CN108686591B - 制备气凝胶颗粒的方法和气凝胶涂布部件 - Google Patents

制备气凝胶颗粒的方法和气凝胶涂布部件 Download PDF

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CN108686591B
CN108686591B CN201810303810.2A CN201810303810A CN108686591B CN 108686591 B CN108686591 B CN 108686591B CN 201810303810 A CN201810303810 A CN 201810303810A CN 108686591 B CN108686591 B CN 108686591B
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D.D.索罗维
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Abstract

提供一种用于制备气凝胶颗粒的方法和涂布部件。所述涂布部件包括基材和涂层。所述涂层包括从热气体射流或等离子体射流喷射的气凝胶颗粒。所述方法包括将一个或多个凝胶颗粒馈入到热气体射流或等离子体射流中的步骤。所述一个或多个凝胶颗粒足够小以准许在所述颗粒位于所述射流中的时间期间进行超临界干燥。所述方法进一步包括以下步骤：将所述一个或多个凝胶颗粒暴露于所述热气体射流或等离子体射流的温度和压力，以在射流发射器外部和/或在不具有经密封压力容器的情况下产生气凝胶颗粒。

Description

制备气凝胶颗粒的方法和气凝胶涂布部件
技术领域
本发明大体上涉及一种制备气凝胶颗粒的方法和气凝胶涂布部件。更具体地说，本发明大体上涉及一种使用热气体射流或等离子体射流来制备气凝胶颗粒的方法和气凝胶涂布部件。
背景技术
由于气凝胶材料的极高孔隙度，其具有极低的导热性系数，从而使其成为极佳的热绝缘体。使用被称为超临界干燥的技术来制成气凝胶，其中对凝胶加热并加压直到凝胶的液体组分超临界为止，其中液体和气体同时存在，且接着将凝胶减压和/或冷却成气相。通过以此方式来避开液相与气相之间的界限，凝胶不会在其结构方面显现出其将会在“典型”干燥中经历的较高表面张力。
通常在腔室中产生气凝胶结构，其中超临界流体扩散到腔室中的空气中，且因此从凝胶扩散出来。在一些工艺中，接着对腔室中的空气清除并用新空气替换通常会重复若干次，直到所有或大部分液体从凝胶中消失，从而留下气凝胶为止。然而，此类方法需要可以进行加压和加热的腔室，并提出一些限制，例如对最终气凝胶产品的大小限制。
发明内容
在示范性实施例中，提供一种用于制备气凝胶颗粒的方法。所述方法包括将一个或多个凝胶颗粒馈入到热气体射流或等离子体射流中的步骤。所述一个或多个凝胶颗粒足够小以准许在所述颗粒位于所述射流中的时间期间进行超临界干燥。所述方法进一步包括以下步骤：将所述一个或多个凝胶颗粒暴露于所述热气体射流或等离子体射流的温度和压力，从而产生所述一个或多个气凝胶颗粒。
除了上述示范性实施例，本发明还提供以下技术方案：
技术方案1：根据上述示范性实施例的方法，所述热气体射流或等离子体射流选自由以下组成的组：等离子体射流、空气射流、空气等离子体射流、CO2射流、HVOF射流和其组合。
技术方案2：根据上述示范性实施例的方法，所述馈入包括雾化所述一个或多个凝胶颗粒。
技术方案3：根据上述示范性实施例的方法，在不具有经密封压力容器的情况下产生所述气凝胶颗粒。
技术方案4：根据上述示范性实施例的方法，进一步包括将所述气凝胶颗粒喷射到所要表面上。
技术方案5：根据技术方案4的方法，所述所要表面是选自以下组成的组的较大部件的表面：可磨耗密封件、涡轮机部件、储存器、低温装置、管线、天然气和石油的管线系统、驳船、轮船和其组合。
技术方案6：根据上述示范性实施例的方法，进一步包括将主涂层涂覆到所要表面上。
技术方案7：根据上述示范性实施例的方法，进一步包括在暴露之前将添加剂材料与所述一个或多个凝胶颗粒混合，以形成混合的复合材料。
技术方案8：根据技术方案7的方法，进一步包括将所述混合的复合材料喷射到所要表面上。
技术方案9：根据技术方案7的方法，所述添加剂材料选自以下组成的组：陶瓷、基于氧化铝的陶瓷、基于硅的陶瓷、基于氧化锆的陶瓷和其组合。
