CN108751933A - 一种利用废瓷制备的3d打印陶瓷膏体及其制备方法和应用 - Google Patents

一种利用废瓷制备的3d打印陶瓷膏体及其制备方法和应用 Download PDF

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CN108751933A
CN108751933A CN201810594846.0A CN201810594846A CN108751933A CN 108751933 A CN108751933 A CN 108751933A CN 201810594846 A CN201810594846 A CN 201810594846A CN 108751933 A CN108751933 A CN 108751933A
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赵敬泽
贺梦鸽
郑叶
陈俊杰
胡可辉
康有伟
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Wuhan University of Technology WUT
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Abstract

本发明提供一种利用废瓷制备的3D打印陶瓷膏体及其制备方法和应用，包括如下组分及其质量份数：废瓷粉≥50份、粘结剂体系≤50份、其余为烧结助剂及pH值调节剂。其制备方法，包括如下步骤：将废瓷经破碎、清洗、球磨、过筛处理成废瓷粉；将粘结剂、增塑剂和分散剂混合后分散到去离子水中，制得胶状粘结剂体系；向废瓷粉中加入胶状粘结剂体系、烧结助剂及pH值调节剂，搅拌混合后真空除泡，即得成品3D打印陶瓷膏体。本发明产品可用3D打印技术打印出多种形状复杂的陶瓷制品，创新性地将废弃陶瓷材料与3D打印技术结合，简化陶瓷制作工艺，降低制作成本，为陶瓷废弃物的回收利用和陶瓷行业的绿色发展提供新的方向。

Description

一种利用废瓷制备的3D打印陶瓷膏体及其制备方法和应用
技术领域
本发明涉及陶瓷3D打印技术领域，具体涉及一种利用废瓷制备的3D打印陶瓷膏体及其制备方法和应用。
背景技术
我国是陶瓷品产销第一大国，据统计，2017年我国陶瓷行业共消耗粘土、石英等矿物原料约2亿吨，每年产生废弃陶瓷1300万吨左右，陶瓷经高温烧结后无法降解，造成了原料的过度消耗和土地资源的占用。经调研，工业废瓷多被破碎后作为原料按一定比例投入原生产线实现再生利用，再生产物附加值较低；日用废瓷由于缺少回收机制而难以集中，被作为不可回收垃圾填埋处理。
增材制造技术可以缩短产品制造周期，降低制作成本，创造出造型复杂和高附加值的陶瓷制品，为废弃陶瓷的回收利用提供了新的方向。因此，设出一种面向增材制造的废弃陶瓷再生技术，以解决废弃陶瓷的回收利用问便具有现实意义。
发明内容
本发明的目的是提供一种利用废瓷制备的3D打印陶瓷膏体及其制备方法和应用，采用废瓷作为主要原料，再加入粘合剂、增塑剂和分散剂(表面活性剂)加工而成，可用于制备多种形状复杂的陶瓷制品，从而创新性地将废弃陶瓷材料与3D打印技术结合，简化陶瓷制作工艺，降低制作成本，为陶瓷废弃物的回收利用和陶瓷行业的绿色发展提供新的方向。
为了实现上述目的，本发明采用的技术方案如下：
一种利用废瓷制备的3D打印陶瓷膏体，包括如下组分及其质量份数：废瓷粉不小于50份、粘结剂体系不大于50份、其余为烧结助剂及pH值调节剂；所述粘结剂体系包括粘结剂、增塑剂、分散剂和溶剂。
根据以上方案，所述粘结剂为聚乙烯醇、分散剂为商用分散剂KH、增塑剂为丙三醇、溶剂为去离子水。
一种利用废瓷制备的3D打印陶瓷膏体的制备方法，包括如下步骤：
1)将收集的废瓷经破碎、清洗、球磨、过筛处理成废瓷粉；
2)将粘结剂、增塑剂和分散剂混合后分散到去离子水中，经干混和湿混捏合后，得到均质稳定的胶状粘结剂体系；
3)向废瓷粉中加入步骤2)制备的胶状粘结剂体系、烧结助剂及pH值调节剂，搅拌混合后真空除泡，即得成品3D打印陶瓷膏体。
根据以上方案，所述废瓷粉的颗粒直径为74μm～180μm。
根据以上方案，所述3D打印陶瓷膏体的pH值为7.0。
根据以上方案，所述3D打印陶瓷膏体的固相含量50vol％。
一种利用废瓷制备的3D打印陶瓷膏体，用于制备再生陶瓷制品，包括如下步骤：
1)通过实验确定3D打印工艺参数并打印出陶瓷坯体；
2)将坯体进行热处理，随炉冷却至室温，得到再生陶瓷制品。
根据以上方案，所述3D打印工艺参数为：扫描速度12～15mm/s，层厚1.1～1.2mm，喷嘴直径为1.25mm。
根据以上方案，所述热处理包括排胶、烧结过程，所述排胶阶段升温速率为5℃/min，排胶后以10℃/min的升温速率升温至1200℃，并保温1h进行烧结。
本发明的有益效果是：
1)本发明以废瓷为原料，通过增材制造技术选用合适的分散介质和处理方法，制备了新型陶瓷膏体，创新性地将废弃陶瓷材料与3D打印技术结合，简化陶瓷制作工艺，降低制作成本，为陶瓷废弃物的回收利用和陶瓷行业的绿色发展提供新的方向。对社会而言，能够保护环境、节约资源，推动绿色制造和先进制造工程的实施；对陶瓷行业而言，促进了产品迭代和技术升级；对消费者而言，降低了3D打印的成本，更好的满足个性化定制需求；
2)本发明产品可用于制备多种形状复杂的陶瓷制品，可实现复杂形状产品制造和个性化产品定制，提高产品附加值。
具体实施方式
下面结合实施例对本发明的技术方案进行说明。
实施例1：
本发明提供一种利用废瓷制备的3D打印陶瓷膏体，包括如下组分及其质量：废瓷粉500g、粘结剂聚乙烯醇50g、分散剂KH20g、增塑剂丙三醇50g、去离子水380g，其制备方法，包括如下步骤：
1)将收集的废瓷经破碎、清洗、球磨粉碎处理8h，依次过80目、100目、200目筛，得到颗粒直径为74μm～180μm的废瓷粉；
2)将粘结剂、增塑剂和分散剂混合后分散到去离子水中，经干混和湿混捏合后，得到均质稳定的胶状粘结剂；
3)向胶状粘结剂中加入废瓷粉、烧结助剂及pH值调节剂，搅拌混合后真空除泡，即得成品。
将本实施例产品用于制备再生陶瓷制品，包括如下步骤：
1)通过实验确定3D打印工艺参数并打印出坯体，具体工艺参数为：扫描速度13mm/s，层厚1.1mm，喷嘴直径1.25mm，使用长度固定为L＝31.4mm的挤出头，挤出头直径不同，每次实验膏体装载量均为50mL；
2)将坯体放入马弗炉内进行热处理：排胶阶段升温速率为5℃/min，排胶后以10℃/min的升温速率升温至1200℃，并保温1h进行烧结，随炉冷却至室温，得到再生陶瓷制品。再生陶瓷制品强度提高，尺寸收缩率约为15％。
实施例2：
本实施例基本同实施例1，不同之处在于：包括如下组分及其质量：废瓷粉500g、粘结剂聚乙烯醇40g、分散剂KH20g、增塑剂丙三醇60g、去离子水380g。
实施例3：
本实施例基本同实施例1，不同之处在于：包括如下组分及其质量：废瓷粉500g、粘结剂聚乙烯醇60g、分散剂KH30g、增塑剂丙三醇40g、去离子水370g。
实施例5：
本实施例基本同实施例1，不同之处在于：包括如下组分及其质量：废瓷粉500g、粘结剂聚乙烯醇60g、分散剂KH30g、增塑剂丙三醇60g、去离子水350g。
实施例6：
本实施例基本同实施例1，不同之处在于：包括如下组分及其质量：废瓷粉500g、粘结剂聚乙烯醇40g、分散剂KH20g、增塑剂丙三醇40g、去离子水400g。
经硅酸盐建筑材料国家重点实验室检验，利用本发明产品制备的再生陶瓷制品检验结果为：吸水率＜0.5％，破坏强度80MPa，外观表面质量无开裂，无坯裂，规格尺寸偏差±2％。
以上实施例仅用以说明而非限制本发明的技术方案，尽管上述实施例对本发明进行了详细说明，本领域的相关技术人员应当理解：可以对本发明进行修改或者同等替换，但不脱离本发明精神和范围的任何修改和局部替换均应涵盖在本发明的权利要求范围内。

