WO2013113178A1 - 一种两件套陶瓷泡壳及其制作方法 - Google Patents

一种两件套陶瓷泡壳及其制作方法 Download PDF

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WO2013113178A1
WO2013113178A1 PCT/CN2012/071486 CN2012071486W WO2013113178A1 WO 2013113178 A1 WO2013113178 A1 WO 2013113178A1 CN 2012071486 W CN2012071486 W CN 2012071486W WO 2013113178 A1 WO2013113178 A1 WO 2013113178A1
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blister
slurry
piece ceramic
ring
ceramic
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PCT/CN2012/071486
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English (en)
French (fr)
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杨潮平
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Yang Chaoping
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J9/00—Apparatus or processes specially adapted for the manufacture, installation, removal, maintenance of electric discharge tubes, discharge lamps, or parts thereof; Recovery of material from discharge tubes or lamps
    • H01J9/24—Manufacture or joining of vessels, leading-in conductors or bases
    • H01J9/26—Sealing together parts of vessels
    • H01J9/265—Sealing together parts of vessels specially adapted for gas-discharge tubes or lamps
    • H01J9/266—Sealing together parts of vessels specially adapted for gas-discharge tubes or lamps specially adapted for gas-discharge lamps
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J61/00—Gas-discharge or vapour-discharge lamps
    • H01J61/02—Details
    • H01J61/30—Vessels; Containers
    • H01J61/302—Vessels; Containers characterised by the material of the vessel

