CN108727028B - Method for manufacturing rigid heat-insulating tile blank by additive manufacturing method - Google Patents

Method for manufacturing rigid heat-insulating tile blank by additive manufacturing method Download PDF

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CN108727028B
CN108727028B CN201810447014.6A CN201810447014A CN108727028B CN 108727028 B CN108727028 B CN 108727028B CN 201810447014 A CN201810447014 A CN 201810447014A CN 108727028 B CN108727028 B CN 108727028B
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slurry
tile blank
liquid
valve
liquid discharge
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CN108727028A (en
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鲁胜
赵英民
刘斌
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Aerospace Research Institute of Materials and Processing Technology
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Aerospace Research Institute of Materials and Processing Technology
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    • C04B35/806—
    • 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
    • B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
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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
    • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
    • C04B35/563—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on boron carbide
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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
    • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/58—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides
    • C04B35/583—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on boron nitride
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/5216—Inorganic
    • C04B2235/522—Oxidic
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/5216—Inorganic
    • C04B2235/522—Oxidic
    • C04B2235/5236—Zirconia
    • C—CHEMISTRY; METALLURGY
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/526—Fibers characterised by the length of the fibers
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/5264—Fibers characterised by the diameter of the fibers
    • C—CHEMISTRY; METALLURGY
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    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/602—Making the green bodies or pre-forms by moulding
    • C04B2235/6026—Computer aided shaping, e.g. rapid prototyping

Abstract

The invention relates to a method for manufacturing a rigid insulating tile blank by an additive manufacturing process, said method comprising the steps of: (1) uniformly mixing ceramic fibers and a non-metal boride with water to obtain slurry; and (2) forming the slurry obtained in the step (1) layer by a jet additive manufacturing method to obtain a rigid heat insulation tile blank. The method of the invention is carried out by means of an apparatus for additive manufacturing of a rigid insulating tile blank. The method can effectively control the density and the thickness precision of the rigid heat-insulating tile blank to obtain the rigid heat-insulating tile blank with high thickness precision, uniform density and good quality, and has the advantages of simple operation, low manufacturing cost, high production efficiency, environmental protection and the like.

Description

Method for manufacturing rigid heat-insulating tile blank by additive manufacturing method
Technical Field
The invention belongs to the technical field of rigid heat insulation tile manufacturing, and particularly relates to a method for manufacturing a rigid heat insulation tile blank by an additive manufacturing method.
Background
At present, the rigid heat insulation tile blank has the problem of uneven density in the manufacturing process.
The manufacturing process of the rigid heat insulation tile generally comprises the steps of placing slurry containing short fibers and sintering aids into a container with a filtering function to filter water in the slurry, then obtaining a rigid heat insulation tile blank (filter cake), and then sequentially drying and sintering the rigid heat insulation tile blank to obtain the rigid heat insulation tile; however, in this method, the density of the rigid insulating tile blank is not uniform in all directions, particularly in the thickness direction, and thus anisotropy in strength, thermal conductivity and the like of the manufactured rigid insulating tile is caused.
Additive manufacturing (e.g., 3D printing) is primarily characterized by layer-by-layer build-up by extrusion, sintering, melting, photocuring, spraying, etc., a "bottom-up" manufacturing process by material build-up. At present, the application field of additive manufacturing technology has been expanded to industries such as medical treatment, electronics, aerospace, automobile manufacturing and the like, and creative industries and even consumption fields; however, since the existing conventional additive manufacturing equipment (e.g. 3D printing equipment) is not suitable for manufacturing the rigid insulating tile blank, the manufacturing of the rigid insulating tile blank by the additive manufacturing method has not been reported.
Disclosure of Invention
In order to solve the problem of uneven density of a rigid heat insulation tile blank in the manufacturing process in the prior art, the invention provides a method for manufacturing the rigid heat insulation tile blank by an additive manufacturing method. The method can effectively control the density and the thickness precision of the rigid heat-insulating tile blank to obtain the rigid heat-insulating tile blank with high thickness precision, uniform density and good quality, and has the advantages of simple operation, low manufacturing cost, high production efficiency, environmental protection and the like.
In order to achieve the above object, the present invention provides a method for manufacturing a rigid insulation tile blank by an additive manufacturing method, the method comprising the steps of:
(1) uniformly mixing ceramic fibers and a non-metal boride with water to obtain slurry; and
(2) and (3) forming the slurry obtained in the step (1) layer by a jet additive manufacturing method to obtain a rigid heat insulation tile blank.
Preferably, the pH of the slurry obtained in the step (1) is adjusted to 9-11 before the step (2) is carried out.
Preferably, the injection additive manufacturing method in step (2) includes the following sub-steps:
(a) laying the slurry obtained in the step (1) in a spraying manner to obtain a slurry layer;
(b) compacting the slurry layer obtained in the step (a) to obtain a first layer of a rigid heat-insulating tile blank; and
(c) and (c) sequentially repeating the step (a) and the step (b) on the basis of the first layer of the rigid heat-insulating tile blank to manufacture a second layer of the rigid heat-insulating tile blank, and repeating the steps till the manufacturing of a preset number of layers is completed to obtain the rigid heat-insulating tile blank containing multiple slurry layers.
Preferably, the ceramic fiber consists of 30-85% of quartz fiber, 4.9-55% of alumina fiber and 0.1-15% of zirconia fiber in percentage by mass; the non-metal boride is selected from the group consisting of boron carbide and boron nitride, and the using amount of the non-metal boride is 0.5 to 20 weight percent of that of the ceramic fiber; and/or the total amount of the ceramic fiber and the non-metal boride is 0.3 wt% -1 wt% of the amount of the water.
Preferably, the method is performed by an apparatus for additive manufacturing of a rigid insulating tile blank, the apparatus comprising: the filtering container can move along the horizontal direction in an operable way, and comprises a peripheral wall, a bottom plate which is fixed at the position close to the lower end of the peripheral wall and is provided with an opening in the middle, a bottom net which is arranged at the lower part of an inner cavity enclosed by the peripheral wall, a reinforcing rib for supporting the bottom net and a liquid collecting part which is arranged below the reinforcing rib, is used for collecting liquid filtered out from the filtering container and is provided with a liquid outlet; a liquid discharge pipe for discharging the liquid in the liquid collecting part, the liquid discharge pipe being communicated with the liquid outlet of the liquid collecting part; the feeding system is used for feeding the materials into the filtering container and comprises a material storage chamber, a feeding pipe, a spray head communicated with the outlet end of the feeding pipe and a perforated plate which is positioned below the spray head and provided with a hole array, wherein holes in the hole array are through holes, and the through holes are arranged corresponding to the nozzles of the spray head and are used for supporting and fixing the nozzles; and the pressurizing device is used for pressurizing the materials in the filtering container, is arranged on one side of the horizontal direction of the spray head, and comprises a pressure head, a pressure arm fixedly connected with the pressure head and a driving device used for driving the pressure arm to stretch and retract along the vertical direction.