Claims (9)

1.一种利用废瓷制备的3D打印陶瓷膏体，其特征在于，包括如下组分及其质量份数：废瓷粉不小于50份、粘结剂体系不大于50份、其余为烧结助剂及pH值调节剂；所述粘结剂体系包括粘结剂、增塑剂、分散剂和溶剂。
2.根据权利要求1所述的利用废瓷制备的3D打印陶瓷膏体，其特征在于，所述粘结剂为聚乙烯醇、分散剂为商用分散剂KH、增塑剂为丙三醇、溶剂为去离子水。
3.根据权利要求1或2所述的利用废瓷制备的3D打印陶瓷膏体的制备方法，包括如下步骤：
1)将收集的废瓷经破碎、清洗、球磨、过筛处理成废瓷粉；
2)将粘结剂、增塑剂和分散剂混合后分散到去离子水中，经干混和湿混捏合后，得到均质稳定的胶状粘结剂体系；
3)向废瓷粉中加入步骤2)制备的胶状粘结剂体系、烧结助剂及pH值调节剂，搅拌混合后真空除泡，即得成品3D打印陶瓷膏体。
4.根据权利要求3所述的利用废瓷制备的3D打印陶瓷膏体的制备方法，其特征在于，所述废瓷粉的颗粒直径为74μm～180μm。
5.根据权利要求3所述的利用废瓷制备的3D打印陶瓷膏体的制备方法，其特征在于，所述3D打印陶瓷膏体的pH值为7.0。
6.根据权利要求3所述的利用废瓷制备的3D打印陶瓷膏体的制备方法，其特征在于，所述3D打印陶瓷膏体的固相含量50vol％。
7.根据权利要求1所述的利用废瓷制备的3D打印陶瓷膏体，其特征在于，用于制备再生陶瓷制品，包括如下步骤：
1)通过实验确定3D打印工艺参数并打印出陶瓷坯体；
2)将坯体进行热处理，随炉冷却至室温，得到再生陶瓷制品。
8.根据权利要求7所述的利用废瓷制备的3D打印陶瓷膏体，其特征在于，所述3D打印工艺参数为：扫描速度12～15mm/s，层厚1.1～1.2mm，喷嘴直径为1.25mm。
9.根据权利要求7所述的利用废瓷制备的3D打印陶瓷膏体，其特征在于，所述热处理包括排胶、烧结过程，所述排胶阶段升温速率为5℃/min，排胶后以10℃/min的升温速率升温至1200℃，并保温1h进行烧结。
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