CN110803918A - 一种基于新成型方法的陶瓷基复合材料的制备工艺 - Google Patents
一种基于新成型方法的陶瓷基复合材料的制备工艺 Download PDFInfo
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Abstract
本发明涉及一种基于新成型方法的陶瓷基复合材料的制备工艺,属于陶瓷基复合材料领域。将无机非金属纤维纸按设定形状成型后浸于陶瓷基高温强化剂液体中完全浸透,使成型的无机非金属纤维纸处于浸入饱和状态,取出,得陶瓷基无机非金属复合材料半成品;将上述半成品干燥后进行烧结,得陶瓷基复合材料产品,所述按设定形状成型是指以无机非金属纤维纸采用折纸法、剪纸法、卷纸法、合成纸板法或纸绳编织法按设定形状进行成型。本发明利用无机非金属纤维纸成型制作陶瓷的方法,颠覆了陶瓷成型的传统理念,是一种新的陶瓷工艺方法的发现,实现了复杂薄壁陶瓷生产工艺简单化、日常化。这种陶瓷工艺方法具有划时代的意义,会对今后陶瓷生产产生深远影响。
Description
技术领域
本发明涉及一种基于新成型方法的陶瓷基复合材料的制备工艺,属于陶瓷基复合材料领域。
背景技术
陶瓷生产成型工艺一般采用干压成型、注浆成型、可塑成型、热压注成型、等静压成型和3D打印成型。这些方法中除3D打印成型以外都无法做出像纸一样薄的形状复杂的陶瓷半成品,而3D打印成型,设备昂贵,对基材要求严格,生产效率低、成本高,3D打印成型最大的问题是在烧成过程中,无法解决烧成变形的问题,无法生产出形状不变、尺寸相对精准的薄壁复杂形的陶瓷制品。
发明内容
本发明的目的是提供一种基于新成型方法的陶瓷基复合材料的制备工艺,按照本发明所述工艺方法,既能做出像纸一样薄的形状复杂并可随意创作的各种不同颜色的折纸陶瓷花、剪纸陶瓷片和编织成陶瓷花篮等艺术陶瓷产品,也能按照卷纸法卷出工业上所需的各种形状的管状陶瓷产品,也可以用合成纸板法叠加成一定厚度的陶瓷板并制成陶瓷箱和陶瓷盒。根据材质的不同,可制作出耐高温等级在1100℃-1300℃之间,用于工业和军工不同用途的陶瓷产品。还可以利用无机非金属纤维纸纤维之间相互交织的特性,做出不同性能要求的多孔陶瓷产品,用于不同用途的工业过滤。
一种基于新成型方法的陶瓷基复合材料的制备工艺,将无机非金属纤维纸按设定形状成型后浸于陶瓷基高温强化剂液体中完全浸透,使成型的无机非金属纤维纸处于浸入饱和状态,取出,得陶瓷基无机非金属复合材料半成品;将上述半成品干燥后进行烧结,得陶瓷基复合材料产品。
所述无机非金属纤维纸采用折纸法、剪纸法、卷纸法、合成纸板法或纸绳编织法按设定形状进行成型。
通过上述折纸法、剪纸法、卷纸法、合成纸板法或纸绳编织法等成型方法制作出不同壁厚、不同复杂形状的纸质半成品。
通过配方和工艺设计,保证产品在烧成的任何温度下,都能保持适宜的强度而不坍塌和变形,是制作薄壁复杂形状陶瓷产品的技术关键。
优选地,所述无机非金属纤维纸的厚度为0.3-1.0mm,进一步优选为0.35-0.5mm。
优选地,所述陶瓷基高温强化剂液体由作为固体组分的无机材料粉体和水组成,固含量为45%-65%,所述陶瓷基高温强化剂液体中的固体组分按质量百分比,由下述组分组成:
SiO2:50-72%,Al2O3:5-20%,CaO:0-15%,MgO:0-5%,BaO:0-8%,B2O3:0-8%,ZrO2:0-8%,ZnO:0-10%,K2O:2-8%,Na2O:0-4%,Fe2O3:<0.3%,陶瓷色料:0-5%。
优选地,所述烧结条件为:将干燥的半成品在30-50分钟内随炉升温至烧结温度后烧结20-60分钟,随炉冷却至室温,烧结温度1000-1300℃,得陶瓷基复合材料产品。
