JPS593079A - Manufacture of ceramic fiber blanket - 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] As a method for manufacturing a ceramic fiber blanket whose main components are alumina and silica, Tokko Sho tlO-/! ;
As shown in Publication No. 3, a raw material such as kaolin is melted and made to flow down as a trickle, and this is made into fibers by a blowing method, a spin-jung method, etc., and this is brought to a collection room by an air stream. Apply an anti-friction agent to the belt conveyor.
There is a known method in which the anti-friction agent is removed by placing the anti-friction agent in a layer on a metal cloth, sandwiching the upper and lower surfaces between wire meshes, and heating under pressure. This is because a layered material that is simply compressed without applying an anti-friction agent has no locking force between the fibers, and is difficult to handle and easily separates, resulting in a layered material with extremely low strength. This is because when the anti-friction agent is removed in a compressed state, the fiber remains compressed so as to maintain the intertwining between the fibers, resulting in a layered material that is strong enough to be handled.

When a ceramic fiber blanket with a thickness of approximately 3 mm or less is manufactured using this method, a wire mesh conveyor is used as a pressurizing body to facilitate the volatilization of the anti-friction agent, so the uneven traces on the surface of the wire mesh are removed from the ceramic fiber blanket. It remains on both sides of the fiber blanket, making the four parts so thin that they can be seen through, making it impossible to manufacture one with uniform thickness. For this reason, thin ceramic fiber sheets are
By shortening the fiber length so that it can be uniformly dispersed in water,
It is manufactured by the papermaking method by dispersing it in water and adding a binder to it. In the case of this wet method, when [1i] is shortened, fiber powder is generated, which impairs the fiber utilization efficiency and requires a lot of effort in production.

SUMMARY OF THE INVENTION An object of the present invention is to provide a method for easily manufacturing ceramic fiber blankets with a certain thickness and high strength through simple steps.

In order to achieve this objective, the present invention
A layered collection of ceramic fibers consisting of silica 3S to OtsuS 7% by weight and other metal oxides of up to 70% by weight and containing an anti-friction agent! A laminate in which organic edges and fiber webs are superimposed on one side mi or both sides of the body is needle-punched, and the lubricant is subsequently removed.

As shown in Publication No. 5.2-ty-3qlI, a single-layer collection of seven Umic fibers with anti-friction agent fJ
A blanket made by applying needle punching to the t-body and removing the anti-friction agent under pressure has a higher
A product with high tensile strength can be obtained. However, even in this method, a mesh conveyor is used as a pressurizing member during the removal of the anti-friction agent, so if a thin product is manufactured, a product of uniform thickness cannot be obtained.

Also, with this method, the needle punch density can be set to 1,
If a needle punch with a needle punch density of 0 or more is performed in an attempt to obtain a material with higher tensile strength, it will stretch and tear in all directions.

Since thin materials are thinner than thick materials, their overall tensile strength is lower. In order to have the same tensile strength as thick materials,
In this method, even if the needle punch density is increased, it will only break.

On the other hand, JP-A-30-7-4A5 discloses that a nonwoven organic fiber web is layered on a nonwoven inorganic fiber mat containing no lubricant and then subjected to needle punching.

This method involves sewing a non-woven inorganic fiber mat with organic fibers. recovers to its original bulk density due to its restorability. That is, this description indicates that this method does not cause entanglement of inorganic fibers.

In contrast to these known techniques, the present invention provides a single-layered ceramic fiber aggregate containing an anti-friction agent, in which an organic fiber web is superimposed on a ceramic fiber single-layered aggregate, and a needle haunch is applied to this laminate. It is possible to increase the number of lino needle punches per unit area than in the conventional above-mentioned known method without causing tears, and after the needle punch treatment, the lubricant can be removed under no pressure. It has been discovered that even if the organic fiber web is then removed, a blanket or felt-like material can be obtained in which the intertwining of the ceramic fibers maintained by needle punching is maintained.

When needle punching is performed only on a single layered ceramic fiber assembly containing an anti-friction agent, if the needle punch density is 10 L' or more of 11-θ, then the most likely cause of tearing is the ceramic fiber single layer assembly. According to the method of the present invention, tearing does not occur even if the density of 21 Dorno Gunchi is made considerably higher than that of J1. The reason is not clear, but perhaps when the organic fibers are drawn into the ceramic fibers by the needles, the organic fibers act as a buffer,
It is thought that this is to buffer the impact that the needle gives to the ceramic link fiber and prevent the ceramic link fiber from breaking.

