JPH05279105A - Inorganic fiber molding and its production - Google Patents

Abstract

PURPOSE:To prevent an inorganic fiber molding form cracking by defibrating an inorganic fiber and transporting and collecting the defibrated material into a mold, subjecting the defibrated inorganic fiber to attaching treatment with an inorganic binder solution and then compressing and dehydrating the attached material in the mold to provide a molding drying the molding and curing an inorganic binder. CONSTITUTION:An inorganic fiber having 0.5-7mum average fiber diameter, e.g. glass fiber is defibrated with a defibrating machine and the defibrated material is transported and collected into a mold while sucking the defibrated material in a reduced pressure of about 40-80mm H2O. The ratio of a fiber oriented in vertical direction is controlled by adjusting the suction. Then the collected fiber material is subjected to attaching treatment with an inorganic binder solution of alumina sol, etc., and the attached material is compressed and dehydrated in the mold under the pressure of about 2.1-7.0Kg/cm<2> and taken out as a wet molding having prescribed thickness and shape. Thereafter, the molding is dried by a hot air drier, etc., so as to cure the inorganic binder to provide the objective inorganic fiber molding excellent in heat resistance and free from crack, breaking and peeling.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an inorganic fiber molded article and a method for producing the same, and particularly to an inorganic fiber molded article which does not contain an organic binder, has excellent heat resistance, and is free from cracking, chipping, and peeling, and an easy method for producing the same. The present invention relates to a manufacturing method that can be manufactured. The inorganic fiber molded article of the present invention utilizes its heat resistance, heat insulation, filterability, etc. to make a heat resistant material, heat insulating material,
It can be widely used in various fields such as cushion materials, packing materials, filters, and lubricants for metal pipe extrusion.
The use is not particularly limited.

[0002]

2. Description of the Related Art Heretofore, an inorganic fiber molded article of this kind has been manufactured by sequentially laminating ceramic raw material slurries of the same kind or different kinds by a papermaking method, as disclosed in JP-A-1-106599. Or, Japanese Patent Laid-Open No. 63-
As disclosed in Japanese Patent No. 254240, the inorganic fiber slurry is compressed and dehydrated in a mold to produce a preform, and then the preform is formed into a main form.

[0003]

However, when an inorganic fiber molded article is produced from a slurry as a raw material as in the above-mentioned conventional method, an organic substance such as a dispersant used to disperse the inorganic fiber in water is molded. Because it remains in the product,
There is a problem in that, when used at a high temperature, gas is generated, carbonization occurs, or strength is reduced due to burning of organic substances. In addition, since the fibers are defibrated in water to eliminate the binding of the fibers, the fiber length becomes shorter than desired, and when molded,
There is a problem that the entanglement of the fibers is reduced and the strength of the molded product is reduced. Further, when compressed and dehydrated from a slurry state, all the fibers are arranged in the horizontal direction, which causes a problem that peeling occurs in the molded product. Furthermore, when molding through a preform,
If the preformed product is molded into a complicated shape in the final mold, if the fiber has a large restoring force, a molded product of the desired shape cannot be obtained.
The bent portion has problems such as wrinkles and unformed portions. It is an object of the present invention to solve these drawbacks, to provide an inorganic fiber molded article having a desired shape that does not contain an organic binder, is excellent in heat resistance, and is free from cracks, chips and peeling, and a method for producing the same.

[0004]

In order to achieve the above-mentioned object, the inorganic fiber molded article of the present invention comprises a part of the inorganic fiber obtained by collecting the inorganic fiber while sucking it and dehydrating it together with the inorganic binder. Is oriented in the vertical direction.

Further, in the method for producing an inorganic fiber molded article of the present invention, the inorganic fiber is defibrated by a defibrating machine, and the defibrated material is transported into a mold while being sucked to collect cotton. It is possible to obtain an inorganic fiber molded product by subjecting a solution of an inorganic binder to an adhesion treatment, compressing and dehydrating the adhered substance in a mold to obtain a wet shaped molded product, and drying the molded product to cure the inorganic binder. Characterize.

