CN114133237A - 一种ptc加热器零功率陶瓷片的制作方法 - Google Patents

一种ptc加热器零功率陶瓷片的制作方法 Download PDF

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CN114133237A
CN114133237A CN202111263979.8A CN202111263979A CN114133237A CN 114133237 A CN114133237 A CN 114133237A CN 202111263979 A CN202111263979 A CN 202111263979A CN 114133237 A CN114133237 A CN 114133237A
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ptc heater
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朱兴文
张楠
贾小晶
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Jiangsu Jun Porcelain Technology Co ltd
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Abstract

本发明公开了一种PTC加热器零功率陶瓷片的制作方法，包括以下步骤：将所述PTC加热器零功率陶瓷片的材料中各组分通过球磨子研磨成粉体混合，形成混合粉料，同时添加水作为介质；添加PVA颗粒或PVA溶剂作为粘结剂，同时球磨所述混合粉体、水和所述粘结剂一预设时间后进行造粒，得到混合粉末状颗粒物；将所述混合粉末状颗粒物压制成预设尺寸的素坯，所述素坯置于预设温度的空气气氛中使其充分烧结为致密陶瓷。所述PTC加热器零功率陶瓷片的材料来自PTC生产企业的废弃回收料或污泥。本发明可以降低废料处理的成本，方法操作简单，易于控制，成本低廉，非常适合产业化实施。

