CN109231995A - 一种碳化硅泡沫陶瓷制备工艺 - Google Patents

一种碳化硅泡沫陶瓷制备工艺 Download PDF

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CN109231995A
CN109231995A CN201811217887.4A CN201811217887A CN109231995A CN 109231995 A CN109231995 A CN 109231995A CN 201811217887 A CN201811217887 A CN 201811217887A CN 109231995 A CN109231995 A CN 109231995A
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王宏德
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Abstract

本发明提供了一种碳化硅泡沫陶瓷制备工艺，本发明中的聚氨酯泡沫是经过特定的发泡工艺制作而成，聚氨酯泡沫的水解率可达到4.2％，在较低温度下便可达到软化，是制备泡沫陶瓷特别适合的模板，当加热烧掉聚氨酯泡沫时，可以通过控制升温速率，使其不产生任何应力，保证未烧结体不发生开裂现象，可提高烧结体的力学强度；另外，本发明针对模板复制法制备碳化硅泡沫陶瓷挂浆过程中，聚氨酯泡沫隔膜多、亲水性差的特点，采用氢氧化钠溶液对聚氨酯泡沫进行水解处理，去除隔膜，增加粗糙度，取得了较好的挂浆效果。

Description

一种碳化硅泡沫陶瓷制备工艺
技术领域
本发明涉及一种陶瓷领域，具体是一种碳化硅泡沫陶瓷制备工艺。
背景技术
在泡沫陶瓷的生产工艺过程中，泡沫起到了两个重要的作用：一是挂浆的作用。在这个过程中，泡沫需要具有好的弹性性能；因为当陶瓷浆料经过辊压均匀分布到泡沫经络和节点上时，泡沫需要承受浆料比重带来的重力；如果弹性不好，陶瓷坯体将无法成型。二是骨架的作用。干燥好的泡沫陶瓷坯体，最后要放入窑炉内高温烧成；在烧成过程中，泡沫会随着温度的逐步升高而慢慢融化，融化过程如果太快，或者泡沫自身耐热度不够，都会导致陶瓷坯体坍塌或者严重开裂，所以需要泡沫具有高的开孔率和强度。
泡沫陶瓷的制备工艺很多，如添加造孔剂工艺、发泡工艺、有机泡沫浸渍工艺、溶胶-凝胶工艺、固态颗粒烧结工艺等，其中，发泡工艺与有机泡沫浸渍工艺是制备高气孔率多孔陶瓷的有效方法，用这两种方法制备的泡沫陶瓷孔径通常达到微纳米级，但发泡反应法的缺点是对原料要求高，工艺条件不易控制。
发明内容
本发明为了解决上述现有技术所存在的不足之处，提供了一种挂浆效果好、性能优良的碳化硅泡沫陶瓷制备工艺。
本发明提供了一种碳化硅泡沫陶瓷制备工艺，包括以下步骤：
1)称取一定量的孔径为5μm碳化硅微粉和一定量的水洗高岭土放入搅拌罐中混合均匀后，加入水和磷酸二氢铝，搅拌2-3h后得到浆料，然后密封浆料24h，其中碳化硅微粉占混合浆料的35wt％-60wt％，磷酸二氢铝占混合浆料的25wt％-40wt％；
2)取开气孔率＞99％、孔径为0.2-0.8mm的聚氨酯泡沫，用去离子水反复冲洗5次除去杂质后浸入温度为60℃、浓度为15wt％的氢氧化钠溶液中水解1-6h，水解结束后取出聚氨酯泡沫，反复揉搓并用清水冲洗晾干；
3)将步骤2)处理后的聚氨酯泡沫置于步骤1)的浆料中，使聚氨酯泡沫自由伸展后，不断搅拌挤压揉搓，以使浆料均匀涂挂在聚氨酯泡沫上，充分排气吸浆后，放入对辊机中按1/6-1/3的挤压比进行挤压排浆，得到泡沫陶瓷预制体；
4)将泡沫陶瓷预制体放入50℃恒温烘箱中干燥48h，干燥前期防止浆料因重力作用集中在泡沫预制体的底部，每隔1h将泡沫预制体翻转一次，使其水份缓慢蒸发，防止泡沫预制体变形；由于浸渍浆料过程中对有机泡沫的揉搓挤压影响，它恢复原来的形状需要一定的时间，同时机泡沫吸附浆料后，由于受重力作用的影响，容易产生变形，如不对其干燥而直接进行烧成，泡沫陶瓷形状会受影响，塌陷甚至断裂；
5)将干燥后的泡沫预制体放入箱式电阻炉进行烧结，炉内温度为室温-800℃时，升温速率设定为100℃/h，炉内温度为800℃-1500℃时，升温速率设定为300℃/h，当温度升到1500℃后，停止升温并保温2h，然后随炉冷却，得到碳化硅泡沫陶瓷。
进一步地，聚氨酯泡沫为弹性开孔网状结构，良好的弹性以使泡沫在浸渍挂浆后仍能恢复原有形状，同时，开孔网状结构保证浆料涂覆时，能够渗入模板内部，相互粘结，使烧成后能够形成三维网状结构。
进一步地，聚氨酯泡沫在低于陶瓷烧成温度下可挥发，使得陶瓷不被污染，聚氨酯泡沫具有良好的亲水性，使得陶瓷浆料能更好的吸附。
与现有技术相比，本发明的聚氨酯泡沫是经过特定的发泡工艺制作而成，聚氨酯泡沫的水解率可达到4.2％，在较低温度下便可达到软化，是制备泡沫陶瓷特别适合的模板，当加热烧掉聚氨酯泡沫时，可以通过控制升温速率，使其不产生任何应力，保证未烧结体不发生开裂现象，可提高烧结体的力学强度。另外，本发明针对模板复制法制备碳化硅泡沫陶瓷挂浆过程中，聚氨酯泡沫隔膜多、亲水性差的特点，采用氢氧化钠溶液对聚氨酯泡沫进行水解处理，去除隔膜，增加粗糙度，取得了较好的挂浆效果。
具体实施方式
为了进一步理解本发明，下面结合实施例对本发明优选实施方案进行描述，但是应当理解，这些描述只是为进一步说明本发明的特征和优点，而不是对本发明权利要求的限制。
实施例一
一种碳化硅泡沫陶瓷制备工艺，步骤如下：
1)称取一定量的孔径为5μm碳化硅微粉和一定量的水洗高岭土放入搅拌罐中混合均匀后，加入水和磷酸二氢铝，搅拌2h后得到浆料，然后密封浆料24h，其中碳化硅微粉占混合浆料的60wt％，磷酸二氢铝占混合浆料的25wt％；
2)取开气孔率＞99％、孔径为0.6mm的聚氨酯泡沫，用去离子水反复冲洗5次除去杂质后浸入温度为60℃、浓度为15wt％的氢氧化钠溶液中水解4h，水解率为4.2％，水解结束后取出聚氨酯泡沫，反复揉搓并用清水冲洗晾干；
3)将步骤2)处理后的聚氨酯泡沫置于步骤1)的浆料中，使聚氨酯泡沫自由伸展后，不断搅拌挤压揉搓，以使浆料均匀涂挂在聚氨酯泡沫上，充分排气吸浆后，放入对辊机中按1/5的挤压比进行挤压排浆，得到泡沫陶瓷预制体，得到的泡沫陶瓷骨架结构粗壮，微裂纹基本没有，通孔结构良好；
4)将泡沫陶瓷预制体放入50℃恒温烘箱中干燥48h，每隔1h将泡沫预制体翻转一次，使其水份缓慢蒸发，防止泡沫预制体变形；
5)将干燥后的泡沫预制体放入箱式电阻炉进行烧结，炉内温度为室温-800℃时，升温速率设定为150℃/h，炉内温度为800℃-1500℃时，升温速率设定为300℃/h，当温度升到1500℃后，停止升温并保温2h，然后随炉冷却，得到碳化硅泡沫陶瓷。
由上述步骤得到的碳化硅泡沫陶瓷拥有(3.24±0.14)MPa的抗折强度，抗折强度较高，另外，本实施例的碳化硅泡沫陶瓷通孔结构良好，性能优异。

