CN116177983A - 一种基于多级研磨技术的高强高韧性瓷绝缘材料配方 - Google Patents
一种基于多级研磨技术的高强高韧性瓷绝缘材料配方 Download PDFInfo
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- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 19
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- DLHONNLASJQAHX-UHFFFAOYSA-N aluminum;potassium;oxygen(2-);silicon(4+) Chemical compound [O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[Al+3].[Si+4].[Si+4].[Si+4].[K+] DLHONNLASJQAHX-UHFFFAOYSA-N 0.000 claims abstract description 12
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- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 2
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Abstract
本发明公开了一种基于多级研磨技术的高强高韧性瓷绝缘材料配方，由以下重量份数的原料制成：铝矾土30‑40份,可塑性粘土35‑45份，钾长石5‑10份，章村土10‑15份。本发明采用了通过刚玉相增强、并设计基质相组成与结构的方案，即以煅烧铝矾土的形式引入刚玉相，达到48‑52％的氧化铝含量，作为力学性能改善的关键，引入0.5‑1％的大原子半径低熔点氧化物，降低液相形成温度，从而降低烧成温度，解决高氧化铝含量带来的高烧成温度的问题，同时不劣化瓷件的电气性能。
Description
技术领域
本发明涉及高强高韧性瓷绝缘材料，尤其涉及一种基于多级研磨技术的高强高韧性瓷绝缘材料配方。
背景技术
随着我国高速铁路近几年的迅速发展，对绝缘子的质量要求越来越高，根据近年来铁路绝缘子运营情况来看，亟需一种具有高性能且能适应各种环境并长期稳定运行的瓷绝缘子产品，目前国内国内瓷绝缘子材料配方有很多弊端，原料大多采用原矿，成分不易控制，以常见的C130高强铝质瓷为例，C130高强铝质瓷的上釉试条强度≥160Mpa，实际产品生产出来的产品断裂破坏应力大多低于80Mpa,材料利用率不足50％，且强度波动大，这类配方产品服役长时间运行后有断裂风险，许多厂家靠添加工业氧化铝的方式来提高配方强度并且很有效果，可是，工业氧化铝的价格高，配方里加多工业氧化铝后降低产品制造时候的可塑性能，严重影响生产合格率，所以这个配方实际不适合大规模使用。
发明内容
本发明的目的是提供一种基于多级研磨技术的高强高韧性瓷绝缘材料配方，所要解决的问题是，由于煅烧矾土形成的刚玉相起到颗粒弥散增强作用，但硬度较高的煅烧矾土在所有原料一次球磨的传统工艺条件下难以达到较小的细度和合理的分布，常存在较粗的颗粒和较宽的粒径分布，其弥散增强机制未充分发挥、且产品稳定性也不佳，为此，采取先部分将矾土预磨到一定细度后再和其他原料混磨的工艺，达到提高力学性能和减小分散性的目的。
为了达到上述目的，本发明是通过以下技术方案实现的：
本发明提供一种基于多级研磨技术的高强高韧性瓷绝缘材料配方，由以下重量份数的原料制成：铝矾土30-40份,可塑性粘土35-45份，钾长石5-10份，章村土10-15份。
优选地，所述铝矾土包括超细矾土、矾土粉，所述超细矾土、矾土粉的氧化铝含量在百分之八十五以上。
优选地，所述超细矾土为5-10份，且超细矾土细度过325目筛余量≤1％。
优选地，所述矾土粉为30-35份。
优选地，该高强高韧性瓷绝缘材料的组分及重量包括：铝矾土30份、可塑性粘土35份、钾长石5份、章村土10份。
优选地，该高强高韧性瓷绝缘材料的组分及重量包括：铝矾土35份、可塑性粘土40份、钾长石8份、章村土12份。
优选地，该高强高韧性瓷绝缘材料的组分及重量包括：铝矾土40份、可塑性粘土45份、钾长石10份、章村土15份。
