CN106604906A - 形成陶瓷产品 - Google Patents

形成陶瓷产品 Download PDF

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Publication number
CN106604906A
CN106604906A CN201580045519.4A CN201580045519A CN106604906A CN 106604906 A CN106604906 A CN 106604906A CN 201580045519 A CN201580045519 A CN 201580045519A CN 106604906 A CN106604906 A CN 106604906A
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Prior art keywords
extruded material
slurry
methods according
kiln
equipment
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Granted
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CN201580045519.4A
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CN106604906B (zh
Inventor
A·C·克拉克
S·桑德斯
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Mandt Technology Ceramic Products Co Ltd
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Mandt Technology Ceramic Products Co Ltd
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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    • C04B35/03—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on magnesium oxide, calcium oxide or oxide mixtures derived from dolomite
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    • C04B33/00—Clay-wares
    • C04B33/32—Burning methods
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/50—Producing shaped prefabricated articles from the material specially adapted for producing articles of expanded material, e.g. cellular concrete
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
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    • B28B11/243—Setting, e.g. drying, dehydrating or firing ceramic articles
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    • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
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    • B28—WORKING CEMENT, CLAY, OR STONE
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
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Abstract

一种形成陶瓷产品的方法，所述方法包括制备浆料形式的陶瓷成形混合物，使所述浆料发泡，挤出该发泡浆料，制备多个挤出材料段，每个挤出材料段的直径小于10mm，烧制挤出材料，使该挤出材料部分烧结，将部分烧结的挤出材料形成为产品所需的形状，然后烧制所述成型的部分烧结的挤出材料以形成陶瓷产品。

Description

形成陶瓷产品
本发明涉及形成陶瓷产品的方法、通过这种方法制造的产品，以及用于形成陶瓷产品的设备。
市场上有两种主要的通用产品用于窑炉耐火衬里：陶瓷纤维和耐火砖。选择一种产品而不是另一种的决定很大程度上取决于被烧制的产品的类型、烧制周期和窑炉的类型。快速烧制产品通常在纤维衬里窑炉中烧制。较长时间、较高温度的烧制产品通常在砖衬窑炉中烧制。
耐火砖通常通过挤出或压制制备。在销售之前，耐火砖进行预烧制，然后使用耐火水泥通过耐火砖层粘结在一起，形成刚性固定壁窑炉衬里。一旦砖衬里安装完成，它们通常够用很多年甚至是几十年。但是，由于它们是砖，与陶瓷纤维相比，它们相对致密并且具有相对更高的热质量/热导率。
高温陶瓷纤维具有比耐火砖更低的热质量/热导率。纤维的主要优点是它比砖衬窑炉烧制快得多。较低的热质量衬里使得窑炉比衬有耐火砖的窑炉更快地加热和冷却。这有助于降低每次烧制的能量成本，并且由于窑炉可以更快地烧制，能增加容量。但是，在高温(即高于1550℃)下陶瓷纤维具有的缺点是会过早地降解/收缩并且通常不具有与砖相同的工作寿命。当它达到其使用寿命时，陶瓷纤维必须作为危险废物处理，需要专业的取出预防措施和通气设备。
在本说明书中表示的所有百分比均为重量百分比。
根据本发明的第一个方面，提供了形成陶瓷产品的方法，所述方法包括制备浆料形式的陶瓷成形混合物，使浆料发泡，挤出发泡浆料，制备多个长段挤出材料，每个长段挤出材料的直径小于10mm，烧制挤出材料，使该挤出材料部分烧结，将部分烧结的挤出材料形成为产品所需的形状，然后烧制所述成型的部分烧结的挤出材料，形成陶瓷产品。
所述长段挤出材料可以在形成所需形状之前被切割或拆分成多个块，并且所述块可以小于25mm长。
为了使浆料发泡，可以将空气引入到浆料中，并将空气和浆料混合在一起以将空气带入到浆料中。空气可以作为压缩空气引入到浆料中，并且该压缩空气的体积可以是0.2-2升/分钟。
可以将发泡剂加入到浆料中以帮助发泡，并且所述发泡剂可以是有机氧化胺。
所述发泡剂可以滴加到浆料中，并且可以以2-15ml/min的速率滴加。为了使浆料发泡，浆料和空气可以被送入发泡单元中，该单元可以包括多个相对旋转的转子和定子，其可以以200-500rpm的速度旋转。
在所述发泡单元中将产生增大的压力，该增大的压力可以在20和80psi之间。
可以设置从所述发泡单元延伸到挤出单元的进料管。
可以将固化剂加入到所述浆料中。该固化剂可以是石膏、铝酸钙水泥、波特兰水泥、PVA加交联聚合物添加剂、藻酸盐或淀粉中的任一种。
所述陶瓷成形混合物可以通过高速搅拌机混合在一起。
所述陶瓷成形混合物可以包含：
10-40％的水
20-80％的陶瓷成形材料
2-10％的添加剂。
所述陶瓷成形材料可以是煅烧的、熔融的或片状的氧化铝；二氧化硅、氧化镁、碳化硅、硅酸锆、硅线石(silliminite)、莫来石、滑石或堇青石中的任意一种。
所述添加剂可以包含有机粘合剂、甲基纤维素、淀粉、树胶、聚乙酸乙烯酯、聚乙烯醇、聚乙二醇、聚环氧乙烷、聚丙烯酸酯、藻酸盐、蜡和蜡乳液中的任意一种。
所述添加剂可以包含有机抗絮凝剂，其可以是三聚磷酸钠。
所述陶瓷成形混合物还可以包含高达50％的粘土以形成浆料，其可以是球粘土或瓷土。
在烧制之前，所述挤出材料可以进行干燥。所述挤出材料的干燥可以在500-750℃的温度下进行。
所述挤出材料的干燥可以进行少于10分钟，并且可以进行1至5分钟，并且可以进行2至4分钟。
所述挤出材料的干燥可以在输送带式干燥机中进行，携带挤出材料的输送带通过该输送带式干燥机。该干燥机可以设置有红外加热器。
