CN106631065B - 一种真空隔热耐火材料制品及其制备方法 - Google Patents

一种真空隔热耐火材料制品及其制备方法 Download PDF

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CN106631065B
CN106631065B CN201611204383.XA CN201611204383A CN106631065B CN 106631065 B CN106631065 B CN 106631065B CN 201611204383 A CN201611204383 A CN 201611204383A CN 106631065 B CN106631065 B CN 106631065B
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马成良
吕桂英
靳亲国
王世界
王斌
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Abstract

本发明公开了一种真空隔热耐火材料制品及其制备方法，该制品由芯材和包裹在芯材外的高阻隔薄膜构成，芯材由重量占比为95~70wt%的低导热微孔粉体和重量占比为5~30wt%散状耐火短纤维均匀分散后压制而成，高阻隔薄膜是以无机材料为主要成分流延法制成的耐高温气密性薄膜。将压制成型好的芯材用高阻隔膜包裹后抽真空热压封装，制备出真空隔热耐火材料制品。该制品可在500~1200℃温度条件下使用,并仍能保持真空结构，具有很低的导热率，性价比高。适合规模化生产，安装使用方便，可与轻质、重质耐火材料配套，用于高温工业窑炉内衬复合高效隔热，节能效果显著。

Description

一种真空隔热耐火材料制品及其制备方法
技术领域
本发明涉及一种真空隔热耐火材料制品及其制备方法，属于耐火材料技术领域。
背景技术
目前我国能源供给形势不容乐观，工业能耗占全社会能耗73%，2010年高耗能工业能源消耗比重达到81.2%，占工业耗能的绝大部分。根据国家节约能源、保护环境的基本国策，如何降低高温工业中的能源和资源的损耗、保护环境势在必行。大量高温工业窑炉外表面的散热损失仍较明显，研究开发高效节能隔热材料迫在眉睫。
现有的真空隔热材料是以粉体、泡沫、纤维、气凝胶等为芯层材料，经过真空封装后得到的高效保温板材，主要用于制冷、建筑等行业，但不能满足高温工业炉衬节能隔热的需求。
如申请号为200420053407.2，海尔集团公司申请的真空绝热板，应用在冰箱等电器上。如申请号为201610067278.X的中国发明专利公布了一种新型气凝胶真空绝热板及其制备方法，可大量应用于高层建筑外墙保温材料，申请号为201320665323.3的中国专利公布了一种气凝胶复合板，该复合板应用范围广泛，如工业、建筑物的外墙体、室内装饰、交通运输车辆、船舶等。但也仅限中低温领域，在高温条件下不能使用。并且由于都采用气凝胶作为填充材料，成本较高，不利于规模化商业生产。
如申请号为201510559717.4及201520682637.3专利，靳亲国、马成良等人发明的真空结构高温隔热板及其制备方法，该真空结构高温隔热板比非真空同材质同比重的轻质材料导热系数低,保温节能效果好,特别是排气热封装后直接使用,无需高温烧成,节约能源,简单方便。但芯材和封装材料仍需要改善，进一步降低其导热系数，提高其隔热性能，并提高使用温度。
发明内容
为克服现有技术无法满足市场对隔热耐火材料的低导热高耐火性能的要求，本发明的目的是提供隔热性能更优异、可以在较高的温度条件下使用、并且生产成本较低，可以规模化商业生产的真空隔热耐火材料制品及其制备方法。
为达到上述目的，本发明所采用的技术方案是：
一种真空隔热耐火材料制品，由芯材和包裹在芯材外的高阻隔薄膜构成，所述芯材是将低导热微孔粉体和散状耐火纤维均匀分散后压制而成的混合物，其中，低导热微孔粉体的重量占比为95~70wt%,散状耐火纤维重量占比为5~30wt%；所述高阻隔薄膜是指以氧化硅、氧化铝、氧化钛、氧化锆、硅酸铝的一种或几种无机材料为主要成分制成的耐高温气密性薄膜，包括能耐高温并保持气密性的陶瓷膜、玻璃膜或复合耐热膜；
所述低导热微孔粉体是具有较低导热率和微米级气孔粉状材料的二氧化硅、氧化铝、氧化钛、氧化锆的一种或几种的混合；
所述散状耐火纤维是散状短切无机纤维，散状短切无机纤维为硅酸铝、高铝、莫来石、氧化铝、氧化锆、碳化硅、硅酸锆的一种或几种的混合。
所述散状短切无机纤维直径0.2-3mm，长度0.5-5mm。
所述制品的芯材厚度为3mm-30mm，高阻隔薄膜厚度为0.1mm-0.8mm。
上述的真空隔热耐火材料制品的制备方法如下：
芯材的制备：将重量占比95~70wt%的低导热微孔粉体和5~30wt%散状耐火纤维在搅拌机里充分搅拌、均匀混合，使纤维与粉体交错穿插，具备一定整体性，压制成型制备成芯材；
高阻隔薄膜的制备：采用流延机制备高阻隔薄膜，首先将90—100份（wt%）氧化硅、氧化铝、氧化钛、氧化锆、或硅酸铝无机材料基料，80—90份浓度5-10%聚乙烯醇水溶液、5-10份丙三醇一起混合均匀制成无机材料浆料，将制备好的无机材料浆料从上部料斗流延嘴流到铜带或不锈钢带上，通过基带与刮刀的相对运动形成素坯，在表面张力的作用下，形成光滑致密的上表面，成坯膜后,采用底板加热的方法烧结，烧结温度200-1200℃，时间15-60min，升温速度0.1-0.5℃/min）制备出高阻隔薄膜，薄膜厚度0.1mm-0.8mm
