CN106495701B - 一种抗冲击陶瓷绝缘子及其制造方法 - Google Patents
一种抗冲击陶瓷绝缘子及其制造方法 Download PDFInfo
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- PMHQVHHXPFUNSP-UHFFFAOYSA-M copper(1+);methylsulfanylmethane;bromide Chemical compound Br[Cu].CSC PMHQVHHXPFUNSP-UHFFFAOYSA-M 0.000 claims description 21
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Abstract
本发明公开了一种抗冲击陶瓷绝缘子及其制造方法，该绝缘子的冲击强度不低于1.5J/cm2、体积电阻率不低于1×1014Ω•cm、介电强度不低于750kV/cm、热导率不低于20W/m·K、抗弯强度不低于600Mpa、杨氏模数不低于450Gpa、断裂韧性不低于55Mpa；通过每4mm‑5mm为一级多次烧结的方式，使成品的绝缘子具有多层缓冲与支撑结构，能承受多角度、高频次的冲击功，又在绝缘子表面进行微构造型，一方面方便了使用，另一方面也增加冲击抗性；本发明的抗冲击陶瓷绝缘子经济性好、耐冲击、断裂韧性高、综合机械性能好。
Description
技术领域
本发明涉及电子元件领域，尤其涉及一种抗冲击陶瓷绝缘子及其制造方法。
背景技术
绝缘子是一种特殊的绝缘控件，能够在架空输电线路中起到重要作用。
早年间绝缘子多用于电线杆，慢慢发展于高型高压电线连接塔的一端挂了很多盘状的绝缘体,它是为了增加爬电距离的,通常由玻璃或陶瓷制成,就叫绝缘子。绝缘子在架空输电线路中起着两个基本作用，即支撑导线和防止电流回地，这两个作用必须得到保证；同时，绝缘子应具有足够的电气绝缘强度、耐潮湿性能和耐高温性能。
在国内已申请的相关专利中，专利《高绝缘碳化硅/氮化硼陶瓷材料及其制备方法》（申请号：201310294766.0，公开日：2015-01-14），公开了一种碳化硅/氮化硼陶瓷材料及其制备方法，但该两种材料均属于脆性材料，且没有任何韧化处理，其断裂韧性不高于6Mpa、冲击强度不高于0.27J/cm2，易在运输和其它振动工况下断裂或破碎，其外该发明属于高温烧结（1900℃-2300℃）加热等静压成型，其成本过高，无法进行工业化生产；专利《一种绝缘导热的无机纳米复合陶瓷及其制备方法和用途》（申请号：201410310359.9，公开日：2015-12-30），公开了一种无机纳米复合陶瓷，保其有效成份制成陶瓷后均为高脆性材料，没有韧化处理，且由于几种有效成份没有明显的功能互补，因此综合机械性能较差。
发明内容
为解决现有技术中存在的上述缺陷，本发明旨在提供一种经济性好、耐冲击、断裂韧性高、综合机械性能好的抗冲击陶瓷绝缘子及其制造方法。
为了实现上述目的，本发明采用以下技术方案：一种抗冲击陶瓷绝缘子的制造方法，包括以下步骤：
1）原材料准备
①按重量份数准备硼酸铝晶须6-10份、颗粒尺寸3μm-5μm的氮化铝微粉70-80份、颗粒尺寸3μm-5μm的碳化硅微粉20-25份、氟化钙粉末5-8份、碳粉2-3份、硅化钼2-3份、正硅酸乙脂1-2份、无水乙醇1-2份、纯净水10-15份、热塑性酚醛树脂4-6份；
②将硼酸铝晶须、碳化硅微粉、碳粉和硅化钼、氮化铝微粉和氟化钙混合并搅拌均匀，作为混合物料；
2）模具的准备
①采用石墨制作模具，所述模具按轮廓三维尺寸分级，每4mm-5mm为一级，按从小到大依次分为第一心部模具、第二心部模具、第三心部模具……表层模具，其中第一心部模具最大有效直径不大于Φ10mm；
②对表层模具的内表面与绝缘子外表面匹配区域进行微造型，该微造型具体为垂直交错的深1mm-1.2mm、宽5mm-6mm的沟槽，相邻平行沟槽边缘间距为3mm-4mm。
3）预制备绝缘子