In the present invention, the anti-friction agent is removed from the needle-treated ceramic phyno (single-layered aggregate) in an uncompressed state, and the organic fiber web is further removed by incineration. The ceramic fiber single-layer aggregate does not return to the bulk density before needle punching, maintains the effect of needle punching, and has a high tensile strength.The reason for this is that the organic fibers Since the anti-friction agent is removed while the monolayer assembly is sewn together, the effect of needle punching on the ceramic fibers can be maintained even without removing the anti-friction agent, especially under pressure. Conceivable.

Oils and fats are usually used as anti-friction agents. Therefore, the organic fibers are volatilized by heating before burning, and the tightening effect of the organic fibers on the ceramic fibers is maintained while the lubricant is volatilized by heating.

The organic fiber web has a length of 3θ to 100 mm, usually 5 to 100 mm.
S denier cotton can be carded to produce a material with a density of 30 g/m or more. Although a carded web can be used in the present invention, it is preferable to use a web that has been needle punched to make it easier to handle, and has a density of 30 g/
When needle punching a laminate in the method of the present invention, a ceramic fiber blanket with a thickness of 3 ram or less, with a substantially uniform thickness and sufficient tensile strength is used. Needle punch density 50, which was not possible before
It is obtained by performing a needle punching process of ~200 needles/injection. However, it goes without saying that the present invention can also be applied to the production of ceramic fiber bras (ceramic fiber bras) that are thicker than this.

The present invention will be described below with reference to Examples.

A raw material having a composition consisting of impurities of alumina/lg%, silica Ω% and ia was melted in an electric furnace and atomized by a blowing method. When this ceramic fiber is introduced into the collection chamber by air flow, fatty acid amine acetate (
A mixture of kerosene with a proportion of S in a volume of Nk (trade name: Armac HT)/0. An anti-friction agent in the form of a water emulsion containing S weight % was sprayed and accumulated in two layers on the belt competition T to obtain a single-layered ceramic fiber assembly. The density of this aggregate is approx. without anti-friction agent! ;30g/m2, average fiber diameter λ0
g μm, and the maximum length was approximately: zsomm.

A polyester fiber with a thickness of mfa, 3 denyl, and a length of 7 mm is carded to form a web, and the needle punch density is g.
A web with a density of 30 g and 7 m2 that was pre-punched at a density of 30 g per half was pulled out from the roll and stacked on both the upper and lower surfaces or the upper surface of the above-mentioned single-layered ceramic fiber assembly. Needle punching was performed at a needle punch density of .

The thus treated laminate was placed in a heating furnace and heated under soo c for 30 minutes without pressure to sequentially incinerate and remove the lubricant and polyester fibers. The thickness, bulk specific gravity, stacking per area, and tensile strength of the ceramic fiber blanket (sheet) thus obtained were as follows.

In contrast, there is a method shown in Japanese Patent Publication No. 3.2-431&, in which needle punching is applied to a monolayered ceramic fiber assembly coated with a lubricant without laminating an organic fiber web to reduce the friction under pressure. In the case of the method of removing the agent, the tensile strength of the blanket obtained is the highest when the needle punch density is approximately Ωθ, but even under this condition, the bulk specific gravity is 0.73 and the thickness is The tensile strength of the material was 00.33 kq 10tr2.

In addition, when the ceramic fiber single-layer assembly used in the above example was needle-punched without applying an anti-friction agent and laminating an organic fiber web, the needle haunch density qθ 1
At 0111, a tear occurred in the ceramic fiber monolayer assembly.

According to the method of the present invention, a ceramic fiber blanket with high tensile strength, which has not been obtained conventionally, can be obtained, and a thin product, which cannot be obtained by methods other than papermaking, can be obtained. However, as shown in the example, when making a product thinner than about 1 mm, when the needle punch density reaches 200 needles and 10 m, the tensile strength decreases from that of /Sθ threads/Sono, and the ceramic fiber plate 5>'r c7) 7 Since the eye bar begins to deteriorate, it is best to stop the needle punch density below this density. If necessary, a lubricant may be applied to the organic fiber nibs laminated in the method of the present invention.

The blanket obtained by the method of the present invention is normally used as a product consisting only of ceramic fibers by incinerating the organic fibers as shown in the above examples, but if necessary, only the antifriction agent is removed to form an organic fiber web. You may use it with it attached, or you may incinerate it by heating during use.

Claims (2)

[Claims] (1) Alumina 35~Otsu S weight%, silica 3! ;
- A laminate in which an organic fiber web is laminated on one or both sides of a layered assembly of ceramic fibers containing an anti-friction agent comprising 43% by weight or less of other metal oxides and 70% by weight or less is needle punched. A method for producing a ceramic fiber blanket, which comprises removing an anti-friction agent following needle punching. (2) Claim (1) in which needle punching is performed in the range of needle punch density SO to ko0θ pieces/deviation
Method for manufacturing the seven ramic fiber blankets described in Section 1.