High-temperature-resistant fireproof anti-deformation composite ceramic fiber board and preparation method thereof

Abstract

The invention discloses a high-temperature-resistant fireproof anti-deformation composite ceramic fiber board and a preparation method thereof.The composite ceramic fiber board comprises an anti-deformation ceramic fiber layer and high-temperature-resistant fireproof ceramic fiber layers arranged on the surfaces of the two sides of the anti-deformation ceramic fiber layer; the high-temperature-resistant and fire-resistant ceramic fiber layer and the anti-deformation ceramic fiber layer are both prepared by drying a wet blank of ceramic fiber mixed slurry. According to the composite ceramic fiber board, the quartz fibers are added into the raw materials of the high-temperature-resistant and fire-resistant ceramic fiber layer to improve the anti-deformation capacity of the high-temperature-resistant and fire-resistant ceramic fiber layer, and the fiber layer, close to the outer side, of the composite ceramic fiber board can have the excellent anti-deformation capacity; the middle ceramic fiber layer is prepared from the three mixed chopped ceramic fibers with high silicon content and low oxygen content, so that the anti-deformation ceramic fiber layer has higher elastic modulus, and the elastic modulus of the composite ceramic fiber board can be improved by a multi-layer fiber structure, so that the anti-deformation capability of the composite ceramic fiber board is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of the preparation of ceramic fiber boards, and in particular to a composite ceramic fiber board with high temperature resistance, fire resistance and anti-deformation and a preparation method thereof. Background Art

[0002] A ceramic fiber board is a fibrous lightweight refractory material board and a common heat insulation material. Because of its advantages such as light weight, high temperature resistance, good thermal stability and low thermal conductivity, it has been widely used in many industries; In the application process of the existing ceramic fiber boards, they may undergo deformation due to various physical and chemical changes, thereby affecting the performance of the ceramic fiber boards.

[0003] The defects of the existing ceramic fiber boards are as follows: 1. The patent document CN112573933B proposes a ceramic fiber board and a preparation method thereof, but the preparation method of the ceramic fiber board in this patent document does not consider improving the anti-deformation ability of the ceramic fiber board; 2. In the prior art, the fiber raw material of most ceramic fiber boards is aluminosilicate fiber, but the ceramic fiber board prepared only from aluminosilicate fiber has poor thermal shock resistance and a high expansion coefficient, and is not suitable for use in an environment with rapid temperature changes; 3. The application document CN104513050A discloses an inorganic fiber heat insulation material and a preparation method thereof, but the ceramic fiber board prepared by this patent document has a small density and poor strength and cannot withstand large pressures; 4. In the prior art, the fiber layers between ordinary composite fiber boards are compounded by means of mechanical splicing and pasting, and there are problems of insecure pasting and easy cracking at the splicing points. Summary of the Invention

[0004] The purpose of the present invention is to provide a composite ceramic fiber board with high temperature resistance, fire resistance and anti-deformation and a preparation method thereof, so as to solve the problems put forward in the above background art.

[0005] To achieve the above purpose, the present invention provides the following technical solution: A composite ceramic fiber board with high temperature resistance, fire resistance and anti-deformation, the composite ceramic fiber board includes an anti-deformation ceramic fiber layer and high temperature resistant and fire resistant ceramic fiber layers arranged on both side surfaces of the anti-deformation ceramic fiber layer; Both the high temperature resistant and fire resistant ceramic fiber layer and the anti-deformation ceramic fiber layer are made after drying the wet blanks of the ceramic fiber mixed slurry, and the ceramic fiber mixed raw slurry includes mixed ceramic fibers, cationic organic binders, anionic inorganic binders and refractory fillers; The mixed ceramic fibers in the ceramic fiber mixed stock solution of the high-temperature resistant refractory ceramic fiber layer include quartz fiber, zirconium silicate fiber and aluminum silicate fiber. The mixed ceramic fibers in the ceramic fiber mixed stock solution of the anti-deformation ceramic fiber layer are chopped mixed ceramic fibers, and the chopped mixed ceramic fibers include aluminum silicate fiber, silicon carbide fiber and alumina fiber.