所述挤出材料的烧制可以在高达1250℃的温度下进行，并且可以在800和1250℃之间的温度下进行。
所述挤出材料的烧制可以进行少于10分钟，可以进行1至5分钟，并且可以进行2至4分钟。
所述挤出材料的烧制可以在窑炉中进行，携带挤出材料的输送机通过该窑炉，并且输送机可以包括可由耐热金属制成的网带。
可以控制在烧制期间所述挤出材料的厚度。可以在所述窑炉的入口处设置门，该门可以是可调节的，以限制窑炉的材料厚度。窑炉上所述材料的厚度可以为2-10cm。
通过将挤出材料基本上完全覆盖在输送机上，随输送机通过窑炉时进行所述挤出材料的烧制。
通过在具有所需形状的模具中挤压挤出材料使所述部分烧结的挤出材料成形为所需形状。
所述部分烧结的挤出材料可以被压制，使其厚度在压制期间减小至至少四分之一，更具体地减小至大约五分之一。
所述成型的部分烧结的挤出产品可以在高于1200℃的温度下烧制，并且可以在1400至1750℃之间的温度下烧制。
根据本发明的第二个方面，提供了通过根据前述二十四段中任一段的方法制造的陶瓷产品。
根据本发明的第三个方面，提供了用于形成陶瓷产品的设备，所述设备包含用于将陶瓷成形混合物的成分混合在一起的混合单元，所述混合单元连接到用于使浆料发泡的发泡单元，所述发泡单元连接到模具单元，所述模具单元用于挤出发泡混合物，制备多个长段挤出材料，每个长段挤出材料的直径小于10mm，所述模具单元连接到窑炉，以部分烧结所述挤出材料。
所述混合单元可以是高速搅拌机的形式。
设置有用于将浆料从混合单元泵送到发泡单元的泵，并且所述泵可以是定量泵。
可以在所述混合单元和发泡单元之间设置滤网，以除去大于预定尺寸的颗粒，例如2mm。
所述发泡单元可以包含用于与浆料混合的压缩空气的入口。所述发泡单元可以包含用于发泡剂的入口，并且能够滴注定量发泡剂。
所述发泡单元可以包括多个相对旋转的转子和定子，用于将空气夹带到浆料中，并且所述转子和定子可以以200-500rpm的速度旋转。可以设置从所述发泡单元延伸到挤出单元的进料管。
所述设备可以包含切割装置，用于将挤压材料切割成所需长度段。
可以在所述模具单元和窑炉之间设置干燥机。所述干燥机可以是输送带式干燥机的形式，并且可以设有红外加热器。
所述窑炉可以包括带式窑，携带挤出材料的输送机通过该窑炉，并且输送机可以包括可由耐热金属制成的网带。
可以在所述窑炉的入口处设置门以限制窑炉内的材料的高度，并且该门的高度可以是可调节的。
所述设备可以包含压制机和用于将部分烧结的挤出材料形成为所需形状的模具。
本发明的实施例现在将仅通过示例并参考附图来描述，其中：
图1是根据本发明的设备的简化侧视图；
图2是图1的设备的一部分更加详细的简化侧视图；和
图3至图5是根据本发明的设备在使用中的简化连续侧视图。
图1示出了用于通过本发明的方法制造陶瓷产品的本发明的设备10。所述设备10包括混合单元12，该混合单元12包括高速搅拌机。
所述混合单元12还包括常规的定量泵(未示出)，其将材料泵送通过磁体和滤网，以除去例如大于2mm的任何固体或未混合的颗粒。该泵连接到通向发泡单元16的管道14。
所述发泡单元16包括与其连接的单元20。所述单元20以0.2-2升/分钟的体积将压缩空气通入到浆料中。所述单元20还将发泡剂滴加到混合物中。
所述发泡单元16还包括混合头22，以接收包含发泡剂的掺有一定比例空气的浆料。所述混合头包含一系列嵌套在一起的相对旋转的转子和定子叶片，其以200-500rpm旋转，通过类似搅拌的动作将空气夹带到浆料中并使完全空气混入浆料中。这会在陶瓷浆料中产生泡沫气泡，其被包埋在浆料中而不会破裂或坍塌。所述发泡剂提供了临时的湿强度，以使气泡维持泡沫结构。
在所述混合头22中将建立20至80psi的自然增大的压力。该增大的压力足以促使材料通过进料管24，进入模具单元26中。如图2所示的所述模具单元26包括多个出口喷嘴28，其产生多个长段挤出材料30，每个挤出材料30具有小于10mm的直径。
所述模具单元26设置用于将挤出材料30供应到配备有红外加热器的输送带式干燥机32。所述干燥机32布置成使得挤出材料在大约2.5分钟内通过，并且干燥机32在大约700℃的温度下操作。
