CN112135701B - 陶瓷过滤器及其制造方法 - Google Patents

陶瓷过滤器及其制造方法 Download PDF

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CN112135701B
CN112135701B CN201880093006.4A CN201880093006A CN112135701B CN 112135701 B CN112135701 B CN 112135701B CN 201880093006 A CN201880093006 A CN 201880093006A CN 112135701 B CN112135701 B CN 112135701B
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precursor
ceramic filter
side wall
holder
sintering
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CN112135701A (zh
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宫原盛明
山本义孝
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Progeru Co ltd
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Progeru Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D29/00—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor
    • B01D29/11—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor with bag, cage, hose, tube, sleeve or like filtering elements
    • B01D29/111—Making filtering elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28C7/00—Controlling the operation of apparatus for producing mixtures of clay or cement with other substances; Supplying or proportioning the ingredients for mixing clay or cement with other substances; Discharging the mixture
    • B28C7/0007—Pretreatment of the ingredients, e.g. by heating, sorting, grading, drying, disintegrating; Preventing generation of dust
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    • B22D43/001—Retaining slag during pouring molten metal
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    • B01D39/14—Other self-supporting filtering material ; Other filtering material
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    • B01D39/2079—Other inorganic materials, e.g. ceramics the material being particulate or granular otherwise bonded, e.g. by resins
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Abstract

本发明稳定地提供一种陶瓷过滤器，其是在金属熔液浴中使用的上方开发筒型的陶瓷过滤器，其侧壁的高度为300mm以上。本发明提供一种陶瓷过滤器的制造方法，其是作为上方开放筒型的一体成形件的、从金属熔液中去除不需要的物质的陶瓷过滤器的制造方法，其中，所述制造方法具备：对由陶瓷颗粒构成的骨料、规定的结合剂以及水的混合物进行混炼来制成坯料的步骤；由制成的该坯料一体形成上方开放筒型的陶瓷过滤器的前体的步骤；对前体进行干燥的步骤；针对前体设置对干燥后的前体的侧壁进行支承的保持件的步骤；之后对前体进行烧结的步骤；以及在烧结后去除保持件的步骤。

Description

陶瓷过滤器及其制造方法
技术领域
本发明涉及陶瓷过滤器及其制造方法。更详细而言，涉及从铝等的金属熔液中去除不需要的物质的陶瓷过滤器的改良。
背景技术
为了从铝(也包括合金，以下相同)金属熔液中去除异物而使用陶瓷过滤器。
以往的陶瓷过滤器是使用结合剂对由陶瓷颗粒构成的骨料进行烧结而成的板状的构件。将该板状的构件组合而制成俯视呈矩形的有底筒状、即上方开放型的筒状，并将其浸渍在铝金属熔液浴中。
另外，在专利文献1中提出了对上方开放型的筒进行一体成形而成的陶瓷过滤器。根据这样构成的陶瓷过滤器，与将板状的陶瓷过滤器连结而成的结构相比，在机械上更稳定。因而，作为在铝金属熔液这样的严酷的环境下使用的陶瓷过滤器，提高了耐久性。
现有技术文献
专利文献
专利文献1：日本特开2017-214268号公报
发明内容
发明所要解决的问题
然而，根据本发明的发明人的研究，在执行专利文献1所记载的制造方法时，作为一体成形的三维结构的陶瓷过滤器，无法得到高度较高的陶瓷过滤器。更具体而言，若将侧壁的高度设为300mm以上，则侧壁会崩解，而无法得到产品。
对由陶瓷颗粒构成的骨料、结合剂以及水进行混炼而准备坯料，利用该坯料对一体成形的三维结构、即上方开放筒型进行赋形。此时，为了确保铝金属熔液的透过性，无法增厚其壁。因而，由烧结前的坯料构成的侧壁较脆，容易因烧结时产生的气氛空气的对流、内部应力的变化而发生变形或崩解。因而，认为若在坯料的阶段将侧壁的高度设为300mm以上，则在烧结时侧壁会发生崩解。
用于解决问题的手段
本发明的发明人为了解决上述问题而反复进行了深入研究的结果是，如下所述，想到了本发明的各方面。
本发明的第一方面规定如下。即，
一种陶瓷过滤器的制造方法，其是作为上方开放筒型的一体成形件的、从金属熔液中去除不需要的物质的陶瓷过滤器的制造方法，所述制造方法具备：
对由陶瓷颗粒构成的骨料、规定的结合剂以及水的混合物进行混炼来制成坯料的混合步骤；
由制成的该坯料一体形成上方开放筒型的陶瓷过滤器的前体的一体成形步骤；
对所述前体进行干燥的干燥步骤；
针对所述前体设置对干燥后的所述前体的侧壁进行支承的保持件的保持件设置步骤；
之后对前体进行烧结的烧结步骤；以及
在烧结后去除所述保持件的保持件去除步骤。
根据这样规定的第一方面的陶瓷过滤器的制造方法，由于在烧结时前体的侧壁被保持件支承，因此即使该侧壁较高，即设为300mm以上、进一步设为500mm以上，其也不会崩解。
在此，作为保持件优选准备对侧壁从其外侧进行支承的第一保持件和从其内侧进行支承的第二保持件。在此，从其外侧支承侧壁的第一保持件优选对侧壁的整周的整个面进行支承。此时，第二保持件间断地对所述侧壁进行支承即可。