优选地,所述无机非金属纤维纸按下述方法制得:,将浓度为0.1%的针叶木浆和待成型的无机非金属材料纤维浆按纤维绝干重量比为1:25-30进行配浆,然后加入全部绝干总纤维重量0.33-0.4%的PAE后,放入纸页成型器加水至成型高度进行抄片,得无机非金属纤维纸,所述无机非金属纤维原料按质量百分比,由下述组分组成:
Al2O3:30-80%,SiO2:20-70%,ZrO2:0-20%,K2O+Na2O:<1.5%,Fe2O3:<1.2%。
本发明一个优选的技术方案为:所述烧结条件为:将干燥的半成品在35-40分钟内随炉升温至烧结温度后烧结20分钟,随炉冷却至室温,烧结温度1100-1130℃,得多孔陶瓷基复合材料产品,所述产品的孔径为50-100μm,孔隙率为40-50%。
所述陶瓷基高温强化剂液体中的固体组分按质量百分比,由下述组分组成:
SiO2:50-65%,Al2O3:5-10%,CaO:5-15%,MgO:0-5%,B2O3:0-8%,ZrO2:0-5%,ZnO:0-10%,K2O:3-8%,Na2O:0-2%,Fe2O3:<0.3。
所述无机非金属纤维原料按质量百分比,由下述组分组成:
Al2O3:60-80%,SiO2:20-40%,K2O+Na2O:<0.5%,Fe2O3:<0.1。
上述所得多孔陶瓷基复合材料产品可以取代一次性过滤的消耗性实验室滤纸,实现永久性过滤的目的,该产品可用于工业过滤的初滤过程。
本发明一个优选的技术方案为:所述烧结条件为:将干燥后的陶瓷半成品,放入箱式电炉内,经40-50分钟随炉升温到烧成温度,烧成温度为:1200-1250℃。保温20分钟,随炉冷却至室温取出,最终,制作多孔白色陶瓷产品。
所述陶瓷基高温强化剂液体中的固体组分按质量百分比,由下述组分组成:
SiO2:50-70%,Al2O3:5-15%,CaO:5-10%,MgO:0-5%,BaO:0-3%,K2O:3-8%,Na2O:1-4%,Fe2O3:<0.3%。
所述无机非金属纤维原料按质量百分比,由下述组分组成:
Al2O3:40-50%,SiO2:50-60%,K2O+Na2O:<1.5%,Fe2O3:<1.2%。
上述所得多孔白色陶瓷产品为艺术陶瓷产品。
本发明一个优选的技术方案为:所述烧结条件为:将干燥的陶瓷半成品,放入箱式电炉内,经40-50分钟随炉升温到烧成温度,烧成温度为:1200-1240℃。保温20分钟,随炉冷却至室温取出,最终,制作出耐热、耐腐蚀工业陶瓷产品。
所述陶瓷基高温强化剂液体中的固体组分按质量百分比,由下述组分组成:
SiO2:50-70%,Al2O3:10-20%,CaO:0-3%,MgO:0-5%,BaO:0-2%,ZrO2:5-15%,B2O3:0-4%,K2O:2-5%,Na2O:1-3%,Fe2O3:<0.3%。
所述无机非金属纤维原料按质量百分比,由下述组分组成:
Al2O3:60-80%,SiO2:20-40%,K2O+Na2O:<0.5%,Fe2O3:<0.1%。
本发明一个优选的技术方案为:所述烧结条件为:将干燥后的陶瓷半成品,放入箱式电炉内,经30-35分钟随炉升温到烧成温度,烧成温度为:1000-1030℃。保温20分钟,随炉冷却至室温取出,最终,制作致密彩色陶瓷产品。
所述陶瓷基高温强化剂液体中的固体组分按质量百分比,由下述组分组成:
SiO2:55-75%,Al2O3:5-10%,CaO:4-7%,MgO:0-2%,BaO:0-8%,B2O3:0-2%,ZnO:0-2%,K2O:3-4%,Na2O:0-4%,陶瓷色料:3-5%,Fe2O3:<0.3%。
所述无机非金属纤维原料按质量百分比,由下述组分组成:
Al2O3:40-50%,SiO2:50-60%,K2O+Na2O:<1.5%,Fe2O3:<1.2%。
上述所得彩色陶瓷产品为艺术陶瓷产品。
