High-strength basalt fiber thermal insulation felt and preparation method thereof

Abstract

The application discloses a high-strength basalt fiber heat preservation and insulation felt and a preparation method thereof. The heat preservation and insulation felt is composed of basalt fiber chopped yarn and low-melting-point polyester fiber. The basalt fiber chopped yarn and the low-melting-point polyester fiber are combined together through a needling process to form the heat preservation and insulation felt. According to mass percentage, the basalt fiber chopped yarn is 60-90%, and the low-melting-point polyester fiber is 10-40%. The low-melting-point polyester fiber is 4080 low-melting-point polyester fiber. The heat preservation and insulation felt has a three-dimensional network structure. Surface fibers of the low-melting-point polyester fiber can connect basalt fibers, and inner layer fibers can connect the basalt fibers to form a fiber network or a fiber group, so that the problem of poor mechanical property of the basalt fiber and easy deformation and damage of the basalt fiber in a construction process in the prior art is solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of thermal insulation materials, in particular to a high-strength basalt fiber thermal insulation felt and a preparation method thereof. BACKGROUND

[0002] At present, the thermal insulation and energy-saving materials used in the industry and construction at home and abroad mainly include: ① basalt fiber felt, rock wool, glass wool, high-performance fiber and its products, ② aerogel and its products, ③ organic foam thermal insulation materials and its products, ④ hard thermal insulation materials and its products, and ⑤ asbestos thermal insulation materials and its products. Compared with traditional materials, the basalt fiber needle felt has low thermal conductivity (25℃) ≤0.028 W / M·K, no toxic and harmful substances, and is easy to cut and process. The working temperature range is-200 to 650℃, and it is an ideal high-performance thermal insulation and energy-saving material. However, at present, the basalt fiber felt only relies on the entanglement and lap joint between the fibers to provide mechanical strength, so its strength is low, and it is easy to deform and break during construction, and can only be used as a thermal insulation filling material. SUMMARY

[0003] In view of the above problems existing in the prior art, the purpose of the present application is to provide a high-strength basalt fiber thermal insulation felt and a preparation method thereof, so as to solve the problems of poor mechanical properties of basalt fiber and easy deformation and breakage during construction in the prior art.

[0004] In order to solve the above technical problems, the present application adopts the following technical scheme:

[0005] A high-strength basalt fiber thermal insulation felt, the thermal insulation felt is composed of basalt fiber chopped yarn and low-melting-point polyester fiber, the basalt fiber chopped yarn and the low-melting-point polyester fiber are combined together by needle punching process to form the thermal insulation felt; wherein, according to the mass percentage, the basalt fiber chopped yarn is 60%~90%, and the low-melting-point polyester fiber is 10%~40%; the low-melting-point polyester fiber is 4080 low-melting-point polyester fiber.

[0006] The present application found in the research that there is difficulty in combining basalt fiber with organic fiber, if relying on adhesive, only basalt fiber is bonded, but basalt fiber itself has no elasticity, it is difficult to make needle felt into a three-dimensional space structure after bonding, resulting in that the performance of the product after bonding is not good, and the mechanical strength is still insufficient. If the organic material is attached to the outside of the basalt fiber by the way of infiltration, the same problem still exists, and the three-dimensional network structure of needle felt cannot be formed. The present application further found that the basalt fiber chopped yarn and the low-melting point polyester fiber are combined together by needle punching process to form a heat insulation felt, which can well solve this problem. The low-melting point polyester fiber is a kind of fiber organization, compared with ordinary polyester fiber, it can melt at a lower temperature, so as to be bonded with other fiber materials. The low-melting point polyester fiber refers to the skin layer which can be melted and bonded at 110-150 DEG C.

[0007] Preferably, the diameter of the basalt fiber chopped yarn is 3-24 μm, and the length is 30-70 mm. According to the mass percentage, the amount of basalt fiber chopped yarn with a diameter of 3 μm is 0-90%, the amount of basalt fiber chopped yarn with a diameter of 5 μm is 0-90%, the amount of basalt fiber chopped yarn with a diameter of 7 μm is 0-90%, the amount of basalt fiber chopped yarn with a diameter of 9 μm is 0-90%, the amount of basalt fiber chopped yarn with a diameter of 13 μm is 0-90%, the amount of basalt fiber chopped yarn with a diameter of 17 μm is 0-90%, and the amount of basalt fiber chopped yarn with a diameter of 24 μm is 0-90%.

