CN101870588B CN2009101310517A CN200910131051A CN101870588B CN 101870588 B CN101870588 B CN 101870588B CN 2009101310517 A CN2009101310517 A CN 2009101310517A CN 200910131051 A CN200910131051 A CN 200910131051A CN 101870588 B CN101870588 B CN 101870588B
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microspheres
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powder
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CN101870588A (zh
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杨金龙
席小庆
葛国军
黄勇
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Hebei Yl Bangda New Materials Ltd
Tsinghua University
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HEBEI YL-INNO Co Ltd
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Priority to PCT/CN2010/000538 priority patent/WO2010121488A1/zh
Priority to EA201171263A priority patent/EA020857B1/ru
Priority to US13/265,463 priority patent/US8845936B2/en
Priority to BRPI1013934A priority patent/BRPI1013934A2/pt
Priority to EP10766579.6A priority patent/EP2431344B1/en
Priority to AU2010239045A priority patent/AU2010239045B2/en
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Abstract

本发明提供一种制备空心陶瓷微珠的方法与装置，将陶瓷粉体与水、分散剂按一定比例混合球磨，球磨后加入一定量发泡剂并搅拌，制备出高固相含量的稳定泡沫浆料；将泡沫浆料加入离心雾化设备，使其雾化形成空心浆料液滴，并喷入成型室内，快速失去水分干燥，形成空心微珠坯体，收集微珠坯体，进行烧结。制备出高质量，低成本的0.01-1.0mm的空心陶瓷微珠。空心微珠指闭孔的空心微珠和开孔的空心微珠两种。该方法与装置对与各种材料体系的陶瓷粉体具有普适性，可以制备不同陶瓷材料的空心微珠。

