CN115010512A - Foamed ceramic filter and preparation method thereof - Google Patents
Foamed ceramic filter and preparation method thereof Download PDFInfo
- Publication number
- CN115010512A CN115010512A CN202210635365.6A CN202210635365A CN115010512A CN 115010512 A CN115010512 A CN 115010512A CN 202210635365 A CN202210635365 A CN 202210635365A CN 115010512 A CN115010512 A CN 115010512A
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- Prior art keywords
- foam
- ceramic filter
- ceramic
- coating layer
- coating
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- 239000000919 ceramic Substances 0.000 title claims abstract description 142
- 238000002360 preparation method Methods 0.000 title abstract description 36
- 239000006260 foam Substances 0.000 claims abstract description 185
- 239000011247 coating layer Substances 0.000 claims abstract description 44
- 238000000034 method Methods 0.000 claims abstract description 35
- 239000011248 coating agent Substances 0.000 claims abstract description 30
- 238000000576 coating method Methods 0.000 claims abstract description 30
- 238000004519 manufacturing process Methods 0.000 claims abstract description 27
- 239000000463 material Substances 0.000 claims abstract description 24
- 238000007581 slurry coating method Methods 0.000 claims abstract description 19
- 238000005245 sintering Methods 0.000 claims abstract description 15
- 238000001035 drying Methods 0.000 claims abstract description 10
- 239000004744 fabric Substances 0.000 claims description 35
- 239000011230 binding agent Substances 0.000 claims description 14
- -1 Polyethylene Polymers 0.000 claims description 12
- 239000004698 Polyethylene Substances 0.000 claims description 12
- 229920006267 polyester film Polymers 0.000 claims description 12
- 229920000573 polyethylene Polymers 0.000 claims description 12
- 229920000742 Cotton Polymers 0.000 claims description 9
- 229920005989 resin Polymers 0.000 claims description 7
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- 239000004743 Polypropylene Substances 0.000 claims description 6
- 239000002985 plastic film Substances 0.000 claims description 6
- 229920006255 plastic film Polymers 0.000 claims description 6
- 229920001155 polypropylene Polymers 0.000 claims description 6
- 239000004745 nonwoven fabric Substances 0.000 claims description 5
- 239000004677 Nylon Substances 0.000 claims description 3
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 claims description 3
- 239000004793 Polystyrene Substances 0.000 claims description 3
- 229920000297 Rayon Polymers 0.000 claims description 3
- 239000000853 adhesive Substances 0.000 claims description 3
- 230000001070 adhesive effect Effects 0.000 claims description 3
- 229920001778 nylon Polymers 0.000 claims description 3
- 239000002694 phosphate binding agent Substances 0.000 claims description 3
- 239000004800 polyvinyl chloride Substances 0.000 claims description 3
- 239000002964 rayon Substances 0.000 claims description 3
- 239000012209 synthetic fiber Substances 0.000 claims description 3
- 229920002994 synthetic fiber Polymers 0.000 claims description 3
- 210000002268 wool Anatomy 0.000 claims description 3
- 244000025254 Cannabis sativa Species 0.000 claims description 2
- 235000012766 Cannabis sativa ssp. sativa var. sativa Nutrition 0.000 claims description 2
- 235000012765 Cannabis sativa ssp. sativa var. spontanea Nutrition 0.000 claims description 2
- 235000009120 camo Nutrition 0.000 claims description 2
- 235000005607 chanvre indien Nutrition 0.000 claims description 2
- 239000011487 hemp Substances 0.000 claims description 2
- 238000005266 casting Methods 0.000 abstract description 21
- 239000002893 slag Substances 0.000 abstract description 16
- 239000002002 slurry Substances 0.000 description 45
- 239000003292 glue Substances 0.000 description 34
- 238000007789 sealing Methods 0.000 description 21
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 16
- 239000000203 mixture Substances 0.000 description 15
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 12
- 235000015895 biscuits Nutrition 0.000 description 12
- 239000004576 sand Substances 0.000 description 10
- 229920005830 Polyurethane Foam Polymers 0.000 description 8
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 8
- 230000000052 comparative effect Effects 0.000 description 8
- 238000002156 mixing Methods 0.000 description 8
- 239000011496 polyurethane foam Substances 0.000 description 8
- 239000002994 raw material Substances 0.000 description 8
- 238000001914 filtration Methods 0.000 description 7
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 7
- 238000000498 ball milling Methods 0.000 description 6
- 230000007547 defect Effects 0.000 description 6
- 239000002657 fibrous material Substances 0.000 description 6
- 239000010410 layer Substances 0.000 description 6
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 6
- 238000004513 sizing Methods 0.000 description 6
- 238000005253 cladding Methods 0.000 description 5
- 239000000395 magnesium oxide Substances 0.000 description 5
- 238000007873 sieving Methods 0.000 description 5
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 5
- 229910010271 silicon carbide Inorganic materials 0.000 description 5
- 230000000694 effects Effects 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- 239000004925 Acrylic resin Substances 0.000 description 3
- 229920000178 Acrylic resin Polymers 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 3
- 239000003822 epoxy resin Substances 0.000 description 3
- 238000009434 installation Methods 0.000 description 3
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 3
- 229910052863 mullite Inorganic materials 0.000 description 3
- 229920000647 polyepoxide Polymers 0.000 description 3
- 239000004814 polyurethane Substances 0.000 description 3
- 239000011241 protective layer Substances 0.000 description 3
- 238000004080 punching Methods 0.000 description 3
- 239000000779 smoke Substances 0.000 description 3
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- DGXAGETVRDOQFP-UHFFFAOYSA-N 2,6-dihydroxybenzaldehyde Chemical compound OC1=CC=CC(O)=C1C=O DGXAGETVRDOQFP-UHFFFAOYSA-N 0.000 description 2
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 239000004642 Polyimide Substances 0.000 description 2
