A low bulk density soluble fibre product and a method for its preparation

Abstract

The application provides a preparation method of low bulk density soluble fiber product, comprising: melting raw materials, fiberizing, cotton collecting, needling, calcining and forming to obtain the low bulk density soluble fiber product; the temperature of the melt to the fiberizing equipment is 100-200 DEG C lower than the temperature of the melt flowing out of the melting equipment during the melting process. The low bulk density soluble fiber product prepared by the method has the advantages of light weight, bulk density of 20-48 kg / m 3 , easy to carry the dead weight, the product can meet various customized needs, is convenient for construction, significantly reduces the manufacturing and operation cost of the user, belongs to A-grade non-combustible and has no safety hazard, has low thermal conductivity of 0.031-0.035 w / m.k, and the heat insulation, sound insulation and insulation effects are significantly improved. The application further provides a low bulk density soluble fiber product.

Description

Technical Field

[0001] This invention belongs to the field of soluble fiber technology, and particularly relates to a low-density soluble fiber product and its preparation method. Background Technology

[0002] Currently, the fireproof insulation materials, thermal insulation and sound insulation materials used in the transportation industry, such as ships, high-speed rail and subways, mainly include soluble fibers, basalt fibers and glass fibers. Among them, the bulk density of soluble fibers is approximately 64-140 kg / m³. 3 Basalt fiber has a bulk density of 45–100 kg / m³. 3 The density of glass fiber is between 24 and 60 kg / m³. 3 The application parts have complex structures, and the required product specifications are complex and vary in shape.

[0003] Although basalt fiber and glass fiber have low density, they pose safety hazards during use due to the presence of organic resins and other organic substances. Traditional soluble fibers, with a fiber diameter of 3–5 μm and a non-fibrous content of 30–40%, have a minimum density of 64 kg / m³. 3 This makes it impossible to meet the requirements of home appliances, ships, high-speed trains and subways to gradually reduce their weight. Summary of the Invention

[0004] In view of this, the purpose of this invention is to provide a low-density soluble fiber product and a method for preparing the same. The low-density soluble fiber product prepared by the method provided by this invention has good performance.

[0005] This invention provides a method for preparing a low-density soluble fiber product, comprising:

[0006] The raw materials are melted, fiberized, collected, needle-punched, calcined and shaped to obtain low-density soluble fiber products.

[0007] The temperature of the melt flowing into the fiber forming equipment during the melting process is 100-200°C lower than the temperature of the melt flowing out of the melting equipment.

[0008] Preferably, the raw materials include CaO, SiO2, and MgO.

[0009] Preferably, the mass ratio of CaO, SiO2 and MgO is (26-32):(64-67):(4-7).

[0010] Preferably, the melting is carried out in a melting device, which includes a fluid port, a body and an intermediate channel for fluid outflow. The body is externally connected to a circuit for conduction, and the conductive body is connected to the high-temperature molten liquid to form a closed circuit, thereby controlling the temperature of the molten liquid and regulating the temperature of the material channel from which the melt flows out.

[0011] Preferably, the temperature of the molten liquid flowing out is controlled by controlling the current of the flow port; the current of the flow port is 100-500A.

[0012] Preferably, the fiber-forming temperature is 1600–1700°C.

[0013] Preferably, the fiber forming method includes spun fiber forming or blown fiber forming.

[0014] Preferably, the speed of spinning the fibers is 120-180 m / s.

[0015] Preferably, the cotton collection is a uniform cotton blank with a diameter of 50-200 mm.

[0016] This invention provides a low-density soluble fiber product prepared by the method described above; the density of the low-density soluble fiber product is 24-48 kg / m³. 3 .

