CN112645734A - 一种气孔率为32~40%的多孔陶瓷及其制备方法和应用 - Google Patents

一种气孔率为32~40%的多孔陶瓷及其制备方法和应用 Download PDF

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CN112645734A
CN112645734A CN202011622643.1A CN202011622643A CN112645734A CN 112645734 A CN112645734 A CN 112645734A CN 202011622643 A CN202011622643 A CN 202011622643A CN 112645734 A CN112645734 A CN 112645734A
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porous ceramic
ceramic
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carbide
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丁萍
杨光辉
李映川
梁裕华
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Guangdong Real Faith Lighting Technology Co ltd
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Abstract

本发明公开了一种气孔率为32～40％的多孔陶瓷及其制备方法和应用。该多孔陶瓷的原料按照质量百分比计包括：陶瓷粉体80～85％，粘结剂15～20％，添加剂粉体0.1～2％；添加剂粉体包括碳化钛、碳化钨、氮化硼和碳化硼中的至少一种；陶瓷粉体包括碳化硅、氧化铝、氧化镁和氧化锆中的至少一种。通过将多孔陶瓷的原料混合密炼、造粒、定型、脱脂和烧结后，得到该多孔陶瓷。本发明通过将少量碳化钛等作为添加剂，使得制得的多孔陶瓷同时具备良好的强度和气孔率，同时能够降低生产成本，更加环保，搭配提出的制备方法更加简单易行，制得的多孔陶瓷的气孔更加均匀，能够满足多孔陶瓷的多样化需求，能够更好的应用在过滤材料等领域中。