- 229920001807 Urea-formaldehyde Polymers 0.000 description 2
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 2
- DHKHKXVYLBGOIT-UHFFFAOYSA-N acetaldehyde Diethyl Acetal Natural products CCOC(C)OCC DHKHKXVYLBGOIT-UHFFFAOYSA-N 0.000 description 2
- 125000002777 acetyl group Chemical class [H]C([H])([H])C(*)=O 0.000 description 2
- GZCGUPFRVQAUEE-SLPGGIOYSA-N aldehydo-D-glucose Chemical compound OC[C@@H](O)[C@@H](O)[C@H](O)[C@@H](O)C=O GZCGUPFRVQAUEE-SLPGGIOYSA-N 0.000 description 2
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- 238000005452 bending Methods 0.000 description 2
- 229910052570 clay Inorganic materials 0.000 description 2
- 239000004927 clay Substances 0.000 description 2
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- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
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- 238000001125 extrusion Methods 0.000 description 2
- 238000010304 firing Methods 0.000 description 2
- OIAUFEASXQPCFE-UHFFFAOYSA-N formaldehyde;1,3-xylene Chemical compound O=C.CC1=CC=CC(C)=C1 OIAUFEASXQPCFE-UHFFFAOYSA-N 0.000 description 2
- 239000007849 furan resin Substances 0.000 description 2
- 238000011056 performance test Methods 0.000 description 2
- 239000005011 phenolic resin Substances 0.000 description 2
- 229920001568 phenolic resin Polymers 0.000 description 2
- 229920001721 polyimide Polymers 0.000 description 2
- 239000013354 porous framework Substances 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
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- 229910002027 silica gel Inorganic materials 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- 229920006305 unsaturated polyester Polymers 0.000 description 2
- 229920002554 vinyl polymer Polymers 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- 239000003570 air Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000001680 brushing effect Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- RGPUVZXXZFNFBF-UHFFFAOYSA-K diphosphonooxyalumanyl dihydrogen phosphate Chemical compound [Al+3].OP(O)([O-])=O.OP(O)([O-])=O.OP(O)([O-])=O RGPUVZXXZFNFBF-UHFFFAOYSA-K 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
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- 239000000945 filler Substances 0.000 description 1
- 239000006261 foam material Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 238000003837 high-temperature calcination Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 239000007791 liquid phase Substances 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 1
- 239000010452 phosphate Substances 0.000 description 1
- 239000002984 plastic foam Substances 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 230000008016 vaporization Effects 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
Classifications
-
- 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
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/06—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances
- C04B38/0615—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances the burned-out substance being a monolitic element having approximately the same dimensions as the final article, e.g. a porous polyurethane sheet or a prepreg obtained by bonding together resin particles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D39/00—Filtering material for liquid or gaseous fluids
- B01D39/14—Other self-supporting filtering material ; Other filtering material
- B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
- B01D39/2068—Other inorganic materials, e.g. ceramics
- B01D39/2093—Ceramic foam
-
- 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
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
-
- 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
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
-
- 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
- C04B2235/34—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
-
- 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
- C04B2235/34—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
- C04B2235/3427—Silicates other than clay, e.g. water glass
- C04B2235/3463—Alumino-silicates other than clay, e.g. mullite
- C04B2235/3481—Alkaline earth metal alumino-silicates other than clay, e.g. cordierite, beryl, micas such as margarite, plagioclase feldspars such as anorthite, zeolites such as chabazite
-
- 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
- C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
- C04B2235/602—Making the green bodies or pre-forms by moulding
-
- 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
- C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
- C04B2235/606—Drying
-
- 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
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
- C04B2235/656—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes characterised by specific heating conditions during heat treatment
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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
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
- C04B2235/656—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes characterised by specific heating conditions during heat treatment
- C04B2235/6567—Treatment time
-
- 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
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
Abstract
The application discloses a foamed ceramic filter and a preparation method thereof, and relates to the technical field of filters for casting. The preparation method of the foamed ceramic filter comprises the following steps: and coating the side surface of the original foam sheet by adopting a coating material to form a coating layer, carrying out ceramic slurry coating on the original foam sheet provided with the coating layer, and drying and sintering to obtain the foamed ceramic filter. The application effectively solves the slag falling problem of the foamed ceramic filter, the operation process is easy to control, the foamed ceramic filter is particularly suitable for a mechanical production line with higher automation degree, the production efficiency can be greatly improved, and the preparation cost is reduced.