Preferably, the through hole is a circular hole, and the aperture of the through hole is 4-6 mm; the through holes are arranged in the porous plate at equal intervals, and the distance between the hole centers of every two adjacent through holes is 8-12 mm; the distribution area of the hole array in the porous plate, the area of the porous plate and/or the area of the pressure surface of the pressure head are/is matched with the cross sectional area of an inner cavity surrounded by the peripheral wall; and/or when the filtering container moves to the position under the porous plate, the height of the porous plate from the filtering container is 2.5-5 cm.
Preferably, the reinforcing ribs are in the shape of laths, and the number of the reinforcing ribs is one or more; the reinforcing ribs are provided with through holes; the bottom net is a steel wire net with 20-40 meshes; the pipe diameter of the feeding pipe is 1.27cm or 2.54 cm; and/or the feeding pipe and/or the liquid discharge pipe are flexible pipes.
Particularly, at least one pulley is arranged on a bottom plate of the filtering container, and a sliding rail matched with the pulley is arranged below the pulley; preferably, the slide rail is a double-rail slide rail, and the number of the pulleys is 4.
Preferably, the feeding system further comprises a spray inlet valve, a spray pump and a spray outlet valve which are sequentially arranged between the inlet end and the outlet end of the feeding pipe; the feeding system also comprises a return pipe and a return valve, wherein the return pipe is communicated with the storage chamber and the outlet of the liquid spraying pump; and/or the drain pipe comprises a main drain pipe and/or a secondary drain pipe, the main drain pipe is provided with a drain inlet valve at one end close to the liquid outlet of the liquid collecting part, a drain outlet valve is arranged at one end far away from the liquid outlet of the liquid collecting part, a drain pump is arranged between the drain inlet valve and the drain outlet valve, and/or the secondary drain pipe is provided with a drain valve.
Preferably, the spray inlet valve, the spray pump switch, the spray outlet valve, the return valve, the drain inlet valve, the drain pump switch, the drain outlet valve and/or the drain valve are solenoid valves, the device for additive manufacturing of rigid insulation tile blanks further comprises a P L C controller (programmable logic controller), a first displacement sensor for sensing the displacement of the filter container in the horizontal direction, a second displacement sensor for sensing the displacement of the ram in the vertical direction and a pressure sensor for sensing the pressure applied to the surface of the ram, the P L C controller is in electrical signal connection with the first displacement sensor, the second displacement sensor, the pressure sensor and the solenoid valves, and the P L C controller is used for receiving signals sensed by the first displacement sensor, the second displacement sensor and the pressure sensor and controlling the movement of the filter container and the ram and the working state of the solenoid valves according to the sensed signals.
Compared with the prior art, the method of the invention at least has the following beneficial effects:
(1) the method can effectively control the density and the precision of the rigid heat-insulating tile blank, and obtain the rigid heat-insulating tile blank with uniform density, accurate thickness and good quality.
(2) The invention is carried out by the device for additive manufacturing of the rigid heat insulation tile blank, and the rigid heat insulation tile blank with uniform density can be obtained to a great extent by multi-channel of a plurality of nozzles and fixed layer-by-layer distribution of each through hole to each corresponding nozzle.
(3) In some preferred embodiments of the present invention, the nozzles in the apparatus for additive manufacturing of the rigid heat insulation tile blank are micron-sized nozzles, and the through holes are formed at equal intervals, and the distance between the centers of every two adjacent through holes is more reasonable, so that the slurry layer on the bottom net can be more uniformly distributed, which is beneficial to obtaining a rigid heat insulation tile blank with more uniform density.
(4) In some preferred embodiments of the present invention, the feeding system in the apparatus for additive manufacturing of rigid heat-insulating tile blanks comprises a return pipe and a return valve, when the spray outlet valve is to be closed, the return valve is opened first, and the return pipe can return the slurry continuously pumped by the spray pump to the storage chamber after the spray outlet valve is closed, so that on one hand, the accuracy of the slurry feeding amount during the feeding of the spray head can be ensured, and on the other hand, the deposition of the slurry in the feeding pipe and/or the storage chamber can be effectively prevented, thereby avoiding the influence on the use effect and the service life of the feeding pipe, and in addition, the arrangement of the return pipe and the return valve can effectively ensure the operation safety of the method of the present invention; the feeding system of the device for additive manufacturing of the rigid heat-insulating tile blank is reasonably arranged, waste of slurry and environmental pollution can be effectively prevented, the utilization rate of the slurry is improved, material resources are saved, and the environment friendliness and the like are realized in a real sense.
(5) In some preferred embodiments of the invention, the device for manufacturing the rigid heat-insulating tile blank by additive manufacturing is provided with an automatic control system, can sense the displacement signal of the filtering container, the displacement signal of the pressure head and the pressure signal applied to the pressure applying surface of the pressure head in real time, and can automatically control the movement of the filtering container and the pressure head and the working state of the electromagnetic valve, so that the manufacturing process of the rigid heat-insulating tile blank can be automatically controlled, the manufacturing time and labor cost of the rigid heat-insulating tile blank can be saved, and the working efficiency can be improved; the method can realize the manufacture of the rigid heat-insulating tile blank with higher efficiency.
(6) The method has the advantages of simple operation, safety, reliability, low manufacturing cost, high production efficiency, environmental protection and the like, and has important significance for popularization of the additive manufacturing technology.
Drawings
The drawings of the present invention are provided for illustrative purposes only, and the proportion and the number of the components in the drawings do not necessarily correspond to those of an actual product.
FIG. 1 is a schematic structural view of an apparatus for additive manufacturing of a rigid insulating tile blank used in one embodiment of the present invention.
Fig. 2 is a simplified schematic view of a feed system and a drain pipe included in the apparatus for additive manufacturing of a rigid insulation tile blank, which is used in one embodiment of the present invention.
Fig. 3 is a schematic cross-sectional view a-a of the pressurization assembly of fig. 1 as it pressurizes the contents of the filtration vessel.
FIG. 4 is a schematic view of the distribution of the well array included in FIG. 1 in a multi-well plate.
Fig. 5 is an enlarged view of a in fig. 4.
