CN107177904A - 一种耐磨的硅酸铝耐火纤维 - Google Patents
一种耐磨的硅酸铝耐火纤维 Download PDFInfo
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Abstract
本发明属于耐火材料技术领域，具体公开了一种耐磨的硅酸铝耐火纤维，由以下重量份组份制备而成：焦宝石粉末100～120份、氧化铝55～65份、二氧化硅30～40份、氮化硅32～36份、ABS树脂20～25份、聚氨酯18～22份、天然橡胶10～15份、炭黑1～2份、锆酯酸偶联剂2～3份、过氧化二异丙苯0.6～0.8份、二氧化硅气凝胶16～20份、分散剂0.2～0.6份、硼砂15～25份、耐火浸渍液20～25份。本发明的耐磨的硅酸铝耐火纤维具有较强的抗摩擦与冲击的能力，能耐热炉渣、热废渣的冲击与磨损，而且耐环境应力、耐老化能力强，可在高温下长期使用，使用寿命长。
Description
技术领域
本发明属于耐火材料技术领域，具体涉及一种耐磨的硅酸铝耐火纤维。
背景技术
耐火纤维属于纤维状隔热耐火材料，具有一般纤维的特性，可以加工成各种纸、线、绳、毯和毡等制品，同时具有一般纤维所不具有的耐高温、耐腐蚀性能，因此被广泛应用于冶金、化工、机械、建材等行业。同时耐火纤维还具有良好的热能力和红外加热效应，可有效节约能源，是理想的节能增效材料。其中硅酸铝耐火纤维是以优质焦宝石、高纯氧化铝为原料，选择适当的工艺处理，经电阻炉熔融喷吹或甩丝，使化学组成与结构相同与不同的分散材料进行聚合纤维化制得的无机材料，性能稳定、纤维长、渣球少，被广泛应用于纤维纺织制品原料、纤维喷涂、浇筑料、设备高温区域缝隙填充料。但是耐火纤维在使用中经常受到热炉渣、热废渣等的冲击与摩擦，造成耐火纤维的使用性能下降，同时长期在恶劣环境下使用会导致耐火纤维出现老化，在外界的冲击与摩擦作用下加剧性能下降的程度。
中国专利CN2016108849171，专利名称一种高强度轻质耐火纤维及其制备方法，申请日期2016年10月10日，公开了一种由铝矾土、高岭土、蒙脱石、蛭石、氧化铝晶须、硅溶胶、吸附剂、结合剂、稀释剂制成的耐火纤维，具有较高的热稳定性与机械强度。但是该纤维承受热炉渣、热废渣等的冲击与摩擦的性能一般，使用一段时间后会出现性能下降的问题。
发明内容
针对耐火纤维受热炉渣、热废渣等冲击与摩擦造成使用性能下降的问题，本发明的目的在于提供一种耐磨的硅酸铝耐火纤维，具有较强的抗摩擦与冲击的能力，能耐热炉渣、热废渣的冲击与磨损，使用寿命长。
本发明提供如下的技术方案：
一种耐磨的硅酸铝耐火纤维，由以下重量份组份制备而成：焦宝石粉末100～120份、氧化铝55～65份、二氧化硅30～40份、氮化硅32～36份、ABS树脂20～25份、聚氨酯18～22份、天然橡胶10～15份、炭黑1～2份、锆酯酸偶联剂2～3份、过氧化二异丙苯0.6～0.8份、二氧化硅气凝胶16～20份、分散剂0.2～0.6份、硼砂15～25份、耐火浸渍液20～25份。
作为本发明的一种改进，所述耐火浸渍液由以下重量份组份混合而成：纳米级蛭石粉50～60份、磷酸铝粘结剂10～15份、钛白粉6～8份、液态硬化剂0.4～0.8份、水300～400份。
一种耐磨的硅酸铝耐火纤维的制备方法，包括以下步骤：
(1)将焦宝石粉末煅烧后与氧化铝、二氧化硅、氮化硅加热熔融混合得到熔融液；
(2)熔融液经高温离心机甩丝处理得到原丝，并切断成长度为6μm～12μm的原丝段；
(3)将ABS树脂、聚氨酯、天然橡胶、炭黑、过氧化二异丙苯、二氧化硅气凝胶、分散剂、混匀并送入螺杆造粒机制成塑料粒子；
