CN106478077A - 一种建筑用多孔保温陶瓷材料及其制备方法 - Google Patents
一种建筑用多孔保温陶瓷材料及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种建筑用多孔保温陶瓷材料及其制备方法,由包含如下质量百分含量的组分组成:固相粉料65‑98.8wt%,增强纤维1‑15wt%,发泡体系0.1‑10wt%,交联体系0.1‑10wt%,采用发泡工艺与注凝成型相结合的方法制备内部结构均匀、保温性能和抗热震性能良好的多孔保温陶瓷,密度为0.55‑0.60g/cm3,气孔率为65‑75%,常温下抗热震性能为32‑37次,导热系数为0.044‑0.0554W/(m2·K),抗弯强度为12.5‑18.2MPa,抗压强度为15.2‑19.5Mpa,达到了建筑用保温材料的性能指标,在建筑节能方面具有广阔的应用市场。
Description
技术领域
本发明属于新型无机非金属材料领域,具体涉及一种建筑用多孔保温陶瓷材料及其制备方法。
背景技术
建筑节能是当前我国节能领域里的重要议题,为了节约能源和保护环境,对建筑材料的隔热保温性能要求愈来愈高。目前,我国的建筑节能使用较多的是有机保温材料,其优点是质轻、可加工性好、保温隔热效果好,但缺点是不耐老化、稳定性差、易燃烧、安全性和生态环保性差;无机保温材料因可以弥补上述缺陷而成为新型保温材料的研究热点。因此,开发既有墙地砖装饰优点,又有保温材料性能的新型墙体材料,对于建筑物节能具有重要意义。
多孔陶瓷作为一种新型无机非金属材料,因其密度低、耐高温及耐腐蚀能力强、比表面积高、强度适中、热导率低等特性,受到的关注与日俱增,已成为陶瓷材料领域的研究热点,并被广泛应用于隔热保温、过滤吸附、吸声隔音、生物医学材料及环保建材等领域,其轻质和隔热性能使其在建筑节能领域具有广阔的应用前景。轻质外墙砖与泡沫陶瓷是两种重要的建筑节能用多孔陶瓷材料,轻质外墙砖被用于薄抹灰外墙外保温系统的表面装饰,具有成本低和施工简便的特点;泡沫陶瓷作为无机类保温材料,具有优良的防火及隔热性能。
目前,多孔陶瓷的制备方法主要有:发泡法、溶胶凝胶法、添加造孔剂法、有机前驱体浸渍法、凝胶注模法、自蔓延高温合成法、泡沫前驱体反应法、有机泡沫堆积法、颗粒堆积法、微波加热法、分相滤出法、固-气共晶法、木材热解构架法等;CN104829264A公开了一种资源节约型多孔陶瓷的制备方法,将煤矿石、造孔剂、烧成改良剂破碎混合,湿法球磨,然后将玄武岩纤维加入混合物中继续搅拌,成型干燥,采用无压坯烧结工艺,在可控温场的隧道窑内烧制,生成含均匀封闭微孔的轻质玄武岩纤维增强陶瓷制品;CN102050636A一种玄武岩纤维增强多孔陶瓷制品及利用煤矿石制备该制品的方法,通过球磨、过筛、混和、成型、干燥、烧成、冷却和纯化等一系列处理手段制备出性价比优良的多孔陶瓷;此外,还有大量国内外文献对多孔陶瓷材料及其改性进行相关研究和报道。但是,目前多孔陶瓷材料普遍具有韧性低、脆性大、易开裂的缺点,限制了此类材料的应用范围。
发明内容
本发明的目的在于提供一种建筑用多孔保温陶瓷材料及其制备方法,采用发泡工艺与注凝成型相结合的方法制备了内部结构均匀,保温性能和抗热震性能良好的多孔保温陶瓷,克服现有技术中多孔陶瓷材料在使用过程中易出现粉化和开裂现象,以及强度不够等缺陷。
本发明的目的通过以下技术方案来实现:
一种建筑用多孔保温陶瓷材料,由包含如下质量百分含量的组分组成:固相粉料65-98.8wt%,增强纤维1-15wt%,发泡体系0.1-10wt%,交联体系0.1-10wt%。
所述的固相粉料含陶瓷粉体和烧结助剂,所述的陶瓷粉体为高岭土、铝矾土和硅微粉的混合物,所述的烧结助剂为氧化钇或氧化锆,其中,高岭土:铝矾土:硅微粉:烧结助剂质量比为1:3:1:(0.2-0.5)。
