CN109457386B - Ceramic fiber integral module and preparation method thereof - Google Patents

Ceramic fiber integral module and preparation method thereof Download PDF

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Publication number
CN109457386B
CN109457386B CN201811641238.7A CN201811641238A CN109457386B CN 109457386 B CN109457386 B CN 109457386B CN 201811641238 A CN201811641238 A CN 201811641238A CN 109457386 B CN109457386 B CN 109457386B
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ceramic fiber
fiber
weight
integral
needling
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CN109457386A (en
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荆桂花
赵生祥
岳耀辉
郑爱杰
张玉磊
刘焕英
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Luyang Energy Saving Materials Co Ltd
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Luyang Energy Saving Materials Co Ltd
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • 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
    • C04B35/62227—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products obtaining fibres
    • C04B35/62231—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products obtaining fibres based on oxide ceramics
    • C04B35/62236—Fibres based on aluminium oxide
    • 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
    • C04B35/62227—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products obtaining fibres
    • C04B35/62231—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products obtaining fibres based on oxide ceramics
    • C04B35/6224—Fibres based on silica
    • C04B35/62245—Fibres based on silica rich in aluminium oxide
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • 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
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3231—Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
    • C04B2235/3244—Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof
    • C—CHEMISTRY; METALLURGY
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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
    • C04B2235/77—Density
    • 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
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
    • 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
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
    • C04B2235/9607—Thermal properties, e.g. thermal expansion coefficient

Abstract

The invention belongs to the field of heat insulation materials, and particularly relates to a ceramic fiber integral module and a preparation method thereof. The preparation method provided by the invention comprises the following steps: a) sequentially melting and forming fibers of the ceramic fiber raw material to obtain ceramic fiber filaments; b) collecting cotton of the ceramic fiber yarns to obtain a ceramic fiber blank; c) and carrying out roller needling on the ceramic fiber blank to obtain the ceramic fiber integral module. The ceramic fiber module with the integral blocky structure is prepared by melting, fiber forming, cotton collecting and roller needling of a ceramic fiber raw material. The preparation method does not need to carry out folding and extrusion processing in the process of preparing the ceramic fiber module, and has low rejection rate; the prepared ceramic fiber module is of an integral block structure, can realize multidirectional extrusion expansion, is large in capacity, does not need a compensation blanket in the construction process, reduces the construction difficulty, obviously improves the heat preservation effect, and is high in airflow scouring resistance and longer in service life.

Description

Ceramic fiber integral module and preparation method thereof
Technical Field
The invention belongs to the field of heat insulation materials, and particularly relates to a ceramic fiber integral module and a preparation method thereof.
Background
The ceramic fiber module is a novel refractory lining product which is pushed out for simplifying and accelerating kiln construction and improving lining integrity. The product has white color and regular size, can be directly fixed on the anchoring nails of the steel plate of the furnace shell of the industrial furnace, has good fire-resistant and heat-insulating effects, improves the integrity of the fire resistance and heat insulation of the furnace, and promotes the progress of the furnace masonry technology.
At present, most of the modules used by domestic ceramic fiber manufacturers are folded blocks as shown in figure 1. The structural moduleThe preparation process generally comprises the steps of firstly preparing the ceramic fiber blanket, wherein the volume weight of the ceramic fiber blanket prepared by the prior art is 160kg/m at most3The maximum thickness is 60 mm; and then carrying out secondary folding, extrusion, cutting and other processes on the ceramic fiber blanket to obtain the ceramic fiber module. The production process of the module is complex and has long period; and the folded ceramic fiber blanket is easy to damage the fiber due to extrusion, so that the volume weight of the product is reduced, and the heat insulation performance is reduced; meanwhile, fiber waste products are generated in the cutting process, so that the fiber utilization rate is low and the cost is high; and the size of the folded block is very regular and difficult to be made, and the folded block can only expand in the extrusion direction in the use process, so that the contraction in the cutting direction is large, the gap possibly causes fire leaping, a compensation blanket needs to be used, and the construction difficulty is increased. In addition, the fiber of the prior folding block is easy to be pulverized when in use, and the airflow scouring resistance is generally poor, so that the service life of the folding block is short and the folding block needs to be frequently replaced.