(4)加热熔融塑料粒子，投入原丝段、锆酯酸偶联剂、硼砂搅拌混合均匀制成熔融浆液；
(5)将熔融浆液送入纺丝装置纺丝，将所得纺丝送入真空环境中加热至1000℃～1200℃并保持2～5小时后得到初级纤维；
(6)在初级纤维置于耐火浸渍液中浸泡，然后置于50℃～60℃的鼓风环境中干燥制成硅酸铝耐火纤维。
作为本发明方法的一种改进，步骤(1)中的熔融温度为2300℃～2500℃，且熔融状态保持45～60分钟。
作为本发明方法的一种改进，步骤(1)中的焦宝石粉末煅烧温度为550℃～650℃，煅烧时间1～2小时。
作为本发明方法的一种改进，步骤(2)中所得原丝的直径为25μm～30μm。
作为本发明方法的一种改进，步骤(4)中的熔融温度为210℃～240℃，搅拌速度20r/min～30r/min。
作为本发明方法的一种改进，步骤(6)中的浸泡温度为40℃～50℃、浸泡时间60～90分钟，耐火浸渍液的pH值为6.5～6.8。
作为本发明方法的一种改进，步骤(6)中鼓风速率为3m/s～5m/s，干燥时间90～120分钟，硅酸铝耐火纤维的直径为100μm～120μm。
本发明的耐磨的硅酸铝耐火纤维以焦宝石、氧化铝、二氧化硅为主料保证耐火纤维的高耐温性能，ABS树脂、聚氨酯树脂具有较强的耐磨、耐冲击性能而且耐热性、化学稳定性高，天然橡胶在炭黑作用下有较高的耐磨损品质，将ABS树脂、聚氨酯树脂与天然橡胶经过氧化二异丙苯交联后形成的聚合物的强度、耐老化、耐环境应力的能力进一步提高，耐磨损、耐冲击能力强。然后将该聚合物添加到含焦宝石、氧化铝、二氧化硅的硅酸铝耐火纤维的制备材料中对硅酸铝耐火纤维进行改性，一方面提升硅酸铝耐火纤维的耐磨损、耐冲击能力，另一方面提高硅酸铝耐火纤维的化学稳定性、耐老化能力。同时ABS树脂、聚氨酯、天然橡胶的耐腐蚀能力强，可以强化硅酸铝耐火纤维的耐环境应力能力。氮化硅具有较高的机械强度、硬度，可以协同ABS树脂、聚氨酯与天然橡胶进一步改善并强化硅酸铝耐火纤维的强度性能、耐环境应力性能。将初级纤维置于耐火浸渍液中浸泡可以使初级纤维表面形成耐火浸渍液成膜，提高硅酸铝耐火纤维的耐火性能和耐热稳定性。耐火浸渍液的弱酸性使初级纤维表面形成蚀刻痕迹，耐火浸渍液成膜稳定附着在初级纤维表面。二氧化硅气凝胶在ABS树脂、聚氨酯树脂、天然橡胶处形成保温防护层，提高耐热能力。
本发明的有益效果如下：
本发明的耐磨的硅酸铝耐火纤维具有较强的抗摩擦与冲击的能力，能耐热炉渣、热废渣的冲击与磨损，而且耐环境应力、耐老化能力强，可在高温下长期使用，使用寿命长。
具体实施方式
下面就本发明的具体实施方式作进一步说明：
如无特别说明，本发明中所采用的原料均可从市场上购得或是本领域常用的，如无特别说明，下述实施例中的方法均为本领域的常规方法。
实施例1
一种耐磨的硅酸铝耐火纤维，由以下组份制备而成：焦宝石粉末100g、氧化铝55g、二氧化硅30g、氮化硅32g、ABS树脂20g、聚氨酯18g、天然橡胶10g、炭黑1g、锆酯酸偶联剂2g、过氧化二异丙苯0.6g、二氧化硅气凝胶16g、分散剂0.2g、硼砂15g、耐火浸渍液20g，其中耐火浸渍液由以下组份混合而成：纳米级蛭石粉50g、磷酸铝粘结剂10g、钛白粉6g、液态硬化剂0.4g、水300g。
一种耐磨的硅酸铝耐火纤维的制备方法，包括以下步骤：
(1)将焦宝石粉末550℃煅烧1小时后与氧化铝、二氧化硅、氮化硅加热熔融混合得到熔融液，熔融温度为2300℃且熔融状态保持45分钟；
(2)熔融液经高温离心机甩丝得到直径为25μm～30μm的原丝，然后将原丝切断成长度为6μm～12μm的原丝段；