所述的增强纤维为玻璃纤维、芳纶纤维、玄武岩纤维中的一种或两种个以上组合,长度为2-10mm。
所述的发泡体系由发泡剂、稳泡剂和去离子水组成,所述的发泡剂为棕榈酸甘油酯,所述的稳泡剂为聚乙烯醇和硬脂酸甘油酯的混合物,其中,发泡剂:稳泡剂:去离子水质量比为1:(0.5-2):15。
所述的交联体系为水基凝胶体系,由交联剂、分散剂和溶剂组成,所述的交联剂为戊二醛或丙烯酸酯,所述的分散剂为聚丙烯酸铵、聚氧乙烯醚、聚羧酸氨中的一种,所述的溶剂为乙醇或乙二醇,其中,交联剂:分散剂和溶剂质量比为1:(0.2-1):10。
一种建筑用多孔保温陶瓷材料的制备方法,包括如下步骤:
(1)将称量好的固相粉料破碎混合,湿法球磨18-24h,然后将增强纤维加入混合物中继续搅拌10-30min;然后加入发泡体系在温度为110-150℃下发泡0.5-1.5h;然后加入交联体系反应0.5-2h形成高固相低粘度浆料,固含量为55-70wt%;
(2)将步骤(1)中的浆料浇筑于模具中,在温度为110-150℃加热0.5-1h,凝固成型为三维多孔网状结构的素坯体,冷却后脱模;
(3)将步骤(2)中的素坯体放置于烧结炉中,在高纯氮气气氛中,先快速升温至1000-1200℃保温1-3h,再缓慢升温至1300-1500℃,进行烧结1-12h,烧结完毕降温至600-1000℃保温1-5h,最后随炉冷却得到三维网状结构的多孔保温陶瓷材料。
本发明具有如下优点:
本发明制备的建筑用多孔保温陶瓷材料孔径大小均一,分布均匀,密度为0.55-0.60g/cm3,气孔率为65-75%,常温下抗热震性能为32-37次,导热系数为0.044-0.0554W/(m2·K),抗弯强度为12.5-18.2MPa,抗压强度为15.2-19.5Mpa,保温性能和抗热震性能良好,达到了建筑用保温材料的性能指标,在建筑节能方面具有广阔的应用市场;采用发泡工艺与注凝成型相结合成型工艺简单,大大降低了生产成本。
附图说明
图1为本发明的工艺流程图。
具体实施方式
以下实施例用于说明本发明,但不用来限制本发明的范围。
实施例1
一种建筑用多孔保温陶瓷材料,由包含如下质量百分含量的组分组成:固相粉料65wt%,增强纤维15wt%,发泡体系10wt%,交联体系10wt%。
固相粉料含陶瓷粉体和烧结助剂,陶瓷粉体为高岭土、铝矾土和硅微粉的混合物,烧结助剂为氧化钇,其中,高岭土:铝矾土:硅微粉:烧结助剂质量比为1:3:1:0.2;增强纤维为玻璃纤维,长度为2-10mm;发泡体系由发泡剂、稳泡剂和去离子水组成,发泡剂为棕榈酸甘油酯,稳泡剂为聚乙烯醇和硬脂酸甘油酯的混合物,其中,发泡剂:稳泡剂:去离子水质量比为1:0.5:15;交联体系为水基凝胶体系,由交联剂、分散剂和溶剂组成,交联剂为戊二醛,分散剂为聚丙烯酸铵,溶剂为乙醇,其中,交联剂:分散剂和溶剂质量比为1:0.2:10。
一种建筑用多孔保温陶瓷材料的制备方法,包括如下步骤:
(1)将称量好的固相粉料破碎混合,湿法球磨18h,然后将增强纤维加入混合物中继续搅拌10min;然后加入发泡体系在温度为110℃下发泡0.5h;然后加入交联体系反应0.5h形成高固相低粘度浆料,固含量为55wt%;(2)将步骤(1)中的浆料浇筑于模具中,在温度为110℃加热0.5h,凝固成型为三维多孔网状结构的素坯体,冷却后脱模;(3)将步骤(2)中的素坯体放置于烧结炉中,在高纯氮气气氛中,先快速升温至1000℃保温1h,再缓慢升温至1300℃,进行烧结1h,烧结完毕降温至600℃保温1h,最后随炉冷却得到三维网状结构的多孔保温陶瓷材料。
实施例2
一种建筑用多孔保温陶瓷材料,由包含如下质量百分含量的组分组成:固相粉料98.8wt%,增强纤维1wt%,发泡体系0.1wt%,交联体系0.1wt%。
