Method for preparing honeycomb ceramic using 3D printing resin template

Abstract

The application discloses a method for preparing honeycomb ceramics by using a 3D printing resin template, and specifically comprises the following steps: S1, printing a porous resin grid template by using a 3D printing technology, wherein the material for the 3D printed porous resin grid template is rigid photosensitive resin and flexible photosensitive resin; S2, preparing a rigid resin grid template; S3, preparing a flexible resin grid template; S4, preparing honeycomb ceramics by using the 3D printed resin grid template and ceramic slurry, wherein the 3D printing technology in the step S1 comprises a photocuring 3D printing technology, a powder laying adhesive jetting 3D printing technology and an extrusion 3D printing technology, and the grid structure of the 3D printed porous resin grid template in the step S1 is a uniform structure or a gradient pore structure. The application relates to the technical field of ceramic production. The method for preparing honeycomb ceramics by using a 3D printing resin template can greatly improve the filtering efficiency, reduce impurity defects caused by structure falling off and improve the structural strength.

Description

Technical Field

[0001] The present invention relates to the technical field of ceramic production, and in particular to a method for preparing honeycomb ceramics using a 3D printing resin template. Background Art

[0002] Porous ceramics are made primarily from high-quality raw materials such as corundum, silicon carbide, and cordierite. Through a special high-temperature sintering process, they are formed and processed to create porous ceramics with open pores and high open porosity. These materials exhibit advantages such as resistance to high temperatures, high pressures, corrosion from acids, alkalis, and organic media, excellent biological inertness, a controllable pore structure, high open porosity, long service life, and excellent product regeneration. Their high porosity makes them suitable for precision filtration and separation of various media, high-pressure gas exhaust silencing, gas distribution, and electrolytic diaphragms. A key characteristic of porous ceramics is their high number of uniform and controllable pores. Pores can be divided into open pores (those in the ceramic matrix that are open to the atmosphere) and closed pores (those in the ceramic matrix that are not open to the atmosphere). Open pores have functions such as filtration, absorption, adsorption, and echo cancellation, while closed pores help block heat, sound, and the transmission of liquids and solid particles, providing increased strength. Porous ceramic materials are generally made by calcining metal oxides, silicon dioxide, silicon carbide, etc. at high temperatures. These materials themselves have high strength. During the calcination process, the boundaries of the raw material particles melt and bond together, forming a ceramic with high strength and stable physical and chemical properties. Porous ceramic materials are resistant to acid and alkali corrosion, and can also withstand high temperatures and high pressures. They are self-cleaning and will not cause secondary pollution. They are green and environmentally friendly functional materials with high filtration accuracy and good regeneration performance. Porous ceramic materials used as filter materials have a narrow pore size distribution range and high porosity and specific surface area. The filtered material is in full contact with the ceramic material, and pollutants such as suspended matter, colloids, and microorganisms are blocked on the surface or inside the filter medium, resulting in a good filtration effect. After a period of use, the porous ceramic filter material can be backwashed with gas or liquid to restore its original filtration capacity.

[0003] Existing porous ceramics are typically manufactured using a template method. Extrusion methods, in particular, only allow for molding, using a honeycomb sponge as a template. After dipping the sponge in ceramic slurry, the sponge is ablated to produce the honeycomb ceramic. Because honeycomb sponges are typically produced using a foaming method, their internal structure is uncontrollable and has sharp corners and blind ends. Consequently, the honeycomb ceramics produced using this template have a monotonous pore structure, prone to chipping during use. The pore size and distribution are highly random, resulting in poorly consistent filtration results. Summary of the Invention

[0004] (1) Technical problems solved

[0005] In response to the shortcomings of the existing technology, the present invention provides a method for preparing honeycomb ceramics using a 3D printing resin template, which solves the problem of the template method commonly used in the existing porous ceramics. The traditional method uses a honeycomb sponge as a template, dips the sponge into the ceramic slurry, and then ablates the sponge to obtain the honeycomb ceramics. Because honeycomb sponges are usually prepared by the foaming method, the internal structure is uncontrollable and has sharp corners and blind ends. As a result, the honeycomb ceramics obtained by this template have a single pore structure and are prone to falling off during use. The pore size and distribution are highly random, and the filtration effect is inconsistent.