[0017] This invention controls the temperature through melting or fiber formation, thereby adjusting the diameter of the fibers and the content of non-fiber materials (other non-fiber materials besides fibers, including large non-fiber particles and fine powders), thus making it suitable for preparing low-density products with a density of 24–48 kg / m³. 3 The soluble fibers in this invention have a diameter of 1–3 μm and are used in the transportation industry. This invention requires no addition of organic matter during preparation and does not produce flammability or odor release during use. Through coating, water-cutting, or engraving processes, this invention can achieve precise cutting of low-density soluble fiber products into any shape and size, meeting the needs of various parts of transportation vehicles.

[0018] The low-density soluble fiber products prepared by the method provided in this invention are lightweight, with a density of 20–48 kg / m³. 3 It is easy to carry the weight of the carrier, and the products can meet various customized needs. It is easy to construct and significantly reduces the manufacturing and operating costs of users. It is classified as Class A non-combustible and has no safety hazards. It has a low thermal conductivity of 0.031 to 0.035 W / mK, which significantly improves the thermal insulation, sound insulation and electrical insulation effects. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of the melting device provided in an embodiment of the present invention;

[0020] Figure 2 This is a schematic diagram of the product structure of the single-sided coated aluminum foil prepared in Example 1 of the present invention;

[0021] Figure 3 This is a schematic diagram of the product structure of the six-sided glass fiber cloth prepared in Example 3 of the present invention. Detailed Implementation

[0022] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other instances that are improved or modified by those skilled in the art are within the scope of protection of the present invention. It should be understood that the embodiments of the present invention are only used to illustrate the technical effects of the present invention, and are not intended to limit the scope of protection of the present invention. Unless otherwise specified, the methods used in the embodiments are conventional methods.

[0023] This invention provides a method for preparing a low-density soluble fiber product, comprising:

[0024] The process involves melting the raw materials, forming fibers, collecting cotton, needle punching, calcining, and shaping.

[0025] In this invention, the raw materials preferably include CaO, SiO2 and MgO.

[0026] In this invention, the preferred mass ratio of CaO, SiO2 and MgO is (26-32):(64-67):(4-7), more preferably (27-31):(65-66):(5-6), and most preferably 30:65.5:5.5.

[0027] In this invention, the melting temperature is 1800–2100°C, preferably 1900–2000°C, and more preferably 1950°C. In this invention, during the melting process, the temperature of the melt reaching the fiber-forming equipment is 100–200°C lower than the temperature of the melt flowing out of the melting equipment, more preferably 120–180°C lower, even more preferably 140–160°C lower, and most preferably 150°C lower. In this invention, during the melting process, the temperature of the melt reaching the spinning roller of the fiber-forming equipment is preferably 100–200°C lower than the temperature of the melt flowing out of the outlet of the melting equipment.

[0028] In this invention, the melting is preferably carried out in a melting device, and the structural schematic diagram of the melting device is preferably shown below. Figure 1 As shown (1 is the outlet, 2 is the temperature control), Figure 1 The flow outlet preferably includes a flow outlet body and an intermediate channel for fluid outflow. The external circuit of the flow outlet body can conduct electricity. The conductive flow outlet body is connected to the high-temperature molten liquid to form a closed circuit loop. By controlling the current A of the flow outlet body, the temperature of the molten liquid flowing out is controlled, and the temperature of the material channel from which the melt flows out is regulated. The temperature of the melt at the spinning roller is kept 100-200°C lower than the temperature of the melt flowing out of the flow outlet of the melting equipment, more preferably 120-180°C lower, more preferably 140-160°C lower, and most preferably 150°C lower.

[0029] In this invention, the current A is preferably 100-500A, more preferably 200-400A, and most preferably 300A.

[0030] In this invention, the fiber-forming temperature is preferably 1600-1700℃, more preferably 1620-1680℃, even more preferably 1640-1660℃, and most preferably 1650℃.

[0031] In this invention, the fiber forming method preferably includes spun fiber forming or blown fiber forming, more preferably spun fiber forming; the equipment for spun fiber forming is preferably a spun roller.