干燥的挤出材料34从所述加热器32被传送到带式窑36。当干燥的挤出材料34落到窑炉36的边缘38上时，干燥的长段挤出材料34有可能断裂。
所述窑炉36包括在窑炉36的入口处的闸门42和烧制区40。所述闸门42监测穿过烧制区40的耐热金属带上的材料的厚度。所述闸门42的高度是可调的，并且通常，传送到窑炉36的带上的干燥挤出材料的厚度将在2至10cm之间。所述窑炉36布置成使得在烧制区40内的整条带有可能被干燥的挤出材料覆盖，从而在烧制期间保护所述带。
所述干燥的挤出材料通常在约1200℃的温度下在烧制区40中闪烧烧制约2.5分钟。这能够部分烧结所述干燥的挤出材料，特别地可能能够完全烧结例如在所述带上的表层材料层的材料，而堆于所述带的底部处的材料至多能被部分烧结。
这种部分烧结的材料44进入料斗46，并且长段的部分烧结的材料44在其进入料斗46时将有可能再次被折断。所述部分烧结的材料44在外观上将趋于部分灰色和部分白色。所述灰色部分至多部分烧结，并且不会是完全烧结的，而白色部分是完全烧结的。所述白色部分将相对较硬，具有较小的微孔，而灰色部分软一些并具有较大的微孔，但可以被显著压缩。
所述部分烧结的材料44被引入模具48中并且由模具50压缩至例如五分之一以制成部分烧结的压制陶瓷砖或陶瓷块52。所述部分烧结的砖或块52可以烧制，如果合适的话可以立即烧制，而不需要例如预干燥。
所述砖或块52在约1750℃下进行最终烧制，经大约12小时冷却下来。这种烧制通常比不通过该方法制造的耐火砖的类似烧制更快。所述块或砖52可以更快地升高到最高温度，并且如所指出的，例如由于不需要烧掉粘合剂，能比传统方式更快地进行烧制。根据本发明的方法可以用于例如不含粘土制品的产品，因为在最终烧制之前所述部分烧结的材料自身能够充分地粘合起来。
在一个实例中，具有约70％氧化铝和其它材料的高氧化铝陶瓷在所述混合单元12中混合，形成固体含量约70％的浆料。然后将浆料通过管道14泵送进入发泡单元16。通过所述滤网或磁体除去大于2mm的任何固体或未混合的颗粒。
将压缩空气以0.2至2升/分钟的所需体积引入所述浆料中，并将有机氧化胺发泡剂以2至15ml/min的速率滴加到浆料中。然后将该混合物在所述混合头22中高速混合，以将空气夹带到陶瓷浆料中并在陶瓷浆料中产生泡沫气泡。在所述混合头22中产生20至80psi的增大的压力。所述发泡剂在烧制之前为这些气泡提供临时的湿强度。
可将固化剂如石膏、铝酸钙水泥、波特兰水泥、PVA加交联聚合物添加剂、藻酸盐或淀粉注入所述浆料中，以促进发泡过程。所述固化剂可以包含促进剂或阻滞剂。
然后将所述发泡混合物加压通过进料管24进入模具单元26，并且如图2所示，挤出相对细的长段30。在这种情况下，所述材料30具有约5mm的直径，但是根据需要可能选择的参数在1和10mm之间。
充气挤出段30以高达700℃的工作温度进入干燥机32。所述充气挤出材料30在干燥机32中保持大约2.5分钟。离开干燥机32的干燥材料34通常具有约10至20％的含水量。随后基本上所有这些水分会在所述窑炉36中被除去。初始陶瓷材料中的一些或有机物含量会被烧掉，但是一些会保留下来，为材料提供一些塑性，这能促进随后的压制。
如在窑炉36中指出的，所述材料34闪烧烧制，从而发生部分烧结，在耐热金属带上的材料34穿过窑炉36时其受控厚度层的表层烧结增加。将材料34完全布满所述带，这给传送带提供了保护并且扩大了传送带能够工作的温度，同时保护其不在使用中的劣化。在约1200℃的最高温度下，闪烧(flash firing)在窑炉36中进行约2.5分钟。
所述部分烧结的材料44可以在合适的模具中压制。在压制期间，所述材料例如在模具中的高度可以减小至大约五分之一，根据被压制的产品的表面积，可以施加例如高达大约一吨的压制压力。较软的少量烧结的灰色材料在压制过程中会破碎，并充当压制助剂以将较硬的烧结白色材料保持在一起，成压制形状。
现在形成的成型产品可以手工处理并且可以烧制以形成所需的产品。所述产品在通常超过1400℃的温度下烧制。由于已经在窑炉36中除去大部分水分以及材料的一些有机物含量，随后的烧制可以相对快速地进行，将所述产品相对快速地升至最高温度，而没有导致产品破裂或其它损坏的常规风险。
如果需要，可将由此形成的产品进一步切割成用于例如在窑炉衬里或其它耐火应用中使用的精确形状。这些产品通常具有65-95％的氧化铝含量。
