CN106495674B - 一种陶瓷聚合物复合材料的原料配方及制备工艺 - Google Patents

一种陶瓷聚合物复合材料的原料配方及制备工艺 Download PDF

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CN106495674B
CN106495674B CN201610927368.1A CN201610927368A CN106495674B CN 106495674 B CN106495674 B CN 106495674B CN 201610927368 A CN201610927368 A CN 201610927368A CN 106495674 B CN106495674 B CN 106495674B
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周峰
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Dehua Houjing Kiln Porcelain Industry Co., Ltd.
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Abstract

本发明涉及陶瓷聚合物复合材料的制备技术领域，尤其涉及一种陶瓷聚合物复合材料的原料配方及制备工艺。本发明要解决的技术问题是提供一种强度高、收缩小、不容易开裂的陶瓷聚合物复合材料的原料配方及制备工艺。一种陶瓷聚合物复合材料的原料配方及制备工艺，每组配方组成中包括以下按重量计的组分：氧化铝粉末：100‑120份；水合硅酸镁超细粉：20‑25份；碳酸钙粉末：10‑15份等。其制备工艺包括有六个步骤。本发明制作出来的陶瓷表面的光滑度更高，表面的光泽度更好，陶瓷的表面精光度得到明显的提高，并且添加的氮化钛粉末能够增加陶瓷的耐高温性、耐腐蚀性、耐磨损性和抗热震等优异性能。

