CN110862269A - 一种高强度泡沫陶瓷的制备方法 - Google Patents

一种高强度泡沫陶瓷的制备方法 Download PDF

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CN110862269A
CN110862269A CN201911257472.4A CN201911257472A CN110862269A CN 110862269 A CN110862269 A CN 110862269A CN 201911257472 A CN201911257472 A CN 201911257472A CN 110862269 A CN110862269 A CN 110862269A
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文卫雄
韩志明
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Abstract

本发明公开一种高强度泡沫陶瓷的制备方法，由以下步骤制备而成：1）称取以下重量份数的各原料：木质纤维素5‑6份；聚醚80‑95份；催化剂0.2‑0.5份；水2‑5份；十二烷基硫酸钠1.5‑3份；甲苯二异氰酸酯6‑8份；2）将步骤1）称取的各组分加入容器中搅拌均匀，待反应10‑15分钟后取出静置8‑12小时固化得到坯体；然后将坯体置于开孔箱内，抽真空后，充入比例为1:1:2的乙炔、氢气和氧气至常压后静置5‑10分钟，然后点火开孔，得到具有空间网状结构的有机载体；本发明通过陶瓷浆料结合有机载体从整体上有效提高了泡沫陶瓷的强度。

Description

一种高强度泡沫陶瓷的制备方法
技术领域
本发明涉及一种高强度泡沫陶瓷的制备方法。
背景技术
泡沫陶瓷是一种具有三维空间网架结构的高气孔率的多孔陶瓷，由于其具有质量轻、强度高、耐高温、耐腐蚀再生简单及良好的过滤和吸附性等优点，被广泛应用于熔铸、化工催化载体材料、隔热材料、燃烧器、吸音材料等。
熔铸是泡沫陶瓷过滤板应用最为广泛的行业之一，它的作用是使紊乱、翻腾的铝水经过陶瓷过滤板三维孔后变得平稳、均匀、干净，从而大大降低了夹杂物等铸造缺陷而导致的废品，节约生产成本。
化工催化载体材料，泡沫陶瓷具有高比表面性，使其作为催化载体，可以增加有效接触面积，增强催化效果。且其具有耐热、不污染、不易中毒、成本低廉等优点，已广泛应用于汽车尾气、化工领域等处理有毒、恶、臭等有害气体，进一步环境保护。
作为隔热材料，泡沫陶瓷由于闭气孔的存在，降低了其放热效率，减少了热传播过程中的对流，使其具有陶瓷热传导率低，抗热震性能优良等特性，是一种理想的隔热材料。目前被应用于航天飞机外壳的隔热等。
燃烧器的应用，泡沫陶瓷又一个用途是作为多孔介质燃烧器，因其通过陶瓷材料提供的良好热交换降低了火焰温度，故在惰性多孔陶瓷表面内或在接近多孔陶瓷表面外进行各种燃烧的预混合燃烧，从而节省了能量，并显著降低了COX、NOX排放。
吸音的应用，泡沫陶瓷具有大量三维空间网络结构的孔隙。声波传入多孔体内部后，引起孔隙中的空气产生振动并使陶瓷经络发生摩擦，由于粘滞的作用，声波转变为热量而消失，从而达到吸收声音的效果。
泡沫陶瓷的制备一般采用有机载体浸渍工艺，用具有空间网状结构的有机载体浸渍陶瓷浆料，干燥后烧掉有机载体，获得泡沫陶瓷，其独特之处在于它凭借了有机载体所具有的开孔三维网状骨架的特殊结构，将制备好的浆料均匀地涂覆在载体网状上，而烧掉有机载体后获得泡沫陶瓷。
但是由于陶瓷浆料为水基浆料，有时有机载体与浆料之间的润湿性差，在浸渍浆料时就会出现载体结构之间的交叉部分附着较厚的浆料，而在结构桥部和棱线部分浆料附着很薄的现象，这种情况会导致制品在烧制过程中胚体开裂，使泡沫陶瓷强度降低。
发明内容
本发明所要解决的技术问题是，克服以上现有技术的缺点：提供一种强度高的泡沫陶瓷的制备方法。
本发明的技术解决方案如下：一种高强度泡沫陶瓷的制备方法，由以下步骤制备而成：
1）称取以下重量份数的各原料：木质纤维素5-6份；聚醚 80-95份；催化剂0.2-0.5份；水 2-5份；十二烷基硫酸钠1.5-3份；甲苯二异氰酸酯6-8份；
2）将步骤1）称取的各组分加入容器中搅拌均匀，待反应10-15分钟后取出静置8-12小时固化得到坯体；然后将坯体置于开孔箱内，抽真空后，充入比例为1:1:2的乙炔、氢气和氧气至常压后静置5-10分钟，然后点火开孔，得到具有空间网状结构的有机载体；
3）将重量份计的高岭土8-12份，氧化铝50-60份、黏土5-15份、羧甲基纤维素10-12份混合均匀后加入去离子水再次搅拌混合均匀配制成固含量为50wt%的陶瓷浆料；
