CN114478012A - 一种碳部件制造方法及其制造的碳部件 - Google Patents
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Abstract
本发明涉及特种材料的制造技术领域,具体而言,涉及一种碳部件制造方法及其制造的碳部件。本发明通过碳源、粘结剂、固化剂等原料的选配、对粉料造粒等方法的利用,提高坯体的密度和强度,降低石墨或碳部件在制造和转移过程中破损的概率;通过浆料挤出、浆料立体光刻、三维印刷、粉料激光固化或选域激光烧结等技术,可以实现复杂结构、大规格、高强度、高纯度石墨或碳部件的一体化快速制造;通过循环预处理和真空压力浸渍,进一步提高坯体的致密度,最终提高石墨或碳部件的密度及力学性能。本发明公开的石墨或碳部件的制造方法,特别适用于半导体、光伏产业和航空航天等领域中。
Description
技术领域
本发明涉特种材料的制造技术领域,具体而言,涉及一种碳部件制造方法及其制造的碳部件。
背景技术
石墨材料在现代科技工业中扮演着非常重要的角色,是制造火箭喷嘴、石墨反应堆的减速材料和反射材料的绝好材料;在民用上也大有作为,是制造单晶炉、金属连铸石墨结晶器、电火花加工用石墨电极等不可替代的材料。
具体到光伏和半导体行业,石墨由于具有耐高温、导电性好、导热性好、辐射率高、稳定性强等特性,石墨材料可以被加工成坩埚、加热器、保温筒等部件,用于高温炉内热场,起到加热、隔热、支撑、保护等作用。
近年来,为了应对光伏和半导体行业的迅猛发展,石墨部件面临着复杂化、大型化、高端化、快速制造的迫切要求。现有的石墨部件通常采用等静压成形、挤压成形或模压成形等制造工艺。这些工艺,正面临着大吨位压机、大尺寸模具和大型机械加工装备不足的挑战,同时存在原料利用率低、难以实现复杂结构制造等问题。
发明内容
本发明解决的问题是针对上述现有技术存在的不足,提供一种可以实现复杂结构、大规格、高强度、高纯度碳部件的一体化快速制造方法。
为解决上述问题,本发明提供一种碳部件制造方法,包括以下步骤:
S1、混合浆料制备:称量质量份数为35-90份的碳源、质量份数为1-30 份的粘结剂、质量份数为1-5份的固化剂、质量份数为0-10份的助剂、质量份数为30-100份的溶剂,并将其投入搅拌机中充分搅拌,得到混合浆料;
S2、坯体制造:将步骤S1所述混合浆料装入设备料斗中,采用浆料挤出技术或浆料立体光刻技术制造所述碳部件的坯体;或将步骤S1所述混合浆料经过造粒,得到碳的混合粉料,再装入设备料斗中,采用三维印刷技术、粉料激光固化技术和选域激光烧结技术中的一种制造所述碳部件的坯体;
S3、预处理:将步骤S2所述碳部件的坯体表面清理干净,采用烘制工艺和预烧工艺对所述坯体进行预处理,得到所述碳部件的预烧体;
S4、预烧体的真空压力浸渍:将步骤S3所述碳部件的预烧体放入密闭容器中;将所述密闭容器抽真空后注入浸渍剂,使所述浸渍剂淹没所述预烧体;然后再施加0.2-0.8MPa压力,保压0.5-12h后卸除压力,除去所述预烧体表面浸渍剂,得到碳部件的浸渍体;
S5、浸渍体的石墨化:将步骤S4所述碳部件的浸渍体放入石墨化炉中,经过石墨化处理得到碳部件。