Description

一种陶瓷聚合物复合材料的原料配方及制备工艺
技术领域
本发明涉及陶瓷聚合物复合材料的制备技术领域，尤其涉及一种新型陶瓷聚合物复合材料的原料配方及制备工艺。
背景技术
用陶土烧制的器皿叫陶器，用瓷土烧制的器皿叫瓷器。陶瓷则是陶器，炻器和瓷器的总称。凡是用陶土和瓷土这两种不同性质的粘土为原料，经过配料、成型、干燥、焙烧等工艺流程制成的器物都可以叫陶瓷。
在传统陶瓷制造工艺中，陶瓷的制作首先通过机械或物理或化学方法制备粉料，在制备坯料时，要控制坯料粉的粒度、形状、纯度及脱水脱气，以及配料比例和混料均匀等质量要求。按不同的成型工艺要求，坯料可以是粉料、浆料或可塑泥团；然后将坯料用一定工具或模具制成一定形状、尺寸、密度和强度的制品坯型（亦称生坯）；最后待生坯经初步干燥后，进行涂釉烧结或直接烧结。高温烧结时，陶瓷内部会发生一系列物理化学变化及相变，如体积减小，密度增加，强度、硬度提高，晶粒发生相变等，使陶瓷制品达到所要求的物理性能和力学性能。但是烧结时也容易产生缺陷和开裂等问题。
由于传统的陶瓷制造工艺存在缺陷，近十几年来涌现了许多用于陶瓷胶态成型的工艺技术，其中包括有流延成型、注射成型等新兴工艺，这些方法的特点是在浆料中加入可使其发生固化的物质，在浆料发生固化前将其注入无孔模具，浆料在模具中固化，就得到素坯，但是有机溶剂存在污染环境严重、成本高、生坯密度低等问题，从而造成陶瓷的制备仍然不尽如人意。
随着社会的发展人们生活质量的提高，人们的爱好和品位也逐渐有所扩大和提升，对陶瓷制品的需求也在慢慢变大，现有的陶瓷制备方法存在容易产生缺陷和开裂、操作复杂的缺点，因此亟需研发一种强度高、收缩小、不容易开裂的新型陶瓷聚合物复合材料的原料配方及制备工艺。
发明内容
（1）要解决的技术问题
本发明为了克服现有的陶瓷制备方法存在容易产生缺陷和开裂、操作复杂的缺点，本发明要解决的技术问题是提供一种强度高、收缩小、不容易开裂的新型陶瓷聚合物复合材料的原料配方及制备工艺。
（2）技术方案
为了解决上述技术问题，本发明提供了这样一种新型陶瓷聚合物复合材料的原料配方及制备工艺，每组配方组成中包括以下按重量计的组分：氧化铝粉末： 100-120份；水合硅酸镁超细粉：20-25份；碳酸钙粉末：10-15份；硼酸钠： 10-15份；胶粘剂：10-15份；水性粘合剂：20-25份；着色剂：5-10份；氮化钛粉末：3-5份；光亮剂：2-5份；固化剂：20-25份。
优选地，胶粘剂可以是脲醛胶和酚醛胶中的一种。
优选地，水性粘合剂可以为丙烯酸类、乙烯类和纤维素醚中的一类，其中丙烯酸类可使用聚丙烯酸、聚丙烯酸-苯乙烯共聚物和聚丙烯酸酯共聚物中的一种或几种，乙烯类可使用聚乙烯醇和聚醋酸乙烯酯中的一种或两种，纤维素醚可使用甲基纤维素、羟乙基纤维素、羟丙基纤维素和羟甲基丙基纤维素中的一种或几种的组合。
优选地，着色剂可以为氧化铜、氧化亚铜和硝酸锰中一种。
优选地，光亮剂可以为苄叉丙酮、壬基酚聚氧乙烯醚、苯甲酸钠和扩散剂 NNO中的一种或几种组合。
优选地，固化剂选用苯磺酸。
一种新型陶瓷聚合物复合材料的制备工艺:
步骤一：按照每组配方组成中包括以下按重量计的组分：首先将氧化铝粉末100-120份加入到研磨机中，研磨时间为10分钟，将其颗粒研磨成直径为 1.5mm的粉末状，使氧化铝粉末的大小均相同。
步骤二：将研磨好的氧化铝粉末、水合硅酸镁超细粉20-25份、胶粘剂5-8 份、水性粘合剂10-12份和按重量组分配比的纯净水加入到搅拌机中搅拌，搅拌的转速为300转每分钟，搅拌时间为15分钟。
步骤三：将氮化钛粉末3-5份加入到研磨机中进行研磨，研磨时间为10 分钟，使其的粒径大小平均为1.5mm，然后将研磨完成的氮化钛粉末加入到搅拌机中继续搅拌，使氮化钛粉末与步骤二中已经搅拌好的产物继续混合，搅拌时间为15分钟，搅拌的转速为300转每分钟。
步骤四：将硼酸钠10-15份、着色剂5-10份、光亮剂2-5份、胶粘剂5-7 份和水性粘合剂10-13份继续加入到步骤三中的产物中，使他们在搅拌机中继续搅拌，搅拌的转速为420转每分钟，搅拌时间为25分钟。
步骤五：然后在研磨机中加入碳酸钙粉末10-15份，并且对其进行研磨，研磨时间为20分钟，使其粒径平均大小为1.5mm，然后将研磨完成的碳酸钙粉末和固化剂20-25份继续加入到搅拌机中，使其余步骤四中的产物继续搅拌混合，搅拌转速为300转每分钟。
步骤六：搅拌2分钟之后将最终产物迅速倒入到磨具中，固化后脱模。
（3）有益效果
本发明使陶瓷的制作无需进行烧结，并且操作简单，没有添加有机溶剂，从而不存在污染环境严重、成本高、生坯密度低等问题，并且利用该配方的方法制作出来的陶瓷表面的光滑度更高，表面的光泽度更好，陶瓷的表面精光度得到明显的提高，并且添加的氮化钛粉末能够增加陶瓷的耐高温性、耐腐蚀性、耐磨损性和抗热震等优异性能。
具体实施方式
下面结合实施例对本发明作进一步的说明。
实施例1
一种新型陶瓷聚合物复合材料的制备工艺:
步骤一：按照每组配方组成中包括以下按重量计的组分：首先将氧化铝粉末110份加入到研磨机中，研磨时间为10分钟，将其颗粒研磨成直径为1.5mm 的粉末状，使氧化铝粉末的大小均相同。