Description

一种气孔率为32～40％的多孔陶瓷及其制备方法和应用
技术领域
本发明属于材料领域，具体涉及一种气孔率为32～40％的多孔陶瓷及其制备方法和应用。
背景技术
多孔陶瓷是一类在骨架支撑，过滤，保温，隔热，耐腐蚀等领域均有广泛应用的材料。一般的多孔陶瓷制备方法为干压法，通过在配方中按体积比例添加较多造孔剂以达到一定的气孔率，但添加过多的造孔剂一方面会影响多孔陶瓷的强度，另一方面会使得多孔陶瓷在脱脂烧结中需更长时间进行脱除从而带来成本的增加；同时，过多的造孔剂也会带来材料成本的增加，并使得排放的废气更多。此外，干压法本身也难以制备长径比偏大，或形状复杂的多孔陶瓷，容易会出现气孔分布不均的问题。
发明内容
本发明的目的是解决背景技术中的至少一个技术问题，提供一种多孔陶瓷及其制备方法，具体采用以下的技术方案：
一种多孔陶瓷，其原料按照质量百分比计包括：陶瓷粉体80～85％，粘结剂15～20％，添加剂粉体0.1～2％；所述添加剂粉体包括碳化钛、碳化钨、氮化硼和碳化硼中的至少一种；所述陶瓷粉体包括碳化硅、氧化铝、氧化镁和氧化锆中的至少一种。
发明人通过大量理论研究和实验探究发现，可以加入少量碳化钛、碳化钨、氮化硼和碳化硼中的至少一种作为制备多孔陶瓷的添加剂粉体，其在高温下与碳化硅、氧化铝、氧化镁和氧化锆等陶瓷粉体互不润湿，能够阻碍陶瓷粉体材料的晶体不断变大，从而能够保证多孔陶瓷具备较大的气孔率(32～40％)，同时具备良好的强度(25～40MPa)，很好的避免了造孔剂的添加所带来的种种弊端。制得的多孔陶瓷可以更好的应用在过滤材料、金属浸渗骨架材料和电子陶瓷领域中。
在一些优选的实施情况中，所述粘结剂包括聚甲醛、聚乙烯、聚丙烯和石蜡中的至少一种。
在一些优选的实施情况中，所述陶瓷粉体和所述添加剂粉体的粒径均为10～150μm，纯度均大于99％。
本发明还提供了一种多孔陶瓷的制备方法，包括以下步骤：
S1、将上述多孔陶瓷的原料混匀，于所述粘结剂的熔点温度下进行密炼，然后进行造粒得到混料颗粒；
S2、将所述混料颗粒加热熔融后，入模定型为中间产品；
S3、将所述中间产品脱脂，然后进行烧结得到所述多孔陶瓷。
本发明根据上述多孔陶瓷的配方，提出了一种配套的制备方法，其工艺简单，仅仅通过调整各原料的质量配比即可实现不同气孔率的多孔陶瓷的制备，也不存在传统干压法所具有的弊端。
在一些优选的实施情况中，在S1中，所述密炼的时间为0.5～2h。所述粘结剂的熔点温度可依据材料具体的物化性质知晓，密炼的具体操作可在密炼机等现有机械设备中进行。
在一些优选的实施情况中，在S1中，所述混料颗粒的直径为2～4mm，长度为2～4mm。造粒的具体操作可在造粒机等现有机械设备中进行。
在一些优选的实施情况中，在S3中，所述脱脂的具体过程为：将所述中间产品置于草酸蒸汽中10～20h进行脱脂，温度为120～140℃。
在一些优选的实施情况中，在S4中，所述烧结的时间为12～24h。具体烧结的温度可由本领域技术人员根据陶瓷粉体的材料性质来确定。
本发明的有益效果为：本发明通过设置少量碳化钛等作为添加剂，使得制得的多孔陶瓷同时具备良好的强度和气孔率，同时也能够降低生产综合成本，使得制备过程更加环保，搭配提出的制备方法更加简单易行，制得的多孔陶瓷气孔更加均匀，能够满足多孔陶瓷的多样化需求，能够更好的应用在过滤材料、金属浸渗骨架材料和电子陶瓷等领域中。
具体实施方式
以下将结合实施例对本发明的构思及产生的技术效果进行清楚、完整的描述，以充分地理解本发明的目的、方案和效果。需要说明的是，在不冲突的情况下，本申请中的实施例及实施例中的特征可以相互组合。
实施例1：
一种多孔陶瓷，其原料按照质量百分比计包括：碳化硅粉体84％，聚甲醛15％，碳化钛粉体1％。其中，碳化硅粉体和碳化钛粉体的粒径均约为100μm，纯度均大于99％。该多孔陶瓷的制备方法包括以下步骤：
S1、将上述多孔陶瓷的原料混匀，加入至密炼机中，在200℃下加热并搅拌挤压1.5h，使得聚甲醛熔融状态下包裹住碳化硅粉体和碳化钛粉体，形成均匀胶块；然后将胶块加入至造粒机中，使胶块在熔融态下挤出多孔口模，并由口模切刀将其切成直径3mm、长度3mm的混料颗粒；
S2、将混料颗粒加入至注塑机中，使其加热熔融后，再由注塑螺杆推入模具中成型，得到中间产品；
S3、将中间产品放入脱脂炉中，在130℃的草酸蒸汽中脱脂12h；随后放入真空烧结炉中，在1850℃下烧结16h，得到本实施例的多孔陶瓷。
对本实施例制得的多孔陶瓷进行检测，其结果如表1所示：
表1
检测项目 数值 标准
体积密度 2.08g/cm3 GB/T 1966
气孔率 35.8％ GB/T 1966
弯曲强度 36MPa GB/T 1965
实施例2：
一种多孔陶瓷，其原料按照质量百分比计包括：氧化铝粉体80％，聚乙烯18％，氮化硼粉体2％。其中，氧化铝粉体和氮化硼粉体的粒径均约为80μm，纯度均大于99％。该多孔陶瓷的制备方法包括以下步骤：
S1、将上述多孔陶瓷的原料混匀，加入至密炼机中，在120℃下加热并搅拌挤压1h，使得聚乙烯熔融状态下包裹住氧化铝粉体和氮化硼粉体，形成均匀胶块；然后将胶块加入至造粒机中，使胶块在熔融态下挤出多孔口模，并由口模切刀将其切成直径3mm、长度4mm的混料颗粒；
S2、将混料颗粒加入至注塑机中，使其加热熔融后，再由注塑螺杆推入模具中成型，得到中间产品；
S3、将中间产品放入脱脂炉中，在134℃的草酸蒸汽中脱脂16h；随后放入真空烧结炉中，在1600℃下烧结15h，得到本实施例的多孔陶瓷。
对本实施例制得的多孔陶瓷进行检测，其结果如表2所示：
表2
检测项目 数值 标准
体积密度 2.46g/cm3 GB/T 1966
气孔率 37.8％ GB/T 1966
弯曲强度 33MPa GB/T 1965
实施例3：
一种多孔陶瓷，其原料按照质量百分比计包括：氧化锆粉体82％，石蜡17.5％，碳化钨粉体0.5％。其中，氧化锆粉体和碳化钨粉体的粒径均约为120μm，纯度均大于99％。该多孔陶瓷的制备方法包括以下步骤：
S1、将上述多孔陶瓷的原料混匀，加入至密炼机中，在85℃下并搅拌挤压0.8h，使得石蜡熔融状态下包裹住氧化锆粉体和碳化钨粉体，形成均匀胶块；然后将胶块加入至造粒机中，使胶块在熔融态下挤出多孔口模，并由口模切刀将其切成直径4mm、长度2mm的混料颗粒；
S2、将混料颗粒加入至注塑机中，使其加热熔融后，再由注塑螺杆推入模具中成型，得到中间产品；
S3、将中间产品放入脱脂炉中，在125℃的草酸蒸汽中脱脂14h；随后放入真空烧结炉中，在1450℃下烧结18h，得到本实施例的多孔陶瓷。
对本实施例制得的多孔陶瓷进行检测，其结果如表3所示：
表3
检测项目 数值 标准
体积密度 3.91g/cm3 GB/T 1966
气孔率 37.8％ GB/T 1966
弯曲强度 38MPa GB/T 1965
实施例4：
一种多孔陶瓷，其原料按照质量百分比计包括：氧化镁粉体83％，聚丙烯15.5％，碳化硼粉体1.5％。其中，氧化镁粉体和碳化硼粉体的粒径均约为50μm，纯度均大于99％。该多孔陶瓷的制备方法包括以下步骤：
S1、将上述多孔陶瓷的原料混匀，加入至密炼机中，在180℃下加热并搅拌挤压0.8h，使得聚丙烯熔融状态下包裹住氧化镁粉体和碳化硼粉体，形成均匀胶块；然后将胶块加入至造粒机中，使胶块在熔融态下挤出多孔口模，并由口模切刀将其切成直径3mm、长度2mm的混料颗粒；
S2、将混料颗粒加入至注塑机中，使其在加热熔融后，再由注塑螺杆推入模具中成型，得到中间产品；
S3、将中间产品放入脱脂炉中，在133℃的草酸蒸汽中脱脂18h；随后放入真空烧结炉中，在1700℃下烧结13h，得到本实施例的多孔陶瓷。
对本实施例制得的多孔陶瓷进行检测，其结果如表4所示：
表4
Figure BDA0002874236840000041
Figure BDA0002874236840000051
以上所述，只是本发明的较佳实施例而已，本发明并不局限于上述实施方式，只要其以相同的手段达到本发明的技术效果，都应属于本发明的保护范围。在本发明的保护范围内其技术方案和/或实施方式可以有各种不同的修改和变化。