Disclosure of Invention
In view of the above, the present invention aims to provide a ceramic fiber integral module and a method for manufacturing the same, which does not require folding and extrusion processing during the process of manufacturing the ceramic fiber module and has a low rejection rate; the prepared ceramic fiber module is of an integral block structure, can realize multidirectional extrusion expansion, is large in capacity, does not need a compensation blanket in the construction process, reduces the construction difficulty, obviously improves the heat preservation effect, and is high in airflow scouring resistance and longer in service life.
The invention provides a preparation method of a ceramic fiber integral module, which comprises the following steps:
a) sequentially melting and forming fibers of the ceramic fiber raw material to obtain ceramic fiber filaments;
b) collecting cotton of the ceramic fiber yarns to obtain a ceramic fiber blank;
c) and carrying out roller needling on the ceramic fiber blank to obtain the ceramic fiber integral module.
Preferably, in step a), the ceramic fiber raw material comprises, by weight:
Al2O332-56 parts;
SiO230-60 parts;
ZrO 20 to 24 parts.
Preferably, in step a), the molten liquid obtained after melting is fiberized in the presence of a grease.
Preferably, in step a), the grease comprises one or more of primary octadecylamine acetate, cocoamine polyoxyethylene ether, cocoalkyl primary amine acetate, polyols, cocoalkyl amino thioacetate and polyethylene wax emulsion;
the mass ratio of the lubricating grease to the molten liquid is (0.2-1.2): 100.
preferably, in step a), the fiber forming mode is centrifugal spinning or blowing fiber forming.
Preferably, the centrifugal wire throwing is carried out in a wire throwing machine, and the roll frequency of the wire throwing machine is 40-70 Hz;
the blowing pressure of the blowing fiber forming is 0.3-0.7 MPa.
Preferably, the roll frequency of the wire throwing machine is 50-60 Hz; the blowing pressure of the blowing fiber forming is 0.35-0.5 MPa.
Preferably, in step c), the roller needling is performed in a roller needling machine.
Preferably, the step c) further comprises:
and cutting the ceramic fiber blank after roller needling.
Preferably, the cutting mode is water cutting.
Preferably, the method further comprises the following steps:
d) the scraps produced in the cutting process are crushed and then returned to the step b) for cotton collection.
Preferably, in the step c), the needling density of the ceramic fiber integral module is 3-20 needles/cm2(ii) a The volume weight of the ceramic fiber integral module is 160-260 kg/m3(ii) a The thickness of the ceramic fiber integral module is 100-240 mm.
The invention provides a ceramic fiber integral module prepared by the preparation method according to the technical scheme.
Compared with the prior art, the invention provides a ceramic fiber integral module and a preparation method thereof. The preparation method provided by the invention comprises the following steps: a) sequentially melting and forming fibers of the ceramic fiber raw material to obtain ceramic fiber filaments; b) collecting cotton of the ceramic fiber yarns to obtain a ceramic fiber blank; c) and carrying out roller needling on the ceramic fiber blank to obtain the ceramic fiber integral module. The ceramic fiber module with the integral blocky structure is prepared by melting, fiber forming, cotton collecting and roller needling of a ceramic fiber raw material. The preparation method does not need to fold and extrude the fiber material, can realize continuous production, and has simple process; in the preferred scheme of the invention, the leftover materials generated in the cutting process are returned to the cotton collecting process for reuse, so that the utilization rate of the ceramic fibers can be improved, and the rejection rate is reduced. Meanwhile, the product prepared by the method has the advantages of large volume weight, good expansibility and good integrity, so that the ceramic fiber integral module prepared by the method does not need to use a compensation blanket in the construction process, the construction difficulty is low, and the heat insulation effect is good. In addition, the ceramic fiber integral module prepared by the method also has good airflow scouring resistance and longer service life. The experimental results show that: the ceramic fiber integral module prepared by the method is of a uniform integral blocky structure, can realize four-side expansion, and has the volume weight of 160-260 kg/m3The heat conductivity coefficient of the material at the average temperature of 500 ℃ is less than 0.16w/m.k, and the sustainable air flow rate is 45 m/s.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the provided drawings without creative efforts.