Fig. 6 is a schematic cross-sectional view showing the distribution of the slurry on the base web under the through-holes in fig. 5 during the distribution.
In the figure: 1: a storage chamber; 2: a feed pipe; 3: a return pipe; 4: a spray head; 5: a nozzle; 6: a perforated plate; 7: a through hole; 8: a filtration vessel; 9: a bottom net; 10: reinforcing ribs; 11: a liquid collecting part; 12: a liquid outlet; 13: a main liquid discharge pipe; 14: a secondary drain pipe; 15: pressing the arm; 16: a pressure head; 17: a pulley; 18: a slide rail; 19: a spray inlet valve; 20: a liquid spraying pump; 21: a spray outlet valve; 22: a reflux valve; 23: a drain inlet valve; 24: a liquid discharge pump; 25: a drain outlet valve; 26: a drain valve; 27: feeding; 28: a base plate.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all embodiments of the present invention. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, are within the scope of the present invention.
The invention provides a method for manufacturing a rigid heat insulation tile blank by an additive manufacturing method, which comprises the following steps:
(1) uniformly mixing ceramic fibers and a non-metal boride (sintering aid) by using water to obtain slurry; and
(2) and (3) forming the slurry obtained in the step (1) layer by a jet additive manufacturing method to obtain a rigid heat insulation tile blank.
In the invention, the ceramic fiber can be short fiber, for example, the length of the short fiber is 500 um-5 um, and the diameter of the short fiber is 1-10 um.
According to some preferred embodiments, the pH of the slurry obtained in step (1) is adjusted to 9-11 (e.g. 9, 9.5, 10, 10.5 or 11), for example by concentrated ammonia, before step (2) is performed. In the invention, the pH value of the slurry obtained in the step (1) is preferably adjusted to 9-11, so that the sedimentation of solid substances (ceramic fibers and non-metal borides) contained in the slurry can be effectively prevented, and the adverse effect on the manufacture of the rigid heat-insulating tile blank with uniform density can be effectively avoided.
According to some preferred embodiments, the injection additive manufacturing method of step (2) includes the following sub-steps:
(a) laying the slurry obtained in the step (1) in a spraying manner to obtain a slurry layer; the slurry obtained in step (1) may be sprayed, for example, through a nozzle, and laid (sprayed) in a vessel for forming;
(b) compacting the slurry layer obtained in step (a) to obtain a first layer of a rigid heat-insulating tile blank, compressing the thickness of the slurry layer obtained in step (a) by a predetermined thickness difference (designated as △ h), for example by the pressing action (compaction action) of a pressing device, wherein said △ h can be set as required, e.g. △ h has a value of 0.4cm when the slurry layer obtained in step (a) having a thickness of 1cm is compacted to 0.6cm, and
(c) and (c) sequentially repeating the step (a) and the step (b) on the basis of the first layer of the rigid heat-insulating tile blank to manufacture a second layer of the rigid heat-insulating tile blank, and repeating the steps till the manufacturing of a preset number of layers is completed to obtain the rigid heat-insulating tile blank containing multiple slurry layers.
According to some preferred embodiments, the ceramic fibers consist of, in mass percent, 30% to 85% (e.g., 30%, 40%, 50%, 60%, 70%, 80%, or 85%) quartz fibers, 4.9% to 55% (e.g., 4.9%, 8%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, or 55%) alumina fibers, and 0.1% to 15% (e.g., 0.1%, 5%, 8%, 10%, 12%, or 15%) zirconia fibers; the non-metallic boride is selected from the group consisting of boron carbide and boron nitride, the non-metallic boride being in an amount of 0.5 wt% to 20 wt% (e.g., 0.5 wt%, 1 wt%, 5 wt%, 10 wt%, 15 wt%, or 20 wt%) of the amount of ceramic fiber; and/or the total amount of the ceramic fibers and the non-metal borides is 0.3 wt% to 1 wt% (e.g., 0.3 wt%, 0.4 wt%, 0.5 wt%, 0.6 wt%, 0.7 wt%, 0.8 wt%, 0.9 wt%, or 1 wt%) of the amount of water.
According to some preferred embodiments, the method is carried out by an apparatus for additive manufacturing of rigid insulating tile blanks, which may, for example, be as shown in fig. 1, comprising a filtration vessel 8 operable to move in a horizontal direction (the direction shown in fig. 1), a drain pipe, a feed system and a pressurizing device.
The filtering container 8 comprises a peripheral wall, a bottom plate 28 fixed at a position close to the lower end of the peripheral wall and provided with an opening at the middle part, a bottom net 9 arranged at the lower part of an inner cavity surrounded by the peripheral wall, a reinforcing rib 10 for supporting the bottom net 9, and a liquid collecting part 11 arranged below the reinforcing rib 10 and used for collecting liquid filtered out from the filtering container 8 and provided with a liquid outlet 12, for example, as shown in fig. 3; in the present invention, the liquid discharge pipe is communicated with the liquid outlet 12 of the liquid collecting portion 11, and is used for discharging the liquid in the liquid collecting portion 11. The material used for the peripheral wall of the filter container 8 and the bottom plate 28 in the present invention is not particularly limited, and may be, for example, a lightweight material such as an aluminum alloy; in the present invention, the reinforcing ribs 10 are disposed in close contact with the bottom net 9, and both ends of the reinforcing ribs 10 may be fixed to the bottom plate 28, for example.
The feeding system of the device for additive manufacturing of the rigid heat insulation tile blank is used for feeding materials into the filtering container 8, and comprises a material storage chamber 1, a feeding pipe 2, a spray head 4 communicated with the outlet end of the feeding pipe 2, and a perforated plate 6 which is positioned below the spray head 4 and is provided with a hole array, as shown in figure 1 (wherein the perforated plate 6 is provided with the hole array which is not shown), the holes in the hole array are through holes 7, and the through holes 7 are arranged corresponding to the nozzles 5 of the spray head 4 and are used for supporting and fixing the nozzles 5. In the present invention, the through holes 7 are holes that vertically penetrate the porous plate 6, and the hole array is formed by arranging a plurality of through holes 7 in an array on the porous plate 6; in the present invention, the storage chamber 1 is used for charging (slurry), the inlet end of the feeding pipe 2 is located in the slurry (slurry) in the storage chamber 1, the number of the nozzles 5 corresponds to the number of the through holes 7, and each nozzle 5 can be fixed in a corresponding through hole 7 included in the hole array of the perforated plate 6 when the nozzle 5 is operated. In the invention, when a feeding pipe 2 starts to convey the slurry (slurry) in the storage chamber 1 to the spray head 4 so that the spray nozzles 5 of the spray head 4 spray the slurry into the filtering container 8, a slurry layer with a required thickness can be obtained on the bottom net 9 of the filtering container 8 by controlling the time for spraying the slurry by the spray nozzles 5; due to the distance between the feeding tube 2 and the spray head 4, there may be a delay (e.g. 1s) between the time the feeding system is started and the time the nozzle 5 starts spraying. According to the invention, through the multi-channel of the plurality of nozzles 5 and the fixed layer-by-layer material distribution of each through hole 7 corresponding to each nozzle 5, the slurry sprayed onto the bottom net 9 of the filtering container 8 is very uniformly distributed, and the rigid heat-insulating tile blank with uniform density is obtained to a great extent.
