CN110922171B - 一种制作高铝瓷绝缘子的原料配方及其方法 - Google Patents

一种制作高铝瓷绝缘子的原料配方及其方法 Download PDF

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CN110922171B
CN110922171B CN201911300580.5A CN201911300580A CN110922171B CN 110922171 B CN110922171 B CN 110922171B CN 201911300580 A CN201911300580 A CN 201911300580A CN 110922171 B CN110922171 B CN 110922171B
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porcelain insulator
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slurry
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苏欢
苏映池
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Pingxiang Yuxiang Electric Ceramics Manufacturing Co ltd
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Abstract

本发明涉及一种制作高铝瓷绝缘子的原料配方及其方法，属于电瓷技术领域；配方中包括：铝矾土、高岭石、长石、莫来石、伊利石、黏土、左云土、珍珠陶土、石榴石、白炭黑，采用多种原料，并且添加少量石榴石，白炭黑和甲基硅树脂混合，制备过程中研磨成两种不同粒度的粉体再混合，阶段升温，降温再升温的烧结工艺，得到的瓷绝缘子力学性能优，满足目前电瓷领域的需求。

Description

一种制作高铝瓷绝缘子的原料配方及其方法
技术领域
本发明涉及一种制作高铝瓷绝缘子的原料配方及其方法，属于电瓷技术领域。
背景技术
瓷绝缘子是发电站和变电站变电设备的重要组成部分，起到支撑导线和绝缘的作用，是由数十种矿物组成经高温烧结而成的一种以玻璃体为主的硅铝酸盐材料，含有莫来石、刚玉、石英和长石等，原材料采用陶土矿物即粘土类矿物，包括高岭土、云母和石英类。
瓷绝缘子的工作环境十分恶劣，受诸多外界因素(如雨雪、大风、覆冰、日晒等)的影响，绝缘子附加应力大；加上高温烧成的瓷绝缘子属于脆性材料，其韧性低，如支柱瓷绝缘子内部存在显微组织结构缺陷，强度不足，就很可能在某些缺陷位置，特别是在表面缺陷处产生应力集中，造成微裂纹失稳扩展，最终导致断裂失效。此外，瓷绝缘子在运行中受自然温差及导体发热等因素的影响，也会经受较大温差的考验。在这种温度变化引发的热应力作用下，绝缘子内的微裂纹也可能失稳扩展，严重影响其使用寿命。
发明内容
本发明提供了一种制作高铝瓷绝缘子的原料配方及其方法，采用特定的原料配方及制备方法，得到的瓷绝缘子不仅提高了强度，而且增强了弹性模量，进一步提高了瓷绝缘子的力学性能。
一种制作高铝瓷绝缘子的原料配方，包括：铝矾土、高岭石、长石、莫来石、伊利石、黏土、左云土、珍珠陶土、石榴石。
优选地，上述原料配方还包括：白炭黑。
