CN108947540B - 一种疏水性多孔陶瓷制品及其制备工艺 - Google Patents
一种疏水性多孔陶瓷制品及其制备工艺 Download PDFInfo
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- CN108947540B CN108947540B CN201811190123.0A CN201811190123A CN108947540B CN 108947540 B CN108947540 B CN 108947540B CN 201811190123 A CN201811190123 A CN 201811190123A CN 108947540 B CN108947540 B CN 108947540B
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- Compositions Of Oxide Ceramics (AREA)
Abstract
本发明涉及陶瓷制品技术领域，具体涉及一种疏水性多孔陶瓷制品及其制备工艺，包括坯体和釉料，所述坯体由以下重量份的原料组成：氮化硅27份、二氧化锆16份、粘土12份、硅酸铝24份、堇青石16份、碳化硅19份、硅藻土14份、钠长石11份、氧化铝18份、助熔料13份；所述釉料由以下重量份的原料组成：白云石21份、碳化硅23份、氧化钙14份、钾长石17份、粘土5份、六偏磷酸钠2份。其制备工艺包括以下步骤：坯体原料改性；热压铸塑型；脱蜡素烧；上釉；烧成。本发明工艺简单，适合规模化生产的需要，所生产出的陶瓷制品具有机械强度高、多孔疏水以及耐高温的优点。
Description
技术领域
本发明涉及陶瓷制品技术领域，具体涉及一种疏水性多孔陶瓷制品及其制备工艺。
背景技术
陶瓷行业是我国最古老的行业之一，其观赏价值一直大于其使用价值，现如今，随着科学技术的不断进步，人们对陶瓷的性能要求也越来越高，使开发各种各样性能的陶瓷成为新的研究热点。其中对陶瓷的疏水化改性是当前的热点之一，固体材质的润湿性是指液体与固体表面接触时，液体可以渐渐渗入或附着在固体表面上，是固体表面的重要特征之一，这种特征由固体表面的化学组成及微观结构共同决定，接触角和滚动角是评价固体表面润湿性的重要参数，理论上疏水表面既要有较大的接触角，又要有较小的滚动角，疏水性表面一般是指与水的接触角大于150°，而滚动角小于10°的表面，这样的表面具有防雪、防污染、抗氧化及防止电流传导等特性。疏水性能主要由材料表面的化学结构、聚集态、表面形貌和微构造协同作用所决定，疏水表面的结构通常采用两种方法，一是在疏水材料表面上构建微观结构，二是在粗糙表面上修饰低表面能物质。由于降低表面自由能在技术上容易实现，因此超疏水表面制备技术的关键在于构建合适的表面微细结构。
多孔陶瓷也同样是当前的热点之一，多孔性陶瓷具有耐高温、高压、抗酸、碱和有机介质腐蚀，还具有良好的生物惰性、可控的孔结构及高的开口孔隙率、使用寿命长、产品再生性能好等优点，可以适用于各种介质的精密过滤与分离、高压气体排气消音、气体分布及电解隔膜等。制备这类多孔陶瓷的工艺也是多种多样，比如有机泡沫浸渍工艺、溶胶－凝胶工艺等，但依然存在缺乏连续、大规模系统成产的工艺，并且多孔陶瓷的脆性依然没有得到有效的解决，有待进一步地研究。
发明内容
本发明的目的在于克服现有技术的不足，提供一种疏水性多孔陶瓷制品及其制备工艺。本发明工艺简单，适合规模化生产的需要，所生产出的陶瓷制品具有机械强度高、多孔疏水以及耐高温的优点。
