CN113418393A - 一种微波窑用节能保温装置及制备方法 - Google Patents

一种微波窑用节能保温装置及制备方法 Download PDF

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CN113418393A
CN113418393A CN202110786248.5A CN202110786248A CN113418393A CN 113418393 A CN113418393 A CN 113418393A CN 202110786248 A CN202110786248 A CN 202110786248A CN 113418393 A CN113418393 A CN 113418393A
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wall
heat
ceramic
cover body
layer
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Inventor
范冰冰
陈勇强
张锐
王海龙
闵志宇
李红霞
李明亮
周亚波
宋博
王海亮
宋礼猛
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Zhengzhou University
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Zhengzhou University
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Priority to CN202110786248.5A priority Critical patent/CN113418393A/zh
Publication of CN113418393A publication Critical patent/CN113418393A/zh
Priority to GB2209696.0A priority patent/GB2605119B/en
Priority to NL2032389A priority patent/NL2032389B1/en
Pending legal-status Critical Current

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Abstract

本发明公开了一种微波窑用节能保温装置及制备方法，属于陶瓷材料制备技术领域，其包括箱体和盖体，箱体具有开口，盖体盖设在箱体的开口侧；箱体包括内壁和外壁，内壁与外壁之间预设有空隙；盖体盖设在内壁和外壁的上端，并与空隙形成容纳腔，容纳腔内填充有陶瓷气凝胶形成中间保温层；内壁的内表面设置有第一红外反射陶瓷层，盖体与箱体的配合面设置有第二红外反射陶瓷层。本发明在内壁的内表面设置高近红外反射陶瓷涂层，提高保温层内表面对工件辐射的反射率；同时，在内壁与外壁之间加入陶瓷气凝胶替代原有的保温棉，减轻了保温装置整体质量，减少了保温装置整体能量消耗，减弱保温层对工件热辐射的吸收量，起到更好的保温效果。

