JPH0437657A - Production of fiber-containing refractory - Google Patents

Abstract

PURPOSE:To satisfactorily disperse an arbitrary amt. of relatively long fibers in refractories by mixing fireproof fibers with a liq. having specified viscosity in a specified ratio under shear, further mixing this mixture with refractory starting material, removing the liq. from the resulting mixture, drying this mixture, adding a binder and carrying out molding, drying and firing. CONSTITUTION:Fireproof fibers having 1-30mum average diameter and 0.01-100mm length are used by 0.1-80 pts.wt. per 100 pts.wt. refractory starting material. The fibers are uniformly dispersed in a liq. having <=0.1Pa.sec viscosity in >=100 volume ratio of the fibers to the liq. by mixing under shear, the refractory starting material is added and they are mixed to obtain a mixture. The liq. is then removed from the mixture, this mixture is dried, a binder is added and they are molded into a desired shape, dried and properly fired.

Description

[Detailed description of the invention] [Industrial application field] The present invention relates to a method for manufacturing a fiber-containing refractory.

[Prior Art] Conventionally, fibers have been dispersed in refractories and ceramic molded bodies to strengthen them.

For example, Japanese Patent Application Laid-open No. 59-207871 discloses that 0.5 to 100 parts of metallic magnesium powder is added to 100 parts by weight of a mixture of 50 to 90% by weight of magnesia clinker and 50 to 10% by weight of scaly graphite containing 97% by weight or more of fixed carbon. A magnesia carbon brick is disclosed which contains 10 parts by weight and 0.1 to 10 parts by weight of carbon fibers having a diameter of 3 to 100 μm.

In addition, Japanese Patent Application Laid-open No. 62-57059 discloses fiber-reinforced 5
As a method for producing iaN-ceramics, a slurry obtained by dispersing Si powder and ceramic fibers in a solvent is placed in a mold that allows only the solvent to pass therethrough, and by applying centrifugal force, the slurry is dispersed in parallel to the inner surface of the mold. A method is disclosed which consists in obtaining a Si molded body with oriented fibers.

[Problems to be Solved by the Invention] However, in the magnesia carbon brick disclosed in JP-A No. 59-207871, as a method for dispersing carbon fiber, fine powder, graphite, metallic magnesium, and carbon fiber are mixed together. A method is adopted in which the mixture is mixed in a Henschel mixer, and then medium grains are added and mixed in a kneader. In this method, the carbon fibers are crushed and turned into fiber pokers in the Henschel mixer, and the carbon fibers are completely crushed in the kneader, causing the risk of the carbon fibers being shredded and rendered useless. This is mainly because the magnesia grains cut the fibers.

Furthermore, the manufacturing method disclosed in JP-A No. 62-216969 is mainly intended to use whiskers as a fiber material, and this method is required to mix relatively long fibers into refractory raw materials. It cannot be applied as is.

Therefore, an object of the present invention is to provide a novel method for producing a fiber-containing refractory material, which allows relatively long fibers to be dispersed in any desired amount in the refractory material.

[Means for Solving the Problems] That is, the present invention provides 0.00 parts per 100 parts by weight of the refractory raw material described below.
1 to 80 parts by weight, average diameter 1 to 30 μm, length 0.01 to
100 mIIl of refractory fiber and a viscosity of 0.1 Pascal/second or less are mixed under shearing force at a fiber/liquid volume ratio of 1/(100 or more) to uniformly disperse the refractory fiber in the liquid, and then Add the entire amount of refractory raw materials and further mix to obtain a mixture, remove the liquid from the mixture, dry it, further add a binder, shape it into a desired shape, dry it, and bake it as appropriate. The present invention relates to a method for producing a fiber-containing refractory, characterized by: Furthermore, the present invention provides 0.1 to 80 parts by weight of an average diameter of 1 to 30 μ■ and a length of 0 per 100 parts by weight of the refractory raw material described below.
．． 01-100I fireproof fiber and viscosity 0.1 Pascal.
The refractory fibers are mixed under shearing force at a fiber/liquid volume ratio of 1/(100 or more) for a few seconds or less to uniformly disperse the refractory fibers in the liquid, and then a part of the refractory raw material is added and further mixed. to obtain a mixture, remove the liquid from the mixture, dry it, add a binder, then add the remainder of the refractory material, shape it into the desired shape, dry it, and optionally fire it. The present invention relates to a method for producing a characterized fiber-containing refractory.

[Function] The method for producing fiber-containing refractories of the present invention is a breakthrough that has not been seen in previous methods for producing fiber-containing refractories in that relatively long fibers can be dispersed in any amount in the refractory material. This is a typical method.

The refractory material used in the present invention is not particularly limited, and can be used in a wide range from basic refractory materials to non-basic refractory materials, such as alumina, silicon carbide, magnesia, zirconia, etc. .

The refractory fibers used in the method of the present invention are not particularly limited, and conventional fibers can be used, such as carbon fibers, graphite fibers, alumina fibers, and zirconia fibers. The shape of the refractory fibers is not particularly limited, and the method of the present invention is characterized in that a relatively large amount of relatively long fibers can be added; the refractory fibers usually have an average diameter of 1 to 30 μm, The length is about 0, O1 to 100Ill111. Further, the amount of the refractory fiber added is not particularly limited, but is usually within the range of 0.1 to 80 parts by weight per 100 parts by weight of the refractory material. The lower limit of the amount of refractory fiber added is not particularly limited, but less than 0.1 parts by weight is not preferred because there is no effect of the addition.