FIG. 1 is a schematic structural view of a ceramic fiber module prepared by a prior art folding extrusion process;
FIG. 2 is a schematic structural diagram of a ceramic fiber monolithic module article according to an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention are clearly and completely described below, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all 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.
The invention provides a preparation method of a ceramic fiber integral module, which comprises the following steps:
a) sequentially melting and forming fibers of the ceramic fiber raw material to obtain ceramic fiber filaments;
b) collecting cotton of the ceramic fiber yarns to obtain a ceramic fiber blank;
c) and carrying out roller needling on the ceramic fiber blank to obtain the ceramic fiber integral module.
In the preparation method provided by the invention, the ceramic fiber raw material is firstly melted. Wherein, Al is preferably included in the ceramic fiber raw material2O3And SiO2(ii) a The Al is2O3The content in the ceramic fiber raw material is preferably 32 to 56 parts by weight, and specifically may be 32 parts by weight, 33 parts by weight, 34 parts by weight, 35 parts by weight, 36 parts by weight, 37 parts by weight, 38 parts by weight, 39 parts by weight, 40 parts by weight, 41 parts by weight, 42 parts by weight, 43 parts by weight, 44 parts by weight, 45 parts by weight, 46 parts by weight, 47 parts by weight, 48 parts by weight, 49 parts by weight, 50 parts by weight, 51 parts by weight, 52 parts by weight, 53 parts by weight, 54 parts by weight, 55 parts by weight or 56 parts by weight; the SiO2The content in the ceramic fiber raw material is preferably 30 to 60 parts by weight, and specifically may be 30 parts by weight, 31 parts by weight, 32 parts by weight, 33 parts by weight, 34 parts by weight, 35 parts by weight, 36 parts by weight, 37 parts by weight, 38 parts by weight, 39 parts by weight, 40 parts by weight, 41 parts by weight, 42 parts by weight, 43 parts by weight, 44 parts by weight, 45 parts by weight, 46 parts by weight, 47 parts by weight, 48 parts by weight, 49 parts by weight, 50 parts by weight, 51 parts by weight, 52 parts by weight, 53 parts by weight, 5 parts by weight4 parts by weight, 55 parts by weight, 56 parts by weight, 57 parts by weight, 58 parts by weight, 59 parts by weight or 60 parts by weight. In the present invention, it is preferable that ZrO be further included in the ceramic fiber raw material2Of said ZrO2The content in the ceramic fiber raw material is preferably 0 to 24 parts by weight, and specifically may be 0, 1 part by weight, 2 parts by weight, 3 parts by weight, 4 parts by weight, 5 parts by weight, 6 parts by weight, 7 parts by weight, 8 parts by weight, 9 parts by weight, 10 parts by weight, 11 parts by weight, 12 parts by weight, 13 parts by weight, 14 parts by weight, 15 parts by weight, 16 parts by weight, 17 parts by weight, 18 parts by weight, 19 parts by weight, 20 parts by weight, 21 parts by weight, 22 parts by weight, 23 parts by weight, or 24 parts by weight. In the present invention, the melting temperature is preferably 1600 to 2500 ℃, and specifically may be 1600 ℃, 1650 ℃, 1700 ℃, 1750 ℃, 1800 ℃, 1850 ℃, 1900 ℃, 1950 ℃, 2000 ℃, 2050 ℃, 2100 ℃, 2150 ℃, 2200 ℃, 2250 ℃, 2300 ℃, 2350 ℃, 2400 ℃, 2450 ℃ or 2500 ℃. And melting the ceramic fiber raw material to obtain molten liquid.
