CN1296933A - 陶瓷吸声材料 - Google Patents
陶瓷吸声材料 Download PDFInfo
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Abstract
一种由陶瓷块构成的陶瓷吸声材料,该陶瓷块通过以下过程获得:向至少一种选自于耐火粘土和耐火粘土熟料的成分中加入可燃性成孔材料,并烧结该掺合物,它具有大多数直径为0.2—2000μm的连通孔,其中在表面上形成大量吸声孔或吸声槽,仅在除吸声孔或吸声槽的内周边表面和底表面之外的表面上涂敷釉,从而形成填满连通孔的一个釉面层,该釉面层基本上没有空气渗透性。该多孔陶瓷吸声材料吸声性能和耐候性优异。
Description
本发明涉及一种耐候性优异的陶瓷吸声材料,其表面很难被弄脏,它适合用作道路或铁路的声障材料。
迄今,吸声材料典型地是矿物纤维吸声材料,如玻璃棉或岩棉。然而,矿物纤维吸声材料存在的缺点是:当其吸收水分时,吸声性能显著下降,并且由于它们是由纤维构成的,随着时间的延续,它们出现变形或易于在高速空气流的作用下开裂或剥落。
还有,其中在石膏板中形成大量渗透孔的吸声材料是众所周知的。在由存在大量渗透孔的石膏板构成的的吸声材料中,通过渗透孔的共振声能被吸收。然而,它存在的一个缺点是:吸声仅在特定的频率下才会出现。为了克服这个缺点,在背面或衬里处形成一个空气层,如在背面放置玻璃棉。然而,这些方法又要求较多的劳力。
最近,已开发了陶瓷或水泥吸声材料,由于其优异的耐候性,它可用于室外,并且其具有绝热效果和阻燃性。例如,日本专利(延迟公开)110692/1995提出了一种其中在多孔陶瓷中形成大量非贯通孔的吸声材料。然而,由多孔陶瓷构成的吸声材料在表面具有大量的细连通孔。当这种材料用于室外时,其易于被弄脏,并且一旦粘附上污垢,就很难清除。
同时,日本专利(延迟公开)27504/1974公开了一种通过在用于吸声的多孔陶瓷外表面上涂一层釉从而改善表面强度的吸声材料。不管怎样,该釉层涂敷在外表面上,当连通孔被釉填满时,无法确保吸声所要求的空气渗透性。因此,为了保留连通孔,从表面到多孔陶瓷组织内部,釉层是可渗透的。结果,连通孔导致在表面上留下细小的凸起或下压部分,因此就容易粘附污垢,并且一旦粘附上污垢,就难以清除。
在此情况下,本发明目的是提供一种在宽广的频率范围内吸声性能优异的多孔陶瓷吸声材料,其具有优异的耐候性,并且特别不容易被弄脏。而且一旦其粘附上污垢也容易清除,并且它在较长的时间内能够保持良好的外观。
本发明的目的可通过包括陶瓷块的陶瓷吸声材料来实现,该陶瓷块是通过向至少一种选自于耐火粘土和耐火粘土熟料的成分中加入可燃性成孔材料并烧结该掺合物而获得的,其所具有的连通孔大多数的孔径为0.2-2000μm,它具有至少1cm3·cm/cm2·sec(秒)·cmH2O的空气渗透率,其中在表面上形成大量吸声孔或吸声槽。仅在除吸声孔或吸声槽的内周边表面和底表面之外的表面上涂敷釉形成一个釉层,该釉层填满了连通孔,并且其基本上没有空气渗透性。
图1是表明实施例1中的各陶瓷吸声材料吸声系数的曲线。
图2是表明实施例2中的各陶瓷吸声材料吸声系数的曲线。
图3是表明实施例3中的各陶瓷吸声材料吸声系数的曲线。
图4是表明实施例4中的各陶瓷吸声材料吸声系数的曲线。
在本发明的陶瓷吸声材料中,吸声孔或吸声槽还能在多孔陶瓷块的表面上形成,并且仅在除吸声孔或吸声槽之外的剩余表面上形成釉层。该釉层填满了陶瓷块表面上的连通孔,因此表面不容易被弄脏,而一旦粘附上污垢也易于清除。同时,本发明的陶瓷吸声材料由于吸声孔或吸声槽没有被釉涂敷,其表现出优异的吸声性能。
