CN115057710A - 一种耐高温弹性陶瓷泡沫及其制备方法 - Google Patents
一种耐高温弹性陶瓷泡沫及其制备方法 Download PDFInfo
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Abstract
本发明属于材料技术领域,具体涉及一种耐高温弹性陶瓷泡沫及其制备方法。包括短切陶瓷纤维、高温粘接剂和造孔剂,陶瓷纤维直径为5nm‑1000nm,高温粘接剂的直径为0.5μm‑5μm。该耐高温弹性陶瓷泡沫可以耐1100℃‑1300℃高温,热导率为0.030W/m·K‑0.040W/m·K,密度为20mg cm‑3‑50mg cm‑3,压缩强度可达0.2MPa‑0.4MPa,孔隙率在97%以上。
Description
技术领域
本发明属于材料技术领域,具体涉及一种耐高温弹性陶瓷泡沫及其制备方法。
背景技术
泡沫材料具有轻质化、多孔结构、低热导率等特性,是一种优异的绝热保温材料,在航天、航空、空间、船舶、核电等许多高技术领域有广阔的应用。其中陶瓷泡沫具有耐高温、低导热的性能可用在高温度环境中,但是存在质脆、力学性能差、耐高温性能不足等缺点亟待改善。因此发展一种具有弹性的无机陶瓷泡沫隔热材料具有重要的意义。
发明内容
针对以上问题,本发明目的在于提供一种耐高温弹性陶瓷泡沫,该弹性陶瓷泡沫具有耐高温、轻质、形状回复能力强、低热导率、高比表面积、抗热震特性等特点,此外,其气孔大小和形状以及弹性可根据使役性能需求进行调控,可以满足高温防热领域的使用需求。
为了达到上述目的,可以采用以下技术方案:
本发明一方面提供了一种耐高温弹性陶瓷泡沫,其包括短切陶瓷纤维、高温粘接剂和造孔剂,陶瓷纤维直径为5nm-1000nm,高温粘接剂的直径为0.5μm-5μm。
本发明另一方面提供了一种上述耐高温弹性陶瓷泡沫的制备方法,包括:(1)将切碎的陶瓷纤维与水混合充分分散得分散液a;(2)将高温粘接剂、造孔剂与分散液a混合均匀得分散液b;(3)将分散液b倒入模具中,制备成湿陶瓷泡沫胚体,干燥得多孔隔热陶瓷泡沫预成型体;(4)将多孔隔热陶瓷泡沫预成型体在马弗炉中热处理后得到耐高温弹性陶瓷泡沫。
本发明有益效果至少包括:
(1)本发明提供的耐高温弹性陶瓷泡沫可以耐1100℃-1300℃高温,热导率为0.030W/m·K-0.040W/m·K,密度为20mg/cm3-50mg/cm3,压缩强度可达0.2MPa-0.4MPa,孔隙率在95%以上;
(2)本发明提供的耐高温弹性陶瓷泡沫压缩强度最高可达0.3Mpa-0.4MPa,且可以实现压缩回复率在90%以上,解决了刚性隔热瓦脆性大,抗震动、抗噪声性能弱等问题;
(3)本发明提供的耐高温弹性陶瓷泡沫的制备方法采用压滤法或真空抽滤的方法成型,工艺简单易行,尺寸及形状可调控,而且易于加工,可根据具体设计要求确定。
具体实施方式
所举实施例是为了更好地对本发明进行说明,但并不是本发明的内容仅局限于所举实施例。所以熟悉本领域的技术人员根据上述发明内容对实施方案进行非本质的改进和调整,仍属于本发明的保护范围。
本文中使用的术语仅用于描述特定实施例,并且无意于限制本公开。除非在上下文中具有明显不同的含义,否则单数形式的表达包括复数形式的表达。如本文所使用的,应当理解,诸如“包括”、“具有”、“包含”之类的术语旨在指示特征、数字、操作、组件、零件、元件、材料或组合的存在。在说明书中公开了本发明的术语,并且不旨在排除可能存在或可以添加一个或多个其他特征、数字、操作、组件、部件、元件、材料或其组合的可能性。如在此使用的,根据情况,“/”可以被解释为“和”或“或”。
本发明一方面提供了一种耐高温弹性陶瓷泡沫,在一些实施例中,其包括短切陶瓷纤维、高温粘接剂和造孔剂,陶瓷纤维直径为5nm-1000nm,比如10nm、100nm、500mm和800mm等;高温粘接剂的直径为0.5μm-5μm;比如1μm、2μm或4μm等;
