CN112341210A - Low-cost ferrite bonding special rubber powder and preparation process of dry-pressed magnetic tile thereof - Google Patents
Low-cost ferrite bonding special rubber powder and preparation process of dry-pressed magnetic tile thereof Download PDFInfo
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- DSSYKIVIOFKYAU-XCBNKYQSSA-N (R)-camphor Chemical compound C1C[C@@]2(C)C(=O)C[C@@H]1C2(C)C DSSYKIVIOFKYAU-XCBNKYQSSA-N 0.000 claims abstract description 13
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- NDLPOXTZKUMGOV-UHFFFAOYSA-N oxo(oxoferriooxy)iron hydrate Chemical compound O.O=[Fe]O[Fe]=O NDLPOXTZKUMGOV-UHFFFAOYSA-N 0.000 description 3
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- DHKHKXVYLBGOIT-UHFFFAOYSA-N acetaldehyde Diethyl Acetal Natural products CCOC(C)OCC DHKHKXVYLBGOIT-UHFFFAOYSA-N 0.000 description 1
- 125000002777 acetyl group Chemical class [H]C([H])([H])C(*)=O 0.000 description 1
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- DPTATFGPDCLUTF-UHFFFAOYSA-N phosphanylidyneiron Chemical compound [Fe]#P DPTATFGPDCLUTF-UHFFFAOYSA-N 0.000 description 1
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- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
- C04B35/632—Organic additives
- C04B35/634—Polymers
- C04B35/63404—Polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- C04B35/6342—Polyvinylacetals, e.g. polyvinylbutyral [PVB]
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
- C04B35/632—Organic additives
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
- C04B35/632—Organic additives
- C04B35/634—Polymers
- C04B35/63448—Polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/74—Physical characteristics
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Abstract
The invention relates to the technical field of sintered ferrites, and discloses low-cost special ferrite bonding rubber powder and a preparation process of a dry-pressed magnetic tile thereof, which comprises the following steps: (1) preferred is a binder, instead of the solid camphor which has been used hitherto; (2) the optimized rubber powder formula meets the requirements of high performance and high strength of the product, and the high strength is higher (Rockwell hardness) HRC1.8 than that of the product bonded by camphor; (3) the powder has good dispersibility and consistency in the aerosol glue mixing process, and the product molding density is improved; (4) the feeding parameters, pressure maintaining parameters, pressure relief parameters, top cylinder micro-retreating parameters, top cylinder static parameters and the like of the forming press are adjusted, so that the consistency and the pressing density of the product are improved; (5) the sintering process parameters are optimized, and a pipeline for exhausting air and moisture in a preheating zone is additionally arranged, so that the product is free from cracking. The low-cost ferrite bonding special rubber powder and the preparation process of the dry-pressed magnetic tile thereof have the advantages that the product manufacturing cost is reduced by 7.87 percent, the clean production and the environmental protection of the application of the sintered ferrite dry-pressed magnetic tile are realized, and the economic benefit and the social benefit are obvious.
Description
Technical Field
The invention relates to the technical field of sintered ferrites, in particular to low-cost ferrite bonding special rubber powder and a preparation process of a dry-pressed magnetic tile thereof.
Background
The dry-pressed anisotropic permanent magnetic ferrite series products are mostly manufactured by taking ferric oxide Fe2O3 iron red magnetic fine powder or iron phosphorus magnetic fine powder as a raw material and solid camphor as a binder through ceramic processes (powder making, press forming, sintering and grinding). Among them, the use of solid camphor as a binder has not changed since the inventions of the sixties of the last century.
The permanent magnetic ferrite material is one of the indispensable important support materials for the high-tech and national economic development, shows a great promoting effect on national defense construction and the whole national economic development, belongs to a national encouragement project and supports the preferential development of the national encouragement project.