①将1）中步骤②获得的混合物料与正硅酸乙脂、无水乙醇、纯净水、热塑性酚醛树脂混合并搅拌均匀，获得待用物料；
②将部分待用物料填充入第一心部模具中，将该第一心部模具置于800℃-850℃下，在保护气氛或真空环境里保温5h-8h，获得第一心部素坯；
③再在第二心部模具底部填充2mm-2.5mm厚的待用物料，再将第一心部素坯置于第二心部模具中心，然后采用待用物料将第二心部模具填充满，将该第二心部模具置于800℃-850℃下，在保护气氛或真空环境里保温5h-8h，获得第二心部素坯；
④按步骤③方法依次反复进行，完成第三心部毛坯……表层毛坯的预烧结，获得绝缘子素坯；
4）绝缘子烧结及完成
①将2）中步骤③获得的预制备绝缘子素坯置于18Mpa-20Mpa的保护气氛中，以1000℃以上保持200℃/h-250℃/h的升温速率升温至1600℃-1700℃，保温时间4h-7h；
②烧结完成后，炉温T不低于1000℃时随炉冷却；炉温T处于800℃≤T＜1000℃半开炉门冷却；炉温T＜800℃出炉空冷；空冷至T＜150℃后将烧结的绝缘子毛坯脱出模具；
③采用金刚石磨料振动去毛刺设备对绝缘子毛坯进行振动去毛刺及抛光处理，即获得所需绝缘子。
该绝缘子按轮廓三维尺寸分级，每4mm-5mm为一级，最内层最大有效直径不大于Φ10mm，其包括如下重量份的成分：硼酸铝晶须6-10份、氮化铝70-80份、碳化硅22-28份、氟化钙5-8份、钼的不定化合物2-3份。
根据上述抗冲击陶瓷绝缘子的制造方法所制造出的绝缘子，其冲击强度不低于4.5J/cm2、体积电阻率不低于1×1014Ω•cm、介电强度不低于750kV/cm、热导率不低于20W/m·K、抗弯强度不低于600Mpa、杨氏模数不低于450Gpa、断裂韧性不低于55Mpa。
与现有技术相比较，本发明具有以下优点：通过以高绝缘高强度的氮化铝陶瓷为基，加入能使其韧化的碳化硅为辅，采用多层反复烧结方式，使最终制造的绝缘子有多层强化支撑结构和缓冲过渡区域，同时氟化钙也能在一定程度上提升表层与心部的结合力及氮化铝本身的韧性，综合也提高了本发明绝缘子的冲击强度，因此本发明的陶瓷断裂韧性可达其它绝缘材料的9倍以上、冲击强度可达抗冲击陶瓷标准值的16倍以上（美国标准M-C-301规定指标为0.27J/cm2）；碳化硅和氮化铝都是绝缘性非常好的材料，但受限于碳化硅易氧化、氮化铝脆性很高的本质特性，单独使用均无法适应恶劣工况（比如运输和安装时碰撞损毁、电线老化短路后高温氧化、风沙或冰雹震动等），本发明以高强度氮化铝陶瓷为基，含部分碳化硅，一方面增加氮化铝的韧性，另外也利于表层氧化生成的二氧化硅进一步提升绝缘性，又不会导致氧化后脆性升高或过渡氧化后绝缘性降低，而氮化铝由于有了碳化硅的加入，加上多层结构的支持，其断裂韧性及冲击强度均有了长足的提升，因此，本发明耐高温、综合性能好且主要材料功能互补，综合机械性能优良；另外，本发明采用的均为同领域中较经济的材料，而且能适应大部分恶劣工况，基础绝缘及导热性能优于其它绝大多数绝缘陶瓷，故而本发明的经济性好，适合大范围应用推广；根据相关研究，陶瓷表面的凸出结构能提升陶瓷20%左右的冲击强度，但由于受模具限制和常规氮化铝陶瓷高温烧结工艺，无法使表面形成规则的、有效的凸出结构，本发明通过采用柔性的石墨模具，又采用了金刚石磨料振动去毛刺设备对成型毛坯进行表面抛光和去应力处理，使得表面光滑、内应力分布均匀获得了更高的断裂韧性和抗冲击性能；另外，本发明在烧结过程中选择了最优升温速率，冷却时又采用阶梯缓冷，本身绝缘子残余的热应力和组织应力都较低，在后期抛光处理中又加入了振动过程，使内应力均匀化，提升了整体性能的均匀性，降低了缺口敏感性，也是本发明断裂韧性及冲击强度高的一个重要原因。
附图说明
图1为本发明的结构示意图
具体实施方式
实施例1：
如图1所示的一种绝缘子，该绝缘子按轮廓三维尺寸分级，每4mm为一级，最内层最大有效直径Φ8mm，其包括如下重量份的成分：硼酸铝晶须6份、氮化铝70份、碳化硅22份、氟化钙5份、钼的不定化合物2份。
