EP0497151B1 - Procédé pour la fabrication en continu d'articles de faible épaisseur à partir de matière céramique - Google Patents

Procédé pour la fabrication en continu d'articles de faible épaisseur à partir de matière céramique Download PDF

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Publication number
EP0497151B1
EP0497151B1 EP92100649A EP92100649A EP0497151B1 EP 0497151 B1 EP0497151 B1 EP 0497151B1 EP 92100649 A EP92100649 A EP 92100649A EP 92100649 A EP92100649 A EP 92100649A EP 0497151 B1 EP0497151 B1 EP 0497151B1
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EP
European Patent Office
Prior art keywords
rolling
ceramic material
process according
ceramic
preform
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
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EP92100649A
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German (de)
English (en)
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EP0497151B2 (fr
EP0497151A1 (fr
Inventor
Edmund Dipl.-Mineraloge Goerenz
Tadeusz Dr. Rymon-Lipinski
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Dyko Industriekeramik GmbH
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Dyko Industriekeramik GmbH
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Application filed by Dyko Industriekeramik GmbH filed Critical Dyko Industriekeramik GmbH
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
    • B28B3/12—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein one or more rollers exert pressure on the material
    • B28B3/126—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein one or more rollers exert pressure on the material on material passing directly between the co-operating rollers

