CN109422543A - 一种保健枕专用硅藻土基多孔陶瓷球的制备方法 - Google Patents

一种保健枕专用硅藻土基多孔陶瓷球的制备方法 Download PDF

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CN109422543A
CN109422543A CN201710716609.2A CN201710716609A CN109422543A CN 109422543 A CN109422543 A CN 109422543A CN 201710716609 A CN201710716609 A CN 201710716609A CN 109422543 A CN109422543 A CN 109422543A
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Abstract

本发明公开了一种保健枕专用硅藻土基多孔陶瓷球的制备方法，以硅藻土、电气石粉、活性炭粉为主料。用氧化锆球将离子水和分散剂混合的料浆球磨至平均粒径小于10μm。用电磁除铁器去除料浆中磁性杂质送至搅拌釜并加入粘结剂和造孔剂。再用料浆泵注入喷雾干燥剂得到平均粒径0.05～0.2mm的硅藻土基微粉。将硅藻土基微粉和离子水放置槽型高效混合机搅拌均匀后用高速自动成球机制成球坯料，球坯料在氮气保护下经800～1000℃烧结、振动筛分筛，得到直径1～10mm的范围内可调的硅藻土基多孔陶瓷球。

Description

一种保健枕专用硅藻土基多孔陶瓷球的制备方法
技术领域：
本发明涉及硅藻土应用和多孔陶瓷生产领域，尤其涉及用于保健产品的硅藻土基多孔陶瓷生产。
背景技术：
硅藻土是一种生物成因的硅质沉积岩，主要由硅藻遗骸组成，其主要成分是SiO2。硅藻土内部有大量规则、大小一致的亚微米孔，因此具有比表面积大、吸附性好的特点，用于家用保健产品则具有吸放空气中水分自动调节湿度、吸附有害气体、去除异味等功能。电气石是一种天然的药物矿石，含有人体所必需的钾、钠、钙、镁、磷常量元素和锌、铁、硒、铜、锶、碘、氟、偏硅酸等十八种微量元素，同时具有长久释放负氧离子和远红外线的功能特性.活性炭则同样具有吸附有害气体、除臭、净化空气等作用。本发明将上述几种功能性材料的特性进行了有机结合，制得的保健枕专用硅藻土基陶瓷球不仅球形化好、尺寸均匀、抗压性强、使用寿命长，而且同时具备了原料的优异保健性能。
发明内容：
本发明的目的是提供一种保健枕专用硅藻土基多孔陶瓷球的制备方法。
本发明的技术方案如下：
一种保健枕专用硅藻土基多孔陶瓷球的制备方法，包括以下步骤：
(1)原料的配置
以硅藻土为基体材料，按比例加入的电气石粉、活性炭粉。
(2)原料的粉碎球磨
原料与定量的去离子水和分散剂混合，加入到滚筒球磨机中，以氧化锆球为研磨介质进行球磨。球磨至料浆中的颗粒平均粒径小于10μm后放出料浆。
(3)料浆的除铁提纯和干燥造粒
料浆经过电磁除铁器去除磁性杂质后，输送至搅拌釜，定量加入粘结剂和造孔剂，经由料浆泵注入压力式喷雾干燥机，得到球形硅藻土基微粉颗粒，平均粒径0.05～0.2mm。
(3)自动成球
将球形硅藻土基微粉加入到槽型高效混合机中，加入定量去离子水，混合搅拌均匀后通过自动成球机高速制成圆球。
(4)低温烧结
球坯料在氮气保护下800～1000℃低温烧结、振动筛分筛，即得到硅藻土基多孔陶瓷球产品，直径1～10mm范围内可调。
本发明的有益效果：
(1)由硅藻土、电气石和活性炭构成的多孔陶瓷球形颗粒，将三种原材料的功能特性有机结合，提升和强化了硅藻土陶瓷材料的保健功效.
(2)与其它方法相比，增加了电磁除铁工序，以消除保健枕填料中磁性杂质材料对人体健康的不利因素.
(3)一般制备硅藻土陶瓷球均采用圆盘式成球机制丸，主要依靠人工操作，成球质量的好坏、球坯尺寸的大小完全依靠操作员工经验，质量稳定性差.本发明采用全自动成球机制丸，成球过程和尺寸控制完全自动化，质量稳定而且降低了人工成本。
(4)通常制备硅藻土多孔陶瓷材料要么不粉碎直接制丸或粉碎后料浆注浆成型，这些方法要么因为一次颗粒大要么因为一次颗粒间距大，所以需要较高的烧结温度，一般在950～1000℃以上。高的烧结温度往往导致硅藻土陶瓷的微孔数量减少，功能性下降。本发明采用原料粉碎和造粒工艺，一方面减小了一次颗粒的尺寸，同时拉近了一次颗粒的间距，提供了材料的烧结活性，所以烧结温度显著降低至800～950℃，减低了能耗和成本的同时，也有利于保持硅藻土的多孔状态。
(5)以往用于保健枕的硅藻土基瓷球多采用人工间歇式生产，自动化程度和生产效率低，质量不稳定。本发明各生产环节主体设备及设备之间的物料输送均采用自动化机械设备，生产效率高，质量可控，产品批次间稳定性高，所以更适合高端保健产品专用硅藻土多孔陶瓷球的批量化生产。
具体实施方式
施例：一种保健枕专用硅藻土基多孔陶瓷球的制备方法，包括以下步骤：
(1)原料的配置
按照硅藻土粉85％wt、电气石粉10％wt、活性炭粉5％wt的比例称取原料。
(2)原料的粉碎球磨
上述原料加入到滚筒球磨机中，按照重量1∶1的比例加入去离子水和1％wt的分散剂三乙醇胺。以氧化锆球为研磨介质进行球磨，球料比5∶1。每球磨半小时取样，用激光粒度仪检测，当料浆中的颗粒平均粒径小于10μm时停止球磨，放出料浆至中间储罐。
(3)料浆的除铁提纯和干燥造粒
中间储罐的料浆由料浆泵输送至电磁除铁器，除铁后回流到中间储罐，如此循环除铁0.5小时。然后将储罐内料浆输送至搅拌釜，加入1.0％wt的粘结剂PVA和0.5％wt造孔剂NaHCO3，搅拌均匀后经由搅拌釜下的料浆泵注入压力式喷雾干燥机，料浆压力0.2～0.5MPa，干燥温度90～110℃。通过旋风分级收集得到球形硅藻土基微粉颗粒，平均粒径0.05～0.2mm.干燥热风经过布袋除尘后达标排放。
(3)自动成球
将球形硅藻土基微粉和去离子水按照重量3∶1的比例加入到槽型高效混合机中，搅拌混合15～30分钟，形成面团状坯料。坯料放入全自动成球机料仓，经过自动挤压成条、切断成粒、高速捻搓成球，得到球坯。根据所需要的产品尺寸预先装配模具和设定自动成球机控制程序。
(4)低温烧结
球坯料装入坩埚，放入箱式烧结炉内，在氮气保护下，以5℃/min的速率升温至850℃，恒温5小时后自动断电降温。炉温降至室温后取出陶瓷球.
(5)筛选和包装
根据所需要尺寸过振动筛进行复查筛选，筛下物即为合格的硅藻土基多孔陶瓷球产品，按照客户要求进行称重、包转。

