CN110655390A - 一种大规格蜂窝蓄热陶瓷体的制备方法 - Google Patents
一种大规格蜂窝蓄热陶瓷体的制备方法 Download PDFInfo
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Abstract
本发明公开了一种大规格蜂窝蓄热陶瓷体的制备方法,它用氧化铝等为主要原料以及辅料、适量水混合球磨、陈腐、去磁制成泥料,将泥料制成平板形陶瓷片和波纹形陶瓷片,将瓷片送入到烘干房中,进行表面烘干定型,高温烧制得到平板陶瓷片和波纹形陶瓷片,在平板形陶瓷片上平面涂胶交错或平行设置波纹形陶瓷片,把平板形陶瓷片和波纹形陶瓷片组合堆砌成蜂窝坯体,再干燥、烧成即可获得大规格蜂窝蓄热陶瓷体。本发明简化了模具结构,大大降低了模具制造材料和工时费用,名种型号需要只需调换转辊上的凸体和凹槽,可采用液压吨位低的液压机进行挤压,节省能耗和动力,降低设备投资,适用产品规格多、数量少的生产模式,降低生产成本。
Description
技术领域
本发明涉及一种蜂窝陶瓷体,尤其是涉及蜂窝蓄热陶瓷体的制备方法。
背景技术
蜂窝陶瓷是一种结构似蜂窝形状的新型陶瓷产品。由最早使用在小型汽车尾气净化广泛应用在化工、电力、冶金、石油、电子电器、机械等工业中,而且越来越广泛,发展前景相当可观,蜂窝陶瓷按用途可以分为蓄热体、填料、催化剂载体和过滤材料四大类,蜂窝陶瓷蓄热体热容量1000kJ/kg以上,产品最高使用温度≥1700℃,在加热炉、烘烤器、均热炉、裂解炉等窑炉中可节省燃料达40%以上,产量提高15%以上,排放烟气温度低于150℃,蜂窝陶瓷填料比其它形状填料的比表面积更大,强度更好等优点,可使汽液分布更均匀,床层阻力降低,效果更好,且可延长使用寿命,在石化、制药和精细化工行业中作填料效果相当好,蜂窝陶瓷催化剂载体方面更具优势。以蜂窝状陶瓷材料为载体,采用独特的涂层材料,以贵金属,稀土金属及过渡金属制备,因而具有高的催化活性,良好的热稳定性,长的使用寿命,高强度等优点,蜂窝陶瓷过滤材料有以下优点:化学稳定性好,耐酸碱及有机溶剂;极好的耐急热急冷性能,工作温度可高达1000℃;抗菌性能好,不易被细菌降解,不易堵塞且易再生;较强的结构稳定性,孔径分布狭窄,渗透率高;无毒,尤其适用于食品和药物的处理,蓄热用蜂窝陶瓷体外形尺寸高达几十厘米,甚至上米,一般外形尺寸达到50厘米的称为大规格蜂窝陶瓷体。
目前蓄热蜂窝陶瓷体无论大小都是采用模具通过挤压一次成型的,但现有大规格蜂窝陶瓷在采用模具挤压一次成型制造时存在以下一些问题:一是模具大且蜂窝孔形成的模具结构复杂,模具尺子精度高,制造费用大,液压设备投资多,占地面积大,动力和能耗多,生产成本高;二是大规格蜂窝陶瓷市场需求量相对较少,设备利用率低;再是成型过程中,工艺控制难度大,产品报废率较高。
现有技术也有用练泥机挤制出的泥块经由对辊机辊压出波纹叠片,然后再用波纹叠片与另一个波纹叠片按峰对峰谷对谷经粘结剂粘结组合成蜂窝陶瓷;操作时波纹片极易滑动变成峰叠峰谷叠谷从而不能形成蜂窝状,必须在谷内放置一个木制或塑料且和组合成蜂窝大小、形状一致的小棒结构进行支撑,才能形成稳定的蜂窝结构,然后按一定的形状和大小尺寸进行切割整形,干燥和烧成。其工艺流程繁多,生产可操作性差,生产效率低。
发明内容
针对上述现有技术中大规格蜂窝蓄热陶瓷体采用模具挤压一次成型所存在的问题,本发明提供了一种模具结构简单,模具和设备投资少,利用率高,便于工艺控制掌握,产品报废率较低的大规格蜂窝蓄热陶瓷体的制备方法。