本发明的第二方面规定如下。即，在第一方面所规定的制造方法中，在所述干燥步骤之后且在所述烧结步骤之前还包括如下步骤：利用相对于所述金属熔液及其氧化物稳定的材料且烧结温度比所述前体的坯料低的材料的层对所述前体的侧壁进行覆盖。
根据这样规定的第二方面所规定的制造方法，由于覆盖层的材料的烧结温度比所述坯料的烧结温度低，因此在烧结时，该覆盖层的材料先玻璃化，其机械刚性变高。该玻璃化后的覆盖层在前体的烧结时对其侧壁进行支承。由此，防止该侧壁的崩解。
从该观点出发，优选在前体的整个侧壁的至少一面侧形成连续的覆盖层。更优选地，对该侧壁的外表面以及内表面的上缘侧形成该覆盖层。覆盖层的宽度没有特别限定。例如，可以对侧壁的整个表面层叠覆盖层。这是因为，在上方开放筒型的陶瓷过滤器中，金属熔液专门从其底壁向内部透过。也可以在不阻碍透过的范围内使该覆盖层迂回至底壁的周缘部。覆盖层的优选宽度为50～400mm。
只要具有防止侧壁的崩解的机械强度，覆盖层的厚度就没有特别限定，例如设为0.1mm～5.0mm。
覆盖层的材料不与金属熔液及其氧化物发生反应，且烧结温度比前体的材料低。在选择铝作为金属熔液时，作为覆盖层的材料，可以使用将不与铝以及氧化铝发生反应的氧化锆、锆石等分散在结合剂中而得到的材料。该结合剂以玻璃化温度比坯料的玻璃化温度低的、例如氧化铝等为主成分。
本发明的第三方面规定如下，即，一种陶瓷过滤器，其是由能够供金属熔液透过的陶瓷颗粒的烧结体构成的、一体成型件的上方开放筒型的陶瓷过滤器，其侧壁从底壁垂直地立起，且该侧壁的高度为500mm以上。
通过执行已述的第一方面以及第二方面的制造方法而得到该构成的陶瓷过滤器。在该陶瓷过滤器中，其侧壁从底壁垂直地立起。由此，在有限面积的金属熔液浴中，能够使底壁的面积最大化。在将陶瓷过滤器沉入金属熔液浴中时，金属熔液专门从其底壁透过。因而，通过使底壁的面积最大化，能够使其过滤能力极大化。
优选地，在该陶瓷过滤器中，在向上方开放的开口部的上缘层叠保护膜，该保护膜由相对于所述金属熔液及其氧化物稳定且烧结温度比所述陶瓷颗粒的烧结温度低的材料构成。
金属熔液在其表面形成有氧化物，该金属氧化物容易与陶瓷颗粒发生反应。因此，通过利用相对于该金属氧化物以及金属熔液自身稳定的保护膜将侧壁的上缘覆盖，能够确保金属熔液中的陶瓷过滤器的独立性。另外，如第二方面所说明的那样，通过由烧结温度比陶瓷颗粒的烧结温度低的材料形成覆盖层，使得陶瓷过滤器的制造稳定。
附图说明
图1是表示在本发明的实施方式中使用的前体的成形模具的剖视图。
图2是前体的立体图。
图3是具备保护膜的前体的剖视图。
图4是表示在烧制中对前体进行支承的保持件的剖视图。
图5是表示变形方式的前体的烧制状态的剖视图。
图6是表示变形方式的前体的侧壁的构成的示意图。
具体实施方式
前体的坯料的材料包含由陶瓷颗粒构成的骨料、规定的结合剂以及水。
在此，在骨料的材料中，例如可以以任意的配合比例使用选自碳化硅、氮化硅、氮化硼、氧化锆(zirconia)、氧化铝(alumina)、锆石中的一种或两种以上。
骨料的粒径可以根据陶瓷过滤器所要求的特性而任意地进行选择，优选为0.01mm～10mm，进一步优选为3mm～6mm。该粒径可以通过一般的筛子来确定。
结合剂可以使用有机结合剂、无机水泥以及粉末玻璃。
有机结合剂在烧结前将骨料结合并进行其形状保持。
作为该有机结合剂，可以利用聚乙烯醇、淀粉等水溶性的增稠剂。
由于该增稠剂会因烧结而烧失，因此作为在烧结中将骨料结合的材料，采用无机水泥。作为无机水泥，优选采用无二氧化硅的水泥(氧化铝水泥)。这是为了将与金属熔液的反应、尤其是与其氧化物的反应防患于未然。
粉末玻璃通过烧结而玻璃化并将骨料最终结合。该粉末玻璃的玻璃化温度(熔点)与金属熔液的温度相比而足够高。
上述结合剂溶解或分散在规定量的水中，且与骨料混合。相对于骨料与结合剂材料的合计质量，有机结合剂优选为0.1～0.5质量％。无机水泥优选为0.5～10质量％。粉末玻璃优选为0.5～10质量％。