本发明的有益效果为:本发明利用无机非金属纤维纸成型制作陶瓷的方法,颠覆了陶瓷成型的传统理念,可以用折纸法、剪纸法、卷纸法、合成纸板法、纸绳编织法制作陶瓷,是一种新的陶瓷工艺方法的发现。同时,本发明通过配方和工艺设计,保证产品在烧成的任何温度下,都能保持适宜的强度而不坍塌和变形,是制作薄壁复杂形状陶瓷产品的技术关键。本发明所述方法可以实现复杂薄壁陶瓷生产工艺简单化、日常化,用这种工艺方法可以生产出不同颜色,不同形状的陶瓷,只要你能用手折成什么形状、剪成什么形状、卷成什么形状、合成纸板做成什么形状、纸绳编织成什么形状,就能做出什么形状的陶瓷,而且,可以根据需要做出多孔陶瓷和致密陶瓷,开辟了一种新门类的艺术陶瓷,产品也可用于化工和食品工业的过滤领域,还可用于隔热和防腐等工业领域和军工领域。而比制作和应用更大的意义是这种工艺方法本身的价值,这种陶瓷工艺方法具有划时代的意义,会对今后陶瓷生产产生深远影响。
附图说明
图1为实施例1所得白色多孔陶瓷花的照片;
图2为实施例3所得兰色陶瓷花的照片;
图3为实施例4所得陶瓷过滤漏斗的照片;
图4为本发明所述方法制得的多种色彩陶瓷花的照片。
具体实施方式
下述非限制性实施例可以使本领域的普通技术人员更全面地理解本发明,但不以任何方式限制本发明。
下述实施例中所述试验方法,如无特殊说明,均为常规方法;所述试剂和材料,如无特殊说明,均可从商业途径获得。
具体实施实施方式之一:
1、无机非金属纤维纸的制作
(1)木浆打浆
选用硫酸盐针叶木浆,称取30g±0.5g浆板,用500ml水浸泡4小时以上,使浆充分软化;把湿浆及浸泡所用的水移入疏解器中(ф6"×7.5";日本东洋精机株式会社),加水是总体积为2000ml,疏解至1200转;疏解后的浆料在布氏漏斗上(用一尼龙布)把悬浮浆过滤,总量为300±5g,浆浓为10%;把10%的浆料移入PFI磨(瑞典L&W有限公司)的打浆室内,并均匀的分布在圆盘壁上,启动空压机,使真空度达到稳定;把打浆室辊刀放入打浆室内,压好室盖,先转动打浆室,然后开动辊刀,达到满速后,施加打浆压力(3.34KN/m),同时开动计数器,计数10000转;木浆叩解度:45°SR±1°SR;辊刀的转数达到设定值后,去掉辊刀压力,提起辊刀及室盖,把浆移入2000ml量筒内,稀释纸浆浓度至0.1%,备用。
(2)无机非金属纤维的疏解及除渣
将一定量的无机非金属纤维(不同种类)放入疏解器中,加水至疏解器容积的3/4处,疏解200-300转,然后倒入到20目金属丝编织网筛中在水中过滤,以除去无机非金属纤维中的渣球,每次过滤后均倒掉过滤水换成清水,共进行3遍过滤,此为1个处理过程。根据不同种类的无机非金属纤维的不同特性,选择1-2个处理过程。经处理后的纤维为待成型纤维。
无机非金属纤维成分范围wt.%
Al<sub>2</sub>O<sub>3</sub> | SiO<sub>2</sub> | ZrO<sub>2</sub> | K<sub>2</sub>O+Na<sub>2</sub>O | Fe<sub>2</sub>O<sub>3</sub> |
30-80 | 20-70 | 0-20 | <1.5 | <1.2 |
(3)无机非金属纤维纸的抄制
将浓度为0.1%的针叶木浆和待成型的无机非金属材料纤维浆按纤维绝干重量比为1:25-30进行配浆,然后加入0.33-0.40%PAE(聚酰胺环氧氯丙烷树脂)(相对于绝干总纤维量),用纸页成型器抄片。具体步骤如下:将配好的浆料放入抄片器内,加水至离网面349mm高度处,用搅拌器插入抄片器筒内水中,上下迅速移动5次,打开抄片器排水阀门排水,进行纸页成型,打开抄片器圆筒,放上抄片布及3层吸水纸,用伏压辊伏压来回4次,抄取手钞片。将一组手钞片放入压榨机进行压榨,压力为0.6MPa,保持4分钟,取出,用弧形干燥器干燥后,制成无机非金属纤维纸(不同种类)。所得无机非金属纤维纸的厚度为0.3-1.0mm。
