Production process of high-stability zirconia fiber felt

Abstract

This invention discloses a production process for high-stability zirconia fiber felt, comprising the following steps: weighing raw materials according to a formula, dispersing and preparing an impregnation slurry in a mixing device, and transferring the impregnation slurry to a slurry tank for later use; selecting zirconia fiber matrix, placing all the zirconia fiber matrix in the slurry tank to fully absorb the impregnation slurry, and pumping air into the slurry tank during this process to accelerate the absorption efficiency. The beneficial effects of this invention are: by preparing zirconia fiber felt through the process of placing zirconia fibers in the impregnation slurry for adsorption and then shaping and sintering, its texture strength can be improved, thereby ensuring its resistance to deformation during use. Furthermore, the addition of zirconium sol, yttrium sol, and white latex to the impregnation slurry ensures that the stable zirconia fibers will not be lost during sintering. The added toughening agent, chromium chloride, and calcium stearate can improve the strength of the prepared zirconia fiber felt, thereby ensuring the stability of the zirconia fiber felt in use.

Description

Technical Field

[0001] This invention relates to the field of zirconia fiber felt technology, specifically a production process for high-stability zirconia fiber felt. Background Technology

[0002] Compared with other inorganic fiber materials such as zirconia aluminum fiber, mullite fiber, and aluminosilicate fiber, zirconia fiber has the advantages of high melting point, high thermal resistance coefficient, good fire resistance, good fiber morphology even at 2500℃ in the atmosphere, resistance to acid and alkali chemical corrosion, and low vapor pressure at high temperatures. Therefore, zirconia fiber can be used as a key basic material for ultra-high temperature insulation filling, composite, structural reinforcement, or toughening. In addition, it can be used to manufacture various zirconia fiber products, mainly including zirconia fiber felt, fiber blanket, zirconia fiber paper, zirconia fiber cloth, and rigid zirconia fiber products, depending on their morphology and structure. Due to its different structure, zirconia fiber is used in various environments with different requirements. Because its coefficient of thermal expansion is similar to that of many metals, alloys, glass, and concrete, it can be used as a reinforcing agent for various matrices such as metals, ceramics, glass, resins, and cement. It has unique advantages in impact-resistant high-temperature thermal insulation composite materials. It can also be used in lasers, fuel cell membranes, satellite and aero-engine components, as well as for filtering or catalyst carriers of high-temperature or chemically corrosive gases. Because of its characteristics such as resistance to ultra-high temperatures, low thermal conductivity, resistance to high-temperature oxidation, and strong corrosion resistance, it is widely used in the fields of advanced military technology and civilian industry.

[0003] A search revealed a patent, CN104671812B, which describes a method for producing stable zirconia powder fiber felt. This method uses fiber felt as a carrier, first soaking it in a saturated zirconia solution, then treating the surface with zirconia sol, and finally sintering it at high temperature to obtain zirconia powder fiber felt. This method is characterized by its simple production process, low production cost, lack of complex equipment, and environmental friendliness. The resulting zirconia powder fiber felt has high strength and high temperature resistance, making it suitable for use in ultra-high temperature environments. However, while using fiber felt as the base material results in a simple process, it suffers from insufficient toughness and poor resistance to deformation during use. Therefore, this invention proposes a production process for highly stable zirconia fiber felt. Summary of the Invention

[0004] The purpose of this invention is to provide a production process for highly stable zirconia fiber felt to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a production process for high-stability zirconia fiber felt, comprising the following steps:

[0006] S1. Weigh the raw materials according to the formula, and place the raw materials in the mixing equipment to disperse and prepare the soaking slurry. After preparation, transfer the soaking slurry to the slurry tank for later use.

[0007] S2. Select zirconia fiber matrix material, place all of the zirconia fiber matrix material in the slurry tank to fully absorb the soaking slurry, and pump air into the slurry tank during this process to accelerate the absorption efficiency and obtain zirconia fiber soaking solution.

[0008] S3. Filter the zirconium oxide fiber soaking solution in S2 to remove excess water, and spread the remaining slurry evenly on the material plate for shaping. After the slurry dries and is shaped, it is sintered at high temperature to form zirconium oxide fiber felt.

[0009] The raw materials for the soaking slurry in step S1 include: 3-5 parts zirconium sol, 1-2 parts yttrium sol, 1-5 parts filler, 1-10 parts foaming agent, 3-9 parts polyvinyl alcohol, 2-3 parts white latex, 1-5 parts toughening agent, 11-19 parts chromium chloride, 5-7 parts calcium stearate, and 75-85 parts water.

[0010] Preferably, the method for preparing the soaking slurry in step S1 is as follows:

[0011] A1. Weigh out the corresponding amounts of water, zirconium sol, yttrium sol and white glue according to the formula, and mix them in a material tank. After the zirconium sol, yttrium sol and white glue are completely dispersed in the water, set aside for later use.