该抗冲击陶瓷绝缘子的制造方法包括以下步骤：
1）原材料准备
①按重量份数准备硼酸铝晶须6份、颗粒尺寸3μm的氮化铝微粉70份、颗粒尺寸3μm的碳化硅微粉20份、氟化钙粉末5份、碳粉2份、硅化钼2份、正硅酸乙脂1份、无水乙醇1份、纯净水10份、热塑性酚醛树脂4份；
②将硼酸铝晶须、碳化硅微粉、碳粉和硅化钼、氮化铝微粉和氟化钙混合并搅拌均匀，作为混合物料；
2）模具的准备
①采用石墨制作模具，所述模具按轮廓三维尺寸分级，每4mm为一级，按从小到大依次分为第一心部模具、第二心部模具、第三心部模具……表层模具，其中第一心部模具最大有效直径Φ8mm；
②对表层模具的内表面与绝缘子外表面匹配区域进行微造型，该微造型具体为垂直交错的深1mm、宽5mm的沟槽，相邻平行沟槽边缘间距为3mm。
3）预制备绝缘子
①将1）中步骤②获得的混合物料与正硅酸乙脂、无水乙醇、纯净水、热塑性酚醛树脂混合并搅拌均匀，获得待用物料；
②将部分待用物料填充入第一心部模具中，将该第一心部模具置于800℃下，在保护气氛或真空环境里保温5h，获得第一心部素坯；
③再在第二心部模具底部填充2mm厚的待用物料，再将第一心部素坯置于第二心部模具中心，然后采用待用物料将第二心部模具填充满，将该第二心部模具置于800℃下，在保护气氛或真空环境里保温5h，获得第二心部素坯；
④按步骤③方法依次反复进行，完成第三心部毛坯……表层毛坯的预烧结，获得绝缘子素坯；
4）绝缘子烧结及完成
①将2）中步骤③获得的预制备绝缘子素坯置于18Mpa的保护气氛中，以1000℃以上保持200℃/h的升温速率升温至1600℃，保温时间4h；
②烧结完成后，炉温T不低于1000℃时随炉冷却；炉温T处于800℃≤T＜1000℃半开炉门冷却；炉温T＜800℃出炉空冷；空冷至T＜150℃后将烧结的绝缘子毛坯脱出模具；
③采用金刚石磨料振动去毛刺设备对绝缘子毛坯进行振动去毛刺及抛光处理，即获得所需绝缘子。
按本实施例生产出的抗冲击陶瓷绝缘子样品，其冲击强度不低于4.8J/cm2、体积电阻率为2×1014Ω•cm、介电强度为860kV/cm、热导率为22W/m·K、抗弯强度为620Mpa、杨氏模数为510Gpa、断裂韧性为63Mpa。
实施例2：
一种绝缘子，该绝缘子按轮廓三维尺寸分级，每5mm为一级，最内层最大有效直径Φ10mm，其包括如下重量份的成分：其包括如下重量份的成分：硼酸铝晶须10份、氮化铝80份、碳化硅28份、氟化钙8份、钼的不定化合物3份。
该抗冲击陶瓷绝缘子的制造方法包括以下步骤：
1）原材料准备
①按重量份数准备硼酸铝晶须10份、颗粒尺寸5μm的氮化铝微粉80份、颗粒尺寸5μm的碳化硅微粉25份、氟化钙粉末8份、碳粉8份、硅化钼8份、正硅酸乙脂2份、无水乙醇2份、纯净水15份、热塑性酚醛树脂6份；
②将硼酸铝晶须、碳化硅微粉、碳粉和硅化钼、氮化铝微粉和氟化钙混合并搅拌均匀，作为混合物料；
2）模具的准备
①采用石墨制作模具，所述模具按轮廓三维尺寸分级，每5mm为一级，按从小到大依次分为第一心部模具、第二心部模具、第三心部模具……表层模具，其中第一心部模具最大有效直径Φ10mm；
②对表层模具的内表面与绝缘子外表面匹配区域进行微造型，该微造型具体为垂直交错的深1.2mm、宽6mm的沟槽，相邻平行沟槽边缘间距为4mm。
3）预制备绝缘子
①将1）中步骤②获得的混合物料与正硅酸乙脂、无水乙醇、纯净水、热塑性酚醛树脂混合并搅拌均匀，获得待用物料；
②将部分待用物料填充入第一心部模具中，将该第一心部模具置于850℃下，在保护气氛或真空环境里保温8h，获得第一心部素坯；
③再在第二心部模具底部填充2.5mm厚的待用物料，再将第一心部素坯置于第二心部模具中心，然后采用待用物料将第二心部模具填充满，将该第二心部模具置于850℃下，在保护气氛或真空环境里保温8h，获得第二心部素坯；
④按步骤③方法依次反复进行，完成第三心部毛坯……表层毛坯的预烧结，获得绝缘子素坯；
4）绝缘子烧结及完成
