CN109678478A - 一种质轻、高强度和低热导率的钙长石多孔陶瓷材料及其制备方法 - Google Patents
一种质轻、高强度和低热导率的钙长石多孔陶瓷材料及其制备方法 Download PDFInfo
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- 239000000919 ceramic Substances 0.000 title claims abstract description 56
- 238000002360 preparation method Methods 0.000 title claims abstract description 49
- 239000000463 material Substances 0.000 title claims abstract description 43
- 229910052661 anorthite Inorganic materials 0.000 title claims abstract description 33
- GWWPLLOVYSCJIO-UHFFFAOYSA-N dialuminum;calcium;disilicate Chemical compound [Al+3].[Al+3].[Ca+2].[O-][Si]([O-])([O-])[O-].[O-][Si]([O-])([O-])[O-] GWWPLLOVYSCJIO-UHFFFAOYSA-N 0.000 title claims abstract description 33
- 239000002002 slurry Substances 0.000 claims abstract description 33
- 239000006260 foam Substances 0.000 claims abstract description 27
- 239000004088 foaming agent Substances 0.000 claims abstract description 24
- 238000005245 sintering Methods 0.000 claims abstract description 21
- 239000003999 initiator Substances 0.000 claims abstract description 16
- 239000003381 stabilizer Substances 0.000 claims abstract description 16
- 239000003054 catalyst Substances 0.000 claims abstract description 15
- 238000005187 foaming Methods 0.000 claims abstract description 12
- 239000000203 mixture Substances 0.000 claims abstract description 4
- 239000000843 powder Substances 0.000 claims description 19
- 238000010792 warming Methods 0.000 claims description 19
- 238000010438 heat treatment Methods 0.000 claims description 17
- 239000000178 monomer Substances 0.000 claims description 17
- 239000003431 cross linking reagent Substances 0.000 claims description 14
- 239000002270 dispersing agent Substances 0.000 claims description 14
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 12
- VTYYLEPIZMXCLO-UHFFFAOYSA-L calcium carbonate Substances [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 12