The prior art has the following defects and shortcomings:
along with the continuous improvement of the requirements of miniaturization, light weight, thinning and environmental protection and energy conservation of products, higher requirements are put forward on the performance and environmental protection indexes of the permanent magnetic ferrite products. The performance and environmental protection indexes of the existing permanent magnetic ferrite product are required to be improved, so that the exploration and research of a high-performance permanent magnetic ferrite material and a preparation technology thereof, and the research and development of a novel clean and environmental-friendly binder to replace a novel process of solid camphor have important innovative significance for improving the structure composition of the existing high-end product, and are always one of the key points in the research field of magnetic materials.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides low-cost ferrite bonding special rubber powder and a preparation process of a dry-pressed magnetic tile thereof, and firstly, the invention researches and develops the special rubber powder which is clean, environment-friendly and cheap; further researching the formula and the glue making process; the powder mixing process by an aerosol method is innovated; adjusting feeding parameters, pressure maintaining parameters, pressure relief parameters, top cylinder micro-retreating parameters, top cylinder static parameters and the like of a forming press to ensure the density and consistency of products; the sintering process parameters are optimized, a preheating zone air exhaust and moisture exhaust pipeline is additionally arranged, the product has no crack, the comprehensive qualification rate is improved by 1% after grinding, and the product manufacturing cost is reduced by 7.87%.
In order to realize the purposes of clean, environment-friendly and low-cost preparation process of the low-cost ferrite bonding special rubber powder and the dry-pressed magnetic tile thereof, the invention provides the following technical scheme: the low-cost ferrite bonding special rubber powder is prepared from the following raw materials: polyvinyl formal modified rubber powder, high-molecular sodium lignosulfonate and other rubber powder, ferrite powder, calcium stearate and water.
The method for optimizing the special adhesive powder for bonding the ferrite with environmental protection and low cost comprises the following steps:
firstly, selecting special rubber powder material. Preferred binders, which must be on the front of being clean, environmentally friendly, inexpensive, replace solid camphor; the preferable binder has excellent binding performance and toughness and has good compatibility with main raw materials such as ferric oxide Fe2O3 iron red magnetic fine powder/iron phosphorus magnetic fine powder and the like.
And step two, preferably, the adhesive rubber powder modified by the polyethylene formal and two rubber powders such as high-molecular sodium lignosulfonate are blended and copolymerized into special rubber powder according to the conditions of the preferable adhesives in the step one.
And step three, exploring the adhesive powder modified by polyethylene alcohol formal optimized in the step two. Polyvinyl formal and polyepichlorohydrin mainly exist in a copolymerization or blending mode, and are researched by performing solid Nuclear Magnetic Resonance (NMR) test on adhesive preparation (C) (shown in the attached drawing 1), and the test result shows that: the 61ppm position corresponds to carbon element in a CH 2-O-structure, the 73ppm position corresponds to carbon element in a-CH-O structure, the 82ppm position corresponds to the peak position of tertiary carbon in-O-CH-CH 2Cl-, and the 103ppm position corresponds to the peak position of carbon in the-O-CH 2-O-structure, which can show that the addition of a sufficient amount of polyvinyl acetal thermoplastic resin can increase toughness and improve the comprehensive performance of the adhesive.
And step four, exploring that the sodium lignosulfonate rubber powder (attached table 1) is preferably selected in the step two, is a chemical modified product of natural lignin, is in a tawny fine powder state, has slightly aromatic smell, and is non-toxic and harmless. The sodium lignosulfonate used as the non-metal bonding additive has the advantages of small doping amount, high water reducing rate, low air content, good workability, low price, convenient use and the like, and is a bonding agent with excellent property.
Furthermore, through tests, the adhesive powder and the sodium lignosulfonate adhesive powder modified by the polyethylene alcohol formal can be independently used with the main raw material formulas of ferric oxide Fe2O3 iron red magnetic fine powder/iron phosphorus magnetic fine powder and the like.
Furthermore, tests show that the modified adhesive powder of the polyethylene alcohol formal and the sodium lignosulfonate adhesive powder are blended and copolymerized and reasonably proportioned, the compatibility is good, and the glue solution does not precipitate. And the product performance price ratio is very ideal, the reasonable use can obviously reduce the cost and increase the economic benefit.
Preferably, the modified rubber powder of the optimized polyvinyl formal adopts an aqueous solution with the water temperature of 60-85 ℃, has high viscosity and is easy to be mixed with ferrite powder; the preferred aromatic smell of the high-molecular sodium lignosulfonate has the advantages of no toxicity, good compatibility, no precipitation of an aqueous solution, less doping amount in the history of ferrite powder, high water reducing rate, low air content, good workability, low price, convenient use and the like, and can obviously reduce the cost and increase the economic benefit by reasonable use. The proportion of the special rubber powder (the adhesive powder modified by the polyethylene alcohol formal, macromolecule sodium lignosulfonate and other rubber powder) is 55-75 percent to 25-45 percent.
