CN203938608U - 用于烧结的垫板 - Google Patents
用于烧结的垫板 Download PDFInfo
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- 238000005245 sintering Methods 0.000 title claims abstract description 20
- QYEXBYZXHDUPRC-UHFFFAOYSA-N B#[Ti]#B Chemical compound B#[Ti]#B QYEXBYZXHDUPRC-UHFFFAOYSA-N 0.000 claims abstract description 33
- 229910033181 TiB2 Inorganic materials 0.000 claims abstract description 33
- 238000010304 firing Methods 0.000 claims abstract description 6
- 150000001875 compounds Chemical class 0.000 claims description 6
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- 238000000034 method Methods 0.000 abstract description 23
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 abstract description 3
- 238000002844 melting Methods 0.000 abstract description 3
- 230000008018 melting Effects 0.000 abstract description 3
- 238000013022 venting Methods 0.000 abstract description 3
- 238000007599 discharging Methods 0.000 abstract description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 abstract 4
- 239000004408 titanium dioxide Substances 0.000 abstract 2
- 238000004519 manufacturing process Methods 0.000 abstract 1
- 239000000463 material Substances 0.000 description 14
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- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 4
- 239000003795 chemical substances by application Substances 0.000 description 4
- 229910002804 graphite Inorganic materials 0.000 description 4
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- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 2
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- 229910052863 mullite Inorganic materials 0.000 description 2
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 2
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- 229910052582 BN Inorganic materials 0.000 description 1
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
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- -1 trichroite Chemical compound 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
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- 238000009736 wetting Methods 0.000 description 1
- 229910052845 zircon Inorganic materials 0.000 description 1
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 description 1
Classifications
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
- C04B35/58—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides
