CN110903071A - Electric porcelain insulator and preparation method thereof - Google Patents
Electric porcelain insulator and preparation method thereof Download PDFInfo
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- CN110903071A CN110903071A CN201911294508.6A CN201911294508A CN110903071A CN 110903071 A CN110903071 A CN 110903071A CN 201911294508 A CN201911294508 A CN 201911294508A CN 110903071 A CN110903071 A CN 110903071A
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- 239000012212 insulator Substances 0.000 title claims abstract description 54
- 229910052573 porcelain Inorganic materials 0.000 title claims abstract description 33
- 238000002360 preparation method Methods 0.000 title claims abstract description 16
- 239000002994 raw material Substances 0.000 claims abstract description 23
- WQZGKKKJIJFFOK-GASJEMHNSA-N Glucose Natural products OC[C@H]1OC(O)[C@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-GASJEMHNSA-N 0.000 claims abstract description 17
- 239000008103 glucose Substances 0.000 claims abstract description 17
- 238000000498 ball milling Methods 0.000 claims abstract description 10
- 229910001570 bauxite Inorganic materials 0.000 claims abstract description 8
- 239000004927 clay Substances 0.000 claims abstract description 8
- 239000000843 powder Substances 0.000 claims abstract description 8
- 239000002689 soil Substances 0.000 claims abstract description 8
- 229910052882 wollastonite Inorganic materials 0.000 claims abstract description 8
- 239000010456 wollastonite Substances 0.000 claims abstract description 8
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 claims abstract description 8
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 claims abstract description 7
- 239000010433 feldspar Substances 0.000 claims abstract description 7
- 229940072033 potash Drugs 0.000 claims abstract description 7
- BWHMMNNQKKPAPP-UHFFFAOYSA-L potassium carbonate Substances [K+].[K+].[O-]C([O-])=O BWHMMNNQKKPAPP-UHFFFAOYSA-L 0.000 claims abstract description 7
- 235000015320 potassium carbonate Nutrition 0.000 claims abstract description 7
- 239000002002 slurry Substances 0.000 claims description 32
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 32
- 238000000034 method Methods 0.000 claims description 25
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 22
- 239000002245 particle Substances 0.000 claims description 22
- 238000001035 drying Methods 0.000 claims description 14
- 229910052742 iron Inorganic materials 0.000 claims description 11
- 238000001125 extrusion Methods 0.000 claims description 10
- 238000007689 inspection Methods 0.000 claims description 10
- 238000005245 sintering Methods 0.000 claims description 10
- 239000002253 acid Substances 0.000 claims description 9
- 239000003638 chemical reducing agent Substances 0.000 claims description 9
- 230000032683 aging Effects 0.000 claims description 7
- 238000007873 sieving Methods 0.000 claims description 7
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 5
- 238000001816 cooling Methods 0.000 claims description 5
- 238000005520 cutting process Methods 0.000 claims description 5
- 238000001914 filtration Methods 0.000 claims description 5
- 238000000227 grinding Methods 0.000 claims description 5
- 238000010438 heat treatment Methods 0.000 claims description 5
- 239000012535 impurity Substances 0.000 claims description 5
- 238000002156 mixing Methods 0.000 claims description 5
- 229910052760 oxygen Inorganic materials 0.000 claims description 5
- 239000001301 oxygen Substances 0.000 claims description 5
- 238000004806 packaging method and process Methods 0.000 claims description 5
- 239000004033 plastic Substances 0.000 claims description 5
- 229920003023 plastic Polymers 0.000 claims description 5
- 238000005498 polishing Methods 0.000 claims description 5
- 238000005086 pumping Methods 0.000 claims description 5
- 238000007493 shaping process Methods 0.000 claims description 5
- 239000000203 mixture Substances 0.000 claims description 4
- 238000003825 pressing Methods 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 claims 1
- 238000010304 firing Methods 0.000 abstract description 8
- 238000005507 spraying Methods 0.000 abstract description 2
- 239000013078 crystal Substances 0.000 description 15
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 14
- 239000000463 material Substances 0.000 description 14
- 229910052863 mullite Inorganic materials 0.000 description 14
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 13
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 12
- 229910052799 carbon Inorganic materials 0.000 description 11
- 230000008569 process Effects 0.000 description 9
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 5
- 239000004020 conductor Substances 0.000 description 5
- 239000011398 Portland cement Substances 0.000 description 4
- 239000006004 Quartz sand Substances 0.000 description 4