[0006] (2) Technical solution

[0007] To achieve the above objectives, the present invention is implemented through the following technical solutions: A method for preparing honeycomb ceramics by 3D printing resin templates, specifically comprising the following steps:

[0008] S1. Printing a porous resin mesh template using 3D printing technology, wherein the materials used for the 3D printed porous resin mesh template are rigid resin and flexible resin;

[0009] S2, preparing a rigid resin grid template;

[0010] S3, preparing a flexible resin grid template;

[0011] S4. Prepare honeycomb ceramics using 3D printed resin grid templates and ceramic slurry.

[0012] Preferably, the 3D printing technology in step S1 includes light-curing 3D printing technology, powder-laying adhesive jetting 3D printing technology and extrusion 3D printing technology.

[0013] Preferably, the grid structure of the porous resin grid template 3D printed in step S1 is a uniform structure or a gradient pore structure.

[0014] Preferably, the step S2 of preparing the rigid resin grid template specifically includes the following steps:

[0015] A1. Fill the container with ceramic slurry;

[0016] A2. Place the porous resin mesh template 3D printed in step S1 into the ceramic slurry and immerse it in a vacuum process;

[0017] A3. Take out the porous resin mesh template soaked and vacuumed in step A2 and spin it rapidly to remove excess slurry from the pores;

[0018] A4. Bake the grid dipped in ceramic slurry at 80-120°C for 20-30 minutes;

[0019] A5. Repeat steps A1-A3 3-5 times;

[0020] A6. Place in heat treatment equipment for degreasing and sintering:

[0021] A7. Cool to room temperature to obtain a porous ceramic part.

[0022] Preferably, the heat treatment equipment in step A6 is a muffle furnace.

[0023] Preferably, in step A3, the rotation centrifugation to remove excess slurry in the pores is performed using an intelligent centrifuge.

[0024] Preferably, the preparation of the flexible resin grid template in step S3 specifically includes the following steps:

[0025] B1. Fill the container with ceramic slurry;

[0026] B2. Soaking the porous resin mesh template 3D printed in step S1 in the ceramic slurry and compressing the template with external force;

[0027] B3. After taking out, quickly spin the centrifuge to throw out the excess slurry in the pores;

[0028] B4. Bake the grid dipped in ceramic slurry at 80-120°C;

[0029] B5. Repeat steps B1-B3 3-5 times;

[0030] B6. Place in a muffle furnace for degreasing and sintering:

[0031] B7. Cool to room temperature to obtain porous ceramic parts.

[0032] Preferably, in step B2, a compressor is used to generate external force to compress the template.

[0033] (3) Beneficial effects

[0034] The present invention provides a method for preparing honeycomb ceramics using a 3D-printed resin template. Compared to existing technologies, this method has the following advantages: The method comprises the following steps: S1. Printing a porous resin mesh template using 3D printing technology, wherein the materials used for the 3D-printed porous resin mesh template are rigid resin and flexible resin; S2. Preparing a rigid resin mesh template; and S3. Preparing a flexible resin mesh template. This method significantly improves filtration efficiency, reduces impurity defects caused by structural shedding, and improves structural strength. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 Flow chart of the preparation method of the present invention. DETAILED DESCRIPTION

[0036] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0037] See also Figure 1 The present invention provides five technical solutions: a method for preparing honeycomb ceramics by 3D printing resin templates, specifically including the following embodiments:

[0038] Example 1

[0039] A method for preparing honeycomb ceramics by 3D printing resin templates, specifically comprising the following steps:

[0040] S1. Printing a porous resin mesh template using 3D printing technology, wherein the materials used for the 3D-printed porous resin mesh template are rigid resin and flexible resin, and the 3D printing technology includes light-curing 3D printing technology, powder-laying adhesive jetting 3D printing technology, and extrusion 3D printing technology, and the mesh structure of the 3D-printed porous resin mesh template is a uniform structure;

[0041] S2, preparing a rigid resin grid template, specifically comprising the following steps:

[0042] A1. Fill the container with ceramic slurry;

[0043] A2. Place the porous resin mesh template 3D printed in step S1 into the ceramic slurry and immerse it in a vacuum process;

[0044] A3. After the porous resin mesh template that has been soaked and vacuumed in step A2 is taken out, the template is rapidly centrifuged to remove excess slurry from the pores. The centrifugation is performed using an intelligent centrifuge.