本发明的有益效果：本发明采用了通过刚玉相增强、并设计基质相组成与结构的方案：即以煅烧铝矾土的形式引入刚玉相，达到48-52％的氧化铝含量，作为力学性能改善的关键，引入大原子半径低熔点氧化物，降低液相形成温度，从而降低烧成温度，解决高氧化铝含量带来的高烧成温度的问题，同时不劣化瓷件的电气性能，引入煅烧高岭土和纳米ZrO2作为基质中莫来石形成的晶核剂，促进玻璃相向莫来石的转变，并抑制莫来石晶粒的粗化，最终形成高含量莫来石网络增强玻璃相的基质，以此提高瓷件的热稳定性，并在一定程度上提高力学性能，引入高可塑性粘土和有机物以改善泥料的可塑性，从而消除高矾土含量带来塑性下降的影响，采用了二次球磨工艺，先预磨铝矾土至一定细度得到超细矾土，再与其他原料一起球磨，以提高整体的研磨效率和有效控制原料的粒径分布，提高产品的稳定性，由于引入了超细铝矾土，促进熔体中二次莫来石相的形成，通过莫来石相的针状网络促进基质与刚玉相的良好结合，从而进一步改善瓷件的力学性能，该配方烧成以后晶粒细小，且均匀分布，初始裂纹尺寸小，断裂面积小，含危险裂纹的机会少，断裂的概率也小，所以该配方生产的绝缘子产品不仅极限强度高，而且内部结构均匀，破坏应力值分散性小，产品可靠性高。
具体实施方式
下面结合实施例，对本发明的具体实施方式作进一步描述。以下实施例仅用于更加清楚地说明本发明的技术方案，而不能以此来限制本发明的保护范围。
实施例1
小份高强高韧性瓷绝缘材料的制作方法，具体步骤如下：
1).采用二次球磨工艺，先预磨铝矾土得到超细矾土；
2).再与其他原料一起球磨，以提高整体的研磨效率和有效控制原料的粒径分布，提高产品的稳定性，其中，铝矾土为30份、可塑性粘土为35份、钾长石为5份、章村土为10份。
实施例2
中份高强高韧性瓷绝缘材料的制作方法，具体步骤如下：
1).采用二次球磨工艺，先预磨铝矾土得到超细矾土；
2).再与其他原料一起球磨，以提高整体的研磨效率和有效控制原料的粒径分布，提高产品的稳定性，其中，铝矾土为35份、可塑性粘土为40份、钾长石为8份、章村土为12份。
实施例3
大份高强高韧性瓷绝缘材料的制作方法，具体步骤如下：
1).采用二次球磨工艺，先预磨铝矾土得到超细矾土；
2).再与其他原料一起球磨，以提高整体的研磨效率和有效控制原料的粒径分布，提高产品的稳定性，其中，铝矾土为40份、可塑性粘土为45份、钾长石为10份、章村土为15份；
采用了通过刚玉相增强、并设计基质相组成与结构的方案：即以煅烧铝矾土的形式引入刚玉相，达到48-52％的氧化铝含量，作为力学性能改善的关键；引入0.5-1％的大原子半径低熔点氧化物，降低液相形成温度，从而降低烧成温度，解决高氧化铝含量带来的高烧成温度的问题，同时不劣化瓷件的电气性能；引入8％的煅烧高岭土和1-2％的纳米ZrO2作为基质中莫来石形成的晶核剂，促进玻璃相向莫来石的转变，并抑制莫来石晶粒的粗化，最终形成高含量莫来石网络增强玻璃相的基质，以此提高瓷件的热稳定性，并在一定程度上提高力学性能；引入3-5％左右的高可塑性粘土和0.3％的有机物以改善泥料的可塑性，从而消除高矾土含量带来塑性下降的影响，采用了二次球磨工艺，先预磨铝矾土至一定细度得到超细矾土，再与其他原料一起球磨，以提高整体的研磨效率和有效控制原料的粒径分布，提高产品的稳定性，由于引入了超细铝矾土，促进熔体中二次莫来石相的形成，通过莫来石相的针状网络促进基质与刚玉相的良好结合，从而进一步改善瓷件的力学性能，该配方烧成以后晶粒细小，且均匀分布，初始裂纹尺寸小，断裂面积小，含危险裂纹的机会少，断裂的概率也小。所以该配方生产的绝缘子产品不仅极限强度高，而且内部结构均匀，破坏应力值分散性小，产品可靠性高。该配方上釉试条强度可达180MPa,生产出来的产品强度可达110MPa以上，材料利用率超过60％，远高于同类型产品水准。
以上所述，仅为本发明较佳的具体实施方式，但本发明的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，根据本发明的技术方案及其发明构思加以等同替换或改变，都应涵盖在本发明的保护范围之内。
Claims (7)
1.一种基于多级研磨技术的高强高韧性瓷绝缘材料配方，其特征在于，由以下重量份数的原料制成：铝矾土30-40份,可塑性粘土35-45份，钾长石5-10份，章村土10-15份。
2.根据权利要求1所述的一种基于多级研磨技术的高强高韧性瓷绝缘材料配方，其特征在于,所述铝矾土包括超细矾土、矾土粉，所述超细矾土、矾土粉的氧化铝含量在百分之八十五以上。
3.根据权利要求2所述的一种基于多级研磨技术的高强高韧性瓷绝缘材料配方，其特征在于,所述超细矾土为5-10份，且超细矾土细度过325目筛余量≤1％。
4.根据权利要求3所述的一种基于多级研磨技术的高强高韧性瓷绝缘材料配方，其特征在于,所述矾土粉为30-35份。
5.根据权利要求4所述的一种基于多级研磨技术的高强高韧性瓷绝缘材料配方，其特征在于,该高强高韧性瓷绝缘材料组分及重量包括：铝矾土30份、可塑性粘土35份、钾长石5份、章村土10份。
6.根据权利要求5所述的一种基于多级研磨技术的高强高韧性瓷绝缘材料配方，其特征在于,该高强高韧性瓷绝缘材料的组分及重量包括：铝矾土35份、可塑性粘土40份、钾长石8份、章村土12份。
7.根据权利要求1所述的一种基于多级研磨技术的高强高韧性瓷绝缘材料配方，其特征在于,该高强高韧性瓷绝缘材料的组分及重量包括：铝矾土40份、可塑性粘土45份、钾长石10份、章村土15份。
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