JPS63145417A - Ceramic fiber with small amount of shot - Google Patents

Abstract

PURPOSE:To obtain the titled fiber suitable as bulk useful as filler for high- temperature insulation such as furnace wall, ceiling, truck, etc., of various ceramic industry furnaces, having <=a fixed value of shot content in fiber state, consisting of silica and alumina. Here shot means unfibrous material and mainly consists of grain with >=40muphi or <5 aspect ratio. CONSTITUTION:A fiber composition 7 consisting essentially of silica and alumina is melted or softened by a container 6 in a furnace, dropped from a thin hole nozzle 5 in the furnace upon a rotator turning at high speed and made into fibers to give the aimed ceramic fibers having <=20wt% shot content. The composition of the silica and alumina is preferably 45-65wt% silica and 55-35wt% alumina.

Description

Detailed Description of the Invention (Industrial Field of Application) The present invention is directed to the use of a centrifugal force of a rotating body rotating at high speed to make a molten fiber composition fly out and turn it into fibers. Bulk used for high-temperature insulation filler, etc., for various types of furnaces, blankets used for high-temperature insulation, firefighting uniforms, firefighting cloths, heat-resistant gloves, fire-resistant curtains, heat-resistant work clothes, heat-resistant aprons, etc. Regarding ceramic fibers that can be used for highly heat-resistant textiles used in various applications, in more detail, the silt content is 2 g weight, H, B%.
The following concerns ceramic fibers with less shot.

(Prior art and its problems) Ordinary ceramic IJ&M is mainly composed of silica and alumina, and the silica is 40 to 521! -% and alumina 60~4 g T<:, %9% - 13%,
M is in a threatening state! Most of the fiber diameter in E is 1~3.5
Most of the fiber length is within the range of 1 to 10 cm, and the average length of most of the fibers is within the range of 1 to 10 cm. The stain content is such that particles with a particle size of 4 Ggm or more are included in 45 to 55 tons. Incidentally, the term "spot" as used herein refers to solid matter of the fibrous composition that has not been made into fibers and has an aspect ratio (ratio of major axis to minor axis) of 5 or less and a particle size of 40 gm or more.

Ordinary ceramic fibers are used as a bulk material for high-temperature insulation in the walls and ceilings of various kilns, and as blankets for high-temperature pHr heating materials used in furnace linings for various industries. Because it contains a large amount of stain, it has poor IR heat resistance, and has the disadvantage that the stain can fall off from the bulk or the blanket, and the fallen stain can damage parts where it is used. In addition, the strength was weak because there were many gaits with a diameter of 5 mm or less, and since there were many thin gaits with a diameter of 2 mm or less, the bulk ratio could not be lowered. On the other hand, those that use ordinary ceramic fibers for spinning yarn or 4J have many short fibers of less than 5 mm in ordinary ceramic fibers, making it difficult to twist the fibers, and the fiber diameter is also thin, less than 2 gm. As a result, hair clumps (small clumps of entangled fibers) called neps are likely to occur. On the other hand, regular ceramic m! I
Textile yarn or 4j made by using it alone has low strength;
I couldn't make it durable enough to use.

Therefore, in order to increase the strength of textile yarn or cloth, 15 to 20% of organic fibers are added to ordinary ceramic fibers.
They were mixed to make yarn or cloth. However, the conventional textile yarns and cloths made in this way are ordinary ceramic ta! with a high shot content. Since it uses a large amount of yarn, it has a poor yield (the ratio of yarn to obtained It to the raw material used) and is expensive, and it also contains a large amount of shot that did not fall during weaving, making it heavy. Also, stains or dents sometimes fell off during use. In addition to this, there are drawbacks such as the possibility of the shot falling off or damaging the parts where it is used, and because it uses a large amount of organic fiber to give it strength, it is not strong enough to withstand use at room temperature. However, at high temperatures of 400°C or higher, organic fibers are fired and their strength becomes very low.
It has the disadvantage that it cannot be used in places where vibration resistance, wind speed resistance, and strength are required at high temperatures of ℃ or higher. Furthermore, when making thin textile yarns or thin textile fabrics, it was necessary to increase the mixing ratio of organic fibers in order to give them enough strength to withstand use. For this reason, textile yarns and fabrics with a content higher than 15~2o, H74% are rarely used as they have low heat resistance, and those sold in the general market are mostly textile yarns. The thread is thick and is called a cross.
It had the disadvantage that it was as thick as 2 mm and therefore bulky, making it difficult to use for clothing, etc.

