CN113956068A - Combined type micro-through hole foam ceramic plate for sound barrier and preparation method thereof - Google Patents
Combined type micro-through hole foam ceramic plate for sound barrier and preparation method thereof Download PDFInfo
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Abstract
The invention discloses a combined type micro-through hole foam ceramic plate for a sound barrier and a preparation method thereof, wherein the foam ceramic plate comprises aggregate, binder, reinforced fiber, surfactant and deionized water; the preparation method of the foamed ceramic plate comprises the following steps: s1, mixing and ball-milling aggregate and deionized water, adding a binder and a surfactant for mixing, and finally adding reinforcing fibers for uniformly mixing to obtain ceramic slurry; s2, carrying out spray granulation and drying treatment on the ceramic slurry to obtain ceramic granules; s3, pressing the ceramic particles into a ceramic plate material and drying the ceramic plate material; s4, calcining, cooling and finishing the ceramic plate to obtain a finished foamed ceramic plate; the foamed ceramic plate prepared by the method has excellent sound shielding effect and structural stability, and is suitable for mass popularization.
Description
Technical Field
The invention relates to the technical field of foam ceramic plate treatment, in particular to a combined type micro-through hole foam ceramic plate for a sound barrier and a preparation method thereof.
Background
With the acceleration of life rhythm of people, the speed of motor vehicles is higher and higher, various vehicles can generate strong noise in the running process on roads or railways, and in order to reduce the influence of the noise on production facilities, buildings and life of people, sound absorption and insulation barriers are often arranged on the roads or railways which pass through bridges, residential areas or industrial areas to realize sound insulation and noise reduction. The sound absorption ceramic plate is used as a rigid ultramicropore ceramic material, has the porosity of more than 60 percent and better sound absorption performance, has the characteristics of high porosity, good weather resistance, good water resistance, corrosion resistance, non-combustibility, durability, stable performance and the like, and is particularly suitable for noise reduction of noise-proof barriers such as highways, railways, urban elevated railways, light rail traffic and the like and underground buildings such as tunnels, underground garages, underground markets and the like.
However, when the existing ceramic sound absorption material meets the requirement of higher sound absorption performance, the strength is greatly attenuated due to the requirement of porosity, the construction difficulty is invisibly increased, and meanwhile, certain potential safety hazards also exist in use; moreover, the existing ceramic sound absorption material cannot effectively suppress and absorb noise of each frequency band.
Disclosure of Invention
Aiming at the technical problems, the invention provides the combined type micro-through hole foam ceramic plate for the sound barrier and the preparation method thereof, wherein the combined type micro-through hole foam ceramic plate has a stable structure and a remarkable noise suppression effect.
The technical scheme of the invention is as follows: a combined type micro-through hole foam ceramic plate for a sound barrier comprises the following raw materials in parts by weight: 30-50 parts of aggregate, 20-45 parts of binder, 3-7 parts of reinforcing fiber, 0.5-1.2 parts of surfactant and 12-18 parts of deionized water;
the aggregate comprises: 8-13 parts of titanium dioxide, 7-11 parts of lepidolite, 6-9 parts of potash-sodalite, 4-9 parts of nano sepiolite and 5-8 parts of perlite;
the binder comprises: 4-11 parts of ceramic powder, 3-7 parts of modified talcum powder, 3-6 parts of water glass, 3-5 parts of nano-scale micro silicon powder, 2-4 parts of epoxy resin powder, 3-7 parts of calcium sulfate and 2-5 parts of modified hydroxymethyl cellulose;
the reinforcing fiber includes: 1-3 parts of special-shaped polypropylene fiber, 1-2 parts of polypropylene reticular fiber and 1-2 parts of lignin fiber;
the surfactant is prepared by mixing triphenyl phosphate, sorbitan fatty acid and polysorbate according to the volume ratio of 1:2: 1.
A preparation method of a combined type micro-through hole foam ceramic plate for a sound barrier comprises the following steps:
s1, mixing materials;
s1-1, placing the aggregate into a ball mill, controlling the ball-material ratio to be 1:1-3, ball-milling until the particle size of the aggregate is 0.02-0.04mm, then adding deionized water into the ball-milled material, and stirring and mixing for 20-45min at the stirring speed of 900-;
s1-2, placing the mixture A obtained in the step S1-1 into a high-speed mixing roll, then adding a binder and a surfactant, and stirring for 35-45min at the temperature of 60-90 ℃ to obtain a mixture B;
s1-3, dividing the reinforced fibers into fiber sections of 3-7mm, adding the fiber sections into the mixture B obtained in the step S1-2, uniformly stirring, heating to 60-80 ℃ under standard atmospheric pressure, and preserving heat for 3-5 hours to obtain ceramic slurry;
s2, granulating;
putting the ceramic slurry obtained in the step S1-3 into spray granulation equipment, controlling the temperature of a nozzle of the spray granulation equipment to be 30-50 ℃, and preparing ceramic granules with the grain diameter of 0.05-0.08 mm; then drying the ceramic granules until the content rate is 3-6%;
s3, pressing the board;
s3-1, placing the ceramic granules dried in the step S2 into a mold of a forming machine, and then pre-pressing the ceramic granules into an initial blank under the pressure of 30-50 MPa;
s3-2, pressing the primary blank obtained in the step S3-1 under the static condition of 150-450MPa to prepare a ceramic plate material, and then drying the ceramic plate material until the water content is 1-3%;
s4, firing a finished product;
s4-1, putting the ceramic plate obtained in the step S3-2 and the die into a preheating furnace together, preheating to 50-90 ℃, then sending the preheated ceramic plate into a calcining furnace, calcining, and controlling the calcining temperature to be 700-1100 ℃ to obtain a semi-finished product of the foamed ceramic plate;
and S4-2, feeding the semi-finished product of the foamed ceramic plate obtained in the step S4-1 into a cooling furnace, cooling for 1-3 hours at the temperature of 60-90 ℃, cutting according to the required size after cooling, and grinding and trimming edges and corners of the plate to obtain the finished product of the foamed ceramic plate.