具体地,上述耐高温弹性陶瓷泡沫为多孔结构,可以向孔内填充二氧化硅气凝胶、氧化锆气凝胶等隔热组元,获得隔热性能更佳优异的耐高温隔热材料。
进一步地,上述耐高温弹性陶瓷泡沫的密度为20mg/cm3-50mg/cm3。
进一步地,上述造孔剂可以为硅粉、碳粉、淀粉、和氯化钠中的一种或几种。
进一步地,上述陶瓷纤维可以为二氧化硅、石英、氧化铝、氧化锆等陶瓷纤维中的一种或多种。例如,陶瓷纤维可以为二氧化硅和氧化铝的混合,质量比可以为4:1。
进一步地,上述高温粘接剂可以为硅粉、碳化硅、氧化硼、二氧化硅、硼硅玻璃中的一种或多种。比如高温粘接剂可以为氮化硼、氧化硼和二氧化硅的混合物,质量比例为3:1:1。
本发明另一方面提供了一种上述耐高温弹性陶瓷泡沫的制备方法,在一些实施例中,可以包括:(1)将切碎的陶瓷纤维与水混合充分分散得分散液a;(2)将高温粘接剂、造孔剂与分散液a混合均匀得分散液b;(3)将分散液b倒入模具中,制备成湿陶瓷泡沫胚体,干燥得多孔陶瓷泡沫预成型体;(4)将多孔陶瓷隔热泡沫预成型体在马弗炉中热处理后得到耐高温弹性陶瓷泡沫。
进一步地,上述步骤(3)中,可以采用压滤法或真空抽滤法制备成所需密度的多孔陶瓷泡沫预成型体,需要说明的是,在步骤中,需要根据耐高温弹性陶瓷泡沫所需的高孔隙率,通过控制造孔剂用量以及压滤过程,使得最终得到的耐高温弹性陶瓷泡沫的密度为20mg/cm3-50mg/cm3。
进一步地,上述耐高温弹性陶瓷泡沫的制备方法中,切碎的陶瓷纤维长度小于1mm。
进一步地,上述耐高温弹性陶瓷泡沫的制备方法中,切碎的陶瓷纤维、高温粘接剂、造孔剂与水的质量比为1:(0.02-0.04):(0.4-0.6):(20-40),切碎的陶瓷纤维、高温粘接剂、造孔剂与水的质量比为1:0.03:0.5:30或1:0.03:0.45:35等。
进一步地,上述耐高温弹性陶瓷泡沫的制备方法中,步骤(2)中,混合均匀的方法包括:搅拌混合均匀,搅拌转速为800r/min-1200r/min,比如900r/min、1000r/min或1150r/min等;搅拌时间为50min-70min,比如55min、60min或65min等;应当理解的是,搅拌的方式或设备可以是本领域所已知的方式或者设备,比如搅拌机、磁石搅拌等。
进一步地,上述耐高温弹性陶瓷泡沫的制备方法中,步骤(3)中,干燥温度可以为75℃-85℃,比如78℃、80℃或82℃等;在某些具体实施例中,为了干燥充分以及节约时间,干燥时间可以为1h;应当理解的是,干燥的方式可以是本领域所已知的方式,比如使用烘箱干燥。
进一步地,上述耐高温弹性陶瓷泡沫的制备方法中,步骤(4)中,热处理温度可以为1100℃-1400℃,比如1200℃、1300℃或1350℃等;热处理时间可以为40min-60min,比如45min、50min或55min等。
具体地,上述高温粘结剂在高温熔融或氧化生成成的氧化物熔融附着在纤维表面作为纤维的粘结剂将纤维搭接起来,在纤维搭接处形成了节点,使得纤维骨架具有很高的力学性能;纤维本身介电性能优良,骨架材料的多孔结构提供了又隔热性能和透波性能,实现了介电性能和隔热性能的协调匹配。
具体地,本发明采用短切陶瓷纤维作为结构单元,陶瓷粉体(硅粉、碳化硅、氧化硼、二氧化硅、硼硅玻璃中的一种或多种)作为粘接剂,通过在陶瓷配料中添加造孔剂(碳粉、氯化钠、淀粉等),利用造孔剂在胚体中占据一定的空间,然后经过高温烧结或挥发,离开基体而在陶瓷体中留下空腔。所制备的材料具有可压缩形变量大、轻质、耐高温、隔热等性能,其气孔大小可控、形状可控,同时弹性可根据使用需求进行调控。
为了更好地理解本发明,下面结合具体示例进一步阐明本发明的内容,但本发明的内容不仅仅局限于下面的示例。
实施例1
