JPS60186452A - Refractory fiber moldings - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a refractory fiber molded article comprising a combination of refractory fibers and molding aids such as an inorganic filler, an inorganic binder, a lubricant, and a plasticizer. In order to improve heat insulation properties, thermal shrinkage rate, moldability, etc., fireproof fibers with a particle size of 5 mm or less are added to a fireproof composition in which a part of the fireproof fibers is composed of an inorganic filler, an inorganic binder, and a molding aid. This invention relates to a refractory fiber molded product made by uniformly dispersing fiber particles.

By the way, the present applicant has previously covered the surface of a fiber bundle made of ceramic fibers impregnated with a tackifier with a refractory aggregate or a mixture of a refractory aggregate and a binder in Japanese Patent Application No. 108421/1982. This paper proposes an invention related to a ceramic fiber composite consisting of: In addition, the special request
Patent Application No. 118384 discloses an invention relating to a fire-resistant and heat-insulating composite of ceramic fibers constituted by a fiber part made of a ceramic aggregate and an inorganic cellular skeleton part made of a refractory material and an inorganic binder.
No. 8996 proposes an invention relating to a ceramic fiber composite composed of a mixture of a ceramic fiber aggregate and an inorganic cellular skeleton member made of synthetic mullite and alumina sol. These inventions are
As shown in Figure 1, the structure of a ceramic fiber fireproof and heat-insulating composite is a fiber bundle made of ceramic fibers (
1) and an inorganic substance (2) that forms a cellular skeleton by coating the surface of the inorganic substance (2). It is characterized by the fact that However, when molding a composite body having the above-mentioned structure using a press molding machine, extrusion molding machine, pour molding machine, etc., There are unresolved issues such as
It was very difficult to mold. In addition, in order to increase the bulk density of the molded product and improve its strength and corrosion resistance, thermal spalling occurs when the composition ratio of inorganic materials consisting of refractory aggregate and binder to the fiber bundle of ceramic fibers increases. There was a drawback that it was easier to do.

The object of the present invention is to provide a refractory fiber molded article that eliminates and improves these drawbacks. That is, in the present invention, the refractory fiber is composed of 70 to 90% by weight, the total amount of the inorganic filler and the inorganic binder is 10 to 25% by weight, and the forming aid is 0.5 to 10% by weight. A portion is in a defibrated state and is uniformly dispersed in the fireproof composition composed of the inorganic filler and the inorganic binder, and the remainder is granular material with a particle size of 58M or less, and the granular material is By providing a refractory fiber molded article having a bulk density of 0.5 to 0.9 f/d and having a structure covered with a refractory composition and refractory fibers in which the refractory fibers are uniformly dispersed around the object, It is something that can achieve its purpose.

Hereinafter, the refractory fiber molded article of the present invention will be explained in detail.

The refractory fiber molded article of the present invention is extremely easy to mold, has good dimensional accuracy, has high bulk density, strength, and corrosion resistance compared to conventional molded articles of this type. It has significantly improved properties and heat spalling resistance.

Next, the refractory fiber molded article of the present invention will be explained in detail based on the drawings.

As shown in Fig. 2, the structure of the refractory fiber molded article of the present invention consists of an inorganic filler, an inorganic binder, and a small amount of molding aid that cover the surface of refractory fiber particles with a particle size of 5 mm or less. The refractory fibers are uniformly dispersed in the composition. Furthermore, it has a structure in which most particulate refractory fibers are independently dispersed in a refractory composition consisting of an inorganic filler, an inorganic high binder, and a small amount of forming aid.

As mentioned above, in the molded article of the present invention, since a part of the refractory fiber is uniformly dispersed in the refractory composition, the flow characteristics of the molding raw material are significantly improved when molded using a press molding machine, an extrusion molding machine, etc. , the dimensional accuracy of the molded body is improved.

