CN109485428A - 一种日用陶瓷用硅板及其制备方法 - Google Patents
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Abstract
本发明提供一种日用陶瓷用硅板及其制备方法,所述日用陶瓷用硅板包括以下重量份的组分:碳化硅粉70‑80份、微晶石墨粉0.5‑3份和铝粉0.5‑5份。本发明提供的日用陶瓷用硅板主要成分为碳化硅粉、微晶石墨粉和铝粉,将这三种组分合理配比,可有效提高产品的性能,硅板厚度相对于传统硅板大大减小,节能轻便,还可增加10%装载量,而且该硅板不粘陶瓷,无需再在表面涂刷铝粉,避免铝粉掉渣产生的损耗,相对传统硅板,综合节省能耗20%以上,降低了生产成本。本发明制得的硅板经客户隧道窑连续使用一年半,表面无缺陷,不变形,且价格易接受,深受客户喜爱。
Description
技术领域
本发明涉及日用陶瓷领域,更具体地,涉及一种日用陶瓷用硅板及其制备方法。
背景技术
传统的日用陶瓷使用硅板主要为氧化硅结合和超细碳化硅与粘土及少量催化剂等氧化烧制而成。但这类型硅板使用寿命大多不超过一年,一般三到六个月就易变形;而且板子较厚,通常要做到15毫米以上,不节能又笨重;另外还要涂刷防粘铝粉涂料,否则易与瓷器相粘,而铝粉易掉渣,使瓷器产生斑点,且目前抗氧化防粘涂料均存在缺陷,掉渣产生5%以上的损耗,需要重新打磨修复,如此造成大量人力物力损耗,使用成本较高。
目前,可以作为高端硅板的碳化硅陶瓷有氮化硅结合碳化硅,反应烧结碳化硅、无压烧结碳化硅和重结晶烧结碳化硅,但这些硅板按照现有工艺要么不耐高温且与有些陶瓷易发生粘黏,要么成型设备贵或原材料贵,工艺不易控制,只有少数厂家能生产,成本较高,不易为客户接受。
因此,急需开发一种成本相对较低且质量较好的日用陶瓷用硅板,以满足市场需求。
发明内容
针对现有技术存在的问题,本发明提供一种日用陶瓷用硅板及其制备方法。
本发明提供一种日用陶瓷用硅板,包括以下重量份的组分:碳化硅粉70-80份、微晶石墨粉0.5-3份和铝粉0.5-5份。
上述技术方案中,将碳化硅粉、微晶石墨粉和铝粉这三种组分合理配比,可有效提高产品的性能,硅板厚度相对于传统硅板大大减小,节能轻便,还可增加10%装载量,而且该硅板不粘陶瓷,无需再在表面涂刷铝粉,避免铝粉掉渣产生的损耗,相对传统硅板,综合节省能耗20%以上,降低了生产成本。
优选地,所述碳化硅粉为亚微米级,所述微晶石墨粉为亚微米微晶石墨粉,所述铝粉为纳米级。
优选地,所述日用陶瓷用硅板,包括以下重量份的组分:碳化硅粉70-80份、微晶石墨粉0.5-3份、铝粉0.5-5份、分散剂0.3-1份、改性剂1-3份、粘结剂2-8份和消泡剂0.1-1份。
优选地,所述分散剂为武汉美琪林新材料有限公司生产的MQ-5088、MQ-301、MQ-568中的一种或多种。
优选地,所述改性剂为武汉美琪林新材料有限公司生产的MQ-105、MQ-9002、MQ-64中的一种或多种。
优选地,所述粘结剂为武汉美琪林新材料有限公司生产的MQ-35、MQ-206、MQ-85中的一种或多种。
作为一种优选方案,本发明的日用陶瓷用硅板包括以下重量份的组分:70-80份亚微米碳化硅粉、0.5-3份亚微米微晶石墨粉、0.5-5份纳米铝粉、0.3-1份分散剂MQ-301、1-3份改性剂MQ-105、2-8份粘结剂MQ-206和0.1-1份消泡剂MQ-1002。
上述技术方案中,通过大量实验发现,将特定的上述组分进行配伍后,制得的日用陶瓷用硅板性能更优。
进一步优选地,所述日用陶瓷用硅板,包括以下重量份的组分:70-75份亚微米碳化硅粉、1-2份亚微米微晶石墨粉、3-4份纳米铝粉、0.3-0.5份分散剂MQ-301、2-3份改性剂MQ-105、5-7份粘结剂MQ-206和0.1-0.2份消泡剂MQ-1002。
本发明还提供上述日用陶瓷用硅板的制备方法,包括以下步骤:先将各组分混合进行湿法球磨,然后采用石膏模具注浆成型,坯体干燥后进行真空烧结。
作为优选方案,所述制备方法具体包括以下步骤:
(1)向球磨机中加入去离子水、分散剂、改性剂、铝粉和微晶石墨粉,球磨10-30min,再加入粘结剂,球磨10-30min,然后加入碳化硅粉,继续球磨20-48h,过滤,加入消泡剂,其中去离子水的加入量为物料的40-50wt%;
