CN106278342A - 一种绝缘子用韧化陶瓷及其制造方法 - Google Patents
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Abstract
本发明公开了一种绝缘子用韧化陶瓷及其制造方法,其原材料包括以下重量份的材料:硼酸铝晶须2‑3份、适当尺寸的碳化硅微粉70‑80份、适当尺寸的氮化铝微粉20‑30份、氟化钙粉末1‑1.5份、碳粉10‑15份、硅化钼10‑15份、正硅酸乙脂6‑8份、无水乙醇3‑5份、纯净水3‑5份、热塑性酚醛树脂1.5‑2.5份;经过原材料准备、预制备绝缘子、绝缘子烧结及完成,形成了体积电阻率≥2×1013Ω•cm、介电强度≥750kV/cm、热导率≥25W/m·K、抗弯强度≥400Mpa、杨氏模数≥320Gpa、断裂韧性≥25Mpa的高韧性绝缘陶瓷。本发明的经济性好、耐高温氧化、断裂韧性高、主要材料功能互补。
Description
技术领域
本发明涉及电子元件领域,尤其涉及一种绝缘子用韧化陶瓷及其制造方法。
背景技术
绝缘子是一种特殊的绝缘控件,能够在架空输电线路中起到重要作用。
早年间绝缘子多用于电线杆,慢慢发展于高型高压电线连接塔的一端挂了很多盘状的绝缘体,它是为了增加爬电距离的,通常由玻璃或陶瓷制成,就叫绝缘子。绝缘子在架空输电线路中起着两个基本作用,即支撑导线和防止电流回地,这两个作用必须得到保证;同时,绝缘子应具有足够的电气绝缘强度、耐潮湿性能和耐高温性能。
在国内已申请的相关专利中,专利《高绝缘碳化硅/氮化硼陶瓷材料及其制备方法》(申请号:201310294766.0,公开日:2015-01-14),公开了一种碳化硅/氮化硼陶瓷材料及其制备方法,但该两种材料均属于脆性材料,其断裂韧性不高于6Mpa,易在运输和其它振动工况下断裂或破碎,其外该发明属于高温烧结(1900℃-2300℃)加热等静压成型,其成本过高,无法进行工业化生产,另一方面,由于碳化硅的氧化温度较低,当电短路产生高温时,该绝缘子易发生表层氧化而导致绝缘性能降低;专利《一种绝缘导热的无机纳米复合陶瓷及其制备方法和用途》(申请号:201410310359.9,公开日:2015-12-30),公开了一种无机纳米复合陶瓷,保其有效成份制成陶瓷后均为高脆性材料,没有韧化处理,同时也没有将材料的综合性能优势发挥出来。
发明内容
为解决现有技术中存在的上述缺陷,本发明旨在提供一种经济性好、耐高温氧化、断裂韧性高、综合性能好且主要材料功能互补的绝缘子用韧化陶瓷及其制造方法。
为了实现上述目的,本发明采用以下技术方案:一种绝缘子用韧化陶瓷的制造方法,其特征在于包括以下步骤:
1)原材料准备
①按重量份数准备硼酸铝晶须2-3份、颗粒尺寸3μm-5μm的碳化硅微粉70-80份、颗粒尺寸3μm-5μm的氮化铝微粉20-30份、氟化钙粉末1-1.5份、碳粉10-15份、硅化钼10-15份、正硅酸乙脂6-8份、无水乙醇3-5份、纯净水3-5份、热塑性酚醛树脂1.5-2.5份;
②将所有硼酸铝晶须、60%-75%的碳化硅微粉、所有碳粉和所有硅化钼微粉混合并搅拌均匀,作为心部物料;将剩余的碳化硅微粉、所有氮化铝微粉和所有氟化钙混合并搅拌均匀,作为表层物料;
2)预制备绝缘子
①将1)中步骤②获得的心部物料与所有正硅酸乙脂、无水乙醇、纯净水、热塑性酚醛树脂混合后放入涂有脱模剂的心部模具中,心部模具的轮廓三维尺寸均在所需目标绝缘子尺寸基础上减少8mm-10mm,将该心部模具置于800℃-850℃下,在保护气氛或真空环境里保温5h-8h,获得心部毛坯;
②将1)中步骤②获得的表层物料在涂有脱模剂的绝缘子模具中铺垫4mm -5mm;再将步骤①获得的心部毛坯置于绝缘子模具正中间,表层物料铺垫层的表面中心;
