CN106220196A - 一种陶瓷纤维隔热材料及其制备方法 - Google Patents

一种陶瓷纤维隔热材料及其制备方法 Download PDF

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CN106220196A
CN106220196A CN201610581955.XA CN201610581955A CN106220196A CN 106220196 A CN106220196 A CN 106220196A CN 201610581955 A CN201610581955 A CN 201610581955A CN 106220196 A CN106220196 A CN 106220196A
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ceramic insulation
fibrous ceramic
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CN106220196B (zh
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刘浩
陈少
陈少一
王周福
王玺堂
马妍
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Wuhan University of Science and Engineering WUSE
Wuhan University of Science and Technology WHUST
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Abstract

本发明涉及一种陶瓷纤维隔热材料及其制备方法。其技术方案是：将含铝原料、含硅原料、含锌原料和结合剂混匀，成型；于800~1200℃条件下热处理3~6小时，研磨，筛分，得到A物料和B物料。将所述A物料、所述结合剂和添加剂混匀，球磨，外加陶瓷纤维和水，搅拌，浇注成型；烘干，于400~700℃条件下热处理3~6小时，破碎，筛分，得到C物料。将所述A物料、所述B物料、所述C物料、所述陶瓷纤维、所述结合剂、无机增稠剂和所述添加剂混匀，加水，搅拌，挤压成型，于50~80℃烘干，再于1000~1300℃条件下热处理3~6小时，制得陶瓷纤维隔热材料。本发明原料来源广泛，生产成本低；所制得的陶瓷纤维隔热材料强度高、体积密度小和导热系数低。