[0008] Preferably, according to the mass percentage, when the diameter of the basalt fiber chopped yarn is 9 μm, the amount is 90%, and the amount of low-melting point polyester fiber is 10%.

[0009] Preferably, according to the mass percentage, the amount of basalt fiber chopped yarn with a diameter of 3 μm is 10%, the amount of basalt fiber chopped yarn with a diameter of 5 μm is 10%, and the amount of basalt fiber chopped yarn with a diameter of 9 μm is 50%, and the amount of low-melting point polyester fiber is 30%.

[0010] Preferably, according to the mass percentage, the amount of basalt fiber chopped yarn with a diameter of 7 μm is 10%, the amount of basalt fiber chopped yarn with a diameter of 13 μm is 10%, the amount of basalt fiber chopped yarn with a diameter of 24 μm is 50%, and the amount of low-melting point polyester fiber is 30%.

[0011] Preferably, the basalt fiber chopped yarn with a diameter of 7 microns is 10%, the basalt fiber chopped yarn with a diameter of 13 microns is 40%, the basalt fiber chopped yarn with a diameter of 17 microns is 10%, and the low-melting-point polyester fiber is 40% by mass percentage

[0012] Preferably, the basalt fiber chopped yarn with a diameter of 3 microns is 10%, the basalt fiber chopped yarn with a diameter of 5 microns is 10%, the basalt fiber chopped yarn with a diameter of 24 microns is 50%, and the low-melting-point polyester fiber is 30% by mass percentage.

[0013] Preferably, the basalt fiber chopped yarn with a diameter of 7 microns is 10%, the basalt fiber chopped yarn with a diameter of 13 microns is 50%, the basalt fiber chopped yarn with a diameter of 24 microns is 10%, and the low-melting-point polyester fiber is 30% by mass percentage.

[0014] Preferably, the bulk density of the heat insulation felt is 50 kg / m 3 120 kg / m 3 .

[0015] The application also provides a preparation method of high-strength basalt fiber heat preservation and insulation felt.

[0016] Step 1: basalt ore is used as raw material to prepare basalt fiber chopped yarn with a diameter of 3 microns to 24 microns and a length of 30 mm to 70 mm;

[0017] Step 2: the basalt fiber chopped yarn and the low-melting-point polyester fiber are uniformly mixed, wherein the basalt fiber chopped yarn accounts for 60% to 90% and the low-melting-point polyester fiber accounts for 10% to 40% by mass percentage;

[0018] Step 3: the fibers after step 2 are uniformly laid on the conveying belt of the opener and are subjected to rough opening treatment by the opener;

[0019] Step 4: the fibers after the rough opening treatment are conveyed to the fine opener and are subjected to fine opening treatment to further loosen the fibers;

[0020] Step 5: the fibers after the fine opening treatment are weighed and then are input into the carding machine to be carded into single fibers to obtain a single-layer two-dimensional thin fiber web;

[0021] Step 6: the two-dimensional thin fiber web is conveyed to the lapper, and the lapper is repeatedly used to perform stacking treatment to obtain a fiber web product;

[0022] Step 7: After the fiber web product is compressed, it is sent to a pre needling machine, and the fiber web product is pre needled by the pre needling machine to make the fiber web product preliminarily entangled and shaped;

[0023] Step 8: The fiber web product after the treatment in step 7 is introduced into a main needling machine, and the fiber web product is non-repeatedly needled by the main needling machine located on the upper and lower sides to form a fiber needled felt;

[0024] Step 9: The needled felt is shaped at high temperature by a drawing device to obtain the heat insulation felt.