Description

一种制备空心陶瓷微珠的方法与装置
技术领域
本发明涉及新型陶瓷成型技术领域，属于陶瓷成型工艺制备异形陶瓷材料的范畴，特别是指制备空心陶瓷小球的方法及装置。
背景技术
空心陶瓷微珠是一种尺寸微小的空心无机非金属材料球体，粒径范围0.01-1.0mm。具有质轻、低导热、隔音、耐磨、高分散、电绝缘性和热稳定性好、制造成本低等优点，是一种用途广泛的质轻、高强，性能优异的新型轻质材料。能够满足石油固井、汽车底盘抗震、船身甲板、树脂等有机物的填料、乳化炸药、高档防火涂料、保温耐火材料，建筑夹层保温、吸声降燥、建筑外墙的保温节能、回归反射材料、生物制药缓释药物的载体等要求，此外在电子工业轻质封装材料、吸波材料、深水浮力材料、低密度粘合剂、轻质高强混凝土等方面也有潜在的用途。与传统的空心玻璃微珠相比，空心陶瓷微珠抗压强度更高，可以达到前者数十倍。
在人造大理石的生产中，用空心陶瓷微珠减轻制品重量，提高制品的抗龟裂能力。用空心陶瓷微珠制造合成木材，制成品具有与木材同样的视感、外观和结构。主要用于高档家具，卫生洁具，家具铸塑件，装饰板材等。
空心陶瓷微珠用于修补用复合材料，典型应用是在树脂中加入空心玻璃微珠取代部分碳酸钙、滑石粉等填料制成各种腻子(原子灰)。这种新型补腻，具有重量轻，附着力强，容易涂抹，低收缩，固化时间短等优点，尤其是显著提高砂磨和抛光性能。广泛用于各种车辆、船舶、机床等修补作业中。
空心陶瓷微珠是中空封闭的球体，内部含有一定量的气体，其导热系数低，所以空心玻璃微珠具有隔音、隔热的特性。是作为各种保温材料、隔音产品的极佳填充剂。同时空心陶瓷微珠在保温涂料中也得到广泛应用。
另外，空心陶瓷微珠还是乳化炸药优良的敏化剂，能提高乳化炸药敏感度，延长炸药的储存期。
发明内容
本发明的目的在于提供一种制备空心陶瓷微珠的方法与装置，该方法与装置对与各种材料体系的陶瓷粉具有普适性，可以制备各种无机非金属材料的空心微珠，包括：氧化物和非氧化物陶瓷粉，以及含无机非金属材料的煤矸石、粉煤灰、尾矿、黄土等。
本发明的技术方案为：
一种制备空心陶瓷微珠的方法，包括以下步骤：步骤一，将陶瓷粉体与水、分散剂混合并球磨，制备出高固相含量的陶瓷浆料；步骤二，将上述高固相含量的陶瓷浆料中加入发泡剂，充分搅拌，将高固相含量的浆料制成稳定的泡沫浆料；步骤三，将稳定的泡沫浆料加入离心雾化设备，使其雾化形成空心浆料液滴，并喷入成型室内，使其快速失去水分干燥，形成空心微珠坯体；步骤四，收集空心微珠坯体，并进行烧结。
其中，步骤一中所述陶瓷粉体为广义的无机非金属材料粉体，包括：氧化物和非氧化物陶瓷粉，以及含无机非金属材料的煤矸石、粉煤灰、尾矿、黄土粉体均可。
步骤一中所述制备高固相含量的陶瓷浆料，陶瓷粉体的体积占加入陶瓷粉料后溶液总体积为25-60％，分散剂占总体积0.1-1％，其余为水。
步骤二中所述的发泡剂指能使陶瓷浆料充分发泡的曲拉通或没食子酸丙脂，其加入量为浆料总体积的0.1-0.5％。
步骤二中所述的稳定泡沫浆料，其气泡直径为0.2-1.5mm，浆料发泡率达到50％-98％之间。
步骤二中所述的气泡直径可以通过步骤二中的发泡剂加入量和步骤二中的搅拌时间来调整。
步骤四中所述的烧结，是指将空心陶瓷微珠坯体装入匣钵中在窑炉内烧结或直接装入回转窑内烧结。
一种制备空心陶瓷微珠的装置，其包含离心雾化设备、成型室、废气系统、分离系统，及为成型室提供热风的热风系统；其中离心雾化设备位于上部，其下部连接有成型室，成型室上部连接有废气系统，成型室下方设有分离系统，成型室与热风系统相连接。
离心雾化设备使泡沫浆料雾化形成空心陶瓷浆料液滴。
成型室内温度为80-300℃。
本发明的有益效果为：该装置成型的空心微珠坯体具有良好的粒径分布，产品粒径可通过改变操作条件进行调整，产品强度高，生产过程简捷，操作控制方便，可以制备各种陶瓷材料体系的空心陶瓷微珠，且其微珠粒径分布和空心微珠壁厚可以通过生产工业来调节，制备工艺简捷，生产效率高，适合规模化工业生产。
附图说明
图1为本发明一种制备空心陶瓷微珠的方法框图；
图2为本发明一种制备空心陶瓷微珠的装置的结构示意图。
【图号说明】
1  离心雾化设备    2    成型室
3  分离系统        4    废气系统
5  热风系统
具体实施方式
为能使贵审查员清楚本发明的结构组成，以及整体运作方式，兹配合图示说明如下：
本发明一种制备空心陶瓷微珠的方法与装置，该方法与装置对与各种材料体系的陶瓷粉具有普适性，可以制备各种无机非金属材料的空心微珠，包括：氧化物和非氧化物陶瓷粉，以及含无机非金属材料的煤矸石、粉煤灰、尾矿、黄土等。其制备工艺过程如图1所示，步骤如下：
步骤一，将陶瓷粉体与水、分散剂按一定比例混合并球磨，制备出高固相含量的陶瓷浆料；
步骤二，将上述陶瓷浆料加入发泡剂，充分搅拌，将高固相含量的浆料制成稳定的泡沫浆料；
步骤三，将稳定的泡沫浆料加入离心雾化设备，使其雾化形成空心浆料液滴，并喷入成型室内，快速失去水分干燥，形成空心微珠坯体；
步骤四，收集空心微珠坯体，并进行烧结。
其中，步骤一中高固相含量的陶瓷浆料是将，陶瓷粉体与水、分散剂一同球磨，其中陶瓷粉体的体积占加入陶瓷粉料后溶液总体积为25-60％，分散剂占总体积0.1-1％。
其中步骤二中的发泡剂是可以上陶瓷浆料发泡的曲拉松、没食子酸丙脂等，发泡剂加入量为浆料总体积的0.1-0.5％经过充分搅拌发泡率达到95％以上。调节发泡剂的用量或品种，控制搅拌速度，可以是泡沫浆料气泡直径在0.02-1.5mm内任意调节。
其中步骤三中，是将泡沫浆料通过本发明所提供的装置成型为空心微珠坯体。
其中步骤四是将空心微珠坯体经过高温烧结，成为空心陶瓷微珠。其中的烧结工艺可以采用回转窑炉。
本发明所提供的一种制备陶瓷空心微珠的装置，其结构示意图如图2，其包含离心雾化设备1、成型室2、废气系统4、分离系统3，及为成型室提供热风的热风系统5；其中离心雾化设备位于上部，其下部连接有成型室，成型室上部连接有废气系统，成型室下方设有分离系统，成型室与热风系统相连接。离心雾化系统是该装置的关键组成部分，泡沫浆料经其分散为直径为0.2-1.5mm的空心液滴，并喷入成型室内。热风系统将空气过滤并加热到80-300℃，从成型室上部呈螺旋状均匀地进入成型室内，与空心液滴并流接触在极短的时间内干燥为空心微珠坯体。废气由废气系统排出，空心微珠坯体连续地由成型室底部分离系统输出。该装置成型速度快，泡沫浆料数秒内完全分散并干燥，特别适用于工业化生产。该装置成型的空心微珠坯体具有良好的粒径分布，产品粒径可通过改变操作条件进行调整，产品强度高，生产过程简捷，操作控制方便。
如上所述，本发明的有益效果在于可以制备各种陶瓷材料体系的空心陶瓷微珠，且其微珠粒径分布和空心微珠壁厚可以通过生产工业来调节，制备工艺简捷，生产效率高，适合规模化工业生产。

