CN114230366A - Light porous sound-absorbing ceramic material, preparation process and application thereof - Google Patents
Light porous sound-absorbing ceramic material, preparation process and application thereof Download PDFInfo
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- CN114230366A CN114230366A CN202210168771.6A CN202210168771A CN114230366A CN 114230366 A CN114230366 A CN 114230366A CN 202210168771 A CN202210168771 A CN 202210168771A CN 114230366 A CN114230366 A CN 114230366A
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- ceramic material
- sound
- lightweight
- absorbing ceramic
- absorbing
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- 238000002360 preparation method Methods 0.000 title claims abstract description 55
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- 239000011148 porous material Substances 0.000 claims abstract description 71
- 238000005245 sintering Methods 0.000 claims abstract description 51
- 239000004088 foaming agent Substances 0.000 claims abstract description 44
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 40
- 238000004519 manufacturing process Methods 0.000 claims abstract description 10
- 238000010438 heat treatment Methods 0.000 claims description 61
- 238000010304 firing Methods 0.000 claims description 54
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 39
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 35
- 238000001816 cooling Methods 0.000 claims description 33
- 238000010521 absorption reaction Methods 0.000 claims description 31
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- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 description 2
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- XCOBTUNSZUJCDH-UHFFFAOYSA-B lithium magnesium sodium silicate Chemical compound [Li+].[Li+].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[Na+].[Na+].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Mg+2].O1[Si](O2)([O-])O[Si]3([O-])O[Si]1([O-])O[Si]2([O-])O3.O1[Si](O2)([O-])O[Si]3([O-])O[Si]1([O-])O[Si]2([O-])O3.O1[Si](O2)([O-])O[Si]3([O-])O[Si]1([O-])O[Si]2([O-])O3.O1[Si](O2)([O-])O[Si]3([O-])O[Si]1([O-])O[Si]2([O-])O3.O1[Si](O2)([O-])O[Si]3([O-])O[Si]1([O-])O[Si]2([O-])O3.O1[Si](O2)([O-])O[Si]3([O-])O[Si]1([O-])O[Si]2([O-])O3 XCOBTUNSZUJCDH-UHFFFAOYSA-B 0.000 description 1
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
- C04B2235/3208—Calcium oxide or oxide-forming salts thereof, e.g. lime
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- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3418—Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/36—Glass starting materials for making ceramics, e.g. silica glass
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B2001/8423—Tray or frame type panels or blocks, with or without acoustical filling
- E04B2001/8433—Tray or frame type panels or blocks, with or without acoustical filling with holes in their face
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
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- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B2001/8457—Solid slabs or blocks
- E04B2001/8476—Solid slabs or blocks with acoustical cavities, with or without acoustical filling
- E04B2001/848—Solid slabs or blocks with acoustical cavities, with or without acoustical filling the cavities opening onto the face of the element
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Abstract
The invention relates to the technical field of sound-absorbing materials, in particular to a light porous sound-absorbing ceramic material, a preparation process and application thereof, wherein the light porous sound-absorbing ceramic material comprises air holes and hole walls for spacing the air holes, at least part of adjacent air holes are provided with communicating channels which pass through the hole walls, and the diameter d of each communicating channel is as follows: pore diameter D = 1: 3-13. Through the addition of the pore-forming agent and the foaming agent, pores are generated in the powder after the foaming agent is decomposed, and the pores are communicated after the pore-forming agent is oxidized and decomposed, so that at least adjacent partial pores in the prepared light porous sound-absorbing ceramic material are intercommunicated pores. The preparation process of the sound-absorbing ceramic material is free from press forming, can be formed by adopting the traditional ceramic sintering step, is simple in process and convenient and quick to operate, does not need to change the existing production equipment on a large scale, and the light porous sound-absorbing ceramic material obtained by adjusting the raw materials and the preparation process has relatively high strength, high sound-absorbing and noise-reducing effects and good water-absorbing effect.
Description
Technical Field
The invention relates to the technical field of sound-absorbing materials, in particular to a light porous sound-absorbing ceramic material, a preparation process and application thereof.
Background
At present, high-silicon solid waste is often used as a main material of the closed-pore foamed ceramic, silicon carbide micro powder with a certain particle size range is used as a foaming agent, and the closed-pore foamed ceramic is prepared through high-temperature foaming.
The density of the existing closed pore foaming ceramic is 380-560kg/m3The air sound insulation amount is between 35 dB and 46dB, and the air sound insulation wall has certain sound insulation performance, as shown in fig. 1 and 2, the honeycomb closed air hole structure of the closed air hole foamed ceramic determines that the product has poor sound absorption and noise reduction functions, the sound absorption and noise reduction coefficient is within 0.09, and particularly when the air sound insulation wall is used as an inner partition wall of a building, the user experience is reduced due to the poor noise reduction function. In addition, in the prior art, the addition amount of the foaming agent in the foamed ceramic is increased, so that air holes generated by the foaming agent are broken during foaming, and the air bubbles are communicated with each other.
Disclosure of Invention
The invention mainly aims to provide a lightweight porous sound-absorbing ceramic material, a preparation process and application thereof, aiming at solving the technical problems that the existing closed-pore foamed ceramic has poor sound insulation and noise reduction functions and has low strength of the connected-pore foamed ceramic.
In order to achieve the above object, the present invention provides a lightweight porous sound-absorbing ceramic material, which comprises air holes and hole walls for partitioning the air holes, wherein at least adjacent parts of the air holes have communication channels penetrating through the hole walls, and the diameter d: pore diameter D = 1: (3-13).
The diameter D of the communicating channel and the pore diameter D of the air hole are in the ratio of 1: 3-13, the strength of the light porous sound-absorbing material is in a better range while the sound-absorbing effect is better, and the quality of the product is better, and in the scheme, when the ratio of D to D is in a range of 1:5-7, various performances of the light porous sound-absorbing ceramic material are further improved.
Preferably, the density of the light porous sound-absorbing ceramic material is 380-620kg/m3The water absorption is 100-180%.
Preferably, the open porosity of the lightweight porous sound-absorbing ceramic material is 10-35%. The open porosity is the proportion of the communicated pores in the ceramic material section to the total pores, and the open porosity is in the range, so that the sound absorption effect is better and the quality of the ceramic material can be controlled in the better range.
Preferably, the diameter D of the communication channel is 0.1-0.5mm, and the pore diameter D of the air hole is 0.7-1.5 mm.
Preferably, the mass percentage of the oxide is 0-K2O+Na2O≤1.5%。
Preferably, the preparation raw materials comprise a foaming agent capable of generating gas in the sintering process and a pore-forming agent capable of burning out in the sintering process, at least part of the pores are obtained by the gas generated by the foaming agent in the sintering process, and at least part of the communicating channels are obtained by vacancies formed by the burning-out pore-forming agent after sintering burning out.