Further, before the step S1-2, the surfactant is subjected to ultrasonic dispersion treatment for 15-30min at an ultrasonic frequency of 80-130kHz, and the ultrasonic dispersion treatment is performed on the surfactant, so that the dispersion performance of the surfactant in the aggregate and the binder can be improved, the use effect of the surfactant can be improved, and the sound shielding effect of the finished foamed ceramic plate can be further improved.
Further, in step S1-3, after the reinforced fiber is cut, putting the fiber section into a mixed solution formed by mixing polyisobutylene succinimide and dilute hydrochloric acid with the mass concentration of 15% in equal volume, continuously stirring for 5-15min, then sieving the fiber section, washing with water until the pH value is 5-7, and putting the fiber section into a 50-80 ℃ oven for drying; through the operation, the bonding strength of the fiber section and the mixture B can be improved, so that the structural strength of a finished foamed ceramic plate product is improved.
Further, after step S1-3 is completed, the ceramic slurry is pre-dried until the water content is below 10%, and is left to stand for 8-14 h. Through the operation, the phase change process in the ceramic slurry tends to be stable, so that the structural stability of the pressed ceramic plate is improved.
Further, in step S3-2, the primary blank pressing comprises two stages, wherein in the first stage, the pressure is continuously increased for 80-110S at the pressure of 150-; in the second stage, the pressure is continuously increased by 260-450MPa for 110-150s, then the pressure is reduced to 180-230MPa and continuously increased for 70-110s, finally the pressure is relieved, and the initial blank is pressed in a segmented manner, so that the compactness of the initial blank can be improved, the distribution uniformity of pores in the foam ceramic plate is improved, and the sound shielding effect is further improved.
Further, in the step S4-1, in the process of calcining the ceramic plate, the temperature of the calcining furnace is firstly raised to 700-; and then, continuously heating to 850-1100 ℃, preserving heat for 2-4h, and calcining the ceramic plate at different calcining temperatures, so that cracking of the ceramic plate in the sintering process can be avoided, and internal defects of the ceramic plate in the sintering process can be avoided.
Further, the preparation method of the modified hydroxymethyl cellulose comprises the following steps: mixing hydroxymethyl cellulose and 78% ethanol solution according to a volume ratio of 1:3-5 until completely dissolving, adding chitosan 15-25% of the volume of the hydroxymethyl cellulose, and stirring and reacting at 50-90 ℃ for 10-30min to obtain modified hydroxymethyl cellulose; the modified hydroxymethyl cellulose prepared by the method has more excellent bonding property, and is beneficial to improving the bonding strength and stability of various materials in a finished product of the foamed ceramic plate.
Further, the preparation method of the modified talcum powder comprises the following steps: 1) uniformly mixing talcum powder and zirconia powder with the same volume, and then ball-milling until the particle size is 15-45 mu m; 2) uniformly mixing sodium lauryl sulfate with the mass concentration of 3.5% and a potassium permanganate solution in the same volume, adding the mixture into the material obtained in the step 1), heating to 30-70 ℃, reacting for 30-55min, and after the reaction is finished, drying the material in vacuum to constant weight to obtain modified talcum powder; wherein, the addition amount of the sodium lauryl sulfate and potassium permanganate solution is 15-30% of the volume of the talcum powder; by modifying the talcum powder, the compactness among the internal raw materials in the calcination process of the finished foamed ceramic plate is promoted effectively, so that the finished foamed ceramic plate with a microporous structure is obtained.
Furthermore, the combined type micro-through hole foam ceramic plate structurally comprises a plate body, wherein a strip-shaped notch is formed in the edge of one side face of the plate body, and a vibration stopping strip is arranged on the surface of the strip-shaped notch; the plate body is respectively provided with a first mounting groove and a second mounting groove in pairs close to the strip-shaped gap, the two first mounting grooves and the two second mounting grooves are arranged oppositely and are perpendicular to each other, a fixed truss is arranged inside each first mounting groove and each second mounting groove, the fixed truss is hollow, and bolt holes are arranged at the positions of the first mounting groove and the two second mounting grooves corresponding to the fixed truss; each fixed truss is provided with 1-3 strip-shaped grooves, and long bolts are slidably clamped in the strip-shaped grooves; the long bolt is clamped in a sliding manner, so that the position of the plate body can be conveniently adjusted during installation, and the convenience during installation is improved.
Compared with the prior art, the invention has the beneficial effects that: according to the invention, titanium oxide, lepidolite, potash albite, nano-sepiolite and perlite are used as aggregates for manufacturing the foamed ceramic plate, so that the structural strength of a finished product of the foamed ceramic plate is effectively improved, and the use effect of the foamed ceramic plate is improved; meanwhile, compared with the common ceramic sound insulation material, the foam ceramic plate prepared by the invention has the advantages that the sound insulation effect is remarkably improved; the invention can improve the dispersing performance of the surfactant in the aggregate and the binder by carrying out ultrasonic dispersion treatment on the surfactant, improve the using effect of the surfactant and further improve the sound shielding effect of the finished product of the foamed ceramic plate; the bonding strength of the fiber section and the mixture B can be improved by placing the fiber section into a mixed solution of polyisobutylene succinimide and dilute hydrochloric acid, so that the structural strength of a finished product of the foamed ceramic plate is improved; through pre-drying and standing treatment of the ceramic slurry, the phase change process in the ceramic slurry tends to be stable, so that the structural stability of the pressed ceramic plate is improved; the initial blank is pressed in a segmented mode, so that the compactness of the initial blank can be improved, the distribution uniformity of pores in the foam ceramic plate is improved, and the sound shielding effect is further improved; by adopting different calcining temperatures to calcine the ceramic plate, cracking of the ceramic plate in the sintering process can be avoided, and internal defects of the ceramic plate in the sintering process can be avoided.
Drawings
FIG. 1 is a schematic view showing the construction of a composite micro via foam ceramic plate of the present invention;
FIG. 2 is a left side view of the composite micro via foam ceramic plate of the present invention;
wherein, 1-plate body, 10-strip-shaped gap, 11-vibration stopping strip, 12-first mounting groove, 13-second mounting groove, 14-bolt hole, 2-fixed truss, 20-strip-shaped groove and 21 long bolt.