该方法和设备非常适合用于在少于十分钟内生产准备由原料烧制的压制产品。所生产的低密度砖或块不需要干燥，并且可以直接从所述压制机快速烧制，从而如上所述通常可以更快地烧制。
重要的是保持材料的部分烧结构成，并且这可以通过穿过窑炉的行进速度、穿过窑炉的材料的厚度和峰值烧制温度来实现。
在不脱离本发明的范围的情况下可以进行各种修改。例如，所述挤出材料的尺寸和/或加热或烧制条件可以采用不同的参数。
除了上述示例之外，该设备和/或方法可以与许多各种不同的陶瓷材料一起使用。例如，可以使用不同比例的氧化铝，并且该氧化铝可以是煅烧的、熔融的或片状的。其它陶瓷成形材料可单独或组合使用，例如二氧化硅、氧化镁、碳化硅、硅酸锆、硅线石(silliminite)、莫来石、滑石或堇青石。可以加入高达50％的粘土，其可以是球粘土或瓷土。其还能够生产不含任何粘土含量的配方。
初始混合物中的添加剂可以包含有机粘合剂、甲基纤维素、淀粉、聚乙酸乙烯酯或其它合适的粘合剂。所述添加剂可以包含有机抗絮凝剂，其可以是三聚磷酸钠。
可以使用不同的混合单元将空气夹带到浆料中。所述模具单元可以采取不同的形式。最终产品的烧制条件将取决于材料的性质。在该过程中通常需要后燃烧器，这是由于由来自部分预烧结材料的任何剩余粘合剂产生的燃烧产物。
事实上，已经发现本发明生产的具有严格控制孔径分布的产品，其具有泡沫陶瓷微孔内部结构。本产品提供两个主要优点。
首先，其具有紧密混合的、均匀的微孔结构贯穿整个部件，其次，其具有比用于陶瓷形状的常规连续制造技术低得多的堆积密度。这种性质的组合使其本身成为用于工业窑炉和熔炉内的优良耐火部件。这种结构是耐火绝缘产品的理想选择。
由于所述充气材料的高孔隙率和将形状结合在一起所需的温和的低压制压力，可以用该方法实现现有的传统压制/挤出砖的约一半的烧制密度。这种低密度与由此获得的低热导率结合制造了低密度高铝砖，其比市场上现有的市售绝缘耐火砖具有更好的节能特性以及由此得到的更高的强度。使用低于0.35W/M/J的热导率可以实现大约0.3-0.6g/cc的烧制密度，并且具有改善的抗压强度。
因此，这提供了具有砖的硬度和寿命的材料，但是其具有更轻的堆积密度，因此能明显的节能。使用这种材料制成的产品可以翻新安装以及安装到新的装置中。
尽管前述说明书中着墨于描述对本发明特别重要的那些特征，但是应当理解，无论是否特别强调，申请人要求保护以上参考和/或在附图中示出的任何可取得专利的特征或特征的组合。

Claims (78)

1.形成陶瓷产品的方法，所述方法包括制备浆料形式的陶瓷成形混合物，使所述浆料发泡，挤出所述发泡浆料，制备多个长段挤出材料，每个长段挤出材料的直径小于10mm，烧制挤出材料，使所述挤出材料部分烧结，将所述部分烧结的挤出材料形成为产品所需的形状，然后烧制所述成型的部分烧结的挤出材料，形成陶瓷产品。
2.根据权利要求1所述的方法，其特征在于，所述长段挤出材料在形成所需形状之前被切割或拆分成多个块。
3.根据权利要求2所述的方法，其特征在于，所述块小于25mm长。
4.根据前述权利要求中任一项所述的方法，其特征在于，将发泡剂加入到所述浆料中促进发泡。
5.根据权利要求4所述的方法，其特征在于，所述发泡剂是有机氧化胺。
6.根据权利要求4或5所述的方法，其特征在于，将所述发泡剂滴加到浆料中。
7.根据权利要求6所述的方法，其特征在于，所述发泡剂以2-15ml/min的速率滴加。
8.根据前述权利要求中任一项所述的方法，其特征在于，为使所述浆料发泡，将空气引入到所述浆料中，并将所述空气和浆料混合在一起，以将空气夹带到浆料中。
9.据权利要求8所述的方法，其特征在于，所述空气作为压缩空气引入到所述浆料中。
10.根据权利要求9所述的方法，其特征在于，所述压缩空气以0.2-2升/分钟的体积进料。
11.根据权利要求8-10中任一项所述的方法，其特征在于，为使所述浆料发泡，将所述浆料和空气引入到发泡单元中。
12.根据权利要求11所述的方法，其特征在于，所述发泡单元包括多个相对旋转的转子和定子。
13.根据权利要求12所述的方法，其特征在于，所述旋转的转子和定子以200-500rpm的速度旋转。
14.根据权利要求11-13中任一项所述的方法，其特征在于，所述发泡单元中将产生增大的压力。