Claims (3)

1.一种碳化硅泡沫陶瓷制备工艺，包括以下步骤：
1)称取一定量的孔径为5μm碳化硅微粉和一定量的水洗高岭土放入搅拌罐中混合均匀后，加入水和磷酸二氢铝，搅拌2-3h后得到浆料，然后密封浆料24h，其中碳化硅微粉占混合浆料的35wt％-60wt％，磷酸二氢铝占混合浆料的25wt％-40wt％；
2)取开气孔率＞99％、孔径为0.2-0.8mm的聚氨酯泡沫，用去离子水反复冲洗5次除去杂质后浸入温度为60℃、浓度为15wt％的氢氧化钠溶液中水解1-6h，水解结束后取出聚氨酯泡沫，反复揉搓并用清水冲洗晾干；
3)将步骤2)处理后的聚氨酯泡沫置于步骤1)的浆料中，不断搅拌挤压揉搓，以使浆料均匀涂挂在聚氨酯泡沫上，充分排气吸浆后，放入对辊机中按1/6-1/3的挤压比进行挤压排浆，得到泡沫陶瓷预制体；
4)将泡沫陶瓷预制体放入50℃恒温烘箱中干燥48h，每隔1h将泡沫预制体翻转一次；
5)将干燥后的泡沫预制体放入箱式电阻炉进行烧结，炉内温度为室温-800℃时，升温速率设定为100-150℃/h，炉内温度为800℃-1500℃时，升温速率设定为300-400℃/h，当温度升到1500℃后，停止升温并保温2h，然后随炉冷却，得到碳化硅泡沫陶瓷。
2.根据权利要求1所述的一种碳化硅陶瓷低温制备工艺，其特征在于：所述聚氨酯泡沫为弹性开孔网状结构。
3.根据权利要求1所述的一种碳化硅陶瓷低温制备工艺，其特征在于：所述聚氨酯泡沫在低于陶瓷烧成温度下可挥发。
CN201811217887.4A 2018-10-18 2018-10-18 一种碳化硅泡沫陶瓷制备工艺 Pending CN109231995A (zh)

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Cited By (2)

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Publication number Priority date Publication date Assignee Title
CN110183232A (zh) * 2019-05-23 2019-08-30 荆州市友联铝材设备有限公司 一种耐压泡沫陶瓷材料及其制备方法和应用
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CN110183232A (zh) * 2019-05-23 2019-08-30 荆州市友联铝材设备有限公司 一种耐压泡沫陶瓷材料及其制备方法和应用
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Application publication date: 20190118