CN1872795A - 硅组合物 - Google Patents

硅组合物 Download PDF

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CN1872795A
CN1872795A CNA200610092377XA CN200610092377A CN1872795A CN 1872795 A CN1872795 A CN 1872795A CN A200610092377X A CNA200610092377X A CN A200610092377XA CN 200610092377 A CN200610092377 A CN 200610092377A CN 1872795 A CN1872795 A CN 1872795A
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silicon composition
silicon
hydrolysis
composition
ceramic
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CN100402469C (zh
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H·德梅斯
H·法肯勒
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Dow Silicones Corp
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Abstract

本发明提供含至少15wt%水解的硅化合物和至少3wt%粘合剂材料的硅组合物。该硅组合物用于制造陶瓷。水解的硅化合物可例如是通过水解较高沸点的有机卤代硅烷而生产的凝胶,其中所述较高沸点的有机卤代硅烷是在通过直接法制造有机卤代硅烷或卤代硅烷中生产的。

Description

硅组合物
本申请是申请号为03812378.9申请的分案申请。
技术领域
本发明涉及含水解的硅化合物的硅组合物,和它在陶瓷制造中的用途。
背景技术
有机卤代硅烷、烷氧基硅烷、卤代硅烷和尤其是甲基氯代硅烷是生产硅氧烷聚合物的结构单元。商业上通过所谓的“直接法”,任选地在催化剂存在下,使硅金属与有机卤化物或氯化氢反应生产有机卤代硅烷和卤代硅烷。直接法是本领域公知的,且例如在US-A-2380995中被公开。例如,在通过直接法商业生产甲基氯代硅烷中,在200℃至500℃的温度下,在催化剂存在下,通过在流化床内流过氯代甲烷气体,使硅粉流化,从而使微细的硅金属粉末与氯代甲烷反应。
除了甲基氯代单硅烷和/或氯代单硅烷之外,由硅金属生产有机硅化合物或卤化硅的直接法和其它方法还产生较高沸点的硅化合物,特别是较高沸点的卤代硅烷,这些是化学活性物质。一旦与直接法的其它反应产物相分离,这些较高沸点的硅化合物可水解,获得凝胶固体混合物,下文称为“硅氧烷凝胶”,它是水解的硅化合物的混合物。例如在US-A-4408030、US-A-4690810和US-A-5876609中公开了生产这种固体或粒状硅氧烷凝胶的方法。
本发明者现已发现一种将硅氧烷凝胶或其它水解的硅化合物加工成证明具有改进的物理和/或物理化学性能的陶瓷制品的有效方式。
发明概述
根据本发明的第一方面,提供一种硅组合物,它包括25-95wt%的硅氧烷凝胶和3-75wt%的粘合剂材料,所述硅氧烷凝胶的主要组分是水解的二硅烷。
根据本发明的第二方面,提供一种硅组合物,它包括15-80wt%的水解的硅化合物,3-75wt%的粘合剂材料,和10-70wt%可与该水解化合物反应但不起粘合剂作用的固体试剂。
本发明还包括制造陶瓷制品的方法,该方法包括使这种硅组合物成型,形成预陶瓷制品,和在升高的温度下焙烧该制品,而且还包括由此生产的陶瓷制品。
本发明还包括在含粘土和氧化铝的预陶瓷组合物中水解的硅化合物作为添加剂的用途,其中在1450℃的温度下,焙烧所述预陶瓷组合物,形成能保持其形状的陶瓷制品。
发明详述
此处所使用的“粘土”以它在字典里的定义给出,即它指各种形式的水合硅铝酸盐,例如通式nAl2O3.mSiO2.xH2O的那些水合硅铝酸盐,其中x是水合度。
此处所使用的“陶瓷”以它通常的定义给出,即在诸如泥土原材料和/或金属氧化物之类的材料上,通过热(称为焙烧)的作用制造的硬且发脆的产品。
水解的硅化合物优选在有机硅材料或卤代硅烷的制造中生产的较高沸点的有机卤代硅烷的水解产物,例如通过水解在直接法的产品中的较高沸点的硅化合物而生产的硅氧烷凝胶。生产硅氧烷凝胶的典型步骤包括用碱例如石灰溶液中和(水解)较高沸点的硅化合物,降低其反应性并脱水,从而导致凝胶固体混合物。如此生产的硅氧烷凝胶的精确组成可以不同,典型地硅氧烷凝胶的主要组分是水解的二硅烷,也就是说,在硅氧烷凝胶内二硅烷的含量大于50%,例如60-80wt%。硅氧烷凝胶也可含有亚甲基硅烷,也就是说含有>Si-CH2-Si<部分的化合物。硅氧烷凝胶的其余部分包括各种材料,典型地包括铁、硅金属、铜、有机材料和盐(例如氯化钙)。