Detailed Description
Example 1: a combined type micro-through hole foam ceramic plate for a sound barrier comprises the following raw materials in parts by weight: 30 parts of aggregate, 20 parts of binder, 3 parts of reinforcing fiber, 0.5 part of surfactant and 12 parts of deionized water;
the aggregate comprises: 8 parts of titanium dioxide, 7 parts of lepidolite, 6 parts of potash-sodalite, 4 parts of sepiolite and 5 parts of perlite;
the binder comprises: 4 parts of ceramic powder, 3 parts of modified talcum powder, 3 parts of water glass, 3 parts of nano-grade micro silicon powder, 2 parts of epoxy resin powder, 3 parts of calcium sulfate and 2 parts of modified hydroxymethyl cellulose;
the reinforcing fiber includes: 1 part of profiled polypropylene fiber, 1 part of polypropylene reticular fiber and 1 part of lignin fiber;
the surfactant is prepared by mixing triphenyl phosphate, sorbitan fatty acid and polysorbate according to the volume ratio of 1:2: 1.
Example 2: this example describes a method for preparing the composite micro via hole foam ceramic plate of example 1, comprising the steps of:
s1, mixing materials;
s1-1, placing the aggregate into a ball mill, controlling the ball-to-material ratio to be 1:1, ball-milling until the particle size of the aggregate is 0.02-0.03 mm, then adding deionized water into the ball-milled material, and stirring and mixing at the stirring speed of 900r/min for 20min to obtain a mixture A;
s1-2, placing the mixture A obtained in the step S1-1 into a high-speed mixing roll, then adding a binder and a surfactant, and stirring for 35min at the temperature of 60 ℃ to obtain a mixture B;
s1-3, dividing the reinforced fibers into 3mm fiber sections, adding the fiber sections into the mixture B obtained in the step S1-2, uniformly stirring, heating to 60 ℃ under standard atmospheric pressure, and preserving heat for 3 hours to obtain ceramic slurry;
s2, granulating;
putting the ceramic slurry obtained in the step S1-3 into spray granulation equipment, controlling the temperature of a nozzle of the spray granulation equipment to be 30 ℃, and preparing ceramic granules with the grain diameter of 0.05-0.06 mm; then drying the ceramic granules until the content rate is 3%;
s3, pressing the board;
s3-1, placing the ceramic granules dried in the step S2 into a mold of a forming machine, and then prepressing the ceramic granules into an initial blank under the pressure condition of 30 MPa;
s3-2, pressing the primary blank obtained in the step S3-1 under a static condition of 150MPa to prepare a ceramic plate material, and then drying the ceramic plate material until the water content is 1%;
s4, firing a finished product;
s4-1, putting the ceramic plate obtained in the step S3-2 and the die into a preheating furnace together, preheating to 50 ℃, then feeding the preheated ceramic plate into a calcining furnace, calcining, and controlling the calcining temperature to be 700 ℃ to obtain a semi-finished product of the foamed ceramic plate;
and S4-2, feeding the semi-finished product of the foamed ceramic plate obtained in the step S4-1 into a cooling furnace, cooling for 1 hour at the temperature of 60 ℃, cutting the semi-finished product of the foamed ceramic plate according to the required size after cooling, and grinding and trimming edges and corners of the plate to obtain the finished product of the foamed ceramic plate.
Example 3: a combined type micro-through hole foam ceramic plate for a sound barrier comprises the following raw materials in parts by weight: 30 parts of aggregate, 20 parts of binder, 3 parts of reinforcing fiber, 0.5 part of surfactant and 12 parts of deionized water;
the aggregate comprises: 8 parts of titanium dioxide, 7 parts of lepidolite, 6 parts of potash-sodalite, 4 parts of sepiolite and 5 parts of perlite;
the binder comprises: 4 parts of ceramic powder, 3 parts of modified talcum powder, 3 parts of water glass, 3 parts of nano-grade micro silicon powder, 2 parts of epoxy resin powder, 3 parts of calcium sulfate and 2 parts of modified hydroxymethyl cellulose;
the reinforcing fiber includes: 1 part of profiled polypropylene fiber, 1 part of polypropylene reticular fiber and 1 part of lignin fiber;
the surfactant is prepared by mixing triphenyl phosphate, sorbitan fatty acid and polysorbate according to the volume ratio of 1:2: 1.
Example 4: this example describes a method for preparing the composite micro via hole foam ceramic plate of example 3, comprising the steps of:
s1, mixing materials;
s1-1, placing the aggregate into a ball mill, controlling the ball-to-material ratio to be 1:1, ball-milling until the particle size of the aggregate is 0.03-0.04 mm, then adding deionized water into the ball-milled material, and stirring and mixing at the stirring speed of 900r/min for 20min to obtain a mixture A;
s1-2, placing the mixture A obtained in the step S1-1 into a high-speed mixing roll, then adding a binder and a surfactant, and stirring for 35min at the temperature of 60 ℃ to obtain a mixture B; before the surfactant is added, the surfactant is subjected to ultrasonic dispersion treatment for 15min at the ultrasonic frequency of 80kHz, and the ultrasonic dispersion treatment is performed on the surfactant, so that the dispersion performance of the surfactant in aggregate and binder can be improved, the use effect of the surfactant is improved, and the sound shielding effect of a finished foamed ceramic plate is further improved;
s1-3, dividing the reinforced fibers into 3mm fiber sections, adding the fiber sections into the mixture B obtained in the step S1-2, uniformly stirring, heating to 60 ℃ under standard atmospheric pressure, and preserving heat for 3 hours to obtain ceramic slurry;
s2, granulating;
putting the ceramic slurry obtained in the step S1-3 into spray granulation equipment, controlling the temperature of a nozzle of the spray granulation equipment to be 30 ℃, and preparing ceramic granules with the grain diameter of 0.05-0.06 mm; then drying the ceramic granules until the content rate is 3%;
s3, pressing the board;
s3-1, placing the ceramic granules dried in the step S2 into a mold of a forming machine, and then prepressing the ceramic granules into an initial blank under the pressure condition of 30 MPa;
s3-2, pressing the primary blank obtained in the step S3-1 under a static condition of 150MPa to prepare a ceramic plate material, and then drying the ceramic plate material until the water content is 1%;
s4, firing a finished product;
s4-1, putting the ceramic plate obtained in the step S3-2 and the die into a preheating furnace together, preheating to 50 ℃, then feeding the preheated ceramic plate into a calcining furnace, calcining, and controlling the calcining temperature to be 700 ℃ to obtain a semi-finished product of the foamed ceramic plate;
and S4-2, feeding the semi-finished product of the foamed ceramic plate obtained in the step S4-1 into a cooling furnace, cooling for 1 hour at the temperature of 60 ℃, cutting the semi-finished product of the foamed ceramic plate according to the required size after cooling, and grinding and trimming edges and corners of the plate to obtain the finished product of the foamed ceramic plate.