Description
Technical Field
The application relates to the technical field of filters for casting, in particular to a foamed ceramic filter and a preparation method thereof.
Background
The foamed ceramic filter is a porous ceramic product with porosity as high as 70-90% and three-dimensional network skeleton and communicated pore structure. As a novel inorganic non-metallic filtering material, besides the performances of common ceramics such as high temperature resistance and corrosion resistance, the foamed ceramic also has the advantages of light weight, high porosity, large specific surface area, high strength, high temperature resistance, corrosion resistance, good thermal shock resistance and the like, and is widely applied to various industries for filtering molten metal, air, fillers and the like. When the foamed ceramic filter is used for filtering molten metal, due to the effects of filtering, rectifying, adsorbing and filtering cakes, the foamed ceramic filter can effectively reduce the defects of casting sand holes, slag holes, air holes, inclusions and the like, improve the quality and yield of castings, improve the surface quality, improve the machining performance and improve the mechanical performance.
Due to the porous framework structure of the foamed ceramic filter, the side burrs and the bulges are more. If the side face of the foamed ceramic filter is not sealed, burrs and bulges with uneven peripheries are easy to scratch and generate a slag falling problem in the production, circulation and transportation processes of the filter, so that the size precision of the filter is influenced. Meanwhile, when the foamed ceramic filter is placed in a casting mold, burrs on the periphery of the filter are easy to contact with a sand cavity to cause sand falling, so that the sand inclusion defect of a casting is caused.
Currently, in order to solve the problem of slag removal, US4568595 discloses a method of forming a solid layer by coating a filter by brushing, spraying or coating the edge of a foam filter with a ceramic slurry of an added binder, followed by dry sintering, which has the disadvantages of difficult automation and rough and irregular surface formation. The coating material easily penetrates into the pores of the ceramic foam, and the coating size is difficult to control precisely. In addition, a method for winding and wrapping the periphery of the ceramic foam filter by using fiber materials is also available, but the fiber materials have low protective strength, and the phenomenon of slag falling is easy to occur when the periphery of the ceramic foam filter is extruded. Meanwhile, common fiber materials such as fiber paper and the like contain organic binders, smoke is easily generated when a filter wrapped by the fiber materials is used for metal filtration and pouring, the smoke can enter a casting to form defects, and meanwhile, the problem of environmental protection is easily caused. For another example, CN200620161459.0 discloses an edge sealing ceramic foam filter for casting, wherein a high-temperature decomposable organic protective layer is adhered to the periphery of the ceramic foam, and when pouring is performed, due to the high-temperature effect of molten iron, the organic protective layer is decomposed, so as to reduce slag, but the strength of the organic protective layer is low, and gas is generated during pouring, so that the gas enters into a casting to affect the quality of the casting. CN201911212694.4 discloses an edge sealing method for a foamed ceramic filter for casting, which is to seal and tightly wrap the periphery of a dried and unsintered filter blank with a film, then coat slurry outside the film, and perform drying and high-temperature calcination treatment to obtain the filter.
Disclosure of Invention
In view of the defects of the technology, the application provides the foamed ceramic filter and the preparation method thereof, so that the problem of slag falling of the foamed ceramic filter is effectively solved, the operation process is easy to control, the foamed ceramic filter is particularly suitable for a mechanical production line with high automation degree, the production efficiency can be greatly improved, and the preparation cost is reduced.
In order to achieve the above purpose, the present application mainly provides the following technical solutions:
the embodiment of the application provides a preparation method of a foamed ceramic filter, which comprises the following steps:
coating the side surface of the foam sheet with a coating material to form a coating layer,
and then carrying out ceramic slurry coating on the foam sheet with the coating layer, and then drying and sintering to obtain the foam ceramic filter.
Preferably, the preparation method further comprises: when the foam sheet provided with the coating layer is subjected to slurry coating, two ends of the foam sheet coated with the slurry, which are not provided with the coating layer, are extruded.
Preferably, the side of the foam base sheet is wrapped at least once with a strip of wrapping material to form a wrapping layer.
Preferably, the coating material is selected from the group consisting of cloth and plastic film.
Preferably, the cloth is selected from cotton cloth, linen, silk, wool fabric, rayon, synthetic fiber or non-woven fabric; the plastic film is selected from Polyethylene (PE), polyvinyl chloride (PVC), Polystyrene (PS), polyester film (PET), polypropylene (PP) or nylon.
Preferably, the coating layer and the foam sheet are bonded through an adhesive.
