CN106495668A - 一种异型陶瓷灯管的制造方法 - Google Patents

一种异型陶瓷灯管的制造方法 Download PDF

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CN106495668A
CN106495668A CN201610385423.9A CN201610385423A CN106495668A CN 106495668 A CN106495668 A CN 106495668A CN 201610385423 A CN201610385423 A CN 201610385423A CN 106495668 A CN106495668 A CN 106495668A
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苗赫濯
汤长兴
展莉菲
胡谦
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Everbright energy saving lighting (Shenzhen) Co., Ltd
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Beijing Crystal Optoelectronics Technology Co Ltd
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Abstract

本发明提供了一种异型陶瓷灯管的制造方法，采用等静压成型的半截陶瓷灯管坯体对接起来的，所以称为对接法；半截坯体采用金属作芯模，橡胶作外模，将喷雾造粒后的透明氧化铝陶瓷粉体原料，填入内外模的间隙中，然后进行冷等静压成型，获得半截陶瓷灯管所需的形状，然后采用粘接剂将两者对接成一个灯管整体，再経过排胶、素烧、打磨直至高温烧结，获得完全致密的两端带有毛细管的异型透明陶瓷灯管。本发明工艺方法过程比较简单，成型坯体密度比较高，内表面比较光滑，而且由于造粒粉体添加有机物比较少，容易获得较高的透光率。

Description

一种异型陶瓷灯管的制造方法
技术领域
本发明涉及陶瓷灯管的制造方法，特别涉及一种异型陶瓷灯管的制造方法。
背景技术
用透明Al2O3陶瓷代替石英玻璃来作金属卤化物灯管，提高了金卤灯的发光效率、显色指数和寿命，陶瓷金卤灯和白钠灯是近年发展起来的高光效、高显色性的节能光源，但他们所采用的陶瓷电弧管却形状远比高压钠灯管复杂，是两端带小管（封接电极用）、中部为椭球形、球形或管形，而且要求内腔两端不要形成死角，这会造成发光物质的积聚，从而影响灯的光效和寿命，所以两端要弧形过渡，这给陶瓷坯体的成型带来很大难度。
目前有采用整体成型，如注浆成型、注射挤制后气压成型等；也有采用凝胶注或注射对接成型。例如发明专利号 CN102249695A就是采用二次注射法进行对接。亦即先注射成型出半截陶瓷管坯，然后对接后进行二次注射，使之成为一整体。但其缺点是采用注射成型工艺过程长，添加有机物多，容易混进杂质，影响透光性。
发明内容
为了克服现有技术的缺陷，本发明提供以下技术方案：
一种异型陶瓷灯管的制造方法，其方法步骤如下：
A:根据透明陶瓷灯管设计的形状，采用等静压方法先成型半截形状的坯体；
B:将成型好的半截坯体进行素烧，使之获得一定的强度；
C:将预先调制好的粘接用料浆对两截坯体进行粘接；
D:将粘接好的坯体放入氧化气氛炉中进行排胶和素烧，使之获得一定强度，然后进行打磨处理；
E:将已排除粘接剂的坯体放入高温氢气炉中进行烧结，获得最终产品。
作为优选技术方案，所述等静压方法为干袋法或湿袋法，其成型压力为150～300MPa。
作为优选技术方案，所述料浆是将晶粒抑制剂、分散剂及粘接剂的高纯超细Al2O3粉体，经过加水或酒精混合磨细制成。
作为优选技术方案，所述晶粒抑制剂是氧化物MgO、Y2O3、La2O3、ZrO2中的两种或三种，其加入量分别为Al2O3粉体质量的的0.01～0.2%。
作为优选技术方案，所述分散剂为聚丙烯酸氨或聚丙烯酸或柠檬酸氨，其加入量为Al2O3粉体质量的0.3～5.0%。
作为优选技术方案，所述粘接剂为聚乙烯醇、甲基纤维素、聚乙二醇、聚乙烯吡咯烷酮和聚乙烯醇缩丁醛中的一种或两种，其用量为Al2O3粉体质量的0.05～5.0%。
本发明所带来的有益效果是：本发明的工艺方法过程比较简单，成型坯体密度比较高，内表面比较光滑，而且由于造粒粉体添加有机物比较少，容易获得较高的透光率。
具体实施方式
下面对本发明的较佳实施例进行详细阐述，以使本发明的优点和特征能更易于被本领域技术人员理解，从而对本发明的保护范围做出更为清楚明确的界定。
实施例1
一种异型陶瓷灯管的制造方法，其方法步骤如下：
1、根据陶瓷灯管半截尺寸的要求，制作胶橡外模以及淬硬钢芯模并在端部连接上W合金芯杆，外模与芯模配合后，形成的间隙正好符合半截陶瓷灯管的形状。
2、将经过喷雾造粒的透明Al2O3陶瓷粉体完全填充间隙，然后封上橡胶顶盖。
3、将装满透明陶瓷造粒粉的模具放入冷等静压液缸中，然后进行施压200 Mpa的等静压压力，使粉体变成具有一定强度的半截椭球形（杯形）压实体，然后从模具中取出。
4、将坯体放入氧化气氛炉中进行排胶与素烧，素烧温度为800℃，时间为1小时，使坯体具有可加工的强度。
5、制备粘接用料浆，其主成份为高纯超细Al2O3粉，添加剂为Y2O3，La2O3，ZrO2，MgO粉体。其中Y2O3，La2O3分别为Al2O3质量的 0.05 %，MgO，ZrO2分别为Al2O3质量的 0.10 %。去离子水质量为固体氧化物粉体总质量的150%，分散剂柠檬酸氨为固体氧化物粉体总质量的0.5%，粘接剂聚乙烯醇（PVA）为氧化物粉体总质量的 1.0 %。
6、采用ZrO2或Al2O3球作为球磨介质，将上述配料在球磨机中混磨12小时，最后获得粘接用料浆。
7、将粘接用料浆涂在对接坯体的端面上，在保持两截坯体中心线在同一轴线状态下将其粘接，然后静置令其干燥并具有可搬移的强度。
8、再次进行素烧，素烧温度为1100℃，保温时间1小时，使粘接剂中的有机物充分排除并使坯体具有一定的加工强度，并将坯体表面进行抛磨加工至表面光滑。
9、将经过打磨而且完整的坯体，放入氢气高温炉中进行最终的烧结，烧结温度为1700～1900℃，时间为0.5～5小时，获得完全致密的、透光率高的、形状复杂的透明氧化铝陶瓷灯管。
实施例2
一种异型陶瓷灯管的制造方法，其方法步骤如下：
1、根据陶瓷灯管半截尺寸的要求，制作胶橡外模以及淬硬钢芯模并在端部连接上W合金芯杆，外模与芯模配合后，形成的间隙正好符合半截陶瓷灯管的形状。
2、将经过喷雾造粒的透明Al2O3陶瓷粉体填充至间隙中，然后封上橡胶顶盖。
3、将装满透明陶瓷造粒粉的复合模具放入干袋法等静压的工作腔中，然后进行施加180 Mpa的等静压压力，使粉体变成具有一定强度的半截椭球形（杯形）压实体，然后从模具中取出。
4、将坯体放入氧化气氛炉中进行排胶与素烧，素烧温度为800℃，时间为1小时，使坯体具有可加工的强度。
5、制备粘接用料浆，其主成份为高纯超细Al2O3粉，添加剂为MgO，La2O3粉体。其中MgO为Al2O3质量的 0.05 %，La2O3为Al2O3质量的 0.1 %，分散剂聚丙烯酸氨（PAA）为固体氧化物粉体总质量的 0.7 %，粘接剂聚乙烯呲咯烷酮（PVP）为氧化物粉体总质量的 1.0 %，酒精质量为固体氧化物粉体总质量的130%。
6、采用ZrO2或Al2O3球作为球磨介质，将上述配料在球磨机中混磨12小时，最后获得粘接用料浆。
7、将粘接用料浆涂在对接坯体的端面上，在保持两截坯体中心线在同一轴线状态下将其粘接，然后静置令其干燥并具有可搬移的强度。
8、再次进行素烧，使粘接剂中的有机物充分排除，素烧温度为1000℃，并将经过素烧而获得一定强度的坯体，进行表面抛磨加工使之表面光滑。
9、将经过打磨而且完整的坯体，放入氢气高温炉中进行最终的烧结，烧结温度为1700～1900℃，时间为0.5～5小时，获得完全致密的、透光率高的、形状复杂的透明氧化铝陶瓷灯管。
以上所述，仅为本发明的具体实施方式，但本发明的保护范围并不局限于此，任何熟悉本领域的技术人员在本发明所揭露的技术范围内，可不经过创造性劳动想到的变化或替换，都应涵盖在本发明的保护范围之内。因此，本发明的保护范围应该以权利要求书所限定的保护范围为准。

