CN117484641A - 一种赛隆陶瓷水阀片的注射成型方法 - Google Patents
一种赛隆陶瓷水阀片的注射成型方法 Download PDFInfo
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- CN117484641A CN117484641A CN202311362775.9A CN202311362775A CN117484641A CN 117484641 A CN117484641 A CN 117484641A CN 202311362775 A CN202311362775 A CN 202311362775A CN 117484641 A CN117484641 A CN 117484641A
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Abstract
本发明涉及一种注射成型方法,尤其涉及一种赛隆陶瓷水阀片的注射成型方法。按以下步骤进行:混料>造粒>注塑成型>催化脱酯>烧结。精度可以达到<基本尺寸*±0.5%精度,避免了后期对陶瓷进行加工,只在需要面接触的情况下,对表面进行加工。节约了加工时间和成本。
Description
技术领域
本发明涉及一种注射成型方法,尤其涉及一种赛隆陶瓷水阀片的注射成型方法。
背景技术
现有的赛隆陶瓷由于硬度高,韧性较好,自润滑性也不错,但其硬度较高,机械加工中很有难度。陶瓷的水阀片目前全部采用了95或96瓷,是一个成熟的产品。随着技术的发展,行业的发展,水阀片向着立体化方向发展。比如恒温水龙头,定温水龙头等。水龙头中会使用到耐腐蚀的部件,塑料件耐性和强度不免,时间久之后,塑料件会变形。铜件,不锈钢件在长期使用过程中也会生锈。这在不同地区,水的酸碱性不同,长时间使用过程中提出了更高要求。在管道给排水的设计中需要一种强度高,韧性好,成本低,耐腐蚀,耐疲劳性好的材料。赛隆材料是比较理想的选择。
查询了专利系统和文献,没有赛隆陶瓷在这个方面的应用。赛隆陶瓷在密封性上有比较成熟的应用。而且高频使用的情况下,寿命也优于普通材料。现有的产品,采用了氧化锆来做类似的产品。氧化锆在使用过程中,性能也还不错。强度,韧性,摩擦系数也低。总体来讲不考虑价格因素和原材料的稀缺性也是一个不错的材料。但氧化锆在200度左右的水条件下,氧化锆容易出现强度丢失而断裂的情况。在200度左右有水的条件下,最好不使用氧化锆。氧化锆的原材料有稀缺性,其储量远不如硅,铝,氧,氮这几种元素的来源丰富。所以在民用上大量使用此材料不太适合。
水龙头的更新中,陶瓷水阀片用于水龙头的生产已经有较长的历史。在此技术传入我国后,基本上取代了传统鸡公水龙头。随着社会的发展,恒温水龙头,定温水龙头等新型产品的出现,水流关断的要求越来越高,原来的生产条件下,已经满足不了精密的3D设计产品。现有的氧化锆材料制作的产品,采用注射成型的氧化锆产品已经能达到使用要求。
现有的技术中使用氧化铝陶瓷,主要是95或96陶瓷,这类产品主要采用了干压和热压铸的工艺技术。干压适合两边对压,结构相对简单且有一定厚度的产品,一般正常的结构宽度方向不低于2mm,不然会有不致密导导致失效的问题。热压铸的产品可以做到一定程度的复杂结构,但其成品的精度比较大,在精密配合时,往往达不到要求。热压铸工艺在做复杂的结构时,在加热脱蜡时,产品结构容易形变,导致产品在配合工作时失效。本发明将材料与注射催化脱酯工艺结合,来达到产品的使用要求。
理论上说赛隆采用热压铸的工艺也是可行的,但由于热压铸的工艺也达不到形状和尺寸要求也不能满足使用要求。