The raw materials of the light porous sound-absorbing ceramic material comprise a pore-forming agent and a foaming agent, wherein the foaming agent enables uniform pores to be generated inside the powder, the pore walls of the uniform pores generated by the foaming agent are communicated after the pore-forming agent is oxidized and decomposed to form a dense interconnected pore state, namely, the pores in the prepared light porous sound-absorbing ceramic material are all interconnected pores, so that sound waves are lost at the dense interconnected pores in the conduction process, and the light porous sound-absorbing ceramic material has a good sound-absorbing effect. The pores in the light porous sound-absorbing ceramic material can be obtained by foaming a foaming agent, and can also be obtained by sintering the rest raw materials. Similarly, the communication channels between the hole walls are mostly formed by pore-forming agents, and can also be formed by the burst of air holes when foaming agents are foamed, or formed by the firing of other raw materials.
The intercommunication passageway (hole) that forms in this scheme is controllable, and can guarantee that ceramic material has certain intensity when having the intercommunicating pore, can guarantee ceramic product's premium rate, light porous sound-absorbing ceramic material has better syllable-dividing function in addition, porous structure still has the water absorption of certain degree, water can not spill over when unsaturated state, spill over behind the saturated condition, along with time lapse and under the action of gravity, water can flow out from light porous sound-absorbing ceramic material's bottom gradually, therefore light porous sound-absorbing ceramic material is 30-200% like the saturated water absorption of panel, possess excellent water absorption.
Besides the addition of the foaming agent and the pore-forming agent, the light porous sound-absorbing ceramic material can adopt a conventional ceramic material, or according to the mass percentage, the light porous sound-absorbing ceramic material can comprise the following raw materials: 5-26% of calcium raw material, 45-87% of silicon-aluminum raw material, 2-15% of sintering aid, 0.01-0.55% of silicon carbide and 3-15% of pore-forming agent, wherein K is more than or equal to 0 and less than or equal to 0 in mass percent of oxide2O+Na2O≤1.5%。
Preferably, the calcareous raw material comprises at least one of steel-making water slag, steel slag, phosphogypsum, desulfurized gypsum, glass slag, ceramic waste glaze, manganese slag or red mud and/or at least one of calcium carbonate minerals; according to the mass percentage, CaO in the calcareous raw material is more than or equal to 5 percent, and K2O+Na2O is less than 1.5 percent; the sintering aid is talc or magnesia. The silica-alumina material includes at least one of building slag, river sand, high temperature sand, waste refractory material, artificial quartz polishing slag, flyash or coal gangue and/or bauxite containing mineral, and has SiO in the silica-alumina material in certain weight proportion2≥50%，Al2O3≥9%，K2O+Na2O is less than 1.5 percent; the waste refractory materials comprise corundum powder, cordierite-mullite refractory waste, refractory fiber cotton or refractory fiber paper. The calcium raw material and the silicon-aluminum raw material in the scheme can use the solid wastes, and the sound-absorbing and sound-insulating material with high added value is prepared by utilizing solid waste resources, so that the scheme is more environment-friendly. The sintering aid in the raw materials can also comprise 0-5% of a lithic raw material, and the lithic raw material is spodumene or laponite. And a lithium raw material is also added, the lithium raw material is mainly used for providing alkali metal Li and reducing the sintering temperature, and the lithium raw material can be natural minerals with higher lithium content.
In the light porous sound-absorbing ceramic material in the scheme, basic components are calcium raw materials and silicon-aluminum raw materials, the raw materials are easy to obtain, a small amount of calcium raw materials (clay or solid waste) are adopted and have viscosity, the component fluctuation caused by precipitation can be prevented, the suspension property of slurry is ensured, and the firing temperature is higher. The calcareous raw material is natural mineral or waste with high calcium content, the silicon-aluminum raw material is natural mineral or waste with high silicon-aluminum content, and the possible formula of the light porous sound-absorbing ceramic material in the scheme is as follows: kaolinite, quartz, calcite, magnesite, talc, cordierite, mullite, mica, corundum, potash feldspar, albite, chlorite and the like. The light porous sound-absorbing ceramic material comprises the following mineral components: quartz, mullite, corundum (alpha-alumina), cordierite, anorthite, alpha-cristobalite, beta-cristobalite, pyroxene, wollastonite and a part of amorphous phase substances such as glass powder.
Preferably, the foaming agent contains silicon carbide, and the pore-forming agent contains a combustible carbon-based material.
Preferably, the particle size distribution D50 of the silicon carbide in the foaming agent is 5-9 microns, D97 is 11-17 microns, and the burnable carbon-based material is at least one of activated carbon, carbon powder, wood dust, coal dust or graphite powder (as will be understood by those skilled in the art, other known burnable organic powders/particles can be used, where burnable does not mean that there is no residue at all after combustion, but means that corresponding vacancies can be formed after combustion); the particle size of the pore-forming agent is 100-200 meshes.
Preferably, the foaming agent further comprises at least one of a carbonate mineral or a bauxite-containing mineral. The foaming agent is added with silicon carbide, and also comprises carbonate mineral and bauxite-containing mineral.
Preferably, the carbonate mineral is at least one of calcium carbonate, magnesium carbonate, calcite or dolomite and the bauxite-containing mineral is at least one of bauxite or corundum. Calcium carbonate mineral as medium temperature foaming agent begins to decompose and generate pores at the temperature of 900-1000 ℃.
Preferably, the lightweight porous sound-absorbing ceramic material has the following chemical composition in percentage by mass: SiO 2259-64%，Al2O39-14%，Fe2O30.2-2.5%，TiO20.1-0.3%，CaO5-20%，MgO0.8-5%，0≤K2O≤1%，0≤K2O+Na2O is less than or equal to 1.5 percent, and LOI12-15.5 percent. Besides, the chemical composition of the light porous sound-absorbing ceramic material can also contain 0.02-0.5% of Li2O。
Preferably, the lightweight porous sound-absorbing ceramic material comprises the following raw materials in percentage by mass: 0-5% of glass powder, 20-40% of river sand tailings, 5-20% of limestone and/or calcite, 27-47% of building residue soil, 2-10% of talcum, 0.10-0.55% of silicon carbide powder, 3-8% of carbon powder and 0-5% of spodumene.
Preferably, the lightweight porous sound-absorbing ceramic material comprises the following raw materials in percentage by mass: 5-10% of glass powder, 3-8% of corundum powder, 5-20% of cordierite-mullite refractory waste, 20-35% of river sand tailings, 10-15% of limestone and/or calcite, 20-30% of building residue soil, 5-9% of talcum, 0.10-0.55% of silicon carbide powder, 3-8% of carbon powder and 0-5% of spodumene.
Preferably, the liquid phase viscosity of the raw material for preparation is 1.5 to 4.5 pas at the maximum firing temperature.
The invention also provides a preparation process of the light porous sound-absorbing ceramic material, which comprises the following steps:
s1, uniformly mixing the preparation raw materials according to the mass percentage, and performing ball milling to obtain slurry;
s2, after spray drying, aging and homogenizing the slurry to obtain powder;
and S3, distributing and sintering the powder to obtain the light porous sound-absorbing ceramic material.