Description

一种陶瓷纤维隔热材料及其制备方法
技术领域
本发明属于耐火材料技术领域。具体涉及一种陶瓷纤维隔热材料及其制备方法。
背景技术
陶瓷纤维是一种纤维状轻质耐火材料，由陶瓷纤维制成的保温隔热材料具有耐高温、热稳定性好、导热率低和耐机械震动等优点，因而在机械、冶金、石化、建材和电子等行业都得到了广泛的应用，陶瓷纤维的研究亦得到本领域技术人员的越来越多的关注：“一种低热导率隔热材料及其制备方法”（ZL200810138024.8）专利技术，将玄武岩纤维加入水中搅成浆料，加入六钛酸钾晶须、结合剂、助剂，将絮状物抄出，成型、烘干，得到低导热率的复合隔热材料。“一种纳米孔硅质复合隔热材料及其制备方法”（ZL200810047741.X）专利技术，以纳米孔硅质粉末、硅酸铝纤维、六钛酸钾晶须和黏合剂等为原料，经纤维预处理、疏解、成型、干燥和热处理工序，制成纳米孔硅质复合隔热材料。“一种钛陶瓷绝热材料及其制备方法和应用”（ZL201110063781.5）专利技术，以六钛酸钾晶须、玻化微珠、蛇纹石、短切玻璃纤维、硅酸铝纤维、膨润土和胶黏剂等为原料制得钛陶瓷绝热材料。
上述技术具有一定的优点，但仍存在以下缺点：⑴引入的有机添加剂、黏合剂或结合剂，在高温下炭化和分解，产生浓烟和刺激性气体，污染环境；⑵黏合剂或结合剂的分解，降低了产品的使用寿命；⑶强度较小，受外部应力、机械振动或气流冲刷等作用后，易发生压缩和变形，影响保温衬体结构稳定性和弱化保温效果；⑷钛酸钾晶须、微珠等以直接添加的形式引入，在材料中无法控制其分布形态，只能以“散落”的形式分布于陶瓷纤维之间，使得材料的保温绝热效果受到明显影响。
发明内容
本发明旨在克服现有技术的不足，目的是提供一种原料来源广泛，生产成本低的陶瓷纤维隔热材料的制备方法；用该方法制备的陶瓷纤维隔热材料强度高、体积密度小和导热系数低。
为实现上述目的，本发明采用的技术方案的具体步骤是：
第一步、将30~50wt%的含铝原料、20~40wt%的含硅原料、10~20wt%的含锌原料和1~10wt%的结合剂混合均匀，在50~100MPa条件下压制成型；然后于800~1200℃条件下热处理3~6小时，破碎，研磨，筛分，得到粒度小于0.045mm的A物料和粒度为0.045~0.5mm的B物料。
第二步、将40~60wt%的所述A物料、30~50wt%的所述结合剂和1~10wt%的添加剂混合均匀，即得混合料Ⅰ；球磨，外加所述混合料Ⅰ10~30wt%的陶瓷纤维和20~40wt%的水，搅拌，浇注成型；于50~80℃条件下烘干12~24小时，再于400~700℃条件下热处理3~6小时，破碎，筛分，得到粒度小于0.5mm的C物料。
第三步、将10~20wt%的所述A物料、10~20wt%的所述B物料、30~50wt%的所述C物料、10~20wt%的所述陶瓷纤维、10~20wt%的所述结合剂、1~10wt%的无机增稠剂和1~10wt%的所述添加剂混合均匀，即得混合料Ⅱ；外加所述混合料Ⅱ10~30wt%的水，搅拌，挤压成型，于50~80℃条件下烘干12~24小时，再于1000~1300℃条件下热处理3~6小时，制得陶瓷纤维隔热材料。
所述含铝原料为氢氧化铝或为氧化铝微粉，所述氢氧化铝中Al(OH)3的含量大于99wt%，所述氧化铝微粉中Al2O3的含量大于99wt%，所述含铝原料的粒度小于0.088 mm。
所述含硅原料为单质硅粉或为白炭黑，所述单质硅粉中Si的含量大于97wt%，所述白炭黑中SiO2的含量大于92wt%，所述含硅原料的粒度小于0.088 mm。
所述含锌原料为硫酸锌或为磷酸锌，所述硫酸锌中ZnSO4的含量大于99wt%，所述磷酸锌中Zn3(PO4)2的含量大于99wt%，所述含锌原料的粒度小于0.088 mm。
所述结合剂为水玻璃或为硅溶胶，所述水玻璃的模数为1.5~2，所述硅溶胶中SiO2的含量为25~30wt%。
所述添加剂为羟乙基纤维素或为改性淀粉。
所述陶瓷纤维为硅酸铝陶瓷纤维或为硅酸镁陶瓷纤维。
所述无机增稠剂为硅藻土或为球粘土，所述无机增稠剂的粒度小于0.088mm。
由于采用上述技术方案，本发明与现有技术相比具有如下积极效果：
本发明所采用的原料来源广泛，生产成本低；本发明通过对各步骤中的粒度、成型及热处理等工序的严格控制，既有利于不同原料颗粒的均化及各种原料颗粒之间的紧密接触，也为微结构的形成提供了合理空间，因而所制备的陶瓷纤维隔热材料强度高、体积密度小和导热系数低。
本发明所制备的陶瓷纤维隔热材料经检测：抗折强度大于0.5MPa；体积密度小于0.4g/cm3；200~1200℃的导热系数为0.05~0.12w/(m·K)。
因此，本发明原料来源广泛，生产成本低；所制备的陶瓷纤维隔热材料强度高、体积密度小和导热系数低。
具体实施方式
下面结合具体实施方式对本发明作进一步的描述，并非对其保护范围的限制。
为避免重复，先将本具体实施方式所涉及的物料统一描述如下，实施例中不再赘述：