一种疏水性多孔陶瓷制品，包括坯体和釉料，所述坯体包括以下重量份的原料：氮化硅24-32份、二氧化锆15-17份、粘土11-16份、硅酸铝23-28份、堇青石14-18份、碳化硅18-22份、硅藻土10-15份、钠长石9-12份、氧化铝14-21份、助熔料12-16份；所述釉料包括以下重量份的原料：白云石18-24份、碳化硅22-26份、氧化钙14-16份、钾长石13-18份、粘土4-6份、六偏磷酸钠1-3份。
进一步地，包括坯体和釉料，所述坯体包括以下重量份的原料：氮化硅27份、二氧化锆16份、粘土12份、硅酸铝24份、堇青石16份、碳化硅19份、硅藻土14份、钠长石11份、氧化铝18份、助熔料13份；所述釉料包括以下重量份的原料：白云石21份、碳化硅23份、氧化钙14份、钾长石17份、粘土5份、六偏磷酸钠2份。
进一步地，所述助熔料由滑石、硅灰石以及硅酸钠按照重量比为2:3:3的比例混合而成。
本发明还提供一种制备所述一种疏水性多孔陶瓷制品的工艺，包括以下步骤：
步骤1、按照重量份称取坯体原料粉碎后放入球磨机中混合，加入坯体原料总质量6％-9％的表面改性剂，球磨12-15h，再通过100-200目筛后得到改性后的坯体粉料；
步骤2、向步骤1所得的改性后的坯体粉料中加入坯体粉料总质量45％-55％的熔化后的石蜡，搅拌均匀后得到坯体浆料；
步骤3、将步骤2得到的坯体浆料放入热压铸成型机中，对坯体浆料进行热压塑型处理，得到素坯；
步骤4、将步骤3得到的素坯埋入装满脱附剂的脱蜡缸中，提升脱蜡缸中的温度至860-1150℃，对素坯进行脱蜡处理；
步骤5、将脱蜡后的素坯放入窑炉中，在窑炉温度为800-900℃下素烧2-5h，冷却后得到素胎；
步骤6、按照重量份称取釉料原料粉碎后放入球磨机中混合，加入釉料原料总重量35％-40％的水，球磨6-8h后通过100-200目筛，得到釉料浆料；
步骤7、将步骤6所得的釉料浆料对步骤5所得的素胎进行上釉，釉层厚度为2-2.6mm，放入窑炉中于1150-1250℃温度下烧成18-26h，得到疏水性多孔陶瓷制品。
进一步地，所述步骤1表面改性剂由聚环氧乙烷与硅烷偶联剂按照质量比为3:1的比例混合而成。
进一步地，所述步骤3中热压温度为160-180℃，热压压力为28-36Mpa，热压时间为35-40s。
进一步地，所述步骤4脱附剂由活性炭和正己烷按照质量比为3:5的比例混合而成。
有益效果
本发明的有益效果如下：
（1）、本发明采用氮化硅、二氧化锆、粘土、硅酸铝、堇青石、碳化硅、硅藻土、钠长石、氧化铝为坯体的主要原料，其中，氮化硅、二氧化锆、堇青石与硅酸铝的热膨胀系数低，在由滑石、硅灰石以及硅酸钠按照重量比为2:3:3的比例混合而成的助熔料的作用下，大幅度降低其熔融温度，使其在烧结过程中收缩率小，导致其密度低，易呈现多孔的特征，微观粗糙多孔的表面能提高陶瓷制品的疏水性，同时，氮化硅与二氧化锆都属于高强度的物质，能有效增加陶瓷制品的韧性，弥补陶瓷制品的脆性缺点；碳化硅具有耐腐蚀、耐高温、强度大、导热性能良好、抗冲击等特性，其与硅藻土配合使用能显著提高陶瓷制品的冲击强度、撕裂强度以及抗压强度，并且硅藻土具有独特的孔隙结构，体重轻软，孔隙度大，能作为各原料的粘合剂，从而增强陶瓷制品的强度；钠长石在烧成前长石能起瘠性原料的作用，与氧化铝结合能减少坯体的干燥收缩和变形，改善干燥性能，缩短干燥时间，在烧成时可作为熔剂充填于坯体，使坯体致密而减少空隙，提高坯体的机械强度。