Claims (10)

1.一种多孔陶瓷，其特征在于，其原料按照质量百分比计包括：陶瓷粉体80～85％，粘结剂15～20％，添加剂粉体0.1～2％；所述添加剂粉体包括碳化钛、碳化钨、氮化硼和碳化硼中的至少一种；所述陶瓷粉体包括碳化硅、氧化铝、氧化镁和氧化锆中的至少一种。
2.根据权利要求1所述的多孔陶瓷，其特征在于，所述多孔陶瓷的气孔率为32～40％。
3.根据权利要求1所述的多孔陶瓷，其特征在于，所述粘结剂包括聚甲醛、聚乙烯、聚丙烯和石蜡中的至少一种。
4.根据权利要求1所述的多孔陶瓷，其特征在于，所述陶瓷粉体和所述添加剂粉体的粒径均为10～150μm，纯度均大于99％。
5.一种多孔陶瓷的制备方法，其特征在于，包括以下步骤：
S1、将权利要求1至4任一项所述多孔陶瓷的原料混匀，于所述粘结剂的熔点温度下进行密炼，然后进行造粒得到混料颗粒；
S2、将所述混料颗粒加热熔融后，入模定型为中间产品；
S3、将所述中间产品脱脂，然后进行烧结得到所述多孔陶瓷。
6.根据权利要求5所述的制备方法，其特征在于，在S1中，所述密炼的时间为0.5～2h。
7.根据权利要求5所述的制备方法，其特征在于，在S1中，所述混料颗粒的直径为2～4mm，长度为2～4mm。
8.根据权利要求5所述的制备方法，其特征在于，在S3中，所述脱脂的具体过程为：将所述中间产品置于草酸蒸汽中10～20h进行脱脂，温度为120～140℃。
9.根据权利要求5所述的制备方法，其特征在于，在S4中，所述烧结的时间为12～24h。
10.权利要求1至4任一项所述的多孔陶瓷在过滤材料领域、金属浸渗骨架材料和电子陶瓷领域中的应用。
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CN1337929A (zh) * 1999-01-26 2002-02-27 卡彭特高级陶瓷公司 氧化镁部分稳定的高强度氧化锆
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