[0045] A4. Bake the grid dipped in ceramic slurry at 100°C for 25 minutes.

[0046] A5. Repeat steps A1-A3 4 times;

[0047] A6. Place in heat treatment equipment for degreasing and sintering. The heat treatment equipment is a muffle furnace:

[0048] A7. Cool to room temperature to obtain a porous ceramic part;

[0049] S3, preparing a flexible resin grid template, specifically comprising the following steps:

[0050] B1. Fill the container with ceramic slurry;

[0051] B2. Soaking the porous resin mesh template 3D printed in step S1 in the ceramic slurry and compressing the template with an external force, using a compressor to generate an external force to compress the template;

[0052] B3. After taking out, quickly spin the centrifuge to throw out the excess slurry in the pores;

[0053] B4. Bake the grid dipped in ceramic slurry at 100°C;

[0054] B5. Repeat steps B1-B3 4 times;

[0055] B6. Place in a muffle furnace for degreasing and sintering:

[0056] B7. Cool to room temperature to obtain porous ceramic parts.

[0057] Example 2

[0058] A method for preparing honeycomb ceramics by 3D printing resin templates, specifically comprising the following steps:

[0059] S1. Printing a porous resin mesh template using 3D printing technology, wherein the materials used for the 3D-printed porous resin mesh template are rigid resin and flexible resin, and the 3D printing technology includes light-curing 3D printing technology, powder-laying adhesive jetting 3D printing technology, and extrusion 3D printing technology, and the mesh structure of the 3D-printed porous resin mesh template is a gradient pore structure;

[0060] S2, preparing a rigid resin grid template, specifically comprising the following steps:

[0061] A1. Fill the container with ceramic slurry;

[0062] A2. Place the porous resin mesh template 3D printed in step S1 into the ceramic slurry and immerse it in a vacuum process;

[0063] A3. After the porous resin mesh template that has been soaked and vacuumed in step A2 is taken out, the template is rapidly centrifuged to remove excess slurry from the pores. The centrifugation is performed using an intelligent centrifuge.

[0064] A4. Bake the grid dipped in ceramic slurry at 80°C for 20 minutes.

[0065] A5. Repeat steps A1-A3 three times;

[0066] A6. Place in heat treatment equipment for degreasing and sintering. The heat treatment equipment is a muffle furnace:

[0067] A7. Cool to room temperature to obtain a porous ceramic part;

[0068] S3, preparing a flexible resin grid template, specifically comprising the following steps:

[0069] B1. Fill the container with ceramic slurry;

[0070] B2. Soaking the porous resin mesh template 3D printed in step S1 in the ceramic slurry and compressing the template with an external force, using a compressor to generate an external force to compress the template;

[0071] B3. After taking out, quickly spin the centrifuge to throw out the excess slurry in the pores;

[0072] B4. Bake the grid dipped in ceramic slurry at 80°C;

[0073] B5. Repeat steps B1-B3 three times;

[0074] B6. Place in a muffle furnace for degreasing and sintering:

[0075] B7. Cool to room temperature to obtain porous ceramic parts.

[0076] Example 3

[0077] A method for preparing honeycomb ceramics by 3D printing resin templates, specifically comprising the following steps:

[0078] S1. Printing a porous resin mesh template using 3D printing technology, wherein the materials used for the 3D-printed porous resin mesh template are rigid resin and flexible resin, and the 3D printing technology includes light-curing 3D printing technology, powder-laying adhesive jetting 3D printing technology, and extrusion 3D printing technology, and the mesh structure of the 3D-printed porous resin mesh template is a uniform structure;

[0079] S2, preparing a rigid resin grid template, specifically comprising the following steps:

[0080] A1. Fill the container with ceramic slurry;

[0081] A2. Place the porous resin mesh template 3D printed in step S1 into the ceramic slurry and immerse it in a vacuum process;

[0082] A3. After the porous resin mesh template that has been soaked and vacuumed in step A2 is taken out, the template is rapidly centrifuged to remove excess slurry from the pores. The centrifugation is performed using an intelligent centrifuge.