③在不影响心部毛坯尺寸的情况下将表层物料继续放入绝缘子模具中,直至将模具填充满,获得预制备绝缘子毛坯;
3)绝缘子烧结及完成
①将2)中步骤③获得的预制备绝缘子毛坯置于2-3倍大气压的保护气氛中,以1000℃以上保持200℃/h-250℃/h的升温速率升温至1600℃-1700℃,保温时间4h-7h;
②烧结完成后,炉温T不低于1000℃时随炉冷却;炉温T处于800℃≤T<1000℃半开炉门冷却;炉温T<800℃出炉空冷;空冷至T<150℃后将烧结的绝缘子毛坯脱出模具;
③采用金刚石磨料振动去毛刺设备对绝缘子毛坯进行振动去毛刺及抛光处理,即获得所需绝缘子。
上述的一种绝缘子用韧化陶瓷的制造方法,其中:2)中步骤①采用的正硅酸乙脂、无水乙醇、纯净水、热塑性酚醛树脂的重量比为4:2:2:1。
上述的一种绝缘子用韧化陶瓷的制造方法,其中:3)中步骤①采用的保护气氛优选为氩气。
一种根据上述制造方法所制造出的绝缘子用韧化陶瓷,其中:分为心部和表层,其中表层包括以下重量份的成分:碳化硅17.5-32份、氮化铝20-30份、氟化钙1-1.5份;心部包括以下重量份的成分:碳化硅58-77.5份、硼酸铝晶须2-3份、钼的不定化合物10-15份。
根据上述方法制备出的绝缘子用韧化陶瓷,其体积电阻率≥2×1013Ω•cm、介电强度≥750kV/cm、热导率≥25W/m·K、抗弯强度≥400Mpa、杨氏模数≥320Gpa、断裂韧性≥25Mpa。
与现有技术相比较,本发明具有以下优点:心部物料中混入了适当比例的硼酸铝晶须、硅化钼颗粒,前者在陶瓷体内植入韧化纤维、后者通过晶间相强化直接提高心部碳化硅陶瓷的韧性,表层的材料由于也混入了一定比例的碳化硅,因此和心部的结合力会非常好,有多个强化结合支撑区域和缓冲过渡区域,同时氟化钙也能在一定程度上提升表层与心部的结合力及氮化铝本身的韧性,因此本发明的陶瓷断裂韧性可达其它绝缘材料的4倍以上;碳化硅和氮化铝都是绝缘性非常好的材料,但受限于碳化硅易氧化、氮化铝脆性很高的本质特性,单独使用均无法适应恶劣工况(比如运输和安装时碰撞损毁、电线老化短路后高温氧化、风沙或冰雹震动等),本发明将碳化硅主要置于心部,表层只含部分碳化硅,一方面增加氮化铝的韧性,另外也利于在使用过程中受高温致表层氧化,生成的二氧化硅进一步提升绝缘性,又不会导致氧化后脆性升高或过渡氧化后绝缘性降低,而氮化铝由于有了碳化硅的加入,加上心部韧性组织的支持,其断裂韧性有长足的提升,因此,本发明耐高温、综合性能好且主要材料功能互补;另外,本发明采用的均为同领域中较经济的材料,而且能适应大部分恶劣工况,基础绝缘及导热性能甚至优于其它绝缘陶瓷,故而本发明的经济性好,适合大范围应用推广;另外,本发明在烧结过程中选择了最优升温速率,冷却时又采用阶梯缓冷,本身绝缘子残余的热应力和组织应力都较低,在后期抛光处理中又加入了振动过程,使内应力均匀化,提升了整体性能的均匀性,降低了缺口敏感性,也是本发明断裂韧性高的一个重要原因;优化的工艺使得心部的碳粉及硅化钼大部分反应成为外来碳化硅及钼的化合物填补了原碳化硅陶瓷粉体的间隙,提升了心部陶瓷的致密性和耐高温性能,而其它心部烧结助剂均可高温气化,由于在真空环境中烧结,所有高温下气化的烧结助剂均通过真空泵抽离,留下了烧结完全的陶瓷体,而不会留下气孔和疏松。
附图说明
图1是本发明的结构示意图;
图中:表层1、心部2。
具体实施方式
实施例1:
一种韧化陶瓷,分为心部2和表层1,其中表层1包括以下重量份的成分:碳化硅17.5份、氮化铝20份、氟化钙1份;心部2包括以下重量份的成分:碳化硅58份、硼酸铝晶须2份、钼的不定化合物10份;
一种绝缘子用韧化陶瓷,制造方法包括以下步骤:
1)原材料准备