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  • the invention belongs to the technical field of preparation of electric light source materials, in particular to a two-piece ceramic foam shell and a manufacturing method thereof.
  • the two-piece blister is generally butt-joined by means of interference fit.
  • the two blanks are separately formed first, and the concave and convex structures of the two blanks are coupled, and the blanks of two different structures are formed.
  • the body is pre-fired according to the shrinkage rate at different temperatures, and then the two pre-fired green bodies are butted together, and then sintered at a high temperature, and the butt joints are combined by means of interference fit to achieve airtight docking.
  • the two-piece blister is achieved by the interference fit by the interference fit. Therefore, it is necessary to form two blanks with different shrinkage ratios and different mating surfaces, and then select different pre-burning temperatures.
  • the pre-firing process is complicated and difficult to control.
  • the interference-connected bulb needs to increase the wall thickness, which also affects the bulb transmittance, and ceramic blister may occur in each assembly and sintering step. Component misalignment or defects such as bonding force and air tightness.
  • the method of abutting a two-piece blister by heating is achieved by forming a pair of blanks containing a large amount of bonding material, by heating the bonding portion, melting the body, and combining the two components under external force, thereby In the subsequent process, it is difficult to discharge a large amount of bonding materials in the green body.
  • the internal impurities are a fatal problem affecting performance, and the whole body is softened by heat conduction, and furthermore The external force is applied, and the deformation of the green body is likely to occur during the docking process.
  • the object of the present invention is to provide a method for manufacturing a two-piece ceramic blister with simple process, reliable docking mode, and no deformed or misaligned blank appearance;
  • the present invention also provides the ceramic blister obtained by the above production method.
  • the technical solution of the present invention is: a method for manufacturing a two-piece ceramic blister, comprising the following steps:
  • a forming a pair of ceramic blister bodies of the same shape, the body consisting of a capillary tube and a cavity;
  • the clamp comprises a steel needle having a diameter smaller than the inner diameter of the capillary and a base coupled to the curved surface of the ceramic blank; the capillary of the blank printed with the slurry is directed downward, fixed in the designed fixture, and then The cavity of another blank body with the slurry is inserted into the steel needle downward, and the two blank bodies are accurately positioned by the steel needle passing through the inner hole of the capillary tube, and pressed under the gravity or external force of the bulb body itself. The paste on the surface of the bond ring is bonded together.
  • step b the height of the convex portion of the coupling ring is 0.5 to 1.0 mm.
  • step c a thin layer of paste for bonding is printed on the surface of the bonding ring of the blister body to be butted by a film printing or pad printing technique, and the thickness of the slurry is 0.03 to 0.05 mm.
  • the main component of the thin layer slurry is the same alumina powder as the blister body component, and 2 to 5% glycerol and 3 to 6% are added.
  • Hydrogenated castor oil is prepared by a slurry preparation technique to prepare a slurry having a viscosity of 30,000 to 40000 mPa ⁇ S for film printing.
  • step e the heating and drying temperature is 50 to 80 °C for 10 to 30 minutes. Or leave it in the air for drying for 100 to 150 minutes.
  • the cavity is semi-ellipsoidal, hemispherical or semi-tubular; the blister body is formed by dry pressing or isostatic pressing.
  • the present invention also provides a two-piece ceramic blister, comprising two cavities and capillaries respectively disposed on the end of the cavity, wherein the joint faces of the two cavities are provided with a coupling ring, and the coupling ring is provided There is a thin layer of slurry, and the two cavities are bonded together by a thin layer of slurry.
  • the height of the convex portion of the bonding ring is 0.5-1.0 mm; the thickness of the thin layer slurry is 0.03-0.05 mm; and the cavity is semi-ellipsoidal, hemispherical or semi-tubular.
  • the blister body of the present invention is formed by dry pressing or isostatic pressing, and contains only a small amount of binder, and drains the organic matter in the body;
  • the cavity joint surface of the blister body body adds a circle of the joint ring, which increases the bonding area of the bond and ensures the bonding reliability;