所述氢氧化铝中Al(OH)3的含量大于99wt%，所述氧化铝微粉中Al2O3的含量大于99wt%；所述含铝原料的粒度小于0.088 mm。
所述单质硅粉中Si的含量大于97wt%，所述白炭黑中SiO2的含量大于92wt%，所述含硅原料的粒度小于0.088 mm。
所述硫酸锌中ZnSO4的含量大于99wt%，所述磷酸锌中Zn3(PO4)2的含量大于99wt%；所述含锌原料的粒度小于0.088 mm。
所述水玻璃的模数为1.5~2，所述硅溶胶中SiO2的含量为25~30wt%。
所述无机增稠剂的粒度小于0.088mm。
实施例1
一种陶瓷纤维隔热材料及其制备方法。本实施例所述制备方法是：
第一步、将30~40wt%的含铝原料、30~40wt%的含硅原料、10~20wt%的含锌原料和1~10wt%的结合剂混合均匀，在50~100MPa条件下压制成型；然后于800~1100℃条件下热处理3~6小时，破碎，研磨，筛分，得到粒度小于0.045mm的A物料和粒度为0.045~0.5mm的B物料。
第二步、将40~50wt%的所述A物料、40~50wt%的所述结合剂和1~10wt%的添加剂混合均匀，即得混合料Ⅰ；球磨，外加所述混合料Ⅰ10~30wt%的陶瓷纤维和20~40wt%的水，搅拌，浇注成型；于50~80℃条件下烘干12~24小时，再于400~600℃条件下热处理3~6小时，破碎，筛分，得到粒度小于0.5mm的C物料。
第三步、将10~15wt%的所述A物料、10~20wt%的所述B物料、40~50wt%的所述C物料、10~20wt%的所述陶瓷纤维、10~20wt%的所述结合剂、1~10wt%的无机增稠剂和1~10wt%的所述添加剂混合均匀，即得混合料Ⅱ；外加所述混合料Ⅱ10~25wt%的水，搅拌，挤压成型，于50~80℃条件下烘干12~24小时，再于1000~1200℃条件下热处理3~6小时，制得陶瓷纤维隔热材料。
本实施例中：
所述含铝原料为氢氧化铝；
所述含硅原料为单质硅粉；
所述含锌原料为硫酸锌；
所述结合剂为水玻璃；
所述添加剂为羟乙基纤维素；
所述陶瓷纤维为硅酸铝陶瓷纤维；
所述无机增稠剂为硅藻土。
实施例2
一种陶瓷纤维隔热材料及其制备方法。除下述物料外其余同实施例1：
所述含铝原料为氧化铝微粉；
所述含硅原料为白炭黑；
所述含锌原料为磷酸锌；
所述结合剂为硅溶胶；
所述添加剂为改性淀粉；
所述陶瓷纤维为硅酸镁陶瓷纤维；
所述无机增稠剂为球粘土。
实施例3
一种陶瓷纤维隔热材料及其制备方法。本实施例所述制备方法是：
第一步、将40~50wt%的含铝原料、20~30wt%的含硅原料、10~20wt%的含锌原料和1~10wt%的结合剂混合均匀，在50~100MPa条件下压制成型；然后于900~1200℃条件下热处理3~6小时，破碎，研磨，筛分，得到粒度小于0.045mm的A物料和粒度为0.045~0.5mm的B物料。
第二步、将50~60wt%的所述A物料、30~40wt%的所述结合剂和1~10wt%的添加剂混合均匀，即得混合料Ⅰ；球磨，外加所述混合料Ⅰ10~30wt%的陶瓷纤维和20~40wt%的水，搅拌，浇注成型；于50~80℃条件下烘干12~24小时，再于500~700℃条件下热处理3~6小时，破碎，筛分，得到粒度小于0.5mm的C物料。
第三步、将15~20wt%的所述A物料、10~20wt%的所述B物料、30~40wt%的所述C物料、10~20wt%的所述陶瓷纤维、10~20wt%的所述结合剂、1~10wt%的无机增稠剂和1~10wt%的所述添加剂混合均匀，即得混合料Ⅱ；外加所述混合料Ⅱ15~30wt%的水，搅拌，挤压成型，于50~80℃条件下烘干12~24小时，再于1100~1300℃条件下热处理3~6小时，制得陶瓷纤维隔热材料。
本实施例中：
所述含铝原料为氢氧化铝；
所述含硅原料为单质硅粉；
所述含锌原料为硫酸锌；
所述结合剂为水玻璃；
所述添加剂为羟乙基纤维素；
所述陶瓷纤维为硅酸铝陶瓷纤维；
所述无机增稠剂为硅藻土。
实施例4
一种陶瓷纤维隔热材料及其制备方法。除下述物料外其余同实施例3：
所述含铝原料为氧化铝微粉；
所述含硅原料为白炭黑；
所述含锌原料为磷酸锌；
所述结合剂为硅溶胶；
所述添加剂为改性淀粉；
所述陶瓷纤维为硅酸镁陶瓷纤维；
所述无机增稠剂为球粘土。
本具体实施方式与现有技术相比具有如下积极效果：
本具体实施方式所采用的原料来源广泛，生产成本低；本具体实施方式通过对各步骤中的粒度、成型及热处理等工序的严格控制，既有利于不同原料颗粒的均化及各种原料颗粒之间的紧密接触，也为微结构的形成提供了合理空间，因而所制备的陶瓷纤维隔热材料强度高、体积密度小和导热系数低。
本具体实施方式所制备的陶瓷纤维隔热材料经检测：抗折强度大于0.5MPa；体积密度小于0.4g/cm3；200~1200℃的导热系数为0.05~0.12w/(m·K)。
因此，本具体实施方式原料来源广泛，生产成本低；所制备的陶瓷纤维隔热材料强度高、体积密度小和导热系数低。

