CN1101304C - 复杂形状中空陶瓷体的形成方法 - Google Patents

复杂形状中空陶瓷体的形成方法 Download PDF

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CN1101304C
CN1101304C CN99125017A CN99125017A CN1101304C CN 1101304 C CN1101304 C CN 1101304C CN 99125017 A CN99125017 A CN 99125017A CN 99125017 A CN99125017 A CN 99125017A CN 1101304 C CN1101304 C CN 1101304C
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core
ceramic material
assembly
volatility
mould
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CN1251330A (zh
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K·J·祖克
J·T·奈尔
C·A·塔里
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Osram Sylvania Inc
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B3/00Producing shaped articles from the material by using presses; Presses specially adapted therefor
    • B28B3/003Pressing by means acting upon the material via flexible mould wall parts, e.g. by means of inflatable cores, isostatic presses
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/34Moulds, cores, or mandrels of special material, e.g. destructible materials
    • B28B7/342Moulds, cores, or mandrels of special material, e.g. destructible materials which are at least partially destroyed, e.g. broken, molten, before demoulding; Moulding surfaces or spaces shaped by, or in, the ground, or sand or soil, whether bound or not; Cores consisting at least mainly of sand or soil, whether bound or not
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01JELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J9/00Apparatus or processes specially adapted for the manufacture, installation, removal, maintenance of electric discharge tubes, discharge lamps, or parts thereof; Recovery of material from discharge tubes or lamps
    • H01J9/24Manufacture or joining of vessels, leading-in conductors or bases
    • H01J9/245Manufacture or joining of vessels, leading-in conductors or bases specially adapted for gas discharge tubes or lamps

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacture Of Electron Tubes, Discharge Lamp Vessels, Lead-In Wires, And The Like (AREA)
  • Compositions Of Oxide Ceramics (AREA)
  • Moulds, Cores, Or Mandrels (AREA)
  • Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)
  • Vessels And Coating Films For Discharge Lamps (AREA)
  • Separation Using Semi-Permeable Membranes (AREA)

Abstract

一种高亮度放电灯的放电管适用的陶瓷材料中空体的形成方法,包括形成构型与该中空体内部构型匹配的基本为纯石墨的挥发性芯。形成并添加该陶瓷材料的包括粘合剂的可流动粉末以填充确定外轮廓的柔顺弹性体模具和确定内轮廓的挥发性芯之间的环状空间。将陶瓷粉末在围绕该芯的模具中等压压缩以形成组件。从模具中移出该组件,在适当的气氛中以某一速率和时间加热组件以挥发该挥发性芯并且随后烧结该组件以形成中空体。

