CN110128112A - 一种陶瓷材料烧结方法 - Google Patents
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Abstract
本发明公开了一种陶瓷材料烧结方法，为在烧结炉内的烧结匣体内铺设有低熔点材料，烧结过程中，该低熔点材料呈液体状、并形成为液态载体，陶瓷胚体漂浮在该液态载体中；在烧结炉内，烧结温度逐步达到最高设定温度并完成保温后，得陶瓷制品，然后进行降温，在液态载体开始凝固前，将陶瓷制品与液态载体分离，完成降温后，制得；低熔点材料的熔点或熔化温度低于烧结炉的炉内温度的最高设定温度。该方法在陶瓷的高温烧结阶段以液态载体代替传统烧结方法中的固态载体，降低陶瓷体与载体之间的摩擦力，减缓陶瓷各方向上的收缩差异，从而避免陶瓷的烧结变形，获得表面光滑平整、尺寸合格的致密陶瓷制品。
Description
技术领域
本发明涉及一种陶瓷材料烧结方法。
背景技术
陶瓷作为人类社会中至关重要的一类材料，在人类生产生活中的各个领域都有广泛应用。高温烧结过程是陶瓷制品生产的一个关键工序，经过多年的技术积累，至今已发展出了常压烧结、热压烧结、气氛烧结、等离子烧结、自蔓延烧结、微波烧结等多种烧结工艺，解决了各种烧结难题。但无论哪种烧结工艺，都无法回避陶瓷材料在烧结过程中的收缩问题，陶瓷材料的烧结过程就是一个排除气孔、减小颗粒间隙的过程，因而必然伴随着一定程度的尺寸收缩。在某些情况下，通过大量的试验摸索，可以掌握陶瓷收缩的规律，从而可以通过坯体尺寸的设计来适应收缩行为；然而在某些情况下，陶瓷的收缩程度会超越人们的预期，轻则造成尺寸偏差，重则造成陶瓷制品变形，甚至破损。尤其在陶瓷坯体与承烧板摩擦力过大时，陶瓷不能自由收缩，极易发生制品不同方向上的不均匀收缩，导致陶瓷产品变形
发明内容
本发明的目的在于克服上述缺陷，本申请提供一种陶瓷烧结方法，以避免或减少烧结过程中，由于摩擦力而导致不均匀变形收缩的问题，具体的技术方案为：
一种陶瓷材料烧结方法，在烧结炉内的烧结匣体内铺设有低熔点材料，烧结过程中，该低熔点材料呈液体状、并形成为液态载体，陶瓷胚体漂浮在该液态载体中；
在烧结炉内，烧结温度逐步达到最高设定温度并完成保温后，得陶瓷制品，然后进行降温，在液态载体开始凝固前，将陶瓷制品与液态载体分离，完成降温后，制得；
低熔点材料的熔点或熔化温度低于烧结炉的炉内温度的最高设定温度。
优选地，所述低熔点材料为玻璃或金属材料；当低熔点材料为玻璃时，该玻璃的熔化温度为500-800℃；当低熔点材料为金属材料时，该金属材料的熔点为200-300℃。进一步优选，所述玻璃为钠硅玻璃或硼硅玻璃；所述金属材料为锡或其合金。
该方法在陶瓷的高温烧结阶段以液态载体代替传统烧结方法中的固态载体，降低陶瓷体与载体之间的摩擦力，减缓陶瓷各方向上的收缩差异，从而避免陶瓷的烧结变形，获得表面光滑平整、尺寸合格的致密陶瓷制品。本方法主要适用于平板陶瓷制品的烧结，其陶瓷坯体的成型方式包括：干压、等静压、热压注、流延等方式。
进一步，为保证在烧结过程，最大限度地避免由于摩擦力而导致的不均匀收缩，烧结炉的最高设定温度与低熔点材料的熔点或熔化温度之间的差值≥400℃。在该温差下，可有效地使陶瓷体在发生大幅度尺寸收缩之前，使低熔点材料完成熔化。
进一步，为有利于陶瓷制品的致密化，陶瓷坯体在进入到烧结炉内进行烧结前，首先进行排胶预烧结，排胶预烧结时的最高烧结温度为850-1100℃。
为提高陶瓷制品的收缩均匀性，陶瓷坯体与烧结匣的内腔的底面无接触，使陶瓷坯体完全漂浮在液态载体中，使烧结过程中，陶瓷坯体在各方向上均能自由地进行收缩变形，避免受到液态载体之外的其他器件的影响。
为避免陶瓷制品被粘结在低熔点材料上，陶瓷制品需在冷却至液态载体熔点之前与载体分离，该分离操作通过向上抬升陶瓷制品使陶瓷与液态载体脱离。
具体地，在液态载体开始凝固前，采用夹具将陶瓷制品从液态载体内取出；或者，在烧结过程中，陶瓷胚体被放置于轨道上，沿推板轨道，陶瓷坯体进入到烧结炉内，并进入到液态载体内，在完成烧结后经推板轨道被送出烧结炉。
本方法适用的陶瓷种类包括氧化铝陶瓷、氧化锆陶瓷、氧化硅陶瓷、氧化钙陶瓷、氧化镁陶瓷以及多种组分复合陶瓷。
附图说明
图1为本发明第一种实施例的示意图。
图2为本发明第二种实施例的示意图。
图3为实施例1所生产的1#陶瓷材料的照片。
图4为采用现有技术所生产的陶瓷材料的照片。
具体实施方式
实施例1：
对1#陶瓷材料进行烧结，该1#陶瓷材料为一陶瓷平板。烧结步骤如下：
并请同步参阅图1，首先将氧化锆陶瓷原料经干压工艺成型为平板状的坯体；然后将坯体进行排胶处理和1000℃预烧结；再在烧结炉内进行高温烧结，具体在本实施例中，采用隧道窑100进行高温烧结。
在隧道窑100内设置有熔池110，在熔池110内堆放有熔点为232℃的金属锡粉末或锡块，在高温下，该金属锡粉末或锡块被融化为液态载体120。