将压制成型制备好的芯材用高阻隔薄膜包裹后先热压封装周边，预留抽真空封口；将预封装好的制品置于真空封装机工作位，薄膜封口处挡夹固定，从封口处抽真空，抽至真空度为0.001Pa，然后对封口进行热压封装，制备出真空隔热耐火材料制品。
真空隔热耐火材料制品耐温500~1200℃，并保持气密性,厚度均匀。
本发明制品与同类产品隔热性能比较：
Figure DEST_PATH_IMAGE001
本发明的积极效果是：
1、采用低导热微孔粉体与纤维的混合物作为芯材，并采用抽真空技术，使其具有真空结构，真空度为0.001Pa，200~800℃导热系数低至0.01~0.05W/m·k，使得制品隔热性能得到很大地提高。
2、芯材中加入耐火纤维，不仅使制品具有一定的强度，而且在使用时能减少烧结收缩，具有较好地高温使役性能。
3、采用低导热微孔粉体与纤维的混合物作为芯材，并采用高阻隔薄膜作为封装包裹膜，使制品可在500~1200℃较高的温度条件下使用,并仍能保持真空结构，具有很低的导热率。
4、以低导热微孔粉体代替气凝胶，耐高温，成本低，性价比高。适合规模化生产，便于推广应用。安装使用方便，可与轻质、重质耐火材料配套，用于高温工业窑炉内衬复合高效隔热，节能效果显著。
具体实施方式
下面结合实施例对本专利进一步解释说明。但本专利的保护范围不限于具体的实施方式。
实施例1
一种真空隔热耐火材料制品，包括芯材和包裹在芯材外的薄膜，芯材是80%的气相二氧化硅粉体和20%的硅酸铝纤维均匀分散的混合物；芯材外高阻隔薄膜为氧化钛陶瓷膜；
制备工艺为：
芯材的制备：称取气相二氧化硅粉体和直径0.5mm、长度1-2mm的硅酸铝纤维，其重量比为4:1，将二者放入搅拌机充分搅拌混合后，使纤维与粉体交错穿插，具备一定整体性，然后压制成型制备成芯材；
氧化钛陶瓷薄膜的制备：采用流延机制备氧化钛陶瓷薄膜，首先将90g氧化钛基料，85g浓度为6%的聚乙烯醇水溶液,7g丙三醇一起混合均匀制氧化钛浆料，将制备好的氧化钛浆料从上部料斗流延到不锈钢基带上，通过基带与刮刀的相对运动形成素坯，在表面张力的作用下，形成光滑致密的上表面，成坯膜后烧结制备出氧化钛陶瓷薄膜；烧结温度1200℃，时间60min，升温速度0.5℃/min。氧化钛陶瓷薄膜厚度0.6mm；
将上述压制成型制备好的芯材用氧化钛陶瓷薄膜包裹后先热压封装大部分周边，预留抽真空封口；将预封装好的芯材置于真空封装机工作位，薄膜封口处挡夹固定，从封口处抽真空，抽至真空度为0.001Pa，然后对封口进行热压封装，制备出气相二氧化硅基真空隔热耐火材料制品。
制备得到的真空隔热耐火材料制品，热面可耐1000~1200℃温度，350℃导热系数为0.022 W/m·k。
实施例2
一种真空隔热耐火材料制品，包括芯材和包裹在芯材外的薄膜，芯材是70%的氧化铝粉体和30%的氧化锆晶质纤维均匀分散的混合物；芯材外高阻隔薄膜为耐热合金复合膜；
制备工艺为：
芯材的制备：称取氧化铝粉体和纤维直径0.7mm，长度1-3mm的氧化锆晶质纤维，其重量比为7:3，将二者放入搅拌机充分搅拌混合后，使纤维与粉体交错穿插，具备一定整体性，然后压制成型制备成芯材；
耐热合金复合膜的制备：首先将100g耐热合金1Cr18Ni9Ti粉，浓度7%的聚乙烯醇水溶液85g,7g丙三醇一起混合均匀后制成浆料，将制备好的浆料从上部料斗流延到不锈钢基带上，通过基带与刮刀的相对运动形成素坯，在表面张力的作用下，形成光滑致密的上表面，成坯膜后烧结制备出耐热合金复合膜，烧结温度800℃，时间40min，升温速度0.3℃/min；制备耐热合金复合膜厚度0.5mm；
将压制成型制备好的芯材用耐热合金复合膜包裹后先热压封装大部分周边，预留抽真空封口；将预封装好的芯材置于真空封装机工作位，薄膜封口处挡夹固定，从封口处抽真空，抽至真空度为0.001Pa，然后对封口进行热压封装，制备出氧化铝/氧化锆基真空隔热耐火材料制品。
制备得到的真空隔热耐火材料制品，热面可耐600~1000℃温度，350℃导热系数为0.025W/m·k。
实施例3
一种真空隔热耐火材料制品，包括芯材和包裹在芯材外的薄膜，芯材是75%的微孔氧化钛粉体和25%的氧化铝晶质纤维均匀分散的混合物；芯材外薄膜为高阻隔硅氧玻璃膜。
制备工艺为：
芯材的制备：称取微孔氧化钛粉体和纤维直径1-2mm，长度2-3mm的氧化铝纤维，其重量比为3:1，将二者放入搅拌机充分搅拌混合后，使纤维与粉体交错穿插，具备一定整体性，然后压制成型制备成芯材；
硅氧玻璃膜的制备：采用流延机制备硅氧玻璃膜，首先将95g硅氧玻璃基料，83g浓度7%的聚乙烯醇水溶液,6g丙三醇一起混合均匀后制成硅氧玻璃浆料，将制备好的硅氧玻璃浆料从上部料斗流延到不锈钢基带上，通过基带与刮刀的相对运动形成素坯，在表面张力的作用下，形成光滑致密的上表面，成坯膜后烧结制备出硅氧玻璃膜，烧结温度1100℃，时间50min，升温速度0.4℃/min；制备氧化钛陶瓷膜厚度0.4mm；
将压制成型制备好的芯材用硅氧玻璃膜包裹后先热压封装大部分周边，预留抽真空封口；将预封装好的芯材置于真空封装机工作位，薄膜封口处挡夹固定，从封口处抽真空，抽至真空度为0.001Pa，然后对封口进行热压封装，制备出氧化钛/氧化铝基真空隔热耐火材料制品。
制备得到的真空隔热耐火材料制品，热面可耐700~1100℃温度，350℃导热系数为0.027W/m·k。

