CN110183243A - 一种发泡陶瓷保温板的制备方法 - Google Patents
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Abstract
一种发泡陶瓷保温板的制备方法,包括将发泡陶瓷原料送入熔炼炉中进行熔炼的步骤、对熔炼后所得熔体进行压延成型的步骤、对压延成型后所得板材进行分切的步骤、以及对分切后所得板体进行应力消除和降温的步骤。本发明的制备方法彻底摒弃了耐火材料成型模具的使用,采用全电能熔炼工艺以及压延成型工艺来制备发泡陶瓷保温板,步骤简单,极大程度的降低了生产能耗,提高了产品的生产效率。
Description
技术领域
本发明涉及到发泡陶瓷保温板的生产技术领域,具体的说是一种烧制发泡陶瓷保温板的新工艺。
技术背景
现有技术中,在烧制发泡陶瓷保温板时,通常会使用耐火材料挡板挡在待烧制的发泡保温板四周形成模具,用于发泡陶瓷的烧结成型。(所述的耐火材料挡板为四到六块,首尾相接围成上部开放的矩形空腔,矩形空腔容纳发泡陶瓷保温板原料)。目前,该传统工艺因耐火材料在烧成过程中需要吸收大量能量(甚至高于产品自身所需的能量),导致生产的能耗高。同时,由于耐火材料抗急冷急热能力有限,无法实现快速升温、高温烧成的条件(如1~2小时升至1150~1200℃),这一点严重制约着产能。
综上两点,在高能耗低产能的共同影响下,现有技术中采用的传统发泡陶瓷保温板生产工艺严重制约了行业的发展。
发明内容
为了解决现有技术中,以耐火材料作为成型模具进行发泡陶瓷保温板烧制导致的高能耗低产能等问题,本发明提供了一种全新的发泡陶瓷保温板的制备方法,该方法彻底摒弃了耐火材料成型模具的使用,采用全电能熔炼工艺以及压延成型工艺来制备发泡陶瓷保温板,步骤简单,极大程度的降低了生产能耗,提高了产品的生产效率。
为实现上述技术目的,本发明所采用的技术方案为:一种发泡陶瓷保温板的制备方法,包括将发泡陶瓷原料送入熔炼炉中进行熔炼的步骤、对熔炼后所得熔体进行压延成型的步骤、对压延成型后所得板材进行分切的步骤、以及对分切后所得板体进行应力消除和降温的步骤。
进一步的,所述的发泡陶瓷原料在送入熔炼炉之前,预先设置有对其进行粉碎和混匀的步骤。
进一步的,在所述熔炼步骤中,熔炼炉中的熔炼温度为1200-1300℃,熔炼时间为1-2h。
进一步的,所述的熔炼炉为全电能熔炼炉或天然气熔炼炉。
进一步的,在所述压延成型步骤中,所述熔体通过两个平行、且异向旋转的辊筒间隙进行挤压延展成型。
进一步的,所述压延成型时的温度为1000-1200℃,压延成型后所得板材的厚度为9-13cm。
进一步的,在所述应力消除和降温的步骤中,将分切后的板体送入多层辊道窑中进行处理。
进一步的,所述的分切步骤可设置在应力消除和降温步骤之后。
有益效果:
1、本发明提供的一种发泡陶瓷保温板的制备方法,采用熔炼炉直接熔炼的方式进行发泡陶瓷保温板的烧制,在工艺上,摒弃了自身升温耗能较高、且抗急冷急热能力差的耐火材料成型模具的使用。实现了发泡陶瓷保温板高温快速烧制,从而大大降低了生产能耗,提高了生产效率。与传统生产工艺相比,在同等的资金投入下,采用本发明的工艺可使发泡陶瓷保温板的产能提高近一倍,耗能降低一倍,具有极高的经济效益。
2、本发明的制备方法,采用熔体通过两个平行异向大旋转辊筒间隙的方式来进行发泡陶瓷保温板的压延、拉伸、成型。该压延成型工艺摒弃了传统模具成型过程中模具的使用,可按照实际需求快速生产特定规格尺寸的连续性片状制品,成型效率高,且产品规格可操作性强。
3、本发明的采用多层辊道窑进行板材冷却段的应力消除和降温,避免了热能的浪费,提高了产能。
具体实施方式
下面将结合本发明实施例,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,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前提下所获得的所有其他实施例,都属于本发明保护范围。
一种发泡陶瓷保温板的制备方法,该方法采用阶梯式全电能熔炼工艺、辅以压延成型工艺来制备发泡陶瓷保温板,摒弃了耐火材料作为成型模具,极大程度的降低了生产能耗,也为产品快速烧成提供了可能。具体包括对发泡陶瓷原料进行粉碎和混匀的步骤、将发泡陶瓷原料送入熔炼炉中进行熔炼的步骤、对熔炼后所得熔体进行压延成型的步骤、对压延成型后所得板材进行分切的步骤、以及对分切后所得板体进行应力消除和降温的步骤。