Claims (4)

1.一种制备空心陶瓷微珠的方法，其特征在于包括以下步骤：
步骤一，将陶瓷粉体与水、分散剂混合并球磨，制备出高固相含量的陶瓷浆料；
步骤二，将上述高固相含量的陶瓷浆料中加入发泡剂，充分搅拌，将高固相含量的陶瓷浆料制成稳定的泡沫浆料；
步骤三，将稳定的泡沫浆料加入离心雾化设备，使其雾化形成空心浆料液滴，并喷入成型室内，使其快速失去水分干燥，形成空心微珠坯体；
步骤四，收集空心微珠坯体，并进行烧结；
步骤一中所述高固相含量的陶瓷浆料，陶瓷粉体的体积占加入陶瓷粉体后溶液总体积为25-60％，分散剂占总体积0.1-1％，其余为水；
步骤二中所述的发泡剂指能使陶瓷浆料充分发泡的曲拉通或没食子酸丙脂，其加入量为浆料总体积的0.1-0.5％；步骤二中所述的稳定的泡沫浆料，其气泡直径为0.2-1.5mm，陶瓷浆料发泡率达到50％-98％之间。
2.如权利要求1所述的一种制备空心陶瓷微珠的方法，其特征在于：步骤一中所述陶瓷粉体为广义的无机非金属材料粉体，包括：氧化物和非氧化物陶瓷粉，以及含无机非金属材料的煤矸石、粉煤灰、尾矿、黄土粉体。
3.如权利要求1所述的一种制备空心陶瓷微珠的方法，其特征在于：步骤二中所述的气泡直径通过步骤二中的发泡剂加入量和步骤二中的搅拌时间来调整。
4.如权利要求1所述的一种制备空心陶瓷微珠的方法，其特征在于步骤四中所述的烧结，是指将空心微珠坯体装入匣钵中在窑炉内烧结或直接装入回转窑内烧结。
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