Preferably, the special rubber powder is free of naphthalene gas (qualified by RoHS 10 and REACH SVHC 197), so that the requirements of clean production, application and environmental protection are met; the optimized rubber powder formula meets the requirements of high performance and high strength of the product, and the high performance of the product is as follows: the central magnetic field is not less than 1056Gs (normal value is not less than 970 Gs), the high strength is detected by the hardness of a product by a SGS third party, and the Rockwell hardness HRC60.5 of the product produced by the special rubber powder and the preparation process is 1.8 greater than the Rockwell hardness HRC58.7 of a similar product using camphor as a binder.
Preferably, the special rubber powder comprises ferrite dry-pressed magnetic tile full-series products.
The preparation process of the low-cost ferrite bonded special rubber powder dry-pressed magnetic tile comprises the following steps:
and step A, preparing glue by using the preferable special glue powder material. Blending the special rubber powder with hot water; adding special glue powder into hot water, and beating into glue by using an electric drill breaker; the temperature of the hot water is 60-85 ℃; the temperature of the glue is reduced to below 40 ℃ and impurities in the glue are removed by filtration.
And step B, spraying atomized glue with the raw material powder in a mixer by adopting an aerosol method. Spraying atomized glue into the powder by using a small compressor or a glue storage tank connected with an air pipe, and optimizing spraying time, powder mixing time, proportion of calcium stearate and mixing time after calcium stearate; and setting forward and backward rotation of the mixer within the mixing time after spraying the glue and the calcium stearate to ensure that the glue, the calcium stearate and the powder are uniformly mixed.
And C, scattering the mixed powder by a scattering machine, and then transferring to a molding pressing process, wherein the powder is made into a variety with multiple brands.
And step D, fully mixing the special rubber powder and the multi-grade raw materials, and pressing the whole dry-pressed magnetic tile.
And E, adjusting the feeding parameters, the pressure maintaining parameters, the pressure unloading parameters, the micro-retreating parameters of the top cylinder, the static parameters of the top cylinder and the like of the forming press to ensure the density and the consistency of the product.
And step F, arranging a dehumidifying exhaust pipeline in a preheating area of the sintering electric kiln, improving the sintering oxygen content of the product entering a high-temperature area, and avoiding cracking of the product.
Preferably, the glue process in the step A is to mix special glue powder and water in a ratio of 1: 10-25; the special glue powder is broken up by hot water to prepare glue, and the breaking time is 10-15 minutes; the temperature of the hot water is 60-85 ℃; the scattering is carried out by using an electric drill, the lower part of a drill rod is welded by staggered overlapping of cross-shaped short steel bars, strong stirring is formed in water after the electric drill is started, and the scattering time is 10-15 minutes; and (4) filtering the glue by using a 80-mesh screen when the temperature of the glue is reduced to be below 40 ℃, and removing impurities in the glue.
Preferably, the atomization glue system sprays atomization glue into the powder by using a small-sized compressor and connecting a glue storage tank, the pressure of the atomization glue is 2MPa, the proportion of the atomization glue is 1.2-5% of the powder, the spraying time is 8-10 minutes, calcium stearate is added after 15 minutes of powder mixing time, the proportion of the calcium stearate is 0.4-0.8% of the powder, the powder is continuously mixed for 15 minutes after calcium stearate is added, the mixing time of the glue and the calcium stearate is within the range of setting the forward rotation and the reverse rotation of the mixer, the exchange time of the forward rotation and the reverse rotation is 7.5 minutes, so that the glue, the calcium stearate and the powder are uniformly mixed, and the powder formula weight ratio in the step B is as follows: raw material powder (100): calcium stearate (0.4-0.8): glue (1.2-5).
Preferably, the step B requires material feeding, material mixing and glue mixing. Sequentially feeding raw materials to a mixer → feeding the mixed materials for 5-10 minutes → feeding atomized glue → continuously mixing the mixed materials for 10-20 minutes → feeding calcium stearate → continuously mixing the mixed materials for 10-20 minutes, wherein the mixed materials are required to be fully and uniformly mixed, then transferring to a conventional powder scattering process, discharging, boxing and transferring to a molding process.
