CN109133853A - 一种耐高温珍珠岩绝热制品的工艺方法 - Google Patents

一种耐高温珍珠岩绝热制品的工艺方法 Download PDF

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CN109133853A
CN109133853A CN201810891330.2A CN201810891330A CN109133853A CN 109133853 A CN109133853 A CN 109133853A CN 201810891330 A CN201810891330 A CN 201810891330A CN 109133853 A CN109133853 A CN 109133853A
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雷泉兴
裘益奇
裘茂法
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Zhejiang Ask Building Materials Technology Co Ltd
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Abstract

本发明公开了一种耐高温珍珠岩绝热制品的工艺方法,包括以下步骤:1)配料、2)压制、3)硬化烘干、4)烧结成型、5)磨光和6)包装入库。本发明的工艺方法步骤简单,不仅提高了珍珠岩绝热制品的加工效率,而且可以同时加工多个坯体,大大缩短了加工时间,提高了珍珠岩绝热制品的加工质量。

Description

一种耐高温珍珠岩绝热制品的工艺方法
技术领域
本发明涉及一种耐高温珍珠岩绝热制品的工艺方法。
背景技术
珍珠岩绝热材料广泛用于冶金、化学、制药、冷藏、石油化工及建筑等行业,作为这些行业中的设备、管道、阀门、冷热附件及建筑物的绝热材料。为此要求绝热制品具有密度小,导热系数小,抗压及抗折强度大,含水量少、不燃、增水性强以及使用温度范围大等性能。
现有技术中在进行珍珠岩绝热制品加工时,由于只能单独对一个坯体进行硬化烘干,效率较低,不利于流水线生产,同时由于加热温度较为集中,容易对坯体造成局部温度升高过快而破裂,废品率较高。
发明内容
本发明目的在于针对现有技术所存在的不足而提供一种耐高温珍珠岩绝热制品的工艺方法的技术方案,该工艺方法步骤简单,不仅提高了珍珠岩绝热制品的加工效率,而且可以同时加工多个坯体,大大缩短了加工时间,提高了珍珠岩绝热制品的加工质量。
为了解决上述技术问题,本发明采用如下技术方案:
一种耐高温珍珠岩绝热制品的工艺方法,其特征在于包括以下步骤:
1)配料
a、首先以膨胀珍珠岩为骨料,用少量水润湿,按所用胶的比例取相应的膨胀珍珠岩放入烧杯中待用;
b、然后取一定量的固化剂,用水进行溶解,待用,按比例取瓷土、耐火粘土、水和粘结剂,放入搅拌器中搅拌5~8min后,按比例加入防水剂继续搅拌5~8min,按比例加入发泡剂,经过充分均匀混合发泡使其充分溶解;
c、接着将搅拌好的溶液倒入盛有膨胀珍珠岩的烧杯中,边倒入边搅拌,将混合料放入破碎机内进行破碎至10目存储;
2)压制
将筛分后的混合料预热至85℃,再倒入模具中进行温压成型,温压温度为50~60℃,压力为5~10Mpa,保温时间5~8min,放气3~4次,形成坯体;