  • the main component of the thin layer slurry is the same as the shell component, and the two shell bodies can be well joined together. Since the body is still dry or isostatically pressed, the green body is not in any state. Heating or passing through the pre-burning process, the deformation of the green body due to heating or pre-burning does not occur;
  • FIG. 1 is a schematic structural view of an interference fit of a two-piece blister case of the prior art
  • FIG. 2 is a schematic structural view of a ceramic blister body according to the present invention.
  • Figure 3 is an enlarged schematic view of a portion A of Figure 2;
  • Figure 4 is a schematic view of the structure of the clamp
  • Figure 5 is a schematic view showing the structure of the ceramic blister body butting
  • Figure 6 is a schematic structural view of a plurality of fixture stations
  • Figure 7 is a schematic view showing the structure of a ceramic hull after molding
  • Figure 8 is a schematic diagram of the bad body placement station when printing a thin layer of slurry.
  • the present invention discloses a method for forming a two-piece ceramic blister, which comprises the following steps:
  • Step 1 Forming a pair of ceramic foam shells of the same shape by dry pressing or isostatic pressing, wherein the binder material content in the blank is less than 1%; the blank consists of a capillary tube 1 and a half ellipsoid A type, hemispherical or semi-tubular cavity 2 is formed.
  • Step 2 In order to increase the bonding area, a ring of coupling rings 3 is formed on the joint surface of the cavity, as shown in FIG. 3: the appearance of the ceramic foam shell after docking is beautiful, the size of the joint ring is not too large, and the height of the convex portion is high. It is 0.5 to 1.0 mm, and the structural status is shown in Figures 2 and 3.
  • Step 3 Using a film printing or pad printing technique, a thin layer of paste for bonding is printed on the surface of the bonding ring of the bulb body to be butted, and the thickness of the slurry generally does not exceed 0.03 to 0.05 mm.
  • the main component of the thin layer slurry is the same alumina powder as the shell body, and 2 to 5% glycerin, 3 to 6% are added.
  • Hydrogenated castor oil is prepared by a slurry preparation technique to prepare a slurry having a viscosity of 30,000 to 40000 mPa ⁇ S for film printing.
  • Step 4 The capillary of a blank of the printed slurry is faced downward and fixed in a designed fixture.
  • the clamp comprises a steel needle 4 having a diameter smaller than the inner diameter of the capillary and a base 5 coupled to the curved surface of the ceramic blank.
  • the cavity of another blank with the slurry printed is inserted into the steel needle downward, and the two blanks are accurately positioned by the steel needle passing through the inner hole of the capillary. Since the slurry layer is thin, the blister body is The slurry under the surface of the bonding ring is bonded together by self-gravity or external force, as shown in Figs. 4 and 5.
  • Step 5 The connected bulbs are placed in a dry box together with the jig to be dried, and after the slurry is dried, the bonded bodies are taken out.
  • the curing temperature and time of the slurry can be adjusted, and it can be dried at room temperature or dried by heating. Heating and drying temperature 50 ⁇ 80 °C, time is 10 ⁇ 30min; if placed in the air for drying, the time is 100 ⁇ 150min.
  • the bonded blister body contains only a small amount of binder, after a short time of discharging, it can be sintered in the sintering furnace, so that the ceramic blister reaches a theoretical density, and the internal grain grows into a hexagonal structure of a certain size. Finally, it becomes a two-piece translucent alumina ceramic blister.
  • the blister discharge cavity is ellipsoidal, spherical or tubular, and the center of the discharge cavity protrudes once, but does not affect the overall light transmission performance. There is a section of capillary at each end, as shown in Figure 7.
  • Example 1 Making a batch of 150W ellipsoidal two-piece ceramic blister
  • a batch of blister bodies is formed by isostatic pressing using high-purity alumina spray granulation according to requirements.
  • the main component is high-purity alumina powder, adding 3% glycerin, 4.5% terpineol, 2% dioctyl phthalate, 1% dinonyl phthalate, 2% Epoxy resin, 0.3% polyamide wax, 0.25% hydrogenated castor oil, test slurry viscosity at 32000mPa ⁇ S, The prepared slurry is sealed and stored at a constant speed on a rotating table in the incubator.
  • the bonded batches are placed in an air furnace and kept at 420 ° C for 2.5 hours to remove less binder in the green body and then into the hydrogen furnace.
  • the high temperature sintering at 1800 °C makes the bonded bulb reach the theoretical density of porcelain, and becomes a translucent two-piece ceramic foam shell.
  • the discharge chamber is an ellipsoidal shape, and the center of the discharge chamber protrudes once. However, it does not affect the overall light transmission performance, and there is a capillary tube at each end of the discharge chamber.