（2）、本发明采用白云石、碳化硅、氧化钙、钾长石、粘土、六偏磷酸钠作为釉料的主要原料，白云石作为致孔剂加入可以提高陶瓷的气孔率、扩大比表面积，增加了陶瓷表面的细微结构，降低了其自由表面能，提高了陶瓷表面的疏水性，但过多的白云石会导致强度下降，并且必须控制白云石的烧结温度，如果烧结温度过高，会与原料中的部分物质形成玻璃相，填充部分已形成的气孔，降低陶瓷的气孔率，因此控制烧结温度在1150-1250℃能达到最好的效果；钾长石的加入能使釉面变得柔软，并能降低釉面的熔融温度，使其烧结更加充分，与碳化硅结合使用能有效的提高釉面的机械强度；六偏磷酸钠与粘土的加入起到了粘结剂的作用，能使各釉面原料更紧密的结合，且能加强釉面与坯体附着程度。
（3）、本发明采用热压铸的加工工艺，先将坯体原料与由聚环氧乙烷与硅烷偶联剂按照质量比为3:1的比例混合而成的表面改性剂混合，提高坯体与蜡的结合程度。在加入蜡后采用热压铸成型机对其进行热压塑型处理，再埋入装满脱附剂的脱蜡缸中加热脱蜡，其中，由活性炭和正己烷按照质量比为3:5的比例混合而成的脱附剂能吸附坯体中的蜡，在860-1150℃的温度下脱附剂能达到最好的脱蜡效果，脱蜡后的坯体呈现出多孔的结构，此工艺即可快速塑型，提高陶瓷制品的生产效率，使陶瓷生产工艺规模化、系统化，又能制出多孔且强度高的陶瓷制品。
具体实施方式
下面结合具体实施例对本发明作进一步详细说明。
实施例1
一种疏水性多孔陶瓷制品，包括坯体和釉料，所述坯体包括以下重量份的原料：氮化硅24份、二氧化锆15份、粘土11份、硅酸铝23份、堇青石14份、碳化硅18份、硅藻土10份、钠长石9份、氧化铝14份、助熔料12份，所述助熔料由滑石、硅灰石以及硅酸钠按照重量比为2:3:3的比例混合而成；所述釉料包括以下重量份的原料：白云石18份、碳化硅22份、氧化钙14份、钾长石13份、粘土4份、六偏磷酸钠1份。
本实施例还提供一种制备所述一种疏水性多孔陶瓷制品的工艺，包括以下步骤：
步骤1、按照重量份称取坯体原料粉碎后放入球磨机中混合球磨，加入坯体原料总质量6％的表面改性剂，所述表面改性剂由聚环氧乙烷与硅烷偶联剂按照质量比为3:1的比例混合而成，球磨12h，再通过100目筛后得到改性后的坯体粉料；
步骤2、向步骤1所得的改性后的坯体粉料中加入坯体粉料总质量45％的熔化后的石蜡，搅拌均匀后得到坯体浆料；
步骤3、将步骤2得到的坯体浆料放入热压铸成型机中，对坯体浆料进行热压塑型处理，热压温度为160℃，热压压力为28Mpa，热压时间为35s，得到素坯；
步骤4、将步骤3得到的素坯埋入装满脱附剂的脱蜡缸中，所述脱附剂由活性炭和正己烷按照质量比为3:5的比例混合而成，提升脱蜡缸中的温度至860℃，对素坯进行脱蜡处理；
步骤5、将脱蜡后的素坯放入窑炉中，在窑炉温度为800℃下素烧2h，冷却后得到素胎；
步骤6、按照重量份称取釉料原料粉碎后放入球磨机中混合球磨，加入釉料原料总重量35％的水，球磨6h后通过100目筛，得到釉料浆料；
步骤7、将步骤6所得的釉料浆料对步骤5所得的素胎进行上釉，釉层厚度为2mm，放入窑炉中于1150℃温度下烧成18h，得到疏水性多孔陶瓷制品。
实施例2
一种疏水性多孔陶瓷制品，包括坯体和釉料，所述坯体包括以下重量份的原料：氮化硅29份、二氧化锆16份、粘土15份、硅酸铝25份、堇青石16份、碳化硅19份、硅藻土12份、钠长石11份、氧化铝17份、助熔料15份，所述助熔料由滑石、硅灰石以及硅酸钠按照重量比为2:3:3的比例混合而成；所述釉料包括以下重量份的原料：白云石22份、碳化硅24份、氧化钙15份、钾长石14份、粘土5份、六偏磷酸钠2份。
本实施例还提供一种制备所述一种疏水性多孔陶瓷制品的工艺，包括以下步骤：
步骤1、按照重量份称取坯体原料粉碎后放入球磨机中混合球磨，加入坯体原料总质量8％的表面改性剂，所述表面改性剂由聚环氧乙烷与硅烷偶联剂按照质量比为3:1的比例混合而成，球磨13h，再通过100目筛后得到改性后的坯体粉料；
步骤2、向步骤1所得的改性后的坯体粉料中加入坯体粉料总质量48％的熔化后的石蜡，搅拌均匀后得到坯体浆料；
