High-wear-resistance automobile ceramic air valve material and preparation method thereof

Abstract

The invention discloses a high-wear-resistance automobile ceramic air valve material and a preparation method thereof, the high-wear-resistance automobile ceramic air valve material comprises the following main components: a mud blank, glaze slip, a binder, a catalyst and a modifier, the mud blank is composed of kaolin, clay, limestone and feldspar, and the glaze slip is composed of chinastone, quartz and talc. By adding silicon nitride and silicon carbide into the high-wear-resistance ceramic air valve material for the automobile, the structural strength of the high-wear-resistance air valve can be greatly improved, the surface material performance of a ceramic material can be improved, bonding of the ceramic material is promoted, and the influence of external friction loss on the ceramic material is reduced; meanwhile, the material performance matching range of the carbon fibers, the nanofibers, the resin fibers, the glass fibers, the epoxy resin, the polyurethane resin and the acrylic resin is wide, the overall strength of the ceramic material can be effectively improved, the use requirements of different environments are met, the application range of the ceramic air valve is greatly widened, and the ceramic air valve is more suitable for being used in the automobile driving environment.

Description

Technical Field

[0001] The present invention relates to the technical field of ceramic valve materials, and particularly to a highly wear-resistant ceramic valve material for automobiles and a preparation method thereof. Background Technique

[0002] A ceramic valve is a device used to control the flow of gas. It is usually made of ceramic materials, which have characteristics such as high heat resistance, high wear resistance, and high corrosion resistance. Therefore, it is suitable for harsh environments such as high temperature, high pressure, and high corrosion. The main function of a ceramic valve is to control the flow of gas, and it can adjust the flow rate and pressure of the gas. It is usually composed of components such as a valve body, a valve core, and a seal. Among them, the valve core is the key component for controlling the flow of gas.

[0003] Ceramic valves can be used to control the gas flow in automobile engines, thereby achieving the power output and emission control of automobiles. For example, the patent number disclosed on the Chinese Patent Network is: 201010178796.1, and the patent name is: A ceramic fiber-reinforced ceramic-based automotive brake friction material and a preparation method thereof. The material formula is calculated by weight percentage as follows: modified sodium aluminosilicate 10-20, phenolic resin / nitrile rubber 5-10, alumina fiber 20-35, aramid pulp 1-2, graphite 6-16, antimony sulfide 3-8, chromite 2-4, organic friction powder 2-5, barite 10-20, composite filler 4-8.

[0004] However, the materials of existing ceramic valves are relatively single. The ceramic strength is mainly improved by single modified sodium aluminosilicate and nitrile rubber. Enhancing the ceramic matrix will increase the cost of the entire product, and the alumina fiber of the metal material will affect other properties of the ceramic, such as thermal conductivity and electrical conductivity, which will affect the driving safety of automobiles.

[0005] Therefore, it is necessary to design and create a highly wear-resistant ceramic valve material for automobiles and a preparation method thereof. Summary of the Invention

[0006] To solve the problems raised in the above background technique, the purpose of the present invention is to provide a highly wear-resistant ceramic valve material for automobiles and a preparation method thereof, which has the advantage of improving the overall wear resistance of the ceramic, and solves the problems that the materials of existing ceramic valves are relatively single, mainly improving the ceramic strength through single modified sodium aluminosilicate and nitrile rubber, enhancing the ceramic matrix will increase the cost of the entire product, and the alumina fiber of the metal material will affect other properties of the ceramic, such as thermal conductivity and electrical conductivity, which will affect the driving safety of automobiles.

[0007] To achieve the above purpose, the present invention provides the following technical solution: A highly wear-resistant ceramic valve material for automobiles and a preparation method thereof. The main components of the wear-resistant automotive ceramic valve material are: clay blank, glaze slurry, adhesive, catalyst, modifier.