Furthermore, the reinforcing effect of the fibers is exhibited, and although the bulk density of the molded product is 0.5 to L9 f/cd, the molded product has very high heat spalling resistance. In addition, since the refractory fiber particles are independently dispersed in the refractory composition, the characteristics of the refractory composition can be fully exhibited even if the bulk density is 0.5 to 0.91A, and the strength is This is a molded product with very high corrosion resistance.

The reason why the composition ratio of refractory fibers is limited to a range of 70 to 90% by weight is that if it is less than 70% by weight, the refractory fibers are used to improve the flow characteristics of the forming raw material used for molding and to reinforce the refractory composition of the molded object. As the remaining particulate matter decreases, the insulation properties become insufficient, while if it exceeds 90% by weight, the particulate matter of the refractory fiber cannot be independently dispersed in the refractory composition, resulting in poor strength and erosion resistance. This is because it is no longer sufficient.

The total composition ratio of inorganic filler and inorganic binder is 10~
The reason for limiting the content to the range of 25% by weight is that if it is less than 10% by weight, the refractory fiber particles cannot be independently dispersed in the refractory composition, whereas if it exceeds 25% by weight, the refractory fibers will be relatively dispersed. This is because the amount of particulate refractory fibers that contribute to heat insulation properties will be insufficient.

Composition ratio of molding aid? : The reason for limiting the amount to the range of 0.5 to 10% by weight is that if it is less than 0.5% by weight, it will be difficult to mold the molding raw material with good dimensional accuracy, whereas if it exceeds 10% by weight, it will be difficult to use the molded product. This is because problems such as smoke generation occur when

The refractory fibers constituting the molded article of the present invention include alumina-silica ceramic fibers, crystalline alumina fibers, crystalline mullite fibers, etc. In particular, refractory compositions comprising an inorganic filler, an inorganic binder, and a forming aid. 1000°C for fire-resistant fibers that are dispersed uniformly in a defibrated state.
It is effective to use crystalline alumina fibers, crystalline mullite fibers, or alumina-silica ceramic fibers that are heat-treated at a temperature of 800 to 1100°C, which have little thermal shrinkage at higher temperatures.

As the inorganic filler constituting the molded article of the present invention, powders of alumina, mullite, and chamotte are particularly effective, and in addition, generally known refractory fillers such as chromium oxide, zirconia, cordierite, silicon carbide, magnesia, and silica are effective. It may be a powder of the material, and it may be one or more selected from these materials.

As the inorganic binder constituting the molded article of the present invention, alumina sol, silica sol, and clay are particularly effective.
Generally known inorganic binders such as monoammonium phosphate, basic aluminum lactate, and aluminum hydroxychloride may be used, and one or more of these may be used.

As molding aids constituting the molded article of the present invention, methylcellulose, carboxymethylcellulose, and polyacrylamide are effective, and in addition, starch, hydroxyethylcellulose, gum arabic, wax emulsion, lignin, dextrin, Commonly known thickeners such as polyvinyl, polyvinyl alcohol, polyethylene oxide, sodium alginate, ammonium alginate, vinyl acetate, gelatin, natural resins, synthetic resins, stearates, and molding aids such as lubricants and plasticizers. It may be any one type or two or more types selected from these.

Next, a method for producing a refractory fiber molded article according to the present invention will be specifically explained. The refractory fibers are cut into predetermined large chips using a cutter mill, a feather mill, etc., which is a type of crusher, a shear mill, or a roll crusher, and if necessary, a type of granulator is used. Granules are granulated using a transfer granulator such as a pan-type, drum-type, vibrating conveyor type, or horizontal vibrating plate, and an inorganic filler, an inorganic binder, a forming aid, and a predetermined amount of water are added to the pellets using a mortar mixer and a knee (9
) The composition is uniformly kneaded using a mixing machine such as a mixer to form a plastic composition, then molded into the desired shape using an extrusion molding machine, press molding machine, pour molding machine, or vibration molding machine, and dried to form a molded product. get. In addition, fireproof fibers are mixed in bulk with an inorganic filler, an inorganic binder, a forming aid, and a predetermined amount of water, and then processed into a bulk fireproofing machine using a blade-type mixer such as a kneader, paddle mixer, cutter mixer, or all-purpose mixer. The fibers are chipped and granulated and simultaneously kneaded uniformly to form a composition having plasticity, and then a molded article is obtained by the above method.