(Problems to be Solved by the Invention) An object of the present invention is to eliminate or modify the drawbacks of the conventional method. That is, as mentioned above.

Conventional ordinary ceramic fibers have a high shot etch rate, so they are used in bulk as fillers for high-temperature insulation of furnace walls, ceilings, stands, etc. of various furnaces, and as high-temperature insulation materials for lining various industrial furnaces as blankets. When used for such purposes, the VIRfh properties deteriorate and the shoft falls out of the bulk blanket, damaging the parts in the place where it is used. In addition, there are many short fibers of 5 pLm or less, and the strength is low. On the other hand, because there are many thin m people under 2gm ＋ ＋? The h ratio cannot be lowered. Also, when used in textile yarn or textile fabric,
The large number of short-male males makes it difficult to twist, and the large number of thin fibers creates hair clumps called neps, which weakens the strength. The high content of shot reduces the yield, and the large amount of stain falls off, making it easy to damage parts at the site of use. On the other hand, conventional ceramic fibers have drawbacks such as a significant decrease in strength due to organic fiber combustion at high temperatures of 400°C or higher, and the inability to reduce organic fibers in thin textile yarns and textile fabrics. The object of the present invention is to eliminate or improve the problem as described above.

In order to achieve the above objects, the present invention provides the novel ceramic m#I of the present invention, which has a small shot content and has a large fiber diameter and fiber length, in place of the conventional ordinary ceramic fiber. It is something to do.

Namely, the novel ceramic m male of the present invention.

Various types of bulk materials - high-temperature F for furnace walls, ceilings, carts, etc.
When used as a filler material or a blanket for high-temperature insulation lining the interior of various industrial furnaces, it contains shot 1 (it has good insulation properties because there is less heat, and it does not stain or fall off, leaving parts in the area where it is used). Less likely to hurt.

In addition, 1 strength is high because there are few short fibers of 5 mm or less, -
Since there are few thin fibers with a strength of 2 pgm or less, the ;ε ratio can be lowered. On the other hand, yarn or cloth made by spinning the novel ceramic fiber of the present invention alone or in combination with other fibers,
Compared to conventional products, short fibers of 5mm or less are 1OiTjFJ
% or less, and the mta is thin or less than 2pm,
Since the fibers are twisted and spun, and neps are less likely to occur, the strength is high, and since the shot content is low in the 1A fibers, the yield is good, so productivity with the same equipment is also high.
The shot content in the textile yarn and 4i is reduced, making the textile yarn and 71i lighter, and less shot falls off, so there is less damage to parts at the place of use.

Furthermore, since it is not necessary to contain a large amount of organic fibers, the strength decreases less even after the a-containing fibers are burned at 400° C. or higher. Furthermore, according to the present invention, strength can be obtained even if the amount of organic fibers is reduced, so even if thin textile yarns or thin textiles are made, the organic content is reduced, and the fibers themselves are light, making them suitable for clothing, etc. It is possible to provide textile yarns and textile fabrics with good high heat resistance.

(f-n and its effects for solving the problems) According to the present invention, ceramic fibers substantially consisting of silica and alumina have a shot content of 20% by weight or less in a fibrous state. The present invention provides a new ceramic fiber with a low shot content.

The present invention is characterized in that it is a ceramic fiber consisting essentially of silica and alumina. Substantially here means that in addition to silica and alumina, it also contains other compositions such as vanadium oxide and boric acid.6 For example, vanadium pentoxide and boric acid are This has the effect of lowering the tension, making it easier to stretch the fibers, and as a result, reducing the shot content to an extremely low level.

According to Unexploded 111, silica should be in the range of 45 to 65 tons, and alumina should be in the range of 55 to 35 weight - 1%, especially silica in the range of 52 to 58 m +1X% and alumina in the range of 48 to 65 tons.
The best results were obtained in the range of 42 ton darkness%.

If alumina exceeds 1% to 55 tons, the fibers are more likely to break during fiberization due to an increase in surface tension and a decrease in viscous resistance, resulting in an increase in silica content. If the amount is more than 65%, the viscous resistance becomes too high and it is difficult to reduce the fiber diameter.