- 238000001035 drying Methods 0.000 claims description 12
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 11
- ROOXNKNUYICQNP-UHFFFAOYSA-N ammonium persulfate Chemical group [NH4+].[NH4+].[O-]S(=O)(=O)OOS([O-])(=O)=O ROOXNKNUYICQNP-UHFFFAOYSA-N 0.000 claims description 10
- 239000002904 solvent Substances 0.000 claims description 10
- 238000000498 ball milling Methods 0.000 claims description 9
- 229910052681 coesite Inorganic materials 0.000 claims description 9
- 229910052906 cristobalite Inorganic materials 0.000 claims description 9
- 229910052594 sapphire Inorganic materials 0.000 claims description 9
- 239000000377 silicon dioxide Substances 0.000 claims description 9
- 229910052682 stishovite Inorganic materials 0.000 claims description 9
- 229910052905 tridymite Inorganic materials 0.000 claims description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 8
- 239000003795 chemical substances by application Substances 0.000 claims description 7
- HRPVXLWXLXDGHG-UHFFFAOYSA-N Acrylamide Chemical group NC(=O)C=C HRPVXLWXLXDGHG-UHFFFAOYSA-N 0.000 claims description 5
- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical compound [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 claims description 5
- KWYHDKDOAIKMQN-UHFFFAOYSA-N N,N,N',N'-tetramethylethylenediamine Chemical group CN(C)CCN(C)C KWYHDKDOAIKMQN-UHFFFAOYSA-N 0.000 claims description 5
- RCEAADKTGXTDOA-UHFFFAOYSA-N OS(O)(=O)=O.CCCCCCCCCCCC[Na] Chemical group OS(O)(=O)=O.CCCCCCCCCCCC[Na] RCEAADKTGXTDOA-UHFFFAOYSA-N 0.000 claims description 5
- 229910001870 ammonium persulfate Inorganic materials 0.000 claims description 5
- LQZZUXJYWNFBMV-UHFFFAOYSA-N dodecan-1-ol Chemical compound CCCCCCCCCCCCO LQZZUXJYWNFBMV-UHFFFAOYSA-N 0.000 claims description 5
- ZIUHHBKFKCYYJD-UHFFFAOYSA-N n,n'-methylenebisacrylamide Chemical group C=CC(=O)NCNC(=O)C=C ZIUHHBKFKCYYJD-UHFFFAOYSA-N 0.000 claims description 5
- 229920000058 polyacrylate Polymers 0.000 claims description 5