[0032] In this invention, the speed of spinning the fibers is preferably 120-180 m / s, more preferably 130-170 m / s, even more preferably 140-160 m / s, and most preferably 150 m / s.

[0033] This invention controls the melting and spinning processes to make the diameter of soluble fibers finer or coarser and reduce the content of non-fibrous materials, thus making it suitable for preparing low-density products with a density of 24–48 kg / m³. 3 With a diameter of 1–3 μm, it is used in the transportation industry.

[0034] In this invention, the cotton collection is preferably a uniform cotton blank of 50-200mm, more preferably 100-150mm, even more preferably 120-130mm, and most preferably 125mm.

[0035] In this invention, the acupuncture method preferably includes:

[0036] The cotton blanks formed by collecting cotton are continuously fed into a needle punching machine for needle punching and shaping.

[0037] In this invention, the needle-punching density of the product is preferably 2 to 10 needles / cm. 2 More preferably, 3-8 stitches / cm 2 More preferably, 4-6 stitches / cm 2 The optimal value is 5 stitches / cm. 2 The preferred bulk density is 24–48 kg / cm³. 3 More preferably 30-40 kg / cm² 3 The optimal value is 35 kg / cm². 3 The thickness is preferably 20-75 mm, more preferably 30-70 mm, even more preferably 40-60 mm, and most preferably 50 mm.

[0038] In this invention, the procedure following acupuncture preferably includes:

[0039] The needle-punched product is then subjected to continuous mechanical cutting and calcination.

[0040] In this invention, the calcination temperature is preferably 600-650℃, more preferably 610-640℃, and most preferably 620-630℃; the calcination time is preferably 10-15 min, more preferably 11-14 min, and most preferably 12-13 min.

[0041] In this invention, the calcination process preferably further includes:

[0042] The calcined product is then coated with aluminum foil or fiberglass cloth and then shaped.

[0043] In this invention, the coating is preferably a single-sided coating or a six-sided coating.

[0044] In this invention, the molding method preferably includes water cutting or engraving to obtain a low-density soluble fiber product with the desired shape and precise dimensions.

[0045] In this invention, the water cutting pressure is preferably 3 to 10 MPa, more preferably 4 to 8 MPa, even more preferably 5 to 7 MPa, and most preferably 6 MPa.

[0046] The present invention also provides a low-density soluble fiber product prepared by the method described above.

[0047] In this invention, the bulk density of the low-bulk soluble fiber product is preferably 24–48 kg / m³. 3 More preferably 30-40 kg / cm² 3 The optimal value is 35 kg / cm². 3 .

[0048] The low-density soluble ceramic fiber products prepared by this invention are Class A non-combustible, with a non-fibrous material content of <30wt%, fiber diameter of 1-3μm, thermal conductivity of 0.031-0.034W / mk (average 25℃), and density of 24-48kg / m³. 3 This invention uses low density (24-48 kg / m³) 3 Soluble fiber products can replace traditional high-density (64-140 kg / m³) fibers. 3 The weight of the carrier itself can be significantly reduced by using soluble fiber products, thereby lowering procurement and operating costs. Furthermore, various shapes of soluble fiber products can be prepared through water-cutting or engraving processes, eliminating the need for on-site cutting, making construction convenient and quick, and reducing construction costs.

[0049] Example 1

[0050] A raw material consisting of calcium oxide, magnesium oxide, and silicon oxide in a mass ratio of 28.2:5.6:65.4 is melted, fiberized, collected, needle-punched, calcined, coated, and shaped to obtain a low-density soluble fiber product; the melting temperature is 1950℃; the collected fibers are uniform cotton blanks with a diameter of 50mm; the needle-punching density is 5 needles / cm. 2 The calcination temperature is 700℃ and the time is 10 min; the calcined product is individually coated with aluminum foil; the forming method is engraving; other process parameters are prepared according to the process parameters in Table 1, and the structural schematic diagram of the obtained low-density soluble fiber product is shown below. Figure 2 As shown.