①将2）中步骤③获得的预制备绝缘子素坯置于20Mpa的保护气氛中，以1000℃以上保持250℃/h的升温速率升温至1700℃，保温时间7h；
②烧结完成后，炉温T不低于1000℃时随炉冷却；炉温T处于800℃≤T＜1000℃半开炉门冷却；炉温T＜800℃出炉空冷；空冷至T＜150℃后将烧结的绝缘子毛坯脱出模具；
③采用金刚石磨料振动去毛刺设备对绝缘子毛坯进行振动去毛刺及抛光处理，即获得所需绝缘子。
按本实施例生产出的抗冲击陶瓷绝缘子样品，其冲击强度不低于4.5J/cm2、体积电阻率为1×1014Ω•cm、介电强度为830kV/cm、热导率为24W/m·K、抗弯强度为640Mpa、杨氏模数为480Gpa、断裂韧性为67Mpa。
对所公开的实施例的上述说明，仅为了使本领域专业技术人员能够实现或使用本发明。对这些实施例的多种修改对本领域的专业技术人员来说将是显而易见的，本文中所定义的一般原理可以在不脱离本发明的精神或范围的情况下，在其它实施例中实现。因此，本发明将不会被限制于本文所示的这些实施例，而是要符合与本文所公开的原理和新颖特点相一致的最宽的范围。
Claims (2)
1.一种抗冲击陶瓷绝缘子的制造方法，其特征在于包括以下步骤：
1）原材料准备
①按重量份数准备硼酸铝晶须6-10份、颗粒尺寸3μm-5μm的氮化铝微粉70-80份、颗粒尺寸3μm-5μm的碳化硅微粉20-25份、氟化钙粉末5-8份、碳粉2-3份、硅化钼2-3份、正硅酸乙酯 1-2份、无水乙醇1-2份、纯净水10-15份、热塑性酚醛树脂4-6份；
②将硼酸铝晶须、碳化硅微粉、碳粉和硅化钼、氮化铝微粉和氟化钙混合并搅拌均匀，作为混合物料；
2）模具的准备
①采用石墨制作模具，所述模具按轮廓三维尺寸分级，每4mm-5mm为一级，按从小到大依次分为第一心部模具、第二心部模具、第三心部模具、 表层模具，其中第一心部模具最大有效直径不大于Φ10mm；
②对表层模具的内表面与绝缘子外表面匹配区域进行微造型，该微造型具体为垂直交错的深1mm-1.2mm、宽5mm-6mm的沟槽，相邻平行沟槽边缘间距为3mm-4mm；
3）预制备绝缘子
①将1）中步骤②获得的混合物料与正硅酸乙酯 、无水乙醇、纯净水、热塑性酚醛树脂混合并搅拌均匀，获得待用物料；
②将部分待用物料填充入第一心部模具中，将该第一心部模具置于800℃-850℃下，在保护气氛或真空环境里保温5h-8h，获得第一心部素坯；
③再在第二心部模具底部填充2mm-2.5mm厚的待用物料，再将第一心部素坯置于第二心部模具中心，然后采用待用物料将第二心部模具填充满，将该第二心部模具置于800℃-850℃下，在保护气氛或真空环境里保温5h-8h，获得第二心部素坯；
④按步骤③方法依次反复进行，完成第三心部素坯、 表层素坯的预烧结，获得绝缘子素坯；
4）绝缘子烧结及完成
①将3）中步骤④获得的绝缘子素坯置于18Mpa-20Mpa的保护气氛中，以1000℃以上保持200℃/h-250℃/h的升温速率升温至1600℃-1700℃，保温时间4h-7h；
②烧结完成后，炉温T不低于1000℃时随炉冷却；炉温T处于800℃≤T＜1000℃半开炉门冷却；炉温T＜800℃出炉空冷；空冷至T＜150℃后将烧结的绝缘子素坯脱出模具；
③采用金刚石磨料振动去毛刺设备对绝缘子素坯进行振动去毛刺及抛光处理，即获得所需绝缘子。
2.根据权利要求1所述抗冲击陶瓷绝缘子的制造方法所制造出的绝缘子，其特征在于：该绝缘子按轮廓三维尺寸分级，每4mm-5mm为一级，最内层最大有效直径不大于Φ10mm，其原材料成份包括硼酸铝晶须6-10份、颗粒尺寸3μm-5μm的氮化铝微粉70-80份、颗粒尺寸3μm-5μm的碳化硅微粉20-25份、氟化钙粉末5-8份、碳粉2-3份、硅化钼2-3份、正硅酸乙酯 1-2份、无水乙醇1-2份、纯净水10-15份、热塑性酚醛树脂4-6份。
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