2、成型
将无机非金属纤维纸(不同种类)采用折纸法、剪纸法、卷纸法、合成纸板法、纸绳编织法,按预想的设计图案进行成型,制作出具有不同复杂形状的无机非金属纤维半成品。
3、用陶瓷基高温强化剂进行高温强化处理
将无机非金属纤维半成品浸没于按照不同要求具有不同配方组成的陶瓷基高温强化剂液体中(固含量45%-65%),达到完全浸透,让无机非金属纤维半成品处于浸入饱和状态,取出后除去表面多余的高温强化剂,成为陶瓷基无机非金属复合材料半成品。将其置于干燥箱内由室温升高到105℃,使其完全干燥,将半成品取出后自然冷却到室温。
陶瓷基高温强化剂配方组成范围wt.%
SiO<sub>2</sub> | Al<sub>2</sub>O<sub>3</sub> | CaO | MgO | BaO | B<sub>2</sub>O<sub>3</sub> | ZrO<sub>2</sub> | ZnO | K<sub>2</sub>O | Na<sub>2</sub>O | Fe<sub>2</sub>O<sub>3</sub> | 色料 |
50-72 | 5-20 | 0-15 | 0-5 | 0-8 | 0-8 | 0-8 | 0-10 | 2-8 | 0-4 | <0.3 | 0-5 |
4、烧成
经高温强化处理干燥后的陶瓷基无机非金属复合材料半成品,放入箱式电炉内,经30-50分钟随炉升温到烧成温度,烧成温度为:1000℃-1300℃。保温20-60分钟,随炉冷却至室温取出,最终制作出陶瓷基复合材料产品。
烧成也可以采用其形式的炉体(如隧道窑、梭式窑、辊道窑等),温度制度应随窑炉的选择形式不同而变化。
采用上述工艺方法,能够保证产品具有在烧成过程中任何温度下都保持适宜的强度而不坍塌和变形的性能特征,从而制作出薄壁复杂形状陶瓷产品,是本发明的技术关键。
实施例1:用折纸法制作白色多孔陶瓷花的工艺过程:
1、木浆打浆,同上述无机非金属纤维纸的制作部分涉及的(1)木浆打浆步骤。
2、称取1号无机非金属纤维8.0g,放入疏解器中,加水1600ml,疏解300转,然后倒入到金属丝编织网试验筛(ф200×50-0.85/0.5)中,在装有2000ml清水的容器中过滤,每次过滤后均倒掉过滤水,换清水。共过滤3遍。过滤三遍后,再放入疏解器中,进行2次疏解,加水1600ml,疏解300转后,同样用金属丝编织网试验筛(ф200×50-0.85/0.5)过滤3遍。
1号无机非金属纤维成分组成wt.%
Al<sub>2</sub>O<sub>3</sub> | SiO<sub>2</sub> | K<sub>2</sub>O+Na<sub>2</sub>O | Fe<sub>2</sub>O<sub>3</sub> |
44.0 | 53.5 | 1.4 | 1.1 |
3、将浓度为0.1%的针叶木浆和待成型的1号无机非金属纤维浆按绝干重1:30比例进行配浆,然后加入0.33%PAE(对绝干总纤维量),用纸页成型器(ф158mm,日本东洋精机株式会社)抄片,将配好的浆料放入抄片器内,加水至离网面349mm高度处,用搅拌器插入抄片器筒内水中,上下迅速移动5次,打开抄片器阀门排水,进行纸页成型,打开抄片器圆筒,放上抄片布及3层吸水纸,用伏压辊伏压来回4次,抄取手钞片。将一组手钞片放入压榨机进行压榨,压力为0.6MPa,保持4分钟,取出,用弧形干燥器干燥,制成1号无机非金属纤维纸。纤维纸定量为:120g/㎡-170g/㎡,所得无机非金属纤维纸的厚度为0.35-0.50mm。