步骤3、将步骤2得到的坯体浆料放入热压铸成型机中，对坯体浆料进行热压塑型处理，热压温度为170℃，热压压力为32Mpa，热压时间为37s，得到素坯；
步骤4、将步骤3得到的素坯埋入装满脱附剂的脱蜡缸中，所述脱附剂由活性炭和正己烷按照质量比为3:5的比例混合而成，提升脱蜡缸中的温度至1020℃，对素坯进行脱蜡处理；
步骤5、将脱蜡后的素坯放入窑炉中，在窑炉温度为850℃下素烧3h，冷却后得到素胎；
步骤6、按照重量份称取釉料原料粉碎后放入球磨机中混合球磨，加入釉料原料总重量38％的水，球磨7h后通过200目筛，得到釉料浆料；
步骤7、将步骤6所得的釉料浆料对步骤5所得的素胎进行上釉，釉层厚度为2.3mm，放入窑炉中于1185℃温度下烧成23h，得到疏水性多孔陶瓷制品。
实施例3
一种疏水性多孔陶瓷制品，包括坯体和釉料，所述坯体包括以下重量份的原料：氮化硅32份、二氧化锆17份、粘土16份、硅酸铝28份、堇青石18份、碳化硅22份、硅藻土15份、钠长石12份、氧化铝21份、助熔料16份，所述助熔料由滑石、硅灰石以及硅酸钠按照重量比为2:3:3的比例混合而成；所述釉料包括以下重量份的原料：白云石24份、碳化硅26份、氧化钙16份、钾长石18份、粘土6份、六偏磷酸钠3份。
本实施例还提供一种制备所述一种疏水性多孔陶瓷制品的工艺，包括以下步骤：
步骤1、按照重量份称取坯体原料粉碎后放入球磨机中混合球磨，加入坯体原料总质量9％的表面改性剂，所述表面改性剂由聚环氧乙烷与硅烷偶联剂按照质量比为3:1的比例混合而成，球磨15h，再通过200目筛后得到改性后的坯体粉料；
步骤2、向步骤1所得的改性后的坯体粉料中加入坯体粉料总质量55％的熔化后的石蜡，搅拌均匀后得到坯体浆料；
步骤3、将步骤2得到的坯体浆料放入热压铸成型机中，对坯体浆料进行热压塑型处理，热压温度为180℃，热压压力为36Mpa，热压时间为40s，得到素坯；
步骤4、将步骤3得到的素坯埋入装满脱附剂的脱蜡缸中，所述脱附剂由活性炭和正己烷按照质量比为3:5的比例混合而成，提升脱蜡缸中的温度至1150℃，对素坯进行脱蜡处理；
步骤5、将脱蜡后的素坯放入窑炉中，在窑炉温度为900℃下素烧5h，冷却后得到素胎；
步骤6、按照重量份称取釉料原料粉碎后放入球磨机中混合球磨，加入釉料原料总重量40％的水，球磨8h后通过200目筛，得到釉料浆料；
步骤7、将步骤6所得的釉料浆料对步骤5所得的素胎进行上釉，釉层厚度为2.6mm，放入窑炉中于1250℃温度下烧成26h，得到疏水性多孔陶瓷制品。
对比例1
对比例1与实施例2的原料配方相同，不同之处在于对比例1坯体没有采用热压铸塑型，而是采用普通人工塑型。
对比例2
对比例1与实施例2的制备方法相同，不同之处在于对比例2中坯体原料中不含氮化硅和二氧化锆。
通过对实施例1-实施例3以及对比例1和对比例2所制成的陶瓷制品分别进硬度和热稳定性测试，测试方法如下：
硬度测试：使用金刚石压头加载压入法，测试维氏硬度，即用对角面为136°的金刚石四棱椎体做压头，在9.807~490.3（1~50kgf）的载荷作用下，压入陶瓷表面，保持一定时间后卸除载荷，材料表面便留下一个压痕，测量压痕对角线的长度和压痕面积，求出单位面积上承受的载荷应力，即维氏硬度HV，数值越高，硬度越大。
热稳定性测试：分别取5片陶瓷制品碎片作为试样，置于280℃条件下保温300分钟，保温结束后取出试样并进行核算，在15s内急速投入温度为20℃的水中，浸泡10分钟，其中，水的重量与试样重量之比为8：1，水面高出试样25mm，取出试样用布揩干，涂上红色墨水，检查有无裂纹，24 h后再复查一次，产生裂纹越少，试样的热稳定性越好。