In the present invention, after obtaining a melt, the melt is fiberized. Wherein the melt is preferably fiberized in the presence of a grease including, but not limited to, one or more of stearylamine acetate, cocoamine polyoxyethylene ether, cocoalkylamine acetate, polyols, cocoalkylaminothioacetate, and polyethylene wax emulsion; the mass ratio of the lubricating grease to the molten liquid is preferably (0.2-1.2): 100, specifically 0.2:100, 0.3:100, 0.4:100, 0.5:100, 0.6:100, 0.7:100, 0.8:100, 0.9:100, 1:100, 1.1:100 or 1.2: 100. In the present invention, the fiber-forming method is preferably centrifugal spinning or blowing fiber-forming. The centrifugal spinning is preferably carried out in a spinning machine, the roll frequency of the spinning machine is preferably 40-70 Hz, more preferably 50-60 Hz, and specifically can be 40Hz, 41Hz, 42Hz, 43Hz, 44Hz, 45Hz, 46Hz, 47Hz, 48Hz, 49Hz, 50Hz, 51Hz, 52Hz, 53Hz, 54Hz, 55Hz, 56Hz, 57Hz, 58Hz, 59Hz, 60Hz, 61Hz, 62Hz, 63Hz, 64Hz, 65Hz, 66Hz, 67Hz, 68Hz, 69Hz or 70 Hz; the fiber forming distance of the centrifugal spinning is preferably 800-1500 mm, and specifically can be 800mm, 850mm, 900mm, 950mm, 1000mm, 1050mm, 1100mm, 1150mm, 1200mm, 1250mm, 1300mm, 1350mm, 1400mm, 1450mm or 1500 mm. In the present invention, the fiber-forming distance is a distance from the melt flowing out of the melting apparatus to the spinning roller of the spinning machine. In the present invention, the blowing pressure of the blown fiber is preferably 0.3 to 0.7MPa, more preferably 0.35 to 0.5MPa, and specifically may be 0.35MPa, 0.36MPa, 0.37MPa, 0.38MPa, 0.39MPa, 0.4MPa, 0.41MPa, 0.42MPa, 0.43MPa, 0.44MPa, 0.45MPa, 0.46MPa, 0.47MPa, 0.48MPa, 0.49MPa or 0.5 MPa. And forming fibers from the molten liquid to obtain ceramic fiber filaments, wherein the diameter of the ceramic fiber filaments is preferably 2-6 μm, and specifically can be 2 μm, 2.5 μm, 3 μm, 3.1 μm, 3.2 μm, 3.3 μm, 3.4 μm, 3.5 μm, 3.6 μm, 3.7 μm, 3.8 μm, 3.9 μm, 4 μm, 4.5 μm, 5 μm, 5.5 μm or 6 μm.
In the invention, after the ceramic fiber yarn is obtained, the ceramic fiber yarn is subjected to cotton collection to obtain a ceramic fiber blank. Wherein the cotton collection is preferably carried out in a cotton collection machine; the thickness of the ceramic fiber blank is preferably 50-500 mm, and specifically can be 50mm, 80mm, 100mm, 120mm, 150mm, 170mm, 200mm, 230mm, 250mm, 280mm, 300mm, 320mm, 350mm, 370mm, 400mm, 420mm, 450mm, 470mm or 500 mm.
