Fiber felt and manufacturing process thereof

Abstract

The invention belongs to the technical field of fiber felt manufacturing and discloses a fiber felt and a manufacturing process thereof. The fiber felt is a superfine basalt fiber felt; basalt fibers of the fiber felt are superfine continuous fibers which are formed by melting basalt stones at 1450-1500 DEG C and then processing the basalt stones through a special superfine fiber kiln, and the diameter of the fibers is 3-6 microns; the fibers are processed into chopped yarns, fiber opening is performed, carding is performed to form a fiber web, and overlapping is performed through a lapping machine to form a multi-layer fiber web structure; the surface and local inner-layer fibers of the fiber web are forcibly pierced into the fibers through a needling machine, and the fibers are mutually entangled to form the fiber felt; the fibers in multiple layers of felt webs are single fibers and have three-dimensional micropore structures; multiple layers of three-dimensional staggered fibers limit rapid flowing and diffusion of air and reduce heat convection of the air; and in addition, the diameter of raw materials is ultra-fine, and dense gaps are formed, so that the fiber felt has good heat insulation performance and physical performance. The heat preservation felt can completely meet the requirement of non-combustible level A1, and is a preferred material for heat preservation, heat insulation and fire prevention.

Description

technical field [0001] The invention belongs to the technical field of fiber mat production, and particularly relates to a fiber mat and a production process thereof. Background technique [0002] At present, the thermal insulation and energy-saving materials used in industry and construction at home and abroad mainly include: ① basalt fiber felt, rock mineral wool, glass wool, high-performance fibers and their products, ② aerogels and their products, ③ organic foam insulation materials and their products Products, ④ rigid thermal insulation materials and their products, ⑤ asbestos thermal insulation materials and their products. All of the above insulation materials have defects: the current basalt needled felt is formed by thermal curing of phenolic resin, that is, the raw material is melted in a cupola to form a melt, and the melt is centrifuged to form fibers, collect cotton, cloth cotton, heat curing and Subsequent cutting and other processes finally form a basalt fibe...

AI Technical Summary

Problems solved by technology

All of the above insulation materials have defects: the current basalt needle felt is formed by thermal curing of phenolic resin, that is, the raw material is melted in a cupola to form a melt, and the melt is centrifuged into fibers, cotton, cotton, thermal curing and Subsequent cutting and other processes finally form a basalt fiber mat with a certain geometric size

The basalt fiber felt is solidified and shaped by phenolic resin. In the production process, a large amount of phenolic resin is used as a binder. Phenolic resin is an organic substance. The product cured by phenolic resin contains certain organic substances, which greatly reduces the temperature of the product. Seriously affects the application range of the product (as long as the working temperature exceeds 400°C, the product cannot be used), the raw material is melted through the cupola, and the process parameters are always in a state of large fluctuations, which greatly affects the stability of product quality

There are many problems in the application process of rock mineral wool: high brittleness, insufficient strength, material sagging, damage, and thermal insulation failure due to its own gravity during use; the toughness and rebound of the material are not enough, and the fiber breaks after compression or kneading. The dust is flying, and the effective insulation thickness cannot be guaranteed, and the desired effect cannot be achieved; rock mineral wool and ordinary glass wool are easy to age and become brittle, and the damage is serious

However, the current starting material for the production of needle-punched basalt fiber felt is basalt fiber with a single filament diameter of 10-17 μm; it has limited applications in the fields of flame retardancy, sound absorption and composite materials