技术方案10：根据技术方案9的方法，所述添加剂材料进一步包括聚酯。
技术方案11：根据技术方案9的方法，进一步包括将主涂层涂覆到所要表面上。
在另一示范性实施例中，提供一种用于制备气凝胶颗粒的方法。所述方法包括将一个或多个凝胶颗粒馈入到热气体射流或等离子体射流中的步骤。所述方法进一步包括以下步骤：将所述一个或多个凝胶颗粒暴露于所述热气体射流或等离子体射流的温度和压力，从而产生所述一个或多个气凝胶颗粒。
在又一示范性实施例中，提供一种涂布部件。所述涂布部件包括基材和涂层。所述涂层包括从热气体射流或等离子体射流喷射的气凝胶颗粒。
除了上述又一示范性实施例，本发明还提供如下技术方案：
技术方案12：根据又一示范性实施例的涂布部件，所述热气体射流或等离子体射流选自由以下组成的组：等离子体射流、空气射流、空气等离子体射流、CO2射流、HVOF射流和其组合。
技术方案13：根据又一示范性实施例的涂布部件，所述气凝胶颗粒与添加剂材料混合，以形成混合的复合材料。
技术方案14：根据技术方案13的涂布部件，所述添加剂材料选自由以下组成的组：陶瓷、基于氧化铝的陶瓷、基于硅的陶瓷、基于氧化锆的陶瓷和其组合。
技术方案15：根据技术方案14的涂布部件，所述添加剂材料进一步包括聚酯。
技术方案16：根据又一示范性实施例的涂布部件，所述基材包括主涂层。
技术方案17：根据又一示范性实施例的涂布部件，所述基材是选自由以下组成的组的较大部件：可磨耗密封件、涡轮机部件、储存器、低温装置、管线、天然气和石油的管线系统、驳船、轮船和其组合。
本发明的其它特征和优点将因结合附图获得的优选实施例的以下更详细描述而变得明显，所述附图通过实例说明本发明的原理。
附图说明
图1说明根据本公开的示范性实施例的方法。
图2展示说明方法的实施例的流程图图示。
图3为示出在“超临界干燥”工艺中的凝胶的相态变化图。
在可能的情况下，将在整个附图中使用相同附图标记来表示相同部分。
具体实施方式
将下文结合附图阐述的详细描述预期为对所公开的主题的各种实施例的描述，其中类似编号指代类似元件，且所述详细描述并不意在表示仅有的实施例。本公开中所描述的每一实施例仅作为实例或说明而提供，且不应被解释为优选的或比其它实施例有利的。本文中所提供的说明性实例并不意图是穷尽性的，或将所要求的主题限于所公开的精确形式。
提供一种用于制备气凝胶颗粒的示范性方法和一种示范性的涂布部件。相较于未利用本文中所公开的一个或多个特征的方法和制品，本公开的实施例使得能够在热气体射流或等离子体射流、不具有接缝的涂层以及具有复杂几何形状的涂布部件中对气凝胶进行超临界干燥。
除非另外指明，否则将表示成分和/或反应条件的量的所有数目理解为在所有情况下通过术语“约”进行修饰。
除非另外指明，否则所有百分比和比率都按重量计。除非另外指明，否则所有百分比都按组合物的总重量计。所有组分或组合物含量是参考所述组分或组合物的起作用的含量，且排除可能存在于市售来源中的杂质，例如残余溶剂或副产物。
如本文中所使用的冠词“一(a和an)”意味着当应用于本说明书和权利要求书中所描述的本发明的实施例中的任何特征时的一个或多个。除非专门陈述此类限制，否则使用“一(a和an)”不会将含义限于单个特征。在单数或复数名词或名词短语之前的冠词“所述(the)”指代一个或多个特别指定的特征，且取决于供其使用的上下文，可具有单数或复数含义。形容词“任何”意味着无论任何量中的一个、一些或无差别的全部。
如本文中所使用的术语“至少一个”意味着一个或多个，且因此包括个别组分以及混合物/组合。
如本文中所使用的术语“包括”(和其语法变化形式)用于包括“具有(having)”或“包括(including)”的意义，且不排除“仅由……组成”的意义。
如本文中所使用的术语“超临界干燥”意味着一种工艺，其中对凝胶加热并加压直到凝胶的液体组分超临界为止，其中液体和气体同时存在，且接着将凝胶减压和/或冷却成气相，如图3中所见。