断裂韧度检测：GB-4161《金属材料平面应断裂韧度实验方法》。
开孔率检测：GB/T 1966-1996 《多孔陶瓷显气孔率、容量试验方法》。
测试结果如下表1所示：
从上表1可以看出氮化硅和二氧化锆对陶瓷的韧性影响很大，热压铸工艺制备出的陶瓷制品开孔率更大，同时，实施例2各项检测数值均最好，为最优实施例。
最后应说明的是：以上所述仅为本发明的优选实施例而已，并不用于限制本发明，尽管参照前述实施例对本发明进行了详细的说明，对于本领域的技术人员来说，其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分技术特征进行等同替换。凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。
Claims (6)
1.一种疏水性多孔陶瓷制品，其特征在于，包括坯体和釉料，所述坯体包括以下重量份的原料：氮化硅24-32份、二氧化锆15-17份、粘土11-16份、硅酸铝23-28份、堇青石14-18份、碳化硅18-22份、硅藻土10-15份、钠长石9-12份、氧化铝14-21份、助熔料12-16份，所述助熔料由滑石、硅灰石以及硅酸钠按照重量比为2:3:3的比例混合而成；所述釉料包括以下重量份的原料：白云石18-24份、碳化硅22-26份、氧化钙14-16份、钾长石13-18份、粘土4-6份、六偏磷酸钠1-3份。
2.根据权利要求1所述的一种疏水性多孔陶瓷制品，其特征在于，包括坯体和釉料，所述坯体包括以下重量份的原料：氮化硅27份、二氧化锆16份、粘土12份、硅酸铝24份、堇青石16份、碳化硅19份、硅藻土14份、钠长石11份、氧化铝18份、助熔料13份；所述釉料包括以下重量份的原料：白云石21份、碳化硅23份、氧化钙14份、钾长石17份、粘土5份、六偏磷酸钠2份。
3.一种制备权利要求1至2任一项所述一种疏水性多孔陶瓷制品的工艺，其特征在于，包括以下步骤：
步骤1、按照重量份称取坯体原料粉碎后放入球磨机中混合球磨，加入坯体原料总质量6％-9％的表面改性剂，球磨12-15h，再通过100-200目筛后得到改性后的坯体粉料；
步骤2、向步骤1所得的改性后的坯体粉料中加入坯体粉料总质量45％-55％的熔化后的石蜡，搅拌均匀后得到坯体浆料；
步骤3、将步骤2得到的坯体浆料放入热压铸成型机中，对坯体浆料进行热压塑型处理，得到素坯；
步骤4、将步骤3得到的素坯埋入装满脱附剂的脱蜡缸中，提升脱蜡缸中的温度至860-1150℃，对素坯进行脱蜡处理；
步骤5、将脱蜡后的素坯放入窑炉中，在窑炉温度为800-900℃下素烧2-5h，冷却后得到素胎；
步骤6、按照重量份称取釉料原料粉碎后放入球磨机中混合球磨，加入釉料原料总重量35％-40％的水，球磨6-8h后通过100-200目筛，得到釉料浆料；
步骤7、将步骤6所得的釉料浆料对步骤5所得的素胎进行上釉，釉层厚度为2-2.6mm，放入窑炉中于1150-1250℃温度下烧成18-26h，得到疏水性多孔陶瓷制品。
4.根据权利要求3所述的一种疏水性多孔陶瓷制品的制备工艺，其特征在于，所述步骤1表面改性剂由聚环氧乙烷与硅烷偶联剂按照质量比为3:1的比例混合而成。
5.根据权利要求3所述的一种疏水性多孔陶瓷制品的制备工艺，其特征在于，所述步骤3中热压温度为160-180℃，热压压力为28-36Mpa，热压时间为35-40s。
6.根据权利要求3所述的一种疏水性多孔陶瓷制品的制备工艺，其特征在于，所述步骤4脱附剂由活性炭和正己烷按照质量比为3:5的比例混合而成。
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