- C04B35/5805—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on borides
- C04B35/58064—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on borides based on refractory borides
- C04B35/58071—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on borides based on refractory borides based on titanium borides
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/64—Burning or sintering processes
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/64—Burning or sintering processes
- C04B35/645—Pressure sintering
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- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/0067—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the density of the end product
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25C—PROCESSES FOR THE ELECTROLYTIC PRODUCTION, RECOVERY OR REFINING OF METALS; APPARATUS THEREFOR
- C25C3/00—Electrolytic production, recovery or refining of metals by electrolysis of melts
- C25C3/06—Electrolytic production, recovery or refining of metals by electrolysis of melts of aluminium
- C25C3/08—Cell construction, e.g. bottoms, walls, cathodes
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D5/00—Supports, screens, or the like for the charge within the furnace
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D5/00—Supports, screens, or the like for the charge within the furnace
- F27D5/0006—Composite supporting structures
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
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- C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
- C04B2235/5436—Particle size related information expressed by the size of the particles or aggregates thereof micrometer sized, i.e. from 1 to 100 micron
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
- C04B2235/602—Making the green bodies or pre-forms by moulding
- C04B2235/6027—Slip casting
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
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Abstract
本实用新型涉及一种用于烧结的垫板。本实用新型还涉及其制备方法。在窑中烧制制品时该垫板用于支撑制品。在本公开的一个方面中,制备了用于烧结生坯二氧化钛形体例如通过多种成形方法制得的铝熔炼阴极的垫板组件。该组件本身由经烧结的二硼化钛形成。该组件的开孔面积和排气口允许在码垛过程中排放废气,以制备具有减少的污染的烧结产品。垫板组件主要由二硼化钛制得,其与生坯二氧化钛形体是化学相容的。
Description
相关申请的交叉引用
本专利申请是2013年6月19日提交的美国临时专利申请号61/836,796的非临时专利申请并且要求其优先权,通过引用以其全文并入本文。
技术领域
本实用新型涉及用于在窑中烧制生坯部件的窑具和支撑体,更具体地涉及用于在烧结过程中支撑生坯物品的垫板(setter plate)。
背景技术