Claims (6)

1.一种异型陶瓷灯管的制造方法，其特征在于，其方法步骤如下：
A:根据透明陶瓷灯管设计的形状，采用等静压方法先成型半截形状的坯体；
B:将成型好的半截坯体进行素烧，使之获得一定的强度；
C:将预先调制好的粘接用料浆对两截坯体进行粘接；
D:将粘接好的坯体放入氧化气氛炉中进行排胶和素烧，使之获得一定强度，然后进行打磨处理；
E:将已排除粘接剂的坯体放入高温氢气炉中进行烧结，获得最终产品。
2.根据权利要求1所述的一种异型陶瓷灯管的制造方法，其特征在于，所述等静压方法为干袋法或湿袋法，其成型压力为150～300 MPa。
3.根据权利要求1所述的一种异型陶瓷灯管的制造方法，其特征在于，所述料浆是将晶粒抑制剂、分散剂及粘接剂的高纯超细Al2O3粉体，经过加水或酒精混合磨细制成。
4.根据权利要求3所述的一种异型陶瓷灯管的制造方法，其特征在于，所述晶粒抑制剂是氧化物MgO、Y2O3、La2O3、ZrO2中的两种或三种，其加入量分别为Al2O3粉体质量的的0.01～0.2%。
5.根据权利要求3所述的一种异型陶瓷灯管的制造方法，其特征在于，所述分散剂为聚丙烯酸氨或聚丙烯酸或柠檬酸氨，其加入量为Al2O3粉体质量的0.3～5.0%。
6.根据权利要求3所述的一种异型陶瓷灯管的制造方法，其特征在于，所述粘接剂为聚乙烯醇、甲基纤维素、聚乙二醇、聚乙烯吡咯烷酮和聚乙烯醇缩丁醛中的一种或两种，其用量为Al2O3粉体质量的0.05～5.0%。
CN201610385423.9A 2016-06-03 2016-06-03 一种异型陶瓷灯管的制造方法 Pending CN106495668A (zh)

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