(2)将步骤(1)得到的混合料在真空搅拌罐中抽真空搅拌20-30min,充氮气加压,然后注浆至石膏模具中成型;
(3)坯体干燥后,在真空环境下进行烧结,先按2-3℃/min升温至2000-2160℃,然后保温1-2h,即得。
上述制备方法采用石膏模具注浆成型,加上合理的真空烧结,所得硅板无缺陷、不变形,且可根据需要调整石膏模具厚度,从而得到厚度不同的硅板。
本发明提供的日用陶瓷用硅板主要成分为碳化硅粉、微晶石墨粉和铝粉,将这三种组分合理配比,可有效提高产品的性能,硅板厚度相对于传统硅板大大减小,节能轻便,还可增加10%装载量,而且该硅板不粘陶瓷,无需再在表面涂刷铝粉,避免铝粉掉渣产生的损耗,相对传统硅板,综合节省能耗20%以上,降低了生产成本。本发明制得的硅板经客户隧道窑连续使用一年半,表面无缺陷,不变形,且价格易接受,深受客户喜爱。
具体实施方式
下面结合具体实施例,对本发明的具体实施方式作进一步详细描述。以下实施例用于说明本发明,但不用来限制本发明的范围。
以下实施例中,所用试剂均为市售购得,其中编号为MQ-开头的试剂均由武汉美琪林新材料有限公司提供。
实施例1
本实施例提供一种日用陶瓷用硅板,由以下重量配比的组分制得:70kg亚微米碳化硅粉、1.2kg亚微米微晶石墨粉、3.6kg纳米铝粉、0.36kg分散剂MQ-301、3kg改性剂MQ-105、6kg粘结剂MQ-206和0.2kg消泡剂MQ-1002。
本实施例还提供上述日用陶瓷用硅板的制备方法,包括以下步骤:
(1)向球磨机中加入36kg去离子水、0.36kg分散剂MQ-301、3kg改性剂MQ-105、3.6kg纳米铝粉和1.2kg亚微米微晶石墨粉,球磨30min,再加入6kg粘结剂MQ-206,球磨30min,继续加入70kg亚微米碳化硅粉,球磨24h,过滤,在所得浆料中加入0.2kg消泡剂MQ-1002排除气泡;
(2)将步骤(1)所得混合料在真空搅拌罐中抽真空搅拌30min,充氮气加压,然后注浆至石膏模具中成型,得到5-10mm厚度的坯体;
(3)待坯体干燥后,放入真空脱脂烧结一体炉中,按2.7℃/min升至2150℃并保温1.5h,制得厚度为4-8mm的日用陶瓷用硅板。
实施例2
本实施例提供一种日用陶瓷用硅板,由以下重量配比的组分制得:75kg亚微米碳化硅粉、3kg亚微米微晶石墨粉、3kg纳米铝粉、0.5kg分散剂MQ-301、3kg改性剂MQ-105、8kg粘结剂MQ-206和0.2kg消泡剂MQ-1002。
本实施例还提供上述日用陶瓷用硅板的制备方法,包括以下步骤:
(1)向球磨机中加入40kg去离子水、0.5kg分散剂MQ-301、3kg改性剂MQ-105、3kg纳米铝粉和3kg亚微米微晶石墨粉,球磨30min,再加入8kg粘结剂MQ-206,球磨30min,继续加入75kg亚微米碳化硅粉,球磨24h,过滤,在所得浆料中加入0.2kg消泡剂MQ-1002排除气泡;
(2)将步骤(1)所得混合料在真空搅拌罐中抽真空搅拌30min,充氮气加压,然后注浆至石膏模具中成型,得到5-10mm厚度的坯体;
(3)待坯体干燥后,放入真空脱脂烧结一体炉中,按2.5℃/min升至2150℃并保温1.5h,制得厚度为4-8mm的日用陶瓷用硅板。
实施例3
本实施例提供一种日用陶瓷用硅板,由以下重量配比的组分制得:80kg亚微米碳化硅粉、2kg亚微米微晶石墨粉、4kg纳米铝粉、0.6kg分散剂MQ-568、2kg改性剂MQ-9002、6kg粘结剂MQ-206和0.2kg消泡剂MQ-1002。
本实施例还提供上述日用陶瓷用硅板的制备方法,包括以下步骤:
(1)向球磨机中加入42kg去离子水、0.6kg分散剂MQ-568、2kg改性剂MQ-9002、4kg纳米铝粉和2kg亚微米微晶石墨粉,球磨30min,再加入6kg粘结剂MQ-206,球磨30min,继续加入80kg亚微米碳化硅粉,球磨24h,过滤,在所得浆料中加入0.2kg消泡剂MQ-1002排除气泡;
(2)将步骤(1)所得混合料在真空搅拌罐中抽真空搅拌30min,充氮气加压,然后注浆至石膏模具中成型,得到6-12mm厚度的坯体;
(3)待坯体干燥后,放入真空脱脂烧结一体炉中,按3℃/min升至2100℃并保温2h,制得厚度为5-10mm的日用陶瓷用硅板。
实施例4