Preferably, the feeding, mixing and glue mixing in the step B are sequentially unchanged or are reversed to the card; the atomized glue is required to be an aerosol method, and water drops cannot be formed to prevent powder from being agglomerated; the mixing time can be properly adjusted according to the change of the weather and humidity; the powder is broken up by adopting a three-phase two-stage motor with 30KW/3000 r/min, the rubber powder material is crushed again by transmission, and the powder falls into a material storage barrel through a 100-mesh and 120-mesh screen by airflow.
Preferably, in the step E, in the product molding process, the feeding parameters of a molding press, pressure maintaining parameters, pressure relief parameters, top cylinder micro-withdrawal parameters, top cylinder static parameters and the like need to be adjusted, and the feeding parameters of the molding press are adjusted to be 1-4.5 s; pressure maintaining and relieving parameters are adjusted to be 1-5s and 0.5-3 s; the micro-retreating of the top cylinder and the adjustment of the static parameters of the top cylinder are both 0.2-1.5 s. The product of the forming press has good forming and high strength, and the qualification rate reaches 99 percent. Ensuring the consistency and the forming density of the product, wherein the density of the product is 5.1g/cm for carrying out the thin film fruit-cutting and the thin film fruit-cutting.
Preferably, in the step F, sintering process parameters are optimized, a preheating zone air exhaust and moisture exhaust pipeline is additionally arranged, the product does not crack, the comprehensive qualified rate is improved by 1% after grinding, the preheating zone of the sintering electric kiln is provided with an air exhaust and moisture exhaust pipeline, the technically improved electric kiln is enhanced in the air exhaust and moisture exhaust functions of the preheating zone, 2-7 zones in a figure II are respectively provided with a zone exhaust pipe, a single plate valve is installed, the optimal opening angle of the single plate valve is 35-45 ℃, the shrinkage ratio of the sintered product is 1.14 by exhausting air and moisture of the product in the preheating zone, the product does not crack, and the finished product rate is 100%.
Preferably, the sintering process parameters are optimized in the step F, and the parameters that relative humidity contained in the formed product must be extracted and dehumidified in a preheating area of the electric kiln are adjusted; the parameter adjustment is through 7 regions to the preheating zone from second district to every regional increase exhaust port of seventh region, preheating zone down connects the exhaust main pipe for every exhaust port ∅ 75mm steel pipe, and the rethread exhaust is responsible for the draught fan on with waste gas upwards 15 meters and discharges into in the air, install the monolithic plate valve in the middle of every ∅ 75mm steel pipe, the parameter adjustment is the opening angle that can adjust the monolithic plate valve wantonly to realize the size control of displacement (see fig. 2).
Preferably, the optimal opening angle of the single plate valve is 35-45 ℃ through air extraction and dehumidification of the preheating zone in the step F, the shrinkage ratio of the sintered product is 1.14 through air extraction and dehumidification of the product in the preheating zone, the product is free of cracking, and the yield is improved by 1%.
Compared with the prior art, the invention provides the low-cost ferrite bonding special rubber powder and the preparation process of the dry-pressed magnetic tile, and the low-cost ferrite bonding special rubber powder has the following beneficial effects:
economic benefits are as follows: taking 3000 tons of dry-pressed magnetic tile enterprises produced every year as an example, the direct cost of using solid camphor as a binder is that (solid camphor) 10 ten thousand yuan/ton is used in a ratio of 1.2% = (1200 yuan/ton 3000 ton) =360 ten thousand yuan; the direct cost of using special rubber powder as a binder is that (special rubber powder) the dosage ratio of 0.8 ten thousand yuan/ton is 1.5 per thousand-2.5 per thousand = (20 yuan/ton 3000 ton) =6 ten thousand yuan. The annual cost is saved by 354 ten thousand yuan; the dry pressure magnetic tile market selling price is 1.5 ten thousand yuan/ton, the profit rate is directly increased by 7.87%, and the economic benefit is good.