Claims (6)

1.一种陶瓷纤维隔热材料的制备方法，其特征在于所述制备方法的具体步骤是：
第一步、将30~50wt%的含铝原料、20~40wt%的含硅原料、10~20wt%的含锌原料和1~10wt%的结合剂混合均匀，在50~100MPa条件下压制成型；然后于800~1200℃条件下热处理3~6小时，破碎，研磨，筛分，得到粒度小于0.045mm的A物料和粒度为0.045~0.5mm的B物料；
第二步、将40~60wt%的所述A物料、30~50wt%的所述结合剂和1~10wt%的添加剂混合均匀，即得混合料Ⅰ；球磨，外加所述混合料Ⅰ10~30wt%的陶瓷纤维和20~40wt%的水，搅拌，浇注成型；于50~80℃条件下烘干12~24小时，再于400~700℃条件下热处理3~6小时，破碎，筛分，得到粒度小于0.5mm的C物料；
第三步、将10~20wt%的所述A物料、10~20wt%的所述B物料、30~50wt%的所述C物料、10~20wt%的所述陶瓷纤维、10~20wt%的所述结合剂、1~10wt%的无机增稠剂和1~10wt%的所述添加剂混合均匀，即得混合料Ⅱ；外加所述混合料Ⅱ10~30wt%的水，搅拌，挤压成型，于50~80℃条件下烘干12~24小时，再于1000~1300℃条件下热处理3~6小时，制得陶瓷纤维隔热材料；
所述含铝原料为氢氧化铝或为氧化铝微粉，所述氢氧化铝中Al(OH)3的含量大于99wt%，所述氧化铝微粉中Al2O3的含量大于99wt%，所述含铝原料的粒度小于0.088 mm；
所述含硅原料为单质硅粉或为白炭黑，所述单质硅粉中Si的含量大于97wt%，所述白炭黑中SiO2的含量大于92wt%，所述含硅原料的粒度小于0.088 mm；
所述含锌原料为硫酸锌或为磷酸锌，所述硫酸锌中ZnSO4的含量大于99wt%，所述磷酸锌中Zn3(PO4)2的含量大于99wt%，所述含锌原料的粒度小于0.088 mm。
2.根据权利要求1所述陶瓷纤维隔热材料的制备方法，其特征在于所述结合剂为水玻璃或为硅溶胶，所述水玻璃的模数为1.5~2，所述硅溶胶中SiO2的含量为25~30wt%。
3.根据权利要求1所述陶瓷纤维隔热材料的制备方法，其特征在于所述添加剂为羟乙基纤维素或为改性淀粉。
4.根据权利要求1所述陶瓷纤维隔热材料的制备方法，其特征在于所述陶瓷纤维为硅酸铝陶瓷纤维或为硅酸镁陶瓷纤维。
5.根据权利要求1所述陶瓷纤维隔热材料的制备方法，其特征在于所述无机增稠剂为硅藻土或为球粘土，所述无机增稠剂的粒度小于0.088mm。
6.一种陶瓷纤维隔热材料，其特征在于所述陶瓷纤维隔热材料是根据权利要求1~5项中任一项所述陶瓷纤维隔热材料的制备方法所制备的陶瓷纤维隔热材料。
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