[0083] A4. Bake the grid dipped in ceramic slurry at 120°C for 30 minutes.

[0084] A5. Repeat steps A1-A3 5 times;

[0085] A6. Place in heat treatment equipment for degreasing and sintering. The heat treatment equipment is a muffle furnace:

[0086] A7. Cool to room temperature to obtain a porous ceramic part;

[0087] S3, preparing a flexible resin grid template, specifically comprising the following steps:

[0088] B1. Fill the container with ceramic slurry;

[0089] B2. Soaking the porous resin mesh template 3D printed in step S1 in the ceramic slurry and compressing the template with an external force, using a compressor to generate an external force to compress the template;

[0090] B3. After taking out, quickly spin the centrifuge to throw out the excess slurry in the pores;

[0091] B4. Bake the grid dipped in ceramic slurry at 120°C;

[0092] B5. Repeat steps B1-B3 5 times;

[0093] B6. Place in a muffle furnace for degreasing and sintering:

[0094] B7. Cool to room temperature to obtain porous ceramic parts.

[0095] Example 4

[0096] A method for preparing honeycomb ceramics by 3D printing resin templates, specifically comprising the following steps:

[0097] S1. Printing a porous resin mesh template using 3D printing technology, wherein the materials used for the 3D-printed porous resin mesh template are rigid resin and flexible resin, and the 3D printing technology includes light-curing 3D printing technology, powder-laying adhesive jetting 3D printing technology, and extrusion 3D printing technology, and the mesh structure of the 3D-printed porous resin mesh template is a gradient pore structure;

[0098] S2, preparing a rigid resin grid template, specifically comprising the following steps:

[0099] A1. Fill the container with ceramic slurry;

[0100] A2. Place the porous resin mesh template 3D printed in step S1 into the ceramic slurry and immerse it in a vacuum process;

[0101] A3. After the porous resin mesh template that has been soaked and vacuumed in step A2 is taken out, the template is rapidly centrifuged to remove excess slurry from the pores. The centrifugation is performed using an intelligent centrifuge.

[0102] A4. Bake the grid dipped in ceramic slurry at 90°C for 23 minutes.

[0103] A5. Repeat steps A1-A3 4 times;

[0104] A6. Place in heat treatment equipment for degreasing and sintering. The heat treatment equipment is a muffle furnace:

[0105] A7. Cool to room temperature to obtain a porous ceramic part;

[0106] S3, preparing a flexible resin grid template, specifically comprising the following steps:

[0107] B1. Fill the container with ceramic slurry;

[0108] B2. Soaking the porous resin mesh template 3D printed in step S1 in the ceramic slurry and compressing the template with an external force, using a compressor to generate an external force to compress the template;

[0109] B3. After taking out, quickly spin the centrifuge to throw out the excess slurry in the pores;

[0110] B4. Bake the grid dipped in ceramic slurry at 90°C;

[0111] B5. Repeat steps B1-B3 4 times;

[0112] B6. Place in a muffle furnace for degreasing and sintering:

[0113] B7. Cool to room temperature to obtain porous ceramic parts.

[0114] Example 5

[0115] A method for preparing honeycomb ceramics by 3D printing resin templates, specifically comprising the following steps:

[0116] S1. Printing a porous resin mesh template using 3D printing technology, wherein the materials used for the 3D-printed porous resin mesh template are rigid resin and flexible resin, and the 3D printing technology includes light-curing 3D printing technology, powder-laying adhesive jetting 3D printing technology, and extrusion 3D printing technology, and the mesh structure of the 3D-printed porous resin mesh template is a uniform structure;

[0117] S2, preparing a rigid resin grid template, specifically comprising the following steps:

[0118] A1. Fill the container with ceramic slurry;

[0119] A2. Place the porous resin mesh template 3D printed in step S1 into the ceramic slurry and immerse it in a vacuum process;

[0120] A3. After the porous resin mesh template that has been soaked and vacuumed in step A2 is taken out, the template is rapidly centrifuged to remove excess slurry from the pores. The centrifugation is performed using an intelligent centrifuge.