Social benefits are as follows: the synthetic camphor is an organic compound, contains naphthalene, smells pungent, has influence on human health after long-term contact, realizes clean production and has high environmental protection difficulty, the product does not meet the detection index requirements of RoHS 10 and REACH SVHC 210, and the product produced by using special rubber powder as a binder has no smell, is completely qualified in environmental protection detection and has good social benefit.
Drawings
FIG. 1 shows an adhesive13C solid nuclear magnetic resonance spectrogram;
FIG. 2 is a schematic diagram of the technical modification of the preheating zone of the electric kiln.
In the figure: 1. a preheating zone; 2. a high temperature zone; 3. a feed inlet; 4. a main exhaust pipe; 5. a main exhaust pipe; 6. exhaust pipes are partitioned; 7. a one-way valve; 8. an induced draft fan.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1-2, a low-cost ferrite bonding special rubber powder and a dry-pressed magnetic tile preparation process thereof are prepared by the method.
In order to more clearly show the technical effects of the special rubber powder-doped copolymerization rubber preparation process and the product production, the following specific examples describe the ferrite bonding special rubber powder and the dry-pressed magnetic tile preparation process thereof in detail.
Example one Dry powder binding and preparation Process (comparative example)
The preparation process of the low-cost ferrite bonding special rubber powder and the dry-pressed magnetic tile thereof adopts the following method to prepare the low-cost ferrite bonding special rubber powder, and the preparation process specifically comprises the following steps:
step A, dry powder: the adhesive powder modified by polyvinyl alcohol formal, high molecular sodium lignosulfonate and the mixture are copolymerized and called as special adhesive powder, and the proportion is 55-75 percent and 25-45 percent.
Step B, formula: the powder formula comprises the following components in percentage by weight: raw material powder (100): calcium stearate (0.3-0.8): special rubber powder (1.2-1.8).
Step C, powder preparation: according to the weight ratio of the raw materials, firstly feeding raw material powder, then feeding calcium stearate and finally feeding special rubber powder into a mixer in sequence. Further mixing for 30 minutes, discharging, further breaking up the powder and then transferring to a forming process.
Step D, forming: the powder is put into a forming press to be operated according to conventional parameters, the product is formed easily and has low strength, and the qualification rate is only 92 percent.
Step E, sintering: and putting the product green body into an electric kiln to run and sinter according to conventional parameters, and measuring the shrinkage ratio after discharging to be 1.06-1.07, wherein the shrinkage ratio is smaller.
Step F, grinding: the product is thicker, the shaft height is larger, the chord width is larger, the product has obvious cracking and dark cracking, and the product percent of pass is 90%.
Step G, performance test: after the product is ground and polished, the tile is magnetized (S.N poles) to measure the value of the center magnetic field Gs, taking dry pressing RS-380 products as an example, and the average center magnetic field of 10 pairs of products is 1020Gs, so that the performance is in accordance with.
And step H, further testing the product density, wherein the product density is 4.6 cm/g.
TABLE 1
The first embodiment is summarized as follows: the special rubber powder is mixed by a dry powder method to produce a finished product with low molding rate, cracking during sintering, small shrinkage ratio, low qualified rate after grinding and processing and low central magnetic field.
In view of the fact that the dry powder mixing method is not feasible, a glue mixing method is adopted.
Example two glue bonding and preparation process 1.
The preparation process of the low-cost ferrite bonding special rubber powder and the dry-pressed magnetic tile thereof adopts the following method to prepare the low-cost ferrite bonding special rubber powder, and the preparation process specifically comprises the following steps:
step A, dry powder: the adhesive powder modified by polyvinyl alcohol formal, high molecular sodium lignosulfonate and the mixture are copolymerized and called as special adhesive powder, and the proportion is 55-75 percent and 25-45 percent.
Step B, glue preparation: mixing special rubber powder with water at a mixing ratio of 1:10-25, wherein the temperature of the hot water is 60-85 ℃; the dry powder is required to be simultaneously broken up when being added, and the breaking time is 10-15 minutes; and (4) filtering the glue by using a 80-mesh screen when the temperature of the glue is reduced to be below 40 ℃, and removing impurities in the glue.
Step C, formula: the powder formula comprises the following components in percentage by weight: raw material powder (100): calcium stearate (0.4-0.8%): special glue (1.2-5%).