硅氧烷凝胶可以以其被生产的形式使用或以例如可通过分离未胶凝固体和/或通过除去盐而改性的形式使用。可在较高沸点的硅化合物水解之前,将它们过滤,这将除去衍生于直接法反应容器的未胶凝固体材料如硅金属、铁和铜。可在硅氧烷凝胶形成之后洗涤硅氧烷凝胶,以除去至少部分可溶盐如氯化钙。洗涤步骤可与进一步的分离步骤结合,以除去重的矿物相,例如可在离心机中进行洗涤步骤。在赋予陶瓷改进的物理和物理化学性能方面,呈凝胶形式的水解的硅化合物通常最有效。与未改性的凝胶/固体混合物相比,未胶凝的固体和盐已从其中分离的改性凝胶可通常以较低含量使用,获得同样的陶瓷耐热性,和可形成更好物理性能的陶瓷。
也可用其它方法生产包括二硅烷在内的较高沸点的硅化合物,例如在铜存在下由硅和甲醇制造三甲氧基硅烷和四甲氧基硅烷的称为Direct TMS的方法。如上所述优选采用脱水法,水解来自该方法的较高沸点的硅化合物流,产生适用于本发明的水解的硅化合物。
此处除非另有说明,所有组分的wt%是硅组合物(焙烧之前)或陶瓷组合物(根据具体情况而定)总重量的重量百分数。组分的wt%是指该组分的干重,除非另有说明。在焙烧之前,对于在硅组合物内的硅氧烷凝胶和其它水解的硅化合物给出的wt%是水合硅氧烷凝胶材料的重量百分数,所述水合硅氧烷凝胶典型地含有约40-50wt%的水。
水解的硅化合物(例如硅氧烷凝胶)在硅组合物内的含量可从约15wt%,优选从25wt%一直变化到约95,优选一直到80wt%。例如,水解的硅化合物的存在量可以是硅组合物的至少40或50wt%。
粘合剂材料通常是改进硅组合物各成分粘接的材料。优选粘合剂材料与水解的硅化合物反应。能中和卤代硅烷的材料通常与硅氧烷凝胶在一定程度上反应。合适的粘合剂材料包括粘土和金属氢氧化物,例如氢氧化铝或氢氧化镁。
粘合剂材料在硅组合物内的含量可从约3wt%变化到约75wt%,这取决于所使用的特定粘合剂材料和在由硅组合物制造的陶瓷制品内所需的性能。优选硅组合物含有至少5wt%,优选至少10wt%的粘合剂材料。
特别有用的粘合剂材料是粘土。合适的粘土可以以3-75wt%,优选3-30wt%,更优选5-25wt%,和仍更优选5-20wt%存在于硅组合物内。
在本发明中,适合用作粘合剂的通常已知的粘土的实例包括漂白土、膨润土、高岭土(陶土)、蒙脱土和硅藻土。优选富氧化铝的粘土。这些粘土通常与水解的硅化合物反应。
当粘土作为粘合剂材料存在时,在硅组合物内的湿硅氧烷凝胶或类似的水解的硅化合物与干燥粘土的重量比范围合适地为30∶1到1∶2,优选20∶1到1∶2,更优选10∶1到2∶1。
硅组合物可另外含有与水解的硅化合物反应但不起粘合剂作用的固体试剂。当粘合剂材料不与水解的硅化合物反应时,强烈优选存在这种固体试剂,和在许多情况下,甚至当粘合剂材料与水解的硅化合物反应时,优选存在这种固体试剂。这种固体试剂的实例是金属氧化物。优选的金属氧化物是氧化铝(Al2O3);氧化锆、氧化钛或氧化镁是替代物。可供替代的固体试剂是金属盐,如碳酸锆、硝酸锆或碳酸镁。
与水解的硅化合物反应但不起粘合剂作用的固体试剂优选以至少10wt%,特别地10-70wt%存在于硅组合物内。氧化铝例如可以以约20-70wt%,优选30-50wt%存在于硅组合物内。
硅组合物可例如包括至少25,特别地25-70wt%的水解的硅化合物,至少10wt%,特别地10-55wt%的粘合剂材料,和至少20wt%,特别地20-65wt%可与水解的硅化合物反应但不起粘合剂作用的固体试剂。
也可存在其它额外的组分。特别地,可存在将硅组合物转化成有用的陶瓷中可用的组分或给由此形成的陶瓷上赋予有用特征的组分。有用的额外组分包括下述:
(i)压制助剂,它例如在硅组合物的挤出中辅助降低所要求的压力。有用的压制助剂包括润滑固体材料,例如石墨、脂肪酸或硬脂酸铝。压制助剂合适地以0.01-0.5wt%的用量存在于硅组合物中。
(ii)“开放(openiong)剂”,它辅助干燥由硅组合物制造的陶瓷制品。诸如氧化铝之类的固体试剂通常具有这种性能,但硅组合物可选择性地或另外含有非反应性开放剂。有用的开放剂包括例如氧化硅,如煅制氧化硅或沉淀氧化硅和石英。这种开放剂合适地以1-10wt%的用量,优选以1-6wt%的用量存在于硅组合物中。例如,已发现含量在4-5wt%下的氧化硅是一种有用的开放剂。
(iii)“增容剂”,即增加孔隙体积并降低由硅组合物制造的陶瓷制品密度的填料。有用的增容剂包括锯屑、聚苯乙烯、PVC、珍珠岩和聚氨酯。可例如以硅组合物重量的0.5-15%使用增容剂,这取决于其密度(在较低的wt%下需要较低密度的填料)。
(iv)“烧结剂”,它用于制造砖,以降低组合物的共晶温度并由此降低烧结温度。有用的烧结剂包括硼酸、硼酸钠和碳酸钙,它可合适地以最多为硅组合物的1.0wt%,优选最多0.5wt%的用量存在。