3)硬化烘干
a、将压制好的坯体放入硬化烘干装置中,首先将坯体依次放置在装载盘上的装载孔内固定,并打开箱体上的防护门和肋条上的螺栓,使肋条打开,再将装载盘水平放置在套筒和定位板之间,通过肋条上的支撑块进行限位固定,直至将所有的装载盘安装完毕,插入螺栓将肋条闭合;
b、然后启动加热层内的加热丝,通过加热丝对箱体进行加热,实现对坯体的烘干;
c、接着启动驱动箱内的驱动电机,通过驱动电机经减速器带动驱动齿轮旋转,并带动齿轮盘旋转,齿轮盘上的限位槽带动限位块移动,进一步带动转动环转动,由转动环带动装载盘转动,使坯体受热均匀;
d、硬化烘干结束后,关闭驱动电机和加热层上的加热丝,通过端盖上的排气管进行排气,待箱体内的温度和压力下降至安全值时,打开防护门,并拆除螺栓,打开肋条将装载盘取出,再将硬化烘干后的坯体依次取出;
4)烧结成型
将硬化烘干后的坯体放入高温炉中进行煅烧,以7~10℃/min的升温速度将炉体加热至350℃,对坯体进行预热,以5~8℃/min的升温速度将炉体加热至550~650℃,保温80~120min,然后以10~15℃/min的降温速度冷却至室温;
5)磨光
将烧结成型后的绝热制品通过磨光机进行磨光处理,得到珍珠岩绝热制品成品;
6)包装入库
对珍珠岩绝热制品成品进行性能测试,将合格的成品直接包装入库。
进一步,步骤1)中的固化剂为芳香族多胺、甲基酚醛树脂、氨基树脂、双氰胺中的一种,粘结剂为磷酸二氢铝,防水剂为烷基硅醇盐、硅烷、硅树脂乳液中的一种,发泡剂为碳酸钙、硅酸钠、碳化硅中的一种,固化剂可以提高绝热制品的强度,防止出现裂缝,防水剂可以使绝热制品的吸水率和吸湿率有明显的下降,发泡剂可以有效降低绝热制品的导热系数。
进一步,步骤3)中的硬化烘干装置包括箱体、端盖和底座,端盖和底座分别位于箱体的上下两侧,箱体的左侧上部设置有驱动箱,驱动箱内设置有驱动机构,箱体内设置有固定环和硬化烘干筒,固定环通过卡座固定连接在箱体的内壁上,固定环上设置有通孔,固定环上设置有限位环和凹槽,限位环上套接有齿轮盘,齿轮盘与固定环之间设置有定位环,硬化烘干筒与通孔相匹配,硬化烘干筒的下方设置有加热层,箱体的右侧面上设置有防护门,通过驱动机构带动硬化烘干筒旋转,可以提高坯体的硬化烘干效率,使各个坯体受热均匀,防止出现坯体局部升温过快造成破裂,降低了次品率,限位环提高了齿轮盘旋转时的稳定性和可靠性,防止齿轮盘旋转发生偏离造成硬化烘干筒偏离,影响坯体的正常硬化烘干,加热层可以有效将箱体进行升温,使箱体达到硬化烘干所需的温度,防护门起到保护作用,便于放入和取出坯体。
进一步,凹槽围绕通孔的外圆周均匀分布,凹槽内设置有托轮,托轮的设计可以使齿轮悬空在固定环的上表面,减小齿轮旋转时的摩擦力,降低对齿轮的磨损,同时提高了硬化烘干筒旋转时的稳定性。
进一步,驱动机构包括驱动电机、减速器和驱动齿轮,驱动电机固定连接在U形框架的底部,减速器连接在驱动电机上,减速器位于U形框架内,U形框架固定连接在卡座上,U形框架的顶面上设置有支撑板,定位环上设置有U形块,驱动齿轮连接在减速器的上方,且位于U形块的顶面上,驱动齿轮与齿轮盘相互啮合,齿轮盘的内侧面上对称设置有限位槽,驱动电机可以通过减速器带动驱动齿轮旋转,进而带动齿轮盘旋转,U形框架提高了驱动电机和减速器安装时的稳定性,U形块提高了驱动齿轮旋转时的稳定性,防止出现滑齿而影响硬化烘干筒的正常旋转。