[0121] A4. Bake the grid dipped in ceramic slurry at 110°C for 27 minutes.

[0122] A5. Repeat steps A1-A3 three times;

[0123] A6. Place in heat treatment equipment for degreasing and sintering. The heat treatment equipment is a muffle furnace:

[0124] A7. Cool to room temperature to obtain a porous ceramic part;

[0125] S3, preparing a flexible resin grid template, specifically comprising the following steps:

[0126] B1. Fill the container with ceramic slurry;

[0127] B2. Soaking the porous resin mesh template 3D printed in step S1 in the ceramic slurry and compressing the template with an external force, using a compressor to generate an external force to compress the template;

[0128] B3. After taking out, quickly spin the centrifuge to throw out the excess slurry in the pores;

[0129] B4. Bake the grid dipped in ceramic slurry at 110°C;

[0130] B5. Repeat steps B1-B3 three times;

[0131] B6. Place in a muffle furnace for degreasing and sintering:

[0132] B7. Cool to room temperature to obtain porous ceramic parts.

[0133] In summary, the present invention utilizes 3D printing technology to print a porous resin grid template, wherein the materials used for the 3D printed porous resin grid template are rigid resin and flexible resin; prepares a rigid resin grid template; and prepares a flexible resin grid template, which can greatly improve the filtration efficiency, reduce impurity defects caused by structural shedding, and improve structural strength.

[0134] Meanwhile, the contents not described in detail in this specification belong to the prior art known to those skilled in the art.

[0135] It should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but also other elements not explicitly listed, or elements inherent to such process, method, article, or apparatus.

[0136] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A method for preparing honeycomb ceramics by 3D printing resin templates, characterized in that: The specific steps include: S1. Printing a porous resin mesh template using 3D printing technology, wherein the materials used for the 3D printed porous resin mesh template are rigid resin and flexible resin; S2. Preparation of a rigid resin grid template: specifically comprising the following steps: A1. Fill the container with ceramic slurry; A2. Place the porous resin mesh template 3D printed in step S1 into the ceramic slurry and immerse it in a vacuum process; A3. Take out the porous resin mesh template soaked and vacuumed in step A2 and spin it rapidly to remove excess slurry from the pores; A4. Bake the grid dipped in ceramic slurry at 80-120°C for 20-30 minutes; A5. Repeat steps A1-A3 3-5 times; A6. Place in heat treatment equipment for degreasing and sintering: A7. Cool to room temperature to obtain a porous ceramic part; S3, preparing a flexible resin grid template: specifically comprising the following steps: B1. Fill the container with ceramic slurry; B2. Soaking the porous resin mesh template 3D printed in step S1 in the ceramic slurry and compressing the template with external force; B3. After taking out, quickly spin the centrifuge to throw out the excess slurry in the pores; B4. Bake the grid dipped in ceramic slurry at 80-120°C; B5. Repeat steps B1-B3 3-5 times; B6. Place in a muffle furnace for degreasing and sintering: B7, cooling to room temperature to obtain a porous ceramic part; S4. Prepare honeycomb ceramics using 3D printed resin grid templates and ceramic slurry.

2. The method for preparing honeycomb ceramics by 3D printing resin template according to claim 1, characterized in that: The 3D printing technology in step S1 includes light-curing 3D printing technology, powder-laying adhesive jetting 3D printing technology and extrusion 3D printing technology.

3. The method for preparing honeycomb ceramics by using a 3D printing resin template according to claim 1, wherein: The grid structure of the porous resin grid template 3D printed in step S1 is a uniform structure or a gradient pore structure.

4. The method for preparing honeycomb ceramics by using a 3D printing resin template according to claim 1, wherein: The heat treatment equipment in step A6 is a muffle furnace.

5. The method for preparing honeycomb ceramics by using a 3D printing resin template according to claim 1, wherein: In step A3, the rotation centrifugation to remove the excess slurry in the pores is performed using an intelligent centrifuge.

6. The method for preparing honeycomb ceramics by using a 3D printing resin template according to claim 1, wherein: In step B2, a compressor is used to generate external force to compress the template.

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