Definitions

  • the invention relates to a process for the continuous production of thin-walled moldings, such as plates, strips, tubes or the like.
  • thin-walled moldings such as plates, strips, tubes or the like.
  • From clay-free ceramic mass by moistening and mixing the raw materials and additives for the ceramic mass, the mixed ceramic mass into a green body shaped, optionally subdivided, and the green body is solidified to form the shaped body by drying and firing.
  • a thin-walled shaped body is understood to mean one with a thickness in the range between approximately 1 to 10 mm.
  • Ceramic raw materials, mostly in powder form, are regarded as raw materials, while plasticizers, plasticizers, binders and the like are among the additives. Like. To be understood.
  • the binder and plasticizer After the evaporation of the solvents, the binder and plasticizer give the cast film a certain flexibility, which allows the film to be wrapped, embossed, punched and, if necessary, laminated in layers on top of one another. Drying and firing give the film or the components made from it its final shape.
  • the green body thus cast is dried, at least in part, on the belt following the casting process.
  • the ceramic mass has a moisture content of about 20 to 30% by weight during film casting (Ceramic Journal No. 9, 1990, pp. 650 to 652).
  • the high moisture content requires special measures when drying the cast film.
  • the green body cannot be easily handled in all cases.
  • the tiles cover the upper region of the thickness.
  • clayey binders are also used in significant proportions by weight, while in the middle region of the thickness there is no special manufacturing possibility.
  • the moisture content is very high, so that there is the disadvantage that large amounts of moisture have to be expelled again during drying and / or firing.
  • ceramic masses, in particular powders must be processed, which must not contain clay as a binder. Such masses have little plasticity and are therefore difficult to process.
  • CH-A-394 013 shows a process for the continuous production of large-area cladding panels made of ceramic material, in which the plastic mass from the mouthpiece of an extrusion press with a somewhat smaller width and a slightly greater thickness than the cross-section of the panel to be produced, in the form brought, that is, shaped.
  • This shaping is followed by a first calibration process between two rollers, with which the thickness of the pressed strip is reduced slightly.
  • undercuts are machined from one surface of the mass strand, and calibration is carried out again between two rollers.
  • the rolling or calibrating process serves the purpose of eliminating the stresses that arise from the extrusion die when the mass strand is pressed out.
  • the ceramic mass used is in particular adjusted to a moisture content of 18% and pressed out through the mouthpiece of the extrusion press. By pre-drying to a water content of about 10%, the emerging strand is brought into a leather-hard state and then processed further.
  • FR-A-1 271 493 and US-A-3 007 222 also show the production of tiles and other wall cladding panels, in which, however, the shaping of the tile is carried out not by an extrusion process but by a rolling process.
  • Such a tile or cladding panel should not be regarded as an extremely thin panel, but rather has a relatively large wall thickness. Wall thicknesses between 0.025 and 3.75 mm are mentioned, but only for relatively small-sized parts. Water contents are given as 7 to 13% when it comes to clay-containing masses. In the case of masses with a higher clay content, water contents of 12 to 18% are stated. It is pointed out to the need for the simultaneous presence of an organic binder, that is, the combination of organic binder and water content. Water contents of 8 to 15% are mentioned.
  • the invention is based on the object of demonstrating a process for the continuous production of thin-walled shaped articles from clay-free ceramic material which can be produced in a particularly energy-saving manner and nevertheless have improved strength properties.
  • this is achieved in the process described at the outset by adjusting the ceramic mass to a moisture content of 2 to 5% by weight and by shaping and compacting the green body by rolling while introducing textures and influencing the structure in the ceramic mass.
  • Rolling is understood here that the ceramic mass z. B. is passed through a nip formed by two opposing rollers and thereby compacted, so that a belt is formed as a green body, which can be subdivided or further processed if necessary.
  • the green body already has a relatively high strength, which is in any case higher than that of the film goysson, so that there are no problems in handling the green body during its further processing.
  • the rolling process influences the formation of the structure in the ceramic mass.
  • the structure is adjustable, and textures in the ceramic mass can be achieved by the typical rolling movement, which have a positive effect on the mechanical and / or thermal and / or electrical properties of the moldings to be produced.
  • Rolling has the further advantage over film casting that molded articles with a comparatively lower porosity can be achieved even without venting the ceramic mass.
  • the moisture content can be set in the range between about 2 to 5% by weight, the properties of the thin-walled moldings being able to be controlled to a certain extent via the moisture content.
  • a lower humidity results in a lower porosity and a high thermal conductivity as well as high strength.
  • a high humidity results in a high porosity and therefore (up to a certain limit) a high resistance to temperature changes.
  • the degree of compaction can be selected and adjusted, which means that the strength properties can be specifically controlled.
  • the new process not only makes it possible to produce moldings in a thickness range of 1 mm or 10 mm, as in the case of film casting on the one hand and in the production of tiles on the other, but it is also possible to make sensible use of the thickness ranges in between.
  • the method can be used for ceramic masses which do not contain any clay or plasticizer.
  • the components of the ceramic mass are compacted by the pressure during rolling.
  • the use of the new process results in particularly low "molding costs" because the rolls used can generally be adjusted relative to one another by changing the roll gap in order to achieve the desired cross section.
  • the new method also allows a multi-stage operation in such a way that several rolling processes or stages are connected in series and in this way the degree of compaction is increased even further.
  • Coarse-grained fractions or parts within the ceramic mass can also be processed with the new process.
  • the ceramics were used, at least preferably, in the coarse grain area.
  • the particular moisture content used in rolling deviates completely from the other moisture contents of slip casting on the one hand and dry pressing, in particular isostatic pressing on the other.
  • the moisture contents within the specified range between 2 and 5 wt .-% thus also stand out against moisture contents, such as z. B. are known in tile manufacture.
  • ceramic materials can advantageously be rolled if such moisture contents are maintained.
  • the resulting textures and structural influences are definitely an advantage and not, as before, a disadvantage.
  • the new process also opens up thickness ranges that were previously difficult or impossible to control.
  • the ceramic mass can be evacuated before rolling. A negative pressure is applied here in order to reduce the porosity of the green body and the shaped body and ultimately also to increase the strength.