According to the invention, after the ceramic fiber blank is obtained, the ceramic fiber blank is subjected to roller needling to obtain the ceramic fiber integral module. Wherein the roller needling is preferably carried out in a roller needling machine; the needling density of the ceramic fiber integral module is preferably 3-20 needles/cm2Specifically, it can be 3 needles/cm24 needles/cm25 needles/cm26 needles/cm27 needles/cm28 needles/cm29 needles/cm210 needles/cm211 needles/cm212 needles/cm213 needles/cm214 needles/cm215 needles/cm216 needles/cm217 needles/cm218 needles/cm219 needles/cm2Or 20 needles/cm2(ii) a The volume weight of the ceramic fiber integral module is preferably 160-260 kg/m3Specifically, it may be 160kg/m3、165kg/m3、170kg/m3、175kgm3、180kg/m3、185kg/m3、190kg/m3、195kg/m3、200kg/m3、205kg/m3、210kg/m3、215kg/m3、220kg/m3、225kg/m3、230kg/m3、235kg/m3、240kg/m3、245kg/m3、250kg/m3、255kg/m3Or 260kg/m3(ii) a The thickness of the ceramic fiber integral module is preferably 100-240 mm, and specifically can be 100mm, 110mm, 120mm, 130mm, 140mm, 150mm, 160mm, 170mm, 180mm, 190mm, 200mm, 210mm, 220mm, 230mm or 240 mm. In the invention, the ceramic fiber integral module obtained by roller needling is preferably cut to change the shape of the ceramic fiber integral module, thereby meeting the requirements of different use scenes; the cutting mode is preferably water cutting; the pressure of the water cutting is preferably 10-38 MPa, and specifically 10MPa, 12MPa, 14MPa, 16MPa, 18MPa, 20MPa, 22MPa, 24MPa, 26MPa, 28MPa, 30MPa, 32MPa, 34MPa, 36MPa or 38 MPa. In the present invention, in order to improve the utilization rate of the ceramic fibers and reduce the rejection rate, it is preferable to crush the scrap generated in the cutting process and return the scrap to the collecting step.
In the invention, after the ceramic fiber integral module is prepared, a plurality of ceramic fiber integral modules can be spliced according to actual needs to obtain a product meeting the requirements of customers. In one embodiment of the present invention, an article having a structure as shown in fig. 2 can be prepared, and fig. 2 is a schematic structural view of a ceramic fiber monolithic module article according to an embodiment of the present invention. In fig. 2, 1 is a first ceramic fiber monolith module; 2 is a second ceramic fiber monolithic module; 3 is an anchoring part used for connecting the two ceramic fiber integral modules; 4, protective plates are positioned on two sides of the ceramic fiber integral module product; and 5, a binding belt for fixing the protection sheet.
The ceramic fiber module with the integral blocky structure is prepared by melting, fiber forming, cotton collecting and roller needling of a ceramic fiber raw material. The preparation method does not need to fold and extrude the fiber material, can realize continuous production, and has simple process; in the preferred scheme of the invention, the leftover materials generated in the cutting process are returned to the cotton collecting process for reuse, so that the utilization rate of the ceramic fibers can be improved, and the rejection rate is reduced. Meanwhile, the product prepared by the method has the advantages of large volume weight, good expansibility and good integrity, so that the ceramic fiber integral module prepared by the method does not need to use a compensation blanket in the construction process, the construction difficulty is low, and the heat insulation effect is good. In addition, the ceramic fiber integral module prepared by the method also has good airflow scouring resistance and longer service life.
In the preferred technical scheme provided by the invention, a certain amount of lubricating grease is added during fiber forming, so that the volume weight of the product can be further improved, the heat conductivity coefficient of the product is reduced, and the heat insulation effect of the product is improved.
In the preferred technical scheme provided by the invention, during fiber forming, the roller frequency of the filament throwing machine is adjusted to 50-60 Hz or the blowing pressure of blowing fiber forming is adjusted to 0.35-0.5 MPa, so that the slag ball content in the product is lower than 8wt%, and the heat preservation effect is further improved.
In the preferred technical scheme provided by the invention, the ceramic fiber integral module obtained by roller needling is subjected to water cutting, and the ceramic fiber integral module can be changed into any shape, so that the product can meet different requirements of the market to a greater extent.
The experimental results show that: the ceramic fiber integral module prepared by the method is of a uniform integral blocky structure, can realize four-side expansion, and has the volume weight of 160-260 kg/m3The heat conductivity coefficient of the material at the average temperature of 500 ℃ is less than 0.16w/m.k, and the sustainable air flow rate is 45 m/s.
The invention also provides a ceramic fiber integral module prepared by the preparation method of the technical scheme. The ceramic fiber integral module provided by the invention is prepared by adopting the method, so that the ceramic fiber integral module is of an integral block structure, can realize multidirectional extrusion expansion, has a large volume, does not need a compensation blanket in the construction process, reduces the construction difficulty, obviously improves the heat preservation effect, has high airflow scouring resistance and has a longer service life.