通过将成孔材料加入到耐火粘土和/或耐火粘土熟料中形成灰浆或泥浆、浇注成型或挤出成型灰浆或泥浆、并进行烧结,从而获得本发明中所用的陶瓷块。成孔材料是在烧结时燃烧形成微孔的材料,并且可以使用粒径大约为0.5-2mm的泡沫聚苯乙烯颗粒或木屑如锯末。当使用泡沫聚苯乙烯颗粒时,同时引入通过将耐火粘土或耐火粘土熟料与表面活性剂混合而获得的气泡是合理的。还有,烧结温度是1000℃或更高,优选1200-1700℃。
用这种方法获得的陶瓷块是具有大多数孔径为0.2-2000μm的连通孔的多孔块体。该多孔陶瓷块的空气渗透率可随与耐火粘土或耐火粘土熟料混合的成孔材料的种类、形状、粒径、粒径分布和烧结条件而变化。当空气渗透率达到至少1cm3·cm/cm2·sec(秒)·cmH2O时,陶瓷本身就提供了吸声性能。
在本发明所用的陶瓷块中,在垂直于以上所获得的陶瓷块的厚度方向的表面上形成大量贯通的或非贯通的吸声孔或吸声槽(当吸声槽以纵向和横向形成时,就是非贯通槽)。这样,通常既形成吸声孔,又形成吸声槽,但也可能形成两种或多种类型的复合孔或槽,如非贯通的吸声孔和贯通的吸声孔;或非贯通的吸声孔和非贯通的吸声槽。
在其中形成吸声孔或吸声槽的陶瓷块中,仅将釉涂敷在表面上以便在表面上形成填满陶瓷块的连通孔并基本没有空气渗透性的釉层。涂敷釉的方法优选地是浸渍法,将釉仅涂敷在表面上,而不将其附着在所形成的吸声孔或吸声槽的内周边表面或底表面上。在喷釉的情况下,要格外小心不要将釉附着在吸声孔或吸声槽的内周边表面或底表面上。当釉附着在吸声孔或吸声槽的内周边表面或底表面上时,穿过吸声孔或吸声槽的空气渗透性将降低,尽管吸声性能取决于被釉层填满的表面积,但吸声性能还是将随之降低。
当所用的釉和作为基体的多孔陶瓷之间的热膨胀差别较大时,釉层有从表面上剥落的危险。因此,陶瓷主要由主要矿物为莫来石且膨胀系数较低的耐火粘土构成,所以,釉的热膨胀系数为4.5-5×10- 6/k,满足这一热膨胀系数是合理的。特别是,含有SiO2、Al2O3、ZnO、CaO、K2O、Na2O和L2O、且控制其中各成分数量以使热膨胀系数落入上述范围内的釉是优选的。还有,当用浸渍法涂敷釉时,根据陶瓷块的吸水性加入有机胶如CMC并结合浸渍时间来控制所粘附的釉的厚度是合理的。
一般认为:本发明表面上具有釉层的的陶瓷吸声材料的吸声机理是具有没有被釉涂敷的吸声孔或吸声槽,这样就产生在陶瓷块内部起背面空气层作用的区域,陶瓷块具有穿过吸声孔或吸声槽的空气渗透性,而且在陶瓷块内部的背面空气层在宽广的频率范围内共振,从而能够保持优异的吸声性能。
在本发明中,陶瓷块本身的空气渗透率至少为1cm3·cm/cm2·sec(秒)·cmH2O,并且从涂敷釉以后的吸声性能来看,优选至少为2cm3·cm/cm2·sec(秒)·cmH2O。然而,当陶瓷块的空气渗透率较大时,陶瓷块的强度将降低,并且表面的不均匀性也将增加。这样就需要大量的釉。由于这个原因,空气渗透率的上限优选为20cm3·cm/cm2·sec(秒)·cmH2O,更优选为8cm3·cm/cm2·sec(秒)·cmH2O。
对于吸声孔来说,其直径为5-15mm、并且开口的比例为5-30%是合理的,还有,对于吸声槽来说,槽的宽度为2-20mm、并且开口的比例为9-40%是合理的。当开口孔或开口槽的开口比例在上述范围之外时,涂敷釉之前的陶瓷块本身吸声系数较低,而本发明涂敷釉以后的陶瓷块吸声系数也不满意。当吸声孔的直径小于5mm、而吸声槽的宽度小于2mm时,稳定的加工处理是困难的,并且当用浸渍法涂敷釉时,釉可能以膜的形式保留在孔或槽的开口部位处。还有,当孔的直径超过15mm、槽的宽度超过20mm时,陶瓷块在加工时易于破损。
还有,当非贯通的吸声孔或吸声槽的深度小于陶瓷块的厚度时,可随意对之进行测定。特别是,在陶瓷块厚度为25mm或更厚的情况下,非贯通的吸声孔或吸声槽的深度优选为20mm或更深。