4）将步骤2）制备的有机载体浸渍步骤3）中制备的陶瓷浆料后再通过挤压的方式将有机载体中的过剩陶瓷浆料挤出，制成泡沫陶瓷坯体，泡沫陶瓷坯体100-120℃下进行干燥，然后升温至600-700℃使有机载体体完全挥发，最后于1500-1600℃烧结5-6h，自然冷却至室温即得空间网状泡沫陶瓷。
其中，所述催化剂为辛酸亚锡、二月桂酸二丁基锡中的一种。
较佳地，步骤1）中木质纤维素5-6份；聚醚 80份；催化剂0.2-0.5份；水 2-5份；十二烷基硫酸钠1.5-3份；甲苯二异氰酸酯6-8份。
最佳地，步骤1）中木质纤维素6份；聚醚 80份；催化剂0.5份；水 5份；十二烷基硫酸钠3份；甲苯二异氰酸酯8份。
较佳地，步骤3）中高岭土8份，氧化铝55份、黏土5份、羧甲基纤维素10份。
本发明的有益效果是：本发明采用自制具有空间网状结构的有机载体结合含有高岭土的陶瓷浆料制备泡沫陶瓷，高岭土使得陶瓷浆料不仅具有一定的流动性而且具有良好的触变性，即浆料具有在静止时处于凝固状态，但在外力的作用下又恢复流动的特性，浆料的流动性能保证浆料在浸渍过程中渗透到有机载体中，并均匀地覆盖在空间网络的脉络上。陶瓷浆料的触变性可以保证在浸渍浆料挤出多余浆料时在剪切作用下降低粘度，提高浆料的流动性，有助于恢复形状，而在恢复形状后，浆料的粘度升高，流动性降低这就使得附着在脉络丝上的浆料容易固化而定型，本发明通过陶瓷浆料结合有机载体从整体上有效提高了泡沫陶瓷的强度。
具体实施方式
下面用具体实施例对本发明做进一步详细说明，但本发明不仅局限于以下具体实施例。
实施例1
按照以下步骤制备高强度泡沫陶瓷：
1）称取以下重量份数的各原料：木质纤维素6份；聚醚95份；辛酸亚锡0.5份；水 5份；十二烷基硫酸钠3份；甲苯二异氰酸酯8份；
2）将步骤1）称取的各组分加入容器中搅拌均匀，待反应15分钟后取出静置12小时固化得到坯体；然后将坯体置于开孔箱内，抽真空后，充入比例为1:1:2的乙炔、氢气和氧气至常压后静置5分钟，然后点火开孔，得到具有空间网状结构的有机载体；
3）将重量份计的高岭土8份，氧化铝60份、黏土15份、羧甲基纤维素12份混合均匀后加入去离子水再次搅拌混合均匀配制成固含量为50wt%的陶瓷浆料；
4）将步骤2）制备的有机载体浸渍步骤3）中制备的陶瓷浆料后再通过挤压的方式将有机载体中的过剩陶瓷浆料挤出，制成泡沫陶瓷坯体，泡沫陶瓷坯体120℃下进行干燥，然后升温至700℃使有机载体体完全挥发，最后于1600℃烧结6h，自然冷却至室温即得泡沫陶瓷。
实施例2
按照以下步骤制备高强度泡沫陶瓷：
1）称取以下重量份数的各原料：木质纤维素6份；聚醚 80份；二月桂酸二丁基锡0.5份；水 5份；十二烷基硫酸钠3份；甲苯二异氰酸酯8份。
2）将步骤1）称取的各组分加入容器中搅拌均匀，待反应15分钟后取出静置12小时固化得到坯体；然后将坯体置于开孔箱内，抽真空后，充入比例为1:1:2的乙炔、氢气和氧气至常压后静置5分钟，然后点火开孔，得到具有空间网状结构的有机载体；
3）将重量份计的高岭土8份，氧化铝55份、黏土5份、羧甲基纤维素10份混合均匀后加入去离子水再次搅拌混合均匀配制成固含量为50wt%的陶瓷浆料；
4）将步骤2）制备的有机载体浸渍步骤3）中制备的陶瓷浆料后再通过挤压的方式将有机载体中的过剩陶瓷浆料挤出，制成泡沫陶瓷坯体，泡沫陶瓷坯体120℃下进行干燥，然后升温至700℃使有机载体体完全挥发，最后于1600℃烧结6h，自然冷却至室温即得泡沫陶瓷。
实施例3
按照以下步骤制备高强度泡沫陶瓷：
1）称取以下重量份数的各原料：木质纤维素5份；聚醚 80份；辛酸亚锡0.2份；水 5份；十二烷基硫酸钠3份；甲苯二异氰酸酯8份。
2）将步骤1）称取的各组分加入容器中搅拌均匀，待反应15分钟后取出静置12小时固化得到坯体；然后将坯体置于开孔箱内，抽真空后，充入比例为1:1:2的乙炔、氢气和氧气至常压后静置5分钟，然后点火开孔，得到具有空间网状结构的有机载体；
3）将重量份计的高岭土8份，氧化铝55份、黏土5份、羧甲基纤维素10份混合均匀后加入去离子水再次搅拌混合均匀配制成固含量为50wt%的陶瓷浆料；
4）将步骤2）制备的有机载体浸渍步骤3）中制备的陶瓷浆料后再通过挤压的方式将有机载体中的过剩陶瓷浆料挤出，制成泡沫陶瓷坯体，泡沫陶瓷坯体120℃下进行干燥，然后升温至700℃使有机载体体完全挥发，最后于1600℃烧结6h，自然冷却至室温即得高强度泡沫陶瓷。
以上仅是本发明的特征实施范例，对本发明保护范围不构成任何限制。凡采用同等交换或者等效替换而形成的技术方案，均落在本发明权利保护范围之内。