(3)将ABS树脂、聚氨酯、天然橡胶、炭黑、过氧化二异丙苯、二氧化硅气凝胶、分散剂、混匀并送入螺杆造粒机制成塑料粒子；
(4)加热熔融塑料粒子，投入原丝段、锆酯酸偶联剂、硼砂搅拌混合均匀，然后加热至210℃得到熔融浆液，搅拌速度20r/min；
(5)将熔融浆液送入纺丝装置纺丝，将所得纺丝送入真空环境中加热至1000℃并保持2小时后得到初级纤维；
(6)调节耐火浸渍液的pH值至6.5～6.8，将初级纤维置于40℃的耐火浸渍液中浸泡60分钟，然后置于50℃的鼓风环境中干燥90分钟制成硅酸铝耐火纤维，鼓风速率为3m/s，硅酸铝耐火纤维的直径为100μm～120μm。
实施例2
一种耐磨的硅酸铝耐火纤维，由以下组份制备而成：焦宝石粉末110g、氧化铝60g、二氧化硅45g、氮化硅34g、ABS树脂22.5g、聚氨酯20g、天然橡胶12.5g、炭黑1.5g、锆酯酸偶联剂2.5g、过氧化二异丙苯0.7g、二氧化硅气凝胶18g、分散剂0.4g、硼砂20g、耐火浸渍液22.5g，其中耐火浸渍液由以下组份混合而成：纳米级蛭石粉55g、磷酸铝粘结剂12.5g、钛白粉7g、液态硬化剂0.6g、水350g。
一种耐磨的硅酸铝耐火纤维的制备方法，包括以下步骤：
(1)将焦宝石粉末在600℃下煅烧1.5小时后与氧化铝、二氧化硅、氮化硅加热熔融混合得到熔融液，熔融温度为2400℃且熔融状态保持50分钟；
(2)熔融液经高温离心机甩丝处理得到直径为25μm～30μm的原丝，然后将原丝切断成长度为6μm～12μm的原丝段；
(3)将ABS树脂、聚氨酯、天然橡胶、炭黑、过氧化二异丙苯、二氧化硅气凝胶、分散剂、混匀并送入螺杆造粒机制成塑料粒子；
(4)加热熔融塑料粒子，投入原丝段、锆酯酸偶联剂、硼砂搅拌混合均匀，然后加热至225℃得到熔融浆液，搅拌速度25r/min；
(5)将熔融浆液送入纺丝装置纺丝，将所得纺丝送入真空环境中加热至1100℃并保持3.5小时后得到初级纤维；
(6)调节耐火浸渍液的pH值至6.5～6.8，将初级纤维置于45℃的耐火浸渍液中浸泡75分钟，然后置于55℃的鼓风环境中干燥105分钟制成硅酸铝耐火纤维，鼓风速率为4m/s，硅酸铝耐火纤维的直径为100μm～120μm。
实施例3
一种耐磨的硅酸铝耐火纤维，由以下组份制备而成：焦宝石粉末120g、氧化铝65g、二氧化硅40g、氮化硅36g、ABS树脂25g、聚氨酯22g、天然橡胶15g、炭黑2g、锆酯酸偶联剂3g、过氧化二异丙苯0.8g、二氧化硅气凝胶20g、分散剂0.6g、硼砂25g、耐火浸渍液25g，其中耐火浸渍液由以下组份混合而成：纳米级蛭石粉60g、磷酸铝粘结剂15g、钛白粉8g、液态硬化剂0.8g、水400g。
一种耐磨的硅酸铝耐火纤维的制备方法，包括以下步骤：
(1)将焦宝石粉末在650℃下煅烧2小时后与氧化铝、二氧化硅、氮化硅加热熔融混合得到熔融液，熔融温度为2500℃且熔融状态保持60分钟；
(2)熔融液经高温离心机甩丝处理得到直径为25μm～30μm的原丝，然后将原丝切断成长度为6μm～12μm的原丝段；
(3)将ABS树脂、聚氨酯、天然橡胶、炭黑、过氧化二异丙苯、二氧化硅气凝胶、分散剂、混匀并送入螺杆造粒机制成塑料粒子；
(4)加热熔融塑料粒子，投入原丝段、锆酯酸偶联剂、硼砂搅拌混合均匀，然后加热至240℃得到熔融浆液，搅拌速度30r/min；
(5)将熔融浆液送入纺丝装置纺丝，将所得纺丝送入真空环境中加热至1200℃并保持5小时后得到初级纤维；
(6)调节耐火浸渍液的pH值至6.5～6.8，将初级纤维置于50℃的耐火浸渍液中浸泡90分钟，然后置于60℃的鼓风环境中干燥120分钟制成硅酸铝耐火纤维，鼓风塑料为5m/s，硅酸铝耐火纤维的直径为100μm～120μm。
