CN113307648B - 一种高孔隙率多孔陶瓷及其制备方法 - Google Patents

一种高孔隙率多孔陶瓷及其制备方法 Download PDF

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CN113307648B
CN113307648B CN202110595574.8A CN202110595574A CN113307648B CN 113307648 B CN113307648 B CN 113307648B CN 202110595574 A CN202110595574 A CN 202110595574A CN 113307648 B CN113307648 B CN 113307648B
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李洁峰
成贵华
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Jiujiang Huitai Technology Co ltd
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Abstract

本发明公开了一种高孔隙率多孔陶瓷及其制备方法，其利用无机发泡剂取代有机生物质粉料作为造孔剂，以硅凝胶乳液取代纤维素作为赋形剂，以亲水性硅油作为脱模剂，所制得的多孔陶瓷颜色洁白，脱模顺畅，强度和耐磨性得到提升，而且孔隙率高；以蛭石粉作为膨胀剂，在升温蛭石粉膨胀段中，在通孔中膨胀，提升了通孔的粗糙程度和比表面积，其通入燃气燃烧时对燃气的利用更充分，通入燃气燃烧时明亮程度得到提升；以三段加热烧制成型工艺取代常规的窑炉一次烧制成型工艺，将造孔和烧制成型分离，在造孔的时候多孔陶瓷尚未烧结硬化，气体膨胀造孔不会破坏内部微孔薄壁，使其在后续使用时接通燃气燃烧时表面发亮均匀，不会形成暗点。

Description

一种高孔隙率多孔陶瓷及其制备方法
技术领域
本发明涉及陶瓷技术工艺，尤其涉及一种高孔隙率多孔陶瓷及其制备方法。
背景技术
红外线炉具是这几年发展得很快的一种节能炉具，它利用多孔陶瓷材料更有利于气体燃烧的特点，使燃料得以充分燃烧，从而提高燃气的利用率，降低燃气的相对使用量，达到节能的效果；同时由于燃气得到充分燃烧，减少了积碳以及挥发到空气中的碳微粒，达到环保的效果。
在多孔陶瓷制品中，其孔隙率大小对于其产品性能有很大影响，孔隙率高的产品，其透气性、热稳定性高，且其密度较低，适用于生产陶瓷加热器的加热部件。
现有技术中，多孔陶瓷制品以纤维素作为粘结剂，同时为提高多孔陶瓷制品的孔隙率，采取在多孔陶瓷胚料中添加如木炭、焦炭或生物质粉料作为造孔剂，使其在使用时经燃烧后留下微孔，提升其孔隙率。
但在实践中发现，纤维素与造孔剂的燃烧，会使多孔陶瓷制品表面发黄，影响多孔陶瓷制品的外观洁白度和美感，同时燃烧残留物会影响多孔陶瓷制品通入燃气燃烧时的明亮程度；而且由于纤维素与造孔剂燃烧与多孔陶瓷烧制成型同时发生，燃烧气体冲击已受热成型的内部微孔薄壁，极易导致多孔陶瓷内部微孔的薄壁破裂，这会导致在后续使用时接通燃气燃烧时多孔陶瓷表面发亮不均匀，并形成暗点；同时这样生产的多孔陶瓷强度低、不耐磨。
发明内容
本发明开发了一种高孔隙率多孔陶瓷及其制备方法，其选用新的造孔剂和粘结剂，并改变了窑炉一次烧制成型的工艺，提升了多孔陶瓷的孔隙率，同时提升了通入燃气燃烧时的明亮程度和均匀程度，并提高了强度和耐磨性。