  • the ceramic mass can be heated before or during the rolling. This improves the workability. This applies in particular to raw materials and aggregates containing pitch and tar.
  • the one provided by the extruder Shaping serves to convey the ceramic mass to the roll gap in an orderly and pre-distributed manner. But it is also possible to use the ceramic mass z. B. pre-compact by extrusion, so that the subsequent rolling process is the actual or final compression process.
  • Rolling can be done by profiling the green body.
  • not only cylindrical roller bodies, but also profiled rollers can be used, for example to form grooves, shoulders or the like into the green body during rolling.
  • Such shapes are particularly useful when the shaped bodies are further processed into firing aids.
  • a meandering deformed film or plate can e.g. B. may also be an intermediate layer in a composite material, similar to what is known in the manufacture of corrugated cardboard in the pulp field.
  • carbide, nitride or metallic powders can also advantageously be rolled in in order to adjust and favor the electrical and / or thermal properties of the shaped body in this way.
  • Ceramic fibers, carbon fibers, metal fibers or the like can also be rolled in. These then represent a thermo-mechanical reinforcement. The rolling process must of course be adapted to the type of fibers.
  • the green body can also be easily wound up into several layers in order to increase the thickness on the one hand and to produce layered bodies with deliberate layer formation on the other hand.
  • Composite bodies can also be produced in this way. Even winding thin strips into tubes and similar shaped bodies is easily possible.
  • a rolling mill is indicated schematically by the rollers 1 and 2.
  • the roller 2 can be mounted in a stationary manner, while the roller 1 can be adjusted hydraulically with the roller 2 to form a nip 3 in order to exert a required pressing pressure on the ceramic mass.
  • the ceramic mass is prepared in its offset consisting of the raw materials and aggregates and, after appropriate mixing and moistening, is placed in a filling funnel 4 in which an agitator 5 is arranged. With the help of the agitator 5, the ceramic mass reaches the effective range of a screw conveyor 6, which conveys the ceramic mass to the roll gap 3, in such a way that the desired set thickness of the ceramic strip to be rolled is produced.
  • a rolled strip 7 is formed in the roll gap 3 and is guided away on a roller strip 8. It can be here connect the subdivision into individual green bodies, which is no longer shown. In the area of the agitator 5 or the screw conveyor 6, the ceramic mass can be vented.
  • FIG. 1 A somewhat modified device is shown in FIG.
  • the ceramic mass of raw materials and additives in mixed form is fed to a ceramic press 9 and expelled through a mouthpiece 10, so that a certain pre-compression of the ceramic mass takes place here.
  • the ceramic mass is fed to a first pair of rollers, consisting of rollers 1 and 2, via a conveyor 11 and further compressed in the nip 3, so that the belt 7 is formed here.
  • the belt 7 then runs into a second roller device with the rollers 1 'and 2' and finally then passes into a pair of shaping rollers 12 and 13, by means of which the belt 7 is brought into a wave shape.
  • a conveyor 14 receives the corrugated belt 15, which is divided into sections in a punch 16. The sections then pass into a drying device 17 and a kiln 18.
  • finished shaped bodies are produced at the end of the kiln in wave form, as can be used, for example, as a firing aid.
  • the compression takes place here in three stages, namely in the first stage in the ceramic press, in the second stage between rollers 1 and 2 and in the third stage between rollers 1 'and 2'.
  • the cross section of the band can be gradually reduced, and finally, as a corrugated band 15, it can have a wall thickness of 5 mm.
  • a fine-grained Al2O3 powder in a grain size smaller than 1 ⁇ m was mixed with different binder proportions.
  • Cellulose ether was used as a binder as a 1% solution in water. In addition, no moisture was introduced.
  • the ceramic mass formed in this way was rolled in a one-stage system, for example as shown in FIG. 1, a ceramic strip having a width of 75 mm and a thickness of 2 mm being produced.
  • the contact pressure of the rollers 1, 2 was 50 bar.
  • the resulting rolled Al2O3 band was divided into plates of 100 mm in length. The plates were dried in a drying oven at 110 ° C for 24 hours. This was followed by firing in a kiln at 1650 ° C for two hours.
  • the bending strength was determined in a 3-point bending test. In the manner described, plates were created which, for. B. appear suitable as kiln furniture. It can be seen from the table given that as the moisture content increases, the bulk density decreases, the porosity increases and the bending strength decreases.
  • the ceramic mass was made of fine Al2O3 powder with a fraction smaller than 1 ⁇ m together with 10% by weight of a powdered binder in the form of a cellulose derivative and with varying amounts of moisture. It was rolled into thin plates with a thickness of about 2 mm under a pressure of 50 bar. After drying similar to that in the exemplary embodiment in FIG. 1, the fire was carried out at 1650 ° C. for 2 hours.
  • the result was aluminum oxide plates with the following properties: Water fraction (weight fraction) Bulk density (g / cm3) Porosity (%) Flexural strength (N / mm2) (3-point bending test) 2nd 3.12 18.6 58.6 + 3.4 7 3.05 22.9 67.8 + 7.5 10th 2.86 25.5 73.1 + 3.0
  • the ceramic mass was made of fine aluminum oxide with a grain size of less than 1 ⁇ m and with the addition of 5% by weight of liquid binder of a 1% solution of cellulose ether in water. A pressure of 50 bar was applied during rolling. In a downstream punch press, small plates measuring 20 x 20 x 2 mm were punched out of the continuous strip. These were dried at 100 ° C in 8 hours and fired tightly in an electric oven at 1650 ° C for 4 hours, so that a porosity of 0% is present. Such moldings are suitable for use as carrier plates in the electrical industry.
  • a zirconium oxide with a grain fraction of less than 0.1 mm was mixed with 5% by weight of liquid binder from cellulose ether as a 1% solution in water and with 5% by weight of graphite with a grain fraction of less than 0.1 mm.
  • the mixed ceramic mass was rolled with a contact pressure of 80 bar and then divided.
  • the result was carbon-containing plates with a homogeneous structure and a porosity of 12.3%.
  • the thickness was 8 mm.
  • the further processing of this material into a composite appears z.
  • An SiC batch was mixed with a binder containing 5% by weight of 1% cellulose ether solution in water and rolled to a thickness of 5 mm.
  • a carbon net was placed on the belt and rolled again under a pressure of 40 bar, so that the carbon fabric was pressed into the ceramic belt.
  • the fire was carried out in an argon protective gas atmosphere at 1500 ° C for 4 hours.
  • the porosity of the material was 28.5%.
  • the rolling system is followed by a winding system in order to roll up the rolled ceramic strip in an inclined spiral and in this way to form a tube.
  • the offset was chosen similarly to Example 3.
  • the wound tube had an inner diameter of 150 mm and an outer diameter of 170 mm on.
  • the tube solidified and the edges sintered after drying in a fire of 1650 ° C for 10 hours.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)
  • Compositions Of Oxide Ceramics (AREA)
  • Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)
  • Producing Shaped Articles From Materials (AREA)