Claims (5)

1.一种保健枕专用硅藻土基多孔陶瓷球的制备方法，其特征在于：以硅藻土为基体材料，和按比例加入的电气石粉、活性炭粉作为原料。原料与定量的去离子水和分散剂混合，加入到滚筒球磨机中，以氧化锆球为研磨介质进行球磨。球磨至料浆中的颗粒平均粒径小于10μm后放出料浆，料浆经过电磁除铁器去除磁性杂质后，输送至搅拌釜，定量加入粘结剂和造孔剂，经由料浆泵注入压力式喷雾干燥机，得到球形硅藻土基微粉颗粒，平均粒径0.05～0.2mm。将球形硅藻土基微粉加入到槽型高效混合机中，加入定量去离子水，混合搅拌均匀后通过自动成球机高速制成圆球，球坯料在氮气保护下800～1000℃低温烧结、振动筛分筛，即得到硅藻土基多孔陶瓷球产品，直径1～10mm范围内可调。
2.根据权利要求1所述的一种保健枕专用硅藻土基多孔陶瓷球的制备方法，其特征在于：以硅藻土为基体材料，和按比例加入的电气石粉、活性炭粉作为生产原料。原料中的硅藻土具有比表面积大、吸附性好、可吸放湿调节湿度等特性；电气石具备长久释放负氧离子和远红外线特性；活性炭具有吸附有害气体、净化空气、除臭、除味等特性。这些原材料本身的特性赋予了最终的保健枕专用硅藻土基多孔陶瓷球产品诸多保健功能：可以令人体水份子活性化，提高身体的含氧量；改善人体微循环系统；促进新陈代谢；平衡身体的酸碱度；消炎、消肿、镇痛等功效。
3.根据权利要求1所述的一种保健枕专用硅藻土基多孔陶瓷球的制备方法，其特征在于：原料与定量的去离子水和分散剂混合，加入到滚筒球磨机中，以氧化锆球为研磨介质进行球磨。球磨至料浆中的颗粒平均粒径小于10μm后放出料浆，料浆经过电磁除铁器去除磁性杂质后，输送至搅拌釜，定量加入粘结剂和造孔剂，经由料浆泵注入压力式喷雾干燥机，得到球形硅藻土基微粉颗粒，平均粒径0.05～0.2mm。经过电磁除铁器磁选，可以去除硅藻土原料中的大部分铁及附着其表面的磁性物质，有利于提高材料本身的功能性。干燥得到的球形硅藻土基微粉颗粒中间产品，不仅可以用于生产本专利所述的陶瓷球产品，还可以作为前驱体制备多种硅藻土多孔陶瓷产品，如直接烧结生产硅藻土基陶瓷微粉或加工成其它形状的硅藻土基多孔陶瓷块体材料。
4.根据权利要求1所述的一种保健枕专用硅藻土基多孔陶瓷球的制备方法，其特征在于：将球形硅藻土基微粉加入到槽型高效混合机中，加入定量去离子水，混合搅拌均匀后通过自动成球机高速制成圆球。本专利采用自动成球机替代传统的半自动圆盘式成球机制丸，不仅自动化程度和生产效率大幅提高，而且得到的球形颗粒更加均匀、规整。
5.根据权利要求1所述的一种保健枕专用硅藻土基多孔陶瓷球的制备方法，其特征在于：自动成球机制成的球坯料在氮气保护下800～950℃低温烧结、振动筛分筛，即得到硅藻土基多孔陶瓷球产品，直径1～10mm范围内可调。因为球形硅藻土基微粉前驱体经过了前期的球磨粉碎，一次颗粒尺寸小，且一次颗粒间距小，烧结活性高，所以烧结温度仅为800～950℃，比传统方法950～1000℃的烧结温度显著降低，节约了能耗。同时，低温烧结也有利于保持硅藻土的多孔状态，从而发挥其最大的保健功能。
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