[0051] The bulk density, non-fibrous material content, and thermal conductivity of the low-bulk soluble fiber product prepared in Example 1 of this invention were tested using the method specified in GB / T17911-2018 "Test Methods for Refractory Fiber Products". The fiber diameter of the low-bulk soluble fiber product prepared in Example 1 of this invention was tested using the method specified in GB / T5480-2017 "Test Methods for Mineral Wool and Its Products". The non-combustibility of the low-bulk soluble fiber product prepared in Example 1 of this invention was tested using the method specified in GB / T8624-2018 "Classification of Combustion Performance of Building Materials and Products".

[0052] The test results are shown in Table 1.

[0053] Examples 2-17 and Comparative Examples 1-10

[0054] Following the process method of Example 1, low-density soluble fiber products were prepared using the process conditions and parameters in Table 1; wherein, the low-density soluble fiber product prepared by calcining and covering six sides with glass fiber cloth in Example 3 is shown in the schematic diagram below. Figure 3 As shown.

[0055] The low-density soluble fiber prepared according to the method in Example 1 was subjected to performance testing, and the test results are shown in Table 1.

[0056] Table 1. Process conditions and performance test results for preparing low-density soluble fibers in the embodiments and comparative examples of the present invention.

[0057]

[0058]

[0059]

[0060] As can be seen from the above embodiments, the present invention controls the temperature through melting or fiber formation, thereby adjusting the diameter of the fibers and the content of non-fiber materials (other non-fiber materials besides fibers, including large non-fiber particles and fine powders), thus making it suitable for preparing low-density products with a density of 24-48 kg / m³. 3 With a diameter of 1–3 μm, it is used in the transportation industry. This invention requires no addition of organic matter during preparation and does not release flammable or odorous substances during use. Through coating, water-cutting, or engraving processes, this invention can achieve precise cutting of low-density soluble fiber products into any shape and size, meeting the needs of various parts of transportation vehicles.

[0061] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A method for preparing a low-density soluble fiber product, comprising: The raw materials are melted, fiberized, collected, needle-punched, calcined and shaped to obtain low-density soluble fiber products. The melting is carried out in a melting device, which includes a fluid inlet. The fluid inlet includes an inlet body and an intermediate channel for fluid outflow. The inlet body is externally connected to a conductive circuit, and the conductive inlet body is connected to the high-temperature molten liquid to form a closed circuit loop, controlling the temperature of the molten liquid outflow and regulating the temperature of the material channel from which the melt flows out. The temperature control of the molten liquid outflow is achieved by controlling the current of the inlet body; the current of the inlet body is 100~500A. During the melting process, the temperature of the melt arriving at the fiber-forming equipment is 100-200°C lower than the temperature of the melt flowing out of the melting equipment; The fiber-forming temperature is 1600~1700℃; The fiber-forming method is fiber spinning; the fiber spinning equipment is a fiber spinning roller; The speed at which the fibers are spun into fibers is 120~180m / s; The bulk density of the low-density soluble fiber product is 24~48 kg / m³. 3 The soluble fibers in the product have a diameter of 1~3μm; the thermal conductivity of the low-density soluble fiber product is as low as 0.031~0.035w / mk.

2. The method according to claim 1, characterized in that, The raw materials include: CaO, SiO2 and MgO.

3. The method according to claim 2, characterized in that, The mass ratio of CaO, SiO2 and MgO is (26~32):(64~67):(4~7).

4. The method according to claim 1, characterized in that, The cotton collection consists of uniform cotton blanks with a diameter of 50-200mm.

5. A low-density soluble fiber product prepared by the method of claim 1; wherein the density of the low-density soluble fiber product is 24~48 kg / m³. 3 The soluble fibers in the product have a diameter of 1~3μm; the thermal conductivity of the low-density soluble fiber product is as low as 0.031~0.035w / mk.

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