CN106631104A - 泡沫陶瓷材料及其制备方法 - Google Patents

泡沫陶瓷材料及其制备方法 Download PDF

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CN106631104A
CN106631104A CN201610826905.3A CN201610826905A CN106631104A CN 106631104 A CN106631104 A CN 106631104A CN 201610826905 A CN201610826905 A CN 201610826905A CN 106631104 A CN106631104 A CN 106631104A
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李洋洋
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Zhengzhou Foamtech Nano Material Co Ltd
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Abstract

本发明提出了一种泡沫陶瓷材料及其制备方法，包括以下原料：陶瓷粉料40～60wt％、硅溶胶5～15wt％、发泡剂6～18wt％、分散剂2～6wt％，余量为水；其中，陶瓷粉末由氮化硅70～80wt％、膨润土10～20wt％、粉煤灰5～10wt％、氧化铝1～5wt％与滑石粉1～5wt％组成。通过陶瓷浆料制备，然后再进行干燥得到坯体，再进行烧结得到。该泡沫陶瓷材料结构均匀一致，在缩短生产周期的同时还可以提高产品性能的稳定性。

Description

泡沫陶瓷材料及其制备方法
技术领域
本发明属于多孔陶瓷技术领域，具体涉及一种泡沫陶瓷材料及其制备方法。
背景技术
泡沫陶瓷是一种造型上像泡沫状的多孔陶瓷。它具有三维连通孔道,同时其形状、孔尺寸、渗透性、表面积及化学性能均可进行适度调整变化。泡沫陶瓷因具有特殊的性能，如高比表面积、高渗透性、低容重、低热导率等而日益引起各方面的重视。这些优异的性能使其在催化剂载体、熔融金属过滤、高温气体过滤、耐火材料、生物材料等领域得到广泛应用。
泡沫陶瓷采用聚氨酯泡沫塑料为载体，将其浸入由陶瓷粉末、粘结剂、助烧结剂、悬浮剂等制成的料浆中，然后挤掉多余料浆，使陶瓷浆料均匀涂覆于载体骨架成为坯体，再将坯体干燥并经高温烧结而成。泡沫陶瓷具有与泡沫塑料相似的孔隙结构，通孔率达85～90％。国内外已根据不同合金的特点，发展了多种不同材质的泡沫陶瓷，如美国专利3893917、3962081、4024056、4075303，中国国家专利87101800.4、92102883.0、200710139286.1、200710139289.5等，这些泡沫陶瓷由氧化铝、氧化硅、氧化锆、氮化硅等材料制成，可用于过滤一般的铝合金、铜合金、铸钢、铸铁等。
专利申请CN103787689公开了一种碳化硅泡沫陶瓷的制备方法，先将聚醚或聚酯多元醇与催化剂、表面活性剂和发泡剂搅拌后，加入碳化硅粉体、高岭土和氧化铝粉、硅溶胶再搅拌均匀后，再加入固化剂，混合均匀后置于成型容器中反应固化，将固化后的泡沫陶瓷海绵体经开孔处理，再经过高温烧结即可得到碳化硅泡沫陶瓷。该方法需要开孔处理，工序多，泡沫陶瓷的生产成本高、生产周期长。
发明内容
本发明提出一种泡沫陶瓷材料，该泡沫陶瓷材料结构均匀一致，在缩短生产周期的同时还可以提高产品性能的稳定性。
本发明的技术方案是这样实现的：
一种泡沫陶瓷材料，包括以下原料：陶瓷粉料40～60wt％、硅溶胶5～15wt％、发泡剂6～18wt％、分散剂2～6wt％，余量为水；其中，陶瓷粉末由氮化硅70～80wt％、膨润土10～20wt％、粉煤灰5～10wt％、氧化铝1～5wt％与滑石粉1～5wt％组成。
进一步，所述发泡剂由白云石30～50wt％、碳酸钙25～35wt％、硫酸钙5～10wt％、碳粉10～15wt％和硅粉5～10wt％组成。
进一步，所述分散剂为聚丙烯酸盐或者单宁酸盐。
本发明的另一个目的是提供一种泡沫陶瓷材料的制备方法，包括以下步骤：
1)陶瓷浆料制备：将分散剂加入水中微波超声分散，得粘性液体，然后向粘性液体中加入陶瓷粉料与硅溶胶混合均匀，再加入发泡剂，机械搅拌10～30min，得到陶瓷浆料；