与现有技术相比,本发明公开的碳部件的制造方法通过碳源、粘结剂、固化剂等原料的选配、对粉料造粒等方法的利用,提高坯体的密度和强度,降低石墨或碳部件在制造和转移过程中破损的概率;在碳部件坯体制造过程中,采用浆料挤出、浆料立体光刻、三维印刷、粉料激光固化或选域激光烧结等技术,主要有以下几方面突出效果:第一,将免去碳部件成型过程中机械加工工序以及相应的时间,可方便实现复杂结构、精细结构、一体化碳部件的快速制造;第二,将突破模具尺寸、压机吨位等装备的能力限制,可以方便实现大尺寸、大重量碳部件的制造;第三,将避免从模具、压机等装备上引入污染物,以装备与原料非直接接触的形式实现高纯度碳部件的制造;第四,将避免产生机械加工边角料和切削料,可以实现原材料全利用,降低综合成本;通过预处理和真空压力浸渍,降低预烧体的气孔率,进一步提高坯体的致密度,最终提高石墨或碳部件的密度及力学性能。
优选地,在步骤S2和步骤S5之间预处理步骤S3和真空压力浸渍步骤 S4循环进行两次以上。循环多次进行预处理和真空压力浸渍步骤,可以有利于浸渍剂更充分填充坯体内部的孔隙,进一步促进碳部件的致密化并提高其力学性能。
优选地,所述碳源选自石墨类碳源、无定形碳类碳源中的一种或两种;所述石墨类碳源选自天然石墨粉、等静压石墨粉和石墨电极粉中的一种或多种;所述无定形碳类碳源选自沥青、焦炭、木炭、糖炭、活性炭和炭黑中的一种或多种。选择天然石墨粉、沥青、焦炭、木炭或糖碳等作为碳源,可以降低原材料成本;选择活性炭或炭黑作为碳源,可以提高石墨化或预烧时的反应活性;选择传统工艺制造等静压石墨部件或石墨电极部件在机械加工过程中切削下来的粉料,将这些粉料作为碳源,可以实现废料回收利用并降低原材料成本。
优选地,所述碳源由多峰分布的小粒径颗粒、中等粒径颗粒和大粒径颗粒组成,所述小粒径颗粒的粒径为0.1-1μm,占碳源总质量的1-10%;所述中等粒径颗粒的粒径为5-30μm,占碳源总质量的10-80%;大粒径颗粒的粒径为60-250μm,占碳源总质量的10-80%。通过优化的碳源的粒径分布,大粒径、中等粒径和小粒径的碳源颗粒相互配合,中等粒径和小粒径的碳源颗粒充分填充在大粒径碳源颗粒之间,有利于提高碳部件的素坯密度和烧结密度,进而提高最终部件的力学性能。
优选地,所述粘结剂选自环氧树脂、酚醛树脂、酚醛环氧树脂、呋喃树脂、脲醛树脂、聚氨酯、多硫醇、聚乙烯醇、聚甲基丙烯酸甲酯和聚乙烯醇缩丁醛中的一种或多种;所述固化剂选自水溶性溶胶、酸类、胺类、酸酐类和酯类固化剂中的一种或多种;所述助剂选自烧结助剂、消泡剂、分散剂、光引发剂、光敏剂和稀释剂中的一种或多种;所述溶剂选自水、甲醇、乙醇、丙酮、乙二醇、二甲苯、乙酸乙酯或石油醚中的一种或多种;所述浸渍剂选自沥青、酚醛树脂、呋喃树脂、纤维素溶液、木质素溶液、糖溶液和淀粉溶液中的一种或多种。选择粘结剂、固化剂、助剂和溶剂将与其坯体制造工艺相适应,提供粘接粉料、强度支撑、快速固化和防止变形等作用,降低产品在制造和转移过程中破损的概率,尤其方便了大尺寸、大重量产品坯体的搬运,确保了碳部件的产率和合格率;所选浸渍剂含碳比例高,有利于碳部件在预烧后有充足的残留碳填充在碳部件坯体的孔隙内,进而提高烧结后碳部件的密度和力学性能。
优选地,步骤S2中所述坯体制造的工作温度为25-100℃,工作气氛为N2气或Ar气保护性气体。工作温度为25-100℃可使坯体快速稳定成型,采用保护气氛可避免坯体被氧化。