- 150000004645 aluminates Chemical class 0.000 description 4
- 239000004568 cement Substances 0.000 description 4
- 239000003795 chemical substances by application Substances 0.000 description 4
- 238000000465 moulding Methods 0.000 description 4
- 239000002667 nucleating agent Substances 0.000 description 4
- 229910021487 silica fume Inorganic materials 0.000 description 4
- 229910052814 silicon oxide Inorganic materials 0.000 description 4
- 239000002562 thickening agent Substances 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 2
- 230000005540 biological transmission Effects 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 230000015556 catabolic process Effects 0.000 description 2
- 239000010431 corundum Substances 0.000 description 2
- 229910052593 corundum Inorganic materials 0.000 description 2
- 239000004615 ingredient Substances 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 239000007791 liquid phase Substances 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- 235000012239 silicon dioxide Nutrition 0.000 description 2
- FKNQFGJONOIPTF-UHFFFAOYSA-N Sodium cation Chemical compound [Na+] FKNQFGJONOIPTF-UHFFFAOYSA-N 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 238000005054 agglomeration Methods 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
- DLHONNLASJQAHX-UHFFFAOYSA-N aluminum;potassium;oxygen(2-);silicon(4+) Chemical compound [O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[Al+3].[Si+4].[Si+4].[Si+4].[K+] DLHONNLASJQAHX-UHFFFAOYSA-N 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 239000002270 dispersing agent Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 230000002209 hydrophobic effect Effects 0.000 description 1
- 239000006148 magnetic separator Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- CHWRSCGUEQEHOH-UHFFFAOYSA-N potassium oxide Chemical compound [O-2].[K+].[K+] CHWRSCGUEQEHOH-UHFFFAOYSA-N 0.000 description 1
- 229910001950 potassium oxide Inorganic materials 0.000 description 1
- 229910001415 sodium ion Inorganic materials 0.000 description 1
- 230000035882 stress Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/13—Compounding ingredients
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/04—Clay; Kaolin
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- C04B33/00—Clay-wares
- C04B33/24—Manufacture of porcelain or white ware
- C04B33/26—Manufacture of porcelain or white ware of porcelain for electrical insulation
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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- C04B33/00—Clay-wares
- C04B33/32—Burning methods
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
- C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
- C04B35/185—Mullite 3Al2O3-2SiO2
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/06—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances
- C04B38/063—Preparing or treating the raw materials individually or as batches
- C04B38/0635—Compounding ingredients
- C04B38/0645—Burnable, meltable, sublimable materials
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B17/00—Insulators or insulating bodies characterised by their form
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B19/00—Apparatus or processes specially adapted for manufacturing insulators or insulating bodies
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- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
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- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3427—Silicates other than clay, e.g. water glass
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3427—Silicates other than clay, e.g. water glass
- C04B2235/3436—Alkaline earth metal silicates, e.g. barium silicate
- C04B2235/3454—Calcium silicates, e.g. wollastonite
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- Chemical & Material Sciences (AREA)
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- Inorganic Chemistry (AREA)
- Compositions Of Oxide Ceramics (AREA)
- Insulators (AREA)
Abstract
The invention provides a high-strength electric porcelain insulator which comprises the following raw materials in parts by weight: 12-18 parts of potash feldspar, 12-16 parts of Guangdong mud, 13-18 parts of bauxite, 12-17 parts of zirconium silicate micro powder, 16-23 parts of Zuoyun soil, 3-9 parts of black clay, 4-8 parts of Hubei mud, 5-11 parts of Fujian mud, 3-8 parts of wollastonite and 1-3 parts of glucose. The invention also provides a preparation method of the high-strength electric porcelain insulator, which is characterized in that the raw materials are not required to be pretreated, and are directly subjected to ball milling after being mixed; the glaze spraying method is adopted, and the glazing is quick and pollution-free; the blank firing temperature is reduced, and energy is saved. The insulator prepared by the invention has high mechanical strength and electrical strength, and ensures the safety of a power grid.