The pressurizing device is used for pressurizing the slurry (slurry) in the filtering container 8 and is arranged on one side of the horizontal direction of the spray head 4, and comprises a pressure head 16, a pressure arm 15 fixedly connected with the pressure head 16 and a driving device (not shown in figures 1 and 3) used for driving the pressure arm 15 to stretch and retract along the vertical direction, and the driving device can drive the pressure head 16 to move along the vertical direction (the direction shown in figure 1) through the pressure arm 15 fixedly connected with the pressure head 16; the rigid heat-insulating tile blank has the advantages that the slurry can be effectively flattened under the pressurizing action of the pressurizing device, redundant liquid (such as water) in the slurry layer is squeezed out, the thickness and the density of the slurry layer are effectively controlled, and therefore the rigid heat-insulating tile blank with higher thickness accuracy, more uniform density and better quality can be obtained. The driving device is not particularly limited, and the driving device can control the pressing arm 15 to stretch in the vertical direction, so that the driving pressure head 16 presses the slurry layer and retracts after pressurization is completed; in particular, the driving device is a pneumatic driving device, which includes a cylinder with a piston rod, the piston rod of the cylinder is connected with the pressure arm 15 (for example, the pressure head 16 is connected at one end of the pressure arm 15, and the driving device is connected at the other end of the pressure arm 15), so that the pressure head 16 can be driven to extend downwards or retract upwards in the vertical direction.
The present invention is not particularly limited to the fixing means for fixing the head 4, the perforated plate 6, and the pressurizing means, as long as the perforated plate 6 is located below the head 4, the perforated plate 6 has through holes 7 corresponding one-to-one to the nozzles 5 of the head 4, and the pressurizing means is located on one side of the head 4 in the horizontal direction.
In particular, the spray head 4, the perforated plate 6 and the pressurizing means may be fixed by a holder, as shown in fig. 1, for example. The holders include a first holder for fixing and, when necessary, adjusting the height of the perforated plate 6 in the vertical direction and a second holder for fixing and, when necessary, adjusting the positions of the feed pipe 2 and the pressurizing means in the horizontal direction. The second bracket and the first bracket may be fixed at different positions in a vertical direction. The perforated plate 6 may be fixed to the first holder, the feed pipe 2 may be fixed to one end (e.g., left end) of the second holder, and the pressurizing means may be fixed to the other end (e.g., right end) of the second holder.
According to a more specific embodiment, the manufacturing of the rigid insulating tile blank by the apparatus for additive manufacturing of a rigid insulating tile blank comprises the steps of:
firstly, mixing 40g of quartz fiber, 5g of alumina fiber, 5g of zirconia fiber and 5g of boron carbide powder by 11kg of water to form slurry containing solid content with the concentration of 0.5 wt%, and then adjusting the pH of the slurry to 10 by using concentrated ammonia water to obtain slurry of the rigid heat insulation tile blank; placing the slurry of the rigid heat insulation tile blank into a storage chamber, conveying the slurry to a spray head through a feeding pipe, and arranging the slurry on a bottom net of the filtering container by a nozzle of the spray head in a spraying manner to form a slurry layer; finally, the filtering container moves to be right below the pressurizing device, the driving device drives the pressure head to move downwards along the vertical direction, the slurry layer in the filtering container is pressurized, and the thickness of the slurry layer is compressed (compacted) by a preset thickness difference, so that a first layer of the rigid heat-insulating tile blank with a certain thickness is obtained.
And manufacturing a second layer of the rigid heat-insulating tile blank on the basis of the first layer of the rigid heat-insulating tile blank according to the operation, and repeating the steps until the manufacturing of the preset number of layers is completed to obtain the rigid heat-insulating tile blank containing multiple slurry layers.
According to some preferred embodiments, the through hole 7 is a circular hole, and the diameter of the through hole 7 is 4 to 6mm (e.g. 4, 4.5, 5, 5.5 or 6mm), preferably 5 mm; the through holes 7 are formed in the porous plate 6 at equal intervals, and the distance between the centers of every two adjacent through holes 7 is 8-12 mm (8, 9, 10, 11 or 12mm), preferably 10 mm.
In the present invention, the distance between the centers of two adjacent through holes 7 (pitch) is L, the nearest distance between two adjacent through holes 7 is L, as shown in fig. 5. in the present invention, when the nozzles 5 are fixed to the through holes 7 and distributed, the cross-sectional view of the distribution of the slurry on the backing web 9 under the through holes 7 is shown in fig. 6. when the slurry discharged from each two nozzles 5 is distributed on the backing web 9, the distance between the highest points of the two guns of the slurry is L, the distance between the highest points of the two guns of the slurry (L14) corresponds to the pitch (L) of the two through holes 7, i.e., L is L, the distance between the farthest points when the slurry discharged from each nozzle 5 is distributed on the backing web 9 is L. in the present invention, preferably, the hole diameters of the through holes 7 are 4 to 6mm, the size of the through holes L is adjusted so that L is 8 to 12mm, when the hole diameters of the through holes 7 are 4 to 6mm, the farthest points when the slurry discharged from each nozzle 5 is distributed on the backing web 9, the bottom web is 639, the size of the two different from the nozzle 7 is 639, and when the two nozzles are uniformly distributed, the size of the slurry is 5394 to 8mm, the lowest points of the slurry, the two nozzles 7, the most uniformly distributed, the two nozzles are respectively, the most uniformly distributed, i.e., the most closely corresponding to 6854 to the most closely, the two nozzles 7, the most closely corresponding to the most closely.
In the present invention, when the diameter of the through-hole 7 is in the micron order, that is, the nozzle 5 is a micron-order nozzle. The nozzle 5 of the device for manufacturing the rigid heat insulation tile in the additive manufacturing mode adopts a micron-sized nozzle, and the distance between the hole centers of every two adjacent through holes 7 is more reasonable, so that slurry on the bottom net 9 can be more uniformly distributed, and a rigid heat insulation tile blank with more uniform density can be obtained.