[0012] A2. Weigh the filler, foaming agent, polyvinyl alcohol, toughening agent, chromium chloride and calcium stearate, and place the above raw materials in the material tank and the solution in A1, and mix them again. After foaming occurs, the preparation of the soaking slurry is completed.

[0013] Preferably, the length of the zirconium oxide fiber matrix in step S1 is 1-10 mm, and more preferably 1-3 mm.

[0014] Preferably, the time for the zirconium oxide fiber matrix to absorb the soaking slurry in step S2 is 12-36 hours.

[0015] Preferably, the gas pumped into the slurry tank in step S2 is an inert gas, preferably argon, and the pumping time is 2-4 hours.

[0016] Preferably, the thickness of the slurry in step S3 is 2-4 mm, and the thickness difference is less than 0.3 mm.

[0017] Preferably, the sintering temperature in step S3 is 900-1600℃, the heating rate during sintering is 3-5℃ / s, and the sintering time is 3-6 hours.

[0018] Compared with the prior art, the beneficial effects of the present invention are as follows: by preparing zirconia fiber felt by placing zirconia fibers in an immersion slurry for adsorption and then shaping and sintering, the texture strength can be improved, thereby ensuring the resistance to deformation during use. Furthermore, the addition of zirconium sol, yttrium sol and white latex to the immersion slurry ensures that the stable zirconia fibers will not be lost during the sintering process. The added toughening agent, chromium chloride and calcium stearate can improve the strength of the prepared zirconia fiber felt, thereby ensuring the stability of the zirconia fiber felt in use. Detailed Implementation

[0019] This invention provides a technical solution: a production process for high-stability zirconia fiber felt, comprising the following steps:

[0020] S1. Weigh the raw materials according to the formula, and place the raw materials in the mixing equipment to disperse and prepare the soaking slurry. After preparation, transfer the soaking slurry to the slurry tank for later use.

[0021] S2. Select zirconia fiber matrix material, place all of the zirconia fiber matrix material in the slurry tank to fully absorb the soaking slurry, and pump air into the slurry tank during this process to accelerate the absorption efficiency and obtain zirconia fiber soaking solution.

[0022] S3. Filter the zirconium oxide fiber soaking solution in S2 to remove excess water, and spread the remaining slurry evenly on the material plate for shaping. After the slurry dries and is shaped, it is sintered at high temperature to form zirconium oxide fiber felt.

[0023] Zirconia fiber felt can be prepared by immersing zirconia fibers in an soaking slurry for adsorption and then sintering it to improve its texture and strength, thereby ensuring its resistance to deformation during use.

[0024] The raw materials for the soaking slurry in step S1 include: 3-5 parts zirconium sol, 1-2 parts yttrium sol, 1-5 parts filler, 1-10 parts foaming agent, 3-9 parts polyvinyl alcohol, 2-3 parts white latex, 1-5 parts toughening agent, 11-19 parts chromium chloride, 5-7 parts calcium stearate, and 75-85 parts water.

[0025] Preferably, the method for preparing the soaking slurry in step S1 is as follows:

[0026] A1. Weigh out the corresponding amounts of water, zirconium sol, yttrium sol and white glue according to the formula, and mix them in a material tank. After the zirconium sol, yttrium sol and white glue are completely dispersed in the water, set aside for later use.

[0027] A2. Weigh the filler, foaming agent, polyvinyl alcohol, toughening agent, chromium chloride and calcium stearate, and place the above raw materials in the material tank and the solution in A1, and mix them again. After foaming occurs, the preparation of the soaking slurry is completed.

[0028] The addition of zirconium sol, yttrium sol, and white glue to the soaking slurry ensures that the stable zirconium oxide fibers are not lost during the sintering process. The added toughening agent, chromium chloride, and calcium stearate can improve the strength of the prepared zirconium oxide fiber felt, thereby ensuring the stability of the zirconium oxide fiber felt in use.

[0029] Preferably, in step S1, the length of the zirconia fiber matrix is ​​1-10 mm, preferably 1-3 mm; in step S2, the zirconia fiber matrix absorbs the soaking slurry for 12-36 hours; in step S2, the gas pumped into the slurry tank is an inert gas, preferably argon, and the pumping time is 2-4 hours; in step S3, the thickness of the slurry spread is 2-4 mm, and the thickness difference is less than 0.3 mm; in step S3, the sintering temperature is 900-1600℃, the heating rate during sintering is 3-5℃ / s, and the sintering time is 3-6 hours.

