CN109133960A - 一种多孔轻质陶瓷吸音板的制备方法 - Google Patents
一种多孔轻质陶瓷吸音板的制备方法 Download PDFInfo
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Abstract
本发明公开了一种多孔轻质陶瓷吸音板的制备方法,属于建筑材料技术领域。本发明按重量份数计,将20~30份竹纤维,2~3份巴氏芽孢杆菌菌液,2~3份尿素,30~40份水混合发酵,接着滴加入竹纤维质量0.1~0.2倍的硝酸钙溶液,冷冻,球磨,过筛,过滤,干燥,炭化,即得改性纤维;按重量份数计,将20~30份骨料,5~8份造孔剂,20~30份高温粘结剂,3~4份烧结助剂,10~20份改性纤维,10~20份改性添加料,40~50份水,搅拌混合,得混合浆料;将混合浆料注入模具中,模压成型,脱模,充氮保温反应,降温,即得多孔轻质陶瓷吸音板。本发明技术方案制备的多孔轻质陶瓷吸音板具有优异的吸音效果和力学性能的特点。
Description
技术领域
本发明公开了一种多孔轻质陶瓷吸音板的制备方法,属于建筑材料技术领域。
背景技术
建筑材料的发展使得建筑装饰中可采用的材料越来越多,吸音板作为一种装饰材料,通过大量的工程实践表明,建筑装饰中使用的吸声板具有吸音、环保、保温、防潮、施工简便以及颜色丰富等优势。现阶段在录音室、演播厅、音乐厅、影剧院、会议室、体育馆等相关建筑中均有应用。现阶段可采用的吸音板材料较多,比如木质吸音板、布艺软包、干挂装饰护墙板、木石板、木丝板等等,当然不同吸音板材料在使用方面存在一定特点。木吸音板作为常用的吸音板材料,也就是在密度板的正面以及背面开设一定的圆孔,依靠圆孔结构达到吸声目的。随着应用的研究,现阶段采用的木吸音板同时具备了隔热、质轻、不改性、防火、防尘、不腐烂等特点,具有较好的吸声效果,且材料本身强度较高。软包吸音板中主要是布艺吸音板,整个吸音结构是以塑胶边框、树脂固化边框、铝合金边框或木质边框为主,然后在框内放置特制吸音棉板,对吸音棉板进行微孔化处理,并在外部包装防火吸音布。木丝吸音板的主要原材料为白杨木纤维,整个结构的结实性,且抗菌防潮性较好,后期安装也相对于简单。吸音材料不仅需要具有足够的耐久程度、防水,耐火,耐腐蚀,而且吸音性能符合地铁内的噪声特性,需要材料的降噪效果好并具有足够的强度和抵抗气流冲击的性能。对于普通的吸音材料无法胜任地铁的特殊环境,而陶粒多孔吸音材料属于水泥基多孔吸音材料,其保持了水泥基多孔吸音材料的基本特性,它具有足够的耐久程度、防水,耐火,耐腐蚀,且降噪效果好,具有足够的强度和抵抗气流冲击的性能,适合作为吸音板的原材料。
而传统陶瓷吸音板还存在吸音效果和力学性能无法进一步提高的问题。因此,如何改善传统陶瓷吸音板的缺点,以获取更高综合性能的提升,是其推广与应用于更广阔的领域,满足工业生产需求亟待解决的问题。
发明内容
本发明主要解决的技术问题是:针对传统防陶瓷吸音板存在吸音效果和力学性能无法进一步提高的问题,提供了一种多孔轻质陶瓷吸音板的制备方法。
为了解决上述技术问题,本发明所采用的技术方案是:
一种多孔轻质陶瓷吸音板的制备方法,具体制备步骤如下:
(1)按重量份数计,将20~30份竹纤维,2~3份巴氏芽孢杆菌菌液,2~3份尿素,30~40份水混合发酵,接着滴加入竹纤维质量0.1~0.2倍的硝酸钙溶液,冷冻,球磨,过筛,过滤,干燥,炭化,即得改性纤维;