2)将步骤1)的陶瓷浆料浇注于模具中，置于80～100℃环境中固化干燥得到坯体；
3)步骤2)的坯体放入烧结炉中，然后从室温以2～10℃/min升温到800℃～1120℃，烧结1～3h，冷却后得到泡沫陶瓷材料。
进一步，所述分散剂为聚丙烯酸盐或者单宁酸盐。
进一步，所述发泡剂由白云石30～50wt％、碳酸钙25～35wt％、硫酸钙5～10wt％、碳粉10～15wt％和硅粉5～10wt％组成。
进一步，所述发泡剂制备方法为：对白云石、碳酸钙、硫酸钙、碳粉与硅粉进行配料，用振动球磨机混合2～4小时后得到粉料即可。
本发明的有益效果：
1、本发明的陶瓷粉料由氮化硅、膨润土、粉煤灰、氧化铝与滑石粉组成，以氮化硅为主，膨润土、粉煤灰以及滑石粉作为助剂，可以降低陶瓷粉末的烧结温度，其中粉煤灰与后续的发泡剂在发泡时，可以提高发泡效率。
2、发泡剂中的白云石，可分解出大量气体，选用的碳粉、硅粉作为调节剂，不但调节发泡剂的发泡性能，而且增强了泡沫陶瓷的耐温性能。
3、本发明的泡沫陶瓷热导率低小于0.080W/(m·K)，强度高至少为13.12MPa。
具体实施方式
实施例1
陶瓷粉末由氮化硅70wt％、膨润土20wt％、粉煤灰5wt％、氧化铝1wt％与滑石粉4wt％组成。
发泡剂由白云石30wt％、碳酸钙35wt％、硫酸钙10wt％、碳粉15wt％和硅粉10wt％组成。
一种泡沫陶瓷材料，包括以下原料：陶瓷粉料40wt％、硅溶胶5wt％、发泡剂6wt％、单宁酸钠2wt％，余量为水。
泡沫陶瓷材料的制备方法，包括以下步骤：
1)陶瓷浆料制备：将分散剂加入水中微波超声分散，得粘性液体，然后向粘性液体中加入陶瓷粉料与硅溶胶混合均匀，再加入发泡剂，机械搅拌10min，得到陶瓷浆料；
2)将步骤1)的陶瓷浆料浇注于模具中，置于80℃环境中固化干燥得到坯体；
3)步骤2)的坯体放入烧结炉中，然后从室温以5℃/min升温到800℃，烧结1h，冷却后得到泡沫陶瓷材料。
实施例2
陶瓷粉末由氮化硅80wt％、膨润土10wt％、粉煤灰5wt％、氧化铝4wt％与滑石粉1wt％组成。
发泡剂由白云石40wt％、碳酸钙30wt％、硫酸钙10wt％、碳粉10wt％和硅粉10wt％组成。
一种泡沫陶瓷材料，包括以下原料：陶瓷粉料50wt％、硅溶胶10wt％、发泡剂10wt％、聚丙烯酸钾3wt％，余量为水。
泡沫陶瓷材料的制备方法，包括以下步骤：
1)陶瓷浆料制备：将分散剂加入水中微波超声分散，得粘性液体，然后向粘性液体中加入陶瓷粉料与硅溶胶混合均匀，再加入发泡剂，机械搅拌20min，得到陶瓷浆料；
2)将步骤1)的陶瓷浆料浇注于模具中，置于90℃环境中固化干燥得到坯体；
3)步骤2)的坯体放入烧结炉中，然后从室温以8℃/min升温到920℃，烧结1.5h，冷却后得到泡沫陶瓷材料。
实施例3
陶瓷粉末由氮化硅80wt％、膨润土10wt％、粉煤灰5wt％、氧化铝2wt％与滑石粉3wt％组成。
发泡剂由白云石50wt％、碳酸钙25wt％、硫酸钙5wt％、碳粉15wt％和硅粉5wt％组成。
泡沫陶瓷材料的制备方法，包括以下步骤：
1)陶瓷浆料制备：将分散剂加入水中微波超声分散，得粘性液体，然后向粘性液体中加入陶瓷粉料与硅溶胶混合均匀，再加入发泡剂，机械搅拌30min，得到陶瓷浆料；
2)将步骤1)的陶瓷浆料浇注于模具中，置于100℃环境中固化干燥得到坯体；
3)步骤2)的坯体放入烧结炉中，然后从室温以10℃/min升温到1120℃，烧结3h，冷却后得到泡沫陶瓷材料。
实施例4
陶瓷粉末由氮化硅75wt％、膨润土10wt％、粉煤灰5wt％、氧化铝5wt％与滑石粉5wt％组成。
发泡剂由白云石35wt％、碳酸钙35wt％、硫酸钙10wt％、碳粉15wt％和硅粉5wt％组成。
泡沫陶瓷材料的制备方法，包括以下步骤：
1)陶瓷浆料制备：将分散剂加入水中微波超声分散，得粘性液体，然后向粘性液体中加入陶瓷粉料与硅溶胶混合均匀，再加入发泡剂，机械搅拌15min，得到陶瓷浆料；
2)将步骤1)的陶瓷浆料浇注于模具中，置于95℃环境中固化干燥得到坯体；
3)步骤2)的坯体放入烧结炉中，然后从室温以4℃/min升温到1000℃，烧结1h，冷却后得到泡沫陶瓷材料。
以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (7)