[0025] Compared with the prior art, the present application has the following beneficial effects:

[0026] 1. The raw material selection of the needled felt is deeply researched in the present application. Although basalt fiber has excellent mechanical properties, the tensile strength can reach ≥3800MPa, the mechanical properties of the basalt fiber needled felt are poor, and the fundamental reason is that the basalt fiber surface is smooth, the flexibility is poor, and it is straight and not easy to bend, thereby reducing the fiber diameter entanglement and lapping effect. Therefore, it is found in the present application that the selection of 4080 fiber as the raw material can well improve the poor mechanical properties of the basalt fiber needled felt, because the 4080 fiber can melt at a lower temperature than general polyester, has the functions of easier bonding and shaping, and can well bond with the basalt fiber, so that the needled felt forming has high filtration efficiency and low resistance. At the same time, the 4080 fiber has no stimulation to the human body, good elasticity, softness, smoothness and good warmth retention. Especially in the hot forming process in the present application, the surface fiber melts to connect the basalt fiber, and the inner layer fiber does not melt to form a whole "fiber web" or "fiber group" with the connected basalt fiber.

[0027] 2. Different diameter sizes of basalt fiber are selected as raw materials in the present application to realize the mutual matching between the basalt fibers of different diameter sizes. Since the needled felt is a three-dimensional network structure, the mutual matching between the basalt fibers of different diameter sizes can reduce the pore size of the needled felt, thereby reducing the air flow, reducing the heat convection, filling the fibers densely, reducing the heat radiation, increasing the number of pores between the needled felts, increasing the fiber contact, increasing the heat conduction path, hindering the heat conduction process, reducing the heat convection, heat conduction and heat radiation, and improving the heat insulation performance. DETAILED DESCRIPTION

[0028] The present application will be further described below in combination with examples.

[0029] I. Examples and Comparative Examples

[0030] Example 1

[0031] The basalt fiber chopped yarn has a diameter of 9 μm, and the basalt fiber is 90% and the 4080 low-melting-point polyester fiber is 10% in terms of mass percentage.

[0032] The needle-punched felt is prepared by the following method:

[0033] Step 1: basalt ore is used as raw material to prepare basalt fiber chopped yarn with a diameter of 9 μm and a length of 30 mm to 70 mm;

[0034] Step 2: the basalt fiber chopped yarn and the low-melting-point polyester fiber are uniformly mixed, wherein the basalt fiber chopped yarn is 90% and the low-melting-point polyester fiber is 10% in terms of mass percentage;

[0035] Step 3: the above fibers are uniformly laid on the conveying belt of the opener and are subjected to rough opening treatment by the special opener;

[0036] Step 4: the rough-opened fibers are drawn to the top of the mixing all-in-one machine by the fan, and after the air pressure is discharged by the air pressure relief device, the fibers are orderly dropped into the mixing all-in-one machine, and the fibers are uniformly thrown and accumulated layer by layer and are taken out by the angle nail curtain;

[0037] Step 5: the fibers taken out by the angle nail curtain are input into the fine opener at a uniform speed through the conveying belt, and are subjected to fine opening treatment to further loosen the fibers;

[0038] Step 6: after the fibers are subjected to the fine opening treatment, the fibers are drawn to the final cotton bin by the fan under stable air pressure, and then are drawn to the air pressure cotton bin by the fan, and the fibers are continuously and continuously conveyed to the continuous leather curtain weighing instrument from the air pressure cotton bin for automatic adjustment;

[0039] Step 7: the weighed fibers are input into the carding machine to be carded and arranged into single fibers, and then a single-layer two-dimensional thin fiber web is formed;

[0040] Step 8: the two-dimensional thin fiber web is sent into the lapper, and is repeatedly stacked by the lapper to obtain a fiber web product with a unit area weight and a width;

[0041] Step 9: the fiber web product is conveyed through the bottom curtain, is input into the holding input device, is thinned after being pressed by the holding input device, is sent into the pre-needling machine, and is preliminarily entangled and shaped by the pre-needling;

[0042] Step 10: the preliminarily entangled and shaped fiber web product is introduced into the main needle-punching machine through the drafting device, is subjected to non-repeated needle-punching by the upper needle-punching machine and the lower needle-punching machine, is further needle-punched and entangled, and is formed into a fiber felt according to the entangling effect and the needle-punching density required by the product process; the needle-punching density is 50 stitches / cm to 300 stitches / cm. 2 ~300 stitches / cm 2, the needle density is too high, the fiber will be damaged by the needle, leading to fiber breakage, affecting the performance of the product, and the needle density is too low, the entangling effect between the fibers will be weakened, affecting the space structure of the product. The needle felt density can control the bulk density of the final product.