Example 5: a combined type micro-through hole foam ceramic plate for a sound barrier comprises the following raw materials in parts by weight: 40 parts of aggregate, 36 parts of binder, 5 parts of reinforcing fiber, 0.8 part of surfactant and 16 parts of deionized water;
the aggregate comprises: 11 parts of titanium dioxide, 8 parts of lepidolite, 7 parts of potash-sodalite, 8 parts of sepiolite and 6 parts of perlite;
the binder comprises: 8 parts of ceramic powder, 6 parts of modified talcum powder, 5 parts of water glass, 4 parts of nano-scale micro silicon powder, 3 parts of epoxy resin powder, 6 parts of calcium sulfate and 4 parts of modified hydroxymethyl cellulose;
the reinforcing fiber includes: 2 parts of profiled polypropylene fiber, 2 parts of polypropylene reticular fiber and 1 part of lignin fiber;
the surfactant is prepared by mixing triphenyl phosphate, sorbitan fatty acid and polysorbate according to the volume ratio of 1:2: 1.
Example 6: this example describes a method for preparing the composite micro via hole foam ceramic plate of example 5, comprising the steps of:
s1, mixing materials;
s1-1, placing the aggregate into a ball mill, controlling the ball-to-material ratio to be 1:2, ball-milling until the particle size of the aggregate is 0.02-0.03 mm, then adding deionized water into the ball-milled material, stirring and mixing for 30min at a stirring speed of 1250r/min to obtain a mixture A;
s1-2, placing the mixture A obtained in the step S1-1 into a high-speed mixing roll, then adding a binder and a surfactant, and stirring for 42min at 80 ℃ to obtain a mixture B;
s1-3, cutting the reinforced fiber into fiber sections with the diameter of 5mm, putting the fiber sections into a mixed solution formed by mixing polyisobutylene succinimide and dilute hydrochloric acid with the mass concentration of 15% in an equal volume, continuously stirring for 12min, then sieving the fiber sections, washing with water until the pH value is 5, and putting the fiber sections into a 50 ℃ oven for drying; through the operation, the bonding strength of the fiber section and the mixture B can be improved, so that the structural strength of a finished product of the foamed ceramic plate is improved, finally, the treated fiber section is added into the mixture B obtained in the step S1-2, the mixture B is uniformly stirred, and then the temperature is raised to 70 ℃ under the standard atmospheric pressure and is kept for 4 hours, so that ceramic slurry is obtained; pre-drying the ceramic slurry until the water content is 9%, and standing for 8 hours; through the operation, the phase change process in the ceramic slurry tends to be stable, so that the structural stability of the pressed ceramic plate is improved;
s2, granulating;
putting the ceramic slurry obtained in the step S1-3 into spray granulation equipment, controlling the temperature of a nozzle of the spray granulation equipment to be 43 ℃, and preparing ceramic granules with the grain diameter of 0.05-0.07 mm; then drying the ceramic granules until the content rate is 5%;
s3, pressing the board;
s3-1, placing the ceramic granules dried in the step S2 into a mold of a forming machine, and then prepressing the ceramic granules into an initial blank under the pressure condition of 40 MPa;
s3-2, pressing the primary blank obtained in the step S3-1 under the static condition of 300MPa to prepare a ceramic plate material, and then drying the ceramic plate material until the water content is 2%;
s4, firing a finished product;
s4-1, putting the ceramic plate obtained in the step S3-2 and the die into a preheating furnace together, preheating to 75 ℃, then sending the preheated ceramic plate into a calcining furnace, calcining, and controlling the calcining temperature to be 980 ℃ to obtain a semi-finished product of the foamed ceramic plate;
and S4-2, feeding the semi-finished product of the foamed ceramic plate obtained in the step S4-1 into a cooling furnace, cooling for 2 hours at the temperature of 80 ℃, cutting the semi-finished product of the foamed ceramic plate according to the required size after cooling, and grinding and trimming edges and corners of the plate to obtain the finished product of the foamed ceramic plate.
Example 7: a combined type micro-through hole foam ceramic plate for a sound barrier comprises the following raw materials in parts by weight: 30 parts of aggregate, 20 parts of binder, 3 parts of reinforcing fiber, 0.5 part of surfactant and 12 parts of deionized water;
the aggregate comprises: 8 parts of titanium dioxide, 7 parts of lepidolite, 6 parts of potash-sodalite, 4 parts of sepiolite and 5 parts of perlite;
the binder comprises: 4 parts of ceramic powder, 3 parts of modified talcum powder, 3 parts of water glass, 3 parts of nano-grade micro silicon powder, 2 parts of epoxy resin powder, 3 parts of calcium sulfate and 2 parts of modified hydroxymethyl cellulose;
the reinforcing fiber includes: 1 part of profiled polypropylene fiber, 1 part of polypropylene reticular fiber and 1 part of lignin fiber;
the surfactant is prepared by mixing triphenyl phosphate, sorbitan fatty acid and polysorbate according to the volume ratio of 1:2: 1.