4、用1号无机非金属纤维纸采用折纸法手工折出纤维纸花半成品。将纤维纸花半成品浸没于1号白色陶瓷基高温强化剂液体中(固含量55%),达到完全浸透,让纸花半成品处于浸入饱和状态,取出后除去表面多余的高温强化剂,成为陶瓷花半成品。将其置于干燥箱内由室温升高到105℃,使其完全干燥,将干燥后的陶瓷花半成品取出后自然冷却到室温。
1号白色陶瓷基高温强化剂配方组成wt.%
SiO<sub>2</sub> | Al<sub>2</sub>O<sub>3</sub> | CaO | MgO | BaO | K<sub>2</sub>O | Na<sub>2</sub>O | Fe<sub>2</sub>O<sub>3</sub> |
66.8 | 11.3 | 8.0 | 3.5 | 2.0 | 7.0 | 1.2 | 0.2 |
5、将干燥后的陶瓷花半成品,放入箱式电炉内,经50分钟随炉升温到烧成温度,烧成温度为:1240℃。保温20分钟,随炉冷却至室温取出,最终,制作出白色多孔陶瓷花产品,该产品为艺术陶瓷产品。
采用上述工艺方法,产品在烧成过程中任何温度下都保持适宜的强度而不坍塌和变形。
实施例2:用卷纸法制作工业陶瓷管件的工艺过程:
1、木浆打浆,同上述无机非金属纤维纸的制作部分涉及的(1)木浆打浆步骤。
2、称取2号无机非金属纤维6.5g,放入疏解器中,加水1600ml,疏解200转,然后倒入到金属丝编织网试验筛(ф200×50-0.85/0.5)中,在装有2000ml清水的容器中过滤,每次过滤后均倒掉过滤水,换清水。共过滤3遍。
2号无机非金属纤维成分组成wt.%
Al<sub>2</sub>O<sub>3</sub> | SiO<sub>2</sub> | K<sub>2</sub>O+Na<sub>2</sub>O | Fe<sub>2</sub>O<sub>3</sub> |
72.5 | 27.1 | 0.35 | 0.05 |
3、将浓度为0.1%的针叶木浆和待成型的2号无机非金属纤维浆按绝干重1:25比例进行配浆,然后加入0.40%PAE(对绝干总纤维量),用纸页成型器(ф158mm,日本东洋精机株式会社)抄片,将配好的浆料放入抄片器内,加水至离网面349mm高度处,用搅拌器插入抄片器筒内水中,上下迅速移动5次,打开抄片器阀门排水,进行纸页成型,打开抄片器圆筒,放上抄片布及3层吸水纸,用伏压辊伏压来回4次,抄取手钞片。将一组手钞片放入压榨机进行压榨,压力为0.6MPa,保持4分钟,取出,用弧形干燥器干燥,制成2号无机非金属纤维纸。纤维纸定量为:120g/㎡-170g/㎡,所得无机非金属纤维纸的厚度为0.35-0.50mm。
4、用2号无机非金属纤维纸采用卷纸法卷出管型纸件,结合接缝处一面用胶带纸粘接,做成管型纸件半成品。将管型纸件半成品浸没于2号耐高温耐腐蚀陶瓷基高温强化剂液体中(固含量60%),达到完全浸透,让管型纸件半成品处于浸入饱和状态,取出后除去表面多余的高温强化剂,成为陶瓷管件半成品。将其置于干燥箱内由室温升高到105℃,使其完全干燥,将陶瓷管件半成品取出后自然冷却到室温。
2号耐高温耐腐蚀陶瓷基高温强化剂配方组成wt.%
SiO<sub>2</sub> | Al<sub>2</sub>O<sub>3</sub> | CaO | MgO | BaO | ZrO<sub>2</sub> | B<sub>2</sub>O<sub>3</sub> | K<sub>2</sub>O | Na<sub>2</sub>O | Fe<sub>2</sub>O<sub>3</sub> |
69.7 | 17.0 | 0.3 | 1.9 | 0.2 | 5.7 | 0.5 | 2.7 | 1.8 | 0.2 |
5、将干燥后的陶瓷管件半成品,放入箱式电炉内,经50分钟随炉升温到烧成温度,烧成温度为:1230℃。保温20分钟,随炉冷却至室温取出,最终,制作出工业陶瓷管件,该产品为工业用耐热、耐腐蚀产品。