[0008] Preferably in the present invention, the clay blank is composed of kaolin, clay, limestone and feldspar, the glaze slurry is composed of petunse, quartz and talc, the adhesive is composed of carbon fiber, nanofiber, resin fiber, glass fiber, epoxy resin, polyurethane resin and acrylic resin, the modifier is composed of modified graphene, nano zirconia, silicate, phosphate and borate, and the catalyst is composed of alumina, zirconia, silicon carbide and silica.

[0009] Preferably in the present invention, based on every 100 g of the wear-resistant automotive ceramic valve material, the content of each component is as follows: kaolin 20 - 25 g, clay 20 - 25 g, limestone 5 - 10 g, feldspar 5 - 10 g, petunse 5 - 10 g, quartz 5 - 10 g, talc 2 - 5 g, carbon fiber 1 - 3 g, nanofiber 1 - 3 g, resin fiber 1 - 3 g, glass fiber 1 - 3 g, epoxy resin 2 - 5 g, polyurethane resin 2 - 5 g, acrylic resin 1 - 3 g, modified graphene 2 - 4 g, nano zirconia 1 - 3 g, silicate 1 - 3 g, phosphate 1 - 3 g, borate 1 - 3 g, alumina 1 - 3 g, zirconia 1 - 3 g, silicon carbide 1 - 3 g, silica 2 - 4 g.

[0010] A wear-resistant automotive ceramic valve material and a preparation method thereof, the steps are as follows: step a) grinding; step b) mixing; step c) spraying; step d) roasting; step e) polishing:

[0011] Step a) grinding: Grind kaolin, clay, limestone, feldspar, petunse, quartz, talc, silicate, phosphate, borate, alumina, zirconia, silicon carbide and silica respectively to prepare raw materials with high purity and particle size.

[0012] Step b) mixing: Mix the ground kaolin, clay, limestone and feldspar with water to form a slurry, then add carbon fiber, nanofiber, resin fiber, glass fiber, epoxy resin, polyurethane resin and acrylic resin into the slurry and knead and stir to form a clay blank. At the same time, stir petunse, quartz, talc, modified graphene, nano zirconia, silicate, phosphate, borate, alumina, zirconia, silicon carbide and silica with water to form a porcelain glaze.

[0013] Step c) roasting: Put the slurry into a mold and prepare the required ceramic valve by molding methods such as pressing or casting. Put the molded ceramic product into a furnace for sintering. After high-temperature firing, a ceramic wear-resistant clay blank with high hardness and high wear resistance is formed.

[0014] Step d) Spraying: Spray the porcelain enamel onto the inner and outer wall surfaces of the ceramic gas valve by spraying, and then fire the ceramic gas valve in a baking furnace again to form a bright and wear-resistant surface glaze on its surface;

[0015] Step e) Polishing: Polish the surface of the ceramic gas valve by polishing. After polishing, a ceramic gas valve with high hardness and high wear resistance is obtained.

[0016] Preferably in the present invention, in step a) grinding, the prepared raw materials are put into a ball mill, an appropriate amount of water is added, and through the rotation of the ball mill, the raw materials are fully mixed and refined.

[0017] Preferably in the present invention, in step b) mixing, the mud embryo is placed in a retting pool, and after standing and fermenting for a certain period of time, the moisture in the mud slurry is further volatilized, and at the same time, the raw materials are more evenly mixed.

[0018] Preferably in the present invention, in step c) roasting, the sintering temperature of the ceramic gas valve is greater than 800 degrees, and after sintering, heat preservation and cooling treatment are carried out at a furnace temperature of 100 degrees.

[0019] Preferably in the present invention, in step d) spraying, the porcelain enamel is extracted by a spray gun and then sprayed onto the surface of the ceramic gas valve. After spraying, a roller is used to smear the porcelain enamel evenly.

[0020] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0021] 1. By adding silicon nitride and silicon carbide inside the high-wear-resistant automotive ceramic gas valve material, the present invention can greatly improve the structural strength of the high-wear-resistant gas valve, can improve the surface material properties of the ceramic material, promote the bonding of the ceramic material, reduce the influence caused by external friction loss, and at the same time, the material properties of carbon fiber, nanofiber, resin fiber, glass fiber, epoxy resin, polyurethane resin and acrylic resin have a wide range of configurations, can effectively improve the overall strength of the ceramic material, meet the use requirements in different environments, greatly improve the applicable range of the ceramic gas valve, and are more suitable for use in the automotive driving environment.