The shapes of the molded products obtained in this way range from plate-like to cylindrical or honeycomb-like, making it possible to mold even quite complex shapes.

Next, examples of refractory fiber molded articles according to the present invention will be shown together with comparative examples.

Example 1 A predetermined amount of water (10) was added to a mixture of refractory fibers made into particles of 2 to 5χ by a predetermined method, bulk refractory fibers, an inorganic filler, an inorganic binder, and a forming aid. When the resulting molded product was analyzed, the results shown in Table 1 were obtained.

Example 2 A predetermined amount of water was added to a mixture of bulk refractory fibers, inorganic fillers, inorganic binders, and forming aids, kneaded in a kneader, then formed into a board shape in a press molding machine, and dried. When the molded product thus obtained was analyzed, the results shown in Table 1 were obtained.

Comparative Example 1 A CMC solution was impregnated into an aggregate of alumina-silica ceramic fibers granulated into oval spheres with a diameter of about 26 gm, and then mullite powder, alumina powder and silica sol were added and mixed in an omni mixer. Table 1 shows the analysis results of the molded body obtained by molding the molding material into a board shape using a full-flow molding machine.

(11) Table 1 (12) As described above, according to the present invention, a refractory fiber molded article composed of refractory fibers, an inorganic filler, an inorganic binder, and a forming aid has high bending strength and low thermal shrinkage. dimensionally stable;
The molded product also has excellent heat insulation properties, and in particular, it is possible to provide a molded product with significantly improved heat spalling resistance.

[Brief explanation of drawings]