Description
Technical Field
The invention relates to the technical field of porcelain insulator preparation, in particular to a high-strength electric porcelain insulator and a preparation method thereof.
Background
Insulators are devices that are mounted between conductors of different potentials or between a conductor and a ground potential member and are able to withstand the effects of voltage and mechanical stress. The insulator is a special insulating control, plays two basic actions in overhead transmission line: the support and the fixation of the bus bar and the live conductor and the sufficient distance and the insulation between the live conductor or the conductor and the ground. The insulator is used for increasing creepage distance, and is a common porcelain insulator and a glass fiber reinforced plastic insulator.
The insulator is widely used in the field of high-voltage transmission, bears the task of ensuring that a wire, a cross arm and a tower have enough insulation, needs to bear the load of the vertical direction and the tension of the horizontal direction of the wire in the operation, and is also subjected to solarization, rain, climate change and corrosion of chemical substances, so that the insulator has good electrical performance and enough mechanical strength. The existing insulator has the advantages that the performance is required to be improved, cracks are easy to occur, breakdown and flashover accidents are easy to occur, the service life is shortened, and the safety of a power grid is influenced.
Disclosure of Invention
The invention aims to solve the problems and provides an electric porcelain insulator with high electrical performance and high mechanical strength and a preparation method thereof.
As one aspect of the object of the invention, the invention provides a high-strength electric porcelain insulator which comprises the following raw materials in parts by weight: 12-18 parts of potash feldspar, 12-16 parts of Guangdong mud, 13-18 parts of bauxite, 12-17 parts of zirconium silicate micro powder, 16-23 parts of Zuoyun soil, 3-9 parts of black clay, 4-8 parts of Hubei mud, 5-11 parts of Fujian mud, 3-8 parts of wollastonite and 1-3 parts of glucose.
The formula widely adopts universal raw materials in most regions, and has wide application range; the variety of the raw materials is multiple, so that the influence caused by price fluctuation of a single raw material is reduced; the prepared insulator material has good insulating property and mechanical property, and solves the problems that the insulator is cracked and easy to puncture after long-time use due to high sodium ion content in the traditional insulator preparation process.
Further, the high-strength electric porcelain insulator comprises the following raw materials in parts by weight: 12-16 parts of potash feldspar, 13-15 parts of Guangdong mud, 15-17 parts of bauxite, 13-15 parts of zirconium silicate micro powder, 19-22 parts of Zuoyun soil, 5-8 parts of black clay, 5-6 parts of Hubei mud, 7-9 parts of Fujian mud, 5-7 parts of wollastonite and 1.5-3 parts of glucose.
Small amounts of glucose play two roles here: firstly, the glucose is decomposed to generate gas in the firing process, so that a certain number of air holes can be formed on the insulator blank, and the combination of the insulator blank and the glaze in the firing process is facilitated; in addition, the glucose is decomposed to obtain carbon which does not participate in any reaction at high temperature, and because the carbon has high melting point, the carbon is dispersed in the whole blank, can be tightly combined with mullite crystals formed in sintering at high temperature, greatly improves the integrity and the strength, and can also be used as a similar nucleating agent at high temperature, so that alumina and silicon oxide in the mullite crystals can better form the mullite crystals. In addition, carbon is added into the insulator material, so that a deflection path is increased to consume more energy when the insulator material is broken, and the fracture toughness of the material is improved. If carbon powder is directly added into the raw materials, the carbon powder is easy to agglomerate together, so a dispersing agent is required to be added during ball milling to prevent agglomeration; and no air holes can be generated during firing, and the glaze can only be attached to the surface of the blank.
