CN109437923A - 一种发泡陶瓷及其制备方法 - Google Patents

一种发泡陶瓷及其制备方法 Download PDF

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CN109437923A
CN109437923A CN201811589727.2A CN201811589727A CN109437923A CN 109437923 A CN109437923 A CN 109437923A CN 201811589727 A CN201811589727 A CN 201811589727A CN 109437923 A CN109437923 A CN 109437923A
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foamed ceramic
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CN109437923B (zh
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李庆德
程万里
陈�峰
刘润泽
桑同慧
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Foshan University
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Abstract

本发明公开了一种发泡陶瓷，按重量份数计，包括以下组分：粉煤灰20‑80份，钛酸钾5‑15份，氧化铝1‑10份，陶土5‑10份，石英10‑15份，钠长石6‑11份，硼砂6‑12份，悬浮剂1‑2份，发泡剂0.4‑1.5份，增强剂1.5‑5份。相对于现有技术，本发明充分利用对环境有害的粉煤灰来制造发泡陶瓷，且粉煤灰的掺杂量高；同时所述发泡陶瓷具有高机械强度和耐磨性好的优点，可使得产品应用领域更广；本发明所述发泡陶瓷的制备方法简单，能耗低。

Description

一种发泡陶瓷及其制备方法
技术领域
本发明属于陶瓷领域，特别涉及一种发泡陶瓷及其制备方法。
背景技术
发泡陶瓷是经高温焙烧而成的高气孔率的闭孔陶瓷材料，产品适用于建筑外墙保温，防火隔离带，建筑自保温冷热桥处理等。产品具有防火阻燃，抗老化，变形系数小，性能稳定，生态环保性好，与墙基层和抹面层相容性好，安全稳固性好，可与建筑物同寿命。但是现有技术中发泡陶瓷由于其耐磨性能和机械强度并不能满足一些应用领域的要求，使得其应用领域受到极大限制。
另外，现有技术中制造发泡陶瓷时有使用粉煤灰，使用粉煤灰可减轻环境压力，有“变废为宝”的功效，但粉煤灰的添加量往往不够，而且如果添加过多粉煤灰，则发泡陶瓷的机械强度又会大大降低。因此，从环境保护和资源利用的角度以及发泡陶瓷的应用考虑，寻找一种粉煤灰添加量高，且发泡陶瓷的机械性能良好的发泡陶瓷产品十分有必要。
发明内容
针对现有技术的不足，本发明提供一种发泡陶瓷及其制备方法，本发明所述发泡陶瓷粉煤灰添加量高，且发泡陶瓷的机械强度良好。
一种发泡陶瓷，按重量份数计，包括以下组分：
优选的，一种发泡陶瓷，按重量份数计，包括以下组分：
进一步优选的，一种发泡陶瓷，按重量份数计，包括以下组分：
所述粉煤灰的粒径范围为50-150μm(优选100-130μm)。
所述陶土的目数为400-500目。
优选的，所述悬浮剂为羧甲基淀粉钠。
优选的，所述增强剂为聚丙烯酸钠。
所述发泡剂为碳化硅粉和/或萤石粉。
优选的，所述碳化硅粉的目数为40-100目(优选60-80目)，所述萤石粉的目数为50-90目。
一种发泡陶瓷的制备方法，包括以下步骤：
(1)按配方量称取各组分，将各组分通过搅拌机(由上海升立机械制造有限公司提供，型号为LHYS)搅拌均匀；
(2)通过造粒机(由江苏福亿机械科技有限公司提供，型号为DH)制成30-55目的颗粒料；
(3)将颗粒料放入铺有硅酸铝纤维纸的莫来石模具中，入辊道窑或者隧道窑中进行热处理。
步骤(1)中搅拌机的搅拌速度为500-900转/分钟。
步骤(3)中的热处理具体过程为：以12-15℃/分钟(优选13℃/分钟)的升温速度，从室温升高到1000℃，保温0.5-1小时，然后以25-28℃/分钟的速度降温到500℃；然后以3-4℃/分钟的速度降温到250℃，保温1-1.5小时；然后以16-20℃/分钟的速度降温到室温，出炉制得本发明所述发泡陶瓷。
本发明所述发泡陶瓷配方中加入了钛酸钾和氧化铝使得即使粉煤灰的掺杂量高也能制得满足一般轻质、隔热、保温、防水、防火、降噪、不老化的性能，特别的所述发泡陶瓷还具有机械强度高，耐磨性良好，有望应用在对机械强度和耐磨性要求高的领域，例如汽车刹车片中的应用。
相对于现有技术，本发明的有益效果如下：
(1)本发明充分利用对环境有害的粉煤灰来制造发泡陶瓷，“变废为宝”，且粉煤灰的掺在量高；
(2)本发明所述发泡陶瓷同时具有高机械强度和耐磨性好的优点，可使得产品应用领域更广；
(3)本发明所述发泡陶瓷的制备方法简单，且最高升温温度为1000℃，能耗低。
具体实施方式
为了让本领域技术人员更加清楚明白本发明所述技术方案，以下列举一些实施例以作说明。但这些实施例并不对本发明的保护范围起到限制作用。
实施例1
一种发泡陶瓷，按重量份数计，包括以下组分：