目前专利还没有将氧化锆用于水阀片技术申请。因此也不方便拿氧化锆来应对描述。赛隆陶瓷已在机械工业上用做轴承、密封件、焊接叁筒和定位销。普通定位销的寿命为7000次,而赛隆定位销可达500万次。赛隆做成密封件,其相互间的贴合性能也优于其他材料。
它还具有良好的高温机械性能,制作成汽车内燃机挺杆,运行60000km,仅磨损0.75μm。
它已用作连铸用的分流环,热电偶保护套管,晶体生长器具,坩埚,高炉下部内衬,铜,铝合金管拉拔芯棒以及滚轧、挤压和压铸用模具材料。
将赛隆陶瓷应用于水阀片也充分发挥了其技术特长。
发明内容
本发明主要是解决现有技术中存在的不足,提供一种产品精度高,避免了后期对陶瓷进行加工,节约了加工时间和成本的一种赛隆陶瓷水阀片的注射成型方法。
本发明的上述技术问题主要是通过下述技术方案得以解决的:
一种赛隆陶瓷水阀片的注射成型方法,按以下步骤进行:
混料>造粒>注塑成型>催化脱酯>烧结;
(一)混料:
赛隆粉体,其混料的基本构成是:
将Si粉30~36份,氧化铝粉30~40份,助烧剂Y2O3 5~8份进行混料组成无机粉体的部份;
(二)造粒:
将混好的物料加入有机物和一维粉体进行充分混合;
一维粉体其占比为赛隆粉体重量的5%~20%;
有机物:POM主剂,POM主剂为聚甲醛塑料,熔融指数>45:重量比100~140份;
骨架剂:4-20份;
偶联剂:2-8份;
其他助剂:排气剂2-5份,流平剂3-8份,熔接助剂3-12份;
首先赛隆粉体加入后,将偶联剂和熔接助剂加入,在低温阶段让三者反复搅拌,使赛隆粉体的表面、偶联剂和熔接助剂的表面进行充分混合,发生表面反应,将赛隆粉体颗粒进行包裹;
搅拌时间:每分60转的机台混料60分钟;
其后再加入POM主剂,骨架剂、一维粉体、排气剂2-5份和流平剂3-8份,对物料升温,边升温边搅拌,等物料全部熔化,成形泥状的流体,再混炼0.5-3小时;
(二)注塑成型:
采用注塑工艺时:采用注塑机将造粒的物料注入到模具中,得到所需形状的工艺;注塑机的设定温度为175-200度,注塑机中的炮筒温度为185-195度,模具温度设定为60-130度,注射速度根据产品结构有所不同为80mm/s到300mm/s之间,注射压力小于200Mpa,保压压力小于100Mpa,成型时间一般小于1秒,大型产品会到10秒左右;
注射采用低速高压模式;
(三)催化脱酯:
在催化脱酯炉中进行,脱酯炉的采用催化的酸不同,设定参数有所不同,脱酯工艺采用二种酸:一种是98%以上的浓硝酸,另一种是固体草酸,纯度97%以上;
采用浓硝酸时:设定脱脂温度是90~120度,进炉量是2-10ml/min,进酸量根据设备大小有所不同,进酸量是在4~10ml/min;
采用固体酸时:进酸量是2~6g/min,脱脂温度设定是125~140度;温度的设定需要考虑到最终产品的尺寸精度有所调整;
氮气流量可依据设备设计时的要求进行,以600L的脱酯炉为例:氮气的流速设定在45~60L/min;经过10小时的脱脂,产品中的POM基本脱除干净,即达到脱酯的目的;
(四)烧结:
烧结的温度为1600~1900度,在氮气条件下烧结,氮气要求纯度99.99%以上的纯度,露点-60度以下;
烧结温度的高低取决于粉体中的助烧剂情况;
助烧结剂的种类比较多,助剂较多时烧结温度较低:
如助烧剂Y2O3含量较高在6%时,则烧结温度在1650度~1700度可以烧结;如助烧剂Y2O3的含量在4%时,其烧结温度1800度~1900度,还需要氮气加压烧结;
在高纯的氮气情况,有加压和无压的烧结工艺:
无压烧结时:是指烧结氮气的压力为正常大气压力;
加压烧结是指烧结的压力在10~50Mpa;