- 229920002873 Polyethylenimine Polymers 0.000 claims description 3
- STVZJERGLQHEKB-UHFFFAOYSA-N ethylene glycol dimethacrylate Chemical class CC(=C)C(=O)OCCOC(=O)C(C)=C STVZJERGLQHEKB-UHFFFAOYSA-N 0.000 claims description 3
- 238000007711 solidification Methods 0.000 claims description 3
- 230000008023 solidification Effects 0.000 claims description 3
- YWYZEGXAUVWDED-UHFFFAOYSA-N triammonium citrate Chemical compound [NH4+].[NH4+].[NH4+].[O-]C(=O)CC(O)(CC([O-])=O)C([O-])=O YWYZEGXAUVWDED-UHFFFAOYSA-N 0.000 claims description 3
- CNCOEDDPFOAUMB-UHFFFAOYSA-N N-Methylolacrylamide Chemical compound OCNC(=O)C=C CNCOEDDPFOAUMB-UHFFFAOYSA-N 0.000 claims 1
- 238000000034 method Methods 0.000 abstract description 20
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- 229910021641 deionized water Inorganic materials 0.000 description 5
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- 239000011268 mixed slurry Substances 0.000 description 4
- 238000002156 mixing Methods 0.000 description 3
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- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 2
- 239000011575 calcium Substances 0.000 description 2
- 229910052791 calcium Inorganic materials 0.000 description 2
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- XZWYZXLIPXDOLR-UHFFFAOYSA-N metformin Chemical compound CN(C)C(=N)NC(N)=N XZWYZXLIPXDOLR-UHFFFAOYSA-N 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
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- CCJAYIGMMRQRAO-UHFFFAOYSA-N 2-[4-[(2-hydroxyphenyl)methylideneamino]butyliminomethyl]phenol Chemical compound OC1=CC=CC=C1C=NCCCCN=CC1=CC=CC=C1O CCJAYIGMMRQRAO-UHFFFAOYSA-N 0.000 description 1
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Abstract
本发明涉及一种质轻、高强度和低热导率的钙长石多孔陶瓷材料及其制备方法。该制备方法包括如下步骤:制备预混浆料;排除浆料中的气泡,然后将发泡剂、稳泡剂加入浆料中,发泡,当发泡体积增大2~3倍时加入催化剂和引发剂,然后将混合料注入模具中,固化,干燥,得到生坯;将生坯烧结,得到所述钙长石多孔陶瓷材料。本发明提供的制备方法通过对烧结条件进行优化,使材料内部在烧结过程中能够形成结构均匀的大气孔且使大气孔内壁上不易粘附形成小气孔,从而既提高了材料的孔隙率,又提高了材料的抗压强度。本发明提供的制备方法在发泡之前排出浆料中的气泡,也在一定程度上降低了多层次气孔的出现。