进一步,硬化烘干筒包括转动环、套筒、定位板、装载盘和竖向肋条,套筒固定连接在转动环的底部,转动环的外侧面上对称设置有限位块,限位块与限位槽相匹配,定位板位于套筒的下方,定位板通过竖向肋条连接套筒,定位板与套筒之间均匀设置有装载盘,竖向肋条上设置有锁紧块,左右相邻两个锁紧块之间通过螺栓连接,转动环可以通过限位块与齿轮盘连接,随齿轮盘一起旋转,套筒减小了与固定环内壁之间的摩擦力,竖向肋条的设计不仅有利于加热烘干,实现热空气的快速流动,而且便于将坯体存放和取出,装载盘可以一次性装载多个坯体,提高了绝热制品的硬化烘干效率,锁紧块和螺栓便于将肋条进行打开或关闭。
进一步,装载盘上均匀设置有装载孔,装载孔有利于将坯体进行限位固定,防止在进行硬化烘干时发生移动而发生碰撞。
进一步,竖向肋条上设置有支撑块,支撑块抵住装载盘,支撑块可以将装载盘进行上下分隔,便于同时放置多个坯体。
本发明由于采用了上述技术方案,具有以下有益效果:
1、本发明的工艺方法步骤简单,不仅提高了珍珠岩绝热制品的加工效率,而且可以同时加工多个坯体,大大缩短了加工时间,提高了珍珠岩绝热制品的加工质量。
2、本发明通过驱动机构带动硬化烘干筒旋转,可以提高坯体的硬化烘干效率,使各个坯体受热均匀,防止出现坯体局部升温过快造成破裂,降低了次品率。
3、限位环提高了齿轮盘旋转时的稳定性和可靠性,防止齿轮盘旋转发生偏离造成硬化烘干筒偏离,影响坯体的正常硬化烘干。
4、加热层可以有效将箱体进行升温,使箱体达到硬化烘干所需的温度,防护门起到保护作用,便于放入和取出坯体。
本发明的工艺方法步骤简单,不仅提高了珍珠岩绝热制品的加工效率,而且可以同时加工多个坯体,大大缩短了加工时间,提高了珍珠岩绝热制品的加工质量。
附图说明
下面结合附图对本发明作进一步说明:
图1为本发明一种耐高温珍珠岩绝热制品的工艺方法中硬化烘干装置的结构示意图;
图2为本发明中驱动机构与固定环的连接示意图;
图3为本发明中硬化烘干筒的结构示意图;
图4为本发明中装载盘的结构示意图;
图5为本发明中固定环的结构示意图;
图6为本发明中肋条的结构示意图。
图中:1-箱体;2-端盖;3-底座;4-驱动箱;5-固定环;6-硬化烘干筒;7-加热层;8-防护门;9-卡座;10-通孔;11-齿轮盘;12-限位槽;13-托轮;14-定位环;15-驱动齿轮;16-支撑板;17-U形框架;18-驱动电机;19-减速器;20-转动环;21-限位块;22-套筒;23-定位板;24-装载盘;25-竖向肋条;26-锁紧块;27-螺栓;28-装载孔;29-限位环;30-凹槽;31-U形块;32-支撑块。
具体实施方式
本发明一种耐高温珍珠岩绝热制品的工艺方法,包括以下步骤:
1)配料
a、首先以膨胀珍珠岩为骨料,用少量水润湿,按所用胶的比例取相应的膨胀珍珠岩放入烧杯中待用;
b、然后取一定量的固化剂,用水进行溶解,待用,按比例取瓷土、耐火粘土、水和粘结剂,放入搅拌器中搅拌5~8min后,按比例加入防水剂继续搅拌5~8min,按比例加入发泡剂,经过充分均匀混合发泡使其充分溶解;
c、接着将搅拌好的溶液倒入盛有膨胀珍珠岩的烧杯中,边倒入边搅拌,将混合料放入破碎机内进行破碎至10目存储;