Preferably, the binder is selected from an organic resin glue, a phosphate binder or a silicate binder. Preferably, the organic resin glue is selected from organic silica gel, epoxy resin glue, Polyurethane (PU) glue, amino resin glue, phenolic resin glue, acrylic resin glue, furan resin glue, resorcinol-formaldehyde resin glue, xylene-formaldehyde resin glue, unsaturated polyester glue, composite resin glue, polyimide glue, urea-formaldehyde resin glue, polyvinyl acetal or vinyl acetate emulsion glue.
Preferably, the thickness of the coating layer is 0.1-5 mm. Preferably, the thickness of the coating layer may be 0.1mm, 0.2mm, 0.5mm, 1mm, 2mm, 3mm, 4mm or 5 mm.
Preferably, the width of the coating layer is not more than the height of the side surface of the foam sheet. Preferably, the width of the cover layer is equal to the height of the side of the foam sheet.
The embodiment of the application also provides the foamed ceramic filter prepared by the preparation method of the foamed ceramic filter.
One or more technical solutions provided in the embodiments of the present application have at least the following technical effects or advantages:
according to the preparation method provided by the embodiment of the application, the edge is wrapped before the foam sheet is coated with the slurry, and the coating layer can form a smooth slurry coating boundary around the foam sheet, so that a foam ceramic filter blank without burrs on the side surface is obtained, the edge and the inside of the ceramic filter blank form a complete integrated structure, and after sintering, the formed hard ceramic edge and the inside of the ceramic filter are also integrated. Therefore, the edge of the prepared foamed ceramic filter has the characteristics of flatness, high strength and high temperature resistance, the phenomena of side sand hanging and slag falling can not occur in the processes of production, transportation, installation and use, and the quality of a casting can not be influenced.
In the preparation method provided by the embodiment of the application, after the foam sheet subjected to edge covering is subjected to slurry coating and drying, the coating layer and the ceramic filter biscuit are sintered together without removing the coating layer, so that the coating layer and the foam sheet are burnt together, the integrity of the ceramic filter biscuit before the ceramic filter finished product is obtained can be ensured, the problem of damage to the ceramic filter biscuit is avoided, and the low yield of the finished product caused by improper operation in the production process is avoided; meanwhile, the operation process is easy to control, so that the method is particularly suitable for a mechanical production line with high automation degree, the production efficiency can be greatly improved, and the preparation cost can be reduced.
In the preparation method provided by the embodiment of the application, when the cladding material is adopted to clad the side face of the original foam sheet, the original foam sheet is softer in texture, the small bulge on the side face of the original foam sheet can be completely cladded in the cladding layer, after the original foam sheet is subjected to sizing, the small bulge on the side face of the original foam sheet can be completely hidden in ceramic slurry, and the ceramic slurry can fill the gap on the side face of the original foam sheet, so that a ceramic filter blank with a smoother side face can be formed, and a ceramic foam filter with a smoother hard ceramic edge sealing can be obtained. The preparation method simultaneously carries out the preparation process and the edge sealing process of the foamed ceramic filter, greatly simplifies the production process and improves the production efficiency.
Detailed Description
To further clarify the technical solutions and functions adopted by the present application for the purpose of attaining the intended application, preferred embodiments, structures, features, and functions according to the present application are described in detail below with reference to the accompanying drawings.
Due to the porous framework structure of the foamed ceramic filter, the side burrs and the bulges are more. If the side face of the foamed ceramic filter is not sealed, burrs and bulges with uneven peripheries are easily scratched to generate a slag falling problem in the production, circulation and carrying processes of the filter, so that the size precision of the filter is influenced. Meanwhile, when the foamed ceramic filter is placed in a casting mold, burrs on the periphery of the filter are easy to contact with a sand cavity to cause sand falling, so that the sand inclusion defect of a casting is caused. In order to solve the problem of slag falling, the method for wrapping the foam ceramic filter by the commonly used fiber material has low protection strength, and the fiber material is easy to generate smoke when filtering molten metal and can enter a casting to form defects.
In order to solve the above problems, the embodiments of the present application provide the following technical solutions, and the general idea is as follows:
the embodiment of the application provides a preparation method of a foamed ceramic filter, which comprises the following steps:
coating the side surface of the foam sheet with a coating material to form a coating layer,
and then carrying out ceramic slurry coating on the foam sheet with the coating layer, and then drying and sintering to obtain the foam ceramic filter.
Specifically, the foam sheet is firstly wrapped, and then the wrapped foam sheet is subjected to slurry coating, so that the ceramic filter blank without burrs on the side surface can be obtained through the step. After sintering, the ceramic filter blank is burned off with the coating layer and the foam base sheet to form a ceramic foam filter with a hard ceramic edge seal.
The foam base sheet in this application means a foam material used as a support for producing a ceramic filter, and any combustible organic plastic foam material having elasticity and capable of recovering its original shape can be used. The foam must be capable of burning or vaporizing at temperatures below the firing temperature of the ceramic material used, such as polyurethane. The foam is cut into a certain shape and size and then used as a foam sheet.