Moreover, if it exceeds 80 parts by weight, the addition amount of the refractory material will be small and the properties of the refractory material will be affected, which is not preferable.

Next, the method of the present invention will be explained in detail.

First, refractory fibers in the range of 0.1 to 80 parts by weight per 100 parts by weight of the refractory material and a liquid with a viscosity of 0.1 buscal seconds or less are sheared at the fiber/liquid volume ratio of 1/(100 or more). Uniformly disperse the refractory fibers in the liquid under application.

Note that when the refractory fibers are in the form of chipped strands or fiber balls, the carbon fibers need to be defibrated before use.

The defibration process can be carried out using a conventional defibrator, high-speed mixer, or the like.

As the liquid having a viscosity of 0.1 Pascal·sec or less used in this dispersion operation, water, alcohol, ether, acetone, or phenol resin, epoxy resin, etc. whose viscosity is lowered by diluting them with these can be used. The amount of these liquids used is determined by the refractory line [/liquid volume ratio 1/<
100 or more).

If the amount of the liquid is 1/(less than 100) in terms of fireproof fiber/liquid volume ratio, the shearing force of the liquid will not work effectively, which is not preferable.

The dispersion operation can be carried out by applying shearing force to the mixture consisting of the refractory fibers and the liquid.

For the operation of applying this shearing force, for example, an omnimixer can be used. 6 By loading the above mixture into an omnimixer and treating it under shearing force, the refractory fibers are uniformly dispersed in the liquid. can be done.

Next, a refractory material is added in whole or in part to the dispersion obtained as described above to further obtain a mixture.

This operation is preferably carried out in an omnimixer following the dispersion operation; it is preferred to add a small amount of surfactant to the dispersion before adding the refractory material. As the surfactant, it is preferable to use, for example, soaps with low foaming properties, dispersants, etc., and, if necessary, an antifoaming agent.

This operation allows the refractory fibers to be randomly dispersed in the refractory material.

Next, the liquid portion is removed from the obtained mixture by an operation such as filtration, and then the refractory material f4/refractory fiber composite can be obtained by drying at a temperature of about 150 to 200°C.

An unfired fiber-containing refractory can be obtained by adding a binder to this refractory material/refractory fiber composite, or by adding the remainder of the refractory material and a binder and molding it into a predetermined shape.

Further, by firing the appropriately obtained unfired fiber-containing refractory, a fired fiber-containing refractory can be obtained.

[Example] The present invention will be further explained with reference to Examples below.

Example: First, a predetermined amount of defibrated refractory fibers and 6R water (approximately 1000 times the weight of the refractory fibers) were loaded into an omnimixer, and processed at a rotational speed of 6 Hz or higher to make the fireproof fibers underwater. The fibers were evenly dispersed.

Next, M 1ran was added to the obtained dispersion as a surfactant.
After adding 0.1 ml of OL HM and a few drops of silicone oil, a predetermined amount of refractory raw material constituting a fine powder part of 50 mesh or less is added, and the refractory raw material is further processed at a rotation speed of 6 Hz or more. A dispersion in which refractory fibers were randomly dispersed was obtained.

next,? Water was removed from the dispersion by filtration, and a refractory containing refractory fibers was obtained by drying at a temperature of 150° C. for 5 hours.

Next, a predetermined amount of a binder was added to the refractory containing refractory fibers, and 50 or more meshes of refractory raw materials previously treated with a binder were added and mixed to obtain the refractory containing refractory fibers of the present invention.

The resulting mixture was molded to 1230mm x wl 14m.
A molded body with dimensions of m×h60 mm was obtained.

Next, either the molded body is made into an unfired product as it is, or the first
A fired product was obtained by firing for 5 hours under the conditions shown in the table. The hot strength and fracture energy of the obtained unfired and fired products at 1000° C. were measured and the results are also listed in Table 1.

[Effects of the Invention] According to the method of the present invention, it is possible to randomly disperse an arbitrary amount of relatively long refractory fibers into a refractory, and to fully bring out the reinforcing effect of the refractory fibers on the refractory. be able to.

Patent applicant Shinagawa White Brick Co., Ltd.

Claims (2)

[Claims] 1. 0.1 to 80 parts by weight per 100 parts by weight of the refractory raw material described below, average diameter 1 to 30 μm, length 0.01 to 100 mm
The refractory fibers having a viscosity of 0.1 Pa/sec or less are mixed under shearing force at the fiber/liquid volume ratio of 1/(100 or more) to uniformly disperse the refractory fibers in the liquid, and then, It is characterized by adding the entire amount of refractory raw materials and further mixing to obtain a mixture, removing the liquid from the mixture, drying, adding a binder, shaping into a desired shape, drying, and firing as appropriate. A method for manufacturing a fiber-containing refractory. 2. 0.1 to 80 parts by weight per 100 parts by weight of the refractory raw material described below, average diameter 1 to 30 μm, length 0.01 to 100 mm
The refractory fibers having a viscosity of 0.1 Pa/sec or less are mixed under shearing force at the fiber/liquid volume ratio of 1/(100 or more) to uniformly disperse the refractory fibers in the liquid, and then, A portion of the refractory raw material is added and further mixed to obtain a mixture, the liquid portion is removed from the mixture, dried, further binder is added, and then the remainder of the refractory material is added to form the desired shape. A method for producing a fiber-containing refractory, which comprises forming, drying, and appropriately firing.