在本发明硅组合物的制备中,将粘合剂材料加入到水解的硅化合物中,和优选采用机械操作如粉碎机或研磨机,混合该混合物,形成硅组合物。可预处理水解的硅化合物,将它们转化成更适合用于混合的形式。例如,在第一步中优选粉碎硅氧烷凝胶,一直到它呈糊状稠度。粘合剂材料优选以粉末(干燥或水合)形式添加,但也可以以糊剂或浆料形式添加。可在添加粘合剂材料之前、同时或之后,掺入其它组分如固体试剂。使用任何合适的混合设备,如碾磨盘、捏合碾磨机或指形碾磨机,混合该混合物,一直到硅组合物基本上均匀。然后可例如通过压制到模具内挤塑并切割成块,使硅组合物成型,形成预陶瓷制品。在使用挤塑的情况下,优选在硅组合物中使用加工助剂。还优选使用开放剂辅助干燥,尤其当使用粘土作为粘合剂材料时。
可通过焙烧由硅组合物组成的预陶瓷混合物来获得各种各样的陶瓷组合物。已发现,如此制造的陶瓷具有有用且有利的性能。它们典型地具有:
(i)良好的强度,其中包括良好的热(即热和冷)强度;
(ii)良好的绝热性能;
(iii)良好的热稳定性(即具有良好的耐火性能);
(iv)高度耐酸性;和/或
(v)良好的孔隙度/密度特征,从而提供轻质但结实的材料。
特别地,已发现陶瓷具有良好的绝热和稳定性能,从而使得它们可用于典型地使用耐火材料的场合。陶瓷的性能当然一定程度上取决于所使用的粘合剂材料的本性而变化。例如,粘土粘合剂材料倾向于产生高度耐酸的陶瓷,和氧化铝材料倾向于产生轻质且结实的陶瓷。由于以上提及的性能,衍生于硅组合物的陶瓷,当用作耐火(耐受高温的材料)和绝缘砖时,具有特殊的优点。耐火用途的一个实例是作为烧窑辅助设备,所述烧窑辅助设备是陶瓷制品,它用作正被焙烧的其它陶瓷制品的载体。在焙烧温度下高的强度与高的热稳定性的结合使本发明生产的陶瓷给烧窑辅助设备带来特殊优点。与已知的耐火砖相比,含有大于25%来自水解的硅化合物的固体的耐火砖和其它耐火材料具有增加的强度。衍生于该硅化合物的陶瓷,当用作陶瓷过滤器、陶瓷膜、催化剂,特别是多孔催化剂和陶瓷喷嘴时,也具有优点。
由该硅组合物制备的陶瓷的密度典型地在0.5-1.6kgdm-3范围内。本发明的优选陶瓷组合物典型地包含25-65wt%衍生于水解的硅化合物的固体,3-30wt%粘合剂材料固体,和30-70wt%非粘合固体试剂。
将预陶瓷制品转化成陶瓷所要求的焙烧温度将根据所讨论的特定硅组合物和所制造的陶瓷类型而变化。焙烧温度合适地在1100至1900℃之间变化。在粘土粘合剂材料的情况下,合适地使用1100-1600℃,优选1200-1500℃的焙烧温度。在高于这些的温度下,粘土倾向于熔融。在基于金属氢氧化物粘合剂材料或含有高比例氧化铝的组合物情况下,合适地使用1400-1900℃,优选1500-1800℃的焙烧温度。由含40wt%或更多氧化铝的本发明硅组合物制造的陶瓷制品通常能在1450℃或甚至在1600℃或更高的温度长期加热下保持其形状。
现通过下述实施例进一步描述本发明。
实施例1
预粉碎水含量为45-50wt%的45%硅氧烷凝胶,所述硅氧烷凝胶是通过水解较高沸点的有机氯代硅烷而生产的,而所述较高沸点的有机氯代硅烷是在通过硅金属与氯代甲烷反应的直接法制造甲基氯代硅烷中生产的。以固体形式添加10%富Al粘土作为粘合剂并与硅氧烷凝胶混合,形成均匀的物料。添加45%的氧化铝粉末,和再次混合该组合物成均匀的硅组合物。
将该硅组合物压制成型并使之干燥2天。在1500℃下焙烧所得干燥的硬质成型品8小时。已焙烧产品的密度为约1.2g/cc,它耐受足以压碎常规绝缘砖的施压。已焙烧产品足够硬到可切割玻璃。已焙烧产品耐受达到1650℃的加热,而没有损失形状。加热2cm厚的已焙烧产品到1500℃并放置在1cm深的水中,没有龟裂,另外还加热到1500℃并投入过量冷水中,没有龟裂。
实施例2
预粉碎70%实施例1的硅氧烷凝胶,并与5%煅制氧化硅和25%球土混合,且使用实施例1的步骤压制和干燥。在1300℃下焙烧干燥硬质成型品8小时。已焙烧产品的比重为约1.0和高度耐酸进攻-它保持与30%的含水硝酸接触超过3个月,和与50%含水硫酸接触超过3个月,没有可见的降解。已焙烧产品的熔融温度为约1470℃。
实施例3
过滤在通过直接法制造甲基氯代硅烷中生产的较高沸点的有机氯代硅烷,以除去固体材料如硅金属、铜和铁。用石灰溶液水解已过滤的有机氯代硅烷,产生硅氧烷凝胶。在离心机中用去离子水洗涤硅氧烷凝胶并与重矿物相分离。预粉碎20%所得改性硅氧烷凝胶并与35%粘土和45%氧化铝粉末混合,且使用实施例1的步骤压制和干燥。粘土是来自Fuchs的富氧化铝粘土。氧化铝(Al2O3)具有下述粒度分布(wt%):10%>90μm;30%>63μm;60%>45μm;80%>32μm。在1450℃下焙烧干燥硬质成型品4小时。在最多1670℃的温度下已焙烧产品保持其形状,和适于用作在焙烧过程中支持陶瓷制品的支架。已焙烧产品还耐受熔融铝和可用作铝锭或铸件用模具。
实施例4
预粉碎25%实施例3的改性硅氧烷凝胶,并与40%氧化铝和35%粘土混合。所使用的氧化铝和粘土如实施例3所述。使用实施例1的步骤压制和干燥该混合物。在1450℃下焙烧干燥硬质成型品4小时。当在1100下,根据DIN EN 993-15测试时,已焙烧产品的绝缘值为1.07W/(mK),和特别适于用作耐火绝缘材料。