Description
技术领域
本发明涉及热防护材料技术领域,尤其涉及一种质轻、高强度和低热导率的钙长石多孔陶瓷材料及其制备方法。
背景技术
钙长石材料的熔点可达1550℃,理论密度为2.74~2.76g/cm3,热膨胀系数为4.82×10-6K-1,热导率为3.67W/(m·K)。因此将钙长石作为基体材料制备多孔陶瓷可以有效的进一步降低钙长石材料的热导率,使其具备体积密度小、导热系数低等优点。这些性能与陶瓷材料本身所具有的耐腐蚀、耐高温等优点相结合,使得钙长石多孔陶瓷可以作为一种新型的陶瓷材料迅速的发展开来,有望满足临近空间高超声速飞行器的超轻、高强高防/隔热要求。
目前开发的钙长石多孔多孔陶瓷较为常见的传统制备方法有发泡法和添加造孔剂法。但现有的钙长石多孔陶瓷的制备方法存在着一些难以克服的问题,如发泡法制备的钙长石多孔陶瓷气孔率和强度都较高,但是对于工艺条件的要求很苛刻,不易控制;通过添加造孔剂法可以制得气孔大小及形状均可控的钙长石多孔陶瓷,且工艺简单,但制备的钙长石试样孔分布均匀性较差,且无法制备高气孔率的钙长石多孔陶瓷,无法满足部分性能的要求。
泡沫注凝法是近几年来越来越受关注的多孔陶瓷材料制备方法,它将机械搅拌发泡和凝胶注膜成型工艺相结合,制得的多孔陶瓷材料具有坯体均匀、孔隙率高等优点。目前的泡沫注凝法一般包括如下步骤:将去离子水、有机单体、分散剂和交联剂配制成预混液,再将陶瓷原料粉加入预混液中进行球磨操作,接着在混匀的料浆中加入适量的发泡剂和稳泡剂进行机械搅拌发泡操作,直到料浆体积不再发生变化,再分别加入催化剂和引发剂,最后,将搅拌均匀的料浆注入模具内,继而固化成型,再进行脱模、干燥以及烧结。这一方法可以获得高孔隙率的多孔陶瓷材料,但该方法制得的多孔陶瓷材料的气孔为多级结构,球形的大气孔壁上分布有亚微米级的气孔,且大气孔内壁上的小尺寸气孔数量较多,这一多层次气孔结构虽然显著地提高了陶瓷材料的孔隙率(最高可达到90%以上),但也导致多孔陶瓷材料的强度降低。
如何既能够利用泡沫注凝法获得孔隙率高的多孔陶瓷陶瓷又能够提高其强度从而满足临近空间高超声速飞行器的超轻、高强、高防热隔热要求是本发明要解决的技术问题。
发明内容
本发明的目的在于提供一种超轻、高强、低热导率的钙长石多孔陶瓷材料的制备工艺,从而解决目前的泡沫注凝法制得的多孔陶瓷材料无法兼顾高孔隙率和强度的问题。
为了实现上述目的,本发明提供了如下技术方案:
1、一种质轻、高强度和低热导率的钙长石多孔陶瓷材料的制备方法,所述制备方法包括如下步骤:
(1)将聚合单体、交联剂、分散剂、陶瓷粉末和溶剂混合并球磨成浆料;
(2)排除浆料中的气泡,然后将发泡剂、稳泡剂加入浆料中,发泡,当发泡体积增大2~3倍时加入催化剂和引发剂,然后将混合料注入模具中,固化,干燥,得到生坯;
(3)将生坯烧结,得到所述钙长石多孔陶瓷材料;其中,烧结条件为:
第一阶段:按照30~40℃/min的升温速率升温至600~700℃,保温1~2小时;
第二阶段:按照10~20℃/min的升温速率升温至900~1000℃,保温1~1.5小时;
第三阶段:按照1~5℃/min的升温速率升温至1350~1400℃,保温5~6小时。
2、根据技术方案1所述的制备方法,所述陶瓷粉末包含α-Al2O3、CaCO3和SiO2;优选地,α-Al2O3、CaCO3和SiO2的摩尔比为1:1:2;更优选地,α-Al2O3的粒径为4~10μm,CaCO3的粒径为0.8~2μm,SiO2的粒径为4~6μm。
3、根据技术方案1所述的制备方法,所述聚合单体为丙烯酰胺或N-羟甲基丙烯酰胺;
所述交联剂为N,N’-亚甲基双丙烯酰胺或多乙二醇二甲基丙烯酸;
所述分散剂为聚丙烯酸铵、聚乙烯亚胺、柠檬酸铵中的任一种或多种;和
所述溶剂为水。
4、根据技术方案3所述的制备方法,所述聚合单体、所述交联剂和所述溶剂的质量比为(100~120):(10~15):(1~2);和
所述分散剂的质量为所述陶瓷粉末质量的0.5wt%~1wt%。
5、根据技术方案4所述的制备方法,在步骤(1)中,所述陶瓷粉末在所述浆料中所占的体积比为20%~35%。
6、根据技术方案4所述的制备方法,所述发泡剂为十二烷基硫酸钠;优选地,所述发泡剂在浆料中的浓度为0.25~8g/L;
所述稳泡剂为十二醇,优选地,所述稳泡剂的质量为所述发泡剂质量的0.5wt%~1wt%。
