JPS61158875A - Plate-form new ceramic composite material and manufacture - 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] [Industrial Application Field] The present invention is applicable not only to structures as a plate-like flexible fireproof plate, but also to heat-resistant mechanical parts, electrically insulating fireproof plate-like materials, or machines. The present invention relates to a new plate-shaped ceramic composite material that can be widely used industrially as a plate-shaped ceramic material with excellent mechanical processability, and a method for producing the same.

[Prior art and its drawbacks]

Conventionally, ceramic materials generally have the advantages of being excellent in heat resistance, fire resistance, chemical corrosion resistance, and high strength, but have the disadvantages of being brittle and easily damaged. Therefore, ceramics with a relatively thin shape, especially those with a thickness of about 3 [basket] or less and a side of 30 to 40 (
3) No matter how carefully you handle square or larger sheet-shaped ceramics, many cracks occur during the manufacturing process, resulting in poor yields and extremely high costs. Even if products are put on the market, many of them will crack or break during the distribution process or during use. In particular, plate-shaped ceramics are prone to cracking, so they have almost no mechanical workability and are completely unusable. It had various drawbacks such as lack of practicality.

On the other hand, conventional fiber compositions having heat resistance, such as conventional heat-resistant woven fabrics, have the disadvantage of being weak and easily damaged.

In addition, as a conventional method for manufacturing plate-shaped ceramics, the so-called doctor blade method, in which soil is passed between elongated gaps and shaped using a thin blade, is known and widely used. Productivity is extremely high, as many processes are used, such as precipitation, filtration, and dehydration of a dilute liquid dispersed with microparticles, or molding of ultrafine particles using an appropriate medium, followed by drying and firing. The drawbacks are that it is cheap and cannot be manufactured at a low price. However, the thickness of the products fired and produced by this method is uneven, and the material content is not particularly advanced from conventional ceramics, so the plate-shaped ceramics are extremely prone to cracking. K has not yet been able to improve the various defects peculiar to the product.

[Object of the present invention]

The present invention eliminates almost all of the drawbacks of the prior art regarding the above-mentioned plate-shaped ceramics and methods for producing the same, and provides a new plate-shaped ceramic composite material that is extremely resistant to cracking and free from distortion, and a method for producing the same. The purpose is to develop and provide.

[Configuration of the present invention: Means for solving the problems of the prior art]

The structure of the plate-shaped new ceramic composite material according to the present invention is that the base material is a heat-resistant fiber composition, and the ceramic is sintered and fixed on one or both sides of the fiber composition and/or inside the fiber texture or fiber composition. It is characterized by having a composition and having a plate-like or sheet-like shape as a whole.

In addition, the manufacturing method includes applying a ceramic composition in the form of powder, grains, or slurry to one or both sides of a heat-resistant fiber composition, and then forming the ceramic composition into a plate or sheet by rolling means. , optionally, the particles of the ceramic composition are integrated by osmotic pressure up to the structure K of the fiber weave of the heat-resistant fiber composition, and then this is sintered using an arbitrary furnace. There is.

In the case of the present invention, the above-mentioned plate shape includes a large sheet shape with a thickness of 3 or less, and squares of each thickness,
It means a rectangular flat plate.

The heat-resistant fibers that are the base materials of the present invention include glass fibers, artificial ceramic fibers such as rock wool, natural ceramic fibers such as asbestos, heat-resistant metal fibers such as titanium and tungsten zircon, whiskers, etc. It means a mixture of the above various fibers. Further, carbon fibers and the like can also be used by adjusting the firing atmosphere in the firing step after molding.

In addition, the heat-resistant fiber composition includes cotton-like materials, strands, woven fabrics, etc. formed from the above-mentioned fibers, and woven fabrics include fabrics woven in various MB directions such as plain weave and twill weave. The dimensions of the included weave can be applied over a wide range.

The ceramic composition may be one type of so-called inorganic material or a mixture of two or more types, but typically there is a ceramic composition, but others are clay-based and alumina-based.

It can be constructed from various refractory materials such as magnesia-based and chromium-based materials.

Next, an explanation will be added regarding the configuration of the manufacturing method.

First, a heat-resistant fiber composition made of inorganic fibers serving as the base material is prepared, and carboxymethyl ceftz is added to this.
o-'s (CMC), methylse/I/I:I-'s (Iv
lC).

After applying an organic glue such as polyvinyl alcohol (PVA), the ceramic composition is applied in powder or slurry form to one or both sides of the heat-resistant fiber composition. Or, one or more of the organic glues may be mixed with powder or slurry of the ceramic composition! 7-[1 to 5 weight] After addition and mixing, the CeraZx composition is applied to one or both sides of the heat-resistant fiber composition. Thereafter, the ceramic composition or its particles are rolled not only on the surface of the heat-resistant fiber composition but also inside the fiber weave or structure by rolling with roller drawing or flat plate pressing. Crimp, penetrate and fix. Next, by firing this using a firing means capable of uniform heating and cooling it, the plate-shaped new ceramic composite material mentioned above can be obtained.