已知各种类型的窑具和垫板,其具有各种组成,例如莫来石、堇青石和碳化硅。由于垫板和在其上支撑的生坯物品在窑中经受高温,所以在生坯物品与由某些材料制得的垫板之间可发生反应。因此,减少垫板与生坯物品之间的反应的替代性的垫板设计和组成是需要的。
实用新型内容
所公开的主题涉及在窑中烧制制品时用于支撑制品的垫板。在一个实施方案中,垫板是由经烧结的二硼化钛形成的多孔板,该经烧结的二硼化钛具有10-12微米的颗粒尺寸并具有20%-50%的开孔面积(open area)。
在另一个实施方案中,在窑中加热制品时垫板能够允许由垫板上支撑的制品所排放的化合物的渗入。
在另一个实施方案中,该制品由二硼化钛制得,并且在窑中加热制品时垫板能够支撑窑中的制品而不与制品化学反应。
在另一个实施方案中,垫板具有多个子部件,包括底板、顶板和至少一个侧板,侧板将顶板与底板隔开并且在其间限定了用于接收制品的空间。
在另一个实施方案中,顶板和底板是有同等范围(coextensive)的矩形板,并且所述至少一个侧板包括围绕矩形顶板和底板外围分布的四个侧板。
在另一个实施方案中,侧板是齿形图案(cut-out),其具有至少一个隆突和至少一个凹部,该凹部能够使顶板与底板之间的空间排气。
在另一个实施方案中,形成二硼化钛制品的方法包括:
(A)形成二硼化钛粉末在液体粘合剂中的浆料;
(B)用浆料填充具有制品形状的空腔的模具;
(C)使空腔中的浆料干燥成固体形体;
(D)将该固体形体置于窑中的二硼化钛垫板上;
(E)加热该固体形体以除去粘合剂;和
(F)烧结该固体形体以产生二硼化钛制品。
在另一个实施方案中,用于制备垫板的方法,包括:粉浆浇注、喷雾干燥并压制、轧辊压实、以及制备糊料/浇注料混合料并将其送入模具中以产生固体形体中的至少一种。
在另一个实施方案中,将该固体形体放置在窑内的二硼化钛表面上并加热以产生垫板材料。
在另一个实施方案中,所述方法还包括将垫板材料切割成顶板、底板和侧板并且将顶板、底板和侧板装配成垫板组件,该垫板组件限定了在其中具有用于接收被码垛(setter)的制品的空间的包裹体(envelope)。
在另一个实施方案中,所述方法还包括在模具中制备多个对应于顶板、底板和侧板的空腔,填充所述多个空腔中的每个空腔,然后在窑中烧结该模具以产生顶板、底板和侧板;并且还包括将顶板、底板和侧板装配成垫板组件的步骤,该垫板组件具有在其中能够接收制品用于码垛的内部空间。
在另一个实施方案中,所述制品为用于铝熔炼炉的阴极。
在另一个实施方案中,垫板与制品是化学相容的。
在另一个实施方案中,垫板是多孔的并且还包括在进行除去粘合剂的步骤时渗入多孔垫板的步骤。
在另一个实施方案中,所述方法包括使粘合剂化合物通过多孔垫板的步骤。
在另一个实施方案中,垫板是具有围绕内部空心的多个板的垫板组件,在加热步骤之前在该内部空心中接收制品。
在另一个实施方案中,所述方法包括在窑中堆叠多个包含有制品的垫板组件的步骤。
在另一个实施方案中,所述方法包括:
(A)形成二硼化钛粉末在液体粘合剂中的浆料;
(B)用浆料填充具有制品形状的空腔的模具,可由其制得垫板;
(C)使空腔中的浆料干燥成固体形体;
(D)将该固体形体置于窑中;
(E)加热该固体形体以除去粘合剂;
(F)烧结该固体形体以产生垫板材料;和
(G)使用垫板材料形成垫板。
在另一个实施方案中,在加热步骤之前将固体形体置于窑内的二硼化钛表面上。
在另一个实施方案中,使用以下步骤,包括将垫板材料切割成顶板、底板和侧板,并且将顶板、底板和侧板装配成垫板组件,该垫板组件限定了在其中具有用于接收被码垛的制品的空间的包裹体。
在另一个实施方案中,步骤(B)的模具具有多个对应于顶板、底板和侧板的空腔,在填充步骤过程中填充每个空腔和并且在步骤(C)至(G)中进行处理以产生顶板、底板和侧板;并且还包括将顶板、底板和侧板组装成垫板组件的步骤,该垫板组件具有在其中能够接收制品用于码垛的内部空间。
在另一个实施方案中,组装步骤包括驱动销子穿过顶板、底板和侧板以将垫板组件固定在一起。
附图说明
为了更完整的理解本实用新型,参考与附图结合考虑的示例性实施方案的以下详细描述。
图1是根据本公开的一个实施方案的垫板组件的立体图。
图2是图1的垫板组件去掉顶板并且在其中具有可包含的制品的立体图。
具体实施方式
图1和2示出了垫板组件10,其具有由多对侧板16和端板18分隔的顶板12和底板14,限定了内部空间S,所示的侧板16和端板18在垫板组件10的各自的相对侧上被复制,这在图1中是不可见的。在一个实施方案中,在完成组件10之前将垫板组件10描述为包含空间S和/或在放置在空间S中的任何物体的包裹体10。更具体地,在该实施方案中,在图2中所示的结构中,将制品C放置在底板14之上,然后在底板14的外围上围绕制品C设置侧板16和端板18。然后将顶板12放置在侧板16和端板18上以覆盖制品C。在一个实施方案中,在底板14上设置侧板16和端板18,然后将制品C放置在它们之间的底板上。侧板16和端板18是齿形的(例如具有切成一端的槽/缺口的结构,例如带齿结构),分别具有隆突16b和18b(例如材料的凸起部分或突出),和分别具有中间的凹部16c、18c。在一些实施方案中,在将制品C置于空间S中之后,驱动销子20进入对齐的孔12a、14a、16a、18a以将垫板组件10固定在一起。在一些实施方案中,销子由耐热材料例如钨或钼制得。在一些实施方案中,销子在一个或两个端部上具有倒角(例如配置成能够将销子引入孔中的切口(relief)),以便引入垫板组件10中。不受特定的机理或理论束缚,认为这适合用于具有高速度正排气的窑。例如,将由凹部16c、18c相对于顶板12限定的空隙配置成充当排气口V,用于例如在将包含在垫板组件10内的制品C放置在窑中并经受热时由制品C排放的废气的通过。在一个实施方案中,侧板16和端板18由较大的材料片材切割得来,该片材的剩余部分用作顶板12和/或底板14。在一些实施方案中,如下面进一步描述的,通过机加工(即放电加工/线切割)或通过在模具中浇注来形成隆突和凹部16b、16c和18b、18c。