(2)按重量份数计,将20~30份骨料,5~8份造孔剂,20~30份高温粘结剂,3~4份烧结助剂,10~20份改性纤维,10~20份改性添加料,40~50份水,搅拌混合,得混合浆料;
(3)将混合浆料注入模具中,模压成型,脱模,充氮保温反应,降温,即得多孔轻质陶瓷吸音板。
步骤(1)所述巴氏芽孢杆菌菌液是由以下重量份数的原料组成:2~3份巴氏芽孢杆菌,1~2份甘油,10~20份去离子水。
步骤(2)所述骨料为α-氧化铝,莫来石或碳化硅中的任意一种。
步骤(2)所述造孔剂为羧甲基纤维素,淀粉,糊精,微晶纤维素或烷基苯磺酸钠中的任意一种。
步骤(2)所述高温粘结剂所述高温粘结剂为高岭土或粘土中的任意一种。
步骤(2)所述烧结助剂为二氧化钛,氧化铜,氧化钡或二氧化硅中的任意一种。
步骤(2)所述改性添加料的制备过程为:将稻壳置于球磨机中粉碎,过筛,得稻壳粉末,再将稻壳粉末置于炭化炉中,通入氮气高温炭化,得炭化稻壳粉末,随后将炭化稻壳粉末和高锰酸钾溶液按质量比1:50~1:100加热搅拌反应,同时滴加盐酸,调节pH,过滤洗涤,干燥,即得改性添加料。
本发明的有益效果是:
本发明通过添加改性纤维,在制备过程中,首先,将竹纤维,巴氏芽孢杆菌菌液,尿素,水混合发酵,接着滴加入硝酸钙溶液,巴氏芽孢杆菌在新陈代谢过程中产生脲酶,脲酶可将体系中的尿素分解生成碳酸根离子和铵根离子,由于巴氏芽孢杆菌细胞壁表面带负电荷,体系中的钙离子会被巴氏芽孢杆菌细胞壁吸附,从而以细胞为晶核,在细菌周围会生成碳酸钙,形成碳酸钙微球,沉积在纤维中,接着经过冷冻使得纤维间和碳酸钙微球中形成冰晶,接着经过冷冻球磨,在球磨挤压力的作用下破裂,形成纳米级的晶须分散在体系中,接着经过炭化,木质纤维孔高度集成,消除了木材的内应力,使木材更坚固,并且不再热胀冷缩,且纳米级的纤维晶须更易伸直,分散性得到提升,从而使得体系的力学性能得到提升,同时,内部的碳酸钙受热分解,生成氧化钙,在混料过程中,体系中的氧化钙与水反应放出大量的热量,大量热量在体系中不均匀的扩散,使得体系中形成大量的气泡,使得体系的孔隙率得到提升,从而进一步提升了体系的隔音降噪性能,另外,在高温烧结过程中,体系中的改性纤维进一步石墨化,从而使得体系的力学性能得到进一步的提升。
具体实施方式
按重量份数计,将2~3份巴氏芽孢杆菌,1~2份甘油,10~20份去离子水置于1号烧杯中,接着将1号烧杯置于数显测速恒温磁力搅拌器中,于温度为30~35℃,转速为300~500r/min条件下,搅拌混合40~60min,得巴氏芽孢杆菌菌液;将稻壳置于球磨机中,于转速为400~500r/min条件下粉碎后,过300~400目的筛,得稻壳粉末,再将稻壳粉末置于炭化炉中,以60~90mL/min向炉内通入氮气,于氮气保护状态下,于温度为550~600℃,转速为100~200mL/min条件下高温炭化1~2h,得炭化稻壳粉末,随后将炭化稻壳粉末和质量分数为10~20%的高锰酸钾溶液按质量比1:50~1:100加入三口烧瓶中,再将三口烧瓶移至数显测速恒温磁力搅拌器中,于温度85~95℃,转速为400~500r/min条件下,加热搅拌混合40~50min,同时用恒压滴液漏斗以2.5mL/min速率滴加质量分数为8~10%盐酸40~50min,待质量分数为8~10%盐酸滴加完毕,于温度为85~95℃,转速为500~600r/min条件下,加热搅拌反应30~40min,反应完毕后,用恒压滴液漏斗以2.5mL/min速率滴加质量分数为10~20%氨