1.一种泡沫陶瓷材料，其特征在于，包括以下原料：
陶瓷粉料40～60wt％、硅溶胶5～15wt％、发泡剂6～18wt％、分散剂2～6wt％，余量为水；其中，陶瓷粉末由氮化硅70～80wt％、膨润土10～20wt％、粉煤灰5～10wt％、氧化铝1～5wt％与滑石粉1～5wt％组成。
2.根据权利要求1所述的泡沫陶瓷材料，其特征在于，所述发泡剂由白云石30～50wt％、碳酸钙25～35wt％、硫酸钙5～10wt％、碳粉10～15wt％和硅粉5～10wt％组成。
3.根据权利要求1所述的泡沫陶瓷材料，其特征在于，所述分散剂为聚丙烯酸盐或者单宁酸盐。
4.一种如权利要求1所述的泡沫陶瓷材料的制备方法，其特征在于，包括以下步骤：
1)陶瓷浆料制备：将分散剂加入水中微波超声分散，得粘性液体，然后向粘性液体中加入陶瓷粉料与硅溶胶混合均匀，再加入发泡剂，机械搅拌10～30min，得到陶瓷浆料；
2)将步骤1)的陶瓷浆料浇注于模具中，置于80～100℃环境中固化干燥得到坯体；
3)步骤2)的坯体放入烧结炉中，然后从室温以2～10℃/min升温到800℃～1120℃，烧结1～3h，冷却后得到泡沫陶瓷材料。
5.根据权利要求4所述的泡沫陶瓷材料的制备方法，其特征在于，所述分散剂为聚丙烯酸盐或者单宁酸盐。
6.根据权利要求4所述的泡沫陶瓷材料的制备方法，其特征在于，所述发泡剂由白云石30～50wt％、碳酸钙25～35wt％、硫酸钙5～10wt％、碳粉10～15wt％和硅粉5～10wt％组成。
7.根据权利要求6所述的泡沫陶瓷材料的制备方法，其特征在于，所述发泡剂制备方法为：对白云石、碳酸钙、硫酸钙、碳粉与硅粉进行配料，用振动球磨机混合2～4小时后得到粉料即可。
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