Description

一种PTC加热器零功率陶瓷片的制作方法
技术领域
本发明涉及陶瓷材料制备技术领域，具体涉及一种PTC加热器零功率陶瓷片的制作方法，应用于电子材料技术领域。
背景技术
PTC加热器是采用PTC热敏电阻陶瓷的定温加热的功能，将PTC陶瓷片与散热器组合在一起，通电后通过强风或液体将热量散发，达到加热的效果。PTC加热器已广泛用于空调、新能源汽车热管理系统等，应用领域十分广泛，市场规模巨大。由于PTC的加热功率与加热器的尺寸相关，而加热器的尺寸是由应用场合决定。因此，通常情况下，所用PTC陶瓷的加和尺寸比加热器总长短，为保证使用过程中不必要的极间放电，需要使用零功率陶瓷片补充PTC陶瓷片的尺寸不足，每套加热器的零功率片的使用数量2～6片，年需求数量可观。目前，该零功率陶瓷片的材质为氧化铝瓷、莫来石瓷或滑石瓷，其制作成本相对较高。
而在PTC陶瓷制作过程中，由于生产工艺要求，不可避免的会产生较多的PTC陶瓷废粉。比如磨片工序，其磨削量约占PTC陶瓷体积的10％，磨削的粉体或浆料不能作为固废填埋。因为废料中含有铅，必须回收后经专业并具有资质部门处理，处理费用较高，这对PTC陶瓷生产企业是一笔不小的开支。
因此，亟待提供一种低成本处理含铅废料的PTC加热器零功率陶瓷片的制作方法。
发明内容
鉴于以上所述现有技术的缺点，本发明的目的是提供一种低成本处理含铅废料的PTC加热器零功率陶瓷片的制作方法。
为了解决或部分解决上述技术问题，本申请提供了一种PTC加热器零功率陶瓷片的制作方法，包括如下步骤：
将所述PTC加热器零功率陶瓷片的材料中各组分通过球磨子研磨成粉体混合，形成混合粉料，同时添加水作为介质；
添加PVA颗粒或PVA溶剂作为粘结剂，同时球磨所述混合粉体、水和所述粘结剂一预设时间后进行造粒，得到混合粉末状颗粒物；
将所述混合粉末状颗粒物压制成预设尺寸的素坯，所述素坯置于预设温度的空气气氛中使其充分烧结为致密陶瓷，制备得到所述PTC加热器零功率陶瓷片；
所述PTC加热器零功率陶瓷片的材料来自PTC生产企业的废弃回收料或污泥。
作为本发明实施方式的进一步改进，所述PTC加热器零功率陶瓷片的材料的配方组成包括如下质量百分比：
Figure BDA0003325750740000021
Figure BDA0003325750740000031
所述烧结助剂为MnO2、Al2O3、SiO2的混合物。
作为本发明实施方式的进一步改进，所述球磨子为氧化锆、氧化铝球、铁球、玛瑙球中一种或任意几种的混合物。
作为本发明实施方式的进一步改进，所述添加水的质量为所述混合粉料质量的0.4～2.0倍。
作为本发明实施方式的进一步改进，所述添加PVA颗粒的量为所述混合粉料质量的0.1～1.5质量％；所述添加PVA溶剂的添加浓度为2～25质量％，添加量为所述混合粉料质量的3～20质量％。
作为本发明实施方式的进一步改进，所述制备方法还包括所述致密陶瓷经研磨并安装电极。
作为本发明实施方式的进一步改进，所述压制的压力为5～15MPa；所述素坯的预设尺寸根据要求设定；所述素坯置于1100～1350℃的空气气氛中使其充分烧结为致密陶瓷。
作为本发明实施方式的进一步改进，所述PTC加热器零功率陶瓷片的材料的电阻≥1×105欧姆，耐电压强度≥400Vac/mm。
作为本发明实施方式的进一步改进，所述造粒具体包括利用所述混合粉料重量的8wt％、浓度为10wt％的聚乙烯醇进行造粒。
作为本发明实施方式的进一步改进，所述电极构造为喷铝或印刷Al电极浆料、Ag浆料后可作为PTC加热器中的零功率片或用作装置陶瓷。
作为本发明实施方式的进一步改进，所述通过球磨子进行研磨的时间为2～24小时。
作为本发明实施方式的进一步改进，所述素坯的预设尺寸为28×17.3×2.9mm。
作为本发明实施方式的进一步改进，所述素坯的烧结时长为10～120分钟之间。
与现有技术相比较，本发明的优点是：
1、本发明将PTC生产企业的废料(包括PTC工艺污泥、磨削料、撒漏料、造粒回收料等)收集，经传统陶瓷工艺，制作零功率陶瓷，解决令PTC企业最为关注的含铅废料处理问题，进行废物利用，同时能产生一定的经济效益；
2、本发明制作的零功率片电阻几近绝缘，其耐电压强度远大于PTC热敏陶瓷本体，其安全可靠性有保障；
3、本发明方法操作简单，易于控制，成本低廉，非常适合产业化实施，符合国家对循环经济产业发展的鼓励政策。
具体实施方式
为使本申请实施例的目的、技术方案和优点更加清楚，下面将结合本申请实施例中，对本申请实施例中的技术方案进行清楚、完整的描述，显然，所描述的实施例是本申请一部分实施例，而不是全部的实施例。基于本申请中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都应当属于本申请保护的范围。
实施例1
实施例1的陶瓷材料的组成如下表1：
表1实施例1原料配料表(单位：Kg)
Figure BDA0003325750740000041
Figure BDA0003325750740000051
以表中的配方回收废料和污泥，以玛瑙球和水为介质，将混合球磨22小时，然后加入粉料总重量8.0wt％的浓度为10wt％的聚乙烯醇(PVA)，继续球磨2小时，然后进行喷雾造粒，所得粉体并以10MPa的压力压片制成尺寸为28×17.3×2.9mm的方形素坯；
在空气气氛中，将压制好的素坯在1210℃烧结，保温烧结20-120mi n，使方形素坯充分烧结和实现固相反应，获得致密陶瓷片。
将上述陶瓷片进行上下表面研磨至2.34～2.37mm厚度，经过喷铝(上电极)工序，获得PTC加热器用零功率陶瓷片
将上述陶瓷片进行电阻测量和耐电压强度测量，其结果如下：室温电阻～3.8MΩ，耐电压强度＞1050Vac
按实施例1的比例的混合料(污泥+回收废料)制作的陶瓷片的电阻满足＞100KΩ、耐电压强度＞900Vac的要求。
实施例2
实施例2的陶瓷材料的组成如下表1：
表2实施例2原料配料表(单位：Kg)
Figure BDA0003325750740000052
Figure BDA0003325750740000061
以表中的配方回收废料和污泥，以玛瑙球和水为介质，将混合球磨22小时，然后加入粉料总重量7.0wt％的浓度为10wt％的聚乙烯醇(PVA)，继续球磨2小时，然后进行喷雾造粒，所得粉体并以10MPa的压力压片制成尺寸为28×17.3×2.9mm的方形素坯；
在空气气氛中，将压制好的素坯在1180℃烧结，保温烧结20-120min，使方形素坯充分烧结和实现固相反应，获得致密陶瓷片。
将上述陶瓷片进行上下表面研磨至2.34～2.37mm厚度，经过喷铝(上电极)工序，获得PTC加热器用零功率陶瓷片
将上述陶瓷片进行电阻测量和耐电压强度测量，其结果如下：室温电阻～3.1MΩ，耐电压强度＞1050Vac
按实施例2的比例的混合料(污泥+回收废料)制作的陶瓷片的电阻满足＞100KΩ、耐电压强度＞900Vac的要求。
实施例3
实施例3的陶瓷材料的组成如下表1：
表1实施例3原料配料表(单位：Kg)
Figure BDA0003325750740000062
Figure BDA0003325750740000071
以表中的配方回收废料和污泥，以玛瑙球和水为介质，将混合球磨22小时，然后加入粉料总重量7.0wt％的浓度为10wt％的聚乙烯醇(PVA)，继续球磨2小时，然后进行喷雾造粒，所得粉体并以10MPa的压力压片制成尺寸为28×17.3×2.9mm的方形素坯；
在空气气氛中，将压制好的素坯在1150℃烧结，保温烧结20-120min，使方形素坯充分烧结和实现固相反应，获得致密陶瓷片。
将上述陶瓷片进行上下表面研磨至2.34～2.37mm厚度，经过喷铝(上电极)工序，获得PTC加热器用零功率陶瓷片
将上述陶瓷片进行电阻测量和耐电压强度测量，其结果如下：室温电阻～2.5MΩ，耐电压强度＞1000Vac
结论：按实施例二的比例的混合料(污泥+回收废料)制作的陶瓷片的电阻满足＞100KΩ、耐电压强度＞900Vac的要求。
与现有技术相比较，本发明的优点是：
1、本发明将PTC生产企业的废料(包括PTC工艺污泥、磨削料、撒漏料、造粒回收料等)收集，经传统陶瓷工艺，制作零功率陶瓷，解决令PTC企业最为关注的含铅废料处理问题，进行废物利用，同时能产生一定的经济效益；
2、本发明制作的零功率片电阻几近绝缘，其耐电压强度远大于PTC热敏陶瓷本体，其安全可靠性有保障；
3、本发明方法操作简单，易于控制，成本低廉，非常适合产业化实施，符合国家对循环经济产业发展的鼓励政策。
应当理解，在本申请实施例中使用的术语是仅仅出于描述特定实施例的目的，而非旨在限制本申请。在本申请实施例和所附权利要求书中所使用的单数形式的“一种”、“所述”和“该”也旨在包括多数形式，除非上下文清楚地表示其他含义，“多种”一般包含至少两种，但是不排除包含至少一种的情况。
还需要说明的是，术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含，从而使得包括一系列要素的商品或者系统不仅包括那些要素，而且还包括没有明确列出的其他要素，或者是还包括为这种商品或者系统所固有的要素。在没有更多限制的情况下，由语句“包括一个……”限定的要素，并不排除在包括所述要素的商品或者系统中还存在另外的相同要素。
最后应说明的是，本领域的普通技术人员可以理解，为了使读者更好地理解本申请，本申请的实施方式提出了许多技术细节。但是，即使没有这些技术细节和基于上述各实施方式的种种变化和修改，也可以基本实现本申请各权利要求所要求保护的技术方案。因此，在实际应用中，可以在形式上和细节上对上述实施方式作各种改变，而不偏离本申请的精神和范围。