所述粉煤灰的粒径范围为50μm。
所述陶土的目数为400目。
所述悬浮剂为羧甲基淀粉钠。
所述增强剂为聚丙烯酸钠。
所述发泡剂为碳化硅粉。
所述碳化硅粉的目数为40目。
一种发泡陶瓷的制备方法，包括以下步骤：
(1)按配方量称取各组分，将各组分通过搅拌机(由上海升立机械制造有限公司提供，型号为LHYS)搅拌均匀；
(2)通过造粒机(由江苏福亿机械科技有限公司提供，型号为DH)制成30-55目的颗粒料；
(3)将颗粒料放入铺有硅酸铝纤维纸的莫来石模具中，入辊道窑或者隧道窑中进行热处理。
步骤(1)中搅拌机的搅拌速度为500转/分钟。
步骤(3)中的热处理具体过程为：以12℃/分钟的升温速度，从室温升高到1000℃，保温1小时，然后以28℃/分钟的速度降温到500℃；然后以3℃/分钟的速度降温到250℃，保温1.5小时；然后以16℃/分钟的速度降温到室温，出炉制得本发明所述发泡陶瓷。
实施例2
一种发泡陶瓷，按重量份数计，包括以下组分：
所述粉煤灰的粒径范围为100μm。
所述陶土的目数为450目。
所述悬浮剂为羧甲基淀粉钠。
所述增强剂为聚丙烯酸钠。
所述发泡剂为萤石粉，所述萤石粉的目数为70目。
一种发泡陶瓷的制备方法，包括以下步骤：
(1)按配方量称取各组分，将各组分通过搅拌机(由上海升立机械制造有限公司提供，型号为LHYS)搅拌均匀；
(2)通过造粒机(由江苏福亿机械科技有限公司提供，型号为DH)制成30-55目的颗粒料；
(3)将颗粒料放入铺有硅酸铝纤维纸的莫来石模具中，入辊道窑或者隧道窑中进行热处理。
步骤(1)中搅拌机的搅拌速度为500-900转/分钟。
步骤(3)中的热处理具体过程为：以12-15℃/分钟(优选13℃/分钟)的升温速度，从室温升高到1000℃，保温0.5-1小时，然后以25-28℃/分钟的速度降温到500℃；然后以3-4℃/分钟的速度降温到250℃，保温1-1.5小时；然后以16-20℃/分钟的速度降温到室温，出炉制得本发明所述发泡陶瓷。
实施例3
一种发泡陶瓷，按重量份数计，包括以下组分：
所述粉煤灰的粒径范围为120μm。
所述陶土的目数为500目。
所述悬浮剂为羧甲基淀粉钠。
所述增强剂为聚丙烯酸钠。
所述发泡剂为碳化硅粉0.5份和萤石粉0.5份。
所述碳化硅粉的目数为70目，所述萤石粉的目数为80目。
一种发泡陶瓷的制备方法，包括以下步骤：
(1)按配方量称取各组分，将各组分通过搅拌机(由上海升立机械制造有限公司提供，型号为LHYS)搅拌均匀；
(2)通过造粒机(由江苏福亿机械科技有限公司提供，型号为DH)制成30-55目的颗粒料；
(3)将颗粒料放入铺有硅酸铝纤维纸的莫来石模具中，入辊道窑或者隧道窑中进行热处理。
步骤(1)中搅拌机的搅拌速度为800转/分钟。
步骤(3)中的热处理具体过程为：以13℃/分钟的升温速度，从室温升高到1000℃，保温1小时，然后以26℃/分钟的速度降温到500℃；然后以4℃/分钟的速度降温到250℃，保温1.5小时；然后以20℃/分钟的速度降温到室温，出炉制得本发明所述发泡陶瓷。
实施例4
一种发泡陶瓷，按重量份数计，包括以下组分：
所述粉煤灰的粒径范围为150μm。
所述陶土的目数为500目。
所述悬浮剂为羧甲基淀粉钠。
所述增强剂为聚丙烯酸钠。
所述发泡剂为碳化硅粉0.5份和萤石粉1份。
所述碳化硅粉的目数为100目，所述萤石粉的目数为90目。
一种发泡陶瓷的制备方法，包括以下步骤：
(1)按配方量称取各组分，将各组分通过搅拌机(由上海升立机械制造有限公司提供，型号为LHYS)搅拌均匀；
(2)通过造粒机(由江苏福亿机械科技有限公司提供，型号为DH)制成30-55目的颗粒料；
(3)将颗粒料放入铺有硅酸铝纤维纸的莫来石模具中，入辊道窑或者隧道窑中进行热处理。
步骤(1)中搅拌机的搅拌速度为900转/分钟。
步骤(3)中的热处理具体过程为：以15℃/分钟的升温速度，从室温升高到1000℃，保温1小时，然后以28℃/分钟的速度降温到500℃；然后以4℃/分钟的速度降温到250℃，保温1.5小时；然后以20℃/分钟的速度降温到室温，出炉制得本发明所述发泡陶瓷。
对比例1
与实施例3相比，对比例1不含钛酸钾和氧化铝，其余组分及其含量和制备过程相同。
对比例2
与实施例2相比，对比例1不含钛酸钾，其余组分及其含量和制备过程相同。
对比例3
与实施例4相比，对比例3中使用的粉煤灰的粒径范围为200μm，所述碳化硅粉为2份，所述萤石粉为2份。
产品效果测试
对实施例1-4和对比例1-3制备的产品进行抗压强度测试(测试标准GB/T5486)、抗折强度测试(测试标准GB/T5486)、燃烧性能等级测试(测试标准GB8642,其中A级为不燃烧，B1级为难燃烧，B2级为可燃，B3为易燃)、导热系数测试(测试标准GB/T10294)和密度测试(GB/T5486)。
表1：
由表1数据可以看出，当产品配方中不含钛酸钾和氧化铝时，产品的抗压强度和抗折强度轻度都大大降低，影响产品的应用。当所含发泡剂含量过高，粉煤灰颗粒尺寸太大时，则产品的导热系数大，产品保温性能不佳。另外，实施例1-4制备的产品的耐摩擦性能是市售发泡陶瓷的2倍以上(采用GB/T4100.1-1999标准测试)，可见本发明所述发泡陶瓷的应用领域更广。
可见，当产品中同时含有钛酸钾和氧化铝，且各组分含量在本发明所述范围内时，所述发泡陶瓷的机械性能(抗压性能和抗折性能)才能最佳。