一种制作高铝瓷绝缘子的原料配方，包括下列质量份数的组分：铝矾土35-45份、高岭石20-30份、长石20-30份、莫来石15-25份、伊利石15-25份、黏土10-15份、左云土10-15份、珍珠陶土8-12份、石榴石4-6份。
优选地，上述原料配方还包括：气相法白炭黑5-10份。
优选地，气相法白炭黑的粒径为20-40nm。
一种制作高铝瓷绝缘子的方法，包括以下步骤：
S1、将铝矾土、黏土、左云土、珍珠陶土混合，湿法研磨至粒度≤20μm，得到泥浆a备用；
S2、将高岭石、长石、莫来石、伊利石、石榴石混合，湿法研磨至粒度≤5μm，得到泥浆b备用；
S3、将泥浆a和泥浆b混合，干燥至水分含量低于6-8％，除铁，得到浆料备用；
S4、把白炭黑与甲基硅树脂混合，加入至浆料中继续混合均匀，挤制获得料泥；
S5、把上述料泥装入模具内成型，得到坯体后干燥，获得烧结用生坯；
S6、在上述生坯表面涂以釉层，进入窑炉进行烧结，冷却后即得高铝瓷绝缘子。
优选地，所述的步骤S4中，白炭黑和甲基硅树脂的固液比为1g:0.6-1ml。
优选地，所述的步骤S5中，干燥温度为2-5℃。
优选地，所述的步骤S6中，烧结分为阶段升温：先升温至500℃保持30min，自然冷却至400℃保持10min，再升温至900℃保持45min，自然冷却至800℃保持15min，最后升温至1200-1300℃烧结。
本发明还提供了一种由上述原料和方法制成的高铝瓷绝缘子。
本发明采用铝矾土、高岭石、长石、莫来石、伊利石、黏土、左云土、珍珠陶土等多种原料，原料中含有多种晶相结构，长石作为助熔剂，在Al2O3-SiO2体系中随着烧结温度的升高，会产生熔融态物质，可以填充于不同的晶相颗粒之间，借助于毛细管力的粘性压紧效应及通过晶相在液相中促进物质传输，从而促进陶瓷的致密化。
本发明原料中还添加了石榴石，增加了高弹性模量晶相，和其他原料共同作用，可以增加瓷绝缘子的耐磨性。
本发明制备方法中研磨成两种不同粒度的粉体，选用合理颗粒级配的粉体原料，不仅有利于烧结，减少了瓷质结构中存在隐晶聚晶体和大颗粒晶体.还增加了瓷微观结构的均匀性和化学成分的稳定性.从而提高了瓷坯的强度。
本发明将小颗粒的白炭黑和甲基硅树脂混合，加入至浆料中，甲基硅树脂的粘合性有利于烧结过程中SiO2与基体的结合，同时小颗粒的白炭黑在甲基硅树脂的粘合下可以填入烧结过程晶相产生的气孔中，减少瓷绝缘子材料的气孔率，增强绝缘子的力学性能。
本发明烧结过程中采用阶段升温，降温再升温的工艺，降低不同的晶体之间产生的应力集中，克服了界面容易脱粘的问题。
本发明的有益效果为：
1、本发明配方中采用多种原料，并且添加少量石榴石，共同作用，增加了瓷绝缘子的弹性模量及耐磨性。
2、本发明制作方法中先研磨成两种不同粒度的粉体，再混合的工艺，可以增加瓷微观结构的化学稳定性，提高了瓷绝缘子的抗弯强度。
3、将小颗粒的白炭黑和甲基硅树脂混合，减少了瓷绝缘子材料的气孔率，增强了绝缘子的力学性能。
4、烧结过程中采用阶段升温，降温再升温的工艺，克服了界面容易脱粘的问题，使得瓷绝缘子断裂负荷有一定的提高。
具体实施方式
一种高铝瓷绝缘子，包括下列质量份数的原料配方：铝矾土35-45份、高岭石20-30份、长石20-30份、莫来石15-25份、伊利石15-25份、黏土10-15份、左云土10-15份、珍珠陶土8-12份、石榴石4-6份、气相法白炭黑(粒径20-40nm)5-10份。
制备方法为：
S1、将铝矾土、黏土、左云土、珍珠陶土混合，湿法研磨至粒度≤20μm，得到泥浆a备用；
S2、将高岭石、长石、莫来石、伊利石、石榴石混合，湿法研磨至粒度≤5μm，得到泥浆b备用；