根据本公开,将垫板组件10配置成具有足够的强度以在窑中烧制之前、之中和之后支撑生坯制品C,其使制品C在整个烧制过程中保持给定的形状。另一个方面是,垫板组件10,它与制品C为化学上非反应性的,特别是在烧制过程中在窑的高热环境中。
在一些实施方案中,将垫板配置成由二硼化钛(TiB2)做成某些制品例如在铝熔炼炉中使用的阴极的形状。不受特定的机理或理论束缚,认为在必要的烧制温度下由石墨、氮化硼、堇青石、莫来石、锆石、氧化铝和碳化硅制得的垫板是反应性的和/或丧失足以支撑生坯二硼化钛制品C的强度。不受特定的机理或理论束缚,可利用二硼化钛作为用于形成垫板的材料,其中在窑中垫板与由其支撑的二硼化钛制品是化学相容的,此外垫板组件10可用于这一目的(例如在必要的烧制温度下保持足够的强度以支撑生坯二硼化钛制品C)。
形成二硼化钛制品C例如阴极的一种非限制性方法是通过形成二硼化钛颗粒在液体粘合剂例如聚合物(例如丙烯酸)中的浆料。在一种方法中,浆料具有液体和在液体中可溶或通过液体乳化的有机粘合剂以及TiB2粉末。将浆料喷雾或闪蒸干燥并将干燥的材料放置(通常处于结块形式)到模具中并用机械压力压实。另一种方法是粉浆浇注。在耐火材料的一些情况下,将湿糊料混合料或浇注料(类似于混凝土)压实到模具中然后干燥。轧辊压实或流延成型是形成陶瓷的其它方法。随后在窑中例如在温度约1500℃-2200℃的温度下将生坯制品C烧制0-10小时。该烧制过程导致生坯二硼化钛制品的烧结和致密化。可使用相同的组成以类似的方式形成垫板组件10的部件12、14等。初始的二硼化钛垫板可通过已知的方法来形成,例如通过在石墨模型中例如在1800℃下热压制二硼化钛粉末或通过利用被码垛在化学反应性表面例如石墨上的垫板,并随后将其机加工以移除受到化学影响的表面,例如移除碳化硼表面层。一旦形成,就可利用垫板组件10来码垛制品C,例如生坯形式的以用于制备垫板组件10的部件12、14、16、18的类似方法由模具中的二硼化钛浇注件制得的阴极板,其可容纳在由垫板组件10形成的包裹体所限定的空间S内。可将含有制品C的垫板组件10放置在窑中,并使其经受烧制/烧结制品C所需的温度。任选地,例如通过直接将一个垫板组件10堆叠在另一个上,通过利用常规的窑具隔开它们,或以其它方式在窑(例如石墨窑)内以有效的方式设置垫板组件10,可将多于一个包含制品C的垫板组件10加载到窑中。
在一个实施方案中,在制品C的烧制/烧结过程中,所述制品排放废气。作为一个非限制性实例,在浇注生坯二硼化钛阴极的情况下,在烧制过程中当粘合剂挥发和/或燃烧时,生坯浇注将排放各种有机化合物。在一个实施方案中,设置在垫板组件10中的排气口V可将一些气体排气进入窑中。在一个实施方案中,通过将窑排气来从炉中移除气体。在一些实施方案中,通过负压或正压排气进行排气。在一些实施方案中,由于根据上述用于制备部件12、14、16、18的方法形成的经烧结的二硼化钛具有约2.7至3.0g/cm3的密度和20%-50%的开孔面积。在这些实施方案中,废气通入并通过部件12、14、16、18进入窑中用于移除。作为一个非限制性实例,扁平制品C,如生坯状态的二硼化钛阴极具有其基本上整个下表面上与垫板组件的底板14接触,在码垛/烧制过程中在该垫板组件中包含它。在该实施方案中,不受任何机理或理论束缚,认为:由于底板14的孔隙率,在紧密接触的该区域中由制品C排放的废气至少部分地渗入与制品C接触的底板14的表面中,并通过垫板组件10的底板14出来并进入窑中用于移除/排气。以这种方式,制备的所得二硼化钛阴极(制品C)具有减少的受到废气和来自生坯制品的相关固体的污染。
本公开的一个方面是一种垫板组件,其具有码垛二硼化钛形体的能力,例如用作通过二硼化钛浆料的低压浇注或上述的方法制得的阴极,并且制备具有减少的来自废气的污染和由与垫板组件10接触所致的烧结产品表面的减少的污染的烧结产品,该垫板组件10主要由二硼化钛制得,其与烧结产品是化学相容的。
将理解的是,本文所描述的实施方案仅仅是示例性的,并且本领域技术人员可以做出许多变化和修改而不脱离本实用新型的精神和范围。旨在将所有这些变化和修改包括在本公开的范围之内。
Claims (7)
1.在窑中烧制制品时用于支撑制品的垫板,其特征在于包含多孔板,该多孔板由具有20%-50%开孔面积的经烧结的二硼化钛形成。
2.权利要求1的垫板,其特征在于,在窑中加热制品时垫板能够允许化合物的渗入,该化合物是由垫板上支撑的制品排放的。
3.权利要求1的垫板,其特征在于,该制品由二硼化钛制成,并且在窑中加热制品时垫板能够支撑窑中的制品,而不与制品化学反应。
4.权利要求1的垫板,其特征在于,垫板具有多个子部件,包括底板、顶板和至少一个侧板,所述侧板将顶板与底板隔开并且在其间限定了用于接收制品的空间。
5.权利要求4的垫板,其特征在于,顶板和底板是有同等范围的矩形板,并且所述至少一个侧板包括围绕矩形顶板和底板外围分布的四个侧板。
6.权利要求5的垫板,其特征在于,侧板是齿形的,其具有至少一个隆突和至少一个凹部,该凹部能够将顶板与底板之间的空间排气。
7.权利要求1的垫板,其特征在于,二硼化钛的颗粒尺寸为10-12微米。
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