The raw materials are mixed and ball-milled to prepare slurry, the slurry is aged and homogenized after spray drying to obtain powder, then the powder enters a material distribution firing stage, the material distribution firing process can directly follow the material distribution mode of a closed-pore foamed ceramic plate such as a cordierite-mullite kiln car, and then the material enters a roller kiln, a tunnel kiln or an intermittent kiln for firing to obtain the light porous sound-absorbing ceramic material. The light porous sound-absorbing ceramic material in the scheme can be formed after being sintered in the oxidation atmosphere of the traditional ceramic production without being pressed and formed, and the light porous sound-absorbing ceramic material is obtained by the raw materials and the preparation processThe sound-absorbing ceramic material has the following performance parameters: the sound absorption coefficient is more than or equal to 0.65, and the density is 380-3The compression strength is between 1.5 and 6.5Mpa, the bending strength is between 1.5 and 3.5Mpa, the softening coefficient is more than or equal to 0.90, the bending resistance bears 6 times of the dead weight of the plate, the drying shrinkage is less than 0.1, and the sound absorption and noise reduction effects are higher while the strength is relatively higher. The preparation process of the light porous sound-absorbing ceramic material is similar to the preparation method of the existing closed-pore foamed ceramic, and has the advantages of simple process, convenient and quick operation and no need of large-scale modification of the existing production equipment.
The calcareous raw material, the silicon-aluminum raw material, the lithium raw material, the foaming agent and the pore-forming agent can be added simultaneously in one batch during preparation. The raw materials can also be added in batches, specifically, the pore-forming agent is not added in the step S1, the pore-forming agent is added after ball milling and spray drying, the pore-forming agent is uniformly mixed with the rest raw materials, the mixture enters a storage bin for ageing and homogenizing, and the kiln firing can be carried out after the ageing and homogenizing for more than 24 hours.
Preferably, the sintering period is 10-30h, and the maximum sintering temperature is less than or equal to 1230 ℃.
Preferably, an embodiment of the firing schedule is as follows: heating from room temperature to 400 ℃, wherein the heating rate is 5-7 ℃/min; heating from 400 ℃ to 900 ℃, wherein the heating rate is 1-4 ℃/min; heating from 900 to 1160 ℃ at a heating rate of 3-5 ℃/min; preserving the heat at 1160 ℃ for 35-50min and cooling to room temperature.
By controlling the sintering system, the light porous sound-absorbing ceramic material has better strength and sound insulation effect, and the cracking and board breaking phenomenon caused by unreasonable cooling system of the light porous sound-absorbing ceramic material can be prevented by adjusting the cooling system. After the light porous sound-absorbing ceramic material in the scheme is subjected to the high-temperature firing process, the light porous sound-absorbing ceramic material has the following characteristics: the pore size of the surface pore is between 0.5-3mm when observed externally, a large number of micropores exist on the pore wall, and the pore size of the micropores is within 0.5 mm.
In another embodiment of the firing system, the temperature is raised from room temperature to 400 ℃, the heating rate is 5-7 ℃/min, and the temperature is kept at 400 ℃ for 60 min; heating from 400 ℃ to 950 ℃, wherein the heating rate is 6-9 ℃/min, and keeping the temperature at 950 ℃ for 40-60 min; heating from 950 to 1150 deg.C at a heating rate of 2-3 deg.C/min, maintaining at 1150 deg.C for 40-55min, and cooling to room temperature.
The two firing systems are suitable for the firing process of a laboratory or an intermittent shuttle kiln, and can ensure that the light porous sound-absorbing ceramic material has better product quality.
In another embodiment of the firing system, the temperature is raised from room temperature to 400 ℃ within 20-60 min; raising the temperature from 400 ℃ to 1120 ℃ within 100-300 min; heating to 1190 deg.C from 1120 deg.C within 30-50 min; heating from 1190 deg.C to 1229 deg.C within 5-15 min; keeping the temperature at 1229 deg.C for 35-55 min; cooling to 1165 deg.C from 1229 deg.C within 5-30 min; cooling from 1165 deg.C to 850 deg.C within 10-50 min; cooling from 850 ℃ to 300 ℃ within 200-360 min; cooling from 300 ℃ to room temperature within 240min at 150-.
The firing system is suitable for the firing process of the continuous roller kiln, and the light porous sound-absorbing ceramic material can be ensured to have better product quality under the firing system.
Preferably, the fineness of the slurry is 0.4-0.6% of the screen residue of 250 meshes, the specific gravity is 1.63-1.69, and the flow rate is 40-70 seconds;
the water content of the powder is 5.5-6.5%, the grain composition is more than 20 meshes and less than or equal to 1.0%, 20-40 meshes and 40-65%, 20-60 meshes and 80-97%, the grain composition is less than 100 meshes and less than or equal to 0.5%, and the volume weight is more than or equal to 0.79%.
The particle composition of the powder in the scheme is different from that of the closed-pore foamed ceramic, and the powder can have enough pores after being mixed through the particle composition, so that natural pores among powder particles can be generated properly, and a passage is provided for discharging the pore-forming agent and the foaming agent.
In addition, the invention also discloses application of the lightweight porous sound-absorbing ceramic material in walls or building structures.
Compared with the prior art, the light porous sound-absorbing ceramic material and the preparation process thereof have the following beneficial effects: through the addition of the pore-forming agent and the foaming agent, the foaming agent starts to decompose at the temperature of about 900-1000 ℃, so that pores are generated in the powder, the pores generated by the foaming agent are communicated to form a communicating channel after the pore-forming agent is subjected to oxidative decomposition, and the content of potassium and sodium in the raw materials is controlled, so that the pores in the prepared light porous sound-absorbing ceramic material are all communicated pores. The preparation process of the sound-absorbing ceramic material is free from press forming, can be formed by adopting the traditional ceramic sintering step, is simple in process and convenient and quick to operate, does not need to change the existing production equipment on a large scale, and the light porous sound-absorbing ceramic material obtained by adjusting the raw materials and the preparation process has relatively high strength, high sound-absorbing and noise-reducing effects and good water-absorbing effect.
Drawings
In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present application, and for those skilled in the art, other related drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a microscopic image of a closed cell foamed ceramic of the prior art of the present application after being magnified 20 times;
FIG. 2 is a microscopic image of the closed cell foamed ceramic of the prior art of the present application after being magnified 50 times;
FIG. 3 is a microscopic image, at 20 times magnification, of a lightweight, porous, sound-absorbing ceramic material provided in example 1 of the present application;
FIG. 4 is a microscopic image, at 50 times magnification, of a lightweight, porous, sound-absorbing ceramic material provided in example 1 of the present application;
FIG. 5 is a schematic partial cross-sectional view of a lightweight porous sound-absorbing ceramic material provided herein;
fig. 6 is a microscopic image, at 20 x magnification, of the ceramic material provided in comparative example 8 provided herein.
In the drawings: 1-air hole, 11-hole wall and 2-communicating channel.
The implementation, functional features and advantages of the objectives of the present application will be further explained with reference to the accompanying drawings.
Detailed Description
The technical solutions in the embodiments of the present invention will be described clearly and completely below, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In addition, technical solutions between various embodiments may be combined with each other, but must be realized by a person skilled in the art, and when the technical solutions are contradictory or cannot be realized, such a combination should not be considered to exist, and is not within the protection scope of the present invention.