水调节pH至7.1~7.3,得反应混合液,随后将反应混合液过滤,得滤饼,再将滤饼置于真空冷冻干燥箱中干燥50~60min,即得改性添加料;按重量份数计,将20~30份竹纤维,2~3份巴氏芽孢杆菌菌液,2~3份尿素,30~40份水置于发酵釜中,于温度为30~35℃,转速为400~600r/min条件下,混合发酵3~5天,接着向发酵釜中滴加入竹纤维质量0.1~0.2倍质量分数为10~20%的硝酸钙溶液,得发酵混合液,再将发酵混合液置于液氮中冷冻,得冷冻块,接着将冷冻块置于球磨机中球磨,过300目的筛,得球磨料,接着将球磨料置于室温条件下解冻,得混合浆液,接着将混合浆液过滤,得滤渣,接着将滤渣置于干燥箱中,于温度为105~110℃条件下,干燥至恒重,得干燥滤渣,接着将干燥滤渣置于炭化炉中,并以60~90mL/min速率向炉内充入氮气,于温度为850~950℃条件下,炭化2~3h,即得改性纤维;按重量份数计,将20~30份骨料,5~8份造孔剂,20~30份高温粘结剂,3~4份烧结助剂,10~20份改性纤维,10~20份改性添加料,40~50份水置于混料机中,于转速为100~200r/min条件下,搅拌混合40~60min,得混合浆料;向模具表面喷洒废弃机油,将混合浆料注入模具中,接着将模具置于成型机中,于压力为1~2MPa条件下,模压成型后,脱模,得坯料,接着将坯料置于烧结炉中,并以110~120mL/min速率向炉内充入氩气,于温度为1350~1550℃条件下,充氮保温反应2~3h后,随炉将至室温,即得多孔轻质陶瓷吸音板。所述骨料为α-氧化铝,莫来石或碳化硅中的任意一种。所述造孔剂为羧甲基纤维素,淀粉,糊精,微晶纤维素或烷基苯磺酸钠中的任意一种。所述高温粘结剂所述高温粘结剂为高岭土或粘土中的任意一种。所述烧结助剂为二氧化钛,氧化铜,氧化钡或二氧化硅中的任意一种。
按重量份数计,将3份巴氏芽孢杆菌,2份甘油,20份去离子水置于1号烧杯中,接着将1号烧杯置于数显测速恒温磁力搅拌器中,于温度为35℃,转速为500r/min条件下,搅拌混合60min,得巴氏芽孢杆菌菌液;将稻壳置于球磨机中,于转速为500r/min条件下粉碎后,过400目的筛,得稻壳粉末,再将稻壳粉末置于炭化炉中,以90mL/min向炉内通入氮气,于氮气保护状态下,于温度为600℃,转速为200mL/min条件下高温炭化2h,得炭化稻壳粉末,随后将炭化稻壳粉末和质量分数为20%的高锰酸钾溶液按质量比1:100加入三口烧瓶中,再将三口烧瓶移至数显测速恒温磁力搅拌器中,于温度95℃,转速为500r/min条件下,加热搅拌混合50min,同时用恒压滴液漏斗以2.5mL/min速率滴加质量分数为10%盐酸50min,待质量分数为10%盐酸滴加完毕,于温度为95℃,转速为600r/min条件下,加热搅拌反应40min,反应完毕后,用恒压滴液漏斗以2.5mL/min速率滴加质量分数为20%氨水调节pH至7.3,得反应混合液,随后将反应混合液过滤,得滤饼,再将滤饼置于真空冷冻干燥箱中干燥60min,即得改性添加料;按重量份数计,将30份竹纤维,3份巴氏芽孢杆菌菌液,3份尿素,40份水置于发酵釜中,于温度为35℃,转速为600r/min条件下,混合发酵5天,接着向发酵釜中滴加入竹纤维质量0.2倍质量分数为20%的硝酸钙溶液,得发酵混合液,再将发酵混合液置于液氮中冷冻,得冷冻块,接着将冷冻块置于球磨机中球磨,过300目的筛,得球磨料,接着将球磨料置于室温条件下解冻