优选地,步骤S2中所述造粒为将所述混合浆料在60-110℃的工作温度进行喷雾造粒;或者为将所述混合浆料烘干、球磨,得到碳的混合粉料,所述烘干采用的工作温度为60-90℃,所述球磨采用的料球比为1:0.5-3,所述球磨时间为2-24h。通过造粒,碳部件的原材料粉体的形貌得到优化改善,造粒后得到粒径尺寸不一致的粉体,多粒度分布粉体混合,有利于提高粉料的堆积密度和提高粉料的流动性,进而提高碳部件坯体的密度。
优选地,步骤S3中所述烘制工艺为将步骤S2所述碳部件的坯体转移至烘箱内,以0.1-10℃/min的升温速度升温至120-250℃,并保温1-24h。采用相应参数烘制工艺,将去除碳部件坯体中的溶剂,加强固化和稳定性。
优选地,步骤S3中所述预烧工艺为将烘制后的所述碳部件的坯体转移至预烧炉内,在Ar气氛下、N2气氛下或真空环境下,以0.2-15℃/min的升温速度至650-1100℃,并保温0.5-10h。在特定气氛下预烧,将有利于去除碳部件坯体中的非碳元素,提高部件的纯度,同时预烧工艺,将有利于打开碳部件坯体中的闭气孔,为后续浸渍剂的进入提供通路。
本发明还提供了采用上述一种碳部件制造方法制造的碳部件,所述碳部件的致密度≥98%,弯曲强度≥15MPa。
综上所述,本发明公开的一种碳部件的制造方法,可以实现复杂结构、大规格、高强度、高纯度碳部件的一体化快速制造;提高坯体的致密度和强度,最终提高碳部件的密度及力学性能,使部件的致密度≥98%,弯曲强度≥15MPa;降低碳部件在制造和转移过程中破损的概率,确保了碳部件的产率和合格率。本发明公开的碳部件的制造方法及碳部件,特别适用于半导体、光伏产业中,用于制造大尺寸、高纯度的坩埚、保温筒,以及具有复杂结构的加热器、保护罩等高温炉内热场部件,也可应用于航空航天等重要领域。
附图说明
图1为实施例5中制备的结构复杂的碳部件实物图。
具体实施方式
为使本发明的上述目的、特征和优点能够更为明显易懂,下面结合实施例对本发明做详细的说明。
实施例1
本实施例提供了一种碳部件制造方法:
S1、按照碳源:酚醛树脂:胺类固化剂:分散剂:乙醇为80:20:2:1:40的质量份数比例称量各种原料;并将其投入搅拌机中搅拌24h,得到混合均匀的浆料;
其中,碳源按照粒径0.5μm左右炭黑占碳源总质量的2%,粒径20μm 左右石墨占碳源总质量的48%,粒径80μm左右的等静压石墨粉占碳源总质量的50%称量;采用切削回收后的等静压石墨粉,将实现废料利用和降低原料成本。
S2、将步骤S1中混合均匀的浆料投入浆料挤出技术设备的料斗中,以 0.2mm层高,200mm/s运动速度,0.1mm/s的挤料速度,75℃的工作温度, N2气保护气氛下,制造碳部件的坯体;
S3、将S2所述碳部件的坯体表面清理干净,转移至烘箱内,以1℃/min 的升温速度至145℃,并保温2h;然后将烘制后的碳部件的坯体转移至预烧炉内,在N2气氛下,以3℃/min的升温速度至850℃,并保温2h,降温后,得到碳部件的预烧体;
S4、将S3所述碳部件的预烧体放入密闭容器中;将容器抽真空后注入木质素溶液浸渍剂,使浸渍剂淹没预烧体;然后再施加0.2MPa压力,保压 2h后卸除压力,除去预烧体表面残留的木质素溶液,得到碳部件的浸渍体;
再循环执行S3和S4步骤三次,使碳部件浸渍体进一步致密。
S5、将S4所述碳部件的浸渍体放入石墨化炉中,经过石墨化处理得到致密度98.2%,弯曲强度16.3MPa的碳部件。
实施例2
本实施例提供了一种碳部件制造方法:
S1、按照碳源:聚乙烯醇:水溶性溶胶:分散剂:水为70:7:1:1:35的质量份数比例称量各种原料;并将其投入搅拌机中搅拌24h,得到混合均匀的浆料;
其中,碳源按照粒径0.5μm左右炭黑占碳源总质量的2%,粒径20μm 左右等静压石墨粉占碳源总质量的40%,粒径100μm左右的沥青占碳源总质量的58%称量;采用切削回收后的等静压石墨粉,将实现废料利用和降低原料成本。
S2、将步骤S1中混合均匀的浆料投入浆料立体光刻技术设备的料斗中,在90℃的工作温度,N2气保护气氛下,制造碳部件的坯体;
S3、将S2所述碳部件的坯体表面清理干净,转移至烘箱内,以2℃/min 的升温速度至160℃,并保温4h;然后将烘制后的碳部件的坯体转移至预烧炉内,在N2气氛下,以5℃/min的升温速度至900℃,并保温2h,降温后,得到碳部件的预烧体;
S4、将S3所述碳部件的预烧体放入密闭容器中;将容器抽真空后注入酚醛树脂浸渍剂,使浸渍剂淹没预烧体;然后再施加0.3MPa压力,保压4 h后卸除压力,除去预烧体表面残留的木质素溶液,得到碳部件的浸渍体;
再循环执行S3和S4步骤四次,使碳部件浸渍体进一步致密。
S5、将S4所述碳部件的浸渍体放入石墨化炉中,经过石墨化处理得到致密度98.6%,弯曲强度16.8MPa的碳部件。
实施例3
本实施例提供了一种碳部件制造方法:
S1、按照碳源:酚醛树脂:胺类固化剂:烧结助剂:乙醇为90:10:4:2:90的质量份数比例称量各种原料;并将其投入搅拌机中搅拌12h,得到混合均匀的浆料;
其中,碳源按照粒径1μm左右炭黑占碳源总质量的5%,粒径30μm 左右高纯石墨电极粉占碳源总质量的80%,粒径150μm左右的焦炭占碳源总质量的15%称量。
S2、将步骤S1中混合均匀的浆料采用80℃的工作温度进行喷雾造粒;然后将造粒粉投入粉料激光固化技术设备的料斗中,以0.1-0.3mm层高, 200-5000mm/s激光速度,75℃的工作温度,Ar气保护气氛下,制造碳部件的坯体。在粉料激光固化技术中,成型的坯体会埋在粉末床中不与加工设备接触,将避免外来因素对坯体的污染,保证高纯度碳部件的制造。
S3、将S2所述碳部件的坯体表面清理干净,转移至烘箱内,以5℃/min 的升温速度至165℃,并保温12h;然后将烘制后的碳部件的坯体转移至预烧炉内,在真空环境下,以8℃/min的升温速度至1000℃,并保温6h,降温后,得到碳部件的预烧体;
S4、将S3所述碳部件的预烧体放入密闭容器中;将容器抽真空后注入沥青浸渍剂,使浸渍剂淹没预烧体;然后再施加0.6MPa压力,保压5h后卸除压力,除去预烧体表面残留的沥青浸渍剂,得到碳部件的浸渍体;
再循环执行S3和S4步骤五次,使碳部件浸渍体进一步致密。
S5、将S4所述碳部件的浸渍体放入石墨化炉中,经过石墨化处理得到致密度99.3%,弯曲强度17.6MPa的碳部件。
由本实施例提供的一种碳部件的制造方法制造的碳部件可以满足半导体、光伏产业用高纯、复杂热场结构件的大批量化应用需求。
实施例4
本实施例提供了一种碳部件制造方法:
S1、按照碳源:酚醛树脂:胺类固化剂:乙醇为35:1:5:2:100的质量份数比例称量各种原料;并将其投入搅拌机中搅拌24h,得到混合均匀的浆料;
其中,碳源按照粒径0.1μm左右炭黑占碳源总质量的10%,粒径5μm 左右高纯石墨电极粉占碳源总质量的10%,粒径60μm左右的焦炭占碳源总质量的80%称量。