Example 8: this example describes a method for preparing the composite micro via hole foam ceramic plate of example 7, comprising the steps of:
s1, mixing materials;
s1-1, placing the aggregate into a ball mill, controlling the ball-to-material ratio to be 1:3, ball-milling until the particle size of the aggregate is 0.02-0.03 mm, then adding deionized water into the ball-milled material, and stirring and mixing for 45min at a stirring speed of 1550r/min to obtain a mixture A;
s1-2, placing the mixture A obtained in the step S1-1 into a high-speed mixing roll, then adding a binder and a surfactant, and stirring for 45min at 90 ℃ to obtain a mixture B;
s1-3, cutting the reinforced fibers into fiber sections of 7mm, adding the fiber sections into the mixture B obtained in the step S1-2, uniformly stirring, heating to 80 ℃ under standard atmospheric pressure, and preserving heat for 5 hours to obtain ceramic slurry;
s2, granulating;
putting the ceramic slurry obtained in the step S1-3 into spray granulation equipment, controlling the temperature of a nozzle of the spray granulation equipment to be 50 ℃, and preparing ceramic granules with the grain diameter of 0.05-0.06 mm; then drying the ceramic granules until the content rate is 6%;
s3, pressing the board;
s3-1, placing the ceramic granules dried in the step S2 into a mold of a forming machine, and then prepressing the ceramic granules into an initial blank under the pressure condition of 50 MPa;
s3-2, pressing the primary blank obtained in the step S3-1 under a static condition of 450MPa to prepare a ceramic plate material, and then drying the ceramic plate material until the water content is 3%; the primary blank pressing comprises two stages, wherein in the first stage, 150MPa of pressure is continuously applied for 80s, then the pressure is released to 120MPa and is continuously applied for 50s, and finally the pressure is released; in the second stage, the pressure is continuously increased for 110s under the pressure of 450MPa, then the pressure is released to 180MPa and continuously maintained for 70s, finally the pressure is relieved, and the compaction degree of the primary blank can be improved, the distribution uniformity of the pores in the foam ceramic plate is improved, and the sound shielding effect is further improved by performing sectional pressing on the primary blank;
s4, firing a finished product;
s4-1, putting the ceramic plate obtained in the step S3-2 and the die into a preheating furnace together, preheating to 90 ℃, then sending the preheated ceramic plate into a calcining furnace, calcining, and controlling the calcining temperature to be 1100 ℃ to obtain a semi-finished product of the foamed ceramic plate;
and S4-2, feeding the semi-finished product of the foamed ceramic plate obtained in the step S4-1 into a cooling furnace, cooling for 3 hours at 90 ℃, cutting according to the required size after cooling, and grinding and trimming edges and corners of the plate to obtain the finished product of the foamed ceramic plate.
Example 9: a combined type micro-through hole foam ceramic plate for a sound barrier comprises the following raw materials in parts by weight: 40 parts of aggregate, 36 parts of binder, 5 parts of reinforcing fiber, 0.8 part of surfactant and 16 parts of deionized water;
the aggregate comprises: 11 parts of titanium dioxide, 8 parts of lepidolite, 7 parts of potash-sodalite, 8 parts of sepiolite and 6 parts of perlite;
the binder comprises: 8 parts of ceramic powder, 6 parts of modified talcum powder, 5 parts of water glass, 4 parts of nano-scale micro silicon powder, 3 parts of epoxy resin powder, 6 parts of calcium sulfate and 4 parts of modified hydroxymethyl cellulose;
the reinforcing fiber includes: 2 parts of profiled polypropylene fiber, 2 parts of polypropylene reticular fiber and 1 part of lignin fiber;
the surfactant is prepared by mixing triphenyl phosphate, sorbitan fatty acid and polysorbate according to the volume ratio of 1:2: 1.
Example 10: this example describes a method for preparing the composite micro-via foam ceramic plate of example 9, including the steps of:
s1, mixing materials;
s1-1, placing the aggregate into a ball mill, controlling the ball-to-material ratio to be 1:3, ball-milling until the particle size of the aggregate is 0.02-0.03 mm, then adding deionized water into the ball-milled material, and stirring and mixing for 20min at a stirring speed of 1550r/min to obtain a mixture A;
s1-2, placing the mixture A obtained in the step S1-1 into a high-speed mixing roll, then adding a binder and a surfactant, and stirring for 45min at the temperature of 60 ℃ to obtain a mixture B;
s1-3, dividing the reinforced fibers into 5mm fiber sections, adding the fiber sections into the mixture B obtained in the step S1-2, uniformly stirring, heating to 80 ℃ under standard atmospheric pressure, and preserving heat for 3 hours to obtain ceramic slurry;
s2, granulating;
putting the ceramic slurry obtained in the step S1-3 into spray granulation equipment, controlling the temperature of a nozzle of the spray granulation equipment to be 50 ℃, and preparing ceramic granules with the grain diameter of 0.06-0.08 mm; then drying the ceramic granules until the content rate is 5%;
s3, pressing the board;
s3-1, placing the ceramic granules dried in the step S2 into a mold of a forming machine, and then prepressing the ceramic granules into an initial blank under the pressure condition of 50 MPa;
s3-2, pressing the primary blank obtained in the step S3-1 under a static condition of 450MPa to prepare a ceramic plate material, and then drying the ceramic plate material until the water content is 3%;
s4, firing a finished product;
s4-1, putting the ceramic plate obtained in the step S3-2 and the die into a preheating furnace together, preheating to 90 ℃, then sending the preheated ceramic plate into a calcining furnace, calcining, and controlling the calcining temperature to be 1100 ℃ to obtain a semi-finished product of the foamed ceramic plate; in the process of calcining the ceramic plate, firstly heating the calcining furnace to 700 ℃, and preserving heat for 1 h; then, continuously heating to 1100 ℃, preserving heat for 4 hours, and calcining the ceramic plate at different calcining temperatures, so that cracking of the ceramic plate in the sintering process can be avoided, and internal defects of the ceramic plate in the sintering process can be avoided;
and S4-2, feeding the semi-finished product of the foamed ceramic plate obtained in the step S4-1 into a cooling furnace, cooling for h at the temperature of 60 ℃, cutting the semi-finished product of the foamed ceramic plate according to the required size after cooling, and grinding and trimming the edges and corners of the plate to obtain the finished product of the foamed ceramic plate.