固相粉料含陶瓷粉体和烧结助剂,陶瓷粉体为高岭土、铝矾土和硅微粉的混合物,烧结助剂为氧化锆,其中,高岭土:铝矾土:硅微粉:烧结助剂质量比为1:3:1:0.5;增强纤维为芳纶纤维,长度为2-10mm;发泡体系由发泡剂、稳泡剂和去离子水组成,发泡剂为棕榈酸甘油酯,稳泡剂为聚乙烯醇和硬脂酸甘油酯的混合物,其中,发泡剂:稳泡剂:去离子水质量比为1:2:15;交联体系为水基凝胶体系,由交联剂、分散剂和溶剂组成,交联剂为丙烯酸酯,分散剂为聚氧乙烯醚,溶剂为乙二醇,其中,交联剂:分散剂和溶剂质量比为1:1:10。
一种建筑用多孔保温陶瓷材料的制备方法,包括如下步骤:
(1)将称量好的固相粉料破碎混合,湿法球磨24h,然后将增强纤维加入混合物中继续搅拌30min;然后加入发泡体系在温度为150℃下发泡1.5h;然后加入交联体系反应2h形成高固相低粘度浆料,固含量为70wt%;(2)将步骤(1)中的浆料浇筑于模具中,在温度为150℃加热1h,凝固成型为三维多孔网状结构的素坯体,冷却后脱模;(3)将步骤(2)中的素坯体放置于烧结炉中,在高纯氮气气氛中,先快速升温至1200℃保温3h,再缓慢升温至1500℃,进行烧结12h,烧结完毕降温至1000℃保温5h,最后随炉冷却得到三维网状结构的多孔保温陶瓷材料。
实施例3
一种建筑用多孔保温陶瓷材料,由包含如下质量百分含量的组分组成:固相粉料80wt%,增强纤维10wt%,发泡体系5wt%,交联体系5wt%。
固相粉料含陶瓷粉体和烧结助剂,陶瓷粉体为高岭土、铝矾土和硅微粉的混合物,烧结助剂为氧化钇,其中,高岭土:铝矾土:硅微粉:烧结助剂质量比为1:3:1:0.3;增强纤维为玄武岩纤维,长度为2-10mm;发泡体系由发泡剂、稳泡剂和去离子水组成,发泡剂为棕榈酸甘油酯,稳泡剂为聚乙烯醇和硬脂酸甘油酯的混合物,其中,发泡剂:稳泡剂:去离子水质量比为1:1:15;交联体系为水基凝胶体系,由交联剂、分散剂和溶剂组成,交联剂为戊二醛,分散剂为聚羧酸氨,溶剂为乙醇,其中,交联剂:分散剂和溶剂质量比为1:0.5:10。
一种建筑用多孔保温陶瓷材料的制备方法,包括如下步骤:
(1)将称量好的固相粉料破碎混合,湿法球磨20h,然后将增强纤维加入混合物中继续搅拌20min;然后加入发泡体系在温度为130℃下发泡1h;然后加入交联体系反应1h形成高固相低粘度浆料,固含量为65wt%;(2)将步骤(1)中的浆料浇筑于模具中,在温度为130℃加热0.8h,凝固成型为三维多孔网状结构的素坯体,冷却后脱模;(3)将步骤(2)中的素坯体放置于烧结炉中,在高纯氮气气氛中,先快速升温至1100℃保温2h,再缓慢升温至1400℃,进行烧结8h,烧结完毕降温至800℃保温3h,最后随炉冷却得到三维网状结构的多孔保温陶瓷材料。
实施例4
一种建筑用多孔保温陶瓷材料,由包含如下质量百分含量的组分组成:固相粉料75wt%,增强纤维13wt%,发泡体系6wt%,交联体系6wt%。
固相粉料含陶瓷粉体和烧结助剂,陶瓷粉体为高岭土、铝矾土和硅微粉的混合物,烧结助剂为氧化锆,其中高岭土:铝矾土:硅微粉:烧结助剂质量比为1:3:1:0.4;增强纤维为玻璃纤维和芳纶纤维的混合物,长度为2-10mm;发泡体系由发泡剂、稳泡剂和去离子水组成,发泡剂为棕榈酸甘油酯,稳泡剂为聚乙烯醇和硬脂酸甘油酯的混合物,其中发泡剂:稳泡剂:去离子水质量比为1:1.5:15;交联体系为水基凝胶体系,由交联剂、分散剂和溶剂组成,交联剂为丙烯酸酯,分散剂为聚丙烯酸铵,溶剂为乙二醇,其中交联剂:分散剂和溶剂质量比为1:0.6:10。
一种建筑用多孔保温陶瓷材料的制备方法,包括如下步骤:
(1)将称量好的固相粉料破碎混合,湿法球磨22h,然后将增强纤维加入混合物中继续搅拌30min;然后加入发泡体系在温度为150℃下发泡1h;然后加入交联体系反应2h形成高固相低粘度浆料,固含量为68wt%;(2)将步骤(1)中的浆料浇筑于模具中,在温度为150℃加热0.5h,凝固成型为三维多孔网状结构的素坯体,冷却后脱模;(3)将步骤(2)中的素坯体放置于烧结炉中,在高纯氮气气氛中,先快速升温至1200℃保温1.5h,再缓慢升温至1500℃,进行烧结10h,烧结完毕降温至900℃保温3h,最后随炉冷却得到三维网状结构的多孔保温陶瓷材料。
本发明制备的建筑用多孔保温陶瓷材料孔径大小均一,分布均匀,密度为0.55-0.60g/cm3,气孔率为70-75%,常温下抗热震性能为32-37次,导热系数为0.044-0.0554W/(m2·K),抗弯强度为12.5-18.2MPa,抗压强度为15.2-19.5MPa;上述实施例测试数据说明该材料保温性能和抗热震性能良好,达到了建筑用保温材料的性能指标,在建筑节能方面具有广阔的应用市场。
虽然,上文中已经用一般性说明及具体实施例对本发明作了详尽的描述,但在本发明基础上,可以对之作一些修改或改进,这对本领域技术人员而言是显而易见的。因此,在不偏离本发明精神的基础上所做的这些修改或改进,均属于本发明要求保护的范围。
Claims (8)
1.一种建筑用多孔保温陶瓷材料,其特征在于,由包含如下质量百分含量的组分组成:固相粉料65-98.8wt%,增强纤维1-15wt%,发泡体系0.1-10wt%,交联体系0.1-10wt%。
2.一种如权利要求1所述的建筑用多孔保温陶瓷材料,其特征在于,所述的固相粉料含陶瓷粉体和烧结助剂,所述的陶瓷粉体为高岭土、铝矾土和硅微粉的混合物,所述的烧结助剂为氧化钇或氧化锆,其中,高岭土:铝矾土:硅微粉:烧结助剂质量比为1:3:1:(0.2-0.5)。
3.一种如权利要求1所述的建筑用多孔保温陶瓷材料,其特征在于,所述的增强纤维为玻璃纤维、芳纶纤维、玄武岩纤维中的一种或两种以上组合,长度为2-10mm。
4.一种如权利要求1所述的建筑用多孔保温陶瓷材料,其特征在于,所述的发泡体系由发泡剂、稳泡剂和去离子水组成,所述的发泡剂为棕榈酸甘油酯,所述的稳泡剂为聚乙烯醇和硬脂酸甘油酯的混合物,其中,发泡剂:稳泡剂:去离子水质量比为1:(0.5-2):15。
5.一种如权利要求1所述的建筑用多孔保温陶瓷材料,其特征在于,所述的交联体系为水基凝胶体系,由交联剂、分散剂和溶剂组成,所述的交联剂为戊二醛或丙烯酸酯,所述的分散剂为聚丙烯酸铵、聚氧乙烯醚、聚羧酸氨中的一种,所述的溶剂为乙醇或乙二醇,其中,交联剂:分散剂和溶剂质量比为1:(0.2-1):10。
6.一种如权利要求1-5任一项所述的建筑用多孔保温陶瓷材料的制备方法,其特征在于,包括如下步骤:
(1)将称量好的固相粉料破碎混合,湿法球磨18-24h,然后将增强纤维加入混合物中继续搅拌10-30min;然后加入发泡体系在温度为110-150℃下发泡反应0.5-1.5h;然后加入交联体系反应0.5-2h形成高固相低粘度浆料;
(2)将步骤(1)中的浆料浇筑于模具中,在温度为110-150℃加热0.5-1h,凝固成型为素坯体,冷却后脱模;
(3)将步骤(2)中的素坯体放置于烧结炉中,在高纯氮气气氛中,先快速升温至1000-1200℃保温1-3h,再缓慢升温至1300-1500℃,进行烧结1-12h,烧结完毕降温至600-1000℃保温1-5h,最后随炉冷却得到三维网状结构的多孔保温陶瓷材料。
7.一种如权利要求6所述的建筑用多孔保温陶瓷材料的制备方法,其特征在于,所述的高固相低粘度浆料的固含量为55-70wt%。
8.一种如权利要求6所述的建筑用多孔保温陶瓷材料的制备方法,其特征在于,所述的素坯体三维多孔网状结构。
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