The methods of making ceramic foam filters provided herein may include conventional ceramic foam filter making techniques including preparing a ceramic slurry, coating the slurry with a foam by impregnating the foam with the slurry and then extruding excess slurry out of the foam, and drying the foam to remove the liquid phase of the slurry, forming a rigid biscuit by a drying step, and then placing the dried biscuit in a kiln (e.g., a tunnel kiln) and subjecting it to a firing process that may include multiple thermal gradients and time periods to fire the filter.
Specifically, the above manufacturing method is suitable for manufacturing any ceramic foam filter requiring edge sealing, including but not limited to aluminum oxide, magnesium oxide, zirconium oxide, silicon carbide, carbon and other ceramic foam filters. Accordingly, the ceramic slurry employed in the preparation method may be of the alumina, magnesia, zirconia, silicon carbide, carbonaceous, etc. type.
According to the preparation method provided by the embodiment of the application, the edge is wrapped before the foam sheet is subjected to slurry coating, the coating layer can form a slurry coating boundary with the periphery of the foam sheet smooth, so that a foam ceramic filter blank without burrs on the side surface is obtained, the edge and the inside of the ceramic filter blank form a complete integrated structure, and after sintering, the formed hard ceramic edge sealing and the inside of the ceramic filter are also complete and integrated. Therefore, the edge of the prepared foamed ceramic filter has the characteristics of flatness, high strength and high temperature resistance, the phenomena of side sand hanging and slag falling can not occur in the processes of production, transportation, installation and use, and the quality of a casting can not be influenced.
In the preparation method provided by the embodiment of the application, after the foam sheet subjected to edge covering is subjected to slurry coating and drying, the coating layer and the ceramic filter biscuit are sintered together without removing the coating layer, so that the coating layer and the foam sheet are burnt off together, the integrity of the ceramic filter biscuit before a ceramic filter finished product is obtained can be ensured, the problem of damage to the ceramic filter biscuit is avoided, and the low qualified rate of the finished product caused by improper operation in the production process is avoided; meanwhile, the operation process is easy to control, so that the method is particularly suitable for a mechanical production line with high automation degree, the production efficiency can be greatly improved, and the preparation cost can be reduced.
In the preparation method provided by the embodiment of the application, when the cladding material is adopted to clad the side face of the original foam sheet, the original foam sheet is softer in texture, the small bulge on the side face of the original foam sheet can be completely cladded in the cladding layer, after the original foam sheet is subjected to sizing, the small bulge on the side face of the original foam sheet can be completely hidden in ceramic slurry, and the ceramic slurry can fill the gap on the side face of the original foam sheet, so that a ceramic filter blank with a smoother side face can be formed, and a ceramic foam filter with a smoother hard ceramic edge sealing can be obtained. The preparation method simultaneously carries out the preparation process and the edge sealing process of the foamed ceramic filter, greatly simplifies the production process and improves the production efficiency.
In some embodiments of the present application, in the above-described production method, the side surface of the foam base sheet is wound at least one turn with a strip-shaped coating material to form a coating layer. The coating material can be cut into strips with certain width and wound on the side surface of the foam sheet to form a coating layer. The strip-shaped coating material is adopted to wind the side face of the original foam sheet, so that the coating material can form a complete closed slurry coating boundary, the coating material is attached to the side face of the original foam sheet, and gaps between the coating material and the side face of the original foam sheet are uniform, so that a ceramic edge sealing with uniform thickness is formed.
In some embodiments of the present application, the coating material is selected from soft coating materials, preferably cloth or plastic film. Cloth includes, but is not limited to, cotton, hemp, silk, wool, rayon, synthetic fiber, or non-woven fabric; the plastic films include, but are not limited to, Polyethylene (PE), polyvinyl chloride (PVC), Polystyrene (PS), polyester film (PET), polypropylene (PP), or nylon.
In some embodiments of the present application, the above preparation method further comprises: when the foam sheet provided with the coating layer is subjected to slurry coating, two ends of the foam sheet coated with the slurry, which are not provided with the coating layer, are extruded. Through the extrusion step, the ceramic slurry can be completely filled in the gap between the coating layer and the foam sheet, so that the obtained biscuit of the foam ceramic filter is smooth in periphery and free of burrs and bulges, and the strength of the edge of the sintered foam ceramic filter can be improved. In addition, the redundant slurry can be extruded from the original foam sheet, so that the internal sizing of the original foam sheet is uniform, and the quality of the foamed ceramic filter is improved. The strip-shaped coating material is wound on the side surface of the foam sheet, and when sizing extrusion is performed, a sizing boundary with stable size can be formed on the foam sheet, so that the size precision of a finished foam ceramic filter product can be controlled.
In some embodiments of the present application, the coating layer is bonded to the foam base sheet by an adhesive when the side surface of the foam base sheet is coated. Through the step, the coating layer can be stably attached to the outer side of the original foam sheet, and the falling and displacement in the subsequent operation process are avoided.