FIG. 1 is an explanatory diagram schematically showing the structure of a conventional ceramic fiber molded product not according to the present invention, and FIG. 2 is an explanatory diagram schematically showing the structure of a refractory fiber molded product according to the present invention. be. 1・・・・・・・・・・・・・・・ Ceramic fiber fiber bundle 2・・・・・・・・・・・・・・・・・・
・Cellular skeleton made of inorganic substances 3・・・・・・・・・・・・
・・・・・・Refractory fiber granules 4・・・・・・・・・・
・・・・・・・・・Defibrated product of fireproof fiber 5・・・・・・・・・
... Fireproof composition patent applicant IBIDEN Co., Ltd. (13) Figure 1 Procedural amendment (voluntary) May 213, 1985 1, Incident indication 1989 Patent Application No. 089965 2, Name of the invention: Refractory fiber molded article 8. Relationship with the person making the amendment: Applicant's residence: 2-1-4 Kanda-cho, Ogaki City, Gifu Prefecture, 508
Target of amendment (1) Entire specification 5, contents of amendment Attached sheet between corrections + 11 As per II, amended specification 1, title of invention refractory fiber molded article 2, scope of claim 1, refractory fiber 70 to 90% by weight, The total amount of inorganic filler and inorganic binder is 10 to 25% by weight, and the molding aid is 0.5% by weight.
~10% by weight, the refractory fibers are partially defibrated and uniformly dispersed in the refractory composition mainly composed of the inorganic filler and the inorganic binder, The remainder is granular matter with a particle size of 5ffi11 or less,
A bulk density of 0.5 having a structure in which the granules are covered with a refractory composition in which the ceramic fibers are uniformly dispersed.
~0.9 Q/eTI refractory fiber molded article. 2. Claim 1, characterized in that the refractory m-fiber is one or more selected from alumina-silica ceramic fiber, crystalline alumina fiber, and crystalline mullite fiber. refractory fiber molded body. 8. The refractory fiber molded article according to claim 1 or 2, wherein the inorganic filler is one or more selected from powders of alumina, mullite, and chamotte. 4. The refractory fiber molded article according to claims 1 to 8, wherein the inorganic binder is one or more selected from alumina sol, silica sol, and clay. 5. Claim 1, characterized in that the molding aid is one or more selected from the group consisting of methylcellulose, poxymethylcellulose, and polyacrylamide. The refractory fiber molded article according to item 4. 8. Detailed description of the invention The present invention provides a refractory fiber molded article comprising a combination of refractory fibers and molding aids such as an inorganic filler, an inorganic binder, a lubricant, and a plasticizer. Regarding fiber molded products, more specifically, we use inorganic fillers, inorganic binders, and molding aids in which a portion of fire-resistant fibers are uniformly dispersed in order to improve strength, heat insulation, thermal shrinkage, moldability, etc. This invention relates to a refractory fiber molded article made by uniformly dispersing granules of one refractory fiber with a particle size of 5 mm or less in a refractory composition composed of No. 51-108421 pertains to a ceramic-tsuku fiber composite in which the entire surface of a fiber bundle made of ceramic fibers impregnated with a tackifier is coated with refractory aggregate or a mixture of refractory aggregate and binder. He is proposing an invention.He also filed a patent application in 1973.
No. 1-118884 discloses an invention relating to a fireproof and heat insulating composite of ceramic fibers consisting of a fiber part made of a ceramic aggregate, an inorganic cellular skeleton part made of a refractory material and an inorganic binder, and K. Showa 5
2-8996, a ceramic is constructed by mixing a ceramic fiber aggregate with an inorganic cellular framework consisting of synthetic mullite and alumina sol. Each of them proposes an invention related to a tough eye bar complex. According to these inventions, the structure of the ceramic fiber refractory heat insulating composite is composed of a fiber bundle (1) made of ceramic fibers and an inorganic material (2) forming a cellular skeleton covering the surface of the fiber bundle (1) as shown in FIG. ), and this composite is characterized by being a monolithic refractory or a molded product in various shapes such as a plate shape or a cylindrical shape. However, when molding a composite body with the above-mentioned structure using a press molding machine, extrusion molding machine, pour molding machine, etc., There were unresolved problems such as, and molding was extremely difficult. Also,