Description

复杂形状中空陶瓷体的形成方法
本发明涉及形成高纯度、复杂形状中空陶瓷体的方法。本发明尤其涉及形成复杂形状的放电灯中弧光管适用的多晶氧化铝体。
在高压钠(HPS)灯中采用多晶氧化铝(PCA)弧光管已经有许多年了。最近,已发现这样的弧光管作金属卤灯的重要应用,其中,非圆筒形弧光管在提高效能上显示了优势。这种非圆筒形状包括椭圆和凸出的几何形状。
现有技术中,已采用冷等压压制法、料浆浇铸法、带式浇铸法、注射成型法、吹塑法、凝胶浇铸法或者挤塑法作为形成这些弧光管的方法。虽然这些方法很适于加工简单的圆筒形,但复杂形状,单件和组合件常常受到困难的限制,有时甚至无法除去确定内部几何形状用的结构芯材。此外,因与芯材接触引起的沾污常常造成问题,尤其在要求高纯度的光学陶瓷情形下。中空陶瓷体的挤塑法和吹塑法由于湿挤出混合物的塑性流动可呈现翘曲,由于直径胀大或材料刚性变化可呈现扭曲或甚至空腔塌陷或令壁厚变化。由于无法除去心轴或芯,压制或浇铸的单件组件的形状受到限制。如果无芯浇铸,内部的几何形状是可变的,烧结部分常常需要进行昂贵的金刚石研磨。
提供一种高压钠灯(HPS)和金属卤灯的放电管所适用的复杂形状的PCA弧光管的可工业化的制造方法,将是本技术领域一个进展。
因此,本发明的目的之一是排除现有技术的弊端。
本发明的另一目的是增加复杂形状的陶瓷体的生产。
本发明的再一目的是通过使用不留残渣挥发性芯材料提高陶瓷体的形成工艺和制造。
本发明的再一目的是在最终变致密的制品形成过程中,保持陶瓷的高纯度和固有的化学和物理性能。
在本发明的一种情况下,通过提供陶瓷材料中空体的一种形成方法实现这些目的,该方法包括形成构型与该中空体内部构型匹配的挥发性芯;形成该陶瓷材料的载体,包括粘合剂;用该陶瓷材料包覆该挥发性芯;在围绕该芯的模具中压制该陶瓷材料以形成组件;从该模具中移出该组件;在适当的气氛中以某一速率和时间加热该组件以挥发该挥发性芯并且随后烧结该组件以形成该中空体。
在更具体的实施方案中,通过装配包括确定内部轮廓的该挥发性芯和确定外部轮廓的柔顺弹性材料的模具形成该体。将含有该陶瓷材料的载体浇铸到该弹性体模具和芯之间的空间和该模具里,从而压制包含其中的该陶瓷粉末以形成组件,然后如上述完成该组件。
在本发明的一个优选实施方案中,用高纯度石墨形成该挥发性芯。
此方法允许以可工业化的、成本可行的方式制造高压钠灯和金属卤灯放电管所适用陶瓷的复杂形状。
为了更好地理解本发明及其别的深远的目的、优点和性能,用以下公开内容和所附的权利要求书作为参考。
现在更加详细地涉及本发明——通过使用挥发性芯制造复杂形状陶瓷体。在本发明的一个优选实施方案中,用高纯度石墨形成该芯。高纯度石墨所意味的是材料至少为99.99%的纯碳。
为了制造本发明的弧光管,用在含氧气氛中加热期间将反应形成CO2的高纯度石墨预构造所要形状的芯,例如椭圆状的。用传统的石墨机器成型方法形成该芯。
制备并喷雾干燥载体,例如含适当粘合剂和增塑剂的坯体材料水浆。将该经喷雾干燥、已可流动的粉末材料浇铸进装有该石墨芯的聚氨酯湿袋(wet-bag)模具中,并冷等压压制到12000psi。将含该石墨芯的完整的陶瓷体从该模具中移出并在空气中以每小时300℃的速率加热到1325℃,将温度1325℃维持必要的时间使该石墨全部转变为二氧化碳。对于大多数应用,该时间为大约24小时。然后在还原气氛,例如8%氢和92%氮中,于1900℃烧结该中空体。
以下实施例举例说明但不限定本发明。实施例1
将含有0.5重量%的有机粘合剂,如聚乙烯醇和2.0重量%增塑剂,如聚乙二醇的经喷雾干燥的氧化铝粉末装入聚氨酯湿袋模具中,该模具有椭圆状空腔并装入了穿在碳化钨心轴上的直径较小的椭圆状高纯度石墨芯(例如,Bay Carbon,Inc.SPK级)。将该含粘合剂的氧化铝粉末填充到聚氨酯和中心石墨芯间的空隙中。将该填充氧化铝的湿袋密封并以12500psi等压压制以形成坯体。压制后,将该氧化铝坯体和几乎被包封的石墨芯从该湿袋和心轴移出,并在1325℃空气中烧制该坯体直到石墨和粘合剂完全挥发。然后,通过在8%氢和92%氮的气氛中于1900℃烧制2小时以烧结该预烧结的已中空的陶瓷体,制成中空的、凸出形状的、高亮度放电灯放电管适用的单件半透明体。高亮度放电灯包括但不限于金属卤灯和高压钠灯。实施例2
按实施例1相同的步骤进行,但粘合剂的量提高到1.0重量%并且不使用增塑剂。所得陶瓷体也适于用作高亮度灯中的放电管,这表明此工艺足以承受各种粘合剂/增塑剂水平和比率。
虽然已经公开并描述了目前所认为的本发明的优选实施方案,但是本领域的熟练技术人员显而易见,在此可以不违背所附权利要求书限定的本发明范围而作出各种变化和改进。

Claims (6)

1、一种陶瓷材料中空体的形成方法,包括以下步骤:形成构型与所述中空体内部构型匹配的挥发性芯,该挥发性芯是高纯度石墨;形成所述陶瓷材料的包括粘合剂的可流动粉末;用所述陶瓷材料包覆所述挥发性芯;在围绕所述芯的模具中压制所述陶瓷材料以形成组件;从所述模具中移出所述组件;在适当的气氛中以某一速率和时间加热所述组件以挥发所述挥发性芯并且随后烧结所述组件以形成所述中空体,其中,所述适当气氛含有氧,并且使所述石墨芯转变成二氧化碳。
2、如权利要求1方法,其特征在于,随后使所述中空体形成为放电灯具所用的弧光管。
3、如权利要求1的方法,其特征在于,所述陶瓷材料主要为氧化铝。
4、如权利要求1的方法,其特征在于,所述温度大于450℃。
5、如权利要求1的方法,其特征在于,所述适当气氛为空气。
6、如权利要求1的方法,其特征在于,所述包覆所述挥发性芯的步骤是按以下方式实现的:装配包括确定内部轮廓的所述挥发性芯和确定外部轮廓的柔性弹性材料的模具;将所述陶瓷材料浇铸到所述弹性体模具和所述芯之间的空间里。
CN99125017A 1998-10-02 1999-10-02 复杂形状中空陶瓷体的形成方法 Expired - Fee Related CN1101304C (zh)

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US09/165,979 US5993725A (en) 1998-10-02 1998-10-02 Method of forming complex-shaped hollow ceramic bodies
US09/165979 1998-10-02
US09/165,979 1998-10-02

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ATE261347T1 (de) 2004-03-15
EP0992327B1 (en) 2004-03-10
DE69915422D1 (de) 2004-04-15
JP2000108116A (ja) 2000-04-18
EP0992327A1 (en) 2000-04-12
JP4555417B2 (ja) 2010-09-29
CA2276763C (en) 2006-09-05
CA2276763A1 (en) 2000-04-02
CN1251330A (zh) 2000-04-26
US5993725A (en) 1999-11-30
DE69915422T2 (de) 2004-08-05

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