[0030] Example 1:

[0031] Weigh out 75 parts water, 3 parts zirconium sol, 1 part yttrium sol, and 2 parts white latex according to the formula, and mix them in a material tank. Once the zirconium sol, yttrium sol, and white latex are completely dispersed in the water, set aside. Weigh out 1 part filler, 1 part foaming agent, 3 parts polyvinyl alcohol, 1 part toughening agent, 11 parts chromium chloride, and 5 parts calcium stearate, and place these raw materials in a material tank with the solution in A1. Mix again until foaming occurs, completing the preparation of the soaking slurry. Then transfer the soaking slurry to a slurry tank for later use. Select zirconium oxide fibers with a length of 1-10 mm. The zirconia fiber matrix is ​​placed entirely in a slurry tank to fully absorb and soak the slurry for 18 hours. During this process, argon gas is pumped into the slurry tank for 2 hours to accelerate the absorption efficiency, resulting in a zirconia fiber soaking solution. The zirconia fiber soaking solution is filtered to remove excess water, and the remaining slurry is evenly spread on a material plate for shaping, with the spreading thickness controlled at 2 mm. After the slurry dries and is formed, it is sintered at high temperature for 3 hours, with the maximum sintering temperature controlled at 1200℃ and the heating rate during the sintering process at 3℃ / s, thereby forming the desired zirconia fiber felt.

[0032] Example 2:

[0033] Weigh out 85 parts water, 5 parts zirconium sol, 2 parts yttrium sol, and 3 parts white latex according to the formula, and mix them in a material tank. Once the zirconium sol, yttrium sol, and white latex are completely dispersed in the water, set aside. Weigh out 3 parts filler, 5 parts foaming agent, 6 parts polyvinyl alcohol, 3 parts toughening agent, 15 parts chromium chloride, and 6 parts calcium stearate, and place these raw materials in a material tank with the solution in A1. Mix again until foaming occurs, completing the preparation of the soaking slurry. Then transfer the soaking slurry to a slurry tank for later use. Select zirconium oxide fibers with a length of 1-10 mm. The zirconia fiber matrix is ​​placed entirely in a slurry tank to fully absorb and soak the slurry for 35 hours. During this process, argon gas is pumped into the slurry tank for 4 hours to accelerate the absorption efficiency, resulting in a zirconia fiber soaking solution. The zirconia fiber soaking solution is filtered to remove excess water, and the remaining slurry is evenly spread on a material plate for shaping, with the spreading thickness controlled at 4 mm. After the slurry dries and is formed, it is sintered at high temperature for 4 hours, with the maximum sintering temperature controlled at 1400℃ and the heating rate during the sintering process at 4℃ / s, thereby forming the desired zirconia fiber felt.

[0034] While embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A process for producing a high-stability zirconia fiber mat, characterized by, Includes the following steps: S1. Weigh the raw materials according to the formula, and place the raw materials in the mixing equipment to disperse and prepare the soaking slurry. After preparation, transfer the soaking slurry to the slurry tank for later use. S2. Select zirconia fiber matrix material, place all of the zirconia fiber matrix material in the slurry tank to fully absorb the soaking slurry, and pump air into the slurry tank during this process to accelerate the absorption efficiency and obtain zirconia fiber soaking solution. S3. Filter the zirconium oxide fiber soaking solution in S2 to remove excess water, and spread the remaining slurry evenly on the material plate for shaping. After the slurry dries and is shaped, it is sintered at high temperature to form zirconium oxide fiber felt. The raw materials for the soaking slurry in step S1 include: 3-5 parts zirconium sol, 1-2 parts yttrium sol, 1-5 parts filler, 1-10 parts foaming agent, 3-9 parts polyvinyl alcohol, 2-3 parts white latex, 1-5 parts toughening agent, 11-19 parts chromium chloride, 5-7 parts calcium stearate, and 75-85 parts water.

2. The production process of a high-stability zirconia fiber felt according to claim 1, characterized in that: The method for preparing the soaking slurry in step S1 is as follows: A1. Weigh out the corresponding amounts of water, zirconium sol, yttrium sol and white glue according to the formula, and mix them in a material tank. After the zirconium sol, yttrium sol and white glue are completely dispersed in the water, set aside for later use. A2. Weigh the filler, foaming agent, polyvinyl alcohol, toughening agent, chromium chloride and calcium stearate, and place the above raw materials in the material tank and the solution in A1, and mix them again. After foaming occurs, the preparation of the soaking slurry is completed.

3. The process for producing a high-stability zirconia fiber felt according to claim 1, characterized by: The length of the zirconium oxide fiber matrix in step S1 is 1-10 mm.

4. The process for producing a high-stability zirconia fiber felt according to claim 1, characterized by: In step S2, the zirconium oxide fiber matrix absorbs the soaking slurry for 12-36 hours.

5. The process for producing a high-stability zirconia fiber felt according to claim 1, characterized by: In step S2, the gas pumped into the slurry tank is an inert gas, and the pumping time is 2-4 hours.

6. The process for producing a high-stability zirconia fiber felt according to claim 1, characterized by: In step S3, the thickness of the slurry spreading is 2-4 mm, and the difference in spreading thickness is less than 0.3 mm.

7. The production process of a high-stability zirconia fiber felt according to claim 1, characterized in that: In step S3, the sintering temperature is 900-1600℃, the heating rate during sintering is 3-5℃ / s, and the sintering time is 3-6 hours.