CN112707718A - 一种轻质多孔陶瓷及其制备方法 - Google Patents

一种轻质多孔陶瓷及其制备方法 Download PDF

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CN112707718A
CN112707718A CN202011579856.0A CN202011579856A CN112707718A CN 112707718 A CN112707718 A CN 112707718A CN 202011579856 A CN202011579856 A CN 202011579856A CN 112707718 A CN112707718 A CN 112707718A
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张恒頔
汪丹越
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Fast Thinking Technology Shanghai Co ltd
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Abstract

本发明公开了一种轻质多孔陶瓷及其制备方法。所述轻质多孔陶瓷的原料包括以质量份数计的粘土35‑45份，熔剂30‑48份，骨料12‑20份，氧化铝8‑16份，氧化硅2‑6份，已膨胀微球0.25‑1.5份。制备方法为：将除已膨胀微球以外的原料混合、研磨；研磨后进行过筛，过筛后加入已膨胀微球，并加入混合物质量50‑70％的水混合成浆料；将浆料震动除去内部空气，注入模具中脱水成型，得到陶瓷坯体；将陶瓷坯体放入窑炉中，煅烧。本发明通过在陶瓷配方中加入已膨胀微球，得到一种低密度的多孔陶瓷，孔径和密度可控，且改善陶瓷制备过程中的开裂情况，简化工艺。

Description

一种轻质多孔陶瓷及其制备方法
技术领域
本发明涉及一种轻质多孔陶瓷的及其制备方法，属于高分子材料技术领域。
背景技术
在现有技术中，轻质多孔陶瓷的制造技术主要包括造孔剂法、有机泡沫浸渍工艺、添加发泡剂法等，或者陶瓷基材中添加在高温下能分解出气体的添加剂，在高温烧制的过程中产生气泡形成泡孔。
通过添加造孔剂的方法是应用最多的方法之一，优点是气孔的大小和形状可控，但是存在气孔均匀性差的缺点，且制备高气孔率的陶瓷时有较大难度。专利1837139A中描述了采用煤灰、木屑、碳粉等材料作为造孔剂，工艺过程中在浆料里加入了含量较多的固体造孔剂，在烧结时容易消耗过多能量，且孔隙无法保证分布均匀和形状均一。专利CN109133855A中通过在陶瓷基材中添加可分解产生CO2气体的原料，在加热过程中形成气孔达到多孔的目标，但是该方法的存在气孔的大小和形状难以控制的问题。
发明内容
本发明所要解决的技术问题是：现有多孔陶瓷孔隙分布不均，同时解决气孔的大小和孔径难以控制的问题。
为了解决上述技术问题，本发明采用如下技术方案：
一种轻质多孔陶瓷，其特征在于，原料包括以下以质量份数计的组分：粘土35-45份，熔剂30-48份，骨料12-20份，氧化铝8-16份，氧化硅2-6份，已膨胀微球0.25-1.5份。
优选地，所述骨料为石英。
优选地，所述的熔剂为长石与滑石的混合物。
优选地，所述熔剂中长石的质量份数为10-18份，滑石的质量份数为20-30份。
所述轻质多孔陶瓷中的粘土为基材原料，用于陶瓷坯体成型；长石、滑石作为熔剂，可降低陶瓷烧成的温度，此外滑石与粘土中的硅酸盐反应，生成堇青石，具有较高的机械强度和良好的热稳定性；石英作为骨料，用于降低烧结时的收缩，减弱变形，并增加强度；氧化铝、氧化硅高温时形成针状晶体，作为骨架并增加机械强度，一部分游离的Al3+提高液相粘度；氧化硅一部分与氧化铝形成骨架，增加机械强度和热稳定性，一部分形成玻璃态物质，增强抵抗变形的能力。
本发明还提供了上述轻质多孔陶瓷的制备方法，其特征在于，包括如下步骤：
步骤1)：将除已膨胀微球以外的原料混合、研磨；
步骤2)：研磨后进行过筛，过筛后加入已膨胀微球，并加入混合物质量50-70％的水混合成浆料；
步骤3)：将浆料震动除去内部空气，注入模具中脱水成型，得到陶瓷坯体；
步骤4)：将陶瓷坯体放入窑炉中，煅烧。
优选地，所述步骤2)中的过筛为过400目筛。
优选地，所述步骤4)中的煅烧采用程序升温。
优选地，所述步骤4)中的煅烧具体为：2-3℃/min升温至300℃保持1h，再以2-3℃/min升温至800℃保温2h，再以4-5℃/min的速度升温至1450℃保温1h，最后以5-10℃/min的速率降至室温。
本发明在陶瓷坯体中加入已膨胀微球发泡剂，微球具有可塑性弹性外壳，还可以有效减弱坯体成型和干燥过程中的开裂问题。本发明通过在陶瓷配方中加入已膨胀微球，得到一种低密度的多孔陶瓷，孔径和密度可控，且改善陶瓷制备过程中的开裂情况，简化工艺。
本发明中采用的微球发泡剂为规则圆形的已膨胀闭孔结构，壳体为热塑性塑料，在高温下可完全分解；已膨胀微球的内部为可燃性烷烃，在高温烧结过程中会彻底分解为CO2，一方面支撑泡孔形状，另一方面也不会对环境造成污染。
与现有技术相比，本发明技术具有如下的有益效果：
(1)本发明在工艺中添加粒径大小均一可控的轻质已膨胀微球，制成的轻质多孔陶瓷的孔径大小可控，且为单一规则的球形；
(2)本发明中采用的已膨胀微球在水中可均匀分散，在制备坯体材料中可均匀分布在坯体的各个部分，避免烧制成品时气孔不均的缺点；
(3)本发明中的已膨胀微球中空材料，外壳为弹性热塑性材料，在坯体成型过程中和干燥过程中缓解收缩，有效减弱了开裂的问题。
具体实施方式
为使本发明更明显易懂，兹以优选实施例，作详细说明如下。
实施例1-4和对比例1-4所采用的陶瓷的制备方法，包括以下步骤：
步骤1)：将除已膨胀微球以外的原料混合、研磨；
步骤2)：研磨后进行过400目筛，过筛后加入已膨胀微球，并加入混合物质量50-70％的水混合成浆料；
步骤3)：将浆料震动除去内部空气，注入模具中脱水成型，得到陶瓷坯体；
步骤4)：将陶瓷坯体放入窑炉中，煅烧：2-3℃/min升温至300℃保持1h，再以2-3℃/min升温至800℃保温2h，再以4-5℃/min的速度升温至1450℃保温1h，最后以5-10℃/min的速率降至室温。
实施例1
一种轻质多孔陶瓷，原料包括以下以质量份数计的组分：粘土35份，长石10份，石英12份，滑石20份，氧化铝8份，氧化钛2份，已膨胀微球0.25份。
对比例1
一种轻质多孔陶瓷，原料包括以下以质量份数计的组分：粘土35份，长石10份，石英12份，滑石20份，氧化铝8份，氧化硅2份。
实施例2
一种轻质多孔陶瓷，原料包括以下以质量份数计的组分：粘土45份，长石18份，石英20份，滑石30份，氧化铝16份，氧化硅6份，已膨胀微球0.5份。
对比例2
一种轻质多孔陶瓷，原料包括以下以质量份数计的组分：粘土45份，长石18份，石英20份，滑石30份，氧化铝16份，氧化硅6份。
实施例3
一种轻质多孔陶瓷，原料包括以下以质量份数计的组分：粘土38份，长石13份，石英16份，滑石25份，氧化铝12份，氧化硅3份，已膨胀微球0.75份对比例3
一种轻质多孔陶瓷，原料包括以下以质量份数计的组分：粘土38份，长石13份，石英16份，滑石25份，氧化铝12份，氧化硅3份
实施例4
一种轻质多孔陶瓷，原料包括以下以质量份数计的组分：粘土40份，长石15份，石英15份，滑石25份，氧化铝14份，氧化硅4份，已膨胀微球1份对比例4
一种轻质多孔陶瓷，原料包括以下以质量份数计的组分：粘土40份，长石15份，石英15份，滑石25份，氧化铝14份，氧化硅4份。
将实施例1、实施例2、实施例3与实施例4分别烧制之后，取一块陶瓷为样本，测试与各自相同配方不添加微球的对比例陶瓷样品相比，密度减少依次为16％、33％、45％、56％；测试气孔率依次为36％、48％、61％、71％。通过裂纹观察，实施例1-3相比于对比例1-3裂纹明显减少，而实施例4的样品几乎没有任何裂纹，说明微球的添加能够明显减少陶瓷样品的裂纹，实施例4中的配比为最优配比。