[0043] Step 11: The needle felt is introduced into the high-temperature roller through the drafting device for high-temperature setting. The temperature of the high-temperature roller is higher than the melting temperature of the low-melting-point polyester fiber.

[0044] Step 12: The product is finished, cut or wound, and then packaged as a finished product.

[0045] Example 2

[0046] The same as example 1, the difference is that the basalt fiber chopped yarn diameter is 3 μm, 5 μm, 9 μm, according to the mass percentage, the amount of basalt fiber chopped yarn with diameter of 3 μm is 10%, the amount of basalt fiber chopped yarn with diameter of 5 μm is 10%, the amount of basalt fiber chopped yarn with diameter of 9 μm is 50%, and the amount of 4080 low-melting-point polyester fiber is 30%.

[0047] Example 3

[0048] The same as example 1, the difference is that the basalt fiber chopped yarn diameter is 7 μm, 13 μm, 24 μm, according to the mass percentage, the amount of basalt fiber chopped yarn with diameter of 7 μm is 10%, the amount of basalt fiber chopped yarn with diameter of 13 μm is 10%, the amount of basalt fiber chopped yarn with diameter of 24 μm is 50%, and the amount of 4080 low-melting-point polyester fiber is 30%.

[0049] Example 4

[0050] The same as example 1, the difference is that the basalt fiber chopped yarn diameter is 7 μm, 13 μm, 17 μm, according to the mass percentage, the amount of basalt fiber chopped yarn with diameter of 7 μm is 10%, the amount of basalt fiber chopped yarn with diameter of 13 μm is 40%, the amount of basalt fiber chopped yarn with diameter of 17 μm is 10%, and the amount of 4080 low-melting-point polyester fiber is 40%.

[0051] Example 5

[0052] The same as example 2, the difference is that the basalt fiber chopped yarn with diameter of 9 μm in example 2 is replaced by basalt fiber chopped yarn with diameter of 24 μm.

[0053] Example 6

[0054] The same as Example 3, except that the basalt fiber chopped yarn with a diameter of 13 μm is used in an amount of 50%, and the basalt fiber chopped yarn with a diameter of 24 μm is used in an amount of 10%.

[0055] Comparative Example 1

[0056] The same as Example 1, except that the 4080 low-melting polyester fiber is not added.

[0057] Comparative Example 2

[0058] The same as Example 1, except that another kind of low-melting polyester fiber is used. The other kind of low-melting polyester fiber is a low-melting polyester fiber of a model other than 4080, which is commercially available.

[0059] Comparative Example 3

[0060] The same as Example 1, except that the basalt fiber chopped yarn has a diameter of 2 μm. Since the basalt fiber has a too small diameter, it is extremely difficult to produce, and the surface of the fiber is greatly damaged during the opening process, so that it is impossible to make a shaped product. There is no basalt fiber chopped yarn with a diameter of 2 μm on the market, and this comparative example is prepared only to verify the technical effect by a small amount of experiment.

[0061] Comparative Example 4

[0062] The same as Example 1, except that the basalt fiber chopped yarn has a diameter of 30 μm. Since the basalt fiber has a too large diameter, it is easily broken, not easily bent, and has extremely poor toughness, so that it is difficult to perform the opening process. Even if the opening process is performed, it is easily broken, so that the entwining and lapping effect between the fibers is reduced, and it is difficult to make a shaped product.

[0063] Comparative Example 5

[0064] The same as Example 4, except that the basalt fiber chopped yarn with a diameter of 13 μm is used in an amount of 30%, and the 4080 low-melting polyester fiber is used in an amount of 50%.

[0065] II. Performance Comparison

[0066] The thermal conductivity and tensile strength of the products prepared in the examples and comparative examples are detected according to GB / T 10294 and GB / T 17911, and the bulk density can be detected by a conventional method, and the results are as follows:

[0067] Table 1

[0068]

[0069] Note: -- indicates that the component is not added; * indicates that another organic fiber is added.

[0070] It is found in the implementation process that the thickness of the product has no direct relationship with the bulk density, tensile strength and thermal conductivity coefficient. The tensile strength of the product can be adjusted by adjusting the amount of basalt fibers with different diameters to meet the needs of different application scenarios.