技术指标
本发明的实施例1～3中的硅酸铝耐火纤维与对比专利CN2016108849171中各项性能技术指标如表1、表2所示。
以1800℃×24h为测试单元，测试本发明的实施例1～3中的硅酸铝耐火纤维与对比专利CN2016108849171的实施例1～3中的硅酸铝耐火纤维分别承受的测试单元的个数，并测试各自的断裂强度与热收缩率。
表1
然后将本发明的实施例1～3中的硅酸铝耐火纤维与对比专利CN2016108849171的实施例1～3中的硅酸铝耐火纤维分别编织成毛毡，编织密度为200×250D，然后分别置于1800℃的环境中测试分别承受的测试单元的个数。
表2
从表1、表2可知，本发明的硅酸铝耐火纤维的强度高、耐高温稳定性好，而且制备的硅酸铝耐火纤维的耐高温稳定性好。
Claims (9)
1.一种耐磨的硅酸铝耐火纤维，其特征在于，由以下重量份组份制备而成：焦宝石粉末100～120份、氧化铝55～65份、二氧化硅30～40份、氮化硅32～36份、ABS树脂20～25份、聚氨酯18～22份、天然橡胶10～15份、炭黑1～2份、锆酯酸偶联剂2～3份、过氧化二异丙苯0.6～0.8份、二氧化硅气凝胶16～20份、分散剂0.2～0.6份、硼砂15～25份、耐火浸渍液20～25份。
2.根据权利要求1所述的耐磨的硅酸铝耐火纤维，其特征在于，所述耐火浸渍液由以下重量份组份混合而成：纳米级蛭石粉50～60份、磷酸铝粘结剂10～15份、钛白粉6～8份、液态硬化剂0.4～0.8份、水150～200份。
3.一种如权利要求1所述的耐磨的硅酸铝耐火纤维的制备方法，包括以下步骤：
（1）将焦宝石粉末煅烧后与氧化铝、二氧化硅、氮化硅加热熔融混合得到熔融液；
（2）熔融液经高温离心机甩丝处理得到原丝，并切断成长度为6 µm～12 µm的原丝段；
（3）将ABS树脂、聚氨酯、天然橡胶、炭黑、过氧化二异丙苯、二氧化硅气凝胶、分散剂、混匀并送入螺杆造粒机制成塑料粒子；
（4）加热熔融塑料粒子，投入原丝段、锆酯酸偶联剂、硼砂搅拌混合均匀制成熔融浆液；
（5）将熔融浆液送入纺丝装置纺丝，将所得纺丝送入真空环境中加热至1000 ℃～1200℃并保持2～5小时后得到初级纤维；
（6）在初级纤维置于耐火浸渍液中浸泡，然后置于50 ℃～60 ℃的鼓风环境中干燥制成硅酸铝耐火纤维。
4.根据权利要求3所述的耐磨的硅酸铝耐火纤维的制备方法，其特征在于，步骤（1）中的熔融温度为2300 ℃～2500 ℃，且熔融状态保持45～60分钟。
5.根据权利要求3所述的耐磨的硅酸铝耐火纤维的制备方法，其特征在于，步骤（1）中的焦宝石粉末煅烧温度为550 ℃～650 ℃，煅烧时间1～2小时。
6.根据权利要求3所述的耐磨的硅酸铝耐火纤维的制备方法，其特征在于，步骤（2）中所得原丝的直径为25 µm～30 µm。
7.根据权利要求3所述的耐磨的硅酸铝耐火纤维的制备方法，其特征在于，步骤（4）中的熔融温度为210 ℃～240 ℃，搅拌速度20 r/min～30 r/min。
8.根据权利要求3所述的耐磨的硅酸铝耐火纤维的制备方法，其特征在于，步骤（6）中的浸泡温度为40 ℃～50 ℃、浸泡时间60～90分钟，耐火浸渍液的pH值为6.5～6.8。
9.根据权利要求3所述的耐磨的硅酸铝耐火纤维的制备方法，其特征在于，步骤（6）中鼓风速率为3 m/s～5 m/s，干燥时间90～120分钟，硅酸铝耐火纤维的直径为100 µm～120µm。
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