Description

一种微波窑用节能保温装置及制备方法
技术领域
本发明属于陶瓷材料制备技术领域，具体涉及一种微波窑用节能保温装置及制备方法。
背景技术
我国能源消耗快速增长，能量利用率低，节能降耗形势依然严峻。以热工窑炉为代表的、用于高温过程的工业能耗约占全国总能耗25％。统计数据分析表明，目前我国热工炉窑装备的平均热效率不足40％，比工业发达国家低10-20％。这一数据表明，热工装备行业的节能潜力巨大。
微波烧结作为一种先进的材料制备技术，它具有升温速度快、能源利用率高、加热效率高和安全无污染等特点，已经成为材料烧结领域新的研究热点。其中，微波加热过程中必不可少的保温装置是保证微波能高效利用的关键因素。
现有技术中，发明专利(ZL 201510308753.3，ZL 201410309340.2)涉及了辅助加热保温装置，但上述专利中仅考虑了保温层的透波和热导性，且结构主要包括内外两侧保温板和中间保温棉，忽略了辐射散热在微波烧结中的重要性，在微波烧结与传统加热烧结区别明显，传统加热靠周围加热元件对工件进行热辐射，周围保温层的温度显著高于工件温度，业内主要通过提高保温层内表面发射率来改善加热效率。而微波烧结的原理是微波层穿过保温层，直接作用于工件，工件吸收微波自身温度升高，因此，微波窑中，工件的温度显著高于周围保温层的温度。众所周知，高温物体向低温物体的热辐射量，远大于低温物体向高温物体的辐射量，因而，工件吸收微波产生的热量通过辐射形式传给保温层，导致保温层及整个保温结构的温度增加，消耗了大量能量。
在传统工业窑炉中，对保温层内壁涂覆高发射率涂层，强化辐射传热是实现热工炉窑节能的有效途径，但在微波窑炉中，工件自身发热向外辐射能量，周围炉壁温度显著低于工件温度，采用传统的高红外辐射涂层将收效甚微。
发明内容
为了解决上述技术问题，本发明采取了如下技术方案：
一种微波窑用节能保温装置，包括箱体和盖体，所述箱体具有开口，所述盖体盖设在所述箱体的开口侧；所述箱体包括内壁和外壁，所述内壁与所述外壁之间预设有空隙；所述盖体盖设在所述内壁和所述外壁的上端，并与所述空隙形成容纳腔，所述容纳腔内填充有中间保温层；所述内壁的内表面设置有第一红外反射陶瓷层，所述盖体与所述箱体的配合面设置有第二红外反射陶瓷层。
进一步地，所述盖体中部设置有测温孔。
进一步地，所述中间保温层为陶瓷气凝胶；所述内壁为多孔陶瓷制成的第一保温层；所述外壁为多孔陶瓷制成的第二保温层。
进一步地，所述盖体包括盖体本体和围设在所述盖体本体周向端面的围边，所述盖体本体包括自上至下依次设置的第一盖体层、盖体保温层和第二盖体层；所述第二盖体层位于与所述箱体配合的一侧；所述第二盖体层的外表面设置有第二红外反射陶瓷层。
一种微波窑用节能保温装置的制备方法，包括以下步骤：
S10、将氧化钛、氧化钇、氧化铈、氧化镧粉体以一定比例混合，加入一定量的酒精，加入聚乙二醇800，进行第一次球磨混合，再加入聚乙烯醇缩丁醛和领苯二甲酸丁苄酯，进行第二次球磨混合；真空除泡，获得红外反射陶瓷浆料；
S20、内壁为多孔陶瓷制成，将所述红外反射陶瓷浆料涂覆在所述内壁的陶瓷板内表面形成第一红外反射陶瓷层，干燥2-4h；高温烧结1-3h，获得内壁复合陶瓷保温层；
S30、外壁为多孔陶瓷制成；在所述内壁与所述外壁之间填充陶瓷气凝胶形成中间保温层；
S40、将所述红外反射陶瓷浆料涂覆在所述盖体与所述箱体配合的陶瓷板表面形成第二红外反射陶瓷层，干燥2-4h；高温烧结1-3h，获得盖体复合陶瓷保温层。
进一步地，在步骤S10中，所述氧化钛、氧化钇、氧化铈、氧化镧粉体以摩尔比7:1:1:1进行混合，所述氧化钛、氧化钇、氧化铈、氧化镧粉体的粒径均小于1μm。
进一步地，在步骤S10中，加入15-30wt％的酒精，加入0.5-1wt％的聚乙二醇800；进行100-200r/min第一次球磨混合4-6h；再加入2wt％的聚乙烯醇缩丁醛和领苯二甲酸丁苄酯混合物，其中，所述聚乙烯醇缩丁醛与所述领苯二甲酸丁苄酯的质量比为1:1；进行100-200r/min第二次球磨混合4-6h；真空除泡30min，获得红外反射陶瓷浆料。
进一步地，在步骤S20中，将所述红外反射陶瓷浆料涂覆在所述内壁的陶瓷板内表面形成第一红外反射陶瓷层后，进行80℃干燥2-4h；然后，1000-1300℃高温烧结1-3h，获得内壁复合陶瓷保温层；
在步骤S40中，将所述红外反射陶瓷浆料涂覆在所述盖体与所述箱体配合的陶瓷板表面形成第二红外反射陶瓷层后，进行80℃干燥2-4h；然后，1000-1300℃高温烧结1-3h，获得盖体复合陶瓷保温层。
进一步地，所述内壁和所述外壁为气孔率15-30％的莫来石或硅氮氧陶瓷中的一种制成；所述内壁的厚度为5-10mm；所述外壁的厚度为10-15mm；所述第一红外反射陶瓷层与所述第二红外反射陶瓷层的厚度为1-2mm。