Claims (11)

  1. Procédé de fabrication en continu de corps façonnés à paroi mince, tels que plaques, bandes, tubes ou similaires, dans une pâte céramique ne contenant pas d'argile, en ce que les matières premières et les additifs pour la pâte céramique sont humidifiés et mélangés, la pâte céramique mélangée est formée en un produit vert, éventuellement subdivisé, et le produit vert est consolidé dans sa forme par séchage et cuisson pour donner le corps façonné, caractérisé en ce que la pâte céramique est réglée sur une humidité de 2 à 5 % en poids et le formage et le compactage du produit vert s'effectuent par laminage, par insertion de textures et influence de la structure dans la pâte céramique.
  2. Procédé selon la revendication 1, caractérisé en ce qu'il est fait le vide dans la masse céramique avant le laminage.
  3. Procédé selon la revendication 1 ou 2, caractérisé en ce que la masse céramique est chauffée avant ou pendant le laminage.
  4. Procédé selon une ou plusieurs des revendications 1 à 3, caractérisé en ce que la masse céramique est extrudée avant le laminage.
  5. Procédé selon les revendications 1 à 3, caractérisé en ce que la masse céramique est précompactée, par exemple par extrudage.
  6. Procédé selon une ou plusieurs des revendications 1 à 5, caractérisé en ce que le laminage s'effectue par profilage de produit vert.
  7. Procédé selon une ou plusieurs des revendications 1 à 6, caractérisé en ce que le produit vert est déformé en méandres, pendant ou après le laminage.
  8. Procédé selon une ou plusieurs des revendications 1 à 7, caractérisé en ce que pendant le laminage, des poudres de carbures, de nitrures ou métalliques sont laminées en même temps.
  9. Procédé selon une ou plusieurs des revendications 1 à 8, caractérisé en ce que pendant le laminage, des fibres céramiques, des fibres de carbone, des fibres métalliques ou similaires sont laminées en même temps.
  10. Procédé selon une ou plusieurs des revendications 1 à 9, caractérisé en ce que directement après le laminage le produit vert éventuellement subdivisé, est séché en continu et éventuellement cuit en continu.
  11. Procédé selon une ou plusieurs des revendication 1 à 10, caractérisé en ce que le produit vert est enroulé, de préférence en plusieurs couches.
EP92100649A 1991-01-28 1992-01-16 Procédé pour la fabrication en continu d'articles de faible épaisseur à partir de matière céramique Expired - Lifetime EP0497151B2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE4102469 1991-01-28
DE4102469A DE4102469A1 (de) 1991-01-28 1991-01-28 Verfahren zur kontinuierlichen herstellung duennwandiger formkoerper aus keramischer masse