其中固化剂为芳香族多胺、甲基酚醛树脂、氨基树脂、双氰胺中的一种,粘结剂为磷酸二氢铝,防水剂为烷基硅醇盐、硅烷、硅树脂乳液中的一种,发泡剂为碳酸钙、硅酸钠、碳化硅中的一种,固化剂可以提高绝热制品的强度,防止出现裂缝,防水剂可以使绝热制品的吸水率和吸湿率有明显的下降,发泡剂可以有效降低绝热制品的导热系数。
2)压制
将筛分后的混合料预热至85℃,再倒入模具中进行温压成型,温压温度为50~60℃,压力为5~10Mpa,保温时间5~8min,放气3~4次,形成坯体;
3)硬化烘干
a、将压制好的坯体放入硬化烘干装置中,首先将坯体依次放置在装载盘24上的装载孔28内固定,并打开箱体1上的防护门8和肋条上的螺栓27,使肋条打开,再将装载盘24水平放置在套筒22和定位板23之间,通过肋条上的支撑块32进行限位固定,直至将所有的装载盘24安装完毕,插入螺栓27将肋条闭合;
b、然后启动加热层7内的加热丝,通过加热丝对箱体1进行加热,实现对坯体的烘干;
c、接着启动驱动箱4内的驱动电机18,通过驱动电机18经减速器19带动驱动齿轮15旋转,并带动齿轮盘11旋转,齿轮盘11上的限位槽12带动限位块21移动,进一步带动转动环20转动,由转动环20带动装载盘24转动,使坯体受热均匀;
d、硬化烘干结束后,关闭驱动电机18和加热层7上的加热丝,通过端盖2上的排气管进行排气,待箱体1内的温度和压力下降至安全值时,打开防护门8,并拆除螺栓27,打开肋条将装载盘24取出,再将硬化烘干后的坯体依次取出;
如图1至图6所示,硬化烘干装置包括箱体1、端盖2和底座3,端盖2和底座3分别位于箱体1的上下两侧,箱体1的左侧上部设置有驱动箱4,驱动箱4内设置有驱动机构,箱体1内设置有固定环5和硬化烘干筒6,固定环5通过卡座9固定连接在箱体1的内壁上,固定环5上设置有通孔10,固定环5上设置有限位环29和凹槽30,凹槽30围绕通孔10的外圆周均匀分布,凹槽30内设置有托轮13,托轮13的设计可以使齿轮悬空在固定环5的上表面,减小齿轮旋转时的摩擦力,降低对齿轮的磨损,同时提高了硬化烘干筒6旋转时的稳定性,限位环29上套接有齿轮盘11,齿轮盘11与固定环5之间设置有定位环14,硬化烘干筒6与通孔10相匹配,硬化烘干筒6的下方设置有加热层7,箱体1的右侧面上设置有防护门8,通过驱动机构带动硬化烘干筒6旋转,可以提高坯体的硬化烘干效率,使各个坯体受热均匀,防止出现坯体局部升温过快造成破裂,降低了次品率,限位环29提高了齿轮盘11旋转时的稳定性和可靠性,防止齿轮盘11旋转发生偏离造成硬化烘干筒6偏离,影响坯体的正常硬化烘干,加热层7可以有效将箱体1进行升温,使箱体1达到硬化烘干所需的温度,防护门8起到保护作用,便于放入和取出坯体。
驱动机构包括驱动电机18、减速器19和驱动齿轮15,驱动电机18固定连接在U形框架17的底部,减速器19连接在驱动电机18上,减速器19位于U形框架17内,U形框架17固定连接在卡座9上,U形框架17的顶面上设置有支撑板16,定位环14上设置有U形块31,驱动齿轮15连接在减速器19的上方,且位于U形块31的顶面上,驱动齿轮15与齿轮盘11相互啮合,齿轮盘11的内侧面上对称设置有限位槽12,驱动电机18可以通过减速器19带动驱动齿轮15旋转,进而带动齿轮盘11旋转,U形框架17提高了驱动电机18和减速器19安装时的稳定性,U形块31提高了驱动齿轮15旋转时的稳定性,防止出现滑齿而影响硬化烘干筒6的正常旋转。