7、根据技术方案4所述的制备方法,所述引发剂为过硫酸铵;优选地,所述引发剂的质量为所述聚合单体质量的20wt%~30wt%;
所述催化剂为N,N,N’,N’-四甲基乙二胺;优选地,所述催化剂的质量为所述引发剂剂质量的40wt%~45wt%。
8、根据技术方案1所述的制备方法,所述固化在室温下进行,固化时间控制在30~40分钟。
9、根据技术方案1所述的制备方法,所述干燥在70~80℃下进行,干燥时间控制在6~8小时。
10、一种质轻、高强度和低热导率的钙长石多孔陶瓷材料,采用技术方案1-9任一项所述的制备方法制得。
有益效果
本发明的上述技术方案具有如下优点:
本发明提供的制备方法通过对烧结条件进行优化,使材料内部在烧结过程中能够形成结构均匀的大气孔且使大气孔内壁上不易粘附形成小气孔,从而既提高了材料的孔隙率,又提高了材料的抗压强度。
本发明提供的制备方法在发泡之前排出浆料中的气泡,也在一定程度上降低了多层次气孔的出现。
附图说明
图1是实施例1制备的钙长石多孔陶瓷材料高倍下的断口微观形貌图;
图2是实施例1工艺制备的钙长石多孔陶瓷材料低倍下的断口微观形貌图。
具体实施方式
为使本发明的目的、技术方案和优点更加清楚,下面将结合本发明实施例,对本发明的技术方案进行清楚、完整地描述。显然,所描述的实施例是本发明的一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动的前提下所获得的所有其他实施例,都属于本发明保护的范围。
本发明提供了一种质轻、高强度和低热导率的钙长石多孔陶瓷材料的制备方法,所述制备方法包括如下步骤:
(1)制备预混浆料
将聚合单体、交联剂、分散剂、陶瓷粉末和溶剂混合并球磨成浆料,球磨可以采用现有的球磨装置,本发明对球磨时间不做具体限定,例如,可以为20小时、21小时、22小时、23小时、24小时、25小时、26小时、27小时、28小时、29小时或30小时
在一些实施例中,所述陶瓷粉末包含α-Al2O3、CaCO3和SiO2;优选地,α-Al2O3、CaCO3和SiO2的摩尔比为1:1:2;更优选地,α-Al2O3的粒径为4~10μm(例如,可以为4μm、5μm、6μm、7μm、8μm、9μm、10μm),CaCO3的粒径为0.8~2μm(例如,可以为0.8μm、0.9μm、1μm、1.1μm、1.2μm、1.3μm、1.4μm、1.5μm、1.6μm、1.7μm、1.8μm、1.9μm、2μm),SiO2的粒径为4~6μm(例如,可以为4μm、5μm、6μm)。
在一些实施例中,所述聚合单体为丙烯酰胺或N-羟甲基丙烯酰胺;所述交联剂为N,N’-亚甲基双丙烯酰胺或多乙二醇二甲基丙烯酸;所述分散剂为聚丙烯酸铵、聚乙烯亚胺、柠檬酸铵中的任一种或多种;所述溶剂为水。优选地,所述聚合单体、所述交联剂和所述溶剂的质量比为(100~120):(10~15):(1~2);所述分散剂的质量为所述陶瓷粉末质量的0.5wt%~1wt%(例如,可以具体为0.5wt%、0.6wt%、0.7wt%、0.8wt%、0.9wt%、1wt%)。
在一些实施例中,所述陶瓷粉末在所述浆料中所占的体积比为20%~35%。
(2)通过发泡制生坯
排除浆料中的气泡,然后将发泡剂、稳泡剂加入浆料中,发泡,当发泡体积增大2~3倍时加入催化剂和引发剂,然后将混合料注入模具中,固化,固化可以在室温下进行,固化时间可以控制在30~40分钟,然后脱模进行干燥,得到生坯,其中所述干燥可以在70~80℃下进行,干燥时间可以控制在6~8小时。
在一些实施例中,所述发泡剂为十二烷基硫酸钠;优选地,所述发泡剂在浆料中的浓度为0.25g/L~8g/L,例如,可以为0.25g/L、0.3g/L、0.35g/L、0.4g/L、0.45g/L、0.5g/L、0.55g/L、0.6g/L、0.65g/L、0.7g/L、0.75g/L、0.8g/L;
所述稳泡剂为十二醇,优选地,所述稳泡剂的质量为所述发泡剂质量的0.5wt%~1wt%,例如,可以具体为0.5wt%、0.6wt%、0.7wt%、0.8wt%、0.9wt%、1wt%。
在一些实施例中,所述引发剂为过硫酸铵;优选地,所述引发剂的质量为所述聚合单体质量的20wt%~30wt%,例如,可以为20wt%、21wt%、22wt%、23wt%、24wt%、25wt%、26wt%、27wt%、28wt%、29wt%、30wt%;
所述催化剂为N,N,N’,N’-四甲基乙二胺;优选地,所述催化剂的质量为所述引发剂剂质量的40wt%~45wt%,例如,可以具体为40wt%、41wt%、42wt%、43wt%、44wt%、45wt%。