Step D, pulverizing: according to the weight ratio of the raw materials, the raw material powder, the special glue and the calcium stearate are sequentially added into a mixer. Spraying the special glue by high-pressure air atomization of an air pump; the calcium stearate is added uniformly at last, and if the calcium stearate is added before the glue is sprayed, glue sticking occurs during subsequent forming, so that the forming quality is influenced.
Further mixing the glue and the calcium stearate for 15 minutes respectively, discharging, further scattering and crushing the powder, and then transferring to a molding process.
Step D, forming: the powder is put into a forming press to be operated according to the conventional parameters, the product is better formed, the strength is high, and the qualification rate reaches 97.5 percent.
Further, adjusting the feeding parameters to 1-4.5 s; pressure maintaining and relieving parameters are adjusted to be 1-5s and 0.5-3 s; the micro-retreating of the top cylinder and the adjustment of the static parameters of the top cylinder are both 0.2-1.5 s. The product has good molding and high strength, and the qualification rate reaches 99 percent.
Step E, sintering: and putting the product green body into an electric kiln to be sintered according to conventional parameters, measuring the shrinkage ratio to be 1.14 after discharging, detecting that the sintered product has cracking or dark-to-open cracking.
Further, the air extraction and dehumidification functions of the preheating area 1 of the electric kiln are enhanced, the subarea exhaust pipes 6 are respectively arranged in the areas 2-7 (shown in the figure II), the one-way valves 7 are installed, the optimal opening angle of the one-way valves 7 is 35-45 ℃, the shrinkage ratio of a sintered product is 1.14 by extracting air and dehumidifying the product in the preheating area 1, the product is free from cracking, and the yield is improved by 100%.
Step F, grinding: because the thickness, the shaft height, the chord width and the like of the sintered product are all within the tolerance range, the grinding efficiency is obviously improved, the product has no obvious cracking and dark cracking, and the product percent of pass reaches more than 99 percent.
Step G, performance test: the product is ground and polished, the tile is magnetized (S.N poles) to measure the value of the center magnetic field Gs, taking dry pressing RS-380 product as an example, the average center magnetic field of 10 pairs of products is over 1045Gs, and the performance is high.
And step H, further testing the product density, wherein the product density is 5.1 cm/g.
TABLE 2
Example two (glue bonding and preparation process 1): the special glue powder is mixed by the glue by an aerosol method, the finished product has high molding rate, the electric kiln is technically improved to enhance the exhaust and dehumidification functions, the product is not cracked during sintering, the shrinkage ratio is normal, the qualified rate after grinding is high, and the central magnetic field is high.
In the third embodiment, the glue bonding and preparation process 2 is adopted to further verify the process stability and maturity of the second embodiment.
The preparation process of the low-cost ferrite bonding special rubber powder and the dry-pressed magnetic tile thereof adopts the following method to prepare the low-cost ferrite bonding special rubber powder, and the preparation process specifically comprises the following steps:
step A, dry powder: the adhesive powder modified by polyvinyl alcohol formal, high molecular sodium lignosulfonate and the mixture are copolymerized and called as special adhesive powder, and the proportion is 55-75 percent and 25-45 percent.
Step B, glue preparation: mixing special rubber powder with water at a mixing ratio of 1:10-25, wherein the temperature of the hot water is 60-85 ℃; the dry powder is required to be simultaneously broken up when being added, and the breaking time is 10-15 minutes; and (4) filtering the glue by using a 80-mesh screen when the temperature of the glue is reduced to be below 40 ℃, and removing impurities in the glue.
Step C, formula: the powder formula comprises the following components in percentage by weight: raw material powder (100): calcium stearate (0.4-0.8%): special glue (1.2-5%).
Step D, pulverizing: according to the weight ratio of the raw materials, the raw material powder, the special glue and the calcium stearate are sequentially added into a mixer. Spraying the special glue by high-pressure air atomization of an air pump; the calcium stearate must be added uniformly at the end.
Further mixing the glue and the calcium stearate for 15 minutes respectively, discharging, further scattering and crushing the powder, and then transferring to a molding process.