硬化烘干筒6包括转动环20、套筒22、定位板23、装载盘24和竖向肋条25,套筒22固定连接在转动环20的底部,转动环20的外侧面上对称设置有限位块21,限位块21与限位槽12相匹配,定位板23位于套筒22的下方,定位板23通过竖向肋条25连接套筒22,定位板23与套筒22之间均匀设置有装载盘24,竖向肋条25上设置有锁紧块26,左右相邻两个锁紧块26之间通过螺栓27连接,转动环20可以通过限位块21与齿轮盘11连接,随齿轮盘11一起旋转,套筒22减小了与固定环5内壁之间的摩擦力,竖向肋条25的设计不仅有利于加热烘干,实现热空气的快速流动,而且便于将坯体存放和取出,装载盘24可以一次性装载多个坯体,提高了绝热制品的硬化烘干效率,锁紧块26和螺栓27便于将肋条进行打开或关闭,装载盘24上均匀设置有装载孔28,装载孔28有利于将坯体进行限位固定,防止在进行硬化烘干时发生移动而发生碰撞,竖向肋条25上设置有支撑块32,支撑块32抵住装载盘24,支撑块32可以将装载盘24进行上下分隔,便于同时放置多个坯体。
4)烧结成型
将硬化烘干后的坯体放入高温炉中进行煅烧,以7~10℃/min的升温速度将炉体加热至350℃,对坯体进行预热,以5~8℃/min的升温速度将炉体加热至550~650℃,保温80~120min,然后以10~15℃/min的降温速度冷却至室温;
5)磨光
将烧结成型后的绝热制品通过磨光机进行磨光处理,得到珍珠岩绝热制品成品;
6)包装入库
对珍珠岩绝热制品成品进行性能测试,将合格的成品直接包装入库。
使用磷酸盐(磷酸二氢铝)作为粘结材料,配制能使磷酸二氢铝粘结剂在<150℃的温度下进行固化的高效固化剂,固化后达到抗折强度≥1.0MPa,抗压强度≥2.0MPa,导热系数≤0.060w/m.k的保温材料,最高使用温度为1000℃。极大提高了珍珠岩绝热制品的保温性能,耐温度性能等。
以上仅为本发明的具体实施例,但本发明的技术特征并不局限于此。任何以本发明为基础,为实现基本相同的技术效果,所作出地简单变化、等同替换或者修饰等,皆涵盖于本发明的保护范围之中。

Claims (8)

1.一种耐高温珍珠岩绝热制品的工艺方法,其特征在于包括以下步骤:
1)配料
a、首先以膨胀珍珠岩为骨料,用少量水润湿,按所用胶的比例取相应的膨胀珍珠岩放入烧杯中待用;
b、然后取一定量的固化剂,用水进行溶解,待用,按比例取瓷土、耐火粘土、水和粘结剂,放入搅拌器中搅拌5~8min后,按比例加入防水剂继续搅拌5~8min,按比例加入发泡剂,经过充分均匀混合发泡使其充分溶解;
c、接着将搅拌好的溶液倒入盛有膨胀珍珠岩的烧杯中,边倒入边搅拌,将混合料放入破碎机内进行破碎至10目存储;
2)压制
将筛分后的混合料预热至85℃,再倒入模具中进行温压成型,温压温度为50~60℃,压力为5~10Mpa,保温时间5~8min,放气3~4次,形成坯体;
3)硬化烘干
a、将压制好的坯体放入硬化烘干装置中,首先将坯体依次放置在装载盘上的装载孔内固定,并打开箱体上的防护门和肋条上的螺栓,使肋条打开,再将装载盘水平放置在套筒和定位板之间,通过肋条上的支撑块进行限位固定,直至将所有的装载盘安装完毕,插入螺栓将肋条闭合;
b、然后启动加热层内的加热丝,通过加热丝对箱体进行加热,实现对坯体的烘干;