本发明实施例中,短切陶瓷纤维由二氧化硅和氧化铝按照质量比4:1组成,平均直径为200nm;高温粘接剂由氮化硼、氧化硼和二氧化硅按照质量比例为3:1:1组成;造孔剂由NaCl和淀粉按1:1组成。
然后按照以下步骤制备耐高温弹性陶瓷泡沫:
(1)将16g二氧化硅纤维和4g氧化铝纤维加入1000g去离子水中,分散均匀,将搅拌好的分散液倒入烧杯中;转速为1000r/min,搅拌时间为2min-3min。
(2)将0.24g氮化硼、0.08g氧化硼和0.08g二氧化硅陶瓷颗粒加入分散液中,用机械搅拌机搅拌均匀,搅拌机转速为1200r/min,搅拌时间为60min;搅拌过程中混合添加3.2g成比例的造孔剂。
(3)将步骤(2)搅拌好的分散液倒入模具中,模具为底部有小孔、长宽高为120*50*250mm的长方形套筒;采用压滤法控制厚度,制备成厚度为20mm的陶瓷泡沫湿坯。将陶瓷泡沫湿坯放入烘箱干燥,得到陶瓷泡沫预成型体,其中烘箱温度为100℃,保温时间为1h;
(4)将步骤(3)中得到的预成型体放入马弗炉中热处理,热处理温度为1100℃,热处理时间为40min得到耐高温弹性陶瓷泡沫;
将制备得到的耐高温弹性陶瓷泡沫采用GB/T10295-2008标准进行热导率测试,测试结果为:室温下热导率为0.03016W/m·K;采用GB/T5597-1999标准进行介电常数测试,测试结果为介电常数为1.1;采用GB/T1964-1996标准进行压缩强度测试,测试结果为:压缩强度为0.2Mpa;根据样品密度(20mg cm-3-50mg cm-3)以及孔隙率计算公式(1-样品密度/所用原材料密度)可得孔隙率范围在97.7%-99%。
最后说明的是,以上实施例仅用以说明本发明的技术方案而非限制,尽管参照较佳实施例对本发明进行了详细说明,本领域的普通技术人员应当理解,可以对本发明的技术方案进行修改或者等同替换,而不脱离本发明技术方案的宗旨和范围,其均应涵盖在本发明的权利要求范围。
Claims (10)
1.一种耐高温弹性陶瓷泡沫,其特征在于,包括短切陶瓷纤维、高温粘接剂和造孔剂,陶瓷纤维直径为5nm-1000nm,高温粘接剂的直径为0.5μm-5μm。
2.根据权利要求1所述的耐高温弹性陶瓷泡沫,其特征在于,造孔剂为硅粉、碳粉、淀粉和氯化钠中的一种或几种。
3.根据权利要求1或2所述的耐高温弹性陶瓷泡沫,其特征在于,陶瓷纤维为二氧化硅、石英、氧化铝、氧化锆等陶瓷纤维中的一种或多种。
4.根据权利要求1或2所述的耐高温弹性陶瓷泡沫,其特征在于,高温粘接剂为硅粉、碳化硅、氧化硼、二氧化硅、硼硅玻璃中的一种或多种。
5.权利要求1至4中任一所述的耐高温弹性陶瓷泡沫的制备方法,其特征在于,包括:(1)将切碎的陶瓷纤维与水混合充分分散得分散液a;(2)将高温粘接剂、造孔剂与分散液a混合均匀得分散液b;(3)将分散液b倒入模具中,制备成陶瓷泡沫湿坯,干燥得多孔陶瓷泡沫预成型体;(4)将多孔陶瓷泡沫预成型体在马弗炉中热处理得耐高温弹性陶瓷泡沫。
6.根据权利要求5所述的耐高温弹性陶瓷泡沫的制备方法,其特征在于,切碎的陶瓷纤维长度小于1mm。
7.根据权利要求5或6所述的耐高温弹性陶瓷泡沫的制备方法,其特征在于,切碎的陶瓷纤维、高温粘接剂、造孔剂与水的质量比为1:(0.02-0.04):(0.4-0.6):(20-40)。
8.根据权利要求5或6所述的耐高温弹性陶瓷泡沫的制备方法,其特征在于,步骤(2)中,混合均匀的方法包括:搅拌混合均匀,搅拌转速为800r/min-1200r/min。
9.根据权利要求5或6所述的耐高温弹性陶瓷泡沫的制备方法,其特征在于,步骤(3)中,干燥温度为75℃-85℃。
10.根据权利要求5或6所述的耐高温弹性陶瓷泡沫的制备方法,其特征在于,步骤(4)中,热处理温度为1100℃-1400℃。
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