As one aspect of the object of the invention, the preparation method of the electric porcelain insulator is characterized by comprising the following steps:
s1, ball milling: mixing the raw materials according to any one of claims 1 to 3 in percentage by mass, transferring into a ball mill, and mixing the raw materials according to the total weight percentage: grinding balls: water 1: 0.8-1.5: 0.8-1.5 (weight ratio) and adding water to ball mill for 8-15 h;
s2, sieving and removing iron: sieving the prepared slurry with a 250-mesh sieve until the residue is within 0.3%, wherein the content of particles below 10 μm in the sieved slurry is not less than 50%, and the content of particles below 20 μm in the sieved slurry is not less than 70%, and then removing iron-containing impurities to obtain clean slurry;
s3, filter pressing and ageing: filtering and dehydrating the slurry to obtain a mud cake, wherein the water content of the mud cake is 25-30%, and then placing the mud cake in a sealed chamber for standing and ageing for 10-15 hours;
s4, vacuum extrusion: putting the aged mud cakes into a horizontal vacuum pugging machine, performing spiral extrusion, pumping out air to obtain long-strip mud sections, and drying and shaping the mud sections in a shade platform;
s5, product molding: adopting a plastic forming method to form the mud segment into a blank with a required shape, wherein the forming moisture content of the blank is 20 +/-2.5%, and the blank is dried for 8-12 h in a drying room at 100-110 ℃ after being formed;
s6, glazing: glazing the dried blank;
s7, sintering: putting the blank into a kiln, keeping the oxygen content in the kiln not higher than 5%, preserving heat for 5-10 h at 600-800 ℃, then heating to 1250-1320 ℃ at the speed of 50-100 ℃/h, preserving heat for 5-10 h, and then cooling to room temperature;
s8, cutting, flattening, polishing, cementing and maintaining;
and S9, packaging the qualified product after inspection and inspection of the finished product and warehousing.
In the preparation method, the raw materials do not need to be pretreated, and are directly subjected to ball milling after being mixed; by adopting the glaze pouring method, the glazing is quick and pollution-free, the glaze layer is uniform, and the obtained product has good quality. The firing time is divided into two sections and is constant in temperature, and a liquid phase appears in the low-temperature process of the first section, so that the appearance of primary mullite crystals is facilitated, and glucose is decomposed to provide pores and a carbon source; in the second stage of high temperature process, alumina part forms corundum crystal, and the other part forms mullite crystal with silicon oxide, so that the folding strength and the tensile strength are improved; meanwhile, carbon is used as a nucleating agent to enhance the formation of mullite crystals, and the glaze flows into the air holes to enable the blank and the glaze to be combined more tightly, so that the stability and the mechanical strength of the insulator material are further improved. And the combination of the blank and the glaze is further enhanced by adopting a temperature programming method, so that a mullite crystal structure is better formed.
Further, the water content of the slurry after ball milling in the step S1 is 55-68%.
Further, the content of particles having a particle size of 10 μm or less in the slurry sieved in step S2 is not less than 60%, and the content of particles having a particle size of 20 μm or less is not less than 80%.
Further, the iron removal method in step S2 is: and (3) removing iron in a magnetic field with the magnetic field intensity of 8000-10000 Gauss.
Further, adding 0.1-1% of a polycarboxylic acid water reducing agent into the glaze in the step S6, wherein the glaze temperature is 50-60 ℃; and/or the glaze spraying time is 10-20 min; and/or the thickness of the glaze layer of the sprayed glaze is 0.27-0.32 mm.
Further, the gluing in step S8 is characterized by using the following glue components: 30-40 parts of Portland cement, 2-6 parts of silica fume, 2-6 parts of aluminate cement, 40-50 parts of quartz sand, 5-12 parts of water, 0.1-1 part of polycarboxylic acid water reducing agent, 0.08-0.2 part of retarder, 0.05-0.1 part of early strength agent and 0.1-0.25 part of thickening agent.
Further, the electric porcelain insulator is obtained according to the preparation method of the high-strength electric porcelain insulator.
The invention can obtain the following beneficial effects:
1. the formula contains the silicon dioxide and the alumina in the proportion, mullite is generated after sintering, the mechanical strength and the cold and hot properties of the porcelain are improved, the silicon dioxide can reduce the drying and sintering shrinkage of a blank body, reduce the bending deformation, and can play a skeleton role of a porcelain blank and improve the mechanical strength of the porcelain blank; the alumina can obviously improve the mechanical strength of the porcelain body; the potassium oxide can reduce the sintering temperature, fill gaps of the porcelain body, increase the compactness of the porcelain and improve the mechanical strength and the electrical property of the porcelain body; therefore, the hydrophobic performance, the anti-pollution performance, the insulating performance and the mechanical performance of the insulator porcelain body are obviously improved by matching the formula with the preparation method.