进一步地，在步骤S30中，在所述内壁与所述外壁之间填充的陶瓷气凝胶为莫来石或碳化硅中的一种，所述中间保温层的厚度为15-30mm。
有益效果：
本发明在内壁的内表面设置高近红外反射陶瓷涂层，提高保温层内表面对工件辐射的反射率；同时，在内壁与外壁之间加入陶瓷气凝胶替代原有的保温棉，减轻了保温装置整体质量，减少了保温装置整体能量消耗，减弱保温层对工件热辐射的吸收量，起到更好的保温效果。
此外，使用发明提供的节能保温装置后，在同样的微波输入功率下，工件升温速率明显提升，保温状态下，所需输入功率明显下降。
附图说明
图1为本发明的整体结构示意图；
图2为实施例2中获得的高红外反射陶瓷涂层的SEM；
其中，1、内壁；2、外壁；3、中间保温层；4、第一红外反射陶瓷层；5、测温孔；6、盖体；61、第一盖体层；62、盖体保温层；63、第二盖体层；64、围边；65、第二红外反射陶瓷层。
具体实施方式
实施例1
一种微波窑用节能保温装置，包括箱体和盖体6，箱体具有开口，盖体6盖设在箱体的开口侧；箱体包括内壁1和外壁2，内壁1与外壁2之间预设有空隙；盖体6盖设在内壁1和外壁2的上端，并与空隙形成容纳腔，容纳腔内填充有陶瓷气凝胶形成中间保温层3；内壁1的内表面设置有第一红外反射陶瓷层4，盖体6与箱体的配合面设置有第二红外反射陶瓷层65。
在本实施例中，内壁1和外壁2均为“U”型结构，且内壁1和外壁2的开口位于同侧。
在本实施例中，盖体6中部设置有测温孔5。
在本实施例中，内壁1为多孔陶瓷制成的第一保温层；外壁2为多孔陶瓷制成的第二保温层。
在本实施例中，盖体6包括盖体本体和围设在盖体本体周向端面的围边64，盖体本体包括自上至下依次设置的第一盖体层61、盖体保温层62和第二盖体层63；第二盖体层63位于与箱体配合的一侧；第二盖体层63的外表面设置有第二红外反射陶瓷层65。
其中，第一盖体层61和第二盖体层63均为多孔陶瓷制成。
实施例2
本实施例为实施例1提供的一种微波窑用节能保温装置的制备方法，包括以下步骤：
S10、将氧化钛、氧化钇、氧化铈、氧化镧粉体以一定比例混合，加入一定量的酒精，加入聚乙二醇800，进行第一次球磨混合，再加入聚乙烯醇缩丁醛和领苯二甲酸丁苄酯，进行第二次球磨混合；真空除泡，获得红外反射陶瓷浆料；
S20、内壁1为多孔陶瓷制成，将红外反射陶瓷浆料涂覆在内壁1的陶瓷板内表面形成第一红外反射陶瓷层4，干燥2-4h；高温烧结1-3h，获得内壁复合陶瓷保温层；
S30、外壁2为多孔陶瓷制成；在内壁1与外壁2之间填充陶瓷气凝胶形成中间保温层3；
S40、将红外反射陶瓷浆料涂覆在盖体6与箱体配合的陶瓷板表面形成第二红外反射陶瓷层65，干燥2-4h；高温烧结1-3h，获得盖体复合陶瓷保温层。
在步骤S10中，氧化钛、氧化钇、氧化铈、氧化镧粉体以摩尔比7:1:1:1进行混合，氧化钛、氧化钇、氧化铈、氧化镧粉体的粒径均小于1μm，加入15-30wt％的酒精，加入0.5-1wt％的聚乙二醇800；进行100-200r/min第一次球磨混合4-6h；再加入2wt％的聚乙烯醇缩丁醛和领苯二甲酸丁苄酯混合物，其中，聚乙烯醇缩丁醛与领苯二甲酸丁苄酯的质量比为1:1；进行100-200r/min第二次球磨混合4-6h；真空除泡30min，获得红外反射陶瓷浆料。
在步骤S20中，将红外反射陶瓷浆料涂覆在内壁1的陶瓷板内表面形成第一红外反射陶瓷层4后，进行80℃干燥2-4h；然后，1000-1300℃高温烧结1-3h，获得内壁复合陶瓷保温层。
在步骤S40中，将红外反射陶瓷浆料涂覆在盖体6与箱体配合的陶瓷板表面形成第二红外反射陶瓷层65后，进行80℃干燥2-4h；然后，1000-1300℃高温烧结1-3h，获得盖体复合陶瓷保温层。
内壁1和外壁2为气孔率15-30％的莫来石或硅氮氧陶瓷中的一种制成；内壁1的厚度为5-10mm；外壁2的厚度为10-15mm；第一红外反射陶瓷层和第二红外反射陶瓷层的厚度为1-2mm。
在步骤S30中，在内壁1与外壁2之间填充的陶瓷气凝胶为莫来石或碳化硅中的一种，中间保温层3的厚度为15-30mm。
对比实验效果：
使用本发明提供的设计节能保温装置后，在同样的微波输入功率下，工件升温速率明显提升，保温状态下，所需输入功率明显下降，以氧化锆陶瓷的微波烧结为例，实验结果对比如下：
升温至1500℃所需时间 1500℃保温所需功率
常规保温装置 约90min 约7kW
节能保温装置 约75min 约6kW
以上所述，仅是本发明较佳实施例而已，并非对本发明的技术范围作任何限制，故凡是依据本发明的技术实质对以上实施例所作的任何细微修改、等同变化与修饰，均仍属于本发明技术方案的范围。