A lightweight porous sound-absorbing ceramic material, comprising air holes 1 and hole walls 11 for partitioning the air holes 1, wherein at least adjacent parts of the air holes 1 have communication channels 2 penetrating through the hole walls 11, and the diameter d of each communication channel 2 is: pore diameter D =1 of the pore 1: (3-13); the density of the light porous sound-absorbing ceramic material is 380-620kg/m3The water absorption is 100-180 percent; the aperture ratio of the light porous sound-absorbing ceramic material is 10-35%; the diameter D of the communication channel 2 is 0.1-0.5mm, and the aperture D of the air hole 1 is 0.7-1.5 mm.
Calculated by mass percent of oxides, wherein K is more than or equal to 02O+Na2O is less than or equal to 1.5 percent. The preparation raw materials comprise a foaming agent capable of generating gas in the sintering process and a pore-forming agent capable of being burnt out in the sintering process, at least part of the pores 1 are obtained by the gas generated by the foaming agent in the sintering process, and at least part of the communicating channels 2 are obtained by vacancies formed by the burnt-out pore-forming agent after sintering and burning out. The foaming agent contains silicon carbide, the pore-forming agent contains a combustible carbon-based material, and the foaming agent also comprises at least one of carbonate mineral or bauxite-containing mineral. The granularity distribution D50 of the silicon carbide in the foaming agent is 5-9 microns, D97 is 11-17 microns, and the burnout carbon-based material is at least one of activated carbon, carbon powder, wood dust, coal dust, organic powder or graphite powder; the grain size of the pore-forming agent is 100-200 meshes, the carbonate mineral is at least one of limestone, calcite or dolomite, and the bauxite-containing mineral is at least one of bauxite or corundumOne kind of the medicine.
The light porous sound-absorbing ceramic material has good sound-absorbing and sound-insulating functions, can be applied to places with high requirements on sound-insulating effects, such as rail transit sound barriers, theater theaters and the like, can replace traditional sound-absorbing materials, such as rock wool, cement fiber boards and the like, and has good advantages in the aspects of durability, strength and the like due to the fact that the material is an inorganic sintered material. As shown in fig. 3 to 5, it can be seen from the microstructure of the lightweight porous sound-absorbing ceramic material that a large number of micro communication channels exist on the pore walls of the pores of the lightweight porous sound-absorbing ceramic material, which provides good flow channels for the flow of the medium and has good sound-absorbing effect.
The light porous sound-absorbing ceramic material comprises the following raw materials in percentage by mass: 5-26% of calcium raw material, 45-87% of silicon-aluminum raw material, 2-15% of sintering aid, 0.01-0.55% of silicon carbide and 3-15% of pore-forming agent; the light porous sound-absorbing ceramic material comprises the following chemical components: SiO 2259-64%，Al2O39-14%，Fe2O30.2-2.5%，TiO20.1-0.3%，CaO5-20%，MgO0.8-5%，0≤K2O≤1%，0≤K2O+Na2O is less than or equal to 1.5 percent, and LOI12-15.5 percent. The liquid phase viscosity of the raw material is 1.5-4.5 pas at the highest firing temperature.
The calcareous raw materials comprise at least one of steelmaking water slag, steel slag, phosphogypsum, desulfurized gypsum, glass slag, ceramic waste glaze, manganese slag or red mud and/or at least one of calcium carbonate minerals; CaO in the calcareous raw material is more than or equal to 5 percent, K2O+Na2O is less than 1.5 percent; the sintering aid is talc or magnesia; the silica-alumina raw material comprises at least one of building residue soil, river sand processing tailings, high-temperature sand, waste refractory materials, artificial quartz polishing slag, fly ash or coal gangue and/or at least one of bauxite-containing minerals, wherein SiO in the silica-alumina raw material2≥50%，Al2O3≥9%，K2O+Na2O is less than 1.5 percent; the waste refractory materials comprise corundum powder, cordierite-mullite refractory waste, refractory fiber cotton or refractory fiber paper; the sintering aid can also comprise 0-5% of a lithiated raw material, and the lithiated raw material is spodumene or spodumene.
In one embodiment: the light porous sound-absorbing ceramic material comprises the following raw materials in percentage by mass: 0-5% of glass powder, 20-40% of river sand tailings, 5-20% of limestone and/or calcite, 27-47% of building residue soil, 2-10% of talcum, 0.10-0.55% of silicon carbide powder, 3-10% of carbon powder and 0-5% of spodumene.
Or, in another embodiment: the light porous sound-absorbing ceramic material comprises the following raw materials in percentage by mass: 5-10% of glass powder, 3-8% of corundum powder, 5-20% of cordierite-mullite refractory waste, 20-35% of river sand tailings, 10-15% of limestone and/or calcite, 20-30% of building residue soil, 5-9% of talcum, 0.10-0.55% of silicon carbide powder, 3-8% of carbon powder and 0-5% of spodumene.
The preparation process of the light porous sound-absorbing ceramic material comprises the following steps: s1, uniformly mixing the preparation raw materials according to the mass percentage, and performing ball milling to obtain slurry; s2, after spray drying, aging and homogenizing the slurry to obtain powder; s3, distributing and sintering the powder to obtain the lightweight porous sound-absorbing ceramic material, wherein the sintering period is 10-30h, the maximum sintering temperature is less than or equal to 1230 ℃, the fineness of the slurry is 0.4-1% of the screen residue of 250 meshes, the specific gravity is 1.63-1.69, and the flow rate is 40-70 seconds; the water content of the powder is 5.5-6.5%, the grain composition is more than 20 meshes and less than or equal to 1.0%, 20-40 meshes and 40-65%, 20-60 meshes and 80-97%, the grain composition is less than 100 meshes and less than or equal to 0.5%, and the volume weight is more than or equal to 0.79%.
In one embodiment: the firing system is as follows: heating from room temperature to 400 ℃, wherein the heating rate is 5-7 ℃/min; heating from 400 ℃ to 900 ℃, wherein the heating rate is 1-4 ℃/min; heating from 900 to 1160 ℃, heating at the rate of 3-5 ℃/min, keeping the temperature at 1160 ℃ for 35-50min, and cooling to room temperature.
Or, in another embodiment: heating from room temperature to 400 ℃ and keeping the temperature for 60min, wherein the heating rate is 5-7 ℃/min; heating from 400 deg.C to 950 deg.C, and maintaining the temperature for 40-60min at a heating rate of 6-9 deg.C/min; heating from 950 to 1150 deg.C at a heating rate of 2-3 deg.C/min, maintaining at 1150 deg.C for 40-55min, and cooling to room temperature.
Or, in another embodiment: heating to 400 deg.C from room temperature within 20-60 min; raising the temperature from 400 ℃ to 1120 ℃ within 100-300 min; heating to 1190 deg.C from 1120 deg.C within 30-50 min; heating from 1190 deg.C to 1229 deg.C within 5-15 min; keeping the temperature at 1229 deg.C for 35-55 min; cooling to 1165 deg.C from 1229 deg.C within 5-30 min; cooling from 1165 deg.C to 850 deg.C within 10-50 min; cooling from 850 ℃ to 300 ℃ within 200-360 min; cooling from 300 ℃ to room temperature within 240min at 150-.