Publications (3)

Publication Number Publication Date
EP0497151A1 EP0497151A1 (fr) 1992-08-05
EP0497151B1 true EP0497151B1 (fr) 1996-03-27
EP0497151B2 EP0497151B2 (fr) 1999-08-25

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EP92100649A Expired - Lifetime EP0497151B2 (fr) 1991-01-28 1992-01-16 Procédé pour la fabrication en continu d'articles de faible épaisseur à partir de matière céramique

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EP (1) EP0497151B2 (fr)
AT (1) ATE135950T1 (fr)
DE (2) DE4102469A1 (fr)
ES (1) ES2086558T5 (fr)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5384030A (en) * 1994-02-15 1995-01-24 General Motors Corporation Exhaust sensor including a composite tile sensing element and methods of making the same
DE19901533C2 (de) * 1999-01-16 2003-04-10 Villeroy & Boch Vorrichtung für die Herstellung von Dekor- oder Glasurmasse aufweisenden Keramikrohlingen
US8679302B2 (en) 2005-11-14 2014-03-25 Guardian Industries Corp. Silicon titanium oxide coating, coated article including silicon titanium oxide coating, and method of making the same
DE102006036624B4 (de) * 2006-08-03 2009-08-20 Schunk Kohlenstofftechnik Gmbh Werkstückträger sowie Verfahren zur Herstellung eines solchen
DE102011120547B4 (de) 2011-12-02 2018-10-18 Technische Universität Dresden Brennhilfsmittel, als Träger für Bauteile bei einer Wärmebehandlung
ES2636930T3 (es) * 2012-10-22 2017-10-10 Imerys Ceramics France Proceso para elaborar una lámina inorgánica

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3007222A (en) * 1953-01-02 1961-11-07 Gladding Mcbean & Co Method for continuous manufacture of ceramic sheets
FR1271493A (fr) * 1959-11-30 1961-09-15 Gladding Procédé de fabrication continue d'objets céramiques très minces
DE1205435B (de) * 1961-05-10 1965-11-18 Gottfried Cremer Dr Verfahren zum kontinuierlichen Herstellen von duennwandigen Wandverkleidungsplatten aus keramischem Werkstoff und Tunnelofen zur Durchfuehrung des Verfahrens
CH394013A (de) * 1960-04-16 1965-06-15 Aton Planungs & Baugesellschaft Fuer Die Keramische Industrie Mbh Verfahren zur kontinuierlichen Herstellung von grossflächigen Verkleidungsplatten aus keramischem Werkstoff
GB982128A (en) * 1962-12-20 1965-02-03 Fetok Gmbh Process for producing thin sheets of plastic ceramic materials
JPS61291445A (ja) * 1985-06-18 1986-12-22 イソライト工業株式会社 セラミツクフアイバ−ブランケツトの処理方法
DD285041A5 (de) * 1989-06-23 1990-12-05 Veb Chemieanlagenbaukombinat Leipzig-Grimma Stammbetrieb,Dd Vorrichtung zur kontinuierlichen herstellung von 3-dimensional profilierten, duennwandigen formlingen aus plastischen baendern oder platten keramischen grundmaterials, deren neutrale faser der profilstruktur entspricht

Also Published As

Publication number Publication date
ES2086558T3 (es) 1996-07-01
ES2086558T5 (es) 1999-12-01
DE59205793D1 (de) 1996-05-02
ATE135950T1 (de) 1996-04-15
EP0497151B2 (fr) 1999-08-25
DE4102469A1 (de) 1992-07-30
EP0497151A1 (fr) 1992-08-05

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