According to some preferred embodiments, the distribution area of the array of holes in the perforated plate 6, the area of the perforated plate 6 and/or the area of the pressure surface of the pressure head 16 matches the cross-sectional area of the cavity enclosed by the peripheral wall, for example the distribution area of the array of holes in the perforated plate 6 has the same or similar shape as the cross-sectional area of the cavity enclosed by the peripheral wall of the filter holder 8 and has an area equal to or slightly smaller than the cross-sectional area of the cavity enclosed by the peripheral wall, for example the perforated plate 6 and/or the pressure head 16 has a shape and area such that they can be placed into the filter holder 8 with the plate plane horizontal, in particular the pressure surface of the perforated plate 6 and/or the pressure head 16 has the same shape as the cross-sectional area of the cavity enclosed by the peripheral wall of the filter holder 8 and has an area equal to or slightly smaller than the cross-sectional area of the cavity enclosed by the peripheral wall, so that it can be more conveniently placed in the filter holder 8 in a manner that the plate plane is horizontal. Specifically, the area of the multi-well plate 6 refers to a single-sided area having an array of wells.
According to some preferred embodiments, the height of the perforated plate 6 from the filtering container 8 when the filtering container 8 moves right below the perforated plate 6 is set such that the nozzles 5 are fixed to all the through holes 7 and such that the nozzles 5 can spray into the filtering container 8 when the slurry is simultaneously sprayed, and more preferably, the height of the perforated plate 6 from the filtering container 8 when the filtering container 8 moves right below the perforated plate 6 is 2.5 to 5cm (e.g., 2.5, 3, 3.5, 4, or 5 cm).
According to some preferred embodiments, the reinforcing ribs 10 are in the shape of a lath, and the number of the reinforcing ribs 10 is one or more; and/or the reinforcing rib 10 is provided with a through hole. In the present invention, the reinforcing bar 10 may be made of, for example, a high-strength material such as stainless steel; in the present invention, when the number of the reinforcing ribs 10 is plural, the plural reinforcing ribs 10 may be arranged in parallel or in a cross arrangement, for example, may be arranged in a grid shape in a cross arrangement, and particularly, when the number of the reinforcing ribs 10 is four, may be arranged in a cross arrangement in a #; in the invention, the reinforcing ribs 10 are preferably in the shape of laths, which can effectively ensure that the flatness of the surface of the bottom net 9 is not affected.
According to some preferred embodiments, the reinforcing bars 10 are provided with through holes (not shown in fig. 3). In the invention, the through holes vertically penetrate through the reinforcing ribs 10, and the arrangement of the through holes can effectively avoid unacceptable influence of the reinforcing ribs 10 on the filtering of the slurry.
According to some preferred embodiments, the bottom net 9 is a steel wire mesh of 20-40 mesh (e.g. 20, 25, 30, 35 or 40 mesh); the pipe diameter of the feeding pipe 2 is 1.27cm (0.5 inch) or 2.54cm (1 inch); and/or the feeding pipe 2 and/or the drain pipe is a hose (e.g. a metal hose). The invention has no particular limitation on the hose, when the feeding pipe 2 is a hose, as long as the length of the hose does not limit the movement of the spray head 4, the nozzle 5 of the spray head 4 can be conveniently fixed in the through hole 7 of the porous plate 6 or pulled out from the through hole 7; and when the height of the porous plate 6 from the filtering container 8 needs to be adjusted, the spray head 4 can be conveniently moved along the vertical direction. When the drain pipe is a hose, the length of the hose does not limit the movement of the filter container 8 in the horizontal direction.
According to some preferred embodiments, at least one pulley 17 is arranged on the bottom plate 28 of the filtering container 8, and a sliding rail 18 matched with the pulley 17 is arranged below the pulley 17; preferably, the slide rail 18 is a double-rail slide rail, and the number of the pulleys 17 is 4.
According to some preferred embodiments, the feed system further comprises a spray inlet valve 19, a spray pump 20 and a spray outlet valve 21, which are arranged in sequence between the inlet end and the outlet end of the feed pipe 2, as shown in fig. 2; the feeding system further comprises a return pipe 3 for communicating the storage chamber 1 with the outlet of the liquid spraying pump 20, and a return valve 22 arranged on the return pipe 3, as shown in fig. 2; in the present invention, the inlet end of the return pipe 3 is communicated with the outlet of the liquid spraying pump 20, the outlet end of the return pipe 3 is disposed in the storage chamber 1, when the liquid spraying outlet valve 21 is to be closed, the return valve 22 is opened first, and the return pipe 3 can return the slurry continuously pumped by the liquid spraying pump 20 to the storage chamber 1 after the liquid spraying outlet valve 21 is closed, so that on one hand, the accuracy of the slurry feeding amount when the spray head 4 feeds the slurry can be ensured, and on the other hand, the deposition of the slurry in the feeding pipe 2 and/or the storage chamber 1 can be effectively prevented, thereby avoiding the influence on the use effect and the service life of the feeding pipe 2, and in addition, the arrangement of the return pipe 3 and the return valve 22 can effectively ensure the safety of the operation of the method of the present.
According to some preferred embodiments, the drain pipes include primary drain pipe 13 and/or secondary drain pipe 14; a drain inlet valve 23 is provided at an end of the primary drain pipe 13 close to the liquid outlet 12 of the liquid collecting portion 11, a drain outlet valve 25 is provided at an end of the liquid outlet 12 remote from the liquid collecting portion 11, a drain pump 24 is provided between the drain inlet valve 23 and the drain outlet valve 25, and/or a drain valve 26 is provided on the secondary drain pipe 14; in the present invention, secondary drain pipe 14 is provided so as to allow liquid filtered by filter container 8 to be discharged (drawn) from secondary drain pipe 14 without using drain pump 24 and while drain inlet valve 23 and drain outlet valve 25 are closed. In the present invention, the drain pump 24 is, for example, a vacuum pump, such as a vacuum filtration pump. In the present invention, when the drain pipes include a main drain pipe 13 and a sub drain pipe 14, the main drain pipe 13 and the sub drain pipe 14 may be provided in parallel (as shown in fig. 2), and the liquid in the liquid collecting unit 11 may be discharged in stages by using them, for example, the sub drain pipe 14 may be used to discharge the liquid at the early stage when the pressurizing means pressurizes the slurry in the filtration vessel 8, and the main drain pipe 13 may be used to discharge the liquid at the late stage when the pressurizing means pressurizes the slurry in the filtration vessel 8.