For the sake of clarity, the following examples are given in detail.
Example 1
Mixing the required raw materials of alumina, silica powder and zircon sand according to Al2O3：SiO2：ZrO245: 35: 20, uniformly mixing; then melting at 2100 ℃, throwing the obtained molten liquid in a throwing machine, wherein the roll frequency of the throwing machine is set to be 52Hz, the fiber forming distance is 1000mm, and the ceramic fiber wire with the diameter of 3.4 mu m is obtained; then processing the ceramic fiber filaments in a cotton collector to form a ceramic fiber blank with the thickness of 120 mm; then the formed ceramic fiber blank is formed by needling in a roller needling machine, and the needling density of the formed product is 10 needles/cm2The volume weight is 160kg/m3The thickness is 180 mm; finally, the molded product is subjected to water cutting under the water cutting pressure of 22MPa, so that the fiber integral block is obtained.
Two of the above-mentioned fiber blocks were connected by an anchor, and then protective sheets were placed on both sides thereof and fixed by a binding tape to obtain a ceramic fiber block-shaped product as shown in FIG. 2.
The fiber monolith prepared in this example was tested and the results were: the slag ball content is 7 wt%, and the heat conductivity coefficient at the average temperature of 500 ℃ is 0.152 w/m.k; the air flow of 45m/s impacts for 72h without cracking and crushing.
Example 2
Mixing the required raw materials of alumina and silica powder according to Al2O3：SiO245: 55, mixing uniformly; then melting at 2200 ℃, throwing the obtained melt in a throwing machine, adding coconut alkyl amino thioacetate accounting for 0.8wt% of the mass of the melt in the throwing process, setting the roll frequency of the throwing machine to be 56Hz, and setting the fiber forming distance to be 1000mm to obtain ceramic fiber wires with the diameter of 3.1 mu m; then processing the ceramic fiber filaments in a cotton collector to form a ceramic fiber blank with the thickness of 150 mm; then the formed ceramic fiber blank is formed by needling in a roller needling machine, and the needling density of the formed product is 10 needles/cm2The volume weight is 200kg/m3The thickness is 150 mm; finally, the molded product is subjected to water cutting under the water cutting pressure of 22MPa, so that the fiber integral block is obtained.
Two of the above-mentioned fiber blocks were connected by an anchor, and then protective sheets were placed on both sides thereof and fixed by a binding tape to obtain a ceramic fiber block-shaped product as shown in FIG. 2.
The fiber monolith prepared in this example was tested and the results were: the slag ball content is 7 wt%, and the heat conductivity coefficient at the average temperature of 500 ℃ is 0.132 w/m.k; the air flow of 45m/s impacts for 72h without cracking and crushing.
Example 3
Mixing the required raw materials of alumina and silica powder according to Al2O3：SiO245: 55, mixing uniformly; then melting at 2100 ℃, throwing the obtained molten liquid in a throwing machine, adding coconut alkyl amino thioacetate accounting for 0.8wt% of the mass of the molten liquid in the throwing process, setting the roll frequency of the throwing machine to be 52Hz, and setting the fiber forming distance to be 800mm to obtain ceramic fiber wires with the diameter of 3.2 mu m; then processing the ceramic fiber filaments in a cotton collector to form a ceramic fiber blank with the thickness of 150 mm; then the formed ceramic fiber blank is formed by needling in a roller needling machine, and the needling density of the formed product is 12 needles/cm2The volume weight is 210kg/m3The thickness is 150 mm; finally, the molded product is subjected to water cutting under the water cutting pressure of 23MPa, so that the fiber integral block is obtained.
Two of the above-mentioned fiber blocks were connected by an anchor, and then protective sheets were placed on both sides thereof and fixed by a binding tape to obtain a ceramic fiber block-shaped product as shown in FIG. 2.