In order to increase the bulk density of the molded product and improve its strength and erosion resistance, thermal spalling is likely to occur when the composition ratio of inorganic materials consisting of refractory aggregate and binder to the ceramic fiber bundle increases. There was a drawback. The object of the present invention is to provide a refractory fiber molded article that eliminates and improves these drawbacks. That is, in the present invention, the refractory fiber is composed of 70 to 90% by weight, the total amount of the inorganic filler and the inorganic binder is 10 to 25% by weight, and the forming aid is 0.5 to 10% by weight, and the refractory fiber is A portion is in a defibrated state and is uniformly dispersed in the fireproof composition composed of the inorganic filler and the inorganic binder, and the remainder is granular material with a particle size of 5 or less. The structure has a structure in which the granules are covered with a refractory composition in which the refractory fibers are uniformly dispersed, and the bulk density is 0.5 to 0. [By providing a refractory fiber molded article of L-, the above object can be achieved. Hereinafter, the refractory fiber molded article of the present invention will be explained in detail. The refractory fiber molded article of the present invention is extremely easy to mold, has good dimensional accuracy, has high bulk density, strength, and corrosion resistance compared to conventional molded articles of this type. It has significantly improved properties and heat spalling resistance. Next, the refractory fiber molded article of the present invention will be described in detail based on the drawings. As shown in Fig. 2, the structure of the refractory fiber molded article of the present invention is composed of an inorganic filler, an inorganic binder, and a small amount of molding aid that cover the surface of refractory fiber particles with a particle size of 5 mm or less. The refractory fibers are uniformly dispersed in the composition. Further, it has a structure in which most particulate refractory fibers are independently dispersed in a refractory composition consisting of an inorganic filler, an inorganic binder, and a small amount of forming aid. As mentioned above, in the molded article of the present invention, since a part of the refractory fiber is uniformly dispersed in the refractory composition, the flow characteristics of the molding raw material are significantly improved when molded using a press molding machine, an extrusion molding machine, etc. , the dimensional accuracy of the molded body is improved. Furthermore, the reinforcing effect of the fibers is exhibited, and although the bulk density of the molded product is 0.5 to 0.911M, the molded product has very high heat spalling resistance. In addition, since the refractory fiber particles are independently dispersed in the refractory composition, the characteristics of the refractory composition can be fully exhibited even if the bulk density is 0.5 to 0.9). Moreover, it is a molded product with extremely high strength and corrosion resistance. The reason why the composition ratio of refractory fibers is limited to a range of 0 to 9% by weight is that if it is less than 70% by weight, the refractory fibers will be defibrated to improve the fluidity of the forming raw material used for molding, and the refractory composition of the molded article will be reduced. As the remaining particulate fibers used for reinforcement of objects are reduced, the insulation properties become insufficient, while 9
If it exceeds 0% by weight, the refractory fiber particles cannot be independently dispersed in the refractory composition, resulting in insufficient strength and corrosion resistance. The total composition ratio of inorganic filler and inorganic binder is 10~
The reason for limiting the content to the range of 25% by weight is that if it is less than 10% by weight, the refractory fiber particles cannot be independently dispersed in the refractory composition, whereas if it exceeds 25% by weight, the refractory fibers will be relatively dispersed. This is because the amount of granular refractory fibers that contribute to heat insulation properties will be insufficient. The reason why the composition ratio of the molding aid is limited to the range of 0.5 to 10% by weight is that if it is less than 0.5% by weight, it will be difficult to mold the molding raw material with good dimensional accuracy. This is because if it exceeds this amount, problems such as smoke generation will occur when the molded product is used. The refractory fibers constituting the molded article of the present invention include alumina-silica ceramic fibers! (1000°
It is effective to use crystalline alumina fibers, crystalline mullite fibers, or alumina-silica ceramic fibers that are heat-treated at a temperature of 800 to 1100°C, which have little thermal shrinkage at high temperatures of C or higher. As the inorganic filler constituting the molded article of the present invention, powders of alumina, mullite, and chamotte are particularly effective, and in addition, generally known refractory materials such as chromium oxide, zirconia, cordierite, expanded silicon, magnesia, and silica are effective. It may be a powder of the material, and it may be one or more selected from these materials. As the inorganic binder constituting the molded article of the present invention, alumina sol, silica μ, and clay are particularly effective, and in addition,