2. A small amount of additive glucose is added in the formula to provide air holes and a carbon source for the insulator material. The air holes can help the combination of the insulator green body and the glaze in the firing process; carbon has three roles: the aluminum oxide and the silicon oxide in the insulator can better form mullite crystals due to the existence of the similar nucleating agent, and can be tightly combined with the mullite crystals formed in sintering, so that the integrity and the strength are greatly improved, and in addition, carbon is added into the insulator material, so that a deflection path is increased during fracture, more energy is consumed, and the fracture toughness of the material is improved.
3. In the preparation method, the raw materials do not need to be pretreated, and are directly subjected to ball milling after being mixed; by adopting the glaze pouring method, the glazing is quick and pollution-free, the glaze layer is uniform, and the obtained product has good quality.
4. The firing time is divided into two sections and is constant in temperature, a liquid phase appears in the low-temperature process of the first stage, which is beneficial to the appearance of a mullite crystal, and meanwhile, the glucose is decomposed to provide pores and a carbon source in the stage; in the second stage of high temperature process, alumina part forms corundum crystal, and the other part forms mullite crystal with silicon oxide, so that the folding strength and the tensile strength are improved; meanwhile, carbon is used as a nucleating agent to enhance the formation of mullite crystals, and the glaze flows into the air holes to enable the blank and the glaze to be combined more tightly, so that the stability and the mechanical strength of the insulator material are further improved. And the combination of the blank and the glaze is further enhanced by adopting a temperature programming method, so that a mullite crystal structure is better formed.
5. The electric porcelain insulator obtained by the invention has high mechanical strength and high breakdown resistance, uniform porcelain structure and small dispersity, solves the problems that the traditional insulator is easy to crack and break down after long-time use, and can be used in the power industry and the railway industry.
Detailed Description
The technical solutions in the embodiments of the present invention are clearly and completely described below, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The glucose is commercial industrial glucose, is low in price and wide in source, and does not increase the material cost; the ball mill, the slurry pump, the magnetic separator and the vacuum pugmill are all commercially available products.
Example 1:
the preparation method of the medium-high strength insulator material comprises the following steps:
s1, preparing the following raw materials: 14.5 percent of potash feldspar, 14 percent of Guangdong mud, 15.5 percent of bauxite, 12 percent of zirconium silicate micro powder, 18 percent of Zuoyun soil, 4.5 percent of black clay, 5 percent of Hubei mud, 8 percent of Fujian mud, 5.5 percent of wollastonite and 3 percent of glucose are mixed according to the following ingredients, and then the mixture is transferred into a ball mill to be mixed according to the total raw materials: grinding balls: water 1: 1: 1.2 (weight ratio) adding water and ball milling for 8h to obtain slurry with the water content of 62%;
s2, sieving the slurry prepared in the step S1 by a 250-mesh sieve, wherein the residue is less than 0.15%, the content of particles with the particle size of less than 10 μm in the sieved slurry is 70%, the content of particles with the particle size of less than 20 μm in the sieved slurry is 90%, and then removing iron-containing impurities in a magnetic field with the magnetic field intensity of 9000 Gauss to obtain clean slurry;
s3, filtering and dehydrating the obtained slurry to obtain a mud cake, controlling the water content of the mud cake to be about 26%, and standing and ageing the mud cake in a sealed chamber with the humidity of 85% for 15 hours;
s4, vacuum extrusion: putting the aged mud cakes into a horizontal vacuum pugging machine, performing spiral extrusion, pumping out air to obtain long-strip mud sections, and drying and shaping the mud sections in a shade platform;
s5, product molding: adopting a plastic forming method to form the mud segment into a blank with a required shape, wherein the forming moisture content of the blank is 21 +/-1%, and the blank is sent into a drying room at 100 ℃ for drying for 10h after being formed;
s6, glazing: pouring glaze on the formed blank for 15min, adding 0.8% of polycarboxylic acid water reducing agent into the glaze slip, wherein the temperature of the glaze slip is 55 ℃, and the thickness of a glaze layer on the blank after glaze pouring is about 0.31 mm;
s7, sintering: putting the blank into a kiln, keeping the oxygen content in the kiln not higher than 4.5%, preserving heat for 6h at 750 ℃, then heating to 1310 ℃ at the speed of 100 ℃/h, preserving heat for 8h, and then naturally cooling to room temperature;
s8, cutting, polishing and flattening the surface of the product, cementing and maintaining; wherein, the adhesive used for cementing comprises the following components: 40% of Portland cement, 4.2% of silica fume, 3.3% of aluminate cement, 45% of quartz sand, 6.5% of water, 0.25% of polycarboxylic acid water reducing agent, 0.18% of retarder, 0.075% of early strength agent and 0.18% of thickening agent;
and S9, packaging the qualified product after inspection and inspection of the finished product and warehousing.