预烧结后的坯体200在推板轨道150的带动下进入到隧道窑100内进行烧结，在该隧道窑100内设置有三个温区，依照坯体200的移动方向，三个温区分别为升温区、高温烧结区和降温区。
在推板轨道150的带动下，坯体200依次经过升温区、高温烧结区和降温区三个温区进行烧结，完成烧结后，被送出隧道窑100，完成烧结。
本实施例中，高温烧结区的炉温为1450℃，坯体在此区段完成烧结收缩，进入降温区，温度逐步降至300℃，推板轨道逐渐抬升将陶瓷体与液态载体分离，并最终冷却至室温，获得烧成制品。
在整个烧结过程中，金属锡粉末或锡块一直完全处于熔化状态，且坯体漂浮在液态载体中，与熔池的底部无接触。该熔池110即为烧结匣。
可以理解，在其它实施例中，坯体还可以采用静压或流延的工艺进行成型。
在其它实施例中，还可以采用其他低熔点金属及其合金来形成液态载体。在进行选择时，要使烧结炉的最高设定温度至少比低熔点金属或合金的熔点高400℃。
可以理解，在其它实施例中，对于排胶预烧结的最高烧结温度，还可以选择为850℃、900℃、950℃、1050℃或1100℃。
图3为采用本实施所生产的1#陶瓷材料的照片。
图4为现有技术由于摩擦而导致变形的陶瓷材料的照片。
由图3和图4的对比可以看出，采用本方法所制备的平板陶瓷制品未出现由于收缩差异而导致的变形，制品的表面光滑平整，结构均匀。
实施例2：
对2#陶瓷材料进行烧结，该2#陶瓷材料为一陶瓷平板。烧结步骤如下：
氧化铝造粒粉，经静压工艺成型为平板坯体；请参阅图2，
坯体500置于烧结匣410内，烧结匣410内铺垫有熔化温度为650-665℃的低熔点硼玻璃，将烧结匣钵置于箱式烧结炉400内，逐步升温至1650℃，在升温过程中，硼玻璃被融化，形成玻璃熔液420，该玻璃熔液420即为液态载体。
陶瓷体致密化过程完成后逐步降温至800℃，用夹钳取出陶瓷品，冷却至室温，获得烧成制品。本实施例中，不进行排胶预烧结。
可以理解，在其它实施例中，还可以采用其他低熔点玻璃，融化温度可以在500-600℃、670-750℃或750-800℃等范围内选择，在进行选择时，要使烧结炉的最高设定温度至少要大于低熔点材料的熔点或融化温度400℃。
采用本实施例所烧结的陶瓷平板与实施例1所生产的陶瓷平板具有相同的特征。
Claims (8)
1.一种陶瓷材料烧结方法，其特征在于，在烧结炉内的烧结匣体内铺设有低熔点材料，烧结过程中，该低熔点材料呈液体状、并形成为液态载体，陶瓷胚体漂浮在该液态载体中；
在烧结炉内，烧结温度逐步达到最高设定温度并完成保温后，得陶瓷制品，然后进行降温，在液态载体开始凝固前，将陶瓷制品与液态载体分离，完成降温后，制得；
低熔点材料的熔点或熔化温度低于烧结炉的炉内温度的最高设定温度。
2.根据权利要求1所述的陶瓷材料烧结方法，其特征在于，
所述低熔点材料为玻璃或金属材料；
当低熔点材料为玻璃时，该玻璃的熔化温度为500-800℃；
当低熔点材料为金属材料时，该金属材料的熔点为200-300℃。
3.根据权利要求2所述的陶瓷材料烧结方法，其特征在于，
所述玻璃为钠硅玻璃或硼硅玻璃；
所述金属材料为锡或其合金。
4.根据权利要求1所述的陶瓷材料烧结方法，其特征在于，
烧结炉的最高设定温度与低熔点材料的熔点或熔化温度之间的差值≥400℃。
5.根据权利要求1所述的陶瓷材料烧结方法，其特征在于，
陶瓷坯体在进入到烧结炉内进行烧结前，首先进行排胶预烧结，排胶预烧结时的最高烧结温度为850-1100℃。
6.根据权利要求1所述的陶瓷材料烧结方法，其特征在于，
陶瓷坯体与烧结匣的内腔的底面无接触。
7.根据权利要求1所述的陶瓷材料烧结方法，其特征在于，
陶瓷制品需在冷却至液态载体熔点之前与载体分离，该分离操作通过向上抬升陶瓷制品使陶瓷与液态载体脱离。
8.根据权利要求1所述的陶瓷材料烧结方法，其特征在于，
在液态载体开始凝固前，采用夹具将陶瓷制品从液态载体内取出；或者，
在烧结过程中，陶瓷胚体被放置于轨道上，沿推板轨道，陶瓷胚体进入到烧结炉内，并进入到液态载体内，在完成烧结后经推板轨道被送出烧结炉。
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| CN115321954A (zh) * | 2022-08-09 | 2022-11-11 | 广东环波新材料有限责任公司 | 陶瓷基板的制备方法以及低温共烧陶瓷基板 |
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| CN115321954A (zh) * | 2022-08-09 | 2022-11-11 | 广东环波新材料有限责任公司 | 陶瓷基板的制备方法以及低温共烧陶瓷基板 |
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