S3、将泥浆a和泥浆b混合，干燥至水分含量低于6-8％，除铁，得到浆料备用；
S4、把白炭黑与甲基硅树脂混合，白炭黑和甲基硅树脂的固液比为1g:0.6-1ml，加入至浆料中继续混合均匀，挤制获得料泥；
S5、把上述料泥装入模具内成型，得到坯体后干燥，干燥温度为2-5℃，获得烧结用生坯；
S6、在上述生坯表面涂以釉层，进入窑炉进行烧结，先升温至500℃保持30min，自然冷却至400℃保持10min，再升温至900℃保持45min，自然冷却至800℃保持15min，最后升温至1200-1300℃烧结，冷却后即得高铝瓷绝缘子。
本发明实施例及对比例中各个原料均为同一批次，具体来源为：
铝矾土：山西阳泉铝矾土矿；
高岭石：辽宁建平县太平庄乡矿；
长石：湖南桂东县致祥钾长石矿；
莫来石：宜昌进诚高岭土有限公司；
伊利石:江西向阳伊利石矿物有限公司；
黏土：乐山市坤元矿业有限公司；
左云土：山西省左云县粘土开发经销公司；
珍珠陶土：宜春市华达石业有限公司；
石榴石：日照石榴石矿业有限公司。
实施例1
一种高铝瓷绝缘子，包括下列质量份数的原料配方：铝矾土35份、高岭石20份、长石20份、莫来石15份、伊利石15份、黏土10份、左云土10份、珍珠陶土8份、石榴石4份、气相法白炭黑(粒径20-40nm)5份。
制备方法为：将铝矾土、黏土、左云土、珍珠陶土混合，湿法研磨至粒度10-20μm，得到泥浆a备用；将高岭石、长石、莫来石、伊利石、石榴石混合，湿法研磨至粒度1-5μm，得到泥浆b备用；将泥浆a和泥浆b混合，干燥至水分含量低于6％，除铁，得到浆料备用；把白炭黑与甲基硅树脂混合，白炭黑和甲基硅树脂的固液比为1g:0.6ml，加入至浆料中继续混合均匀，挤制获得料泥；把料泥装入模具内成型，得到坯体后干燥，干燥温度为2℃，获得烧结用生坯；在生坯表面涂以釉层，进入窑炉进行烧结，先升温至500℃保持30min，自然冷却至400℃保持10min，再升温至900℃保持45min，自然冷却至800℃保持15min，最后升温至1200℃烧结，冷却后即得高铝瓷绝缘子。
实施例2
一种高铝瓷绝缘子，包括下列质量份数的原料配方：铝矾土40份、高岭石25份、长石25份、莫来石20份、伊利石20份、黏土12份、左云土12份、珍珠陶土10份、石榴石5份、气相法白炭黑(粒径20-40nm)8份。
制备方法为：将铝矾土、黏土、左云土、珍珠陶土混合，湿法研磨至粒度10-20μm，得到泥浆a备用；将高岭石、长石、莫来石、伊利石、石榴石混合，湿法研磨至粒度1-5μm，得到泥浆b备用；将泥浆a和泥浆b混合，干燥至水分含量低于7％，除铁，得到浆料备用；把白炭黑与甲基硅树脂混合，白炭黑和甲基硅树脂的固液比为1g:0.8ml，加入至浆料中继续混合均匀，挤制获得料泥；把料泥装入模具内成型，得到坯体后干燥，干燥温度为3℃，获得烧结用生坯；在生坯表面涂以釉层，进入窑炉进行烧结，先升温至500℃保持30min，自然冷却至400℃保持10min，再升温至900℃保持45min，自然冷却至800℃保持15min，最后升温至1250℃烧结，冷却后即得高铝瓷绝缘子。
实施例3
一种高铝瓷绝缘子，包括下列质量份数的原料配方：铝矾土45份、高岭石30份、长石30份、莫来石25份、伊利石25份、黏土15份、左云土15份、珍珠陶土12份、石榴石6份、气相法白炭黑(粒径20-40nm)10份。