,得混合浆液,接着将混合浆液过滤,得滤渣,接着将滤渣置于干燥箱中,于温度为110℃条件下,干燥至恒重,得干燥滤渣,接着将干燥滤渣置于炭化炉中,并以90mL/min速率向炉内充入氮气,于温度为950℃条件下,炭化3h,即得改性纤维;按重量份数计,将30份骨料,8份造孔剂,30份高温粘结剂,4份烧结助剂,20份改性纤维,20份改性添加料,50份水置于混料机中,于转速为200r/min条件下,搅拌混合60min,得混合浆料;向模具表面喷洒废弃机油,将混合浆料注入模具中,接着将模具置于成型机中,于压力为2MPa条件下,模压成型后,脱模,得坯料,接着将坯料置于烧结炉中,并以120mL/min速率向炉内充入氩气,于温度为1550℃条件下,充氮保温反应3h后,随炉将至室温,即得多孔轻质陶瓷吸音板。所述骨料为α-氧化铝。所述造孔剂为羧甲基纤维素。所述高温粘结剂所述高温粘结剂为高岭土。所述烧结助剂为二氧化钛。
按重量份数计,将3份巴氏芽孢杆菌,2份甘油,20份去离子水置于1号烧杯中,接着将1号烧杯置于数显测速恒温磁力搅拌器中,于温度为35℃,转速为500r/min条件下,搅拌混合60min,得巴氏芽孢杆菌菌液;将稻壳置于球磨机中,于转速为500r/min条件下粉碎后,过400目的筛,得稻壳粉末,再将稻壳粉末置于炭化炉中,以90mL/min向炉内通入氮气,于氮气保护状态下,于温度为600℃,转速为200mL/min条件下高温炭化2h,得炭化稻壳粉末,随后将炭化稻壳粉末和质量分数为20%的高锰酸钾溶液按质量比1:100加入三口烧瓶中,再将三口烧瓶移至数显测速恒温磁力搅拌器中,于温度95℃,转速为500r/min条件下,加热搅拌混合50min,同时用恒压滴液漏斗以2.5mL/min速率滴加质量分数为10%盐酸50min,待质量分数为10%盐酸滴加完毕,于温度为95℃,转速为600r/min条件下,加热搅拌反应40min,反应完毕后,用恒压滴液漏斗以2.5mL/min速率滴加质量分数为20%氨水调节pH至7.3,得反应混合液,随后将反应混合液过滤,得滤饼,再将滤饼置于真空冷冻干燥箱中干燥60min,即得改性添加料;按重量份数计,将30份骨料,8份造孔剂,30份高温粘结剂,4份烧结助剂,20份改性添加料,50份水置于混料机中,于转速为200r/min条件下,搅拌混合60min,得混合浆料;向模具表面喷洒废弃机油,将混合浆料注入模具中,接着将模具置于成型机中,于压力为2MPa条件下,模压成型后,脱模,得坯料,接着将坯料置于烧结炉中,并以120mL/min速率向炉内充入氩气,于温度为1550℃条件下,充氮保温反应3h后,随炉将至室温,即得多孔轻质陶瓷吸音板。所述骨料为α-氧化铝。所述造孔剂为羧甲基纤维素。所述高温粘结剂所述高温粘结剂为高岭土。所述烧结助剂为二氧化钛。
按重量份数计,将3份巴氏芽孢杆菌,2份甘油,20份去离子水置于1号烧杯中,接着将1号烧杯置于数显测速恒温磁力搅拌器中,于温度为35℃,转速为500r/min条件下,搅拌混合60min,得巴氏芽孢杆菌菌液;按重量份数计,将30份竹纤维,3份巴氏芽孢杆菌菌液,3份尿素,40份水置于发酵釜中,于温度为35℃,转速为600r/min条件下,混合发酵5天,接着向发酵釜中滴加入竹纤维质量0.2倍质量分数为20%的硝酸钙溶液,得发酵混合液,再将发酵混合液置于液氮中冷冻,得冷冻块,接着将冷冻块置于球磨机中球磨,过300目的筛,得球磨料,接着将球磨料置于室温条件下解冻,得混合浆液,接着