S2、将步骤S1中混合均匀的浆料采用85℃烘干,再用1:2的料球比球磨12h,得到造粒粉;然后将造粒粉投入三维印刷技术设备的料斗中,80℃的工作温度,Ar气保护气氛下,制造碳部件的坯体。在三维印刷技术中,成型的坯体会埋在粉末床中不与加工设备接触,将避免外来因素对坯体的污染,保证高纯度碳部件的制造。
S3、将S2所述碳部件的坯体表面清理干净,转移至烘箱内,以10℃/min 的升温速度至250℃,并保温1h;然后将烘制后的碳部件的坯体转移至预烧炉内,在真空环境下,以15℃/min的升温速度至1100℃,并保温0.5h,降温后,得到碳部件的预烧体;
S4、将S3所述碳部件的预烧体放入密闭容器中;将容器抽真空后注入沥青浸渍剂,使浸渍剂淹没预烧体;然后再施加0.2MPa压力,保压12h 后卸除压力,除去预烧体表面残留的沥青浸渍剂,得到碳部件的浸渍体;
再循环执行S3和S4步骤五次,使碳部件浸渍体进一步致密。
S5、将S4所述碳部件的浸渍体放入石墨化炉中,经过石墨化处理得到致密度98.3%,弯曲强度15.6MPa的碳部件。
实施例5
本实施例提供了一种碳部件制造方法:
S1、按照碳源:酚醛树脂:胺类固化剂:烧结助剂:乙醇为90:30:1:10:30的质量份数比例称量各种原料;并将其投入搅拌机中搅拌12h,得到混合均匀的浆料;
其中,碳源按照粒径1μm左右炭黑占碳源总质量的1%,粒径5μm 左右高纯石墨电极粉占碳源总质量的80%,粒径250μm左右的焦炭占碳源总质量的19%称量。
S2、将步骤S1中混合均匀的浆料采用110℃的工作温度进行喷雾造粒;然后将造粒粉投入粉料激光固化技术设备的料斗中,以0.1-0.3mm层高, 200-5000mm/s激光速度,75℃的工作温度,Ar气保护气氛下,制造碳部件的坯体。在粉料激光固化技术中,成型的坯体会埋在粉末床中不与加工设备接触,将避免外来因素对坯体的污染,保证高纯度碳部件的制造。
S3、将S2所述碳部件的坯体表面清理干净,转移至烘箱内,以1℃/min 的升温速度至120℃,并保温24h;然后将烘制后的碳部件的坯体转移至预烧炉内,在真空环境下,以0.2℃/min的升温速度至650℃,并保温24h,降温后,得到碳部件的预烧体;
S4、将S3所述碳部件的预烧体放入密闭容器中;将容器抽真空后注入沥青浸渍剂,使浸渍剂淹没预烧体;然后再施加0.8MPa压力,保压0.5h 后卸除压力,除去预烧体表面残留的沥青浸渍剂,得到碳部件的浸渍体;
再循环执行S3和S4步骤五次,使碳部件浸渍体进一步致密。
S5、将S4所述碳部件的浸渍体放入石墨化炉中,经过石墨化处理得到致密度98.6%,弯曲强度16.5MPa的碳部件。
由本实施例提供的一种碳部件制造方法制造的碳部件如图1所示。
虽然本公开披露如上,但本公开的保护范围并非仅限于此。本领域技术人员,在不脱离本公开的精神和范围的前提下,可进行各种变更与修改,这些变更与修改均将落入本发明的保护范围。
Claims (10)
1.一种碳部件制造方法,其特征在于,包括以下步骤:
S1、混合浆料制备:称量质量份数为35-90份的碳源、质量份数为1-30份的粘结剂、质量份数为1-5份的固化剂、质量份数为0-10份的助剂、质量份数为30-100份的溶剂,并将其投入搅拌机中充分搅拌,得到混合浆料;
S2、坯体制造:将步骤S1所述混合浆料装入设备料斗中,采用浆料挤出技术或浆料立体光刻技术制造所述碳部件的坯体;或将步骤S1所述混合浆料经过造粒,得到碳的混合粉料,再装入设备料斗中,采用三维印刷技术、粉料激光固化技术和选域激光烧结技术中的一种制造所述碳部件的坯体;