步骤二：将研磨好的氧化铝粉末、水合硅酸镁超细粉22份、脲醛胶6份、聚丙烯酸、聚丙烯酸-苯乙烯共聚物和聚丙烯酸酯共聚物的混合物11份和按重量组分配比的纯净水加入到搅拌机中搅拌，搅拌的转速为300转每分钟，搅拌时间为15分钟。
步骤三：将氮化钛粉末4份加入到研磨机中进行研磨，研磨时间为10分钟，使其的粒径大小平均为1.5mm，然后将研磨完成的氮化钛粉末加入到搅拌机中继续搅拌，使氮化钛粉末与步骤二中已经搅拌好的产物继续混合，搅拌时间为15分钟，搅拌的转速为300转每分钟。
步骤四：将硼酸钠13份、氧化铜8份、苄叉丙酮和壬基酚聚氧乙烯醚的混合物3份、脲醛胶6份和聚丙烯酸、聚丙烯酸-苯乙烯共聚物和聚丙烯酸酯共聚物的混合物12份继续加入到步骤三中的产物中，使他们在搅拌机中继续搅拌，搅拌的转速为420转每分钟，搅拌时间为25分钟。
步骤五：然后在研磨机中加入碳酸钙粉末12份，并且对其进行研磨，研磨时间为20分钟，使其粒径平均大小为1.5mm，然后将研磨完成的碳酸钙粉末和苯磺酸22份继续加入到搅拌机中，使其余步骤四中的产物继续搅拌混合，搅拌转速为300转每分钟。
步骤六：搅拌2分钟之后将最终产物迅速倒入到磨具中，固化后脱模。
实验1：将采用传统方法制作的陶瓷制品为A组，将采用本发明实施例1 的方法制作的陶瓷制品为B组，A为正常对照组。
对以上两组的陶瓷表面的光滑度、耐高温性和耐腐蚀性进行对比性的研究。
结果：通过触摸感受A组和B组制得的陶瓷，明显感觉B组的光滑度大于 A组的光滑度；将A组和B组制得的陶瓷同样放置在1000摄氏度的高温条件下，并且放置1个小时，1个小时后将A组和B组制得的陶瓷拿出，发现A组的陶瓷产生裂痕，而B组的陶瓷表面光滑，没有裂痕；将A组和B组制得的陶瓷放置在浓度为1摩尔每升的氢氧化钠溶液中，并且放置30分钟后取出，并且将A 组和B组制得的陶瓷表面擦干净，然后观察A组和B组制得的陶瓷表面，明显发现A组的陶瓷表面被腐蚀的面积远远大于B组陶瓷表面被腐蚀的面积。
实施例2
一种新型陶瓷聚合物复合材料的制备工艺:
步骤一：按照每组配方组成中包括以下按重量计的组分：首先将氧化铝粉末120份加入到研磨机中，研磨时间为10分钟，将其颗粒研磨成直径为1.5mm 的粉末状，使氧化铝粉末的大小均相同。
步骤二：将研磨好的氧化铝粉末、水合硅酸镁超细粉25份、酚醛胶8份、甲基纤维素、羟乙基纤维素、羟丙基纤维素和羟甲基丙基纤维素的混合物12 份和按重量组分配比的纯净水加入到搅拌机中搅拌，搅拌的转速为300转每分钟，搅拌时间为15分钟。
步骤三：将氮化钛粉末5份加入到研磨机中进行研磨，研磨时间为10分钟，使其的粒径大小平均为1.5mm，然后将研磨完成的氮化钛粉末加入到搅拌机中继续搅拌，使氮化钛粉末与步骤二中已经搅拌好的产物继续混合，搅拌时间为15分钟，搅拌的转速为300转每分钟。
步骤四：将硼酸钠15份、硝酸锰10份、苄叉丙酮和苯甲酸钠的混合物5 份、酚醛胶7份和甲基纤维素、羟乙基纤维素、羟丙基纤维素和羟甲基丙基纤维素的混合物13份继续加入到步骤三中的产物中，使他们在搅拌机中继续搅拌，搅拌的转速为420转每分钟，搅拌时间为25分钟。
步骤五：然后在研磨机中加入碳酸钙粉末15份，并且对其进行研磨，研磨时间为20分钟，使其粒径平均大小为1.5mm，然后将研磨完成的碳酸钙粉末和苯磺酸25份继续加入到搅拌机中，使其余步骤四中的产物继续搅拌混合，搅拌转速为300转每分钟。
步骤六：搅拌2分钟之后将最终产物迅速倒入到磨具中，固化后脱模。
实施例3
一种新型陶瓷聚合物复合材料的制备工艺:
步骤一：按照每组配方组成中包括以下按重量计的组分：首先将氧化铝粉末100份加入到研磨机中，研磨时间为10分钟，将其颗粒研磨成直径为1.5mm 的粉末状，使氧化铝粉末的大小均相同。
步骤二：将研磨好的氧化铝粉末、水合硅酸镁超细粉20份、脲醛胶5份、聚乙烯醇和聚醋酸乙烯酯的混合物10份和按重量组分配比的纯净水加入到搅拌机中搅拌，搅拌的转速为300转每分钟，搅拌时间为15分钟。
步骤三：将氮化钛粉末3份加入到研磨机中进行研磨，研磨时间为10分钟，使其的粒径大小平均为1.5mm，然后将研磨完成的氮化钛粉末加入到搅拌机中继续搅拌，使氮化钛粉末与步骤二中已经搅拌好的产物继续混合，搅拌时间为15分钟，搅拌的转速为300转每分钟。
步骤四：将硼酸钠10份、氧化亚铜5份、苄叉丙酮和扩散剂NNO的混合物2份、脲醛胶5份和聚乙烯醇和聚醋酸乙烯酯10份继续加入到步骤三中的产物中，使他们在搅拌机中继续搅拌，搅拌的转速为420转每分钟，搅拌时间为25分钟。
步骤五：然后在研磨机中加入碳酸钙粉末10份，并且对其进行研磨，研磨时间为20分钟，使其粒径平均大小为1.5mm，然后将研磨完成的碳酸钙粉末和苯磺酸20份继续加入到搅拌机中，使其余步骤四中的产物继续搅拌混合，搅拌转速为300转每分钟。
步骤六：搅拌2分钟之后将最终产物迅速倒入到磨具中，固化后脱模。
以上所述实施例仅表达了本发明的优选实施方式，其描述较为具体和详细，但并不能因此而理解为对本发明专利范围的限制。应当指出的是，对于本领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干变形、改进及替代，这些都属于本发明的保护范围。因此，本发明专利的保护范围应以所附权利要求为准。