15.根据权利要求14所述的方法，其特征在于，所述增大的压力将在20和80psi之间。
16.根据权利要求11-15中任一项所述的方法，其特征在于，设有从所述发泡单元延伸到挤出单元的进料管。
17.根据前述权利要求中任一项所述的方法，其特征在于，可以将固化剂添加到所述浆料中。
18.根据权利要求17所述的方法，其特征在于，所述固化剂是石膏、铝酸钙水泥、波特兰水泥、PVA加交联聚合物添加剂、藻酸盐或淀粉中的任一种。
19.根据前述权利要求中任一项所述的方法，其特征在于，所述陶瓷成形混合物通过高速搅拌机混合在一起。
20.根据前述权利要求中任一项所述的方法，其特征在于，所述陶瓷成形混合物包含：
10-40％的水
20-80％的陶瓷成形材料
2-10％的添加剂。
21.根据权利要求20所述的方法，其特征在于，所述陶瓷成形材料是可煅烧、熔融或片状的氧化铝、二氧化硅、氧化镁、碳化硅、硅酸锆、硅线石、莫来石、滑石或堇青石中的任意一种。
22.根据权利要求20或21的方法，其特征在于，所述添加剂包含任意有机粘合剂、甲基纤维素、淀粉、树胶、聚乙酸乙烯酯、聚乙烯醇、聚乙二醇、聚环氧乙烷、聚丙烯酸酯、藻酸盐、蜡和蜡乳液。
23.根据权利要求20-22中任一项所述的方法，其特征在于，所述添加剂包含有机抗絮凝剂。
24.根据权利要求23所述的方法，其特征在于，所述有机抗絮凝剂是三聚磷酸钠。
25.根据权利要求20-24中任一项所述的方法，其特征在于，所述陶瓷成形混合物包含高达50％的粘土以形成浆料。
26.根据权利要求25所述的方法，其特征在于，所述粘土是球粘土或瓷土。
27.根据前述权利要求中任一项所述的方法，其特征在于，所述挤出材料在烧制之前进行干燥。
28.根据权利要求27所述的方法，其特征在于，所述挤出材料的干燥在500-750℃的温度下进行。
29.根据权利要求27或28所述的方法，其特征在于，所述挤出材料的干燥进行少于10分钟。
30.根据权利要求29所述的方法，其特征在于，所述挤出材料的干燥进行1至5分钟。
31.根据权利要求30所述的方法，其特征在于，所述挤出材料的干燥进行2至4分钟。
32.根据权利要求27-31中任一项所述的方法，其特征在于，所述挤出材料的干燥在输送带式干燥机中进行，携带挤出材料的输送机穿过该输送带式干燥机。
33.根据权利要求32所述的方法，其特征在于，所述干燥机设有红外加热器。
34.根据前述权利要求中任一项所述的方法，其特征在于，所述挤出材料的烧制在高达1250℃的温度下进行。
35.根据权利要求34所述的方法，其特征在于，所述挤出材料的烧制在800至1250℃的温度下进行。
36.根据前述权利要求中任一项所述的方法，其特征在于，所述挤出材料的烧制进行少于10分钟。
37.根据前述权利要求中任一项所述的方法，其特征在于，所述挤出材料的烧制进行1至5分钟。
38.根据前述权利要求中任一项所述的方法，其特征在于，所述挤出材料的烧制进行2至4分钟。
39.根据前述权利要求中任一项所述的方法，其特征在于，所述挤出材料的烧制在窑炉中进行，通过输送机携带所述挤出材料穿过该窑炉。
40.根据权利要求39所述的方法，其特征在于，所述输送机包括网带。
41.根据权利要求40所述的方法，其特征在于，所述网带由耐热金属制成。
42.根据权利要求39-41中任一项所述的方法，其特征在于，所述挤出材料的烧制是在挤出材料完全覆盖在输送机上并随输送机通过窑炉时进行的。
43.根据前述权利要求中任一项所述的方法，其特征在于，在烧制期间所述挤出材料的厚度是受控的。
44.根据权利要求43所述的方法，其特征在于，所述窑炉的入口处设有门，以限制所述窑炉的材料的厚度。
45.根据权利要求44所述的方法，其特征在于，所述门是可调节的，以限制所述窑炉的材料的厚度。
46.根据权利要求43-45中任一项所述的方法，其特征在于，所述窑炉上的材料厚度在2至10cm之间。
47.根据前述权利要求中任一项所述的方法，其特征在于，通过在具有所需形状的模具中压制所述挤出材料来进行将所述部分烧结的挤出材料形成为所需形状。
48.根据前述权利要求中任一项所述的方法，其特征在于，所述部分烧结的挤出材料被压制成使得其厚度在压制期间减小至至少四分之一。