Step D, forming: adjusting the feeding parameters to 1-4.5 s; pressure maintaining and relieving parameters are adjusted to be 1-5s and 0.5-3 s; the micro-retreating of the top cylinder and the adjustment of the static parameters of the top cylinder are both 0.2-1.5 s. The product has good molding and high strength, and the qualification rate reaches 100 percent.
Step E, sintering: in the technically improved electric kiln, the air extraction and dehumidification functions of the preheating zone 1 are enhanced, the partition exhaust pipes 6 are respectively arranged for 2-7 partitions (shown in figure two), the check valves 7 are installed, the optimal opening angle of the check valves 7 is 35-45 ℃, the shrinkage ratio of a sintered product is 1.14, the product is not cracked, and the yield is 100 percent.
Step F, grinding: because the thickness, the shaft height, the chord width and the like of the sintered product are all within the tolerance range, the grinding efficiency is obviously improved, the product has no obvious cracking and dark cracking, and the product percent of pass reaches more than 99 percent.
Step G, performance test: after the product is ground and polished, the tile is magnetized (S.N poles) to measure the value of the center magnetic field Gs, taking dry pressing RS-380 products as an example, and after the test of 400 pairs of products, the average center magnetic field is more than 1056Gs, and the performance is high.
And step H, further testing the product density, wherein the product density is 5.1 cm/g.
Furthermore, the hardness of the product is detected by SGS third party, and the Rockwell hardness HRC60.5 of the product produced by the special rubber powder and the preparation process is 1.8 greater than the Rockwell hardness HRC58.7 of the similar product using camphor as the binder (see Table 2).
Further, products RoHS 10 and REACH SVHC 197 are all qualified through detection of SGS third parties.
TABLE 2
Example iii (glue bonding and preparation process 2): the special glue powder is mixed by glue making water by an aerosol method to produce a finished product with high molding rate, the electric kiln is technically improved to enhance the exhaust and dehumidification functions, the product is not cracked during sintering, the shrinkage ratio is normal, the qualified rate after grinding is high, the central magnetic field is high, and the consistency of batch production is good.
In the above embodiment, the special rubber powder is used as the ferrite dry-pressing magnetic tile binder, the best method is to prepare the rubber powder into the glue and mix the glue with the powder by using the aerosol method, and meanwhile, the process technologies such as changing the forming parameters of the press, increasing the dehumidifying and air-extracting functions of the electric kiln and the like are adopted, so that the product has high forming qualification rate, normal sintering shrinkage ratio, high grinding qualification rate, high product density, high central magnetic field and good hardness. The method completely replaces the process method of using camphor as the binder all the time, greatly saves the manufacturing cost of the product, realizes clean production and is environment-friendly in application.
It is noted that, herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (8)
1. The low-cost ferrite bonding special rubber powder is prepared from the following raw materials: polyvinyl formal modified rubber powder, high-molecular sodium lignosulfonate and other rubber powder, ferrite powder, calcium stearate and water.
The preparation process of the low-cost ferrite bonding special rubber powder and the dry-pressed magnetic tile thereof comprises the following steps:
step one, preparing a special rubber powder material. The special rubber powder material is preferably prepared by mixing and copolymerizing a plurality of rubber powders such as bonding rubber powder modified by polyethylene alcohol formal and high-molecular sodium lignosulfonate, and the special rubber powder replaces the solid camphor which is used all the time.
And step two, manufacturing glue by using special glue powder materials. Blending the special rubber powder with hot water; the special glue powder is poured into hot water and is beaten into glue by an electric drill beater in real time, and impurities in the glue are filtered out and removed.
And thirdly, spraying atomized glue with the raw material powder in a mixer by adopting an aerosol method. Spraying atomized glue into the powder by using a small compressor or a glue storage tank connected with an air pipe, and optimizing spraying time, powder mixing time, proportion of calcium stearate and mixing time after calcium stearate; and setting forward and backward rotation of the mixer within the mixing time after spraying the glue and the calcium stearate to ensure that the glue, the calcium stearate and the powder are uniformly mixed.
And step four, scattering the mixed powder by a scattering machine, and then transferring to a molding pressing process, wherein the powder is made into a variety with multiple brands.
And step five, fully mixing the special rubber powder and the multi-grade raw materials to press all the dry-pressed magnetic tiles.