Claims (9)

1.一种PTC加热器零功率陶瓷片的制作方法，其特征在于，包括以下步骤：
将所述PTC加热器零功率陶瓷片的材料中各组分通过球磨子研磨成粉体混合，形成混合粉料，同时添加水作为介质；
添加PVA颗粒或PVA溶剂作为粘结剂，同时球磨所述混合粉体、水和所述粘结剂一预设时间后进行造粒，得到混合粉末状颗粒物；
将所述混合粉末状颗粒物压制成预设尺寸的素坯，所述素坯置于预设温度的空气气氛中使其充分烧结为致密陶瓷，制备得到所述PTC加热器零功率陶瓷片；
所述PTC加热器零功率陶瓷片的材料来自PTC生产企业的废弃回收料或污泥。
2.根据权利要求1所述的PTC加热器零功率陶瓷片的制作方法，其特征在于，所述PTC加热器零功率陶瓷片的材料的配方组成包括如下质量百分比：
Figure FDA0003325750730000011
所述烧结助剂为MnO2、Al2O3、SiO2的混合物。
3.根据权利要求1所述的PTC加热器零功率陶瓷片的制作方法，其特征在于，所述球磨子为氧化锆、氧化铝球、铁球、玛瑙球中一种或任意几种的混合物。
4.根据权利要求1所述的PTC加热器零功率陶瓷片的制作方法，其特征在于，所述添加水的质量为所述混合粉料质量的0.4～2.0倍。
5.根据权利要求1所述的PTC加热器零功率陶瓷片的制作方法，其特征在于，所述添加PVA颗粒的量为所述混合粉料质量的0.1～1.5质量％；所述添加PVA溶剂的添加浓度为2～25质量％，添加量为所述混合粉料质量的3～20质量％。
6.根据权利要求1所述的PTC加热器零功率陶瓷片的制作方法，其特征在于，所述制备方法还包括所述致密陶瓷经研磨并安装电极；所述电极构造为喷铝或印刷Al电极浆料、Ag浆料后可作为PTC加热器中的零功率片。
7.根据权利要求1所述的PTC加热器零功率陶瓷片的制作方法，其特征在于，所述压制的压力为5～15MPa；所述素坯的预设尺寸根据要求设定；所述素坯置于1100～1350℃的空气气氛中使其充分烧结为致密陶瓷。
8.根据权利要求1所述的PTC加热器零功率陶瓷片的制作方法，其特征在于，所述PTC加热器零功率陶瓷片的材料的电阻≥1×105欧姆，耐电压强度≥400Vac/mm。
9.根据权利要求1所述的PTC加热器零功率陶瓷片的制作方法，其特征在于，所述造粒具体包括利用所述混合粉料重量的8wt％、浓度为10wt％的聚乙烯醇进行造粒。
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