Claims (8)

1.一种轻质多孔陶瓷，其特征在于，原料包括以下以质量份数计的组分：粘土35-45份，熔剂30-48份，骨料12-20份，氧化铝8-16份，氧化硅2-6份，已膨胀微球0.25-1.5份。
2.如权利要求1所述的轻质多孔陶瓷，其特征在于，所述骨料为石英。
3.如权利要求1所述的轻质多孔陶瓷，其特征在于，所述的熔剂为长石与滑石的混合物。
4.如权利要求1或3所述的轻质多孔陶瓷，其特征在于，所述熔剂中长石的质量份数为10-18份，滑石的质量份数为20-30份。
5.权利要求1所述的轻质多孔陶瓷的制备方法，其特征在于，包括如下步骤：
步骤1)：将除已膨胀微球以外的原料混合、研磨；
步骤2)：研磨后进行过筛，过筛后加入已膨胀微球，并加入混合物质量50-70％的水混合成浆料；
步骤3)：将浆料震动除去内部空气，注入模具中脱水成型，得到陶瓷坯体；
步骤4)：将陶瓷坯体放入窑炉中，煅烧。
6.如权利要求5所述的轻质多孔陶瓷的制备方法，其特征在于，所述步骤2)中的过筛为过400目筛。
7.如权利要求5所述的轻质多孔陶瓷的制备方法，其特征在于，所述步骤4)中的煅烧采用程序升温。
8.如权利要求5所述的轻质多孔陶瓷的制备方法，其特征在于，所述步骤4)中的煅烧具体为：2-3℃/min升温至300℃保持1h，再以2-3℃/min升温至800℃保温2h，再以4-5℃/min的速度升温至1450℃保温1h，最后以5-10℃/min的速率降至室温。
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CN102256695A (zh) * 2008-12-18 2011-11-23 株式会社吴羽 中空微球的制造方法和多孔质陶瓷成型体的制造方法
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