As the inorganic fibers constituting the molded body, glass fibers, ceramic fibers, slag wool fibers,
Rock wool etc. can be used. In this case, it is preferable to use an inorganic fiber having an average fiber diameter of 7 microns or less. This is because when the average fiber diameter exceeds 7 μm, the number of fibers that are easily broken increases, resulting in chipping or cracking of the molded product, and when it comes into contact with the human body, it causes discomfort such as itch. In addition, the smaller the fiber diameter of the inorganic fiber is, the more self-adhesive growth is increased, which is preferable from the viewpoint of the strength of the molded product. However, the fiber having an average fiber diameter of less than 0.5 micron has no general versatility, Also, there are many fibers having an average fiber diameter of less than 0.8 micron, but they are very expensive and not economical. Therefore, the average fiber diameter of the inorganic fibers is 0.5 to 7 microns, particularly 0.8 to 7 microns. Are preferred. Further, the inorganic fibers include long fibers and short fibers, and when used in the molded article of the present invention, it is preferable to use a composition mainly composed of short fibers, in which glass having a small average fiber diameter is easily obtained, but the average fiber diameter As long as is within the range of 7 microns or less, long fibers having a large fiber diameter may be mixed with the short fibers. Further, as the inorganic fibers, it is preferable to use fibers defibrated by a defibrating machine, which allows the fibers to be formed into a desired small lump and has a good fiber orientation at the time of sucking and collecting, and a shot which remains in the inorganic fibers without being fibrillated. Is preferable in that it can remove

As the inorganic binder, alumina sol, silica sol, water glass, titania sol and alkoxides of these inorganic materials are suitable, but in view of cost, it is preferable to use alumina sol, silica sol or water glass.

In order to obtain an inorganic fiber molded product from the inorganic fiber and the inorganic binder, first, the inorganic fiber is defibrated by a defibrating machine, and the defibrated material is molded while suctioned with a static pressure of about 40 to 80 mmH ₂ O. Transport it inside and collect cotton. By adjusting the suction at this time, the ratio of the inorganic fibers oriented in the vertical direction can be adjusted. In addition, when mixing two or more kinds of fibers here, each fiber is defibrated by a defibrating machine without mixing two or more kinds of fibers, and the defibrating machine is sequentially adjusted to a desired mixing ratio. Transport more into the mold. Next, an aqueous solution of an inorganic binder is applied to the collected cotton material, and the applied material is 2.1 to 7.0 kg / in a mold.
A molded product having a desired thickness and a desired shape, which has been compressed and dehydrated by a pressure of about cm ² , is taken out, and the molded product is taken out. Then, drying is performed by appropriately selecting from drying methods such as natural drying, hot air drying, contact drying, high frequency drying, and far infrared ray drying to cure the inorganic binder to obtain an inorganic fiber molded article.

[0009]

In the present invention, since the inorganic fiber molded article is composed only of the inorganic fiber and the inorganic binder, it does not contain an organic substance, and does not generate gas or carbonize at high temperature.
Alternatively, the strength is not reduced due to the burning of organic substances. In addition, since it is defibrated by a defibrator without disintegrating in water, the inorganic fibers are not cut and the fiber length becomes extremely short, and after defibrating, cotton is collected while sucking into the mold. In order to adhere the inorganic binder in this state and compress and dehydrate it, part of the fibers is oriented in the direction of air flow, that is, in the vertical direction,
An inorganic fiber molded product that does not cause delamination can be obtained. Therefore, the molded product does not crack or chip.

[0010]

Embodiments of the present invention will now be described with reference to the drawings. FIG. 1 shows an inorganic fiber molded product of the present invention. In the present embodiment, it is formed in a disk shape having a through hole 1a at the center.

2 to 6 show each step of the method for producing an inorganic fiber molded article of the present invention. First, as shown in FIG. 2, the mat-like inorganic fiber 2 is defibrated by a defibrating machine 10. ,
A defibrated material 2 ′ of the inorganic fiber 2 is obtained. The defibrated material 2 ′ of the inorganic fiber 2 thus obtained is pneumatically transported while sucking it into the mold 12 having a predetermined shape according to the shape of the molded article 1 arranged in the cotton collection chamber 11. Collect cotton. Next, the mold 12 is taken out from the cotton collection chamber 11 and moved below the inorganic binder spraying device 13 to apply a predetermined amount of the aqueous solution of the inorganic binder 3 to the defibrated material 2'which has been collected.
Next, the mold 12 is moved below the compression device 14, and the defibrated material 2'collected is compressed and dehydrated to obtain a wet shaped article 1'having a predetermined shape. Next, the thus-obtained molded product 1'in a wet state is moved to a drying chamber 16 equipped with a heater 15 and dried to cure the inorganic binder 3 to obtain the inorganic fiber molded product shown in FIG. obtain.