本发明所述大规格蜂窝蓄热陶瓷体的制备方法步骤是:
1、用氧化铝、石英、长石、高岭土、滑石、氧化钛、碳化硅、锂瓷石、锂辉石为主要原料以及占主要原料总重量3-5%的粘接剂以及适量水混合球磨、陈腐、去磁制成泥料,
2、将泥料用制泥机制成板状泥段,再将泥段通过挤压机制成平板形陶瓷片雏坯,同时将泥段输入到对转挤压成型机的上转辊和下转辊之间,利用在表面上设置有凸体的上转辊和与在其表面上设置有与凸体相配的凹槽的下转辊同步相对旋转挤压制成波纹形陶瓷片雏坯,
3、将平板形陶瓷片雏坯和波纹形陶瓷片雏坯送入到烘干房中,加热至200-260℃,保持1-2小时低温除湿,进行表面烘干定型,
4、将定型的平板形陶瓷片和波纹形陶瓷片加热至700℃-800℃,并保温3小时进行煅烧,再加热至1200-1500℃,并保温2-4小时进行还原,冷却至常温出炉得到平板形陶瓷片和波纹形陶瓷片,
5、将波纹形陶瓷片通过涂胶辊自动在波峰上用高温粘合剂涂胶后与平板形陶瓷片自动叠在一起,然后再在平板形陶瓷片上平面涂胶交错或平行设置波纹形陶瓷片,把平板形陶瓷片和波纹形陶瓷片组合堆砌成蜂窝坯体,然后干燥,待涂胶固化后,用机械手按一定长度切割,再通过人工或机械手两侧面用可塑泥料扶皮,再干燥、烧成即可获得大规格蜂窝蓄热陶瓷体。
所述氧化铝、石英、长石、高岭土、滑石、氧化钛、碳化硅、锂瓷石、锂辉石等为主要原料重量比为氧化铝10%-90%、石英0.1%-80%、长石0.1%-50%、高岭土5%-30%、滑石1-3%、氧化钛1-3%、碳化硅1-3%、锂瓷石1-2%,所述粘结剂为聚乙烯醇、甲基纤维素、乙基纤维素、羟丙基纤维素其中的至少一种,所述粘结剂为上述主要原料重量的3-5%。
本发明所述上转辊表面上设置有凸体,下转辊表面上设置有与凸体形状相配的凹槽,凸体与凹槽之间间隙即为波纹形陶瓷片的厚度,所述凸体(形成蜂窝孔)横截面形状为梯形(如图1所示),或三角形(如图2所示),还可为半圆弧形(如图3所示)或椭圆形等。相应制得具有蜂窝孔的波纹形陶瓷片,所述波纹形陶瓷片包括梯形陶瓷片、三角形陶瓷片、半圆形陶瓷片或椭圆形陶瓷片等,波纹形陶瓷片与平板形陶瓷片用涂胶组合,并经干燥固化和烧制后形成蜂窝孔为梯形、三角形、半圆形或椭圆形的大规格蜂窝蓄热陶瓷体。
本发明所述波纹形陶瓷片(或为波纹叠片)的长宽尺寸和平板形陶瓷片(平板片)外形尺寸一致,可以根据需求将大规格蜂窝蓄热陶瓷体切割成宽度为10mm-500mm,长度为10mm-500mm的各种规格;所述的切割方式可以是切刀、自动切割机等。
所述涂胶用高温粘合剂,所述高温粘合剂量用制造波纹或平板形陶瓷片的主要原体为基料,再加上占基料重量0.1-30%的无机胶、0.1-5.0%有机胶及20%-80%的水分混合而成。所述无机胶是硅溶胶、铝溶胶、水玻璃、磷铝胶、钛溶胶等中一种或几种复合;所述有机胶为聚乙烯醇、甲基纤维素、丙基纤维素等中的至少一种。
本发明所述扶皮用可塑泥料,用制造波纹形或平板形陶瓷片的主要原料为基料,再加上占基料重量0.1-30%的无机胶、0.1-5.0%有机胶及20%-40%的水分混合而成,用刮板以一定的角度在波纹蜂窝体两侧把泥料刮入两侧面片堆叠形成的缝隙里,完成坯体扶皮(植皮)操作。