Claims (1)

1.一种真空隔热耐火材料制品的制备方法，该真空隔热耐火材料制品由芯材和包裹在芯材外的高阻隔薄膜构成，其特征在于：所述芯材是80%的气相二氧化硅粉体和20%的硅酸铝纤维均匀分散的混合物；芯材外高阻隔薄膜为氧化钛陶瓷膜；
该真空隔热耐火材料制品的制备方法为：
芯材的制备：称取气相二氧化硅粉体和直径0.5mm、长度1-2mm的硅酸铝纤维，其重量比为4:1，将二者放入搅拌机充分搅拌混合后，使纤维与粉体交错穿插，具备一定整体性，然后压制成型制备成芯材；
氧化钛陶瓷薄膜的制备：采用流延机制备氧化钛陶瓷薄膜，首先将90g氧化钛基料，85g浓度为6%的聚乙烯醇水溶液，7g丙三醇一起混合均匀制氧化钛浆料，将制备好的氧化钛浆料从上部料斗流延到不锈钢基带上，通过基带与刮刀的相对运动形成素坯，在表面张力的作用下，形成光滑致密的上表面，成坯膜后烧结制备出氧化钛陶瓷薄膜；烧结温度1200℃，时间60min，升温速度0.5℃/min，氧化钛陶瓷薄膜厚度0.6mm；
将上述压制成型制备好的芯材用氧化钛陶瓷薄膜包裹后先热压封装大部分周边，预留抽真空封口；将预封装好的芯材置于真空封装机工作位，薄膜封口处挡夹固定，从封口处抽真空，抽至真空度为0.001Pa，然后对封口进行热压封装，制备出气相二氧化硅基真空隔热耐火材料制品。
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