The present invention is characterized by the fact that the stain content 1 in the fibrous state is
(heka 211 ton!
It can be produced by the inorganic fiber manufacturing method and manufacturing apparatus proposed in ``T'', in which a ta mat composition (7) of silica and alumina is melted or softened in a furnace container (5), and The composition (7) is poured onto a rotating body which is rotated at high speed through a small hole nozzle (5) provided in the section and heated to a temperature higher than the softening temperature of the composition (7).
While maintaining the composition in a thin film state at a uniform temperature where it is melted or softened, the composition is uniformly flowed by centrifugal force to the peripheral edge of the rotating body, and the composition is made to fly out using the edge as a fulcrum (8) to form fibers. ”.

According to the invention, ceramic m! The average fiber diameter of l is 2
．． 5 to 9 pm is preferable; if it is more than 9 gm, the fibers tend to get stuck in the hand, and when used in textiles, the fibers tend to break during spinning, reducing the strength of the yarn or cloth after spinning. did. On the other hand, less than 2.5 gm like conventional ceramic fibers.

There was a tendency for the production grade in fiberization to become fewer and more expensive, and the shot content to increase. Also,
There is a tendency for the number of short fibers of 5 mm or less to increase, which weakens the strength of the blanket, lowers the bulk and catabolism of the blanket, and makes it difficult to produce a thermal insulation material that is cheap in rn' units. This is because the fibers tend to get entangled during weaving, making it easier for hair clumps called neps to grow.

According to the present invention, the average m reading of the ceramic fibers is between 3 and 3.
It is preferable to use one with a length of 50 cm. If the length is less than 3 cm, the fibers will be less entangled and the strength of the blanket will be weakened, and it will be difficult to twist the fibers of textile yarns and textile fabrics, resulting in a weakening of their strength. On the other hand, since the average tam length of the ceramic fibers is 50 cm or more, the fibers become too entangled at the time of forming into am, making it difficult to collect the fibers. Therefore, the average fiber of ceramic fiber! ! Good results can be obtained with a length in the range of 3 to 50 cm. However, depending on the spinning machine, fibers of 5 cm or more may be too long, and the best results are obtained with fibers cut into 3 to 5 cm. In addition, short fibers of 5 mm or less were conventionally available at 10 to 30% by weight.

It is preferable to use IQ of 575% or less, and short fibers of 5 mm or less are la! Because there is very little entanglement in l, the handling strength, wind speed resistance, and vibration resistance of the blanket are weakened, and bulk and blanket ° are used as fillers for high-temperature insulation and various lining high-temperature insulation materials.
It becomes difficult to produce heat insulators with low dissimilation, light weather, and low rn'trt values. In addition, it is difficult to twist the yarn over a length of 1 m, and the effect of increasing the strength of the textile yarn or 41 is that it is difficult to twist, the fibers are easily scattered, and the yield is poor.

(Example) Next, the most typical example of the present invention will be described with reference to the drawings.

Example 1 A composition (7) of 56 tons of silica and 44 tons of alumina (7) was heated in a molybdenum container with a pore nozzle with a diameter of 5 to 5 mm at the bottom under the thermal radiation of a W heater. After softening by heating to a temperature of 1,800°C and a viscosity of 2 mm, a 30" conical tip inserted from the upper center of the pore nozzle was placed in one position. Elute at a rate of 500g per minute and rotate once (1)
The molybdenum rotating body (1) was heated to 1800'c by the thermal radiation of the W heater fixed to the F section of the
When the rotating body (1) with a diameter of 200φ was rotated at a high speed of pm to perform fiberization, most of the fiber diameters were 4 to 6 g.
m, with the average fiber length being 5 m and most of the fiber length being 1 m.
It was possible to form new ceramic fibers with a shot content of 9%, ranging from 5 to 25 cm, with an average length of 20 cm, and a shot content of 9% over 40%.

The new ceramic taIn obtained in this way has
A surface treatment agent is a co-propylene oxide-ethylene oxide combined aqueous solution having a concentration of 1 fi 'IJ%.