在最高烧结温度下,一般保持2~4小时后,断电降温冷却,即完成烧结;氮气加压烧结一般时在高温段进行加压,正常升温段,基本不加压烧结。
2、根据权利要求1所述的一种赛隆陶瓷水阀片的注射成型方法,其特征在于:步骤(一)中,混合可以采用球磨、行星磨相关工艺将成份均匀化;根据不同设备,其球磨工艺会有不同;但要求行星磨采用氧化铝球、氧化铝瓷罐进行球磨,防止其他元素对产品进行污染;
混合时,需采用氮化保护,防止金属硅粉氧化;行星磨是每分钟30~200转/每分,球磨机是20~80转/每分;待粉体小于5um后即达到要求;
步骤(二)中,一维粉体为碳化硅晶须,石墨纤维,碳纤,氧化镁晶须,氧化铝晶须,硼酸铝晶须,氮化硅晶须中的一种或多种;
密炼机的温度为165~180度,搅拌转速为60~200转/每分。
3、根据权利要求1所述的一种赛隆陶瓷水阀片的注射成型方法,其特征在于:POM主剂为共聚POM。
4、根据权利要求1所述的一种赛隆陶瓷水阀片的注射成型方法,其特征在于:POM主剂为共聚POM。
5、根据权利要求1所述的一种赛隆陶瓷水阀片的注射成型方法,其特征在于:骨架剂的选择:骨架剂的选择范围比较多:
选择PA尼龙系列时,注塑品的强度较高;
选择聚醋酸乙烯EVA系列的产品时,注塑时的流动性较好;
选择聚乙烯聚丙烯系列产品,如氧化聚乙烯,氧化聚两烯相关材料时,在注塑时提供更好的韧性;
选择聚酯PC,PS的材料做为骨架剂时会提供注塑品更好的表面性能和更好的抗缩性能。
技术效果:
1.性能远优于现在的氧化铝陶瓷。强度和韧性比氧化铝强,在水流控制的结构件中可以取代铜应用于此领域。
2.成本高于氧化铝,成本却低于氧化锆。从耐腐性来看,应用环境比氧化铝要更广一些,在碱性水质的条件下,寿命更长。总的来看,其性价比比较高。
3.材料来源丰富,不会受到矿产的限制。
赛隆一般使用β-Sialon、α-Sialon以及二种赛隆粉的混合材料。β-Sialon具有更好的韧性和耐疲劳性,在水阀片的使用中上,占主体。α-Sialon赛隆具夺更好的强度和硬度,多使用于替代铜,塑料件用于对强度和耐腐蚀有要求的应用场合。在二者就用之间,可以调节二者的比例。一般α-Sialon在占比上约是总体重量比的45%以下。
POM主剂是催化脱脂系统的主要载剂,在目前的技术水平上均要求POM主剂的的熔融指数在45以上为宜。比较典型的是旭化成的9520,F520的型号。在将来的技术开发中,也会定制适合的POM主剂。本发明中指定保护是共聚POM主剂,均聚POM不是本发明要求体系。
骨架剂:在催化脱脂结束之后,用来维持产品结构形状。骨架剂与POM以及其他助剂共同维持注塑胚的强度。骨架剂的选择范围比较多:选择PA尼龙系列时,注塑品的强度较高,选择聚醋酸乙烯EVA系列的产品时,注塑时的流动性较好,选择聚乙烯聚丙烯等系列产品,如氧化聚乙烯,氧化聚两烯等材料时,在注塑时提供更好的韧性,选择聚酯PC,PS的材料做为骨架剂时会提供注塑品更好的表面性能和更好的抗缩性能。骨架剂的的选择大本专利中,提供的了PA,EVA,PC,PS,PE,PP,PMMA等及其衍生品种,衍生品种如PE,PP的氧化系列,PP,PE,PC等的接枝系列产品。骨架剂的选择与粉体和偶联剂存在关联性,不同的粉体,选择不同的骨架剂时其偶联剂的选择也是不同,需要适时进行调整。
偶联剂:偶联剂是解决粉体与POM,骨架剂之间的相溶性问题的助剂。常见的硅酸酯系,钛系,铝系列,锆系列的偶联剂,不太常见的如:双金属偶联剂、磷酸酯偶联剂、硼酸酯偶联剂、木质素偶联剂、铬络合物及其它高级脂酸、醇、酯的偶联剂。偶联剂的选择视不同厂家的粉体,以及不同的骨架剂,需要对偶联剂进行选择。