c、接着启动驱动箱内的驱动电机,通过驱动电机经减速器带动驱动齿轮旋转,并带动齿轮盘旋转,齿轮盘上的限位槽带动限位块移动,进一步带动转动环转动,由转动环带动装载盘转动,使坯体受热均匀;
d、硬化烘干结束后,关闭驱动电机和加热层上的加热丝,通过端盖上的排气管进行排气,待箱体内的温度和压力下降至安全值时,打开防护门,并拆除螺栓,打开肋条将装载盘取出,再将硬化烘干后的坯体依次取出;
4)烧结成型
将硬化烘干后的坯体放入高温炉中进行煅烧,以7~10℃/min的升温速度将炉体加热至350℃,对坯体进行预热,以5~8℃/min的升温速度将炉体加热至550~650℃,保温80~120min,然后以10~15℃/min的降温速度冷却至室温;
5)磨光
将烧结成型后的绝热制品通过磨光机进行磨光处理,得到珍珠岩绝热制品成品;
6)包装入库
对珍珠岩绝热制品成品进行性能测试,将合格的成品直接包装入库。
2.根据权利要求1所述的一种耐高温珍珠岩绝热制品的工艺方法,其特征在于:步骤1)中的所述固化剂为芳香族多胺、甲基酚醛树脂、氨基树脂、双氰胺中的一种,所述粘结剂为磷酸二氢铝,所述防水剂为烷基硅醇盐、硅烷、硅树脂乳液中的一种,所述发泡剂为碳酸钙、硅酸钠、碳化硅中的一种。
3.根据权利要求1所述的一种耐高温珍珠岩绝热制品的工艺方法,其特征在于:步骤3)中的所述硬化烘干装置包括箱体、端盖和底座,所述端盖和所述底座分别位于所述箱体的上下两侧,所述箱体的左侧上部设置有驱动箱,所述驱动箱内设置有驱动机构,所述箱体内设置有固定环和硬化烘干筒,所述固定环通过卡座固定连接在所述箱体的内壁上,所述固定环上设置有通孔,所述固定环上设置有限位环和凹槽,所述限位环上套接有齿轮盘,所述齿轮盘与所述固定环之间设置有定位环,所述硬化烘干筒与所述通孔相匹配,所述硬化烘干筒的下方设置有加热层,所述箱体的右侧面上设置有防护门。
4.根据权利要求3所述的一种耐高温珍珠岩绝热制品的工艺方法,其特征在于:所述凹槽围绕所述通孔的外圆周均匀分布,所述凹槽内设置有托轮。
5.根据权利要求3所述的一种耐高温珍珠岩绝热制品的工艺方法,其特征在于:所述驱动机构包括驱动电机、减速器和驱动齿轮,所述驱动电机固定连接在U形框架的底部,所述减速器连接在所述驱动电机上,所述减速器位于所述U形框架内,所述U形框架固定连接在所述卡座上,所述U形框架的顶面上设置有支撑板,所述定位环上设置有U形块,所述驱动齿轮连接在所述减速器的上方,且位于所述U形块的顶面上,所述驱动齿轮与所述齿轮盘相互啮合,所述齿轮盘的内侧面上对称设置有限位槽。
6.根据权利要求5所述的一种耐高温珍珠岩绝热制品的工艺方法,其特征在于:所述硬化烘干筒包括转动环、套筒、定位板、装载盘和竖向肋条,所述套筒固定连接在所述转动环的底部,所述转动环的外侧面上对称设置有限位块,所述限位块与所述限位槽相匹配,所述定位板位于所述套筒的下方,所述定位板通过所述竖向肋条连接所述套筒,所述定位板与所述套筒之间均匀设置有所述装载盘,所述竖向肋条上设置有锁紧块,左右相邻两个所述锁紧块之间通过螺栓连接。
7.根据权利要求6所述的一种耐高温珍珠岩绝热制品的工艺方法,其特征在于:所述装载盘上均匀设置有装载孔。
8.根据权利要求6所述的一种耐高温珍珠岩绝热制品的工艺方法,其特征在于:所述竖向肋条上设置有支撑块,所述支撑块抵住所述装载盘。
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