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  • Manufacturing & Machinery (AREA)
  • Ceramic Products (AREA)

Abstract

提供一种属于电光源材料制备技术领域的两件套陶瓷泡壳及其制造方法，所述方法包括以下步骤：a、成型一对形状相同的陶瓷泡壳坯体，坯体由毛细管（1）及腔体（2）组成；b、在腔体（2）的结合面成型一圈结合圈（3）；c、在待对接泡壳坯体的结合圈（3）表面印刷一层用于粘结的薄层浆料；d、通过夹具将两泡壳坯体进行定位，使结合圈（3）表面的浆料粘结在一起；e、将连接的泡壳进行干燥，待浆料干燥后取出粘结在一起的坯体；经过高温烧结，最后成型为两件套结构陶瓷泡壳。本发明具有工艺简单，对接方式可靠，坯体对接外观无变形、错位，泡壳高温烧结后不影响整体透明率的优点。

Description

一种两件套陶瓷泡壳及其制作方法
技术领域
本发明属于电光源材料制备技术领域，尤其涉及一种两件套陶瓷泡壳及其制作方法。
背景技术
目前两件套泡壳一般采用过盈配合的方式实现对接，如图1所示，首先分别成型两个坯体，在两个坯体的对接部分有耦合的凹凸结构，两种不同结构的坯体根据收缩率在不同温度下预烧好，再将预烧好的两个素坯对接起来，再进行高温烧结，对接部分通过过盈配合的方式结合在一起，实现气密性对接。
近些年来出现了另外一种两件套泡壳实现连接的方法，就是成型一种含有较多粘合材料的陶瓷坯体，两个坯体的形状相同，在生坯状态下对陶瓷体的结合面加热软化后在夹具中将两个陶瓷体结合起来，再进行排胶、烧结，实现陶瓷泡壳的气密性对接。
两件套泡壳采用过盈配合的方式对接是靠烧结过程中收缩率不同来实现的，因此需要成型两种收缩率不同且对接面结构不同的坯体，然后还要选择不同的预烧温度进行预烧，过程比较复杂，控制难度较大，另外过盈配合连接的泡壳需增加壁厚，这样还会影响泡壳透光率，并且在每个装配和烧结步骤中可能发生陶瓷泡壳组件错位或者结合力及气密性等缺陷。
采用加热的方式对接两件套泡壳的方法是通过成型一对含有大量粘合材料的坯体，通过加热结合部位，使坯体熔化，将两个组件在外力下结合在一起实现的，因此在后续的工艺中很难排尽坯体中的大量结合材料，对透明氧化铝陶瓷泡壳来讲内部含有杂质是影响性能的致命问题，另外坯体受热传导整体变软，再加上还要施加外力作用，在对接过程中很容易出现坯体变形的情况。
发明内容
针对现有技术的缺点，本发明的目的是提供一种工艺简单，对接方式可靠，坯体对接外观无变形、错位的两件套陶瓷泡壳的制作方法；
除此之外，本发明还提供了上述制作方法所获得的陶瓷泡壳。
为实现上述目的，本发明的技术方案为：一种两件套陶瓷泡壳的制作方法，其包括以下步骤：
a 、成型一对形状相同的陶瓷泡壳坯体，坯体由毛细管及腔体组成；
b 、在腔体的结合面成型一圈结合圈；
c 、在待对接泡壳坯体的结合圈表面印刷一层用于粘结的薄层浆料；
d 、通过专用工装夹具将两泡壳坯体进行定位，使结合圈表面的浆料粘结在一起；
e 、将连接的泡壳进行干燥，待浆料干燥后取出粘结在一起的坯体；经过高温烧结，最后成型为两件套陶瓷泡壳。
步骤d中，所述夹具包括直径比毛细管内径细的钢针和与陶瓷坯体弧面耦合的底座；将印刷好浆料的一个坯体的毛细管朝下，固定在设计好的夹具中，再取另外一个印有浆料的坯体的腔体朝下插入钢针中，靠穿过毛细管内孔的钢针将两个坯体准确定位，并在泡壳坯体自身重力或外力下压下使结合圈表面的浆料粘结在一起。
步骤b中，所述结合圈外凸部分的高度为0.5～1.0mm。步骤c中，采用薄膜印刷或移印技术在待对接的泡壳坯体的结合圈表面印刷一层用于粘结的薄层浆料，浆料厚度为0.03～0.05mm。
步骤c中，薄层浆料的主要成分是与泡壳坯体成分相同的氧化铝粉末，还添加2 ~ 5% 甘油、3 ~ 6% 松油醇、1 ~ 4% 邻苯二甲酸二辛酯、0.5 ~ 2% 邻苯二酸二癸酯、1 ~ 3% 环氧树脂、0.1 ~ 0.5% 聚酰胺蜡及0.1 ~ 0.5% 氢化蓖麻油，并采用浆料制备技术制备成满足薄膜印刷需要的粘度30000 ~ 40000mPa × S 的浆料。
步骤e中，加热干燥温度50 ～ 80 ℃ ，时间为10 ～ 30min ；或放置在空气中进行干燥，时间为100 ～ 150min 。
步骤a中，腔体为半椭球型、半球型或半管型；泡壳坯体通过干压或等静压成型。
同时，本发明还提供了一种两件套陶瓷泡壳，包括两腔体及分别设于腔体末端上的毛细管，其中，两腔体的结合面上均设有结合圈，且结合圈设有薄层浆料，两腔体通过薄层浆料粘结在一起。
所述结合圈外凸部分的高度为0.5～1.0mm；所述薄层浆料厚度为0.03～0.05mm；所述腔体为半椭球型、半球型或半管型。