Example 2:
the preparation method of the medium-high strength insulator material comprises the following steps:
s1, preparing the following raw materials: 15% of potassium feldspar, 13.5% of Guangdong mud, 14% of bauxite, 12.5% of zirconium silicate micro powder, 20.5% of Zuoyun soil, 4.8% of black clay, 5.5% of Hubei mud, 7.5% of Fujian mud, 5.2% of wollastonite and 1.5% of glucose, mixing the materials, and then transferring the mixture into a ball mill according to the total raw materials: grinding balls: water 1: 1.5: 1.2 (weight ratio) adding water and ball milling for 8h to obtain slurry with the water content of 60%;
s2, sieving the slurry prepared in the step S1 by a 250-mesh sieve, wherein the residue is less than 0.2%, the content of particles with the particle size of less than 10 μm in the sieved slurry is 65%, the content of particles with the particle size of less than 20 μm in the sieved slurry is 90%, and then removing iron-containing impurities in a magnetic field with the magnetic field intensity of 9000 Gauss to obtain clean slurry;
s3, filtering and dehydrating the obtained slurry to obtain a mud cake, controlling the water content of the mud cake to be about 28%, and standing and ageing the mud cake in a sealed chamber with the humidity of 75% for 10 hours;
s4, vacuum extrusion: putting the aged mud cakes into a horizontal vacuum pugging machine, performing spiral extrusion, pumping out air to obtain long-strip mud sections, and drying and shaping the mud sections in a shade platform;
s5, product molding: adopting a plastic forming method to form the mud segment into a blank with a required shape, wherein the water content of the formed blank is 20 +/-1 percent, and the blank is dried for 10 hours in a drying room at 105 ℃ after being formed;
s6, glazing: pouring glaze on the formed blank for 10min, adding 0.75% of polycarboxylic acid water reducing agent into the glaze slip, wherein the temperature of the glaze slip is 55 ℃, and the thickness of a glaze layer on the blank after glaze pouring is about 0.28 mm;
s7, sintering: putting the blank into a kiln, keeping the oxygen content in the kiln not higher than 1.5%, preserving heat for 7.5h at 680 ℃, then heating to 1280 ℃ at the rate of 70 ℃/h, preserving heat for 10h, and then naturally cooling to room temperature;
s8, cutting, polishing and flattening the surface of the product, cementing and maintaining; wherein, the adhesive used for cementing comprises the following components: 35% of Portland cement, 4.5% of silica fume, 4.5% of aluminate cement, 44.8% of quartz sand, 10% of water, 0.81% of polycarboxylic acid water reducing agent, 0.15% of retarder, 0.09% of early strength agent and 0.15% of thickening agent;
and S9, packaging the qualified product after inspection and inspection of the finished product and warehousing.