其他助剂:其他助剂主要用途是改善物料的其他性能,诸如流动性,保形性,表面流平性,脱模韧性所提供的改变性能。这有时需要考虑到脱酯所用的酸品种,采用草酸时脱酯温度会比较高,如果高温下保型能力不佳,最终产品的尺寸精度会达不到理想的结果。此时需要其他的助剂进行一定的补偿。
脱酯:由于碳化硅可能与硝酸可能产生反应,优先草酸进行脱酯脱脂。
精磨和抛光在水阀片需要面对面的滑动或转动进行水流的通断控制时,需要对配合面进行一个表面精磨或精抛的工艺。
因此,本发明的一种赛隆陶瓷水阀片的注射成型方法,精度可以达到<基本尺寸*±0.5%精度,避免了后期对陶瓷进行加工,只在需要面接触的情况下,对表面进行加工。节约了加工时间和成本。
具体实施方式
下面通过实施例,对本发明的技术方案作进一步具体的说明。
实施例1:硅粉体:粒度1.2um,含氧量小于<1%,称取6160份;烧结助剂称取880份,氧化铝称取6160份,一维粉体采用1um的碳化硅粉体,中位粒径1um,长度20um~40um,称取220份,其他物料按份数比例称取如下:POM取融熔指数75的进口品种,2960份,骨架剂560份,排气剂80份,流平剂360份,熔接助剂240份。
采用20升的密炼机进入加工:将硅粉加入到密练腔中,接着加入氧化铝粉,加入烧接助剂,加入一维的碳化硅粉体。将转速调节到20转/分,将无机粉体反复翻转,约20分钟后混合完成,停机加入其他有机粉体,继续将偶联剂熔融助剂放入。将机台转速设定到20转/分,将腔体密封进行搅拌。此阶段温度设定到80度,对无机粉体进行表面进行处理。
处理60分后,停机,加入POM,骨架剂等剩余物料。将温度提到170度,密练机的转带提高到60转/分,待物料熔化形成泥料后,再将边角余料翻动到料腔中间。然后再降密炼机的压头加压密炼0.5~3小时。期间为防止物料自发热升温过高,将设定温度设定到140~160度,搅拌过程中物料的粘滞升温会维护腔体的温度。
密练时间完成后,将压头升起来,机台转速调节到15转/分以下,将温度设定到100~140度之间,将出口温度设定到140到150度,进行挤出造料。颗粒维持在3~5mm长即可。
将得到的物料冷却后转到注塑机进行注塑加工。机台的料筒的温度设定在195度到185度之间,模具设定温度在100度,以灯座的模具进行注塑,射速140mm/s,压力180MPa,保压50MPa,保压时间0.5秒。即可得到完整的产品。
脱脂工艺,产品放到脱酯炉中,采用的是600L的草酸固体脱脂炉。脱脂温度130度,草酸流量3克/分,氮气是45升/分,按正常脱酯10小时,脱脂完成。
烧结流程,烧结采用氮气保护烧结,炉子有效容积是600L,氮气流量是100L/min,升温到1700度时,保温4个小时,然后断电,氮气保持流量到100L冷却到500度后,断氮气。自然冷却得到成品。
Claims (5)
1.一种赛隆陶瓷水阀片的注射成型方法,其特征在于,按以下步骤进行:混料>造粒>注塑成型>催化脱酯>烧结;
(一)混料:
赛隆粉体,其混料的基本构成是:
将Si粉30~36份,氧化铝粉30~40份,助烧剂Y2O3 5~8份进行混料组成无机粉体的部份;
(二)造粒:
将混好的物料加入有机物和一维粉体进行充分混合;
一维粉体其占比为赛隆粉体重量的5%~20%;
有机物:POM主剂,POM主剂为聚甲醛塑料,熔融指数>45:重量比100~140份;
骨架剂:4-20份;
偶联剂:2-8份;
其他助剂:排气剂2-5份,流平剂3-8份,熔接助剂3-12份;
首先赛隆粉体加入后,将偶联剂和熔接助剂加入,在低温阶段让三者反复搅拌,使赛隆粉体的表面、偶联剂和熔接助剂的表面进行充分混合,发生表面反应,将赛隆粉体颗粒进行包裹;