①按重量份数准备硼酸铝晶须2份、颗粒尺寸3μm-5μm的碳化硅微粉70份、颗粒尺寸3μm-5μm的氮化铝微粉20份、氟化钙粉末1份、碳粉10份、硅化钼10份、正硅酸乙脂6份、无水乙醇3份、纯净水3份、热塑性酚醛树脂1.5份;
②将所有硼酸铝晶须、75%的碳化硅微粉、所有碳粉和所有硅化钼微粉混合并搅拌均匀,作为心部2物料;将剩余的碳化硅微粉、所有氮化铝微粉和所有氟化钙混合并搅拌均匀,作为表层1物料;
2)预制备绝缘子
①将1)中步骤②获得的心部2物料与所有正硅酸乙脂、无水乙醇、纯净水、热塑性酚醛树脂混合后放入涂有脱模剂的心部2模具中,其中正硅酸乙脂、无水乙醇、纯净水、热塑性酚醛树脂的重量比为4:2:2:1,心部2模具的轮廓三维尺寸均在所需目标绝缘子尺寸基础上减少8mm,将该心部2模具置于800℃下,在保护气氛或真空环境里保温8h,获得心部2毛坯;
②将1)中步骤②获得的表层1物料在涂有脱模剂的绝缘子模具中铺垫4mm;再将步骤①获得的心部毛坯置于绝缘子模具正中间,表面1物料铺垫层的表面中心;
③在不影响心部2毛坯尺寸的情况下将表层1物料继续放入绝缘子模具中,直至将模具填充满,获得预制备绝缘子毛坯;
3)绝缘子烧结及完成
①将2)中步骤③获得的预制备绝缘子毛坯置于2倍大气压的氩气中,以1000℃以上保持250℃/h的升温速率升温至1700℃,保温时间4h;
②烧结完成后,炉温T不低于1000℃时随炉冷却;炉温T处于800℃≤T<1000℃半开炉门冷却;炉温T<800℃出炉空冷;空冷至T<150℃后将烧结的绝缘子毛坯脱出模具;
③采用金刚石磨料振动去毛刺设备对绝缘子毛坯进行振动去毛刺及抛光处理,即获得所需绝缘子。
按本实施例生产出的绝缘子用韧化陶瓷,其体积电阻率为5×1013Ω•cm、介电强度为810kV/cm、热导率为29W/m·K、抗弯强度为430Mpa、杨氏模数为370Gpa、断裂韧性为31Mpa。
实施例2:
一种韧化陶瓷,分为心部2和表层1,其中表层1包括以下重量份的成分:碳化硅32份、氮化铝30份、氟化钙1.5份;心部2包括以下重量份的成分:碳化硅77.5份、硼酸铝晶须3份、钼的不定化合物15份;
一种绝缘子用韧化陶瓷,制造方法包括以下步骤:
1)原材料准备
①按重量份数准备硼酸铝晶须3份、颗粒尺寸3μm-5μm的碳化硅微粉80份、颗粒尺寸3μm-5μm的氮化铝微粉30份、氟化钙粉末1.5份、碳粉15份、硅化钼15份、正硅酸乙脂8份、无水乙醇5份、纯净水5份、热塑性酚醛树脂2.5份;
②将所有硼酸铝晶须、60%的碳化硅微粉、所有碳粉和所有硅化钼微粉混合并搅拌均匀,作为心部2物料;将剩余的碳化硅微粉、所有氮化铝微粉和所有氟化钙混合并搅拌均匀,作为表层1物料;
2)预制备绝缘子
①将1)中步骤②获得的心部2物料与所有正硅酸乙脂、无水乙醇、纯净水、热塑性酚醛树脂混合后放入涂有脱模剂的心部2模具中,其中正硅酸乙脂、无水乙醇、纯净水、热塑性酚醛树脂的重量比为4:2:2:1,心部2模具的轮廓三维尺寸均在所需目标绝缘子尺寸基础上减少10mm,将该心部2模具置于850℃下,在保护气氛或真空环境里保温5h,获得心部2毛坯;
②将1)中步骤②获得的表层1物料在涂有脱模剂的绝缘子模具中铺垫5mm;再将步骤①获得的心部毛坯置于绝缘子模具正中间,表面1物料铺垫层的表面中心;
③在不影响心部2毛坯尺寸的情况下将表层1物料继续放入绝缘子模具中,直至将模具填充满,获得预制备绝缘子毛坯;
3)绝缘子烧结及完成
①将2)中步骤③获得的预制备绝缘子毛坯置于3倍大气压的氩气中,以1000℃以上保持200℃/h的升温速率升温至1600℃,保温时间7h;
②烧结完成后,炉温T不低于1000℃时随炉冷却;炉温T处于800℃≤T<1000℃半开炉门冷却;炉温T<800℃出炉空冷;空冷至T<150℃后将烧结的绝缘子毛坯脱出模具;
③采用金刚石磨料振动去毛刺设备对绝缘子毛坯进行振动去毛刺及抛光处理,即获得所需绝缘子。