Claims (10)

1.一种微波窑用节能保温装置，其特征在于，包括箱体和盖体，所述箱体具有开口，所述盖体盖设在所述箱体的开口侧；所述箱体包括内壁和外壁，所述内壁与所述外壁之间预设有空隙；所述盖体盖设在所述内壁和所述外壁的上端，并与所述空隙形成容纳腔，所述容纳腔内填充有中间保温层；所述内壁的内表面设置有第一红外反射陶瓷层，所述盖体与所述箱体的配合面设置有第二红外反射陶瓷层。
2.根据权利要求1所述的微波窑用节能保温装置，其特征在于，所述盖体中部设置有测温孔。
3.根据权利要求1所述的微波窑用节能保温装置，其特征在于，所述中间保温层为陶瓷气凝胶；所述内壁为多孔陶瓷制成的第一保温层；所述外壁为多孔陶瓷制成的第二保温层。
4.根据权利要求1所述的微波窑用节能保温装置，其特征在于，所述盖体包括盖体本体和围设在所述盖体本体周向端面的围边；所述盖体本体包括自上至下依次设置的第一盖体层、盖体保温层和第二盖体层；所述第二盖体层位于与所述箱体配合的一侧；所述第二盖体层的外表面设置有第二红外反射陶瓷层。
5.根据权利要求1至4任一项所述的微波窑用节能保温装置的制备方法，其特征在于，包括以下步骤：
S10、将氧化钛、氧化钇、氧化铈、氧化镧粉体以一定比例混合，加入一定量的酒精，加入聚乙二醇800，进行第一次球磨混合，再加入聚乙烯醇缩丁醛和领苯二甲酸丁苄酯，进行第二次球磨混合；真空除泡，获得红外反射陶瓷浆料；
S20、内壁为多孔陶瓷制成，将所述红外反射陶瓷浆料涂覆在所述内壁的陶瓷板内表面形成第一红外反射陶瓷层，干燥2-4h；高温烧结1-3h，获得内壁复合陶瓷保温层；
S30、外壁为多孔陶瓷制成；在所述内壁与所述外壁之间填充陶瓷气凝胶形成中间保温层；
S40、将所述红外反射陶瓷浆料涂覆在所述盖体与所述箱体配合的陶瓷板表面形成第二红外反射陶瓷层，干燥2-4h；高温烧结1-3h，获得盖体复合陶瓷保温层。
6.根据权利要求5所述的微波窑用节能保温装置的制备方法，其特征在于，在步骤S10中，所述氧化钛、氧化钇、氧化铈、氧化镧粉体以摩尔比7:1:1:1进行混合，所述氧化钛、氧化钇、氧化铈、氧化镧粉体的粒径均小于1μm。
7.根据权利要求6所述的微波窑用节能保温装置的制备方法，其特征在于，在步骤S10中，加入15-30wt％的酒精，加入0.5-1wt％的聚乙二醇800；进行100-200r/min第一次球磨混合4-6h；再加入2wt％的聚乙烯醇缩丁醛和领苯二甲酸丁苄酯混合物，其中，所述聚乙烯醇缩丁醛与所述领苯二甲酸丁苄酯的质量比为1:1；进行100-200r/min第二次球磨混合4-6h；真空除泡30min，获得红外反射陶瓷浆料。
8.根据权利要求7所述的微波窑用节能保温装置的制备方法，其特征在于，在步骤S20中，将所述红外反射陶瓷浆料涂覆在所述内壁的陶瓷板内表面形成第一红外反射陶瓷层后，进行80℃干燥2-4h；然后，1000-1300℃高温烧结1-3h，获得内壁复合陶瓷保温层；
在步骤S40中，将所述红外反射陶瓷浆料涂覆在所述盖体与所述箱体配合的陶瓷板表面形成第二红外反射陶瓷层后，进行80℃干燥2-4h；然后，1000-1300℃高温烧结1-3h，获得盖体复合陶瓷保温层。
9.根据权利要求8所述的微波窑用节能保温装置的制备方法，其特征在于，所述内壁和所述外壁为气孔率15-30％的莫来石或硅氮氧陶瓷中的一种制成；所述内壁的厚度为5-10mm；所述外壁的厚度为10-15mm；所述第一红外反射陶瓷层与所述第二红外反射陶瓷层的厚度为1-2mm。
10.根据权利要求9所述的微波窑用节能保温装置的制备方法，其特征在于，在步骤S30中，在所述内壁与所述外壁之间填充的陶瓷气凝胶为莫来石或碳化硅中的一种，所述中间保温层的厚度为15-30mm。
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