本实施例提供一种日用陶瓷用硅板,由以下重量配比的组分制得:75kg碳化硅微粉、1.5kg亚微米微晶石墨粉、3.5kg纳米铝粉、0.5kg分散剂MQ-5088、2kg改性剂MQ-105、7kg粘结剂MQ-35和0.1kg消泡剂MQ-1002。
本实施例还提供上述日用陶瓷用硅板的制备方法,包括以下步骤:
(1)向球磨机中加入40kg去离子水、0.5kg分散剂MQ-5088、2kg改性剂MQ-105、3.5kg纳米铝粉和1.5kg亚微米微晶石墨粉,球磨30min,再加入7kg粘结剂MQ-35,球磨30min,继续加入75kg亚微米碳化硅粉,球磨30h,过滤,在所得浆料中加入0.1kg消泡剂MQ-1002排除气泡;
(2)将步骤(1)所得混合料在真空搅拌罐中抽真空搅拌30min,充氮气加压,然后注浆至石膏模具中成型,得到5-10mm厚度的坯体;
(3)待坯体干燥后,放入真空脱脂烧结一体炉中,按2.7℃/min升至2150℃并保温1.5h,制得厚度为4-8mm的日用陶瓷用硅板。
本发明实施例1-4制得的硅板厚度相对于传统硅板大大减小,节能轻便,还可增加10%装载量,而且不粘陶瓷,无需再在表面涂刷铝粉,避免铝粉掉渣产生的损耗,相对传统硅板,综合节省能耗20%以上,降低了生产成本;经客户隧道窑连续使用一年半,表面无缺陷,不变形,其中实施例1所得硅板质量最优。
最后应说明的是:以上实施例仅用以说明本发明的技术方案,而非对其限制;尽管参照前述实施例对本发明进行了详细的说明,本领域的普通技术人员应当理解:其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换;而这些修改或者替换,并不使相应技术方案的本质脱离本发明各实施例技术方案的精神和范围。
Claims (10)
1.一种日用陶瓷用硅板,其特征在于,包括以下重量份的组分:碳化硅粉70-80份、微晶石墨粉0.5-3份和铝粉0.5-5份。
2.根据权利要求1所述的日用陶瓷用硅板,其特征在于,所述碳化硅粉为亚微米级,所述微晶石墨粉为亚微米微晶石墨粉,所述铝粉为纳米级。
3.根据权利要求1或2所述的日用陶瓷用硅板,其特征在于,包括以下重量份的组分:碳化硅粉70-80份、微晶石墨粉0.5-3份、铝粉0.5-5份、分散剂0.3-1份、改性剂1-3份、粘结剂2-8份和消泡剂0.1-1份。
4.根据权利要求3所述的日用陶瓷用硅板,其特征在于,所述分散剂为武汉美琪林新材料有限公司生产的MQ-5088、MQ-301、MQ-568中的一种或多种。
5.根据权利要求3或4所述的日用陶瓷用硅板,其特征在于,所述改性剂为武汉美琪林新材料有限公司生产的MQ-105、MQ-9002、MQ-64中的一种或多种。
6.根据权利要求3-5任一项所述的日用陶瓷用硅板,其特征在于,所述粘结剂为武汉美琪林新材料有限公司生产的MQ-35、MQ-206、MQ-85中的一种或多种。
7.根据权利要求3所述的日用陶瓷用硅板,其特征在于,包括以下重量份的组分:70-80份亚微米碳化硅粉、0.5-3份亚微米微晶石墨粉、0.5-5份纳米铝粉、0.3-1份分散剂MQ-301、1-3份改性剂MQ-105、2-8份粘结剂MQ-206和0.1-1份消泡剂MQ-1002。
8.根据权利要求7所述的日用陶瓷用硅板,其特征在于,包括以下重量份的组分:70-75份亚微米碳化硅粉、1-2份亚微米微晶石墨粉、3-4份纳米铝粉、0.3-0.5份分散剂MQ-301、2-3份改性剂MQ-105、5-7份粘结剂MQ-206和0.1-0.2份消泡剂MQ-1002。
9.权利要求1-8任一项所述的日用陶瓷用硅板的制备方法,其特征在于,包括以下步骤:先将各组分混合进行湿法球磨,然后采用石膏模具注浆成型,坯体干燥后进行真空烧结。
10.根据权利要求9所述的制备方法,其特征在于,具体包括以下步骤:
(1)向球磨机中加入去离子水、分散剂、改性剂、铝粉和微晶石墨粉,球磨10-30min,再加入粘结剂,球磨10-30min,然后加入碳化硅粉,继续球磨20-48h,过滤,加入消泡剂,其中去离子水的加入量为物料的40-50wt%;
(2)将步骤(1)得到的混合料在真空搅拌罐中抽真空搅拌20-30min,充氮气加压,然后注浆至石膏模具中成型;
(3)坯体干燥后,在真空环境下进行烧结,先按2-3℃/min升温至2000-2160℃,然后保温1-2h,即得。
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