Claims (5)

1.一种高强度泡沫陶瓷的制备方法，其特征在于：由以下步骤制备而成：
1）称取以下重量份数的各原料：木质纤维素5-6份；聚醚 80-95份；催化剂0.2-0.5份；水 2-5份；十二烷基硫酸钠1.5-3份；甲苯二异氰酸酯6-8份；
2）将步骤1）称取的各组分加入容器中搅拌均匀，待反应10-15分钟后取出静置8-12小时固化得到坯体；然后将坯体置于开孔箱内，抽真空后，充入比例为1:1:2的乙炔、氢气和氧气至常压后静置5-10分钟，然后点火开孔，得到具有空间网状结构的有机载体；
3）将重量份计的高岭土8-12份，氧化铝50-60份、黏土5-15份、羧甲基纤维素10-12份混合均匀后加入去离子水再次搅拌混合均匀配制成固含量为50wt%的陶瓷浆料；
4）将步骤2）制备的有机载体浸渍步骤3）中制备的陶瓷浆料后再通过挤压的方式将有机载体中的过剩陶瓷浆料挤出，制成泡沫陶瓷坯体，泡沫陶瓷坯体100-120℃下进行干燥，然后升温至600-700℃使有机载体体完全挥发，最后于1500-1600℃烧结5-6h，自然冷却至室温即得空间网状泡沫陶瓷。
2.根据权利要求1所述的高强度泡沫陶瓷的制备方法，其特征在于：所述催化剂为辛酸亚锡、二月桂酸二丁基锡中的一种。
3. 根据权利要求1所述的高强度泡沫陶瓷的制备方法，其特征在于：步骤1）中木质纤维素5-6份；聚醚 80份；催化剂0.2-0.5份；水 2-5份；十二烷基硫酸钠1.5-3份；甲苯二异氰酸酯6-8份。
4. 根据权利要求1所述的高强度泡沫陶瓷的制备方法，其特征在于：步骤1）中木质纤维素6份；聚醚 80份；催化剂0.5份；水 5份；十二烷基硫酸钠3份；甲苯二异氰酸酯8份。
5.根据权利要求1所述的高强度泡沫陶瓷的制备方法，其特征在于：步骤3）中高岭土8份，氧化铝55份、黏土5份、羧甲基纤维素10份。
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