Generally known inorganic binders such as monoammonium phosphate, basic aluminum lactate, and aluminum hydroxychloride may be used, and one or more of these may be used. As molding aids constituting the molded article of the present invention, methylcellulose, carpoxymethylcellulose, and polyacrylamide are effective; in addition, starch, hydroxyethylcellulose, gum arabic, wax emulsion, lignin, dextrin, polyvinyl, Commonly known thickeners such as polyvinyl alcohol, polyethylene oxide, sodium alginate, ammonium alginate, vinyl acetate, gelatin, natural resins, synthetic resins, and stearates, as well as molding aids such as lubricants and plasticizers. Any one type or two or more types selected from these may be used. Next, a method for producing a refractory fiber molded article according to the present invention will be specifically explained. Cutting refractory fibers in advance using a cutter mill, feather mill, etc., which is a type of crusher. It is made into a predetermined large chip shape using a mill or a roll crusher, and is granulated as necessary using a transfer granulator such as a pan type, drum type, vibrating conveyor type, or horizontal vibrating plate. Add an inorganic filler, an inorganic binder, a molding aid, and a predetermined amount of water to the material, mix it with 7 remixers,
The composition is uniformly kneaded using a kneader such as a kneader to form a plastic composition, then molded into a desired shape using an extruder, press molding machine, cast molding machine, or perturbation molding machine, and dried to form a molded product. get. In addition, the refractory fibers can be made into bulk refractory fibers by blending them with inorganic fillers, inorganic binders, forming aids, and a predetermined amount of water. The fibers are chipped and granulated and simultaneously kneaded uniformly to form a composition having plasticity, and then a molded article is obtained by the above method. The shapes of the molded objects thus obtained range from plate-like to cylindrical or honeycomb-like, making it possible to mold even fairly complex shapes. Next, examples of refractory fiber molded articles according to the present invention will be shown together with comparative examples. Example 1 Alumina-silica yarn ceramic fibers made into granules of 2 to 5''g by a predetermined method, bulk crystalline alumina, mullite fibers, an inorganic filler, an inorganic binder, and a forming aid were prepared. A predetermined amount of water was added to the mixture and kneaded with a mortar mixer, then molded into a board shape with a casting machine and dried. The resulting molded product was analyzed, and the results shown in Table 1 were obtained. Example 2 A predetermined amount of water was added to a mixture of bulk alumina-silica yarn ceramic fibers, an inorganic filler, an inorganic binder, and a forming aid, and the mixture was kneaded in a kneader, and then in a press molding machine. Analysis of the molded product obtained by molding it into a board shape and drying it was performed, and the results shown in Table 1 were obtained. Comparative Examples 10 to 201 Alumina-silica granulated into an elliptical sphere shape with an Ell diameter. 1. Impregnate the yarn ceramic fiber aggregate with the CMC solution, then add mullite powder, alumina powder and silica sol, mix with an omni mixer, and form the forming raw material into a board shape using a full-flow molding machine. The analysis results of the obtained molded product are shown in Table 1. As described above, according to the present invention, the refractory fiber molded product composed of refractory fibers, an inorganic filler, an inorganic binder, and a forming aid has a high bending strength. , low heat shrinkage and dimensional stability,
The molded product also has excellent heat insulation properties, and in particular, it is possible to provide a molded product with significantly improved heat spalling resistance. 4. Brief description of the drawings Fig. 1 is an explanatory diagram schematically showing the structure of a conventional ceramic fiber molded product not according to the present invention, and Fig. 2 is a schematic illustration of the structure of a refractory fiber molded product according to the present invention. FIG. 1... Ceramic fiber bundle 2... Seven-shaped skeleton made of inorganic material 8...
・・・・・・Particles of fireproof fiber 4・・・・・・・・・
Fire-resistant fiber defibrated product 5 Fire-resistant composition patent applicant Jun Taga, representative of IBIDEN Co., Ltd.

Claims (1)

[Claims] 1. 70 to 90% by weight of fire-resistant fibers, 10 to 25% by weight of inorganic filler and inorganic binder in total, and 0.5% of forming aid.
~10% by weight, and the refractory fiber is partially defibrated and uniformly dispersed in the refractory composition mainly composed of the inorganic filler and the inorganic binder, The bulk density is 0.5 to 0.9, the remainder being granules with a particle size of 5H or less, and having a structure covered with a refractory composition in which the ceramic fibers are uniformly dispersed around the granules.
f/d refractory fiber molded body. 2. The refractory fiber is one or more selected from alumina-silica ceramic fiber, crystalline alumina fiber, and crystalline mullite fiber, as set forth in claim 1. Fireproof fiber molded body. 3. The refractory fiber molded article according to claim 1 or 2, wherein the inorganic filler is one or more selected from powders of alumina, mullite, and chamotte. 4. The refractory fiber molded article according to claims 1 to 3, wherein the binder is one or more selected from alumina sol, silica sol, and clay. 5. The molding aid according to claims 1 to 4, wherein the molding aid is one or more selected from methyl cellulose, carboxymethyl cellulose, and polyacrylamide. Fireproof fiber molded body.