制备方法为：将铝矾土、黏土、左云土、珍珠陶土混合，湿法研磨至粒度10-20μm，得到泥浆a备用；将高岭石、长石、莫来石、伊利石、石榴石混合，湿法研磨至粒度1-5μm，得到泥浆b备用；将泥浆a和泥浆b混合，干燥至水分含量低于8％，除铁，得到浆料备用；把白炭黑与甲基硅树脂混合，白炭黑和甲基硅树脂的固液比为1g:1ml，加入至浆料中继续混合均匀，挤制获得料泥；把料泥装入模具内成型，得到坯体后干燥，干燥温度为5℃，获得烧结用生坯；在生坯表面涂以釉层，进入窑炉进行烧结，先升温至500℃保持30min，自然冷却至400℃保持10min，再升温至900℃保持45min，自然冷却至800℃保持15min，最后升温至1300℃烧结，冷却后即得高铝瓷绝缘子。
实施例4
一种高铝瓷绝缘子，包括下列质量份数的原料配方：铝矾土38份、高岭石26份、长石24份、莫来石22份、伊利石18份、黏土14份、左云土12份、珍珠陶土11份、石榴石4份、气相法白炭黑(粒径20-40nm)6份。
制备方法为：将铝矾土、黏土、左云土、珍珠陶土混合，湿法研磨至粒度10-20μm，得到泥浆a备用；将高岭石、长石、莫来石、伊利石、石榴石混合，湿法研磨至粒度1-5μm，得到泥浆b备用；将泥浆a和泥浆b混合，干燥至水分含量低于6％，除铁，得到浆料备用；把白炭黑与甲基硅树脂混合，白炭黑和甲基硅树脂的固液比为1g:0.8ml，加入至浆料中继续混合均匀，挤制获得料泥；把料泥装入模具内成型，得到坯体后干燥，干燥温度为2-5℃，获得烧结用生坯；在生坯表面涂以釉层，进入窑炉进行烧结，先升温至500℃保持30min，自然冷却至400℃保持10min，再升温至900℃保持45min，自然冷却至800℃保持15min，最后升温至1300℃烧结，冷却后即得高铝瓷绝缘子。
实施例5
一种高铝瓷绝缘子，包括下列质量份数的原料配方：铝矾土35份、高岭石25份、长石30份、莫来石15份、伊利石20份、黏土15份、左云土10份、珍珠陶土10份、石榴石6份、气相法白炭黑(粒径20-40nm)5份。
制备方法为：将铝矾土、黏土、左云土、珍珠陶土混合，湿法研磨至粒度10-20μm，得到泥浆a备用；将高岭石、长石、莫来石、伊利石、石榴石混合，湿法研磨至粒度1-5μm，得到泥浆b备用；将泥浆a和泥浆b混合，干燥至水分含量低于8％，除铁，得到浆料备用；把白炭黑与甲基硅树脂混合，白炭黑和甲基硅树脂的固液比为1g:1ml，加入至浆料中继续混合均匀，挤制获得料泥；把料泥装入模具内成型，得到坯体后干燥，干燥温度为2-5℃，获得烧结用生坯；在生坯表面涂以釉层，进入窑炉进行烧结，先升温至500℃保持30min，自然冷却至400℃保持10min，再升温至900℃保持45min，自然冷却至800℃保持15min，最后升温至1250℃烧结，冷却后即得高铝瓷绝缘子。
对比例1
一种高铝瓷绝缘子，与实施例1的区别在于：
原料配方中未添加石榴石。
对比例2
一种高铝瓷绝缘子，与实施例2的区别在于：
制备方法中：将铝矾土、黏土、左云土、珍珠陶土、高岭石、长石、莫来石、伊利石、石榴石混合，湿法研磨至粒度1-5μm，干燥至水分含量低于7％，除铁。
对比例3
一种高铝瓷绝缘子，与实施例3的区别在于：
制备方法中：把白炭黑直接加入至浆料中继续混合均匀，挤制获得料泥。
对比例4
一种高铝瓷绝缘子，与实施例4的区别在于：
制备方法中：在生坯表面涂以釉层，进入窑炉升温至1300℃进行烧结，冷却后即得高铝瓷绝缘子。
试验例：
将实施例及对比例制得的瓷绝缘子从绝缘子中心部位取样，参照GB/T8411.2-2008《陶瓷和玻璃绝缘材料第二部分：试验方法》的要求，在CMT5105型微机控制电子万能试验机上进行室温弯曲试验，压头移动速率为0.5mm/min，跨距L为40mm，试样规格为50mm×3mm×4mm。每种试样取6个，测试断裂负荷、抗弯强度及弹性模量，取平均值，结果如表1所示。