Claims (11)

1.一种硅组合物,它包含25-95wt%硅氧烷凝胶和3-75wt%的粘合剂材料,所述硅氧烷凝胶的主要组分是水解的二硅烷。
2.权利要求1的硅组合物,其特征在于所述水解的二硅烷组分是在有机硅材料或卤代硅烷的制造中生产的有机卤代硅烷的水解产物。
3.权利要求2的硅组合物,其特征在于所述水解的二硅烷组分是通过水解较高沸点的有机卤代硅烷而生产的凝胶,而所述较高沸点的有机卤代硅烷是在通过硅金属与有机卤化物或氯化氢反应的直接法制备有机卤代硅烷或卤代硅烷中生产的。
4.权利要求3的硅组合物,其特征在于通过水洗涤和通过从凝胶或从较高沸点的有机卤代硅烷中除去固体材料来改性该凝胶。
5.权利要求1的硅组合物,其特征在于粘合剂材料与水解的二硅烷反应。
6.权利要求5的硅组合物,其中粘合剂材料选自粘土和氢氧化铝。
7.一种制造陶瓷制品的方法,该方法包括使权利要求1-4任何一项的硅组合物成型,形成预陶瓷制品,和在高温下焙烧该制品。
8.权利要求7的方法,其特征在于在1100-1900℃的温度范围内焙烧该制品。
9.权利要求7或8的方法,其特征在于将硅组合物成型为烧窑辅助设备。
10.权利要求7或8的方法,其用于生产耐火绝缘材料。
11.通过权利要求7的方法生产的陶瓷制品。
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CN1656106A (zh) 2005-08-17
US20050176864A1 (en) 2005-08-11
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WO2003099828A1 (en) 2003-12-04
AU2003238503A1 (en) 2003-12-12
DE60333633D1 (de) 2010-09-16
EP1513850B1 (en) 2010-08-04
US7101821B2 (en) 2006-09-05
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ATE476435T1 (de) 2010-08-15
CN1321998C (zh) 2007-06-20

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