In some embodiments herein, the binder is selected from an organic resin glue or an inorganic binder. Organic resin glues include, but are not limited to, silicone gum, epoxy resin glue, Polyurethane (PU) glue, amino resin glue, phenolic resin glue, acrylic resin glue, furan resin glue, resorcinol-formaldehyde resin glue, xylene-formaldehyde resin glue, unsaturated polyester glue, composite resin glue, polyimide glue, urea-formaldehyde resin glue, polyvinyl acetal, vinyl acetate emulsion glue, and other high molecular glues; inorganic binders include, but are not limited to, phosphate binders, silicate binders, and other inorganic binders.
In some embodiments of the present application, the coating layer has a thickness of 0.1 to 5 mm. For example, the thickness of the cladding layer may be 0.1mm, 0.2mm, 0.5mm, 1mm, 2mm, 3mm, 4mm, 5mm, or any range or subrange therebetween. The thickness of the coating layer can be determined according to the thickness of the coating material so as to ensure that the coating material is wound at least one circle on the side surface of the foam sheet.
In some embodiments of the present application, the width of the cover is no greater than the side height of the foam base sheet. When the width of the coating layer is less than or equal to the height of the side surface of the original foam sheet, the coating layer does not protrude out of the two ends of the original foam sheet. When the coating layer protrudes from two ends of the original foam sheet, a sharp-angled protrusion is formed at the protruding part of the coating layer after sizing, so that end face burrs of a finished foam ceramic filter product are formed, and a slag falling phenomenon is caused. Preferably, the width of the coating layer is equal to the height of the side surface of the foam sheet.
The application also provides the foamed ceramic filter prepared by the preparation method, the foamed ceramic filter is provided with ceramic edge sealing, the edge sealing process is not needed, the edge of the foamed ceramic filter has the characteristics of flatness, high strength and high temperature resistance, the phenomena of side surface sand hanging and slag falling can not occur in the production, transportation, installation and use processes, and the casting quality can not be influenced.
The following examples are non-limiting and merely illustrative, and the scope of the present application is defined by the claims.
Example 1
Take the preparation of an alumina ceramic foam filter as an example. Firstly, a polyurethane foam sample block with the length, width and height of 70mm 20mm is punched by using a die, cotton cloth is cut into strips with the height of 20mm and the length of 300mm, acrylic resin glue is coated on one side of a cloth strip, the glued side of the cloth strip is attached to the side face of the foam sample block for bonding, and the two sides of the cloth strip are aligned with the two ends of the foam sample block and are wound on the side face of the foam sample block. And (3) preparing alumina slurry for foamed ceramics simultaneously after bonding and curing, and mixing the raw material components according to the following weight ratio: and (3) preparing a slurry by ball milling the mixture for 2 hours and sieving the mixture by a 200-mesh sieve, coating the foam sample block with the slurry, and extruding the two ends of the foam sample block, which are not coated with the cloth strips, of the mixture. And then dried at 60-120 ℃ for 1h to form a green foam ceramic filter. And sintering the green foam ceramic filter at 1300 ℃ for 1h, and burning off the foam and the cotton cloth to form a finished foam ceramic filter product with an edge seal.
Example 2
Take the preparation of a zirconia ceramic foam filter as an example. Firstly, a polyurethane foam sample block with the diameter of 75mm and the height of 25mm is blanked by using a die, a polyethylene film is cut into a strip with the height of 25mm and the length of 250mm, aluminum dihydrogen phosphate binder is coated on one side of the polyethylene film and the side surface of the foam sample block, the side of the polyethylene film coated with the binder is attached to the side surface of the foam sample block for bonding, and the two sides of the polyethylene film are aligned with the two ends of the foam sample block and are wound on the side surface of the foam sample block. And preparing zirconia slurry for foamed ceramics simultaneously after bonding and curing, and mixing the raw material components in the following weight ratio: zirconia, alumina and silica sol are 8:1:1, the mixture is ball-milled for 1 hour and sieved by a 100-mesh sieve to obtain slurry, the slurry is adopted to carry out slurry coating on the foam sample block, and two ends of the foam sample block, which are not coated with the polyethylene film, are extruded. And then dried at 60-120 ℃ for 1h to form a green foam ceramic filter. And sintering the green foam ceramic filter at 1600 ℃ for 2h, and burning off the foam and the polyethylene film to form a finished foam ceramic filter with an edge seal.
Example 3
Take the preparation of silicon carbide ceramic foam filters as an example. Firstly, a polyurethane foam sample block with the length, width and height of 100mm x 22mm is punched by using a die, a non-woven fabric is cut into a strip with the height of 22mm and the length of 400mm, organic silica gel is coated on one side of a cloth strip, the side, coated with glue, of the cloth strip is attached to the side face of the foam sample block for bonding, and the two sides of the cloth strip are aligned with the two ends of the foam sample block and are wound on the side face of the foam sample block. And preparing silicon carbide slurry for the foamed ceramic simultaneously after bonding and curing, and mixing the raw material components according to the following weight ratio: and (2) silicon carbide, alumina and silica sol are mixed in a ratio of 6:3:1, the mixture is subjected to ball milling for 2 hours and is sieved by a 100-mesh sieve to obtain slurry, the slurry is adopted to carry out slurry coating on the foam sample block, and two ends of the foam sample block, which are not coated with the cloth strips, are extruded. And then dried at 60-120 ℃ for 1h to form a green foam ceramic filter. And sintering the green foam ceramic filter blank at 1280 ℃ for 1.5h, and burning off foam and non-woven fabrics to form a finished foam ceramic filter product with an edge seal.