According to some preferred embodiments, the spray inlet valve 19, the switch of the spray pump 20, the spray outlet valve 21, the return valve 22, the drain inlet valve 23, the switch of the drain pump 24, the drain outlet valve 25 and/or the drain valve 26 are solenoid valves, in particular, when the spray head 4 and/or the nozzle 5 itself has a switch, the switch of the spray head 4 and/or the nozzle 5 is also a solenoid valve, the apparatus for additive manufacturing of rigid insulating tile blanks further comprises a P L C controller, a first displacement sensor for sensing the displacement of the filter container 8 in the horizontal direction, a second displacement sensor for sensing the displacement of the filter container 16 in the vertical direction, and a pressure sensor for sensing the pressure on the surface (pressing surface) of the head 16, the P L C controller is electrically connected to the first displacement sensor, the second displacement sensor, the pressure sensor and the solenoid valve, the P L C controller is adapted to receive signals from the first displacement sensor, the second displacement sensor and the pressure sensor (displacement signal, the pressure sensor and the solenoid valve is electrically connected to the P9C controller is adapted to receive signals from the first displacement sensor, the second displacement sensor, the displacement sensor and the pressure sensor, the pressure sensor is adapted to receive signals from the signal from the drive signal of the second displacement sensor, the drive motor is adapted to switch the drive the filter container 8, the drive motor of the filter container 16, the drive motor, the filter container 16, the drive motor is adapted to switch, the drive motor, the drive the filter container, the drive motor, the drive.
In the invention, the P L C controller is electrically connected with the electromagnetic valve to realize automatic liquid spraying of the nozzle 5, the P L C controller can automatically control the feeding amount of the feeding pipe 2 by setting time parameters so as to control the thickness of a slurry layer, and in addition, the P L C controller can realize automatic backflow of the backflow pipe 3 and automatic liquid discharging of the liquid discharging pipe.
In the invention, the P L C controller, the first displacement sensor, the second displacement sensor, the pressure sensor and the electromagnetic valve form an automatic control system, and the operation of the device for manufacturing the rigid heat-insulating tile blank in the invention can be automatically controlled, so that the manufacturing process of the rigid heat-insulating tile blank can be automatically controlled, the manufacturing time and labor cost of the rigid heat-insulating tile blank can be saved, the working efficiency is improved, and the method can realize the manufacture of the rigid heat-insulating tile blank with higher efficiency.
In some more specific embodiments, the automated control process of the apparatus for additive manufacturing of a rigid insulating tile blank of the present invention may be, for example:
for convenience of description, the position S will be referred to as when the filter container 8 is directly below the perforated plate 60The position S is indicated when the filter container 8 is located right below the head 161(ii) a The initial position of the ram 16 is denoted by h0The displacement at which the surface of the ram 16 begins to sense pressure from the slurry is denoted as h1The difference in thickness of the slurry to be compressed (predetermined difference in thickness) is noted as △ h, where △ h can be set as desired, such as △ h having a value of 0.4cm when it is desired to pressurize a slurry layer having a thickness of 1cm to 0.6 cm.
When the filter vessel 8 is in position S0When the displacement signal is sensed by the first displacement sensor, the displacement signal is transmitted to the P L C controller, the P L C controller closes the return valve 22, the liquid spraying inlet valve 19, the liquid spraying pump 20 and the liquid spraying outlet valve 21 are sequentially opened, the material is distributed on the bottom net 9 of the filtering container 8 through the nozzle 5, the thickness of the slurry layer on the bottom net 9 is controlled by controlling the material spraying time of the nozzle 5, after the material distributing time is finished, the P L C controller opens the return valve 22 and closes the liquid spraying outlet valve 21, the slurry pumped by the liquid spraying pump 20 is circulated back to the storage chamber 1 through the return pipe 3, the slurry keeps flowing and circulating, so that solid matters such as fibers are prevented from being deposited in the feeding pipe 2 and the storage chamber 1, in addition, the filtering container 8 moves on the slide rail 18 through the control pulley 17 and moves to the position S1At this time, the first displacement sensor senses the displacement signal and transmits the signal to the P L C controller, so that the movement of the filter container 8 is stopped, and the driving head 16 is driven by the driving device to move from the position h0Starts to move downwards along the vertical direction to the filtering container 8, the second displacement sensor senses the displacement of the pressure head 16 at any time during the movement, and when the position of the pressure head 16 reaches the position h1Thereafter, the displacement △ h continues to be moved downward according to the setting requirements.
At the pressure head 16 from h1Start to move downward △ hIn the process, the P L C controller opens the liquid discharge valve 26 to discharge the liquid in the liquid collecting part 12 through the secondary liquid discharge pipe 14, after a predetermined time t, the P L C controller closes the liquid discharge valve 26, sequentially opens the liquid discharge inlet valve 23, the liquid discharge pump 24 and the liquid discharge outlet valve 25 to discharge the residual liquid in the liquid collecting part 12 through the primary liquid discharge pipe 13, stops moving the pressure head 16 after the movement displacement of the pressure head 16 reaches △ h, closes the liquid discharge inlet valve 23, the liquid discharge pump 24 and the liquid discharge outlet valve 25, and controls the pressure head 16 to move upwards to a position h0. The ram 16 reaches position h0Then, the P L C controller moves the filter container 8 on the slide rail 18 to the position S by controlling the pulley 170. And repeating the process to obtain the rigid heat-insulating tile blank with the required thickness.
The process according to the invention will be further illustrated by way of example, without however the scope of protection of the invention being limited to these examples.
Example 1
The manufacturing of the rigid insulating tile blank is performed by an apparatus for additive manufacturing of a rigid insulating tile blank, which is shown in fig. 1, the apparatus for additive manufacturing of a rigid insulating tile blank comprises a feeding system, a filtering container, a drain pipe, a pressurizing device and an automatic control system (P L C controller, a first displacement sensor, a second displacement sensor, a pressure sensor and a solenoid valve).
The filtering container comprises a peripheral wall, a bottom plate, a bottom net (30-mesh steel wire net), 3 lath-shaped reinforcing ribs (through holes are formed in the reinforcing ribs) which are arranged in parallel and a liquid collecting part arranged below the reinforcing ribs, wherein a liquid outlet of the liquid collecting part is communicated with the liquid discharge pipe, and the liquid discharge pipe comprises a main liquid discharge pipe and a secondary liquid discharge pipe. Wherein, be provided with the pulley on the bottom plate, the below of pulley be provided with pulley assorted slide rail.