一种高孔隙率多孔陶瓷的制备方法，所述制备方法如下：
(1)原料组成
堇青石粉50～75份；蛭石粉1～3份；贝壳粉10～20份；发泡剂10～20份；硅凝胶乳液20～30份；
(2)制备方法
在硅凝胶乳液中继续溶解发泡剂，搅拌均匀，然后加入其他粉料并混合搅拌、混炼得到黏土，然后经制胚-压模机打孔压花成型-自然干燥-预热发泡造孔-升温蛭石粉膨胀-烧制成型，制得多孔陶瓷。
本发明原料组成均为质量份。
进一步的，所述硅凝胶乳液的制备方法为：
(1)在水中溶解质量5％～10％的水玻璃和2％～3％硅烷偶联剂，搅拌均匀后加入3％～5％的亲水性硅油，以均质机高速搅拌乳化，制成乳液；
(2)在上述乳液中边搅拌边滴加稀盐酸，调pH至7.0～7.5，静置老化2～3h，制成硅凝胶乳液。
进一步的，所述堇青石粉、贝壳粉的粒度为30～150目，所述蛭石粉的粒度为200～300目。
进一步的，所述发泡剂为碳酸氢铵、碳酸氢钠中的一种或多种。
进一步的，所述水玻璃模数为2.2～2.9。
进一步的，所述硅烷偶联剂为KH550、KH560、KH570中的一种或多种。
进一步的，所述亲水性硅油为华谷2042、道康宁DC-193、ZBH-204中的一种或多种。
进一步的，所述预热发泡造孔段温度控制为均匀升温至270℃～280℃。
进一步的，所述升温蛭石粉膨胀段温度控制为在所述预热发泡造孔段基础上均匀升温至380℃～400℃。
进一步的，所述烧制成型段为在所述升温蛭石粉膨胀段基础上快速升温至1100℃～1300℃。
本发明制得的多孔陶瓷孔隙率高，通入燃气燃烧时明亮程度和均匀程度得到提升，降低了吸水率，并提高了强度和耐磨性。
本发明的优点：
1、本发明利用无机发泡剂取代有机生物质粉料作为造孔剂，以硅凝胶乳液取代纤维素作为赋形剂，以亲水性硅油作为脱模剂，所制得的多孔陶瓷颜色洁白，脱模顺畅，强度和耐磨性得到提升，而且孔隙率高；
2、本发明以蛭石粉作为膨胀剂，在升温蛭石粉膨胀段中，在通孔中膨胀，提升了通孔的粗糙程度和比表面积，其通入燃气燃烧时对燃气的利用更充分，通入燃气燃烧时明亮程度得到提升；
3、本发明以三段加热烧制成型工艺取代常规的窑炉一次烧制成型工艺，将造孔和烧制成型分离，在造孔的时候多孔陶瓷尚未烧结硬化，气体膨胀造孔不会破坏内部微孔薄壁，使其在后续使用时接通燃气燃烧时表面发亮均匀，不会形成暗点。
具体实施方式
实施例1
一种高孔隙率多孔陶瓷的制备方法，所述制备方法如下：
(1)原料组成
堇青石粉50份；蛭石粉1份；贝壳粉10份；发泡剂10份；硅凝胶乳液20份；
(2)制备方法
在硅凝胶乳液中继续溶解发泡剂，搅拌均匀，然后加入其他粉料并混合搅拌、混炼得到黏土，然后经制胚-压模机打孔压花成型-自然干燥-预热发泡造孔-升温蛭石粉膨胀-烧制成型，制得多孔陶瓷。
所述硅凝胶乳液的制备方法为：
(1)在水中溶解质量5％的水玻璃和2％硅烷偶联剂，搅拌均匀后加入3％的亲水性硅油，以均质机高速搅拌乳化，制成乳液；
(2)在上述乳液中边搅拌边滴加稀盐酸，调pH至7.5，静置老化3h，制成硅凝胶乳液。
所述堇青石粉、贝壳粉的粒度为30目，所述蛭石粉的粒度为200目。
所述发泡剂为碳酸氢铵。
所述水玻璃模数为2.9。
所述硅烷偶联剂为KH550。
所述亲水性硅油为华谷2042。
所述预热发泡造孔段温度控制为均匀升温至270℃。
所述升温蛭石粉膨胀段温度控制为在所述预热发泡造孔段基础上均匀升温至380℃。
所述烧制成型段为在所述升温蛭石粉膨胀段基础上快速升温至1100℃。
实施例2
一种高孔隙率多孔陶瓷的制备方法，所述制备方法如下：
(1)原料组成