The fiber monolith prepared in this example was tested and the results were: the slag ball content is 7 wt%, and the heat conductivity coefficient at the average temperature of 500 ℃ is 0.129 w/m.k; the air flow of 45m/s impacts for 72h without cracking and crushing.
Therefore, after the lubricating grease is added, the volume weight of the product can be improved, the heat conductivity coefficient of the product is reduced, and the heat insulation effect of the product is improved.
The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and decorations can be made without departing from the principle of the present invention, and these modifications and decorations should also be regarded as the protection scope of the present invention.

Claims (3)

1. A method of making a ceramic fiber monolithic modular article comprising the steps of:
mixing the required raw materials of alumina, silica powder and zircon sand according to Al2O3：SiO2：ZrO2= 45: 35: 20, uniformly mixing the components in a mass ratio; then melting at 2100 ℃, throwing the obtained molten liquid in a throwing machine, wherein the roll frequency of the throwing machine is set to be 52Hz, the fiber forming distance is 1000mm, and the ceramic fiber wire with the diameter of 3.4 mu m is obtained; then processing the ceramic fiber filaments in a cotton collector to form a ceramic fiber blank with the thickness of 120 mm; then the formed ceramic fiber blank is formed by needling in a roller needling machine, and the needling density of the formed product is 10 needles/cm2The volume weight is 160kg/m3The thickness is 180 mm; then, performing water cutting on the molded product, wherein the water cutting pressure is 22MPa, and obtaining a fiber integral block; and finally, connecting the two fiber integral blocks by using an anchoring part, arranging protective plates on two sides of the fiber integral blocks and fixing the protective plates by using a binding belt to obtain the ceramic fiber integral module product.
2. A method of making a ceramic fiber monolithic modular article comprising the steps of:
mixing the required raw materials of alumina and silica powder according to Al2O3：SiO2= 45: 55, uniformly mixing the components in a mass ratio; then melting at 2200 ℃, throwing the obtained melt in a throwing machine, adding coconut alkyl amino thioacetate accounting for 0.8wt% of the mass of the melt in the throwing process, setting the roll frequency of the throwing machine to be 56Hz, and setting the fiber forming distance to be 1000mm to obtain ceramic fiber wires with the diameter of 3.1 mu m; then processing the ceramic fiber filaments in a cotton collector to form a ceramic fiber blank with the thickness of 150 mm; then the formed ceramic fiber blank is formed by needling in a roller needling machine, and the needling density of the formed product is 10 needles/cm2The volume weight is 200kg/m3The thickness is 150 mm; then, performing water cutting on the molded product, wherein the water cutting pressure is 22MPa, and obtaining a fiber integral block; finally, connecting the two fiber integrated blocks by using an anchoring part,protective plates are arranged on two sides of the ceramic fiber and are fixed by a binding belt, and a ceramic fiber integral module product is obtained.
3. A method of making a ceramic fiber monolithic modular article comprising the steps of:
mixing the required raw materials of alumina and silica powder according to Al2O3：SiO2= 45: 55, uniformly mixing the components in a mass ratio; then melting at 2100 ℃, throwing the obtained molten liquid in a throwing machine, adding coconut alkyl amino thioacetate accounting for 0.8wt% of the mass of the molten liquid in the throwing process, setting the roll frequency of the throwing machine to be 52Hz, and setting the fiber forming distance to be 800mm to obtain ceramic fiber wires with the diameter of 3.2 mu m; then processing the ceramic fiber filaments in a cotton collector to form a ceramic fiber blank with the thickness of 150 mm; then the formed ceramic fiber blank is formed by needling in a roller needling machine, and the needling density of the formed product is 12 needles/cm2The volume weight is 210kg/m3The thickness is 150 mm; then, performing water cutting on the molded product, wherein the water cutting pressure is 23MPa, and obtaining a fiber integral block; and finally, connecting the two fiber integral blocks by using an anchoring part, arranging protective plates on two sides of the fiber integral blocks and fixing the protective plates by using a binding belt to obtain the ceramic fiber integral module product.
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