[0022] 2. By setting carbon fiber, the present invention can enhance the strength and toughness of the ceramic, endowing it with better impact resistance and durability, and enhancing the electrical conductivity and thermal conductivity of the ceramic, enabling it to maintain stable performance in high-temperature environments. By setting epoxy resin, the impact resistance and durability of the ceramic can be improved, the processing performance of the ceramic can be enhanced, the production difficulty can be reduced, and the tensile strength, compressive strength, hardness and other properties of the ceramic can be improved. By setting polyurethane resin, the ceramic valve can have good toughness and elasticity, the impact resistance and durability of the ceramic can be improved, and at the same time, the tensile strength, compressive strength, hardness and other properties of the ceramic can be increased. Moreover, the price of polyurethane resin is relatively low, which can reduce the cost of ceramic products. By setting acrylic resin, the ceramic valve can have good bonding properties and plasticity. Acrylic resin can be used as a binder to bond ceramic powder particles together to form the required shape. The thermal decomposition products of acrylic resin can also fill the pores of ceramic particles, improving the density and mechanical properties of the ceramic valve.

[0023] 3. By setting modified graphene, the strength and toughness of the ceramic can be improved: making the ceramic valve more impact-resistant and wear-resistant. Graphene is a good thermal conductive material, and adding it to the ceramic can improve its thermal conductivity, making the ceramic more suitable for use in high-temperature environments. By setting nano-zirconia, its insulation performance can be improved, making the ceramic more suitable for use in environments such as high-voltage electric fields. Moreover, the sintering temperature of the ceramic valve can be reduced and the sintering process can be optimized, making the ceramic easier to process and form.

[0024] 4. By setting alumina, zirconia, silicon carbide and silicon oxide, the hardness and stability of the ceramic valve can be improved, a more stable structure can be formed, making it more resistant to chemical substance erosion, thereby improving the chemical stability of the product and extending its service life. Specific Embodiments

[0025] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0026] A highly wear-resistant ceramic valve material for automobiles and its preparation method provided by the present invention. The main components of the wear-resistant automotive ceramic valve material are: clay blank, glaze slurry, adhesive, catalyst, modifier.

[0027] By setting modified graphene, the strength and toughness of ceramics can be improved, making ceramic air valves more impact-resistant and wear-resistant. Graphene is a good thermal conductor, and adding it to ceramics can improve their thermal conductivity, making ceramics more suitable for use in high-temperature environments. By setting nano-zirconia dioxide, its insulation performance can be improved, making ceramics more suitable for use in environments such as high-voltage electric fields. Moreover, it can reduce the sintering temperature of ceramic air valves and optimize the sintering process, making ceramics easier to process and form.

[0028] As a technical optimization scheme of the present invention, the clay blank is composed of kaolin, clay, limestone and feldspar, the glaze slurry is composed of petunse, quartz and talc, the adhesive is composed of carbon fiber, nanofiber, resin fiber, glass fiber, epoxy resin, polyurethane resin and acrylic resin, the modifier is composed of modified graphene, nano-zirconia dioxide, silicate, phosphate and borate, and the catalyst is composed of alumina, zirconia, silicon carbide and silica.

[0029] By adding silicon nitride and silicon carbide inside the high-wear-resistant automotive ceramic air valve material, the structural strength of the high-wear-resistant air valve can be significantly improved, the surface material properties of the ceramic material can be enhanced, the bonding of the ceramic material can be promoted, and the influence caused by external friction loss can be reduced. At the same time, the material properties of carbon fiber, nanofiber, resin fiber, glass fiber, epoxy resin, polyurethane resin and acrylic resin have a wide range of configurations, which can effectively improve the overall strength of the ceramic material, meet the usage requirements in different environments, greatly improve the application range of ceramic air valves, and be more suitable for use in the automotive driving environment.