By adopting the different firing systems, different properties of the light porous sound-absorbing ceramic material can be improved to different degrees.
In addition, the invention also discloses application of the lightweight porous sound-absorbing ceramic material in walls or building structures.
The technical solutions of the present invention are further described in detail with reference to the following specific examples, which should be understood as merely illustrative and not limitative.
Example 1
A preparation process of a lightweight porous sound-absorbing ceramic material comprises the following steps:
s1, uniformly mixing the raw materials according to the mass percentage in the following table, and performing ball milling to obtain slurry;
s2, after spray drying, aging and homogenizing the slurry to obtain powder;
s3, distributing and sintering the powder to obtain the lightweight porous sound-absorbing ceramic material, wherein the sintering period is 15h, and the sintering temperature is 1215 ℃.
The components and the mixture ratio of the raw materials are shown in the following table (the preparation steps and parameters of the following 4 groups are all consistent), wherein the particle size of the pore-forming agent is 200 meshes, the particle size distribution D50 of silicon carbide in the foaming agent is 6.9 microns, and the particle size distribution D97 is 15.1 microns:
during actual production, the foaming agent can be limestone or a mixture of calcite and silicon carbide, the pore-forming agent is activated carbon or charcoal powder, the limestone or the calcite mainly provides calcium carbonate for use as a medium-temperature foaming agent, the calcium carbonate starts to decompose at the temperature of about 900-; the pore-forming agent starts to decompose and oxidize at the temperature of 300-500 ℃, so that a large number of cavity pore individuals exist in the powder, and a liquid phase generated by the decomposition and oxidation of the limestone opens and communicates the cavity pore individuals with air holes generated by the decomposition of the limestone, so that a cavity communicating structure is generated in the powder, and after a large number of through hole structures are formed, air or fluid media can convolute and move in the cavity, so that the sound absorption effect is good.
The light porous sound-absorbing ceramic material of 4 groups in example 1 comprises the following chemical components in percentage by mass:
the performance test of the lightweight porous sound-absorbing ceramic material prepared by the groups 1 to 4 in the example 1 is carried out, and the test results are shown in the following table:
note: since the sizes of the communicating pore channels are different and are all in the range of 0.1-0.5mm, the average diameter of the communicating pore channels in the table refers to the average diameter of all the communicating pore channels on the section of the light porous sound-absorbing ceramic material, and the average pore diameter of the pores refers to the average diameter of all the pores on the section of the light porous sound-absorbing ceramic material.
The density of the light porous sound-absorbing ceramic material is 380-620kg/m3Within the range of 1.5-6.5Mpa in compressive strength and 1.5-3.5Mpa in flexural strength, and can replace the traditional sound-absorbing materials such as rock wool, cement fiber boards and the like. The test data of the four groups of embodiments in the table above show that the performance of the light porous sound-absorbing material in the present scheme can be improved by the cooperation of the foaming agent and the pore-forming agent, wherein the sound absorption coefficient of the material is greater than 0.5, the compressive strength is above 3Mpa, and the flexural strength is above 2Mpa, that is, the light porous sound-absorbing materialThe material has high strength while having good sound absorption effect, and the water absorption effect is also excellent.
Example 2
A preparation process of a lightweight porous sound-absorbing ceramic material comprises the following steps:
s1, uniformly mixing the preparation raw materials according to the mass percentage, and performing ball milling to obtain slurry; the preparation raw materials in the embodiment are conventional raw materials, specifically 3.76% of glass powder, 40% of high-temperature super white sand, 15% of calcite, 23% of quartz powder, 8% of calcined talcum powder, 9% of carbon powder, 1% of brown corundum powder and 0.24% of green silicon (silicon carbide);
s2, after spray drying, aging and homogenizing the slurry to obtain powder;
s3, distributing and sintering the powder to obtain the lightweight porous sound-absorbing ceramic material, wherein the sintering period is 15h, and the sintering temperature is 1215 ℃.
Wherein the particle size of the pore-forming agent is 200 meshes, the particle size distribution D50 of the silicon carbide in the foaming agent is 6.9 microns, and the particle size distribution D97 is 15.1 microns.
The prepared light porous sound-absorbing ceramic material comprises the following chemical components:
the prepared light porous sound-absorbing ceramic material is in the chemical composition range limited by the scheme, and K is2O+Na2O content of 1.07%, sound absorption coefficient of 0.65, density of 421kg/m3The compression strength is 5.88Mpa, the breaking strength is 3.17Mpa, the water absorption is 129%, the softening coefficient is 0.95, the drying shrinkage is 0.2, the aperture ratio is 24%, the average diameter of the communication channel is 0.2mm, the average aperture of the air holes is 1.03mm, d: d = 1: 5.15.
example 3
A preparation process of a lightweight porous sound-absorbing ceramic material comprises the following steps:
s1, uniformly mixing the preparation raw materials according to the mass percentage, and performing ball milling to obtain slurry; the preparation raw materials in the embodiment are conventional raw materials, specifically 38% of high-temperature super white sand, 22% of calcite, 22% of quartz powder, 8.7% of calcined talcum powder, 8% of carbon powder, 1% of brown corundum powder and 0.3% of green silicon (silicon carbide);
s2, after spray drying, aging and homogenizing the slurry to obtain powder;
s3, distributing and sintering the powder to obtain the lightweight porous sound-absorbing ceramic material, wherein the sintering period is 15h, and the sintering temperature is 1215 ℃.
Wherein the particle size of the pore-forming agent is 200 meshes, the particle size distribution D50 of the silicon carbide in the foaming agent is 6.9 microns, and the particle size distribution D97 is 15.1 microns.
The prepared light porous sound-absorbing ceramic material comprises the following chemical components:
the prepared light porous sound-absorbing ceramic material is in the chemical composition range limited by the scheme, and K is2O+Na2O content of 1.18%, sound absorption coefficient of 0.65, and density of 389kg/m3The compression strength is 5.63Mpa, the breaking strength is 3.07Mpa, the water absorption is 175%, the softening coefficient is 0.95, the drying shrinkage is 0.2, the aperture ratio is 30%, the average diameter of the communication channel is 0.2mm, the average aperture of the air holes is 1.25mm, d: d = 1: 6.25.
example 4
A preparation process of a lightweight porous sound-absorbing ceramic material comprises the following steps:
s1, uniformly mixing the preparation raw materials according to the mass percentage, and performing ball milling to obtain slurry; the preparation raw materials in the embodiment are conventional raw materials, specifically 5.81% of glass powder, 2% of limestone, 34% of high-temperature super white sand, 15% of calcite, 24% of quartz powder, 8% of calcined talcum powder, 8% of carbon powder, 3% of brown corundum powder and 0.19% of green silicon (silicon carbide);
s2, after spray drying, aging and homogenizing the slurry to obtain powder;
s3, distributing and sintering the powder to obtain the lightweight porous sound-absorbing ceramic material, wherein the sintering period is 15h, and the sintering temperature is 1215 ℃.
Wherein the particle size of the pore-forming agent is 200 meshes, the particle size distribution D50 of the silicon carbide in the foaming agent is 6.9 microns, and the particle size distribution D97 is 15.1 microns.