堇青石粉60份；蛭石粉2份；贝壳粉15份；发泡剂15份；硅凝胶乳液25份；
(2)制备方法
在硅凝胶乳液中继续溶解发泡剂，搅拌均匀，然后加入其他粉料并混合搅拌、混炼得到黏土，然后经制胚-压模机打孔压花成型-自然干燥-预热发泡造孔-升温蛭石粉膨胀-烧制成型，制得多孔陶瓷。
所述硅凝胶乳液的制备方法为：
(1)在水中溶解质量7％的水玻璃和3％硅烷偶联剂，搅拌均匀后加入4％的亲水性硅油，以均质机高速搅拌乳化，制成乳液；
(2)在上述乳液中边搅拌边滴加稀盐酸，调pH至7.2，静置老化2h，制成硅凝胶乳液。
所述堇青石粉、贝壳粉的粒度为100目，所述蛭石粉的粒度为300目。
所述发泡剂为碳酸氢钠。
所述水玻璃模数为2.6。
所述硅烷偶联剂为KH560。
所述亲水性硅油为道康宁DC-193。
所述预热发泡造孔段温度控制为均匀升温至280℃。
所述升温蛭石粉膨胀段温度控制为在所述预热发泡造孔段基础上均匀升温至400℃。
所述烧制成型段为在所述升温蛭石粉膨胀段基础上快速升温至1200℃。
实施例3
一种高孔隙率多孔陶瓷的制备方法，所述制备方法如下：
(1)原料组成
堇青石粉75份；蛭石粉3份；贝壳粉20份；发泡剂20份；硅凝胶乳液30份；
(2)制备方法
在硅凝胶乳液中继续溶解发泡剂，搅拌均匀，然后加入其他粉料并混合搅拌、混炼得到黏土，然后经制胚-压模机打孔压花成型-自然干燥-预热发泡造孔-升温蛭石粉膨胀-烧制成型，制得多孔陶瓷。
所述硅凝胶乳液的制备方法为：
(1)在水中溶解质量10％的水玻璃和3％硅烷偶联剂，搅拌均匀后加入5％的亲水性硅油，以均质机高速搅拌乳化，制成乳液；
(2)在上述乳液中边搅拌边滴加稀盐酸，调pH至7.0，静置老化2h，制成硅凝胶乳液。
所述堇青石粉、贝壳粉的粒度为150目，所述蛭石粉的粒度为300目。
所述发泡剂为碳酸氢钠。
所述水玻璃模数为2.2。
所述硅烷偶联剂为KH570。
所述亲水性硅油为ZBH-204。
所述预热发泡造孔段温度控制为均匀升温至280℃。
所述升温蛭石粉膨胀段温度控制为在所述预热发泡造孔段基础上均匀升温至400℃。
所述烧制成型段为在所述升温蛭石粉膨胀段基础上快速升温至1300℃。
对比例1
一种多孔陶瓷的制备方法，其未使用蛭石粉，其余同实施例2。
对比例2
一种多孔陶瓷的制备方法，其未使用道康宁DC-193，其余同实施例2。
对比例3
一种多孔陶瓷的制备方法，其以硬脂酸替代道康宁DC-193，其余同实施例2。
对比例4
一种多孔陶瓷的制备方法，其直接使用水玻璃，而未制成硅凝胶乳液，其余同实施例2。
对比例5
一种多孔陶瓷的制备方法，其窑炉1200℃一次烧制成型，其余同实施例2。
对比例6
采用CN107399987A《采用生物质粉料为造孔剂的多孔陶瓷》所述工艺制得的多孔陶瓷。
性能检测与对比：
将上述实施例与对比例多孔陶瓷规格统一为137mm*92mm*13mm，同时压模机打孔压花规格统一为孔径1.25mm、孔数3600个。
1、脱模难易程度：记录各实施例与对比例脱模后多孔陶瓷边角有缺损的比例，脱模缺损比例越低，脱模越容易；
2、孔隙率：以压汞法测试各实施例与对比例多孔陶瓷的孔隙率；
3、黄度：烧制成型后，以HunterLab Labscan XE型黄色指数仪测量各实施例与对比例多孔陶瓷的黄色指数YI；
黄色指数YI可正可负，正值越大黄色越深，负值则表示呈蓝色；
YI＝100(1.28X-1.06Z)/Y
4、强度：以抗压强度仪测试各实施例与对比例多孔陶瓷的抗压负荷(N)，抗压负荷越高，则多孔陶瓷的抗压强度越好；
5、根据GB/T 16401-1996《矿物棉制品吸水性试验方法》测量各实施例与对比例多孔陶瓷的吸水率；