Example 3:
the preparation method of the medium-high strength insulator material comprises the following steps:
s1, preparing the following raw materials: 12.5 percent of potash feldspar, 13.5 percent of Guangdong mud, 15.5 percent of bauxite, 13 percent of zirconium silicate micro powder, 19.5 percent of Zuoyun soil, 5.3 percent of black clay, 5.2 percent of Hubei mud, 8 percent of Fujian mud, 5.3 percent of wollastonite and 2.2 percent of glucose are mixed by ingredients, and then the mixture is transferred into a ball mill to be mixed according to the total raw materials: grinding balls: water 1: 1: 1 (weight ratio) adding water and ball milling for 12h to obtain slurry with the moisture content of 58%;
s2, sieving the slurry prepared in the step S1 by a 250-mesh sieve, wherein the residue is less than 0.1%, the content of particles with the particle size of less than 10 μm in the sieved slurry is 65%, the content of particles with the particle size of less than 20 μm in the sieved slurry is 80%, and then removing iron-containing impurities in a magnetic field with the magnetic field intensity of 8500 Gauss to obtain clean slurry;
s3, filtering and dehydrating the obtained slurry to obtain a mud cake, controlling the water content of the mud cake to be about 28%, and standing and ageing the mud cake in a sealed chamber with the humidity of 85% for 15 hours;
s4, vacuum extrusion: putting the aged mud cakes into a horizontal vacuum pugging machine, performing spiral extrusion, pumping out air to obtain long-strip mud sections, and drying and shaping the mud sections in a shade platform;
s5, product molding: adopting a plastic forming method to form the mud segment into a blank with a required shape, wherein the forming moisture content of the blank is 21 +/-0.5 percent, and the blank is sent into a drying room at 100 ℃ for drying for 12 hours after being formed;
s6, glazing: pouring glaze on the formed blank for 15min, adding 0.3% of polycarboxylic acid water reducing agent into the glaze slip, wherein the temperature of the glaze slip is 58 ℃, and the thickness of a glaze layer on the blank after glaze pouring is about 0.31 mm;
s7, sintering: putting the blank into a kiln, keeping the oxygen content in the kiln not higher than 2.5%, preserving heat for 6h at 780 ℃, then heating to 1290 ℃ at the rate of 80 ℃/h, preserving heat for 9h, and then naturally cooling to room temperature;
s8, cutting, polishing and flattening the surface of the product, cementing and maintaining; wherein, the adhesive used for cementing comprises the following components: 40% of Portland cement, 3.2% of silica fume, 4.2% of aluminate cement, 42.4% of quartz sand, 9% of water, 0.85% of polycarboxylic acid water reducing agent, 0.13% of retarder, 0.07% of early strength agent and 0.15% of thickening agent;
and S9, packaging the qualified product after inspection and inspection of the finished product and warehousing.
The insulators prepared in examples 1 to 3 were tested, and the results were as follows: the glaze surface is smooth and clean, has no appearance quality defect, and the insulator appearance, size, mechanical strength, electrical strength and other performances are detected according to the relevant standards of GB/T772 and GB/T8287, which all meet the requirements of the relevant standards. The performance indexes of the insulator products obtained in the embodiments 1 to 3 are shown in table 1.
TABLE 1
The insulator prepared by the formula and the process has the mechanical strength and the electrical strength higher than the industrial standard, and the glucose is added into the formula, so that the appearance and the product performance of the product cannot be influenced by air holes generated in the firing process, and the mechanical strength and the anti-breakdown capability of the product can be enhanced.
Finally, it should be noted that: although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that modifications may be made to the embodiments or portions thereof without departing from the spirit and scope of the invention.
Claims (9)
1. The high-strength electric porcelain insulator is characterized by comprising the following raw materials in parts by weight: 12-18 parts of potash feldspar, 12-16 parts of Guangdong mud, 13-18 parts of bauxite, 12-17 parts of zirconium silicate micro powder, 16-23 parts of Zuoyun soil, 3-9 parts of black clay, 4-8 parts of Hubei mud, 5-11 parts of Fujian mud, 3-8 parts of wollastonite and 1-3 parts of glucose.
2. The high-strength electric porcelain insulator according to claim 1, comprising the following raw materials in parts by weight: 12-16 parts of potash feldspar, 13-15 parts of Guangdong mud, 15-17 parts of bauxite, 13-15 parts of zirconium silicate micro powder, 19-22 parts of Zuoyun soil, 5-8 parts of black clay, 5-6 parts of Hubei mud, 7-9 parts of Fujian mud, 5-7 parts of wollastonite and 1.5-3 parts of glucose.