采用上述工艺方法,产品在烧成过程中任何温度下都保持适宜的强度而不坍塌和变形。
实施例3:用折纸法制作兰色陶瓷花的工艺过程:
1、木浆打浆,同上述无机非金属纤维纸的制作部分涉及的(1)木浆打浆步骤。
2、称取1号无机非金属纤维8.0g,放入疏解器中,加水1600ml,疏解300转,然后倒入到金属丝编织网试验筛(ф200×50-0.85/0.5)中,在装有2000ml清水的容器中过滤,每次过滤后均倒掉过滤水,换清水。共过滤3遍。过滤三遍后,再放入疏解器中,进行2次疏解,加水1600ml,疏解300转后,同样用金属丝编织网试验筛(ф200×50-0.85/0.5)过滤3遍。
1号无机非金属纤维成分组成wt.%
Al<sub>2</sub>O<sub>3</sub> | SiO<sub>2</sub> | K<sub>2</sub>O+Na<sub>2</sub>O | Fe<sub>2</sub>O<sub>3</sub> |
44.0 | 53.5 | 1.4 | 1.1 |
3、将浓度为0.1%的针叶木浆和待成型的1号无机非金属纤维浆按绝干重1:30比例进行配浆,然后加入0.33%PAE(对绝干总纤维量),用纸页成型器(ф158mm,日本东洋精机株式会社)抄片,将配好的浆料放入抄片器内,加水至离网面349mm高度处,用搅拌器插入抄片器筒内水中,上下迅速移动5次,打开抄片器阀门排水,进行纸页成型,打开抄片器圆筒,放上抄片布及3层吸水纸,用伏压辊伏压来回4次,抄取手钞片。将一组手钞片放入压榨机进行压榨,压力为0.6MPa,保持4分钟,取出,用弧形干燥器干燥,制成1号无机非金属纤维纸。纤维纸定量为:120g/㎡-170g/㎡,所得无机非金属纤维纸的厚度为0.35-0.50mm。
4、用1号无机非金属纤维纸采用折纸法手工折出纤维纸花半成品。将纤维纸花半成品浸没于3号兰色陶瓷基高温强化剂液体中(固含量50%),达到完全浸透,让纸花半成品处于浸入饱和状态,取出后除去表面多余的高温强化剂,成为陶瓷花半成品。将其置于干燥箱内由室温升高到105℃,使其完全干燥,将陶瓷花半成品取出后自然冷却到室温。
3号兰色陶瓷基高温强化剂配方组成wt.%
SiO<sub>2</sub> | Al<sub>2</sub>O<sub>3</sub> | CaO | MgO | BaO | B<sub>2</sub>O<sub>3</sub> | ZnO | K<sub>2</sub>O | Na<sub>2</sub>O | Fe<sub>2</sub>O<sub>3</sub> | Co<sub>2</sub>O<sub>3</sub> |
67.1 | 7.7 | 4.5 | 0.7 | 6.3 | 1.0 | 1.0 | 3.1 | 3.5 | 0.2 | 4.9 |
5、将干燥后的陶瓷花半成品,放入箱式电炉内,经30分钟随炉升温到烧成温度,烧成温度为:1020℃。保温20分钟,随炉冷却至室温取出,最终,制作出兰色陶瓷花产品,该产品为艺术陶瓷产品。
采用上述工艺方法,产品在烧成过程中任何温度下都保持适宜的强度而不坍塌和变形。
实施例4:用卷纸法制作陶瓷过滤漏斗的工艺过程:
1、木浆打浆,同上述无机非金属纤维纸的制作部分涉及的(1)木浆打浆步骤。
2、称取2号无机非金属纤维6.5g,放入疏解器中,加水1600ml,疏解200转,然后倒入到金属丝编织网试验筛(ф200×50-0.85/0.5)中,在装有2000ml清水的容器中过滤,每次过滤后均倒掉过滤水,换清水。共过滤3遍。
2号无机非金属纤维成分组成wt.%
Al<sub>2</sub>O<sub>3</sub> | SiO<sub>2</sub> | K<sub>2</sub>O+Na<sub>2</sub>O | Fe<sub>2</sub>O<sub>3</sub> |