[0030] As a technical optimization scheme of the present invention, based on every 100 g of wear-resistant automotive ceramic air valve material, the content of each component is: kaolin 20 - 25 g, clay 20 - 25 g, limestone 5 - 10 g, feldspar 5 - 10 g, petunse 5 - 10 g, quartz 5 - 10 g, talc 2 - 5 g, carbon fiber 1 - 3 g, nanofiber 1 - 3 g, resin fiber 1 - 3 g, glass fiber 1 - 3 g, epoxy resin 2 - 5 g, polyurethane resin 2 - 5 g, acrylic resin 1 - 3 g, modified graphene 2 - 4 g, nano-zirconia dioxide 1 - 3 g, silicate 1 - 3 g, phosphate 1 - 3 g, borate 1 - 3 g, alumina 1 - 3 g, zirconia 1 - 3 g, silicon carbide 1 - 3 g, silica 2 - 4 g.

[0031] By setting carbon fibers, the strength and toughness of ceramics can be enhanced, endowing them with better impact resistance and durability. The electrical conductivity and thermal conductivity of ceramics can also be enhanced, enabling them to maintain stable performance in high-temperature environments. By setting epoxy resin, the impact resistance and durability of ceramics can be improved, the processing performance of ceramics can be enhanced, the production difficulty can be reduced, and the tensile strength, compressive strength, hardness and other properties of ceramics can be improved. By setting polyurethane resin, the ceramic valve can have good toughness and elasticity, the impact resistance and durability of ceramics can be increased, and at the same time, the tensile strength, compressive strength, hardness and other properties of ceramics can be improved. Moreover, the price of polyurethane resin is relatively low, which can reduce the cost of ceramic products. By setting acrylic resin, the ceramic valve can have good bonding properties and plasticity. Acrylic resin can be used as a binder to bond ceramic powder particles together to form the required shape. The thermal decomposition products of acrylic resin can also fill the pores of ceramic particles, improving the density and mechanical properties of the ceramic valve.

[0032] By setting alumina, zirconia, silicon carbide and silicon oxide, the hardness and stability of the ceramic valve can be improved, a more stable structure can be formed, making it more resistant to chemical substance erosion, thereby enhancing the chemical stability of the product and extending its service life.

[0033] A highly wear-resistant ceramic valve material for automobiles and its preparation method, step a) grinding; step b) mixing; step c) spraying; step d) roasting; step e) polishing:

[0034] Step a) Grinding: Grind kaolin, clay, limestone, feldspar, petunse, quartz, talc, silicate, phosphate, borate, alumina, zirconia, silicon carbide and silicon oxide respectively to prepare raw materials with high purity and particle size;

[0035] Step b) Mixing: Mix the ground kaolin, clay, limestone and feldspar with water to form a slurry, then add carbon fibers, nanofibers, resin fibers, glass fibers, epoxy resin, polyurethane resin and acrylic resin into the slurry and knead and stir to form a clay blank. At the same time, stir the petunse, quartz, talc, modified graphene, nano-zirconia, silicate, phosphate, borate, alumina, zirconia, silicon carbide and silicon oxide with water to form a porcelain glaze;

[0036] Step c) Roasting: Put the slurry into a mold and prepare the required ceramic valve through forming methods such as pressing or casting. Put the formed ceramic product into a furnace for sintering. After high-temperature firing, a ceramic wear-resistant clay blank with high hardness and high wear resistance is formed;

[0037] Step d) Spraying: Spray the porcelain enamel onto the inner and outer wall surfaces of the ceramic gas valve by spraying, and then fire the ceramic gas valve in a baking furnace again to form a bright and wear-resistant surface glaze on its surface;

[0038] Step e) Polishing: Polish the surface of the ceramic gas valve by polishing. After polishing, a ceramic gas valve with high hardness and high wear resistance is obtained.

[0039] As a technical optimization scheme of the present invention, in step a) grinding, put the prepared raw materials into a ball mill, add an appropriate amount of water, and through the rotation of the ball mill, make the raw materials fully mixed and refined.