Next, the present invention will be explained in more detail with reference to Examples.

[Example 1] Figure 1 shows an example of the process of the manufacturing method of the present invention,
1 is a base sheet made of a heat-resistant fiber composition, 2 is a coating device for ceramic composition slurry, 3 is an infrared double-sided drying device, 4 is a rolling roller, 5 is a tension intransitive feeding roller, and 6 is an organic material. A glue incinerator, 7 is a firing furnace, and 8 is a cutting device.0 To explain the manufacturing method in this example, first, Isolite Kogyo Co., Ltd.
We used strong Owl Ace paper made by Manufacturer. The heat resistance of this product is about 12601:'C), and the composition is A, 47.3 (ch), Sin, 52.3 (:g) by weight.
The thickness was approximately 0.5 (m). Next, a ceramic composition was used as the ceramic composition, and the weight was 60 [chi] of feldspar.
Limestone 4 [C] Talcite 36 [J: After adjusting the elementary composition of l, the sintered powder was sintered to 1180 [:”C] and ground to 200 [Mets] or less, and raw frog's eye clay 15 [ blood〕.

The above C, M, C, 2C] was added and applied as a slurry with a water content of 55 [h], and the overall water content was 12 to 13 (%).
It was heated in a firing furnace for [minutes] and then sintered for 5 minutes in 17Q150[:'C] to obtain a plate-shaped sintered body with a thickness of 1.0 [■].

The thus obtained sintered body, that is, the plate-shaped new ceramic composite material according to the present invention, has a bulk density of 2.2 Cgr/yd).
Regarding flexibility, the maximum amount of deflection until failure when a load was applied to the center of the fulcrum of a test specimen with a width of 30 [pigeons] was 10 to 15 [:m]K. This amount of deflection was about three times that of a 1.0 [■] thin plate manufactured by casting a conventional composition containing no fibrous base material onto a stone board.

That is, the plate-shaped new ceramic composite material as an example of the product of the present invention obtained in this example has flexibility:
It was epoch-making superior to conventional products.

[Example 2] In the same manner as in Example 1, the calcium sulfate-based fibrous new ceramic composite material was viewed from the back side with a magnifying glass. ). In FIG. 2, reference numeral 9 indicates the calcium phosphate fiber, and reference numeral 10 indicates particles of a ceramic composition that are baked and fixed in the weave of the woven fabric. When this product was subjected to a deflection test in the same manner as in Example 1 with the side coated with the ceramic composition facing upward, the deflection amount reached approximately 5 times that of the conventional product shown in Example IK. Therefore, it was found that the flexibility performance of the ceramic composition coated only on one side is further improved than that of the coated ceramic composition coated on both sides.

[Example 3] In substantially the same manner as in Example 1, a new plate-shaped ceramic composite material according to the present invention was produced using βCaO* 5i01 as a ceramic composition. When this material was tested, it was found that the amount of flexibility was approximately four times that of conventional products, and it was also found to be excellent in terms of machinability such as drilling and cutting, which is close to that of wood boards.

[Effects of the present invention]

From the above description, it is clear that the manufacturing method for the plate-shaped new ceramic composite material disk according to the present invention has the following effects.

(1) The new plate-shaped ceramic composite material according to the present invention has extremely superior flexibility performance compared to conventional ceramics and TSUKSU. In particular, the thin sintered plate exhibits several times the flexibility of conventional products when a heat-resistant fiber composition is combined with the base material Lamix composition.

(2) In addition, the new plate-shaped ceramics according to the present invention are excellent.

(3) Therefore, the plate-shaped new ceramic composite material according to the present invention can be used as a non-combustible flexible material for construction and as a flexible mechanical member.

As a flexible electrical insulator, it can exhibit unprecedented excellent performance as a member of a new product. Figure 1 shows an example of the manufacturing process of the new plate-shaped ceramic composite material according to the present invention, and Figure 2 2(a) is an explanatory plan view of an enlarged structure of the plate-shaped new ceramic composite material according to the present invention, and FIG. 2(b) is a longitudinal section thereof.

1... Heat-resistant woven fabric base sheet 2... Ceramic composition slurry coating device 3...
・Infrared double-sided drying device 4...Rolling roller 5...Tension intransitive conveyance sheeting roller 6...Organic paste incinerator 7...Calcination furnace 8...Cutting device electric

Claims (4)

[Claims] (1) A new plate-shaped ceramic composite material comprising a heat-resistant fiber composition and a ceramic composition sintered and fixed on one or both sides thereof and/or inside the weave of the fiber composition. . (2) The ceramic composition is αCaO・SiO_2
The plate-shaped new ceramic composite material according to claim 1, which contains βCaO·SiO_2. (3) A plate-shaped new material characterized in that a ceramic composition is attached to one or both sides of a heat-resistant fiber composition, and then crimped and integrated by a rolling means to form a flat plate, and then sintered. Method for manufacturing ceramic composite materials. (4) The ceramic composition is αCaO・SiO_2
The method for producing a new plate-shaped ceramic composite material according to claim 3, which contains βCaO·SiO_2.