The prepared light porous sound-absorbing ceramic material comprises the following chemical components:
the prepared light porous sound-absorbing ceramic material is in the chemical composition range limited by the scheme, and K is2O+Na2O content of 1.06%, sound absorption coefficient of 0.55, density of 587kg/m3The compression strength is 6.63Mpa, the breaking strength is 2.67Mpa, the water absorption is 105%, the softening coefficient is 0.95, the drying shrinkage is 0.2, the aperture ratio is 21%, the average diameter of the communication channel is 0.1mm, the average aperture of the air holes is 1.28mm, d: d = 1: 12.8.
example 5
A preparation process of a lightweight porous sound-absorbing ceramic material comprises the following steps:
s1, uniformly mixing the preparation raw materials according to the mass percentage, and performing ball milling to obtain slurry; the preparation raw materials in the embodiment are conventional raw materials, specifically 5% of glass powder, 37.75% of high-temperature super-white sand, 17% of calcite, 25% of quartz powder, 6% of calcined talcum powder, 8% of carbon powder, 1% of brown corundum powder and 0.25% of green silicon (silicon carbide);
s2, after spray drying, aging and homogenizing the slurry to obtain powder;
s3, distributing and sintering the powder to obtain the lightweight porous sound-absorbing ceramic material, wherein the sintering period is 15h, and the sintering temperature is 1215 ℃.
Wherein the particle size of the pore-forming agent is 200 meshes, the particle size distribution D50 of the silicon carbide in the foaming agent is 6.9 microns, and the particle size distribution D97 is 15.1 microns.
The prepared light porous sound-absorbing ceramic material comprises the following chemical components:
the prepared light porous sound-absorbing ceramic material is in the chemical composition range limited by the scheme, and K is2O+Na2O content of 1.15%, absorptionThe acoustic coefficient is 0.65, and the density is 411kg/m3The compression strength is 5.63Mpa, the breaking strength is 4.17Mpa, the water absorption is 130%, the softening coefficient is 0.95, the drying shrinkage is 0.2, the aperture ratio is 24%, the average diameter of the communication channel is 0.2mm, the average aperture of the air holes is 1.1mm, d: d = 1: 5.5.
from the above test results, the preparation parameters of the light porous sound-absorbing material are adjusted so that the ratio of D to D is in the range of 1 (5-7), and the properties of the light porous sound-absorbing material are further improved, wherein the sound absorption coefficient is greater than or equal to 0.6, the compressive strength is greater than 5MPa, the flexural strength is greater than 3MPa, the water absorption is 100-180%, and the density is 380-620kg/m3Within the range.
Comparative example 1
The preparation steps and parameters in this comparative example are identical to those in example 1, except that: the preparation raw materials are different, and the raw materials of the comparative example 1 comprise the following components in percentage by weight: according to the mass percentage, the artificial quartz stone polishing slag is 41.88 percent, the building residue soil is 8 percent, the granite stone powder is 13 percent, the pressed mud is 17.9 percent, the foamed ceramic fine powder is 5 percent, the high-alumina sand is 5 percent, the glass powder is 6 percent, the carbon powder is 3 percent, and the silicon carbide powder is 0.22 percent.
Comparative example 2
The preparation steps and parameters in this comparative example are identical to those of group 1 in example 1, except that: no pore-forming agent-active carbon is added, and the rest raw materials are in proportion: 5% of glass slag (powder), 42% of river sand processing tailings (sand washing tailings), 38% of building slag soil, 8% of limestone, 2% of calcite and 5% of silicon carbide powder.
Comparative example 3
The preparation steps and parameters in this comparative example are identical to those of group 1 in example 1, except that: the foaming agent-silicon carbide powder is not added, and the rest raw materials are in proportion: 5% of glass slag (powder), 42% of river sand processing tailings (sand washing tailings), 8% of limestone, 2% of calcite, 36.8% of building residue soil, 6% of activated carbon and 0.2% of charcoal powder.
Comparative example 3 the degree of sintering was insufficient and part of the data could not be determined.
Comparative example 4
The preparation steps and parameters in this comparative example are identical to those of group 1 in example 1, except that: the foaming agent is silicon carbide powder, the addition amount of the silicon carbide powder is 16.2%, limestone is not added, and the component proportion is adjusted as follows: 8% of glass powder, 41% of river sand processing tailings, 38% of building residue soil, 1% of silicon carbide powder, 5% of talc and 7% of activated carbon.
Comparative example 4 does not contain limestone, the sintering temperature of the powder is too high, the sintering degree of the powder is not enough, the powder does not shrink to generate enough liquid phase, and the foaming agent cannot be wrapped in the liquid phase for foaming after pyrolysis, so that the foaming failure is caused.
Comparative example 5
The proportions, preparation steps and parameters of the components in this comparative example are identical to those in group 1 of example 1, except that: the particle size of the pore former is 60 meshes.
Compared with the prior art, the pore-forming agent in the comparative example 5 has thick particles, so that the pore after pore forming is large, the cavity structure is enlarged, the sound wave retardation effect is reduced, and the sound absorption effect is reduced after the sound wave penetrates through the plate.
Comparative example 6
The proportions, preparation steps and parameters of the components in this comparative example are identical to those in group 1 of example 1, except that: the particle size distribution of the silicon carbide in the blowing agent was 9.5 microns for D50 and 18.2 microns for D97.
In comparative example 6, the particles of silicon carbide (foaming agent) were coarser, and the corresponding sound absorption effect was reduced.
Comparative example 7
The proportions, preparation steps and parameters of the components in this comparative example are identical to those in group 1 of example 1, except that: and pressing and molding the aged and homogenized powder under the molding pressure of 20Mpa, and then firing.
The sheet material formed by pressing in comparative example 7 was seriously deformed after firing, and the fracture large and small holes were seriously uneven and no communicating pore was formed, and the analysis reason was that the amount of the foaming agent was too large, the carbon substance removal channel after pressing was not enough, and the exterior of the sheet material was prematurely closed, and the product after firing expanded, foamed and deformed to be turtleback-shaped, and the cross section was opened without communicating pores, and the holes were uneven, large holes were more than 3mm, and small holes were about 1 mm.
Comparative example 8
The preparation steps and parameters in this comparative example are identical to those of group 1 in example 1, except that: the addition amount of silicon carbide in the foaming agent is increased to 0.35%, no pore-forming agent is added, and correspondingly, the river sand processing tailing is adjusted to 40.75% from 38.9%, and the building residue soil is adjusted to 34.9% from 31.9%.
In comparative example 8, only a large amount of foaming agent was used to form the communicating pores, and the pores formed when the pores were broken were large, resulting in too large voids and too low strength inside the foamed ceramics.
According to the test results, the content of potassium and sodium in the raw materials is strictly controlled when the lightweight porous sound-absorbing ceramic material is prepared in the scheme, after the content of potassium and sodium in the prepared raw materials is increased in the comparative example 1, a large amount of liquid phase is correspondingly generated during firing, a large amount of air holes formed by the pore-forming agent are closed, so that the material is finally the closed air hole foamed ceramic which is impermeable to water and has no communicated pore channels, and the air holes in the material are the air holes generated by the decomposition of silicon carbide, so that the material prepared in the comparative example 1 has high strength, but no communicated pores are generated, and the sound-absorbing effect and the water-absorbing effect are poor. In contrast, comparative example 2, the pore-forming agent was not added, and the silicon carbide powder increased in amount, and a part of the communicating pores were generated due to excessive foaming of the foaming agent, so that the density and strength of the material were reduced, and the sound-absorbing effect was not good. In comparative example 3, the pore-forming agent alone was added, and interconnected pores could not be formed.