[0040] As a technical optimization scheme of the present invention, in step b) mixing, place the mud embryo in a retting pond, and after standing and fermenting for a certain period of time, make the water in the mud slurry further volatilize, and at the same time make the raw materials more evenly mixed.

[0041] As a technical optimization scheme of the present invention, in step c) roasting, the sintering temperature of the ceramic gas valve is greater than 800 degrees, and after sintering, heat preservation and cooling treatment are carried out at a furnace temperature of 100 degrees.

[0042] As a technical optimization scheme of the present invention, in step d) spraying, extract the porcelain enamel with a spray gun and then spray it onto the surface of the ceramic gas valve. After spraying, use a roller to spread the porcelain enamel evenly.

[0043] First embodiment:

[0044] Based on every 100g of the wear-resistant automotive ceramic gas valve material, the content of each component is: kaolin 25g, clay 25g, limestone 10g, feldspar 10g, porcelain stone 10g, quartz 10g, talc 5g, carbon fiber 1g, nanofiber 1g, resin fiber 1g, glass fiber 1g, epoxy resin 2g, polyurethane resin 2g, acrylic resin 1g, modified graphene 2g, nano zirconia 1g, silicate 1g, phosphate 1g, borate 1g, alumina 1g, zirconia 1g, silicon carbide 1g, silica 2g.

[0045] Through experiments, it can be obtained that the water absorption rate of the wear-resistant automotive ceramic gas valve material in the first embodiment is 10%, the breaking strength is 10kg, the modulus of rupture is 25kPa, and the wear resistance is 10g / cm 2 .

[0046] Second embodiment:

[0047] Based on every 100g of the wear-resistant automotive ceramic valve material, the content of each component is as follows: kaolin 25g, clay 25g, limestone 10g, feldspar 10g, petunse 10g, quartz 10g, talc 5g, carbon fiber 3g, nanofiber 3g, resin fiber 3g, glass fiber 3g, epoxy resin 5g, polyurethane resin 5g, acrylic resin 3g, modified graphene 4g, nano zirconia 3g, silicate 3g, phosphate 3g, borate 3g, alumina 3g, zirconia 3g, silicon carbide 3g, silicon oxide 4g.

[0048] Through experiments, it can be obtained that the water absorption rate of the wear-resistant automotive ceramic valve material in the second embodiment is 8%, the breaking strength is 8 kg, the modulus of rupture is 20 kPa, and the wear resistance is 13 g / cm 2 .

[0049] It can be seen from this that by increasing the high proportion of carbon fiber, nanofiber, resin fiber, glass fiber, epoxy resin, polyurethane resin and acrylic resin, the structural wear resistance effect and strength can be greatly improved.

[0050] In summary: For the high-wear-resistant automotive ceramic valve material and its preparation method, by adding silicon nitride and silicon carbide inside the high-wear-resistant automotive ceramic valve material, the structural strength of the high-wear-resistant valve can be greatly improved, the surface material properties of the ceramic material can be enhanced, the bonding of the ceramic material can be promoted, the influence caused by external friction loss can be reduced. At the same time, the material performance of carbon fiber, nanofiber, resin fiber, glass fiber, epoxy resin, polyurethane resin and acrylic resin has a wide range of configurations, which can effectively improve the overall strength of the ceramic material, meet the usage requirements in different environments, greatly expand the application range of the ceramic valve, and is more suitable for use in the automotive driving environment.

[0051] It should be noted that in this article, relational terms such as first and second are only used 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 term "comprising", "including" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements not only includes those elements, but also includes other elements not expressly listed, or elements inherent to such process, method, article or device.

[0052] Although the embodiments of the present invention have been shown and described, for those of ordinary skill in the art, it can be understood that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A highly wear-resistant ceramic valve material for automobiles, characterized in that: The main components of the wear-resistant automotive ceramic valve material are: clay blank, glaze slurry, adhesive, catalyst, and modifier.