The feeding system comprises a storage chamber filled with slurry, a feeding pipe (the pipe diameter is 2.54cm), a liquid spraying inlet valve, a liquid spraying pump and a liquid spraying outlet valve which are arranged between the inlet end and the outlet end of the feeding pipe, a return pipe which communicates the storage chamber with the outlet of the liquid spraying pump, a return valve arranged on the return pipe, a spray head which is communicated with the outlet end of the feeding pipe and a porous plate with a hole array. The holes in the hole array are through holes (round holes with the aperture of 5mm), the through holes are arranged at equal intervals, the distance between the hole centers of every two adjacent through holes is 10mm, and when the filtering container moves to the position right below the porous plate, the height between the porous plate and the filtering container is 5 cm; the distribution area of the hole array in the porous plate, the area of the porous plate and the area of the pressure surface of the pressure head are matched with the cross sectional area of an inner cavity enclosed by the peripheral wall of the filtering container; the spray inlet valve, the switch of the spray pump, the spray outlet valve, the reflux valve, the liquid discharge inlet valve, the switch of the liquid discharge pump, the liquid discharge outlet valve and the liquid discharge valve are all electromagnetic valves.
The rigid heat-insulating tile blank is manufactured by adopting the device for manufacturing the rigid heat-insulating tile blank in an additive manufacturing method:
firstly, mixing 40g of quartz fiber, 5g of alumina fiber, 5g of zirconia fiber and 5g of boron carbide powder by 11kg of water to form slurry containing solid content with the concentration of 0.5 wt%, and then adjusting the pH of the slurry to 10 by using concentrated ammonia water to obtain slurry of the rigid heat insulation tile blank; placing the slurry of the rigid heat-insulating tile blank into a storage chamber, and forming the slurry of the rigid heat-insulating tile blank layer by a jet additive manufacturing method by using the device for additive manufacturing of the rigid heat-insulating tile blank in the embodiment to obtain a rigid heat-insulating tile blank containing 7 slurry layers; wherein the length of quartz fiber, alumina fiber and zirconia fiber is 500um ~ 5um, and the diameter is 1 ~ 10 um.
The thickness of each layer of the rigid heat insulation tile blank manufactured by the embodiment is 0.6 cm; among them, 7 slurry layers were sequentially the first to seventh layers from bottom to top, and the results of density tests were shown in table 1 for the 7 slurry layers included in the rigid heat insulating tile blank manufactured in this example.
Example 2
Example 2 is essentially the same as example 1, except that: the pH of the slurry was not adjusted to 10 with concentrated ammonia.
Example 3
Example 3 is essentially the same as example 1, except that: example 3 used in an apparatus for additive manufacturing of a rigid insulating tile blank: the distance between the centers of every two adjacent through holes is 8 mm.
The rigid insulating tile blanks produced in this example were subjected to density testing for 7 slurry layers, the results of which are shown in table 1.
Example 4
Example 4 is essentially the same as example 1, except that: example 4 used in an apparatus for additive manufacturing of a rigid insulating tile blank: the distance between the centers of every two adjacent through holes is 12 mm.
The rigid insulating tile blanks produced in this example were subjected to density testing for 7 slurry layers, the results of which are shown in table 1.
Example 5
Example 5 is essentially the same as example 1, except that: example 5 used in an apparatus for additive manufacturing of a rigid insulating tile blank: the distance between the centers of every two adjacent through holes is 7 mm.
The rigid insulating tile blanks produced in this example were tested for density in 7 slurry layers, the results of which are shown in table 1.
Example 6
Example 6 is essentially the same as example 1, except that: example 6 employed in an apparatus for additive manufacturing of a rigid insulating tile blank: the distance between the centers of every two adjacent through holes is 13 mm.
The rigid insulating tile blanks produced in this example were subjected to density testing for 7 slurry layers, the results of which are shown in table 1.
Example 7
Example 7 is essentially the same as example 1, except that: example 7 used in an apparatus for additive manufacturing of a rigid insulating tile blank: the liquid discharge pipe only comprises a main liquid discharge pipe and does not comprise a secondary liquid discharge pipe.
The rigid insulating tile blanks produced in this example were subjected to density testing for 7 slurry layers, the results of which are shown in table 1.
Example 8
Example 8 is essentially the same as example 1, except that: example 8 employed an apparatus for additive manufacturing of a rigid insulating tile blank wherein: the drain pipe only comprises a secondary drain pipe and does not comprise a primary drain pipe.
The rigid insulating tile blanks produced in this example were subjected to density testing for 7 slurry layers, the results of which are shown in table 1.
Example 9
Example 9 is essentially the same as example 1, except that: example 9 used an apparatus in which: the feed system does not include a perforated plate.
The rigid insulating tile blanks produced in this example were subjected to density testing for 7 slurry layers, the results of which are shown in table 1.
Example 10
Example 10 is essentially the same as example 1, except that: example 10 used an apparatus in which: the device does not include a pressurizing device.
The thickness of the rigid heat insulation tile blank manufactured by the embodiment is that the upper layer is large (the thickness of the seventh layer is 0.8cm), and the thickness of the lower layer is small (the thickness of the first layer is 0.45 cm); the density test was performed on 7 slurry layers included in the rigid insulating tile green body manufactured in this example, and as a result, as shown in table 1, it was found that the density of the manufactured rigid insulating tile green body was decreased in order from the first layer to the seventh layer; the apparatus employed in this embodiment does not include a pressing device, i.e., the slurry layer is not compacted during the manufacturing process of this embodiment; the density of the rigid heat insulation tile blank manufactured by the embodiment is that the density of the upper layer is small, and the density of the lower layer is large.
Comparative example 1
Firstly, mixing 40g of quartz fiber, 5g of alumina fiber, 5g of zirconia fiber and 5g of boron carbide powder by 11kg of water to form slurry containing solid content with the concentration of 0.5 wt%, and then adjusting the pH of the slurry to 10 by using concentrated ammonia water to obtain slurry of the rigid heat insulation tile blank; then placing the slurry of the rigid heat insulation tile blank into a container with a filtering function to filter water in the slurry, and then obtaining the rigid heat insulation tile blank; wherein the length of quartz fiber, alumina fiber and zirconia fiber is 500um ~ 5um, and the diameter is 1 ~ 10 um.
The total thickness of the rigid heat insulating tile green body obtained in this comparative example was measured, and was equally divided into seven slurry layers artificially from the bottom to the top according to the total thickness, and the densities of the slurry layers from the first layer to the seventh layer were measured, and the results are shown in table 1.