Example 6
The preparation steps and parameters in the present example are the same as those in example 1, and the prepared sound absorbing material is within the chemical composition range defined in the present scheme, and the difference is only that: the preparation raw materials are different, the firing temperature is reduced by 5 ℃ (1210 ℃), and the raw material components and the mixture ratio of the example 6 are as follows: according to the mass percentage, the glass powder is 5 percent, the river sand tailings are 40 percent, the limestone is 13 percent, the building slag soil is 28 percent, the talcum is 6.7 percent, the silicon carbide powder is 0.3 percent, the carbon powder is 6 percent and the spodumene is 1 percent.
The prepared light porous sound-absorbing ceramic material comprises the following chemical components:
example 7
The preparation steps and parameters in this example are the same as those in example 1, and the prepared sound-absorbing material falls within the chemical composition range defined in this scheme, except that: the preparation raw materials are different, the firing temperature is reduced by 5 ℃ (1210 ℃), and the raw material components and the mixture ratio of the example 7 are as follows: according to the mass percentage, the glass powder is 5 percent, the corundum powder is 3 percent, the cordierite-mullite refractory waste is 10 percent, the river sand tailing is 20 percent, the limestone is 15 percent, the building residue soil is 27.7 percent, the talcum powder is 9 percent, the silicon carbide powder is 0.3 percent, the carbon powder is 8 percent and the spodumene is 2 percent.
The chemical composition is as follows:
the lightweight, porous, and sound-absorbing ceramic materials prepared in examples 6 to 7 were subjected to performance tests, and the test results are shown in the following table:
according to the test results, the firing temperature can be reduced after spodumene or spodumene is introduced, the sound absorption performance and other auxiliary performances of the plate are not obviously changed, in addition, the firing temperature of the powder is increased after corundum and refractory materials are introduced, the performance can be ensured not to be changed by reducing the firing temperature through introducing Li, and the sound absorption effect and the strength of the porous sound absorption ceramic material are good.
Example 8
The conditions in this example were the same as those in example 6, except that the firing process was different, and the firing profile in this example was: heating from room temperature to 400 ℃, wherein the heating rate is 6.25 ℃/min; heating from 400 ℃ to 900 ℃, wherein the heating rate is 2.78 ℃/min; heating from 900 to 1160 ℃, wherein the heating rate is 3.25 ℃/min, preserving the heat at 1160 ℃ for 40min, and then cooling to room temperature.
Example 9
The conditions in this example were the same as those in example 6, except that the firing process was different, and the firing profile in this example was: heating from room temperature to 400 ℃ and keeping the temperature for 60min, wherein the heating rate is 6.25 ℃/min; heating from 400 ℃ to 950 ℃ and keeping the temperature for 50min, wherein the heating rate is 7.85 ℃/min; heating from 950 deg.C to 1150 deg.C at a heating rate of 2.86 deg.C/min, maintaining at 1150 deg.C for 50min, and cooling to room temperature.
The two firing systems are suitable for the firing process of a laboratory or an intermittent shuttle kiln, and can ensure that the light porous sound-absorbing ceramic material has better product quality.
Example 10
The conditions in this example were the same as those in example 6, except that the firing process was different, and the firing profile in this example was: the firing period is 12h, and the temperature is increased from room temperature to 400 ℃ within 21 min; heating from 400 deg.C to 1120 deg.C within 177 min; heating to 1190 deg.C from 1120 deg.C within 32 min; heating from 1190 ℃ to 1229 ℃ within 5 min; keeping the temperature at 1229 deg.C for 45 min; cooling to 1165 deg.C from 1229 deg.C within 8 min; cooling from 1165 deg.C to 850 deg.C within 30 min; cooling to 300 deg.C from 850 deg.C within 223 min; cooled from 300 ℃ to room temperature within 196 min.
Example 11
The conditions in this example were the same as those in example 6, except that the firing process was different, and the firing profile in this example was: the firing period is 15h, and the temperature is increased from room temperature to 400 ℃ within 26 min; heating from 400 ℃ to 1120 ℃ within 245 min; heating to 1190 deg.C from 1120 deg.C within 44 min; heating from 1190 ℃ to 1229 ℃ within 11 min; keeping the temperature at 1229 deg.C for 55 min; cooling to 1165 deg.C from 1229 deg.C within 14 min; cooling from 1165 deg.C to 850 deg.C within 22 min; cooling to 300 ℃ from 850 ℃ within 297 min; cooling from 300 deg.C to room temperature within 160 min.
The two firing systems are suitable for the firing process of the continuous roller kiln, and the light porous sound-absorbing ceramic material can be ensured to have better product quality under the firing system.
The foamed ceramics obtained in examples 8 to 11 were subjected to the property test, and the test results are shown in the following table:
according to the test results, the performance of the product is different under different sintering curves, and the main reasons are the length of high-temperature heat preservation time and reasonable control of high-temperature sintering temperature, the high-temperature viscosity of the powder is reduced due to overlong and overhigh temperature, the communication holes are sealed, the density is larger due to overlong and overlong, and the cavity structure is unreasonable.
Comparative example 9
The preparation steps and parameters in this comparative example are identical to those of example 10, except that: the firing period is shortened, and the heat preservation time at 1229 ℃ is shortened to 15 min.
Comparative example 10
The preparation steps and parameters in this comparative example are identical to those of example 10, except that: the maximum firing temperature (1229 ℃) was adjusted to 1330 ℃ and the other systems were not changed.
Comparative example 11
The preparation steps and parameters in this comparative example are identical to those of example 10, except that: the cooling process is adjusted to be that the temperature is reduced from 850 ℃ to 300 ℃ within 120 min; cooling from 300 ℃ to room temperature within 160min, the shrinkage stress generated too rapidly in the plate crystal transformation (573 ℃) in this comparative example causes stress cracking of the product.
The foamed ceramics obtained in comparative examples 9 to 11 were subjected to the property test, and the test results are shown in the following table:
as can be seen from the comparison of the above test results with the test results of example 11, the maximum firing temperature and the heat-insulating duration are both strictly controlled, and an excessively high temperature or an excessively short heat-insulating duration will result in the loss of a part of the interconnected pore structure of the panel, resulting in a serious decrease in the sound absorption coefficient and even a loss of the sound absorption performance. In addition, the cooling temperature needs to be strictly controlled so as to ensure that the plate does not have stress cracking due to unreasonable cooling system and reduce the product quality.
The above description is only a preferred embodiment of the present invention, and not intended to limit the scope of the present invention, and all modifications and equivalents of the present invention, which are made by the present specification and directly/indirectly applied to other related technical fields within the spirit of the present invention are included in the scope of the present invention.