参看图1，提供射流发射器102。将来自容器106的一个或多个凝胶颗粒101馈入到射流发射器102中。在射流发射器102中对一个或多个凝胶颗粒101加压，并将经加压的一个或多个凝胶颗粒101发射到热气体射流或等离子体射流103。接着，发射所述一个或多个凝胶颗粒101，从而暴露于热气体射流或等离子体射流103的温度和压力，并将所述一个或多个凝胶颗粒101快速减压和/或冷却以产生气凝胶颗粒105。所述一个或多个凝胶颗粒101足够小以准许在热气体射流或等离子体射流103中进行超临界干燥。在一个实施例中，足够小的一个或多个凝胶颗粒101的直径小于或等于约2mm。如果一个或多个凝胶颗粒101足够小，并且热气体射流或等离子体射流103的温度和压力足够用于对凝胶的液体组分进行超临界干燥，那么一个或多个凝胶颗粒101应经历热气体射流或等离子体射流103中的超临界干燥以使液体从凝胶扩散出来，借此产生气凝胶颗粒105。
在一个实施例中，可以将气凝胶颗粒105喷射到基材104上。在一个实施例中，气凝胶颗粒105通过机械结合或化学结合附接到基材104。基材104可以是包括可磨耗密封件、涡轮机部件、储存器、低温装置、管线、天然气和石油的管线系统、驳船、轮船或其组合的较大部件的表面，或其它表面。在一个实施例中，可以在喷射之前对基材104预加热。在一个实施例中，被喷射到基材104上的气凝胶颗粒105充当热屏障涂层(TBC)或环境屏障涂层(EBC)。在一个实施例中，气凝胶颗粒105可适用于增材制造工艺(additivemanufacturingprocess)。
参看图2，根据示范性实施例，提供一种用于制备气凝胶颗粒105的方法200。方法200包括提供凝胶颗粒101的步骤(步骤201)。方法200进一步包括将凝胶颗粒101传递到热气体射流或等离子体射流103的步骤(步骤202)。方法200进一步包括在热气体射流或等离子体射流103中形成气凝胶颗粒105的步骤(步骤203)。方法200进一步包括将气凝胶颗粒105引导到基材104的步骤(步骤204)。
在一个实施例中，当一个或多个凝胶颗粒101暴露于热气体射流或等离子体射流103的超临界温度和压力时，将所述一个或多个凝胶颗粒101与添加剂材料混合以形成混合的复合材料。将混合的复合材料喷射到基材104上。一个或多个凝胶颗粒101可以包括但不限于二氧化硅、氧化锆、氧化钇掺杂的氧化锆、悬浮于氧化锆中的陶瓷颗粒、氧化钇掺杂的氧化锆或其组合。凝胶颗粒101的液体部分可以包括但不限于水、液体CO2、其组合或任何合适液体。添加剂材料可以包括但不限于陶瓷、基于氧化铝的陶瓷、基于硅的陶瓷、基于氧化锆的陶瓷或其组合。在一实施例中，基于氧化锆的陶瓷包括掺杂有钇的氧化锆凝胶。添加剂材料可以进一步包括聚酯以增大孔隙度。
在一个实施例中，将气凝胶颗粒105以粉末、珠粒、块、碎片或其组合的形式喷射到表面，从而产生气凝胶。
在一个实施例中，在将气凝胶颗粒喷射到所要表面上之前，将主涂层涂覆到基材104上。主涂层可以包括但不限于陶瓷TBC、HVOF、铝化物或其组合。在另一实施例中，在将气凝胶颗粒喷射到所要表面上之前，不将主涂层涂覆到基材104上。
在一个实施例中，热气体射流或等离子体射流103包括等离子体射流、空气射流、空气等离子体射流、真空等离子体射流、CO2射流、HVOF射流(高速氧气燃料射流)、爆炸喷涂(D-gun)、冷喷涂(cold spray)、火焰喷涂(flame spray)、电弧喷涂(wire arc)或其组合。
在一个实施例中，在将来自容器106的一个或多个凝胶颗粒101馈入到射流发射器102中之前，雾化所述一个或多个凝胶颗粒101。雾化可以包括喷嘴雾化、超声雾化或离心雾化。
在一个实施例中，在不具有经密封压力容器的情况下产生气凝胶颗粒105。如本文中所使用的术语“经密封压力容器”是封闭的并能够控制内部压力的容器或腔室。在一个实施例中，在射流发射器102外部产生气凝胶颗粒105。在一个实施例中，在不具有经密封压力容器的情况下和/或在射流发射器102外部产生气凝胶颗粒105。
在一个实施例中，提供包括基材104和涂层部分105的涂布部件107。涂层105包括从热气体射流或等离子体射流103喷射的气凝胶颗粒。基材104可以包括但不限于不锈钢、基于镍的合金、钢、钛、CMC、基于铝的合金或其组合。
虽然已参考优选实施例描述了本发明，但所属领域的技术人员应理解，在不脱离本发明范围的情况下可以进行各种改变并且其多种元素可以由多种等效物代替。此外，在不脱离本发明的基本范围的情况下，可进行许多修改以使具体情况或材料适应本发明的教示。因此，不希望本发明限于作为预期用于执行本发明的最佳模式而公开的特定实施例，而是本发明将包括属于所附权利要求书的范围内的所有实施例。

