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CN102757229A - 一种共形陶瓷超材料及其制备方法 - Google Patents

一种共形陶瓷超材料及其制备方法 Download PDF

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CN102757229A
CN102757229A CN2012102264999A CN201210226499A CN102757229A CN 102757229 A CN102757229 A CN 102757229A CN 2012102264999 A CN2012102264999 A CN 2012102264999A CN 201210226499 A CN201210226499 A CN 201210226499A CN 102757229 A CN102757229 A CN 102757229A
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conformal
ceramic
pottery
ultra
mould
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刘若鹏
赵治亚
缪锡根
熊晓磊
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Kuang Chi Innovative Technology Ltd
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Kuang Chi Innovative Technology Ltd
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Priority to CN2012102264999A priority Critical patent/CN102757229A/zh
Publication of CN102757229A publication Critical patent/CN102757229A/zh
Priority to PCT/CN2013/078714 priority patent/WO2014005514A1/zh
Priority to US14/412,432 priority patent/US20150152013A1/en
Priority to EP13812697.4A priority patent/EP2871172A4/en
Priority to CN201310277217.2A priority patent/CN103524136B/zh
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Abstract

本发明提供一种共形陶瓷超材料及其制备方法，将含有陶瓷粉料和有机体系的悬浮体脱气、预聚得到浆料，将浆料浇注到第一模具中，固化后得到生坯；将陶瓷粉料制成陶瓷浆料并流延制成生瓷片，通过丝网印刷技术在生瓷片上制备金属微结构；将制备好的含金属微结构的生瓷片贴覆于所述生坯外表面，得到带金属微结构的生坯；将浆料浇注到第二模具中，插入带金属微结构的生坯，固化后得到含金属微结构的共形结构坯料；将含金属微结构的共形结构坯料排胶、烧结，获得共形陶瓷超材料。采用凝胶注模成型法与LTCC或HTCC技术有机地结合起来，制备曲面共形陶瓷超材料，不仅透波性能好、耐高温，由于内外两层陶瓷片共形结合，提高了这种共形陶瓷超材料的强度。

Description

一种共形陶瓷超材料及其制备方法
【技术领域】
本发明涉及超材料领域，尤其涉及一种共形陶瓷超材料及其制备方法。
【背景技术】
超材料是近十年来发展起来的对电磁波起调制作用的材料。超材料一般是由一定数量的金属微结构附在具有一定力学、电磁学的基板上，这些具有特定图案和材质的微结构会对经过其身的特定频段的电磁波产生调制作用。
目前的超材料都是在平面基板上覆上金属微结构，而实际需要的超材料是曲面而非平面的。用低介电常数低损耗的陶瓷制备的超材料，虽然透波性能好且耐高温，但满足不了高强度性能。
【发明内容】
本发明所要解决的技术问题是：提供一种透波性能好、耐高温且强度高的曲面共形陶瓷超材料。
本发明解决上述技术问题所采用的技术方案是：一种共形陶瓷超材料的制备方法，所述制备方法包括以下步骤：
a、制备生坯：将含有陶瓷粉料和有机体系的悬浮体脱气、预聚得到浆料，将浆料浇注到第一模具中，并插入模具芯子，固化后得到凝胶注模成型的生坯；
b、制备含金属微结构的生瓷片：将陶瓷粉料制成陶瓷浆料并流延制成生瓷片，通过丝网印刷技术在生瓷片上制备金属微结构；
c、将制备好的含金属微结构的生瓷片贴覆于所述生坯外表面，得到带金属微结构的生坯；
d、将与步骤a中相同的浆料浇注到第二模具中，插入步骤c中带金属微结构的生坯，固化后得到凝胶注模成型的含金属微结构的共形结构坯料；
e、将含金属微结构的共形结构坯料排胶、烧结，获得共形陶瓷超材料。
所述第一模具和所述第二模具都为双开模具，并且所述第二模具的口径大于所述第一模具的口径。
所述步骤b中在所述生瓷片上丝网印刷金属微结构后，在所述金属微结构的表面覆一层与步骤b中相同成分的生瓷片。
所述含金属微结构的共形结构坯料在排胶之前通过等静压技术在100~150MPa的压力下定型。
所述生坯的内外表面为曲面。
所述有机体系包括分散剂、有机单体和交联剂。
向所述已脱气的浆料中加入引发剂和催化剂并搅拌均匀。
制备所述金属微结构所用的金属为银、铂、钼或钨。
一种共形陶瓷超材料，包括上述方法制备的共形陶瓷超材料。
本发明的有益效果为：采用凝胶注模成型法与LTCC或HTCC技术有机地结合起来，制备曲面共形陶瓷超材料，不仅透波性能好、耐高温，由于内外两层陶瓷片共形结合，提高了这种共形陶瓷超材料的强度。
【附图说明】
图1为本发明步骤b中制备的含金属微结构的生瓷片示意图；
图2为本发明制备的共形陶瓷超材料示意图。
【具体实施方式】
为了使本发明的目的、技术方案及优点更加清楚明白，以下结合附图及实施例，对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅仅用以解释本发明，并不用于限定本发明。
一种共形陶瓷超材料的制备方法，所述制备方法包括以下步骤：
a、制备生坯：将含有陶瓷粉料（如堇青石、氧化铝或非氧化物Si3N4等）和有机体系的悬浮体脱气、预聚得到浆料，将浆料浇注到第一模具中，并插入模具芯子，固化后得到凝胶注模成型的生坯；
其中具体过程为：将有机单体和交联剂溶解于水中，并加入水溶性高分子作为分散剂，制成单体溶液；再向单体溶液中加入陶瓷粉料充分混合，、真空脱气后后再加入引发剂和催化剂搅拌均匀、预聚得到所需浆料；将得到的浆料浇注到第一模具中，并插入模具芯子，室温固化后得到凝胶注模成型的生坯，并且所制成的生坯的内外表面为曲面。
b、制备含金属微结构的生瓷片：将与步骤a中相同的陶瓷粉料制成陶瓷浆料并流延制成生瓷片，通过丝网印刷技术在生瓷片上制备金属微结构；
其中金属微结构是由金属丝构成的具有一定几何形状的平面或者立体结构，如工字型、雪花型等，可以采用丝网印刷技术制备出金属微结构，也可以采用其他蚀刻、光刻、离子刻等技术，加工金属微结构所采用的金属为银、铂、钼、钨、或银钯合金等。
当然也可以在金属微结构的表面再覆上一层相同成分的生瓷片，使金属微结构夹在两层流延而成的生瓷片之间，如图1所示，增强它们的机械强度。
c、将步骤b中制备的含金属微结构的生瓷片贴覆于步骤a中的生坯外表面，得到带金属微结构的生坯；
d、将与步骤a中相同的浆料浇注到第二模具中，插入步骤c中带金属微结构的生坯，室温固化后得到凝胶注模成型的含金属微结构的共形结构坯料；
其中第一模具和第二模具都为双开模具，并且第二模具的口径大于第一模具的口径。
e、含金属微结构的共形结构坯料通过等静压技术（冷等静压技术或温等静压技术）在100~150MPa的压力下定型；
f、将定型后的含金属微结构的共形结构坯料排胶、烧结，获得共形陶瓷超材料，如图2所示；
g、对已制成的共形陶瓷超材料进行切割、打磨等加工，获得所需形状、大小的产品；当然切割、打磨等加工步骤也可以在等静压之后进行，因为陶瓷坯料比烧结后的陶瓷更易加工。
采用凝胶注模成型法与LTCC或HTCC技术有机地结合起来，制备的曲面共形陶瓷超材料，不仅透波性能好、耐高温，由于内外两层陶瓷片共形结合及金属微结构也夹在两片陶瓷片之间，提高了这种共形陶瓷超材料的强度。
在上述实施例中，仅对本发明进行了示范性描述，但是本领域技术人员在阅读本专利申请后可以在不脱离本发明的精神和范围的情况下对本发明进行各种修改。