And step six, adjusting the feeding parameters, the pressure maintaining parameters, the pressure relief parameters, the micro-withdrawal parameters of the top cylinder, the static parameters of the top cylinder and the like of the forming press to ensure the density and the consistency of the product.
And step seven, arranging a dehumidifying exhaust pipeline in the preheating area of the sintering electric kiln, improving the sintering oxygen content of the product entering the high-temperature area, and avoiding the cracking of the product.
2. The low-cost ferrite bonding special rubber powder and the preparation process of the dry-pressed magnetic tile thereof according to the step one of the claim 1, wherein the process comprises the following steps: the rubber powder modified by the optimized polyvinyl formal adopts an aqueous solution at the water temperature of 60-85 ℃. The proportion of the special rubber powder (the adhesive powder modified by the polyethylene alcohol formal, macromolecule sodium lignosulfonate and other rubber powder) is 55-75 percent to 25-45 percent.
3. The low-cost ferrite bonding special rubber powder and the dry-pressing magnetic tile preparation process thereof according to the step two of claim 1, wherein the process comprises the following steps: the mixing ratio of the special rubber powder to hot water is 1: 10-25; the special rubber powder is broken up by hot water to prepare glue, and the breaking time is 10-15 minutes; the temperature of the hot water is 60-85 ℃; and (3) reducing the temperature of the glue to be below 40 ℃, and filtering the glue by using a 80-mesh screen.
4. The low-cost ferrite bonding special rubber powder and the dry-pressing magnetic tile preparation process thereof according to the third step of claim 1, wherein the process comprises the following steps: the atomization glue system is connected with a glue storage tank through a small compressor to spray atomized glue to powder, the pressure of the atomized glue is 2MPa, the proportion of the atomized glue is 1.2-5% of the powder, the spraying time is 8-10 minutes, calcium stearate is added after 15 minutes of powder mixing time, the proportion of calcium stearate is 0.4-0.8% of the powder, the material is continuously mixed for 15 minutes after the calcium stearate is added, the mixing time of the glue and the calcium stearate is set to be 7.5 minutes for forward rotation and reverse rotation of the mixer.
5. The low-cost ferrite bonding special rubber powder and the dry-pressing magnetic tile preparation process thereof according to the steps one to five of the claim 1, characterized in that: the special rubber powder comprises ferrite dry-pressed magnetic tile full-series products.
6. The low-cost ferrite bonding special rubber powder and the dry-pressing magnetic tile preparation process thereof according to the sixth step of claim 1, wherein the process comprises the following steps: adjusting the feeding parameters of the forming press to 1-4.5 s; pressure maintaining and relieving parameters are adjusted to be 1-5s and 0.5-3 s; the micro-retreating of the top cylinder and the adjustment of the static parameters of the top cylinder are both 0.2-1.5 s. The molding press has the advantages of good product molding, high strength and high qualification rate of 99 percent. Ensuring the density and the consistency of the product, wherein the density of the product is 5.1g/cm for carrying out the year.
7. The low-cost ferrite bonding special rubber powder and the dry-pressing magnetic tile preparation process thereof according to the seventh step of claim 1, wherein the process comprises the following steps: the preheating area of the sintering electric kiln is provided with a dehumidifying exhaust pipeline, the air exhausting and dehumidifying functions of the preheating area of the technically improved electric kiln are enhanced, 2-7 areas in the second drawing are respectively provided with a subarea exhaust pipe, and a single-plate valve is installed, wherein the optimal opening angle of the single-plate valve is 35-45 ℃.
8. The special low-cost ferrite adhesive powder and the preparation process of the dry-pressed magnetic tile thereof according to the claims 1 to 7, are characterized in that: the special rubber powder is free of naphthalene gas (the RoHS 10 item and the REACH SVHC 197 item are qualified in detection), and the requirements of clean production, application and environmental protection are met; the optimized rubber powder formula meets the requirements of high performance and high strength of the product, and the high performance of the product is as follows: the central magnetic field is not less than 1056Gs (normal value is not less than 970 Gs), the high strength is detected by the hardness of a product by a SGS third party, and the Rockwell hardness HRC60.5 of the product produced by the special rubber powder and the preparation process is 1.8 greater than the Rockwell hardness HRC58.7 of a similar product using camphor as a binder.
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