2. The high wear-resistant ceramic valve material for automobiles according to claim 1, wherein: The clay blank is composed of kaolin, clay, limestone, and feldspar. The glaze slurry is composed of petunse, quartz, and talc. The adhesive is composed of carbon fiber, nanofiber, resin fiber, glass fiber, epoxy resin, polyurethane resin, and acrylic resin. The modifier is composed of modified graphene, nano-zirconium dioxide, silicate, phosphate, and borate. The catalyst is composed of alumina, zirconia, silicon carbide, and silica.

3. A highly wear-resistant ceramic valve material for automobiles according to claim 2, characterized in that: Based on every 100g of the wear-resistant automotive ceramic valve material, the content of each component is: kaolin 20 - 25g, clay 20 - 25g, limestone 5 - 10g, feldspar 5 - 10g, petunse 5 - 10g, quartz 5 - 10g, talc 2 - 5g, carbon fiber 1 - 3g, nanofiber 1 - 3g, resin fiber 1 - 3g, glass fiber 1 - 3g, epoxy resin 2 - 5g, polyurethane resin 2 - 5g, acrylic resin 1 - 3g, modified graphene 2 - 4g, nano-zirconium dioxide 1 - 3g, silicate 1 - 3g, phosphate 1 - 3g, borate 1 - 3g, alumina 1 - 3g, zirconia 1 - 3g, silicon carbide 1 - 3g, silica 2 - 4g.

4. The preparation method of a highly wear-resistant ceramic valve material for automobiles according to any one of the above claims, characterized in that: The steps are as follows: a) grinding; b) mixing; c) spraying; d) roasting; e) polishing: Step a) Grinding: Grind kaolin, clay, limestone, feldspar, petunse, quartz, talc, silicate, phosphate, borate, alumina, zirconia, silicon carbide, and silica respectively to prepare raw materials with high purity and particle size. Step b) Mixing: Mix the ground kaolin, clay, limestone, and feldspar with water to form a slurry, then add carbon fiber, nanofiber, resin fiber, glass fiber, epoxy resin, polyurethane resin, and acrylic resin into the slurry and knead and stir to form a clay blank. At the same time, stir petunse, quartz, talc, modified graphene, nano-zirconium dioxide, silicate, phosphate, borate, alumina, zirconia, silicon carbide, and silica with water to form porcelain glaze. Step c) Roasting: Put the slurry into a mold and prepare the required ceramic valve through forming methods such as pressing or casting. Then put the formed ceramic product into a furnace for sintering. After high-temperature firing, a ceramic wear-resistant clay blank with high hardness and high wear resistance is formed. Step d) Spraying: Spray the porcelain glaze onto the inner and outer wall surfaces of the ceramic valve by spraying, and then fire the ceramic valve in a baking furnace again to make the glaze surface on its surface form a bright and wear-resistant surface. Step e) Polishing: Polish the surface of the ceramic valve by polishing. After polishing, a ceramic valve with high hardness and high wear resistance is obtained.

5. The preparation method of a highly wear-resistant ceramic valve material for automobiles according to claim 4, characterized in that: For step a) grinding, put the prepared raw materials into a ball mill, add an appropriate amount of water, and through the rotation of the ball mill, make the raw materials fully mixed and refined.

6. The preparation method of a highly wear-resistant ceramic valve material for automobiles according to claim 4, characterized in that: In the step b) of mixing, the mud embryo is placed in a retting pond, and after standing and fermenting for a certain period of time, the moisture in the mud is further volatilized, and at the same time, the raw materials are more evenly mixed.

7. The preparation method of a highly wear-resistant ceramic valve material for automobiles according to claim 4, characterized in that: In the step c) of roasting, the sintering temperature of the ceramic air valve is higher than 800 degrees, and after sintering, heat preservation and cooling treatment are carried out at a furnace temperature of 100 degrees.

8. The preparation method of a highly wear-resistant ceramic valve material for automobiles according to claim 4, characterized in that: In the step d) of spraying, the porcelain glaze is extracted by a spray gun and then sprayed onto the surface of the ceramic air valve. After spraying, a roller is used to evenly apply the porcelain glaze.