搅拌时间:每分60转的机台混料60分钟;
其后再加入POM主剂,骨架剂、一维粉体、排气剂2-5份和流平剂3-8份,对物料升温,边升温边搅拌,等物料全部熔化,成形泥状的流体,再混炼0.5-3小时;
(二)注塑成型:
采用注塑工艺时:采用注塑机将造粒的物料注入到模具中,得到所需形状的工艺;注塑机的设定温度为175-200度,注塑机中的炮筒温度为185-195度,模具温度设定为60-130度,注射速度根据产品结构有所不同为80mm/s到300mm/s之间,注射压力小于200Mpa,保压压力小于100Mpa,成型时间一般小于1秒,大型产品会到10秒左右;
注射采用低速高压模式;
(三)催化脱酯:
在催化脱酯炉中进行,脱酯炉的采用催化的酸不同,设定参数有所不同,脱酯工艺采用二种酸:一种是98%以上的浓硝酸,另一种是固体草酸,纯度97%以上;
采用浓硝酸时:设定脱脂温度是90~120度,进炉量是2-10ml/min,进酸量根据设备大小有所不同,进酸量是在4~10ml/min;
采用固体酸时:进酸量是2~6g/min,脱脂温度设定是125~140度;温度的设定需要考虑到最终产品的尺寸精度有所调整;
氮气流量可依据设备设计时的要求进行,以600L的脱酯炉为例:氮气的流速设定在45~60L/min;经过10小时的脱脂,产品中的POM基本脱除干净,即达到脱酯的目的;
(四)烧结:
烧结的温度为1600~1900度,在氮气条件下烧结,氮气要求纯度99.99%以上的纯度,露点-60度以下;
烧结温度的高低取决于粉体中的助烧剂情况;
助烧结剂的种类比较多,助剂较多时烧结温度较低:
如助烧剂Y2O3含量较高在6%时,则烧结温度在1650度~1700度可以烧结;如助烧剂Y2O3的含量在4%时,其烧结温度1800度~1900度,还需要氮气加压烧结;
在高纯的氮气情况,有加压和无压的烧结工艺:
无压烧结时:是指烧结氮气的压力为正常大气压力;
加压烧结是指烧结的压力在10~50Mpa;
在最高烧结温度下,一般保持2~4小时后,断电降温冷却,即完成烧结;氮气加压烧结一般时在高温段进行加压,正常升温段,基本不加压烧结。
2.根据权利要求1所述的一种赛隆陶瓷水阀片的注射成型方法,其特征在于:步骤(一)中,混合可以采用球磨、行星磨相关工艺将成份均匀化;根据不同设备,其球磨工艺会有不同;但要求行星磨采用氧化铝球、氧化铝瓷罐进行球磨,防止其他元素对产品进行污染;
混合时,需采用氮化保护,防止金属硅粉氧化;行星磨是每分钟30~200转/每分,球磨机是20~80转/每分;待粉体小于5um后即达到要求;
步骤(二)中,一维粉体为碳化硅晶须,石墨纤维,碳纤,氧化镁晶须,氧化铝晶须,硼酸铝晶须,氮化硅晶须中的一种或多种;
密炼机的温度为165~180度,搅拌转速为60~200转/每分。
3.根据权利要求1所述的一种赛隆陶瓷水阀片的注射成型方法,其特征在于:POM主剂为共聚POM。
4.根据权利要求1所述的一种赛隆陶瓷水阀片的注射成型方法,其特征在于:POM主剂为共聚POM。
5.根据权利要求1所述的一种赛隆陶瓷水阀片的注射成型方法,其特征在于:骨架剂的选择:骨架剂的选择范围比较多:
选择PA尼龙系列时,注塑品的强度较高;
选择聚醋酸乙烯EVA系列的产品时,注塑时的流动性较好;
选择聚乙烯聚丙烯系列产品,如氧化聚乙烯,氧化聚两烯相关材料时,在注塑时提供更好的韧性;
选择聚酯PC,PS的材料做为骨架剂时会提供注塑品更好的表面性能和更好的抗缩性能。
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