表1本发明制成的绝缘子的力学性能测试结果
组别 断裂负荷(N) 抗弯强度(MPa) 弹性模量(GPa)
实施例1 74.5 108.6 96.9
实施例2 76.2 109.7 97.8
实施例3 75.6 109.1 96.6
实施例4 75.2 108.8 97.3
实施例5 74.9 109.4 97.0
对比例1 74.1 107.9 85.4
对比例2 73.7 99.2 96.1
对比例3 68.0 102.3 90.5
对比例4 64.9 107.1 95.7
从表1测试数据可以看出，本发明实施例1-5的力学性能较好，断裂负荷可以达到74.5N以上、抗弯强度可以达到108.6MPa以上、弹性模量可以达到96.6GPa以上；其中，原料中未添加石榴石的对比例1，弹性模量明显低于本发明实施例1-5，说明石榴石的添加与其他原料中的多种晶相结构结合，增加了高弹性模量晶相，提高了绝缘子的弹性模量；制备方法中直接将原料研磨成同一粒径的对比例2，抗弯强度明显低于本发明实施例1-5，说明本发明将原料分为两种不同粒度，选用合理颗粒级配的粉体原料，可以提高瓷绝缘子的抗弯强度；直接加入白炭黑的对比例3，力学性能均不如本发明实施例1-5，说明加入白炭黑和甲基硅树脂混合物，有助于瓷绝缘子材料的气孔的减少，增强其力学性能；烧结工艺一次升温的对比例4，断裂负荷明显低于本发明实施例1-5，说明本发明烧结采用阶段升温，降温再升温的工艺，降低不同的晶体之间产生的热应力集中，提高了瓷绝缘子的断裂负荷。
综上，本发明采用多种原料，并且添加少量石榴石，白炭黑和甲基硅树脂混合，制备过程中研磨成两种不同粒度的粉体再混合，阶段升温，降温再升温的烧结工艺，得到的瓷绝缘子力学性能优，满足目前电瓷领域的需求。
本发明并不局限于上述具体实施方式，本领域技术人员还可据此做出多种变化，但任何与本发明等同或者类似的变化都应涵盖在本发明权利要求的范围内。

Claims (5)

1.一种制作高铝瓷绝缘子的方法，其特征为：包括以下步骤：
S1、将铝矾土、黏土、左云土、珍珠陶土混合，湿法研磨至粒度≤20μm，得到泥浆a备用；
S2、将高岭石、长石、莫来石、伊利石、石榴石混合，湿法研磨至粒度≤5μm，得到泥浆b备用；
S3、将泥浆a和泥浆b混合，干燥至水分含量低于6-8%，除铁，得到浆料备用；
S4、把白炭黑与甲基硅树脂混合，加入至浆料中继续混合均匀，挤制获得料泥；
S5、把上述料泥装入模具内成型，得到坯体后干燥，获得烧结用生坯；
S6、在上述生坯表面涂以釉层，进入窑炉进行烧结，冷却后即得高铝瓷绝缘子。
2.如权利要求1所述的一种制作高铝瓷绝缘子的方法，其特征为：所述的步骤S4中，白炭黑和甲基硅树脂的固液比为1g:0.6-1ml。
3.如权利要求1所述的一种制作高铝瓷绝缘子的方法，其特征为：所述的步骤S5中，干燥温度为2-5℃。
4.如权利要求1-3任意一项所述的一种制作高铝瓷绝缘子的方法，其特征为：所述的步骤S6中，烧结分为阶段升温：先升温至500℃保持30min，自然冷却至400℃保持10min，再升温至900℃保持45min，自然冷却至800℃保持15min，最后升温至1200-1300℃烧结。
5.一种高铝瓷绝缘子，由权利要求1-4任意一项所述的制备方法制得。
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