与现有技术相比较，本发明的有益效果在于，
1.本发明的泡壳坯体通过干压或等静压成型，只含有少量结合剂，便与排尽坯体中的有机物；
2.泡壳坯体的腔体结合面增加了一圈结合圈，增加了粘结的粘结面积，保证了粘结可靠性；
3.薄层浆料主要成分和泡壳成分相同，可以很好的将两个泡壳坯体连接到一起，由于粘结时坯体还是干压或等静压出的生坯状态，没有任何加热或经过预烧过程，不会出现坯体因加热或预烧带来的变形情况；
4.粘结时采用夹具定位，两个坯体固定在同一根钢针上，同轴度得到保证，不会出现对接错位的情况。
附图说明
图1 为现有技术两件套泡壳过盈配合的结构示意图；
图2 为本发明 陶瓷泡壳坯体的结构示意图；
图3 为图2中A部分的放大示意图；
图4 为夹具的结构示意图；
图5 为 陶瓷泡壳坯体对接的结构示意图；
图6 为多个 夹具工位的结构示意图；
图7 为成型后的 陶瓷泡壳的结构示意图；
图8 为印刷薄层浆料时坏体放置工位示意图。
具体实施方式
如图1所示，本发明公开了一种两件套陶瓷泡壳的成型方法，其包括以下步骤：
步骤1、采用干压或者等静压的方法成型一对形状相同的陶瓷泡壳坯体，其中坯体中的结合剂材料含量低于1%；该坯体由一段毛细管1和半个椭球型、半球型或半管型的腔体2组成。
步骤2、为了增加粘结面积，在腔体的结合面成型了一圈结合圈3，如图3示：使对接后的陶瓷泡壳的外形美观，结合圈尺寸不宜太大，外凸部分高度为0.5～1.0mm,结构现状如图2、3所示。
步骤3、采用薄膜印刷或移印技术在待对接的泡壳坯体的结合圈表面印刷一层用于粘结的薄层浆料，浆料厚度一般不超过0.03～0.05mm。
其中，薄层浆料的主要成分是与泡壳坯体成分相同的氧化铝粉末，还添加2 ~ 5% 甘油、3 ~ 6% 松油醇、1 ~ 4% 邻苯二甲酸二辛酯、0.5 ~ 2% 邻苯二酸二癸酯、1 ~ 3% 环氧树脂、0.1 ~ 0.5% 聚酰胺蜡及0.1 ~ 0.5% 氢化蓖麻油，并采用浆料制备技术制备成满足薄膜印刷需要的粘度30000 ~ 40000mPa × S 的浆料。
步骤4、将印刷好浆料的一个坯体的毛细管朝下，固定在设计好的夹具中，所述夹具包括直径比毛细管内径细的钢针4和与陶瓷坯体弧面耦合的底座5，再取另外一个印有浆料的坯体的腔体朝下插入钢针中，靠穿过毛细管内孔的钢针将两个坯体准确定位，由于浆料层很薄，在泡壳坯体自身重力或外力下压下使结合圈表面的浆料粘结在一起，如图4及图5所示。
步骤5、再将连接的泡壳连同夹具一起放到干燥箱中干燥，待浆料干燥后取出粘结在一起的坯体。
上述步骤中，为了方便操作及高效率生产，可以在一块平板上根据泡壳坯体的几何尺寸加工很多这种夹具工位，如图6示，等所有工位的泡壳都粘结好以后，整体移入干燥箱中干燥。
浆料固化温度、时间可调，可以常温晾干，也可加热烘干。加热干燥温度50 ～ 80 ℃ ，时间为10 ～ 30min ；若放置在空气中进行干燥，时间为100 ～ 150min 。
粘结好的泡壳坯体由于只含有少量的结合剂，经过较短时间的排胶后就可进烧结炉烧结，使陶瓷泡壳达到理论密度，内部晶粒生长为一定尺寸的六方结构，最后成为一个两件套半透明氧化铝陶瓷泡壳，泡壳放电腔为椭球型、球型或管型，放电腔的中心部凸出一圈，但不影响整体透光性能，放电腔两端各有一段毛细管，如图7所示。
以下结合实施例对本发明进行进一步的描述。
实施例1、制作一批150W的椭球型两件套陶瓷泡壳
1、根据要求使用喷雾造粒的高纯氧化铝采用等静压的的方法成型一批泡壳坯体。
2、配置一批浆料，主要成分为高纯氧化铝粉，添加3%甘油、4.5%松油醇、2%邻苯二甲酸二辛酯、1%邻苯二酸二癸酯、2%环氧树脂、0.3%聚酰胺蜡、0.25%氢化蓖麻油，测试浆料粘度在32000mPa × S, 制备好的浆料密封保存在恒温箱内的转动台上匀速转动。
3、将成型好的坯体毛细管朝下，腔体结合圈朝上的方向放入如图8示的夹具中，采用薄膜印刷技术在坯体腔体结合圈的表面印刷上一层薄浆料层，测试浆料层厚度约0.04mm。
4、将印刷好浆料的坯体取一半从图8的夹具中转移到图6的专用夹具中，剩下的一般坯体一一与转移到图6夹具中的坯体通过穿过毛细管的内孔的钢芯针固定对接起来。
5、使用坯体都对接好后空气中放置10min。
6、放置时间到后将夹具连同坯体一起转移到干燥箱中干燥，温度设定在65℃，时间20min，干燥后取出放置等待热处理和高温烧结。
7、按以上方法制备一批粘结好的坯体后，将这些粘结好的一批集中放进空气炉中420℃保温2.5小时排除坯体中较少的结合剂后再进氢气炉中1800℃高温烧结，使粘结好的泡壳达到成瓷的理论密度，成为半透明状的两件套结构的陶瓷泡壳，放电腔为椭球型，放电腔的中心部凸出一圈，但不影响整体透光性能，放电腔两端各有一段毛细管。