Example 11: a combined type micro-through hole foam ceramic plate for a sound barrier comprises the following raw materials in parts by weight: 50 parts of aggregate, 45 parts of binder, 7 parts of reinforcing fiber, 1.2 parts of surfactant and 18 parts of deionized water;
the aggregate comprises: 13 parts of titanium dioxide, 11 parts of lepidolite, 9 parts of potash-sodalite, 9 parts of sepiolite and 8 parts of perlite;
the binder comprises: 11 parts of ceramic powder, 7 parts of modified talcum powder, 6 parts of water glass, 5 parts of nano-grade micro silicon powder, 4 parts of epoxy resin powder, 7 parts of calcium sulfate and 5 parts of modified hydroxymethyl cellulose;
the reinforcing fiber includes: 3 parts of profiled polypropylene fiber, 2 parts of polypropylene reticular fiber and 2 parts of lignin fiber;
the surfactant is prepared by mixing triphenyl phosphate, sorbitan fatty acid and polysorbate according to the volume ratio of 1:2: 1.
Example 12, this example describes a method for preparing the composite micro via hole foam ceramic plate of example 11, including the steps of:
s1, mixing materials;
s1-1, placing the aggregate into a ball mill, controlling the ball-to-material ratio to be 1:3, ball-milling until the particle size of the aggregate is 0.02-0.03 mm, then adding deionized water into the ball-milled material, and stirring and mixing for 45min at a stirring speed of 1550r/min to obtain a mixture A;
s1-2, placing the mixture A obtained in the step S1-1 into a high-speed mixing roll, then adding a binder and a surfactant, and stirring for 45min at 90 ℃ to obtain a mixture B; before the surfactant is added, the surfactant is subjected to ultrasonic dispersion treatment for 30min at the ultrasonic frequency of 130kHz, and the ultrasonic dispersion treatment is performed on the surfactant, so that the dispersion performance of the surfactant in aggregate and binder can be improved, the use effect of the surfactant is improved, and the sound shielding effect of a finished foamed ceramic plate is further improved;
s1-3, cutting the reinforced fiber into fiber sections of 5mm, putting the fiber sections into a mixed solution formed by mixing polyisobutylene succinimide and dilute hydrochloric acid with the mass concentration of 15% in an equal volume, continuously stirring for 15min, sieving the fiber sections, washing with water until the pH value is 7, and putting the fiber sections into an oven at 80 ℃ for drying; through the operation, the bonding strength of the fiber section and the mixture B can be improved, so that the structural strength of a finished product of the foamed ceramic plate is improved; adding the fiber section into the mixture B obtained in the step S1-2, uniformly stirring, and then heating to 80 ℃ under standard atmospheric pressure and preserving heat for 5 hours to obtain ceramic slurry; the ceramic slurry is pre-dried until the water content is 9%, and is kept stand for 14h, the stability of the phase change process in the ceramic slurry can be improved through the operation, and the structural stability of the pressed ceramic plate is improved;
s2, granulating;
putting the ceramic slurry obtained in the step S1-3 into spray granulation equipment, controlling the temperature of a nozzle of the spray granulation equipment to be 50 ℃, and preparing ceramic granules with the grain diameter of 0.05-0.06 mm; then drying the ceramic granules until the content rate is 3%;
s3, pressing the board;
s3-1, placing the ceramic granules dried in the step S2 into a mold of a forming machine, and then prepressing the ceramic granules into an initial blank under the pressure condition of 50 MPa;
s3-2, pressing the primary blank obtained in the step S3-1 under a static condition of 450MPa to prepare a ceramic plate material, and then drying the ceramic plate material until the water content is 1%; the primary blank pressing comprises two stages, wherein in the first stage, the pressure is continuously increased for 110s at 260MPa, then the pressure is released to 150MPa and is continuously increased for 80s, and finally the pressure is released; in the second stage, the pressure is continuously increased for 150s under the pressure of 450MPa, then the pressure is released to 130MPa and continuously maintained for 110s, finally the pressure is relieved, and the compaction degree of the primary blank can be improved, the distribution uniformity of the pores in the foam ceramic plate is improved, and the sound shielding effect is further improved by performing sectional pressing on the primary blank;
s4, firing a finished product;
s4-1, putting the ceramic plate obtained in the step S3-2 and the die into a preheating furnace together, preheating to 90 ℃, then sending the preheated ceramic plate into a calcining furnace, calcining, and controlling the calcining temperature to be 1100 ℃ to obtain a semi-finished product of the foamed ceramic plate; in the process of calcining the ceramic plate, firstly heating the calcining furnace to 850 ℃, and preserving heat for 2.5 hours; then, continuously heating to 1100 ℃, preserving heat for 4 hours, and calcining the ceramic plate at different calcining temperatures, so that cracking of the ceramic plate in the sintering process can be avoided, and internal defects of the ceramic plate in the sintering process can be avoided;
and S4-2, feeding the semi-finished product of the foamed ceramic plate obtained in the step S4-1 into a cooling furnace, cooling for 3 hours at 90 ℃, cutting according to the required size after cooling, and grinding and trimming edges and corners of the plate to obtain the finished product of the foamed ceramic plate.