(3)烧结
将生坯烧结,得到所述钙长石多孔陶瓷材料;其中,烧结条件为:
第一阶段:按照30~40℃/min(例如,可以具体为30℃/min、31℃/min、32℃/min、33℃/min、34℃/min、35℃/min、36℃/min、37℃/min、38℃/min、39℃/min或40℃/min)的升温速率升温至600~700℃,保温1~2小时;
第二阶段:按照10~20℃/min(例如,可以具体为10℃/min、11℃/min、12℃/min、13℃/min、14℃/min、15℃/min、16℃/min、17℃/min、18℃/min、19℃/min或20℃/min)的升温速率升温至900~1000℃,保温1~1.5小时;
第三阶段:按照1~5℃/min(例如,可以具体为1℃/min、2℃/min、3℃/min、4℃/min或5℃/min)的升温速率升温至1350~1400℃,保温5~6小时。
本发明提供的上述制备方法通过对烧结条件进行优化,使材料内部在烧结过程中能够形成结构均匀的大气孔且使大气孔内壁上不易粘附形成小气孔,从而既提高了材料的孔隙率,又提高了材料的抗压强度。而且,该制备方法在发泡之前排出浆料中的气泡,也在一定程度上降低了多层次气孔的出现。
本发明还提供了一种质轻、高强度和低热导率的钙长石多孔陶瓷材料,采用上述制备方法制得。
以下是本发明列举的实施例。
实施例1
制备组分包含:
陶瓷粉末:实施例1所用的陶瓷粉末包含粒径为4μm的α-Al2O3、粒径为0.8μm的CaCO3和粒径为4μm的SiO2,三者的摩尔比为1:1:2,纯度均为分析纯。
聚合单体:丙烯酰胺;
交联剂:N,N’-亚甲基双丙烯酰胺;
分散剂:聚丙烯酸铵;
溶剂:去离子水;
发泡剂:十二烷基硫酸钠;
稳泡剂:十二醇;
催化剂:N,N,N’,N’-四甲基乙二胺;
引发剂:过硫酸铵。
制备步骤:
将去离子水、聚合单体、交联剂和分散剂配制成预混液,将陶瓷粉末与预混液按照2:8的体积比混料,滚筒球磨20小时,得到浆料。
在混合均匀的浆料中加入发泡剂与稳泡剂并进行机械搅拌发泡,发泡剂的用量按照如下方法确定:发泡剂在浆料中的浓度为1g/L,稳泡剂的用量占发泡剂用量的0.5wt%。当发泡体积增大到2倍时依次缓慢加入催化剂及引发剂并搅拌,最后将充分混合的浆料注入模具中,室温固化30分钟后脱模,置于70℃下干燥6小时,得到生坯。
将生坯置于烧结炉中进行烧结,烧结曲线按照如下方法进行设定:
第一阶段:按照30℃/min的升温速率升温至600℃,保温2小时;
第二阶段:按照20℃/min的升温速率升温至1000℃,保温1小时;
第三阶段:按照1℃/min的升温速率升温至1350℃,保温6小时。
完成第三阶段后,随炉冷却,即得到所述钙长石多孔陶瓷材料。
本实施例制得的钙长石多孔陶瓷材料为单一钙长石相,物理性能为:显气孔率89.56%,体积密度0.277g/cm3,抗压强度5.35MPa,热导率0.052W/m·K。
对照组实验1:
制备组分同实施例1。
制备步骤同实施例1基本上相同,不同之处在于:
球磨得到浆料后未进行排除浆料中气泡的操作;
干燥方法为:将脱模后的坯体置于微波干燥器中干燥,微波作用10秒时间后,静置2分钟后再次微波作用,而后循环至干燥终止,干燥时间约6小时;
在烧结时,烧结条件为:按照2℃/min的升温速率升温至600℃,保温1小时,然后按照2℃/min的升温速率升温至1400℃,保温5小时。
对照组实验1制得的钙长石多孔陶瓷材料气孔为多级结构,球形的大气孔壁上分布有亚微米级的气孔,且大气孔内壁上的小尺寸气孔数量较多,物理性能为:显气孔率90.19%,体积密度0.256g/cm3,抗压强度0.27MPa,热导率0.040W/m·K。
实施例2
制备组分包含:
陶瓷粉末:实施例2所用的陶瓷粉末包含粒径为4μm的α-Al2O3、粒径为0.8μm的CaCO3和粒径为4μm的SiO2,三者的摩尔比为1:1:2,纯度均为分析纯。
聚合单体:丙烯酰胺;
交联剂:N,N’-亚甲基双丙烯酰胺;
分散剂:聚丙烯酸铵;
溶剂:去离子水;
发泡剂:十二烷基硫酸钠;
稳泡剂:十二醇;
催化剂:N,N,N’,N’-四甲基乙二胺;
引发剂:过硫酸铵。
制备步骤:
将去离子水、聚合单体、交联剂和分散剂配制成预混液,将陶瓷粉末与预混液按照35:65的体积比混料,滚筒球磨20小时,得到浆料。