因此,在本发明陶瓷吸声材料中,在除吸声孔或吸声槽以外的多孔陶瓷剩余表面上形成釉层。因此,陶瓷块表面上的连通孔可被釉层填满,其表面不容易被弄脏,而一旦粘附上污垢,也易于清理。另外,由于在表面上保留了没有釉的吸声孔或吸声槽,其表现出几乎和未涂敷釉之前一样的优异吸声性能。
因此,本发明可提供一种吸声性能优异的多孔陶瓷吸声材料,其耐候性优异,它特别不容易被弄脏,而一旦粘附上污垢,也易于清除,其在较长的时间内能够保持良好的外观。
在本发明中,按照JIS A 1405导管法用建筑材料标准传声吸收系数测试方法测量吸声系数。还有,按照JIS R 2115测量陶瓷块空气渗透率,并以没有考虑空气粘弹性的数值表示。
实施例
实施例1
将锯末成孔材料和水加入到耐火粘土和耐火粘土熟料中从而形成泥浆,对之进行挤出成型、干燥、然后在1300℃下烧结,从而形成大多数孔径为0.2-2000μm、表观比重为0.8、气孔率为70%、空气渗透率为2.6cm3·cm/cm2·sec(秒)·cmH2O和厚度为65mm的陶瓷块。切割该陶瓷块从而形成用于测量标准传声吸收系数的试样(直径为91.6mm)。在其表面上几乎有规律地形成十二个直径为8mm、深度为40mm的非贯通吸声孔,并且其开口比例为9.2%。
随后,通过浸渍法在具有吸声孔的该陶瓷块试样的吸声表面上涂敷组成为:SiO2∶55重量%、Al2O3∶20重量%、ZnO∶10重量%、CaO∶8重量%、K2O∶2重量%、Na2O∶2重量%、Li2O∶2重量%的釉,并在1100℃下进行烧结,从而在除吸声孔内周边表面和底表面之外的表面上形成大约8.2克的光滑釉面层。
测量所获得的陶瓷吸声材料的标准传声吸收系数,结果表示在表1中,还有,表1还表示了具有同样吸声孔的的陶瓷块在涂敷釉之前的吸收系数和将釉涂敷在吸声孔内部时的吸声系数。从图1中可明显看出:在本发明吸声材料中,在高峰频率以上时,吸声系数有些降低。但在高峰频率以下时,吸声系数得到改善,并且在吸声峰值处,吸声系数没有变化,这就有可能保持较高的吸声性能。当在吸声孔的内部涂敷釉时,发现吸声性能明显降低。
实施例2
在与实施例1所用相同的陶瓷块试样上面,几乎有规律地形成六个直径为12mm、深度为25mm的非贯通吸声孔和六个直径为12mm、深度为60mm的非贯通吸声孔,其开口比例为20.7%。用浸渍法在该试样的吸声表面上涂敷与实施例所用相同的釉,并在1100℃下烧结,从而在除吸声孔内周边表面和底表面之外的表面上形成6.5克的光滑釉面层。
所获得的陶瓷吸声材料的标准传声吸收系数表示在表2中,同时也表示出具有吸声孔的陶瓷块在未涂敷釉之前的吸声系数。在涂敷釉前后,没有观察到吸声性能降低,而且可获得较高的吸声性能。实施例3
将泡沫聚苯乙烯珠成孔剂和通过将水和表面活性剂形成的泡沫加入到耐火粘土和耐火粘土熟料中从而形成料浆。对料浆进行浇注、干燥、并随后在1300℃下烧结,从而形成大多数孔径为0.2-2000μm、表观比重为0.52、气孔率为80%、空气渗透率为7.7cm3·cm/cm2·sec(秒)·cmH2O和厚度为65mm的陶瓷块。
切割该陶瓷块,从而形成用于测量标准传声吸收系数的试样(直径为91.6mm),在其表面上几乎有规律地形成两个直径为12mm、深度为25mm的吸声孔、八个深度为45mm的吸声孔和两个贯通孔,其开口比例为20.7%。
随后,在具有吸声孔的陶瓷块试样的吸声表面上涂敷与实施例1所用相同的釉,并在1100℃下烧结从而在除吸声孔内周边表面和底表面之外的表面上形成7.0克光滑的釉面层。
所获得的陶瓷吸声材料的标准传声吸收系数表示在表3中,同时也表示出具有吸声孔的陶瓷块在未涂敷釉之前的吸声系数。在涂敷釉前后,没有观察到吸声性能降低,而且可获得较高的吸声性能。