Example 13, the present example describes the raw materials of the composite type micro-via foam ceramic plate of examples 1, 3, and 5:
the preparation method of the modified hydroxymethyl cellulose comprises the following steps: mixing hydroxymethyl cellulose and 78% ethanol solution according to a volume ratio of 1:3 until completely dissolved, adding chitosan with a volume of 15% of the hydroxymethyl cellulose, and stirring and reacting at 50 ℃ for 10min to obtain modified hydroxymethyl cellulose; the modified hydroxymethyl cellulose prepared by the method has more excellent bonding property, and is beneficial to improving the bonding strength and stability of materials in a finished product of the foamed ceramic plate;
the preparation method of the modified talcum powder comprises the following steps: 1) uniformly mixing talcum powder and zirconia powder with the same volume, and then ball-milling until the particle size is 25-45 mu m; 2) uniformly mixing sodium lauryl sulfate with the mass concentration of 3.5% and a potassium permanganate solution in the same volume, adding the mixture into the material obtained in the step 1), heating to 30 ℃, reacting for 30min, and after the reaction is finished, drying the material in vacuum to constant weight to obtain modified talcum powder; wherein, the addition amount of the sodium lauryl sulfate and potassium permanganate solution is 15 percent of the volume of the talcum powder; by modifying the talcum powder, the compactness among the internal raw materials in the calcination process of the finished foamed ceramic plate is promoted effectively, so that the finished foamed ceramic plate with a microporous structure is obtained.
Example 14, which describes the present example, is the combined type micro through hole foamed ceramic plate raw material of examples 7, 9, 11:
the preparation method of the modified hydroxymethyl cellulose comprises the following steps: mixing hydroxymethyl cellulose and 78% ethanol solution according to a volume ratio of 1:5 until completely dissolved, adding chitosan with a volume of 25% of the hydroxymethyl cellulose, and stirring and reacting at 90 ℃ for 30min to obtain modified hydroxymethyl cellulose; the modified hydroxymethyl cellulose prepared by the method has more excellent bonding property, and is beneficial to improving the bonding strength and stability of materials in a finished product of the foamed ceramic plate;
the preparation method of the modified talcum powder comprises the following steps: 1) uniformly mixing talcum powder and zirconia powder with the same volume, and then ball-milling until the particle size is 15-30 mu m; 2) uniformly mixing sodium lauryl sulfate with the mass concentration of 3.5% and a potassium permanganate solution in the same volume, then adding the mixture into the material obtained in the step 1), heating to 70 ℃, reacting for 55min, and after the reaction is finished, drying the material in vacuum to constant weight to obtain modified talcum powder; wherein, the addition amount of the sodium lauryl sulfate and potassium permanganate solution is 30 percent of the volume of the talcum powder; by modifying the talcum powder, the compactness among the internal raw materials in the calcination process of the finished foamed ceramic plate is promoted effectively, so that the finished foamed ceramic plate with a microporous structure is obtained.
Example 15: the embodiment describes a combined micro-through-hole foamed ceramic plate structure of embodiments 1, 3, 5, 7, 9, and 11, as shown in fig. 1 and 2, including a plate body 1, a strip-shaped notch 10 is provided at an edge of one side surface of the plate body 1, and a vibration stopping strip 11 is provided on a surface of the strip-shaped notch 10; the plate body 1 is provided with a first mounting groove 12 and a second mounting groove 13 close to the strip-shaped gap 10 in pairs respectively, the two first mounting grooves 12 and the two second mounting grooves 13 are arranged in pairs and are perpendicular to each other, a fixed truss 2 is arranged inside each first mounting groove 12 and each second mounting groove 13, the fixed truss 2 is hollow, and bolt holes 14 are arranged at positions of the first mounting groove 12 and the two second mounting grooves 13 corresponding to the fixed truss 2; each fixed truss 2 is provided with 1-3 strip-shaped grooves 20, and a long bolt 21 is slidably clamped inside each strip-shaped groove 20; the long bolt 21 is clamped in a sliding manner, so that the position of the plate body 1 can be conveniently adjusted during installation, and the convenience during installation is improved.
Test example: the finished foamed ceramic plates prepared according to examples 2, 4, 6, 8, 10 and 12 of the present invention were subjected to performance tests, respectively, and the results are shown in table 1:
table 1, effect of different preparation conditions on finished performance of foamed ceramic plates;
as can be seen from the data in table 1, in example 4, compared with example 2, by performing ultrasonic dispersion treatment on the surfactant, the dispersion performance of the surfactant in the aggregate and the binder can be improved, the use effect of the surfactant can be improved, and the sound shielding effect of the finished foamed ceramic plate can be further improved; example 6 compared with example 2, the bonding strength of the fiber segment and the mixture B can be improved by placing the fiber segment into the mixed solution of polyisobutylene succinimide and dilute hydrochloric acid, thereby improving the structural strength of the finished foamed ceramic plate; through pre-drying and standing treatment of the ceramic slurry, the phase change process in the ceramic slurry tends to be stable, so that the structural stability of the pressed ceramic plate is improved; example 8 compared with example 2, the compaction degree of the primary blank can be improved, the distribution uniformity of fine pores in the foam ceramic plate can be improved, and the sound shielding effect can be further improved by performing the sectional pressing on the primary blank; compared with the embodiment 2, the embodiment 10 has the advantages that the ceramic plate is calcined at different calcining temperatures, so that cracking of the ceramic plate in the sintering process can be avoided, and internal defects of the ceramic plate in the sintering process can be avoided; example 12 compared with examples 2, 4, 6 and 8, the properties of the finished foamed ceramic plate are optimized due to the comprehensive optimization of the favorable conditions.
Claims (10)
1. A combined type micro-through hole foam ceramic plate for a sound barrier is characterized by comprising the following raw materials in parts by weight: 30-50 parts of aggregate, 20-45 parts of binder, 3-7 parts of reinforcing fiber, 0.5-1.2 parts of surfactant and 12-18 parts of deionized water;
the aggregate comprises: 8-13 parts of titanium dioxide, 7-11 parts of lepidolite, 6-9 parts of potash-sodalite, 4-9 parts of nano sepiolite and 5-8 parts of perlite;
the binder includes: 4-11 parts of ceramic powder, 3-7 parts of modified talcum powder, 3-6 parts of water glass, 3-5 parts of nano-scale micro silicon powder, 2-4 parts of epoxy resin powder, 3-7 parts of calcium sulfate and 2-5 parts of modified hydroxymethyl cellulose;
the reinforcing fiber includes: 1-3 parts of special-shaped polypropylene fiber, 1-2 parts of polypropylene reticular fiber and 1-2 parts of lignin fiber;
the surfactant is prepared by mixing triphenyl phosphate, sorbitan fatty acid and polysorbate according to the volume ratio of 1:2: 1.