Claims (11)

  1. 一种两件套陶瓷泡壳的制作方法，其特征在于，包括以下步骤：
    a 、成型一对形状相同的陶瓷泡壳坯体，坯体由毛细管（1）及腔体（2）组成；
    b 、在腔体的结合面成型一圈结合圈（3）；
    c 、在待对接泡壳坯体的结合圈表面印刷一层用于粘结的薄层浆料；
    d 、通过夹具将两泡壳坯体进行定位，使结合圈表面的浆料粘结在一起；
    e 、将连接的泡壳进行干燥，待浆料干燥后取出粘结在一起的坯体；最后成型为两件套陶瓷泡壳。
  2. 根据权利要求1所述的两件套陶瓷泡壳的制作方法，其特征在于，步骤d中，所述夹具包括直径比毛细管内径细的钢针（4）和与陶瓷坯体弧面耦合的底座（5）；将印刷好浆料的一个坯体的毛细管朝下，固定在设计好的夹具中，再取另外一个印有浆料的坯体的腔体朝下插入钢针中，靠穿过毛细管内孔的钢针将两个坯体准确定位，并在泡壳坯体自身重力或外力下压下使结合圈表面的浆料粘结在一起。
  3. 根据权利要求1所述的两件套陶瓷泡壳的制作方法，其特征在于，步骤b中，所述结合圈（3）外凸部分的高度为0.5～1.0mm。
  4. 根据权利要求1所述的两件套陶瓷泡壳的制作方法，其特征在于，步骤c中，采用薄膜印刷或移印技术在待对接的泡壳坯体的结合圈表面印刷一层用于粘结的薄层浆料，浆料厚度为0.03～0.05mm。
  5. 根据权利要求1所述的两件套陶瓷泡壳的制作方法，其特征在于，步骤c中，薄层浆料与泡壳坯体主要成分均为氧化铝粉末，还添加2 ~ 5% 甘油、3 ~ 6% 松油醇、1 ~ 4% 邻苯二甲酸二辛酯、0.5 ~ 2% 邻苯二酸二癸酯、1 ~ 3% 环氧树脂、0.1 ~ 0.5% 聚酰胺蜡及0.1 ~ 0.5% 氢化蓖麻油，并采用浆料制备技术制备成满足薄膜印刷需要的粘度30000 ~ 40000mPa × S 的浆料。
  6. 根据权利要求1所述的两件套陶瓷泡壳的制作方法，其特征在于，步骤e中，加热干燥温度50 ～ 80 ℃ ，时间为10 ～ 30min ；或放置在空气中进行干燥，时间为100 ～ 150min 。
  7. 根据权利要求1所述的两件套陶瓷泡壳的制作方法，其特征在于，步骤a中，泡壳坯体通过干压或等静压成型。
  8. 一种两件套陶瓷泡壳，包括两腔体（2）及分别设于腔体（2）末端上的毛细管（1），其特征在于，两腔体（2）的结合面上均设有结合圈（3），且结合圈（3）设有薄层浆料，两腔体通过薄层浆料粘结在一起。
  9. 根据权利要求8所述的两件套陶瓷泡壳，其特征在于，所述结合圈（3）外凸部分的高度为0.5～1.0mm。
  10. 根据权利要求8所述的两件套陶瓷泡壳，其特征在于，所述薄层浆料厚度为0.03～0.05mm。
  11. 根据权利要求8所述的两件套陶瓷泡壳，其特征在于，所述腔体（2）为半椭球型、半球型或半管型。
PCT/CN2012/071486 2012-01-31 2012-02-23 一种两件套陶瓷泡壳及其制作方法 WO2013113178A1 (zh)

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