按本实施例生产出的绝缘子用韧化陶瓷,其体积电阻率为1×1014Ω•cm、介电强度为830kV/cm、热导率为27W/m·K、抗弯强度为410Mpa、杨氏模数为360Gpa、断裂韧性为29Mpa。
本发明的工作原理为:表层氮化铝/碳化硅本身断裂韧性不低,又由于有韧化的心部,在受到外部冲击时,通过心部的相对柔性支撑层缓冲,提升了对冲击的耐受能力,同时硼酸铝晶须如同植物根系一样交错在心部陶瓷内,提升了心部陶瓷的结合力和断裂韧性,另外加上工艺上的细节优化处理,三种因素共同作用使本发明的韧性是常规绝缘陶瓷的4倍以上,足以适应其它绝缘陶瓷不能适应的恶劣工况。
对所公开的实施例的上述说明,仅为了使本领域专业技术人员能够实现或使用本发明。对这些实施例的多种修改对本领域的专业技术人员来说将是显而易见的,本文中所定义的一般原理可以在不脱离本发明的精神或范围的情况下,在其它实施例中实现。因此,本发明将不会被限制于本文所示的这些实施例,而是要符合与本文所公开的原理和新颖特点相一致的最宽的范围。
Claims (4)
1.一种绝缘子用韧化陶瓷的制造方法,其特征在于包括以下步骤:
1)原材料准备
①按重量份数准备硼酸铝晶须2-3份、颗粒尺寸3μm-5μm的碳化硅微粉70-80份、颗粒尺寸3μm-5μm的氮化铝微粉20-30份、氟化钙粉末1-1.5份、碳粉10-15份、硅化钼10-15份、正硅酸乙脂6-8份、无水乙醇3-5份、纯净水3-5份、热塑性酚醛树脂1.5-2.5份;
②将所有硼酸铝晶须、60%-75%的碳化硅微粉、所有碳粉和所有硅化钼微粉混合并搅拌均匀,作为心部物料;将剩余的碳化硅微粉、所有氮化铝微粉和所有氟化钙混合并搅拌均匀,作为表层物料;
2)预制备绝缘子
①将1)中步骤②获得的心部(2)物料与所有正硅酸乙脂、无水乙醇、纯净水、热塑性酚醛树脂混合后放入涂有脱模剂的心部(2)模具中,心部(2)模具的轮廓三维尺寸均在所需目标绝缘子尺寸基础上减少8mm-10mm,将该心部(2)模具置于800℃-850℃下,在保护气氛或真空环境里保温5h-8h,获得心部(2)毛坯;
②将1)中步骤②获得的表层(1)物料在涂有脱模剂的绝缘子模具中铺垫4mm -5mm;再将步骤①获得的心部毛坯置于绝缘子模具正中间,表层(1)物料铺垫层的表面中心;
③在不影响心部(2)毛坯尺寸的情况下将表层(1)物料继续放入绝缘子模具中,直至将模具填充满,获得预制备绝缘子毛坯;
3)绝缘子烧结及完成
①将2)中步骤③获得的预制备绝缘子毛坯置于2-3倍大气压的保护气氛中,以1000℃以上保持200℃/h-250℃/h的升温速率升温至1600℃-1700℃,保温时间4h-7h;
②烧结完成后,炉温T不低于1000℃时随炉冷却;炉温T处于800℃≤T<1000℃半开炉门冷却;炉温T<800℃出炉空冷;空冷至T<150℃后将烧结的绝缘子毛坯脱出模具;
③采用金刚石磨料振动去毛刺设备对绝缘子毛坯进行振动去毛刺及抛光处理,即获得所需绝缘子。
2.根据权利要求1所述的一种绝缘子用韧化陶瓷的制造方法,其特征在于:2)中步骤①采用的正硅酸乙脂、无水乙醇、纯净水、热塑性酚醛树脂的重量比为4:2:2:1。
3.根据权利要求2所述的一种绝缘子用韧化陶瓷的制造方法,其特征在于:3)中步骤①采用的保护气氛优选为氩气。
4.一种根据权利要求2或3所述制造方法所制造出的绝缘子用韧化陶瓷,其特征在于:分为心部(2)和表层(1),其中表层(1)包括以下重量份的成分:碳化硅17.5-32份、氮化铝20-30份、氟化钙1-1.5份;心部(2)包括以下重量份的成分:碳化硅58-77.5份、硼酸铝晶须2-3份、钼的不定化合物10-15份。
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