Suspension type porcelain insulator blank and porcelain insulator preparation method
By accurately controlling the ratio of porcelain clay, stone and mineral additives, a new suspended porcelain insulator blank was prepared, which solved the problem of moisture inconsistency in traditional manufacturing, achieved efficient and low-energy production, and improved product quality.
Patent Information
- Application Number
- CN202510159856.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-02-13
- Publication Date
- 2025-05-23
AI Technical Summary
During the manufacturing process of traditional suspended porcelain insulator blanks, the molding and blanking process require different moisture conditions, which makes it difficult to ensure moisture consistency in the hollow drying process, affecting the product geometric size and internal quality, and the hollow drying process reduces production efficiency and increases costs.
By accurately controlling the ratio of porcelain clay, stone and mineral additives, a new suspended porcelain insulator blank was prepared, which directly enters the blank repair process after forming, eliminating the middle dry link.
The goals of improving production efficiency, reducing energy consumption and improving product quality have been achieved, ensuring the uniformity and stability of the moisture of the blank, reducing product geometric dimensional deviation and inherent quality control difficulty.
Abstract
Claims
1. A suspension porcelain insulator blank, characterized in that: The blank material is composed of porcelain clay, stone and mineral additives in a mass ratio of 2:1:1; The porcelain clay is composed of the following components in percentage by weight: 18% to 25% of Faku clay, 15% to 22% of Jiayao clay, 7% to 12% of Xingtai clay, 8% to 13% of Inner Mongolia white clay, and 35% to 45% of Manchurian ash clay; The stone material is composed of the following components in percentage by weight: 65% to 80% of feldspar for blank, 1% to 5% of feldspar for glaze, 15% to 25% of quartz powder, 1% to 5% of wollastonite, and 3% to 7% of pebbles; The mineral additive is composed of the following components in percentage by weight: 96.5% to 99.5% of aluminum oxide and 0.1% to 4.5% of talc powder.
2. A suspension porcelain insulator blank according to claim 1, characterized in that: The porcelain clay is composed of the following components in percentage by weight: Faku clay 19%-23%, Jiayao clay 17%-20%, Xingtai clay 8%-11%, Inner Mongolia white clay 9%-11%, and ash soil 37%-42%.
3. The suspension porcelain insulator blank according to claim 1, characterized in that: The stone material is composed of the following components in percentage by weight: 70% to 75% of feldspar for blank, 2% to 4% of feldspar for glaze, 18% to 22% of quartz powder, 2% to 4% of wollastonite and 4% to 6% of pebbles.
4. A suspension porcelain insulator blank according to claim 3, characterized in that: The blank is made of feldspar i The weight percentage of O2 is 69% to 73%, and the content of Al2O3 is 8% to 11%; the S in the glaze feldspar i The weight percentage of O2 is 75% to 79%, and the weight percentage of Al2O3 is 5% to 8%.
5. A method for preparing a suspension porcelain insulator blank according to any one of claims 1 to 4, characterized in that: The following steps are involved: a. Mixing porcelain clay, stone and mineral additives in a mass ratio of 2:1:1; b. Putting the above mixture into a ball mill for ball milling, then screening the ball milled mixture through a 325-mesh vibrating screen and removing iron through an automatic cleaning iron remover to remove impurities; c. Stirring and mixing the sieved and iron-removed raw materials; d. Squeeze the mixed mud, apply constant pressure to the mud, and discharge excess water until it reaches a mud cake shape; e. Transport the mud cake to a mud cutter for rough smelting, cut it into long strips, and stack it; f. Age the long strips of mud obtained by rough smelting, and the aging time is ≥ 72 hours; g. Use a vacuum mud smelter to smelt the aged mud; h. Shape the raw materials after smelting to make the mud body present a round roll shape; i. Repairing the blank obtained after forming; j. Dry the blank after trimming; k. Inspect the blank after drying; if the blank is qualified, glaze the qualified blank; if the blank is unqualified, send the unqualified blank to the pulping pool for pulping treatment, and then screen the treated mud to remove iron.
6. The method for preparing suspension porcelain insulator blank according to claim 5, characterized in that: In step b, the ball milling conditions are as follows: 300 alumina balls with a specification of Φ150 or Φ100 and 300 zirconia balls with a specification of Φ500 to Φ180 are arranged in the ball mill; the rotation speed of the ball mill is 15 r / min to 20 r / min; the ball milling time is 3 h to 5 h; the feed particle size is not greater than 1.4 mm, and the discharge particle size is not greater than 0.9 mm.
7. The method for preparing a suspension porcelain insulator blank according to claim 5, characterized in that: The aging conditions in step c are: aging is carried out indoors at a temperature of 18° C. to 24° C. and a humidity of 60% to 70%.
8. The method for preparing a suspension porcelain insulator blank according to claim 5, characterized in that: After squeezing the mud in step d and before step e, microwave pretreatment is performed on the mud cake after preliminary dehydration using a microwave drying device: the mud cake is placed in a microwave treatment container, and then the microwave drying device is started, the microwave power is set to 200 W, and the mud cake is microwave treated for 3 minutes. During the microwave treatment, ultrasonic vibration with a frequency of 20 kHz is applied. After the mud cake is microwave treated for 3 minutes, the microwave power is adjusted to 1000 W, and the mud cake is continued to be microwave treated for 7 minutes. During the entire 10-minute microwave treatment process, microwave frequencies of 915 MHz and 2450 MHz are used alternately, and the frequency is switched every 30 seconds. After the treatment is completed, the microwave drying device is turned off, the mud cake is taken out, and it is allowed to cool naturally to room temperature.
9. The method for preparing a suspension porcelain insulator blank according to claim 8, characterized in that: Before the mud cake is placed in the microwave treatment container, a layer of phase change material is laid on the bottom of the microwave treatment container. The phase change material is hexadecane, and its phase change temperature range is 18°C to 25°C. Hexadecane absorbs heat and melts within this temperature range to absorb and store the heat generated during the microwave treatment process.
10. The method for preparing a suspension porcelain insulator blank according to claim 8, characterized in that: During the microwave treatment, a static magnetic field is applied with a magnetic field strength of 50mT to 200mT. During the microwave treatment, a vacuum extraction operation is performed for 30 seconds every 3 minutes to reduce the internal pressure of the microwave drying equipment to 10kPa to 30kPa, and the low-pressure environment is used to accelerate the evaporation of water.