3. The preparation method of the high-strength electric porcelain insulator is characterized by comprising the following steps of:
s1, ball milling: mixing the raw materials according to the claim 1 or 2 according to the mass percentage, transferring the mixture into a ball mill, and mixing the raw materials according to the total raw materials: grinding balls: water 1: 0.8-1.5: 0.8-1.5 (weight ratio) and adding water to ball mill for 8-15 h;
s2, sieving and removing iron: sieving the prepared slurry with a 250-mesh sieve until the residue is within 0.3%, wherein the content of particles below 10 μm in the sieved slurry is not less than 50%, and the content of particles below 20 μm in the sieved slurry is not less than 70%, and then removing iron-containing impurities to obtain clean slurry;
s3, filter pressing and ageing: filtering and dehydrating the slurry to obtain a mud cake, wherein the water content of the mud cake is 25-30%, and then placing the mud cake in a sealed chamber for standing and ageing for 10-15 hours;
s4, vacuum extrusion: putting the aged mud cakes into a horizontal vacuum pugging machine, performing spiral extrusion, pumping out air to obtain long-strip mud sections, and drying and shaping the mud sections in a shade platform;
s5, forming and drying a product: adopting a plastic forming method to form the mud segment into a blank with a required shape, wherein the forming moisture content of the blank is 20 +/-2.5%, and the blank is dried for 8-12 h in a drying room at 100-110 ℃ after being formed;
s6, glazing: glazing the dried blank;
s7, sintering: putting the blank into a kiln, keeping the oxygen content in the kiln not higher than 5%, preserving heat for 5-10 h at 600-800 ℃, then heating to 1250-1320 ℃ at the speed of 50-100 ℃/h, preserving heat for 5-10 h, and then cooling to room temperature;
s8, cutting, flattening, polishing, cementing and maintaining;
and S9, packaging the qualified product after inspection and inspection of the finished product and warehousing.
4. The method of manufacturing a high-strength electric porcelain insulator according to claim 3, wherein the slurry sieved in step S2 contains particles of 10 μm or less in an amount of not less than 60% and particles of 20 μm or less in an amount of not less than 80%.
5. The method for preparing the high-strength electric porcelain insulator according to claim 4, wherein the iron removal method in step S2 is: and (3) removing iron in a magnetic field with the magnetic field intensity of 8000-10000 Gauss.
6. The method for preparing a high-strength electric porcelain insulator according to claim 5, wherein 0.1-1% of polycarboxylic acid water reducing agent is added to the glaze in step S6, and the glaze temperature is 50-60 ℃.
7. The method for preparing the high-strength electric porcelain insulator according to claim 6, wherein the glaze pouring time in the step S6 is 10-20 min.
8. The method for preparing a high-strength electric porcelain insulator according to claim 7, wherein the thickness of the glaze layer sprayed in the step S6 is 0.27-0.32 mm.
9. The electric porcelain insulator obtained by the method for preparing a high-strength electric porcelain insulator according to any one of claims 3 to 8.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN110194656A (en) * | 2019-04-30 | 2019-09-03 | 江西新龙电瓷电器制造有限公司 | A kind of middle high strength insulator material prescription and preparation method thereof |
| CN113053598A (en) * | 2021-03-16 | 2021-06-29 | 江西省萍乡市南溪电瓷电器制造有限公司 | Lightning protection needle type electric porcelain insulator and preparation method thereof |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN110194656A (en) * | 2019-04-30 | 2019-09-03 | 江西新龙电瓷电器制造有限公司 | A kind of middle high strength insulator material prescription and preparation method thereof |
| CN110194656B (en) * | 2019-04-30 | 2021-12-03 | 江西新龙电瓷电器制造有限公司 | Medium-high strength insulator material formula and preparation method thereof |
| CN113053598A (en) * | 2021-03-16 | 2021-06-29 | 江西省萍乡市南溪电瓷电器制造有限公司 | Lightning protection needle type electric porcelain insulator and preparation method thereof |
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