6、以多孔陶瓷同样大小的钢丝绒，并施加100N的压力，在各实施例与对比例多孔陶瓷的表面摩擦100次，测得摩擦减重率；摩擦减重率越高，耐磨性越差；
摩擦减重率(％)＝(1-摩擦后重量/摩擦前重量)*100％
7、以0.5m3/h的流速通入燃气，以红外温枪测量多孔陶瓷表面温度，记为本试样的燃烧温度；
上述2-7测试均随机选取各实施例与对比例制备的多孔陶瓷各20块，记录结果取平均值；
8、上述7测试时观察是否有暗点，并记录总例数。
Figure BDA0003090931570000081
从上表可知，本发明利用无机发泡剂取代有机生物质粉料作为造孔剂，以硅凝胶乳液取代纤维素作为赋形剂，以亲水性硅油作为脱模剂，所制得的多孔陶瓷颜色洁白，脱模顺畅，强度和耐磨性得到提升，而且孔隙率高；
本发明以蛭石粉作为膨胀剂，水玻璃制成硅凝胶乳液，提升了多孔陶瓷的比表面积，其燃气燃烧更充分，多孔陶瓷燃烧温度和明亮程度得到提升；
本发明以三段加热烧制成型工艺取代常规的窑炉一次烧制成型工艺，将造孔和烧制成型分离，在造孔的时候多孔陶瓷尚未烧结硬化，气体膨胀造孔不会破坏内部微孔薄壁，使其在后续使用时接通燃气燃烧时表面发亮均匀，不会形成暗点。
对比例6中，如提高生物质粉料比例以达到提高孔隙率的目的，则会发现多孔陶瓷的强度、耐磨性呈快速下滑趋势，而且燃烧暗点频发，继续提高孔隙率应该如本发明进行新工艺、新方法的开发。
最后：以上所述仅为本发明的优选实施例而已，并不用于限制本发明，凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (8)

1. 一种高孔隙率多孔陶瓷的制备方法，其特征在于：所述制备方法如下：
（1）原料组成
堇青石粉50～75份；蛭石粉1～3份；贝壳粉10～20份；发泡剂10～20份；硅凝胶乳液20～30份；上述均为质量份；
所述发泡剂为碳酸氢铵、碳酸氢钠中的一种或多种；
（2）制备方法
在硅凝胶乳液中继续溶解发泡剂，搅拌均匀，然后加入其他粉料并混合搅拌、混炼得到黏土，然后经制胚-压模机打孔压花成型-自然干燥-预热发泡造孔-升温蛭石粉膨胀-烧制成型，制得多孔陶瓷；
所述硅凝胶乳液的制备方法为：
（1）在水中溶解质量5%～10%的水玻璃和2%～3%硅烷偶联剂，搅拌均匀后加入3%～5%的亲水性硅油，以均质机高速搅拌乳化，制成乳液；
（2）在上述乳液中边搅拌边滴加稀盐酸，调pH至7.0～7.5，静置老化2～3h，制成硅凝胶乳液。
2.一种如权利要求1所述制备方法，其特征在于：所述堇青石粉、贝壳粉的粒度为30～150目，所述蛭石粉的粒度为200～300目。
3.一种如权利要求1所述制备方法，其特征在于：所述水玻璃模数为2.2～2.9。
4.一种如权利要求1所述制备方法，其特征在于：所述硅烷偶联剂为KH550、KH560、KH570中的一种或多种。
5.一种如权利要求1所述制备方法，其特征在于：所述亲水性硅油为华谷2042、道康宁DC-193、ZBH-204中的一种或多种。
6.一种如权利要求1所述制备方法，其特征在于：所述预热发泡造孔段温度控制为均匀升温至270℃～280℃。
7.一种如权利要求1所述制备方法，其特征在于：所述升温蛭石粉膨胀段温度控制为在所述预热发泡造孔段基础上均匀升温至380℃～400℃。
8.一种如权利要求1所述制备方法，其特征在于：所述烧制成型段为在所述升温蛭石粉膨胀段基础上快速升温至1100℃～1300℃。
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