Claims (2)

1.一种陶瓷聚合物复合材料，其原料配方包括以下按重量计的组分：氧化铝粉末：100-120份；水合硅酸镁超细粉：20-25份；碳酸钙粉末：10-15份；硼酸钠：10-15份；胶粘剂：10-15份；水性粘合剂：20-25份；着色剂：5-10份；氮化钛粉末：3-5份；光亮剂：2-5份；固化剂：20-25份;
胶粘剂是脲醛胶和酚醛胶中的一种;
水性粘合剂为丙烯酸类、乙烯类和纤维素醚中的一类，其中丙烯酸类使用聚丙烯酸、聚丙烯酸-苯乙烯共聚物和聚丙烯酸酯共聚物中的一种或几种，乙烯类使用聚乙烯醇和聚醋酸乙烯酯中的一种或两种，纤维素醚使用甲基纤维素、羟乙基纤维素、羟丙基纤维素和羟甲基丙基纤维素中的一种或几种的组合;
着色剂为氧化铜、氧化亚铜和硝酸锰中一种;
光亮剂为苄叉丙酮、壬基酚聚氧乙烯醚、苯甲酸钠和扩散剂NNO中的一种或几种组合;
固化剂选用苯磺酸。
2.一种陶瓷聚合物复合材料的制备工艺:其特征在于，
步骤一：按照每组配方组成中包括以下按重量计的组分：首先将氧化铝粉末100-120份加入到研磨机中，研磨时间为10分钟，将其颗粒研磨成直径为1.5mm的粉末状，使氧化铝粉末的大小均相同；
步骤二：将研磨好的氧化铝粉末、水合硅酸镁超细粉20-25份、胶粘剂5-8份、水性粘合剂10-12份和按重量组分配比的纯净水加入到搅拌机中搅拌，搅拌的转速为300转每分钟，搅拌时间为15分钟；
步骤三：将氮化钛粉末3-5份加入到研磨机中进行研磨，研磨时间为10分钟，使其的粒径大小平均为1.5mm，然后将研磨完成的氮化钛粉末加入到搅拌机中继续搅拌，使氮化钛粉末与步骤二中已经搅拌好的产物继续混合，搅拌时间为15分钟，搅拌的转速为300转每分钟；
步骤四：将硼酸钠10-15份、着色剂5-10份、光亮剂2-5份、胶粘剂5-7份和水性粘合剂10-13份继续加入到步骤三中的产物中，使它们在搅拌机中继续搅拌，搅拌的转速为420转每分钟，搅拌时间为25分钟；
步骤五：然后在研磨机中加入碳酸钙粉末10-15份，并且对其进行研磨，研磨时间为20分钟，使其粒径平均大小为1.5mm，然后将研磨完成的碳酸钙粉末和固化剂20-25份继续加入到搅拌机中，使其与步骤四中的产物继续搅拌混合，搅拌转速为300转每分钟；
步骤六：搅拌2分钟之后将最终产物迅速倒入到模具中，固化后脱模。
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