Claims (24)

1.一种用于制备气凝胶颗粒的方法，其包括：
将一个或多个凝胶颗粒馈入到热气体射流或等离子体射流中，所述一个或多个凝胶颗粒足够小以准许在所述热气体射流或等离子体射流中进行超临界干燥；
将所述一个或多个凝胶颗粒暴露于所述热气体射流或等离子体射流的温度和压力，以产生所述气凝胶颗粒。
2.根据权利要求1所述的方法，其特征在于，所述热气体射流或等离子体射流选自由以下组成的组：空气射流、空气等离子体射流、CO2射流、HVOF射流和其组合。
3.根据权利要求1所述的方法，其特征在于，所述馈入包括雾化所述一个或多个凝胶颗粒。
4.根据权利要求1所述的方法，其特征在于，在不具有经密封压力容器的情况下产生所述气凝胶颗粒。
5.根据权利要求1所述的方法，其特征在于，进一步包括将所述气凝胶颗粒喷射到期望表面上。
6.根据权利要求5所述的方法，其特征在于，所述期望表面是选自由以下组成的组的大部件的表面：可磨耗密封件、涡轮部件、储存器、低温装置、管线、驳船、轮船和其组合。
7.根据权利要求5所述的方法，其特征在于，所述期望表面是天然气和石油的管线系统的表面。
8.根据权利要求5所述的方法，其特征在于，进一步包括将主涂层涂覆到所述期望表面上。
9.根据权利要求5所述的方法，其特征在于，进一步包括在暴露之前将添加剂材料与所述一个或多个凝胶颗粒混合，以形成混合的复合材料。
10.根据权利要求9所述的方法，其特征在于，进一步包括将所述混合的复合材料喷射到期望表面上。
11.根据权利要求9所述的方法，其特征在于，所述添加剂材料包括陶瓷。
12.根据权利要求11所述的方法，其特征在于，所述陶瓷选自由以下组成的组：基于氧化铝的陶瓷、基于硅的陶瓷、基于氧化锆的陶瓷和其组合。
13.根据权利要求11所述的方法，其特征在于，所述添加剂材料进一步包括聚酯。
14.根据权利要求11所述的方法，其特征在于，进一步包括将主涂层涂覆到所述期望表面上。
15.一种用于制备气凝胶颗粒的方法，其包括：
将一个或多个凝胶颗粒馈入到热气体射流或等离子体射流中；
将所述一个或多个凝胶颗粒暴露于所述热气体射流或等离子体射流的温度和压力，以产生所述气凝胶颗粒。
16.一种涂布部件，其包括：
基材；
涂层，其包括根据权利要求1-15中的任一项所述的方法制备的气凝胶颗粒。
17.根据权利要求16所述的涂布部件，其特征在于，所述热气体射流或等离子体射流选自由以下组成的组：空气射流、空气等离子体射流、CO2射流、HVOF射流和其组合。
18.根据权利要求16所述的涂布部件，其特征在于，所述气凝胶颗粒与添加剂材料混合，以形成混合的复合材料。
19.根据权利要求18所述的涂布部件，其特征在于，所述添加剂材料包括陶瓷。
20.根据权利要求19所述的涂布部件，其特征在于，所述陶瓷选自由以下组成的组：基于氧化铝的陶瓷、基于硅的陶瓷、基于氧化锆的陶瓷和其组合。
21.根据权利要求19所述的涂布部件，其特征在于，所述添加剂材料进一步包括聚酯。
22.根据权利要求16所述的涂布部件，其特征在于，所述基材包括主涂层。
23.根据权利要求16所述的涂布部件，其特征在于，所述基材是选自由以下组成的组的大部件：可磨耗密封件、涡轮部件、储存器、低温装置、管线、驳船、轮船和其组合。
24.根据权利要求16所述的涂布部件，其特征在于，所述基材是天然气和石油的管线系统。
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