S3、预处理:将步骤S2所述碳部件的坯体表面清理干净,采用烘制工艺和预烧工艺对所述坯体进行预处理,得到所述碳部件的预烧体;
S4、预烧体的真空压力浸渍:将步骤S3所述碳部件的预烧体放入密闭容器中;将所述密闭容器抽真空后注入浸渍剂,使所述浸渍剂淹没所述预烧体;然后再施加0.2-0.8MPa压力,保压0.5-12h后卸除压力,除去所述预烧体表面浸渍剂,得到碳部件的浸渍体;
S5、浸渍体的石墨化:将步骤S4所述碳部件的浸渍体放入石墨化炉中,经过石墨化处理得到碳部件。
2.根据权利要求1所述的碳部件制造方法,其特征在于,在步骤S2和S5之间预处理步骤S3和真空压力浸渍步骤S4循环进行两次以上。
3.根据权利要求1所述的碳部件的制造方法,其特征在于,所述碳源选自石墨类碳源、无定形碳类碳源中的一种或两种;所述石墨类碳源选自天然石墨粉、等静压石墨粉和石墨电极粉中的一种或多种;所述无定形碳类碳源选自沥青、焦炭、木炭、糖炭、活性炭和炭黑中的一种或多种。
4.根据权利要求1所述的碳部件制造方法,其特征在于,所述碳源由多峰分布的小粒径颗粒、中等粒径颗粒和大粒径颗粒组成,所述小粒径颗粒的粒径为0.1-1μm,占碳源总质量的1-10%;所述中等粒径颗粒的粒径为5-30μm,占碳源总质量的10-80%;大粒径颗粒的粒径为60-250μm,占碳源总质量的10-80%。
5.根据权利要求1所述的碳部件制造方法,其特征在于,所述粘结剂选自环氧树脂、酚醛树脂、酚醛环氧树脂、呋喃树脂、脲醛树脂、聚氨酯、多硫醇、聚乙烯醇、聚甲基丙烯酸甲酯和聚乙烯醇缩丁醛中的一种或多种;所述固化剂选自水溶性溶胶、酸类、胺类、酸酐类和酯类固化剂中的一种或多种;所述助剂选自烧结助剂、消泡剂、分散剂、光引发剂、光敏剂和稀释剂中的一种或多种;所述溶剂选自水、甲醇、乙醇、丙酮、乙二醇、二甲苯、乙酸乙酯或石油醚中的一种或多种;所述浸渍剂选自沥青、酚醛树脂、呋喃树脂、纤维素溶液、木质素溶液、糖溶液和淀粉溶液中的一种或多种。
6.根据权利要求1所述的碳部件制造方法,其特征在于,步骤S2中所述坯体制造的工作温度为25-100℃,工作气氛为N2气或Ar气保护性气体。
7.根据权利要求1所述的碳部件制造方法,其特征在于,步骤S2中所述造粒为将所述混合浆料在60-110℃的工作温度进行喷雾造粒;或者为将所述混合浆料烘干、球磨,得到碳的混合粉料,所述烘干采用的工作温度为60-90℃,所述球磨采用的料球比为1:0.5-3,所述球磨时间为2-24h。
8.根据权利要求1所述的碳部件制造方法,其特征在于,步骤S3中所述烘制工艺为将步骤S2所述碳部件的坯体转移至烘箱内,以0.1-10℃/min的升温速度升温至120-250℃,并保温1-24h。
9.根据权利要求1所述的碳部件制造方法,其特征在于,步骤S3中所述预烧工艺为将烘制后的所述碳部件的坯体转移至预烧炉内,在Ar气氛下、N2气氛下或真空环境下,以0.2-15℃/min的升温速度至650-1100℃,并保温0.5-10h。
10.一种根据权利要求1所述的碳部件制造方法制造的碳部件,其特征在于,所述碳部件的致密度≥98%,弯曲强度≥15MPa。
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