Figure BDA0001657478330000201
The invention manufactures the rigid heat-insulating tile blank by a jet additive manufacturing method, can effectively control the density of the rigid heat-insulating tile blank, has small density difference among all layers of slurry, and can obtain the rigid heat-insulating tile blank with uniform density and accurate thickness.
In the description of the present invention, it is to be noted that, unless otherwise specified, "a plurality" means two or more; the terms "horizontal direction", "vertical direction", "lower end", "above", "below", "lower part", "left end", "right end", and the like indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience in describing and simplifying the present invention, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and thus, should not be construed as limiting the present invention.
Finally, it should be noted that: the above examples are only intended to illustrate the technical solution of the present invention, but not to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some technical features may be equivalently replaced; and such modifications or substitutions do not depart from the spirit and scope of the corresponding technical solutions of the embodiments of the present invention.

Claims (9)

1. A method of manufacturing a rigid insulating tile blank by an additive manufacturing process, the method comprising the steps of:
(1) uniformly mixing ceramic fibers and a non-metal boride with water to obtain slurry; and
(2) forming the slurry obtained in the step (1) layer by a jet additive manufacturing method to obtain a rigid heat insulation tile blank;
the method is performed by an apparatus for additive manufacturing of a rigid insulating tile blank, the apparatus comprising:
the filtering container can move along the horizontal direction in an operable way, and comprises a peripheral wall, a bottom plate which is fixed at the position close to the lower end of the peripheral wall and is provided with an opening in the middle, a bottom net which is arranged at the lower part of an inner cavity enclosed by the peripheral wall, a reinforcing rib for supporting the bottom net and a liquid collecting part which is arranged below the reinforcing rib, is used for collecting liquid filtered out from the filtering container and is provided with a liquid outlet;
a liquid discharge pipe for discharging the liquid in the liquid collecting part, the liquid discharge pipe being communicated with the liquid outlet of the liquid collecting part;
the feeding system is used for feeding the materials into the filtering container and comprises a material storage chamber, a feeding pipe, a spray head communicated with the outlet end of the feeding pipe and a perforated plate which is positioned below the spray head and provided with a hole array, wherein holes in the hole array are through holes, and the through holes are arranged corresponding to the nozzles of the spray head and are used for supporting and fixing the nozzles; and
the pressurizing device is used for pressurizing materials in the filtering container, is arranged on one side of the horizontal direction of the spray head, and comprises a pressure head, a pressure arm fixedly connected with the pressure head and a driving device used for driving the pressure arm to stretch and retract along the vertical direction.
2. The method of claim 1, wherein:
adjusting the pH value of the slurry obtained in the step (1) to 9-11 before the step (2).
3. The method according to claim 1, wherein the injection additive manufacturing method of step (2) comprises the sub-steps of:
(a) laying the slurry obtained in the step (1) in a spraying manner to obtain a slurry layer;
(b) compacting the slurry layer obtained in the step (a) to obtain a first layer of a rigid heat-insulating tile blank; and
(c) and (c) sequentially repeating the step (a) and the step (b) on the basis of the first layer of the rigid heat-insulating tile blank to manufacture a second layer of the rigid heat-insulating tile blank, and repeating the steps till the manufacturing of a preset number of layers is completed to obtain the rigid heat-insulating tile blank containing multiple slurry layers.
4. The method of claim 1, wherein:
the ceramic fiber consists of 30 to 85 mass percent of quartz fiber, 4.9 to 55 mass percent of alumina fiber and 0.1 to 15 mass percent of zirconia fiber;
the non-metal boride is selected from the group consisting of boron carbide and boron nitride, and the using amount of the non-metal boride is 0.5 to 20 weight percent of that of the ceramic fiber; and/or
The total amount of the ceramic fiber and the non-metal boride is 0.3 wt% -1 wt% of the amount of the water.
5. The method of claim 1, wherein:
the through hole is a circular hole, and the aperture of the through hole is 4-6 mm;
the through holes are arranged in the porous plate at equal intervals, and the distance between the hole centers of every two adjacent through holes is 8-12 mm;
the distribution area of the hole array in the porous plate, the area of the porous plate and/or the area of the pressure surface of the pressure head are/is matched with the cross sectional area of an inner cavity surrounded by the peripheral wall; and/or
When the filtering container moves to the position under the porous plate, the distance between the porous plate and the filtering container is 2.5-5 cm.
6. The method of claim 1, wherein:
the reinforcing ribs are in a lath shape, and the number of the reinforcing ribs is one or more;
the reinforcing ribs are provided with through holes;
the bottom net is a steel wire net with 20-40 meshes;
the pipe diameter of the feeding pipe is 1.27cm or 2.54 cm; and/or
The feeding pipe and/or the liquid discharge pipe are flexible pipes.
7. The method of claim 1, wherein:
at least one pulley is arranged on the bottom plate of the filtering container, and a sliding rail matched with the pulley is arranged below the pulley;
the slide rail is the double track way slide rail, the quantity of pulley is 4.
8. The method of claim 1, wherein:
the feeding system also comprises a spray inlet valve, a spray pump and a spray outlet valve which are sequentially arranged between the inlet end and the outlet end of the feeding pipe;
the feeding system also comprises a return pipe and a return valve, wherein the return pipe is communicated with the storage chamber and the outlet of the liquid spraying pump; and/or
The liquid discharge pipe comprises a main liquid discharge pipe and/or a secondary liquid discharge pipe, a liquid discharge inlet valve is arranged at one end, close to the liquid outlet of the liquid collecting part, of the main liquid discharge pipe, a liquid discharge outlet valve is arranged at one end, far away from the liquid outlet of the liquid collecting part, a liquid discharge pump is arranged between the liquid discharge inlet valve and the liquid discharge outlet valve, and/or a liquid discharge valve is arranged on the secondary liquid discharge pipe.
9. The method of claim 8, wherein:
the spray inlet valve, the switch of the spray pump, the spray outlet valve, the reflux valve, the drain inlet valve, the switch of the drain pump, the drain outlet valve and/or the drain valve are electromagnetic valves;
the apparatus for additive manufacturing of a rigid insulating tile blank further comprises a P L C controller, a first displacement sensor for sensing displacement of the filter container in a horizontal direction, a second displacement sensor for sensing displacement of the ram in a vertical direction, and a pressure sensor for sensing pressure against the ram surface;
the P L C controller is electrically connected with the first displacement sensor, the second displacement sensor, the pressure sensor and the solenoid valve, and the P L C controller is used for receiving signals sensed by the first displacement sensor, the second displacement sensor and the pressure sensor and controlling the movement of the filtering container and the pressure head and the working state of the solenoid valve according to the sensed signals.
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