Example 4
Take the preparation of a magnesia ceramic foam filter as an example. Firstly, a polyurethane foam sample block with the diameter of 50mm and the height of 20mm is punched by a mould, a polyester film is cut into strips with the height of 20mm and the length of 160mm, silica sol is coated on one side of the polyester film, the coated side of the polyester film is attached to the side face of the foam sample block for bonding, and the two sides of the polyester film are aligned with the two ends of the foam sample block and are wound on the side face of the foam sample block. And (3) preparing the magnesium oxide slurry for the foamed ceramics simultaneously after bonding and curing, and mixing the raw material components according to the following weight ratio: and (3) magnesium oxide and cellulose are 9:1, ball milling is carried out on the mixture for 1h, the mixture is sieved by a 100-mesh sieve, slurry is prepared, the slurry is adopted to carry out slurry coating on the foam sample block, and two ends of the foam sample block, which are not coated with the polyester film, are extruded. And then dried at 60-120 ℃ for 1h to form a green foam ceramic filter. And sintering the green foam ceramic filter blank at 1400 ℃ for 1h, and burning off the foam and the polyester film to form a finished foam ceramic filter product with an edge seal.
Example 5
Take the preparation of mullite foam ceramic filter as an example. Firstly, a polyurethane foam sample block with the length, width and height of 60mm, 60mm and 22mm is punched by using a die, a linen is cut into a strip with the height of 22mm and the length of 240mm, epoxy resin glue is coated on one side of a cloth strip, the glued side of the cloth strip is attached to the side surface of the foam sample block for bonding, and the two sides of the cloth strip are aligned with the two ends of the foam sample block and are wound on the side surface of the foam sample block. And (2) preparing mullite slurry for the foam ceramic when the bonding and curing are carried out, and mixing the raw material components according to the following weight ratio: and (3) mullite, namely alumina and silica sol, performing ball milling on the mixture for 2 hours, sieving the mixture by using a 100-mesh sieve to obtain slurry, coating the foam sample block with the slurry, and extruding the two ends of the foam sample block, which are not coated with the cloth strips. And then dried at 60-120 ℃ for 1h to form a green foam ceramic filter. And sintering the green body of the foamed ceramic filter at 1100 ℃ for 0.5h, and burning off the foam and the linen to form a finished product of the foamed ceramic filter with an edge sealing.
Comparative example 1
Take the preparation of an alumina ceramic foam filter as an example. Firstly, punching a polyurethane foam sample block with the length, width and height of 70mm x 20mm by using a die, then preparing alumina slurry for foamed ceramics, and mixing the raw material components according to the following weight ratio: and (3) carrying out ball milling on the mixture for 2h and sieving the mixture through a 200-mesh sieve to obtain slurry, carrying out slurry coating on the foam sample block by using the slurry, and extruding out excessive slurry. Cutting cotton cloth into strips with the height of 20mm and the length of 300mm, attaching the cloth strips to the side surfaces of the foam sample blocks after slurry coating, aligning the two sides of the cloth strips with the two ends of the foam sample blocks, winding the cloth strips on the side surfaces of the foam sample blocks, and drying the cloth strips at the temperature of 60-120 ℃ for 1 hour to form a biscuit of the foam ceramic filter. The biscuit of the foam ceramic filter is sintered for 1 hour at 1300 ℃, foams and cotton cloth are burnt off to form a finished product of the foam ceramic filter, the side surface of the foam ceramic filter is layered and cracked, and the edge sealing is not dense.
Comparative example 2
Take the preparation of an alumina ceramic foam filter as an example. Firstly, punching a polyurethane foam sample block with the length, width and height of 70mm x 20mm by using a die, then preparing alumina slurry for foamed ceramics, and mixing the raw material components according to the following weight ratio: the method comprises the following steps of preparing alumina, clay and silica sol, performing ball milling on a mixture for 2 hours, sieving the mixture by a 200-mesh sieve to obtain slurry, coating the slurry on a foam sample block, cutting cotton cloth into strips with the height of 20mm and the length of 300mm, attaching cloth strips to the side faces of the foam sample block after slurry coating, aligning the two sides of the cloth strips with the two ends of the foam sample block, winding the two ends of the foam sample block on the side faces of the foam sample block, and extruding the two ends of the foam sample block to squeeze out excessive slurry. And then dried at 60-120 ℃ for 1h to form a green foam ceramic filter. Sintering the biscuit of the foam ceramic filter at 1300 ℃ for 1h, burning off the foam and the cotton cloth to form a finished product of the foam ceramic filter, wherein the cloth strips attached to the side surface of the foam sample block are displaced in the process of extruding the foam sample block, and the side surface of the foam ceramic filter does not form a complete and compact edge sealing and is provided with a small amount of burrs.