实施例4
在与实施例1所用相同的陶瓷块上以20mm的间距有规律地形成宽度为9.4mm、深度为40mm的槽,其开口比例为43%。用浸渍法在该试样的吸声表面上涂敷与实施例1所用相同的釉,并在1100℃下烧结,从而在除吸声槽的内表面和底表面之外的表面上形成5.0克光滑的釉面层。
所获得的陶瓷吸声材料的标准传声吸收系数表示在表4中,同时也表示出具有吸声槽的陶瓷块在未涂敷釉之前的吸声系数。在涂敷釉前后,没有观察到吸声性能降低,而且可获得较高的吸声性能。
Claims (7)
1.一种包括陶瓷块的陶瓷吸声材料,该陶瓷块通过以下过程获得:向至少一种选自于耐火粘土和耐火粘土熟料的成分中加入可燃性成孔材料,并烧结该掺合物,它具有大多数直径为0.2-2000μm的连通孔,其空气渗透率至少为1cm3·cm/cm2·sec(秒)·cmH2O,其中在表面上形成大量吸声孔或吸声槽,仅在除吸声孔或吸声槽的内周边表面和底表面之外的表面上涂敷釉,从而形成填充连通孔的一个釉面层,该釉面层基本上没有空气渗透性。
2.权利要求1的陶瓷吸声材料,其中,釉面层的热膨胀系数为4.5-5×10-6/K。
3.权利要求1或2的陶瓷吸声材料,其中,釉主要由SiO2、Al2O3、ZnO、CaO、K2O、Na2O和Li2O组成。
4.权利要求1的陶瓷吸声材料,其中,成孔材料是粒径为0.5-2mm的泡沫聚苯乙烯颗粒或锯末。
5.权利要求1的陶瓷吸声材料,其中,吸声孔或吸声槽是贯通的或非贯通的。
6.权利要求1的陶瓷吸声材料,其中,吸声孔的直径为5-15mm,并且开口比例为5-30%。
7.权利要求1的陶瓷吸声材料,其中,吸声槽的宽度为2-20mm,并且开口比例为9-40%。
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WO2006021127A1 (fr) * | 2004-08-24 | 2006-03-02 | Yang Cao | Procede de production de produit insonorise et sa production |
CN101217033A (zh) * | 2008-01-21 | 2008-07-09 | 蒋彩峰 | 相互连通衍射孔洞吸音隔噪搪土板及制作方法 |
WO2012058922A1 (zh) | 2010-11-07 | 2012-05-10 | 佛山欧神诺陶瓷股份有限公司 | 吸声陶瓷及其生产方法 |
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TWI586630B (zh) * | 2011-09-20 | 2017-06-11 | 贏創羅恩有限責任公司 | 輕陶瓷材料的製造方法 |
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JP3474817B2 (ja) * | 1999-11-17 | 2003-12-08 | イソライト工業株式会社 | セラミックス吸音材 |
EP2025658A1 (en) * | 2007-08-08 | 2009-02-18 | Imerys Ceramics France | Porous ceramic bodies and process for their preparation |
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US6416852B1 (en) | 2002-07-09 |
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