The Preparation Methods of Spherical Quartz Powder

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Spherical quartz powder Has excellent properties including smooth surface, high surface area, hardness, and chemical stability. The spherical particles are fluid and can be mixed evenly with resin to create a film. The amount added of resin is low, while the amount of quartz is high.
The lower the thermal conductivity and the smaller thermal expansion coefficient the molding compound, the higher the amount of quartz powder. The performance of electronic components is improved when they are closer to monocrystalline silicon’s thermal expansion coefficient.

It is made by purifying and ultra-finely grinding natural quartz stone, and then passing it through a high temperature field. This causes its phase, shape and crystal to change instantly, from solid to molten to solid, and from crystalline to amorphous. Its preparation methods are currently mainly high-temperature plasma melt method, high temperature melting injection method and flame gas combustion method.

High Temperature plasma Melting
The high temperature plasma melting method sprays quartz powder into the plasma flame using high-temperature gases generated by AC/DC arc plasma. The powder is heated to melt and instantly vaporize, then quenched and collected with a cyclone. This produces spherical silica powder. The process is characterized with a high heating temperature which can achieve a temperature field more than five times higher than chemical burning (above 3000K). A high temperature, a high heat level and a high active atmosphere cause the chemical reaction to proceed quickly. This leads to the rapid formation high temperature phase compounds, which are difficult for liquid phase chemistry to synthesize. Such as nitrides carbides and borides etc. After rapid cooling, particles that have left the plasma will not grow.

The technology of plasma is extremely difficult. First, magnetic and electric properties of plasma can affect the plasma temperature field. The temperature field has a small and concentrated size. Second, the generation of plasma energy by the current through the medium of ionized gases is achieved. A plasma that is too diluted will interfere with the current, and the effect will be lost. It is hard to control how fast the product spheroidizes.

High Temperature Melt Injection
The high-temperature injection method involves melting the material to a liquid by putting it in a hot field. When the melt comes out of the ejector it is sprayed by high pressure air. This causes the melt to be dispersed into mist. When the droplets cool down, they shrink back into smooth spheres. The method of high temperature melt atomization is the most effective way to achieve spheroidization. The key technologies of viscous quartz melting atomization in furnaces, high temperature materials for the quartz, and the prevention of secondary pollutants have yet to be developed. This makes it difficult to make high-purity spherical powder.

Gas Combustion Flame method
The gas combustion method produces a flame using acetylene and hydrogen. It also uses natural gas, other fuel gases, and oxygen as a support gas. The airflow is used to transport the angular quartz into the flame. As the angular particles pass through the high temperature flame field, they are first melted to amorphous powder. It shrinks immediately into spherical powder when it exits the high temperature field. The cyclone then collects the final product. Thermodynamics, particle hydrodynamics and gas dynamics are all involved in this method. The temperature field in plasma high-temperature fires is much lower and there are also fewer factors that influence it. It does not involve electromagnetic theory or the flow ions in an electromagnetic field. The movement problem makes it easier to manage various conditions. Equipment manufacturing is simplified, industrialization is easy, and development prospects are better.

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