[0071] Compared with Comparative Example 1, the addition of 4080 low-melting-point fibers not only improves the thermal conductivity of the product, but also improves the tensile strength of the product, and further reduces the bulk density, which is beneficial to reducing the weight of the product.

[0072] Compared with Example 2 and Example 5, the use of basalt fibers with a diameter of 24 μm instead of basalt fibers with a diameter of 9 μm makes the tensile strength of the product slightly decrease, which may be that the basalt fibers with a smaller diameter are more advantageous in supporting the three-dimensional structure of the needle punched felt, and the thermal conductivity coefficient also increases.

[0073] Compared with Example 3 and Example 6, under the condition of increasing the amount of basalt fibers with a diameter of 13 μm and reducing the amount of basalt fibers with a diameter of 24 μm, the performance of the product also changes, the tensile strength is improved, and the thermal conductivity coefficient decreases, which further confirms that the basalt fibers with a smaller diameter are more advantageous in supporting the three-dimensional structure of the needle punched felt.

[0074] In Comparative Example 2, other low-melting-point polyester fibers purchased in the market are used to replace the 4080 low-melting-point polyester fibers of the present application. Although the thermal conductivity coefficient is relatively low, compared with Example 1, the tensile strength decreases greatly, which may be that other low-melting-point polyester fibers cannot be better connected with basalt fibers, and the improvement effect on the mechanical properties of basalt fiber needle punched felt is poor.

[0075] Comparative Examples 3 and 4 are even difficult to make products, and cannot be tested for performance.

[0076] In Comparative Example 5, with the increase of the amount of 4080 low-melting-point polyester fibers, the product collapses after high-temperature forming, the amount of basalt fibers is insufficient to support the structure of the product, so that the mechanical properties of the product are relatively poor compared with other examples, but the thermal conductivity coefficient increases greatly, which shows that the increase of the amount of 4080 low-melting-point polyester fibers will adversely affect the thermal conductivity of the product, which may be that the increase of the amount of 4080 low-melting-point polyester fibers reduces the number of three-dimensional network structures in the basalt fiber needle punched felt and reduces the number of pores, so that heat transfer becomes easier, and therefore the heat insulation performance decreases.

[0077] Finally, it needs to be explained that the above examples are only used to illustrate the technical solutions of the present application but not to limit the technical solutions, and those of ordinary skill in the art should understand that the technical solutions of the present application are modified or equivalently replaced without departing from the purpose and scope of the technical solutions, which should be covered in the scope of claims of the present application.

Claims

1. A high-strength basalt fiber thermal insulation felt, characterized in that, The heat insulation felt comprises basalt fiber chopped strands and low-melting-point polyester fiber, which are bonded together by a needle punching process to form the heat insulation felt. Of these, by mass percentage, 10% is chopped basalt fiber with a diameter of 3μm, 10% is chopped basalt fiber with a diameter of 5μm, and 50% is chopped basalt fiber with a diameter of 9μm; the amount of low-melting-point polyester fiber is 30%. Alternatively, by mass percentage, the amount of basalt fiber chopped strands with a diameter of 7μm is 10%, the amount of basalt fiber chopped strands with a diameter of 13μm is 10%, the amount of basalt fiber chopped strands with a diameter of 24μm is 50%, and the amount of low-melting-point polyester fiber is 30%. Alternatively, by mass percentage, the amount of 7μm diameter basalt fiber chopped strands is 10%, the amount of 13μm diameter basalt fiber chopped strands is 40%, the amount of 17μm diameter basalt fiber chopped strands is 10%, and the amount of low-melting-point polyester fiber is 40%. Alternatively, by mass percentage, the amount of 3μm diameter basalt fiber chopped strands is 10%, the amount of 5μm diameter basalt fiber chopped strands is 10%, the amount of 24μm diameter basalt fiber chopped strands is 50%, and the amount of low melting point polyester fiber is 30%. Alternatively, by mass percentage, the amount of 7μm diameter basalt fiber chopped strands is 10%, the amount of 13μm diameter basalt fiber chopped strands is 50%, the amount of 24μm diameter basalt fiber chopped strands is 10%, and the amount of low melting point polyester fiber is 30%.

Images