The shape of the molded product is a mold 1 for collecting cotton.
If the shape of 2 is changed to a desired shape, it can be molded into any shape. The basis weight, thickness, density, etc. of the molded product can be arbitrarily adjusted by adjusting the amount of the cotton-collected material and the compression pressure. The manufacturing method of the present invention is not limited to the badge type manufacturing method as in the above-mentioned embodiment.

Specific examples will be described below together with comparative examples. A specific example of manufacturing the inorganic fiber molded product shown in FIG. 1 by the manufacturing method shown in FIGS. 2 to 6 will be described. Although various combinations of the inorganic fiber and the inorganic binder are possible, glass fiber is used as a typical example. An example using silica sol will be described. The drying method used was hot air drying.

Example 1 Short glass fibers having an average fiber diameter of 3 microns were defibrated by a defibrating machine and collected in a mold while sucking. Next, a silica sol having a solid content of 1.5 wt% was attached and subjected to compression dehydration to obtain a molded article having a predetermined shape in a wet state. This molded product had an average fiber diameter of 3 microns, an average fiber length of 10 mm, and an organic substance content of 0.1% or less. The peel strength was 1 kg / cm ² , and neither cracking, chipping nor peeling occurred. Furthermore, when used at a high temperature of about 550 ° C., no decrease in strength was observed.

Example 2 Inorganic fibers were prepared in the same manner as in Example 1 except that short glass fibers having an average fiber diameter of 1 micron and long glass fibers having an average fiber diameter of 9 microns were defibrated by a defibrating machine. A molded product was produced. This molded product had an average fiber diameter of 5 microns, an average fiber length of 5 mm, and an organic matter content of 0.1% or less. The peel strength is 0.8 kg /
It was cm ² , and neither cracking, chipping nor peeling occurred. Furthermore, when used at a high temperature of about 550 ° C., no decrease in strength was observed.

(Comparative Example) A slurry of short glass fibers having an average fiber diameter of 3 microns was compression dehydrated in a mold by a conventional papermaking method, then impregnated with silica sol and dried with hot air to obtain a molded product. This molded product has an average fiber diameter of 3 microns,
The average fiber length was 1 mm or less, and the organic matter content was 2.0%. Further, the peel strength is 0.1 kg / cm ² or less,
Peeling occurred. Moreover, cracks and chips were generated, and paper dust was also generated. Furthermore, when used at a high temperature of about 550 ° C., a decrease in strength was observed.

[0017]

As described above, according to the present invention, since a part of the inorganic fiber is formed in a vertically oriented state, an inorganic fiber molded product which is easy to handle without cracking, chipping or peeling is obtained. Be done. Further, since it does not contain an organic binder, there is an effect that even when used at high temperature, there is no generation of gas due to burning of organic matter and reduction in strength.

[Brief description of drawings]

FIG. 1 is a perspective view of an embodiment of an inorganic fiber molded product of the present invention.

FIG. 2 is an explanatory diagram showing a defibration process which is one manufacturing process of the method for producing an inorganic fiber molded article of the present invention.

FIG. 3 is an explanatory diagram showing a cotton collecting step which is one manufacturing step of the method for manufacturing an inorganic fiber molded article of the present invention.

FIG. 4 is an explanatory diagram showing a binder adhesion treatment step which is one manufacturing step of the method for manufacturing an inorganic fiber molded article of the present invention.

FIG. 5 is an explanatory diagram showing a dehydration step which is one manufacturing step of the method for manufacturing an inorganic fiber molded article of the present invention.

FIG. 6 is an explanatory diagram showing a drying step which is one manufacturing step of the method for manufacturing an inorganic fiber molded article of the present invention.

[Explanation of symbols]

 1 inorganic fiber molded product 1'molded product in a wet state 1a through hole 2 inorganic fiber 2'defibrated material 3 inorganic binder 10 defibrator 11 cotton collection chamber 12 mold 13 inorganic binder spraying device 14 compression device 15 heater 16 drying chamber

Claims (3)

[Claims] 1. An inorganic fiber molded article obtained by orienting a part of the inorganic fibers in a vertical direction by collecting the inorganic fibers while sucking them and performing dehydration molding together with the inorganic binder. 2. The inorganic fiber molded article according to claim 1, wherein the inorganic fiber is defibrated by a defibrating machine. 3. An inorganic fiber is defibrated by a defibrating machine, the defibrated material is sucked and transported into a mold to collect cotton, and a solution of an inorganic binder is adhered to the cotton collected material to obtain the adhered material. A method for producing an inorganic fiber molded article, which comprises compressing and dehydrating in a mold to obtain a wet shaped molded article, and drying the molded article to cure the inorganic binder.