2. The method of preparing a composite micro via foam ceramic plate for a sound barrier according to claim 1, comprising the steps of:
s1, mixing materials;
s1-1, placing the aggregate into a ball mill, controlling the ball-to-material ratio to be 1:1-3, ball-milling until the particle size of the aggregate is 0.02-0.04mm, then adding the deionized water into the ball-milled material, and stirring and mixing at the stirring speed of 900-;
s1-2, placing the mixture A obtained in the step S1-1 into a high-speed mixing roll, then adding the binder and the surfactant, and stirring for 35-45min at the temperature of 60-90 ℃ to obtain a mixture B;
s1-3, dividing the reinforced fibers into fiber sections of 3-7mm, adding the fiber sections into the mixture B obtained in the step S1-2, uniformly stirring, heating to 60-80 ℃ under standard atmospheric pressure, and preserving heat for 3-5 hours to obtain ceramic slurry;
s2, granulating;
putting the ceramic slurry obtained in the step S1-3 into spray granulation equipment, controlling the temperature of a nozzle of the spray granulation equipment to be 30-50 ℃, and preparing ceramic granules with the grain diameter of 0.05-0.08 mm; then drying the ceramic granules until the content rate is 3-6%;
s3, pressing the board;
s3-1, placing the ceramic granules dried in the step S2 into a mold of a forming machine, and then pre-pressing the ceramic granules into an initial blank under the pressure of 30-50 MPa;
s3-2, pressing the primary blank obtained in the step S3-1 under the static condition of 150-450MPa to prepare a ceramic plate material, and then drying the ceramic plate material until the water content is 1-3%;
s4, firing a finished product;
s4-1, putting the ceramic plate obtained in the step S3-2 and the die into a preheating furnace together, preheating to 50-90 ℃, then sending the preheated ceramic plate into a calcining furnace, calcining, and controlling the calcining temperature to be 700-1100 ℃ to obtain a semi-finished product of the foamed ceramic plate;
and S4-2, feeding the semi-finished product of the foamed ceramic plate obtained in the step S4-1 into a cooling furnace, cooling for 1-3 hours at the temperature of 60-90 ℃, cutting according to the required size after cooling, and grinding and trimming edges and corners of the plate to obtain the finished product of the foamed ceramic plate.
3. The method for preparing a composite micro through-hole foam ceramic plate for a sound barrier as claimed in claim 2, wherein the surfactant is subjected to ultrasonic dispersion treatment at an ultrasonic frequency of 80-130kHz for 15-30min before the step S1-2 is performed.
4. The method for preparing a composite micro through hole foam ceramic plate for a sound barrier according to claim 2, wherein in step S1-3, after the reinforced fiber is cut, the fiber segment is placed into a mixed solution formed by mixing polyisobutylene succinimide and dilute hydrochloric acid with a mass concentration of 15% in equal volume, the mixed solution is continuously stirred for 5-15min, then the fiber segment is sieved, washed with water until the pH is 5-7, and placed into an oven with a temperature of 50-80 ℃ for drying.
5. The method of preparing a composite micro via hole foam ceramic plate for a sound barrier as claimed in claim 2, wherein the ceramic slurry is pre-dried to a water content of 10% or less after completion of the step S1-3, and left to stand for 8-14 hours.
6. The preparation method of the combined micro-porous foam ceramic plate for sound barrier as claimed in claim 2, wherein in step S3-2, the primary blank pressing comprises two stages, the first stage comprises continuously pressurizing at 150-260MPa for 80-110S, then depressurizing to 120-150MPa for 50-80S, and finally relieving the pressure; in the second stage, the pressure is continuously increased to 110-150s at the pressure of 260-450MPa, then the pressure is released to 180-230MPa and is continuously increased to 70-110s, and finally the pressure is released.
7. The preparation method of the combined type micro-through hole foam ceramic plate for the sound barrier as claimed in claim 2, wherein in the step S4-1, the temperature of the calcinator is first raised to 850 ℃ at 700 ℃ and the temperature is kept for 1-2.5h during the calcination of the ceramic plate; then the temperature is continuously increased to 850 ℃ and 1100 ℃, and the temperature is kept for 2-4 h.
8. The composite micro through hole foam ceramic plate for sound barrier as claimed in claim 1, wherein the modified hydroxymethyl cellulose is prepared by the following method: mixing hydroxymethyl cellulose and 78% ethanol solution according to a volume ratio of 1:3-5 until completely dissolving, adding chitosan 15-25% of hydroxymethyl cellulose, and stirring at 50-90 deg.C for 10-30min to obtain modified hydroxymethyl cellulose.
9. The combined micro-through-hole foam ceramic plate for the sound barrier as claimed in claim 1, wherein the structure of the combined micro-through-hole foam ceramic plate comprises a plate body (1), a strip-shaped gap (10) is arranged at one side edge of the plate body (1), and a vibration stopping strip (11) is arranged on the surface of the strip-shaped gap (10); the plate body (1) is provided with a first mounting groove (12) and a second mounting groove (13) in pairs close to the strip-shaped gap (10), the two first mounting grooves (12) and the two second mounting grooves (13) are arranged in a corresponding mode and are perpendicular to each other, a fixed truss (2) is arranged inside each first mounting groove (12) and each second mounting groove (13), the fixed truss (2) is hollow, and bolt holes (14) are formed in positions, corresponding to the fixed truss (2), of the first mounting groove (12) and the two second mounting grooves (13); all be provided with 1-3 bar groove (20) on each fixed truss (2), each equal slip joint has stay bolt (21) inside bar groove (20).
10. The preparation method of the combined type micro-through hole foam ceramic plate for the sound barrier as claimed in claim 1, wherein in the step S4-1, the temperature of the calcinator is first raised to 850 ℃ at 700 ℃ and the temperature is kept for 1-2.5h during the calcination of the ceramic plate; then the temperature is continuously increased to 850 ℃ and 1100 ℃, and the temperature is kept for 2-4 h.
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