在混合均匀的浆料中加入发泡剂与稳泡剂并进行机械搅拌发泡,发泡剂的用量按照如下方法确定:发泡剂在浆料中的浓度为0.25g/L,稳泡剂的用量占发泡剂用量的0.5wt%。当发泡体积增大到3倍时依次缓慢加入催化剂及引发剂并搅拌,最后将充分混合的浆料注入模具中,室温固化30分钟后脱模,置于70℃下干燥6小时,得到生坯。
将生坯置于烧结炉中进行烧结,烧结曲线按照如下方法进行设定:
第一阶段:按照40℃/min的升温速率升温至700℃,保温1小时;
第二阶段:按照10℃/min的升温速率升温至900℃,保温1.5小时;
第三阶段:按照2℃/min的升温速率升温至1400℃,保温6小时。
完成第三阶段后,随炉冷却,即得到所述钙长石多孔陶瓷材料。
本实施例制得的钙长石多孔陶瓷材料为单一钙长石相,微观形貌见图1和图2,物理性能为:显气孔率60.06%,体积密度1.079g/cm3,抗压强度19.98MPa,热导率0.325W/m·K。
对照组实验2
制备组分同实施例2。
制备步骤同实施例2基本上相同,不同之处在于:
球磨得到浆料后未进行排除浆料中气泡的操作;
干燥方法为:将脱模后的坯体置于微波干燥器中干燥,微波作用10秒时间后,静置2分钟后再次微波作用,而后循环至干燥终止,干燥时间约6小时;
在烧结时,烧结条件为:按照2℃/min的升温速率升温至600℃,保温1小时,然后按照2℃/min的升温速率升温至1400℃,保温5小时。
对照组实验2制得的钙长石多孔陶瓷材料气孔为多级结构,球形的大气孔壁上分布有亚微米级的气孔,且大气孔内壁上的小尺寸气孔数量较多,物理性能为:显气孔率61.23%,体积密度1.041g/cm3,抗压强度12.04MPa,热导率0.281W/m·K。
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)
1.一种质轻、高强度和低热导率的钙长石多孔陶瓷材料的制备方法,其特征在于:所述制备方法包括如下步骤:
(1)将聚合单体、交联剂、分散剂、陶瓷粉末和溶剂混合并球磨成浆料;
(2)排除浆料中的气泡,然后将发泡剂、稳泡剂加入浆料中,发泡,当发泡体积增大2~3倍时加入催化剂和引发剂,然后将混合料注入模具中,固化,干燥,得到生坯;
(3)将生坯烧结,得到所述钙长石多孔陶瓷材料;其中,烧结条件为:
第一阶段:按照30~40℃/min的升温速率升温至600~700℃,保温1~2小时;
第二阶段:按照10~20℃/min的升温速率升温至900~1000℃,保温1~1.5小时;
第三阶段:按照1~5℃/min的升温速率升温至1350~1400℃,保温5~6小时。
2.根据权利要求1所述的制备方法,其特征在于:所述陶瓷粉末包含α-Al2O3、CaCO3和SiO2;优选地,α-Al2O3、CaCO3和SiO2的摩尔比为1:1:2;更优选地,α-Al2O3的粒径为4~10μm,CaCO3的粒径为0.8~2μm,SiO2的粒径为4~6μm。
3.根据权利要求1所述的制备方法,其特征在于:所述聚合单体为丙烯酰胺或N-羟甲基丙烯酰胺;
所述交联剂为N,N’-亚甲基双丙烯酰胺或多乙二醇二甲基丙烯酸;
所述分散剂为聚丙烯酸铵、聚乙烯亚胺、柠檬酸铵中的任一种或多种;和
所述溶剂为水。
4.根据权利要求3所述的制备方法,其特征在于:所述聚合单体、所述交联剂和所述溶剂的质量比为(100~120):(10~15):(1~2);和
所述分散剂的质量为所述陶瓷粉末质量的0.5wt%~1wt%。
5.根据权利要求4所述的制备方法,其特征在于:在步骤(1)中,所述陶瓷粉末在所述浆料中所占的体积比为20%~35%。
6.根据权利要求4所述的制备方法,其特征在于:所述发泡剂为十二烷基硫酸钠;优选地,所述发泡剂在浆料中的浓度为0.25~8g/L;
所述稳泡剂为十二醇,优选地,所述稳泡剂的质量为所述发泡剂质量的0.5wt%~1wt%。
7.根据权利要求4所述的制备方法,其特征在于:所述引发剂为过硫酸铵;优选地,所述引发剂的质量为所述聚合单体质量的20wt%~30wt%;
所述催化剂为N,N,N’,N’-四甲基乙二胺;优选地,所述催化剂的质量为所述引发剂剂质量的40wt%~45wt%。
8.根据权利要求1所述的制备方法,其特征在于:所述固化在室温下进行,固化时间控制在30~40分钟。
9.根据权利要求1所述的制备方法,其特征在于:所述干燥在70~80℃下进行,干燥时间控制在6~8小时。
10.一种质轻、高强度和低热导率的钙长石多孔陶瓷材料,其特征在于:采用权利要求1-9任一项所述的制备方法制得。
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