Claims (22)
1. A lightweight porous sound-absorbing ceramic material, characterized in that it comprises air holes (1) and hole walls (11) for spacing apart the air holes (1), at least adjacent parts of the air holes (1) having communication channels (2) between them, the diameter d of the communication channels (2): the pore diameter D =1 of the pores (1): (3-13).
2. The lightweight porous sound-absorbing ceramic material as claimed in claim 1, wherein the lightweight porous sound-absorbing ceramic material has a density of 380-620kg/m3The water absorption is 100-180%.
3. The lightweight, porous, acoustical ceramic material of claim 1, wherein the lightweight, porous, acoustical ceramic material has an open cell content of 10-35%.
4. The lightweight porous sound-absorbing ceramic material according to claim 1, wherein the diameter D of the communication channel (2) is 0.1 to 0.5mm, and the pore diameter D of the pores (1) is 0.7 to 1.5 mm.
5. The lightweight, porous, acoustical ceramic material of claim 1, in which the ceramic material is present in the amount of an oxideThe ratio is counted as K is more than or equal to 02O+Na2O≤1.5%。
6. The lightweight, porous, sound-absorbing ceramic material according to claim 1, wherein the raw materials for the preparation thereof comprise a blowing agent capable of generating gas during sintering and a pore-forming agent capable of burning out during sintering, at least a portion of the pores (1) being obtained from the gas generated by the blowing agent during sintering, and at least a portion of the communicating channels (2) being obtained from vacancies formed in the pore-forming agent after burning out during sintering.
7. The lightweight, porous, sound-absorbing ceramic material of claim 6, wherein the blowing agent comprises silicon carbide and the pore former comprises a burnable carbon-based material.
8. The lightweight porous sound-absorbing ceramic material according to claim 1, which comprises the following raw materials in percentage by mass: 5-26% of calcium raw material, 45-87% of silicon-aluminum raw material, 2-15% of sintering aid, 0.01-0.55% of silicon carbide and 3-15% of pore-forming agent.
9. The lightweight, porous, sound-absorbing ceramic material of claim 7, wherein the foaming agent further comprises at least one of a carbonate mineral or a bauxite-containing mineral.
10. The lightweight, porous, sound-absorbing ceramic material of claim 9, wherein the carbonate mineral is at least one of calcium carbonate, magnesium carbonate, calcite, or dolomite; the bauxite-containing mineral is at least one of bauxite or corundum.
11. The lightweight, porous, sound-absorbing ceramic material of claim 7, wherein the silicon carbide in the blowing agent has a particle size distribution D50 of 5-9 microns and D97 of 11-17 microns; the burnout carbon-based material is at least one of activated carbon, carbon powder, wood dust, coal powder or graphite powder; the particle size of the pore-forming agent is 100-200 meshes.
12. The lightweight porous sound-absorbing ceramic material according to claim 5, wherein the lightweight porous sound-absorbing ceramic material has a chemical composition, in mass percent, as follows: SiO 2259-64%，Al2O3 9-14%，Fe2O30.2-2.5%，TiO20.1-0.3%，CaO5-20%，MgO0.8-5%，0≤K2O≤1%，0≤K2O+Na2O≤1.5%，LOI12-15.5%。
13. The lightweight porous sound-absorbing ceramic material of claim 1, which is prepared by firing the following raw materials in percentage by mass: 0-5% of glass powder, 20-40% of river sand tailings, 5-20% of limestone and/or calcite, 27-47% of building residue soil, 2-10% of talcum, 0.10-0.55% of silicon carbide powder, 3-10% of carbon powder and 0-5% of spodumene.
14. The lightweight porous sound-absorbing ceramic material of claim 1, which is prepared by firing the following raw materials in percentage by mass: 5-10% of glass powder, 3-8% of corundum powder, 5-20% of cordierite-mullite refractory waste, 20-35% of river sand tailings, 10-15% of limestone and/or calcite, 20-30% of building residue soil, 5-9% of talcum, 0.10-0.55% of silicon carbide powder, 3-8% of carbon powder and 0-5% of spodumene.
15. The lightweight, porous, sound-absorbing ceramic material of claim 6, wherein the liquid phase viscosity of the starting material is 1.5 to 4.5 Pa-s at the maximum firing temperature.
16. A process for preparing a lightweight porous sound-absorbing ceramic material according to any one of claims 6 to 15, comprising the steps of:
s1, uniformly mixing the preparation raw materials according to mass percentage, and performing ball milling to obtain slurry;
s2, after spray drying, aging and homogenizing the slurry to obtain powder;
and S3, distributing and sintering the powder to obtain the light porous sound-absorbing ceramic material.
17. The preparation process of the lightweight porous sound-absorbing ceramic material according to claim 16, wherein the firing period is 10-30 hours, and the maximum firing temperature is not more than 1230 ℃.
18. The process for preparing a lightweight, porous, sound-absorbing ceramic material according to claim 16, wherein the firing schedule is as follows: heating from room temperature to 400 ℃, wherein the heating rate is 5-7 ℃/min; heating from 400 ℃ to 900 ℃, wherein the heating rate is 1-4 ℃/min; heating from 900 to 1160 ℃, heating at the rate of 3-5 ℃/min, keeping the temperature at 1160 ℃ for 35-50min, and cooling to room temperature.
19. The process for preparing a lightweight, porous, sound-absorbing ceramic material according to claim 16, wherein the firing schedule is as follows: heating from room temperature to 400 ℃ and keeping the temperature for 60min, wherein the heating rate is 5-7 ℃/min; heating from 400 deg.C to 950 deg.C, and maintaining the temperature for 40-60min at a heating rate of 6-9 deg.C/min; heating from 950 to 1150 deg.C at a heating rate of 2-3 deg.C/min, maintaining at 1150 deg.C for 40-55min, and cooling to room temperature.
20. The process for preparing a lightweight, porous, sound-absorbing ceramic material according to claim 16, wherein the firing schedule is as follows: heating to 400 deg.C from room temperature within 20-60 min; raising the temperature from 400 ℃ to 1120 ℃ within 100-300 min; heating to 1190 deg.C from 1120 deg.C within 30-50 min; heating from 1190 deg.C to 1229 deg.C within 5-15 min; keeping the temperature at 1229 deg.C for 35-55 min; cooling to 1165 deg.C from 1229 deg.C within 5-30 min; cooling from 1165 deg.C to 850 deg.C within 10-50 min; cooling from 850 ℃ to 300 ℃ within 200-360 min; cooling from 300 ℃ to room temperature within 240min at 150-.
21. The process for preparing a lightweight, porous, sound-absorbing ceramic material according to claim 16, wherein the slurry has a fineness of 0.4 to 1% screen residue of 250 mesh, a specific gravity of 1.63 to 1.69, and a flow rate of 40 to 70 seconds;
the water content of the powder is 5.5-6.5%, the grain composition is more than 20 meshes and less than or equal to 1.0%, 20-40 meshes and 40-65%, 20-60 meshes and 80-97%, the grain composition is less than 100 meshes and less than or equal to 0.5%, and the volume weight is more than or equal to 0.79%.
22. Use of a lightweight porous acoustical ceramic material according to any of claims 1-15 in a wall or building structure.
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