49.根据权利要求48所述的方法，其特征在于，所述部分烧结的挤出材料被压制成使得其厚度在压制期间减小至大约五分之一。
50.根据前述权利要求中任一项所述的方法，其特征在于，所述成型的部分烧结的挤出产品在高于1200℃的温度下烧制。
51.根据权利要求50所述的方法，其特征在于，所述成型的部分烧结的挤出产品在1400至1750℃的温度下烧制。
52.根据前述权利要求中任一项所述的方法制造的陶瓷产品。
53.用于形成陶瓷产品的设备，所述设备包括用于将陶瓷成形混合物的各成分混合在一起的混合单元，所述混合单元连接到用于使浆料发泡的发泡单元，所述发泡单元连接到用于挤出发泡混合物的模具单元，以制备多个长段挤出材料，每个长段挤出材料的直径小于10mm，所述模具单元连接到窑炉，部分烧结所述挤出材料。
54.根据权利要求53所述的设备，其特征在于，所述混合单元是高速搅拌机的形式。
55.根据权利要求53或54所述的设备，其特征在于，设有泵，该泵用于将浆料从所述混合单元泵送到所述发泡单元。
56.根据权利要求55所述的设备，其特征在于，所述泵是定量泵。
57.根据权利要求53-56中任一项所述的设备，其特征在于，在所述混合单元和发泡单元之间设置有滤网，用于除去预定尺寸以上的颗粒。
58.根据权利要求57所述的设备，其特征在于，所述滤网用于除去2mm以上的颗粒。
59.根据权利要求53-58中任一项所述的设备，其特征在于，所述发泡单元包含用于与所述浆料混合的压缩空气的入口。
60.根据权利要求53-59中任一项所述的设备，其特征在于，所述发泡单元包含用于发泡剂的入口。
61.根据权利要求60所述的设备，其特征在于，所述发泡单元允许滴加所述发泡剂。
62.根据权利要求53-61中任一项所述的设备，其特征在于，所述发泡单元包括多个相对旋转的转子和定子，用于将空气夹带到浆料中。
63.根据权利要求62所述的设备，其特征在于，所述转子和定子以200-500rpm的速度旋转。
64.根据权利要求53-63中任一项所述的设备，其特征在于，设有从所述发泡单元延伸到所述挤出单元的进料管。
65.根据权利要求53-64中任一项所述的设备，其特征在于，所述设备包含切割装置，用于将所述挤出材料切割成所需长度。
66.根据权利要求53-65中任一项所述的设备，其特征在于，在所述模具单元和所述窑炉之间设置有干燥机。
67.根据权利要求66所述的设备，其特征在于，所述干燥机的形式是输送带式干燥机。
68.根据权利要求67所述的设备，其特征在于，所述干燥机设有红外加热器。
69.根据权利要求53-68中任一项所述的设备，其特征在于，所述窑炉包括带式窑，携带挤出材料的输送机穿过该窑炉。
70.根据权利要求69所述的设备，其特征在于，所述输送机包括网带。
71.根据权利要求70所述的设备，其特征在于，所述网带由耐热金属制成。
72.根据权利要求53-71中任一项所述的设备，其特征在于，在所述窑炉的入口处设有门，以限制所述输送机上的材料的高度。
73.根据权利要求72所述的设备，其特征在于，所述门的高度是可调节的。
74.根据权利要求53-73中任一项所述的设备，其特征在于，所述设备包含压制机和用于将部分烧结的挤出材料形成为所需形状的模具。
75.形成陶瓷产品的方法，该方法基本上如上文参考附图所作的描述。
76.基本上如上文参考附图所描述的陶瓷产品。
77.用于形成陶瓷产品的设备，该设备基本上如上文参考附图所作的描述。
78.任意新颖主题或包含本文所公开的新颖主题的组合，无论是否在与前述权利要求中任一项相同的发明的范围内或与前述权利要求中任一项相同的发明相关。
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EP3341169C0 (en) 2023-06-07
EP3341169B1 (en) 2023-06-07
WO2016009183A1 (en) 2016-01-21
EP3341169A1 (en) 2018-07-04
GB201412683D0 (en) 2014-09-03
US10759702B2 (en) 2020-09-01

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