72.5 | 27.1 | 0.3 | 0.05 |
3、将浓度为0.1%的针叶木浆和待成型的2号无机非金属纤维浆按绝干重1:25比例进行配浆,然后加入0.40%PAE(对绝干总纤维量),用纸页成型器(ф158mm,日本东洋精机株式会社)抄片,将配好的浆料放入抄片器内,加水至离网面349mm高度处,用搅拌器插入抄片器筒内水中,上下迅速移动5次,打开抄片器阀门排水,进行纸页成型,打开抄片器圆筒,放上抄片布及3层吸水纸,用伏压辊伏压来回4次,抄取手钞片。将一组手钞片放入压榨机进行压榨,压力为0.6MPa,保持4分钟,取出,用弧形干燥器干燥,制成2号无机非金属纤维纸。纤维纸定量为:120g/㎡-170g/㎡,所得无机非金属纤维纸的厚度为0.35-0.50mm。
4、用2号无机非金属纤维纸采用卷纸法卷出纤维纸锥形体,结合接缝处一面用胶带纸粘接,做成纤维纸漏斗半成品。将纤维纸漏斗半成品浸没于4号陶瓷基高温强化剂液体中(固含量50%),达到完全浸透,让纤维纸漏斗半成品处于浸入饱和状态,取出后除去表面多余的高温强化剂,成为陶瓷过滤漏斗半成品。将其置于干燥箱内由室温升高到105℃,使其完全干燥,将陶瓷过滤漏斗半成品取出后自然冷却到室温。
4号陶瓷基高温强化剂配方组成wt.%
SiO<sub>2</sub> | Al<sub>2</sub>O<sub>3</sub> | CaO | MgO | B<sub>2</sub>O<sub>3</sub> | ZrO<sub>2</sub> | ZnO | K<sub>2</sub>O | Na<sub>2</sub>O | Fe<sub>2</sub>O<sub>3</sub> |
58.4 | 6.0 | 12.2 | 2.7 | 5.1 | 1.9 | 8.1 | 4.6 | 0.8 | 0.2 |
5、将干燥后的陶瓷漏斗半成品,放入箱式电炉内,经40分钟随炉升温到烧成温度,烧成温度为:1110℃。保温20分钟,随炉冷却至室温取出,最终,制作出陶瓷过滤漏斗产品。
采用上述工艺方法,产品在烧成过程中任何温度下都保持适宜的强度而不坍塌和变形。
陶瓷过滤漏斗技术指标:过滤孔径:50-100μm,孔隙率40-50%。可以取代一次性过滤的消耗性实验室滤纸,实现永久性过滤的目的,该产品可用于工业过滤的初滤过程。
Claims (9)
1.一种基于新成型方法的陶瓷基复合材料的制备工艺,其特征在于:将无机非金属纤维纸按设定形状成型后浸于陶瓷基高温强化剂液体中完全浸透,使成型的无机非金属纤维纸处于浸入饱和状态,取出,得陶瓷基无机非金属复合材料半成品;将上述半成品干燥后进行烧结,得陶瓷基复合材料产品,
所述按设定形状成型是指以无机非金属纤维纸采用折纸法、剪纸法、卷纸法、合成纸板法或纸绳编织法按设定形状进行成型。
2.根据权利要求1所述的工艺,其特征在于:所述陶瓷基高温强化剂液体由作为固体组分的无机材料粉体和水组成,固含量为45%-65%,所述陶瓷基高温强化剂液体中的固体组分按质量百分比,由下述组分组成:
SiO2:50-72%,Al2O3:5-20%,CaO:0-15%,MgO:0-5%,BaO:0-8%,B2O3:0-8%,ZrO2:0-8%,ZnO:0-10%,K2O:2-8%,Na2O:0-4%,Fe2O3:<0.3%,陶瓷色料:0-5%。
3.根据权利要求1所述的工艺,其特征在于:所述烧结条件为:将干燥的陶瓷基无机非金属复合材料半成品在30-50分钟内随炉升温至烧结温度后烧结20分钟,随炉冷却至室温,烧结温度1000-1300℃,得陶瓷基复合材料产品。