Comparative example 3
Take the preparation of an alumina ceramic foam filter as an example. Firstly, punching a polyurethane foam sample block with the length, width and height of 70mm x 20mm by using a die, then preparing alumina slurry for foamed ceramics, and mixing the raw material components according to the following weight ratio: and (3) grinding the mixture for 2 hours and sieving the mixture through a 200-mesh sieve to obtain the slurry, wherein the ratio of the alumina to the clay to the silica sol is 7:2: 1. The slurry is adopted to carry out slurry hanging on the foam sample block, and redundant slurry is squeezed out. And then dried at 60-120 ℃ for 1h to form a green foam ceramic filter. And sintering the green foam ceramic filter blank at 1300 ℃ for 1h, and burning off foams to form a finished foam ceramic filter product, wherein the side surface of the foam ceramic filter has no edge sealing and a large amount of burrs.
The performance tests were performed on the ceramic foam filters prepared in the above examples and comparative examples to obtain the test results shown in table 1. Wherein, the normal temperature compression strength and the high temperature bending strength are tested according to the GB/T25139-2010 standard.
TABLE 1 Performance test results of ceramic foam filters
As can be seen from table 1, the room temperature compressive strength and the high temperature bending strength of the alumina ceramic foam filter with edge sealing prepared in example 1 of the present application are higher than those of the alumina ceramic foam filters with edge sealing prepared in comparative examples 1 and 2, which have poor edge sealing effect, and comparative example 3, which has no edge sealing.
In terms of the slag removal rate, the ceramic foam filters with edge seals prepared in examples 1 to 5 of the present application exhibited only a very small slag removal rate; the filter of the comparative examples 1 and 2 has high slag-dropping rate, and the filter of the comparative example 3 without edge sealing has higher slag-dropping rate, and the filter with high slag-dropping rate seriously affects the quality of the casting in the casting production. Therefore, the foamed ceramic filter with the edge sealing, which is prepared by the preparation method provided by the application, can obviously solve the problem of slag falling in the actual casting process, can obviously improve the yield of castings, and has great economic benefit.
It should be noted that different "one embodiment" or "an embodiment" in this application do not necessarily refer to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. It should be understood that the examples are illustrative of the present application and are not to be construed as limiting the scope of the present application.
Ranges can be expressed herein as from "about" one particular value, and/or to "about" another particular value. When such a range is expressed, examples include from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
Unless otherwise stated, it is not intended that any method described herein be construed as requiring that its steps be performed in a particular order. Thus, where a method claim does not actually recite an order to be followed by its steps or it does not otherwise specifically imply that the steps are to be limited to a specific order in the claims or specification, it is not intended that any particular order be implied.
Although the transition term "comprising" may be used to disclose various features, elements or steps of a particular embodiment, it should be understood that this implies that alternative embodiments may be included which may be described using the transition term consisting of, or consisting essentially of. Thus, for example, implied alternative embodiments to a process comprising a + B + C include embodiments where the process consists of a + B + C and embodiments where the process consists essentially of a + B + C.
Finally, although the present application has been described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the true spirit and scope of the present application, which is defined by the claims.
Claims (10)
1. A method of making a ceramic foam filter, comprising:
coating the side surface of the foam sheet with a coating material to form a coating layer,
and then carrying out ceramic slurry coating on the foam sheet with the coating layer, and then drying and sintering to obtain the foam ceramic filter.
2. The method of manufacturing a ceramic foam filter according to claim 1, further comprising: when the coating layer is coated on the foam sheet, the two ends of the foam sheet coated with the coating layer, which are not provided with the coating layer, are extruded.
3. The method of manufacturing a ceramic foam filter according to claim 1, wherein the strip-shaped coating material is wound around the side of the raw foam sheet at least one turn to form the coating layer.
4. The method of claim 1, wherein the coating material is selected from the group consisting of cloth and plastic film.
5. The method of claim 4, wherein the cloth is selected from cotton cloth, hemp cloth, silk, wool, rayon, synthetic fiber, or non-woven fabric; the plastic film is selected from Polyethylene (PE), polyvinyl chloride (PVC), Polystyrene (PS), polyester film (PET), polypropylene (PP) or nylon.
6. The method of claim 1, wherein the coating layer is bonded to the foam base sheet by an adhesive.
7. The method of claim 6, wherein the binder is selected from the group consisting of an organic resin binder, a phosphate binder, and a silicate binder.
8. The method of claim 1, wherein the coating layer has a thickness of 0.1 to 5 mm.
9. The method of claim 1, wherein the width of the coating layer is not greater than the height of the side of the foam base sheet.
10. A ceramic foam filter produced by the method for producing a ceramic foam filter according to any one of claims 1 to 9.
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