水的量以使混合物的粘度达到所期望的值的方式适当进行调整。
这样得到的混合物几乎不具备流动性。将该混合物填充到模具中，一体地形成陶瓷过滤器的前体。
图1表示形成前体1的模具10。
模具10具备外模11和内模13。附图标记15为基座。外模11为板状构件，能够由金属、陶瓷形成。为了使前体1的脱模变得容易，在其型腔面上涂布有脱模剂。
内模13采用了发泡树脂。为了避免混合物浸透，在其型腔面上层叠同样树脂制的保护膜。作为保护膜，可以使用热收缩的胶带、涂料。为了使前体1的脱模变得容易，保护膜的表面涂布有脱模剂。
在本发明中，前体1在脱模前，换言之，至少在残留有内模的状态下进行干燥。
干燥的条件为80℃～100℃下5小时～15小时这样的一般的干燥条件。在该条件下，发泡树脂材料进行热收缩。因而，即使前体1的侧壁变高，其脱模操作也很容易。
发泡树脂材料的热收缩的收缩系数只要能够使内模从干燥后的前体1脱模即可，可以为1％～10％左右。也可以使用具有同样的收缩系数的其他材料来代替发泡树脂材料。
脱模后的前体1的整体如图2所示。前体1具备垂直的侧壁3，其高度为500mm以上。侧壁3的厚度可以根据陶瓷过滤器所要求的特性而任意地进行选择，但设为20～35mm。底壁5也是相同的厚度(参照图3)。
用保护膜7将该前体1的侧壁3的上缘覆盖。覆盖的方法采用涂布或喷涂。
如上所述，该保护膜7由相对于金属熔液及其氧化物稳定的材料且烧结温度比前体的坯料低的材料构成。覆盖保护膜7的范围是任意的，优选能够在金属熔液的吃水面的上下形成100mm以上的余量。另外，从涂布的容易性以及强度的赋予的观点出发，优选将侧壁的上缘的整个面覆盖。
该保护膜7在前体1的烧制时，先于前体1的坯料即粉末玻璃而玻璃化。
将设置有保护膜7的前体1放入烧制炉内。此时，为了防止侧壁3崩解，设置保持件20(图4)。保持件20由从外侧支承侧壁3的第一保持件21和从内侧支承侧壁3的第二保持件23构成。
第一保持件21对侧壁3的外侧的整个面进行支承。优选第一保持件21与侧壁3的外侧面紧密地接触。由于在烧制时侧壁具有以膨胀的方式进行变形的倾向，因此优选第一保持件21与侧壁的外侧面的整个面对置。
第二保持件23防止侧壁向内侧进行变形。防止因烧制时的热量而欲向外侧进行变形的侧壁与第一保持件21发生干涉而向内侧反弹。该第二保持件不需要与侧壁的内侧面的整个面对置，在该例子中，在侧壁的上缘侧对侧壁的内侧面进行支承。另外，也可以是间断的支承，在该例子中，将L字型的陶瓷板(宽度为100mm)作为第二保持件23并尽可能紧密地排列，嵌合于前体1以及第一保持件21的上缘。
在使用该保持件20的情况下，可以将保护膜7省略。
另一方面，如果将保护膜7形成为宽幅(沿上下方向)，则也可以将第二保持件23或全部保持件20的设置省略。
图5表示使侧壁33向外侧倾斜的前体31的例子。该前体31能够仅利用与其侧壁33的外侧面对置的第一保持件42对烧结时的侧壁33的变形进行支承。
此外，烧结时的前体的侧壁的变形起因于将该侧壁增高至超过300mm而产生的自重。另一方面，由于侧壁的厚度受到透过性的限制，因此无法将侧壁的厚度增厚至一定以上。因此，如图6中的(a)所示，可以使侧壁53形成弯曲57而提高纵向上的刚性。另外，如图6中的(b)所示，也可以对侧壁63设置沿纵向连续的肋67。
实施例
接下来，对本发明的实施例进行说明。
首先，得到下述的混合物。下述配合比例以质量份进行表示。
骨料1(碳化硅，粒径：3-6mm)：70质量份
骨料2(碳化硅，最大粒径：8mm)：30质量份
有机系结合剂(聚乙酸乙烯酯，型号：可乐丽株式会社制造的ISOBAN-110)：0.6质量份
无机水泥(氧化铝水泥，型号：电化株式会社制造的高铝水泥Super S)：5质量份
粉末玻璃(玻璃料，型号：日本珐琅釉药株式会社制造的4791)：5.5质量份
水(自来水)：3.8质量份
将上述混合物用万能混合搅拌机(三惠制作所公司制造)进行混炼。