4.根据权利要求1所述的工艺,其特征在于:所述无机非金属纤维纸按下述方法制得:将浓度为0.1%的针叶木浆和待成型的无机非金属材料纤维浆按纤维绝干重量比为1:25-30进行配浆,然后加入全部绝干总纤维重量0.33-0.4%的PAE后,放入纸页成型器加水至成型高度进行抄片,得无机非金属纤维纸,所述无机非金属纤维原料按质量百分比,由下述组分组成:
Al2O3:30-80%,SiO2:20-70%,ZrO2:0-20%,K2O+Na2O:<1.5%,Fe2O3:<1.2%。
5.根据权利要求1所述的工艺,其特征在于:所述烧结条件为:将干燥的半成品在35-40分钟内随炉升温至烧结温度后烧结20分钟,随炉冷却至室温,烧结温度1100-1130℃,得多孔陶瓷基复合材料产品,所述产品的孔径为50-100μm,孔隙率为40-50%,
所述陶瓷基高温强化剂液体中的固体组分按质量百分比,由下述组分组成:
SiO2:50-65%,Al2O3:5-10%,CaO:5-15%,MgO:0-5%,B2O3:0-8%,ZrO2:0-5%,ZnO:0-10%,K2O:3-8%,Na2O:0-2%,Fe2O3:<0.3;
所述无机非金属纤维原料按质量百分比,由下述组分组成:
Al2O3:60-80%,SiO2:20-40%,K2O+Na2O:<0.5%,Fe2O3:<0.1。
6.根据权利要求1所述的工艺,其特征在于:所述烧结条件为:将干燥后的陶瓷半成品,放入箱式电炉内,经40-50分钟随炉升温到烧成温度,烧成温度为:1200-1250℃,保温20分钟,随炉冷却至室温取出,最终,制作多孔白色陶瓷产品,
所述陶瓷基高温强化剂液体中的固体组分按质量百分比,由下述组分组成:
SiO2:50-70%,Al2O3:5-15%,CaO:5-10%,MgO:0-5%,BaO:0-3%,K2O:3-8%,Na2O:1-4%,Fe2O3:<0.3%;
所述无机非金属纤维原料按质量百分比,由下述组分组成:
Al2O3:40-50%,SiO2:50-60%,K2O+Na2O:<1.5%,Fe2O3:<1.2%。
7.根据权利要求1所述的工艺,其特征在于:所述烧结条件为:将干燥的半成品,放入箱式电炉内,经40-50分钟随炉升温到烧成温度,烧成温度为:1200-1240℃,保温20分钟,随炉冷却至室温取出,最终,制作出耐热、耐腐蚀工业陶瓷产品,
所述陶瓷基高温强化剂液体中的固体组分按质量百分比,由下述组分组成:
SiO2:50-70%,Al2O3:10-20%,CaO:0-3%,MgO:0-5%,BaO:0-2%,ZrO2:5-15%,B2O3:0-4%,K2O:2-5%,Na2O:1-3%,Fe2O3:<0.3%;
所述无机非金属纤维原料按质量百分比,由下述组分组成:
Al2O3:60-80%,SiO2:20-40%,K2O+Na2O:<0.5%,Fe2O3:<0.1。
8.根据权利要求1所述的工艺,其特征在于:所述烧结条件为:将干燥后的陶瓷半成品,放入箱式电炉内,经30-35分钟随炉升温到烧成温度,烧成温度为:1000-1030℃,保温20分钟,随炉冷却至室温取出,最终,制作致密彩色陶瓷产品,
所述陶瓷基高温强化剂液体中的固体组分按质量百分比,由下述组分组成:
SiO2:55-75%,Al2O3:5-10%,CaO:4-7%,MgO:0-2%,BaO:0-8%,B2O3:0-2%,ZnO:0-2%,K2O:3-4%,Na2O:0-4%,陶瓷色料:3-5%,Fe2O3:<0.3%。
所述无机非金属纤维原料按质量百分比,由下述组分组成:
Al2O3:40-50%,SiO2:50-60%,K2O+Na2O:<1.5%,Fe2O3:<1.2%。
9.一种多孔陶瓷过滤件,其特征在于:所述过滤件为权利要求5所述工艺制得的产品。
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