所述波纹形陶瓷片或平板形陶瓷片化学成分:SiO2:15-90%、Al2O3:15-90%、Fe2O3:0.1-6%、TiO2:0.1-6%、CaO:0.1-6%、MgO:0.1-15%、K2O:0.1-3%、Na2O:0.1-3%、LiO2:0.1-3%、其他:0.1-3%,或Sic:0-95%。
本发明所述大规格蜂窝蓄热陶瓷体经检测后,其各项技术指标是:
抗压强度:20-30Mpa 比表面积:300-500mm2/g
耐酸度≥99.8% 体积密度:1.6-3.8g/cm3
耐碱度≥97.5% 堆积空隙率:60-70%,
吸水率:0.1%-25%, 孔隙率:0.1%-55%。
本发明在制造大规格蜂窝蓄热陶瓷体时,不需要用现有技术中装有紧密排列且高度较长、数量多的细长金属芯模,以及结构复杂庞大的模具和液压吨位大的液压机来一次性完成蓄热蜂窝陶瓷体制造,一只蜂窝孔高度和大小不是用一根芯模来形成,而是利用结构简单的辊压模具先制成片状和波纹片状单体,再通过叠加组合形成蓄热蜂窝陶瓷体,所有蜂窝孔的高度由一根水平的转辊表面上的凸体来完成,与现有技术相比具有以下特点:
1、简化了模具结构,大大降低了模具制造材料和工时费用,各种型号需要只需调换转辊上的凸体和凹体,
2、可采用液压吨位低的液压机进行挤压,节省能耗和动力,降低设备投资,
3、 适用产品规格多、数量少的生产模式,降低生产成本。
附图说明
图1是本发明波纹形陶瓷片挤压成型示意图,
图2是蜂窝孔为梯形的蜂窝蓄热蜂窝陶瓷体局部结构示意图,
图3是蜂窝孔为三角形的蜂窝蓄热蜂窝陶瓷体局部结构示意图,
图4是蜂窝孔为半圆形的蜂窝蓄热蜂窝陶瓷体局部结构示意图。
在图中,1、梯形陶瓷片 2、蜂窝孔 3、平板形陶瓷片 4、三角形陶瓷片 5、半圆形陶瓷片 6、凸体 7、上转辊 8、凹槽 9、下转辊 10、泥段。
具体实施方式
实施例1,在图1和图2中,本发明所述大规格蜂窝蓄热陶瓷体由梯形陶瓷片1峰对谷、谷对峰和位于梯形陶瓷片之间的平板形陶瓷片3相对叠加形成蜂窝孔2并用高温粘接剂粘接胶合成整体,其制备方法步骤是:
1、按下述配方将氧化铝70%、石英10%、长石2%、高岭土11%、滑石2%、氧化钛2%、碳化硅1%、锂瓷石1%、锂辉石1%以及占上述各种原料总重量4%的粘接剂(如甲基纤维素)和适量水混合球磨、陈腐、去磁制成泥料。
2、将泥料用制泥机制成板状泥段10,再将泥段通过挤压机制成厚度为3-5毫米的平板形陶瓷片3雏坯,同时将泥段输入到对转挤压成型机的上转辊和下转辊之间,利用在表面上设置有凸体6的上转辊7和与在其表面上设置有与凸体相配的凹槽8的下转辊9同步相对以25-30转/分钟旋转挤压制成厚度为3-5毫米的梯形陶瓷片1雏坯,
3、将平板形陶瓷片雏坯和梯形陶瓷片雏坯送入到烘干房中,加热至200-260℃,保持1-2小时低温除湿,进行表面烘干定型,
4、将定型的平板陶瓷片和波纹形陶瓷片加热至700℃-800℃,并保温3小时进行煅烧,再加热至1200-1500℃,并保温2-4小时进行还原,冷却至常温出炉得到平板形陶瓷片和波纹形陶瓷片,
5、将波纹形陶瓷片通过涂胶辊自动在波峰上用高温粘合剂涂胶后与平板陶瓷片自动叠在一起,然后再在平板陶瓷片上平面涂胶交错设置梯形陶瓷片1,把平板形陶瓷片3和梯形陶瓷片1组合堆砌成具有蜂窝孔2的坯体,然后干燥,待涂胶固化后,用机械手按一定长度切割,再通过人工或机械手两侧面用可塑泥料扶皮,再干燥、烧成即可获得大规格蜂窝蓄热陶瓷体,高温粘合剂用制造波纹或平板陶瓷片的粉体为基料,再在基料中加上占基料重量0.1-30%的无机胶、0.1-5.0%有机胶及20%-80%的水分混合而成,所述无机胶是硅溶胶和铝溶胶的混合物(重量比1:1);所述有机胶为聚乙烯醇。