设置外模11和内模13，准备前体1的模具10。前体1为高度为500mm、宽度为500mm、深度为700mm的上方开放箱型。侧壁3以及底壁5的厚度为25mm。在此，外模11整体为铁板制。内模13由发泡聚苯乙烯(EPS；发泡倍率为90)构成，在其表面的整个面上粘贴胶带(株式会社NITOMS制造的PYOLAN CLOTH粘接胶带)。在外模11以及内模13的型腔形成面上涂布凡士林(中京油脂株式会社制造)作为脱模剂。
向模具10的型腔中填充混炼后的混合物，在安装有模具10的状态下，在通用的干燥炉中，在80℃×15小时的条件下进行干燥。由此，使内模13收缩，能够容易地进行脱模。
在干燥后的前体1的侧壁的上缘涂布保护膜7。保护膜7的材料是使氧化锆的颗粒分散在结合剂中而成的材料。在此，作为氧化锆，使用了福岛精钢公司的型号：G325F。结合剂采用了Calderys公司制造的商品名ALKONPATCH PT85U。氧化锆与结合剂的配合比例为3∶7(质量比)。涂布厚度在目视下为1～2mm。
在保护膜7干燥之后，将前体1放入烧制炉中。此时，如图4所示那样设置保持件20。第一保持件21采用耐火砖，紧密贴合于侧壁3的外表面。第二保持件23以不会强行嵌合的方式将第一保持件21和侧壁3覆盖。
之后，以最高温度1100℃×27小时进行烧制。达到最高温度为止的温度上升条件、烧制后的冷却条件为通用的条件，没有特别限制。
这样得到的陶瓷过滤器维持了前体的形状。能够将该陶瓷过滤器使用于铝的熔液浴。与作为平板的组合件的以往的陶瓷过滤器相比，该实施例的陶瓷过滤器的耐久性优异。
本发明不受上述发明的实施方式及其变形例的说明任何限定。在不脱离权利要求书、本领域技术人员容易想到的范围内，各种变形方式也包含在本发明中。
附图标记说明
1：前体；
3、33、53、63：侧壁；
7：保护膜；
10：模具；
11：外模；
13：内模；
20：保持件；
21、42：第一保持件；
23：第二保持件。

Claims (4)

1.一种陶瓷过滤器的制造方法，其是作为上方开放筒型的一体成形件的、从金属熔液中去除不需要的物质的陶瓷过滤器的制造方法，其中，
所述制造方法具备：
对由陶瓷颗粒构成的骨料、规定的结合剂以及水进行混炼来制成混合物的混合步骤；
由制成的该混合物一体形成上方开放筒型的陶瓷过滤器的前体的一体成形步骤；
对所述前体进行干燥的干燥步骤；
针对所述前体设置对干燥后的所述前体的侧壁进行支承的保持件的保持件设置步骤；
之后对前体进行烧结的烧结步骤；以及
在烧结后去除所述保持件的保持件去除步骤，
所述制造方法在所述干燥步骤之后且在所述烧结步骤之前还包括如下步骤：利用相对于所述金属熔液及其氧化物稳定的材料且烧结温度比所述混合物低的材料的层对所述前体的侧壁进行覆盖。
2.一种陶瓷过滤器的制造方法，其是作为上方开放筒型的一体成形件的、从金属熔液中去除不需要的物质的陶瓷过滤器的制造方法，其中，
所述制造方法具备：
对由陶瓷颗粒构成的骨料、规定的结合剂以及水的混合物进行混炼来制成坯料的步骤；
由制成的该坯料一体形成上方开放筒型的陶瓷过滤器的前体的步骤；
对所述前体进行干燥的步骤；
利用相对于所述金属熔液及其氧化物稳定的材料且烧结温度比所述前体的坯料低的材料的层对干燥后的所述前体的侧壁的上缘进行覆盖的步骤；以及
之后对前体进行烧结的步骤。
3.一种陶瓷过滤器，其由权利要求1所述的陶瓷过滤器的制造方法制造，且是由能够供金属熔液透过的陶瓷颗粒的烧结体构成的、一体成型件的上方开放筒型的陶瓷过滤器，其中，
其侧壁从底壁垂直地立起，且该侧壁的高度为500mm以上。
4.根据权利要求3所述的陶瓷过滤器，其中，
向上方开放的开口部的上缘被保护膜覆盖，该保护膜由相对于所述金属熔液及其氧化物稳定且烧结温度比所述陶瓷颗粒的烧结温度低的材料构成。
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