将混合浆液过滤,得滤渣,接着将滤渣置于干燥箱中,于温度为110℃条件下,干燥至恒重,得干燥滤渣,接着将干燥滤渣置于炭化炉中,并以90mL/min速率向炉内充入氮气,于温度为950℃条件下,炭化3h,即得改性纤维;按重量份数计,将30份骨料,8份造孔剂,30份高温粘结剂,4份烧结助剂,20份改性纤维,50份水置于混料机中,于转速为200r/min条件下,搅拌混合60min,得混合浆料;向模具表面喷洒废弃机油,将混合浆料注入模具中,接着将模具置于成型机中,于压力为2MPa条件下,模压成型后,脱模,得坯料,接着将坯料置于烧结炉中,并以120mL/min速率向炉内充入氩气,于温度为1550℃条件下,充氮保温反应3h后,随炉将至室温,即得多孔轻质陶瓷吸音板。所述骨料为α-氧化铝。所述造孔剂为羧甲基纤维素。所述高温粘结剂所述高温粘结剂为高岭土。所述烧结助剂为二氧化钛。
对比例:佛山某材料生产有限公司生产的陶瓷吸音板。
将实例1至实例3所得的多孔轻质陶瓷吸音板及对比例产品进行性能检测,具体检测方法如下:
检测上述试件在500Hz,2000Hz和4000Hz时的吸声率并检测抗压强度。
具体检测结果如表1所示:
表1多孔轻质陶瓷吸音板具体检测结果
由表1检测结果可知,本发明技术方案制备的多孔轻质陶瓷吸音板具有优异的吸音效果和力学性能的特点,在建筑材料技术行业的发展中具有广阔的前景。
Claims (7)
1.一种多孔轻质陶瓷吸音板的制备方法,其特征在于具体制备步骤如下:
(1)按重量份数计,将20~30份竹纤维,2~3份巴氏芽孢杆菌菌液,2~3份尿素,30~40份水混合发酵,接着滴加入竹纤维质量0.1~0.2倍的硝酸钙溶液,冷冻,球磨,过筛,过滤,干燥,炭化,即得改性纤维;
(2)按重量份数计,将20~30份骨料,5~8份造孔剂,20~30份高温粘结剂,3~4份烧结助剂,10~20份改性纤维,10~20份改性添加料,40~50份水,搅拌混合,得混合浆料;
(3)将混合浆料注入模具中,模压成型,脱模,充氮保温反应,降温,即得多孔轻质陶瓷吸音板。
2.根据权利要求1所述一种多孔轻质陶瓷吸音板的制备方法,其特征在于:步骤(1)所述巴氏芽孢杆菌菌液是由以下重量份数的原料组成:2~3份巴氏芽孢杆菌,1~2份甘油,10~20份去离子水。
3.根据权利要求1所述一种多孔轻质陶瓷吸音板的制备方法,其特征在于:步骤(2)所述骨料为α-氧化铝,莫来石或碳化硅中的任意一种。
4.根据权利要求1所述一种多孔轻质陶瓷吸音板的制备方法,其特征在于:步骤(2)所述造孔剂为羧甲基纤维素,淀粉,糊精,微晶纤维素或烷基苯磺酸钠中的任意一种。
5.根据权利要求1所述一种多孔轻质陶瓷吸音板的制备方法,其特征在于:步骤(2)所述高温粘结剂所述高温粘结剂为高岭土或粘土中的任意一种。
6.根据权利要求1所述一种多孔轻质陶瓷吸音板的制备方法,其特征在于:步骤(2)所述烧结助剂为二氧化钛,氧化铜,氧化钡或二氧化硅中的任意一种。
7.根据权利要求1所述一种多孔轻质陶瓷吸音板的制备方法,其特征在于:步骤(2)所述改性添加料的制备过程为:将稻壳置于球磨机中粉碎,过筛,得稻壳粉末,再将稻壳粉末置于炭化炉中,通入氮气高温炭化,得炭化稻壳粉末,随后将炭化稻壳粉末和高锰酸钾溶液按质量比1:50~1:100加热搅拌反应,同时滴加盐酸,调节pH,过滤洗涤,干燥,即得改性添加料。
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