Claims (9)

1.一种发泡陶瓷，其特征在于，按重量份数计，包括以下组分：
所述粉煤灰的粒径范围为50-150μm。
2.一种根据权利要求1所述的发泡陶瓷，其特征在于，按重量份数计，包括以下组分：
3.一种根据权利要求1所述的发泡陶瓷，其特征在于，按重量份数计，包括以下组分：
4.根据权利要求1-3中任一项所述的发泡陶瓷，其特征在于，所述陶土的目数为400-500目。
5.根据权利要求1-3中任一项所述的发泡陶瓷，其特征在于，所述悬浮剂为羧甲基淀粉钠。
6.根据权利要求1-3中任一项所述的发泡陶瓷，其特征在于，所述发泡剂为碳化硅粉和/或萤石粉；所述碳化硅粉的目数为40-100目，所述萤石粉的目数为50-90目。
7.一种根据权利要求1-6中任一项所述的发泡陶瓷的制备方法，其特征在于，包括以下步骤：
(1)按配方量称取各组分，将各组分通过搅拌机搅拌均匀；
(2)通过造粒机制成30-55目的颗粒料；
(3)将颗粒料放入铺有硅酸铝纤维纸的莫来石模具中，然后放入辊道窑或者隧道窑中进行热处理。
8.一种根据权利要求7所述的发泡陶瓷的制备方法，其特征在于，步骤(1)中搅拌机的搅拌速度为500-900转/分钟。
9.一种根据权利要求7-8中任一项所述的发泡陶瓷的制备方法，其特征在于，步骤(3)中的热处理具体过程为：以12-15℃/分钟的升温速度，从室温升高到1000℃，保温0.5-1小时，然后以25-28℃/分钟的速度降温到500℃；然后以3-4℃/分钟的速度降温到250℃，保温1-1.5小时；然后以16-20℃/分钟的速度降温到室温，制得所述发泡陶瓷。
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