实施例2,在图1和图3中,本发明所述大规格蜂窝蓄热陶瓷体由三角形陶瓷片1峰对谷、谷对峰和位于三角形陶瓷片4之间的平板形陶瓷片3相对叠加形成蜂窝孔2并用高温粘接剂粘接胶合成整体,其制备方法步骤除氧化铝、石英、长石、高岭土、滑石、氧化钛、碳化硅、锂瓷石、锂辉石与实施例1不同外,其它内容与实施1相同或相近。实施例2中氧化铝50%、石英18%、长石2%、高岭土20%、滑石2%、氧化钛3%、碳化硅1%、锂瓷石2%、锂辉石2%。
实施例3,在图1和图4中,本发明所述大规格蜂窝蓄热陶瓷体由半圆形陶瓷片5峰对谷、谷对峰和位于半圆形陶瓷片5之间的平板形陶瓷片3相对叠加形成蜂窝孔2并用高温粘接剂粘接胶合成整体,其制备方法步骤除氧化铝、石英、长石、高岭土、滑石、氧化钛、碳化硅、锂瓷石、锂辉石与实施例1不同外,其它内容与实施1相同或相近。实施例3中氧化铝70%、石英8%、长石5%、高岭土8%、滑石2%、氧化钛3%、碳化硅2%、锂瓷石1%、锂辉石1%。
Claims (4)
1.一种大规格蜂窝蓄热陶瓷体的制备方法:其特征在于:所述方法步骤是:
a、用氧化铝、石英、长石、高岭土、滑石、氧化钛、碳化硅、锂瓷石、锂辉石为主要原料以及占主要原料总重量3-5%的粘接剂以及适量水混合球磨、陈腐、去磁制成泥料,
b、将泥料用制泥机制成板状泥段,再将泥段通过挤压机制成平板形陶瓷片雏坯,同时将泥段输入到对转挤压成型机的上转辊和下转辊之间,利用在表面上设置有凸体的上转辊和与在其表面上设置有与凸体相配的凹槽的下转辊同步相对旋转挤压制成波纹形陶瓷片雏坯,
c、将平板形陶瓷片和波纹形陶瓷片送入到烘干房中,加热至200-260℃,保持1-2小时低温除湿,进行表面烘干定型,
d、将定型的平板形陶瓷片和波纹形陶瓷片加热至700℃-800℃,并保温3小时进行煅烧,再加热至1200-1500℃,并保温2-4小时进行还原,冷却至常温出炉得到平板形陶瓷片和波纹形陶瓷片,
e、将波纹形陶瓷片通过涂胶辊自动在波峰上用高温粘合剂涂胶后与平板形陶瓷片自动叠在一起,然后再在平板形陶瓷片上平面涂胶交错或平行设置波纹形陶瓷片,把平板形陶瓷片和波纹形陶瓷片组合堆砌成蜂窝坯体,然后干燥,待涂胶固化后,用机械手按一定长度切割,再通过人工或机械手两侧面用可塑泥料扶皮,再干燥、烧成即可获得大规格蜂窝蓄热陶瓷体。
2.根据权利要求1所述的一种大规格蜂窝蓄热陶瓷体的制备方法:其特征在于:所述高温粘合剂量用制造波纹形或平板形陶瓷片的主要原料为基料,再加上占基料重量0.1-30%的无机胶、0-5.0%有机胶及20%-80%的水分混合而成。
3.根据权利要求1所述的一种大规格蜂窝蓄热陶瓷体的制备方法:其特征在于:所述蜂窝孔(3)横截面形状为梯形、三角形、半圆弧形或椭圆形。
4.根据权利要求1所述的一种大规格蜂窝蓄热陶瓷体的制备方法:其特征在于:所述波纹形或平板形陶瓷片化学成分:SiO2:15-90%、Al2O3:15-90%、Fe2O3:0.1-6%、TiO2:0.1-6%、CaO:0.1-6%、MgO:0.1-15%、K2O:0.1-3%、Na2O:0.1-3%、LiO2:0.1-3%、其他:0.1-3%,或Sic:0-95%。
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