Claims (9)

1.一种共形陶瓷超材料的制备方法，其特征在于，所述制备方法包括以下步骤：
a、制备生坯：将含有陶瓷粉料和有机体系的悬浮体脱气、预聚得到浆料，将浆料浇注到第一模具中，并插入模具芯子，固化后得到凝胶注模成型的生坯；
b、制备含金属微结构的生瓷片：将陶瓷粉料制成陶瓷浆料并流延制成生瓷片，通过丝网印刷技术在生瓷片上制备金属微结构；
c、将制备好的含金属微结构的生瓷片贴覆于所述生坯外表面，得到带金属微结构的生坯；
d、将与步骤a中相同的浆料浇注到第二模具中，插入步骤c中带金属微结构的生坯，固化后得到凝胶注模成型的含金属微结构的共形结构坯料；
e、将含金属微结构的共形结构坯料排胶、烧结，获得共形陶瓷超材料。
2.根据权利要求1所述的共形陶瓷超材料的制备方法，其特征在于，所述第一模具和所述第二模具都为双开模具，并且所述第二模具的口径大于所述第一模具的口径。
3.根据权利要求1所述的共形陶瓷超材料的制备方法，其特征在于，所述步骤b中在所述生瓷片上丝网印刷金属微结构后，在所述金属微结构的表面覆一层与步骤b中相同成分的生瓷片。
4.根据权利要求1所述的共形陶瓷超材料的制备方法，其特征在于，所述含金属微结构的共形结构坯料在排胶之前通过等静压技术在100~150MPa的压力下定型。
5.根据权利要求1所述的共形陶瓷超材料的制备方法，其特征在于，所述生坯的内外表面为曲面。
6.根据权利要求1所述的共形陶瓷超材料的制备方法，其特征在乎，所述有机体系包括分散剂、有机单体和交联剂。
7.根据权利要求1所述的共形陶瓷超材料的制备方法，其特征在于，向所述已脱气的浆料中加入引发剂和催化剂并搅拌均匀。
8.根据权利要求1所述的共形陶瓷超材料的制备方法，其特征在于，制备所述金属微结构所用的金属为银、铂、钼或钨。
9.一种共形陶瓷超材料，其特征在于，包括权利要求1~8任一项制备的共形陶瓷超材料。
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Application publication date: 20121031