其中,阶梯式全电能熔炼工艺是将已混合好的物料投入全电能熔炼炉中,经过高温熔制使得物料呈具有一定流动性的液态熔体,并且熔体内部还存在均匀的泡孔。(这一过程的熔炼时间为1-2h,熔炼温度为1200-1300℃,所述的全电能熔炼炉可替换成天然气熔炼炉)。
在完成了产品晶化烧制过程后,需将制得的熔体做成型处理,这时将熔体通过两个平行异向大旋转辊筒的间隙,使熔体受到辊筒挤压延展、拉伸而成为具有一定规格尺寸要求的连续片状制品。该压延成型过程中的温度为1000-1200℃,压延成型后所得板材的厚度为9-13cm。
获得连续片状的发泡陶瓷保温板后,在退火段对板材进行分切,制成满足所需规格的不连续产品。
最后将指定规格的发泡陶瓷保温板送入多层辊道窑中,进行应力消除及降温工序。
当然,该分切步骤也可设置在应力消除和降温步骤之后。
作为本发明的另一种优选实施方案,降温过程可以采用传统的单层辊道窑。
实施例 1
一种发泡陶瓷保温板的制备方法,制备步骤如下:
(1)将陶瓷废渣与矿物原料、化工原料按质量百分比配料,其中以陶瓷废渣73%、钠长石8%、高岭土4%、膨润土4%、白云石3%、纯碱4%、碳酸钡3.5%、碳化硅0.5%的比例称量各组分原料组分,粉碎后加入混料机中混合均匀。
(2)将步骤(1)所制得的物料加入至全电能熔炼炉中,在1250℃高温下熔炼一小时,使其形成具有一定流动性并有气孔特征的熔体。
(3)将步骤(2)所制得的熔体在1100℃下压延成型,制成厚度11cm的半成品板材。
(4)在800℃时,对经压延成型制得的连续片状板材进行分切,得到1200*2400*110mm规格的产品。
(5)通过升降平台将步骤(4)所得产品送入多层辊道窑中进行降温,冷却至80℃出窑。
(6)抛光定厚,产品入库。
实施例2
一种发泡陶瓷保温板的制备方法,制备步骤如下:
(1)将煤矸石与矿物原料、化工原料按质量百分比配料,其中以煤矸石70%、钠长石13%、方解石6%、滑石4%、纯碱4%、碳酸钡2.5%、碳化硅0.5%的比例称量各组分原料,粉碎后加入混料机中混合均匀。
(2)将步骤(1)所制得的物料加入至全电能熔炼炉中,在1290℃高温下熔炼1.5小时,使其形成具有一定流动性并有气孔特征的熔体。
(3)将步骤(2)所制得的熔体在1100℃下压延成型,制成厚度11cm的半成品板材。
(4)在800℃时,对经压延成型制得的连续片状板材进行分切,得到1200*2400*110mm规格的产品。
(5)通过升降平台将步骤(4)所得产品送入多层辊道窑中进行降温,冷却至80℃出窑。
(6)抛光定厚,产品入库。
以上公开的仅为本申请的几个具体实施例,但并非用于限定本发明的保护范围。任何熟悉本领域的技术人员,在本发明的基础上所做的改动与润饰,都应属于本发明的保护范围。
Claims (8)
1.一种发泡陶瓷保温板的制备方法,其特征在于:包括将发泡陶瓷原料送入熔炼炉中进行熔炼的步骤、对熔炼后所得熔体进行压延成型的步骤、对压延成型后所得板材进行分切的步骤、以及对分切后所得板体进行应力消除和降温的步骤。
2.根据权利要求1所述的一种发泡陶瓷保温板的制备方法,其特征在于:所述的发泡陶瓷原料在送入熔炼炉之前,预先设置有对其进行粉碎和混匀的步骤。
3.根据权利要求1所述的一种发泡陶瓷保温板的制备方法,其特征在于:在所述熔炼步骤中,熔炼炉中的熔炼温度为1200-1300℃,熔炼时间为1-2h。
4.根据权利要求1所述的一种发泡陶瓷保温板的制备方法,其特征在于:所述的熔炼炉为全电能熔炼炉或天然气熔炼炉。
5.根据权利要求1所述的一种发泡陶瓷保温板的制备方法,其特征在于:在所述压延成型步骤中,所述熔体通过两个平行、且异向旋转的辊筒间隙进行挤压延展成型。
6.根据权利要求1所述的一种发泡陶瓷保温板的制备方法,其特征在于:所述压延成型时的温度为1000-1200℃,压延成型后所得板材的厚度为9-13cm。
7.根据权利要求1所述的一种发泡陶瓷保温板的制备方法,其特征在于:在所述应力消除和降温的步骤中,将分切后的板体送入多层辊道窑中进行处理。
8.根据权利要求1所述的一种发泡陶瓷保温板的制备方法,其特征在于:所述的分切步骤可设置在应力消除和降温步骤之后。
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