＋! The cotton was collected by spraying at a ratio of l = 1, and
Perform needling with 6 strokes per crn', 700°C
The surface treatment agent was burned and the thickness was 25mm.
A blanket with a diameter of 6110 mm and a grain density of 0.13 was prepared. The tensile strength at room temperature and thermal conductivity at room temperature and 1000 DEG C. of the blanket thus obtained were examined and the results are shown in Table 2.

Example 2 1 - In the same manner as in Example 1, a novel ceramic m! of the present invention was prepared. In making the blanket by l.

It was prepared according to Example 1 except for the bulk specific gravity. In addition.

1. New ceramic fiber f-uniform fiber as described in i! l diameter, ′J
iL uniform fiber! Fibers with an i length of 5mm or less! The l-length content, shot content, and bulk specific gravity are as shown in Table 1.

The tensile strength at room temperature and thermal conductivity at room temperature and 1000° C. of the blanket thus obtained were examined and the results are shown in Table 2.

Comparative Example 1 A conventional blanket was made in the same manner as in Example 1.2, except that ordinary ceramic fibers were used to make the blanket. Created accordingly. In addition, the above-mentioned ordinary ceramic 7-ri H&fiber 1
L average Jj1m diameter, average fiber length, containing fiber length of 5 mm or less (a), containing shot (b), bulk specific gravity are as shown in Table 1.

The tensile temperature at room temperature and thermal conductivity at room temperature and 1000'C of the blanket thus obtained were examined and the results were as shown in Table 2.

Example 3 Obtained in the same manner as in Example 1.2. Unreleased 111 new ceramic fibers 6190% and rayon!
a! A yarn with a diameter of 0.7 mm was prepared using a spinning machine, and the tensile strength and yield were determined as shown in Table 3 at room temperature and after 2 hours and 8 hours of IO old C. there were.

Ordinary ceramic fibers similar to Comparative Example 1
And 10 tons of rayon fiber! 4% and made a direct PiO thread of 7mm using a spinning machine, and then heated it at room temperature and 100°C.
The tensile strength and yield after heating for hours were determined and were as shown in Table 3.

Example 4 The novel ceramic fiber A1100% of the present invention obtained in the same manner as in Examples 1 and 2.3 was processed using a spinning machine.
A thread with a diameter of 0.7 mm was prepared, and the tensile strength and yield after heating at room temperature and 1000° C. for 2 hours were determined as shown in Table 3.

(The following is the margin) Table 1 (The following is the margin) Table 2 Table 3 (Effects of Issue 131) Below 1. According to the present invention, there is provided a ceramic fiber which is a ceramic fiber consisting essentially of silica and alumina, and which has a shot content of 20% or less in the fibrous state. It has been found that there are some excellent effects as shown below.

(+) It became possible to produce lightweight blankets, textile yarns, and textiles with a low shot content.

(2) It has become possible to produce bulk products, blankets, textile yarns, and textile fabrics with less shot dropout.

(3) It has low thermal conductivity, making it possible to create bulks and blankets with good heat insulation properties.

(4) Textile yarns and spun fabrics with less organic fibers have become available.

(5) Yield has improved, and productivity with the same equipment has increased.

[Brief explanation of the drawing]

No. 11M is an example of a schematic cross-sectional view of an apparatus for manufacturing the novel ceramic fiber used in No. 1 of the present invention. Explanation of symbols 11... High-speed rotating body, 2... Rotating shaft, 3... Heater, 4... Furnace,
5... Pore nozzle, 6... Heating container, 7-... Composition softened by heating, 8... Fiber fulcrum, 9...
fiber. that's all

Claims (1)

[Scope of Claims] l) Ceramic fiber with little shot, which is a ceramic fiber consisting essentially of silica and alumina, characterized in that the content of shot in the fiberized state is 20% by weight or less. . 2), the composition ratio of silica and alumina is silica 45
65% by weight of alumina and 55-35% by weight of alumina. 3) The average fiber diameter of the ceramic fibers is 2.5 to 9.
The ceramic fiber with less shot according to claim 1, characterized in that the ceramic fiber has a diameter of .mu.m. 4), the average fiber length of the ceramic fiber is 3 to 50c
The ceramic fiber with less shot according to claim 1, characterized in that the ceramic fiber is m. 5) The ceramic fiber with less shot according to claim 1, wherein the ceramic fiber contains 10% by weight or less of ceramic fibers having a fiber length of 5 mm or less.