[0006] Preferably, the raw materials of the ceramic fiber mixed slurry of the high-temperature resistant refractory ceramic fiber layer include 50 to 65 parts by weight of mixed ceramic fibers, 2.5 to 12 parts of cationic organic binder, 2 to 18 parts of anionic inorganic binder, and 3 to 12 parts of refractory filler. The raw materials of the ceramic fiber mixed slurry of the anti-deformation ceramic fiber layer include 65 to 78 parts by weight of mixed ceramic fibers, 2.5 to 12 parts of cationic organic binder, 2 to 18 parts of anionic inorganic binder, and 3 to 12 parts of refractory filler.

[0007] Preferably, the anionic inorganic binder is silica sol, the solid content of the silica sol is 8% to 35%, the cationic organic binder is pregelatinized starch, and the refractory filler is kaolin.

[0008] Preferably, the mass ratio of the aluminum silicate fiber, silicon carbide fiber and alumina fiber is (2 to 3):(5 to 8):(4 to 5).

[0009] Preferably, the length of the chopped mixed ceramic fibers is 0.08 mm to 0.85 mm.

[0010] Preferably, the mass ratio of the quartz fiber, zirconium silicate fiber and aluminum silicate fiber is (3 to 4):(2 to 4):(1 to 3).

[0011] Preferably, the thickness of the anti-deformation ceramic fiber layer is 1 mm to 1.5 mm, and the thickness of the high-temperature resistant refractory ceramic fiber layer is 0.5 mm to 0.6 mm.

[0012] Preferably, a preparation method of a high-temperature resistant, refractory and anti-deformation composite ceramic fiber board includes the following steps: Step S1: Weigh the mixed ceramic fibers, cationic organic binder and refractory filler of the high-temperature resistant refractory ceramic fiber layer according to parts by weight, mix the weighed raw materials with water and beat them into a slurry, stir evenly, and add an anionic inorganic binder for flocculation to obtain a flocculated mixed slurry A; Step S2: Weigh the chopped mixed ceramic fibers, cationic organic binder and refractory filler of the anti-deformation ceramic fiber layer according to parts by weight, mix the weighed raw materials with water and beat them into a slurry, stir evenly, and add an anionic inorganic binder for flocculation to obtain a flocculated mixed slurry B; Step S3: Inject the bottom-layer mixed slurry A into the facade forming mold, dehydrate it, then inject the middle-layer mixed slurry B and dehydrate it, then inject the upper-layer mixed slurry A and dehydrate it, and then perform pressing to obtain a composite green body; Step S4: Dry the composite green body to obtain a composite ceramic fiber board.

[0013] Preferably, in Step S1 and Step S2, the time for weighing the raw materials and mixing them with water for pulping is 6 min to 13 min.

[0014] Preferably, in Step S3 and Step S4, the dehydration of the mixed slurry is vacuum filtration dehydration, the vacuum degree of dehydration is 0.03 MPa to 0.05 MPa, the dehydration time is 3 min to 7 min, the drying temperature is 95 °C to 120 °C, and the drying time is 8 h to 10 h Compared with the prior art, the beneficial effects of the present invention are as follows: 1. In the present invention, by adding quartz fiber to the raw materials of the high-temperature resistant refractory ceramic fiber layer, the anti-deformation ability of the high-temperature resistant refractory ceramic fiber layer is improved. The quartz fiber is mixed with zirconium silicate fiber and aluminum silicate fiber to prepare the high-temperature resistant refractory ceramic fiber layer, so that the outer fiber layer of the composite ceramic fiber board can have excellent high-temperature resistant and refractory properties while also having superior anti-deformation ability. The raw materials of the middle anti-deformation ceramic fiber layer are aluminum silicate fiber, silicon carbide fiber, and alumina fiber. The middle ceramic fiber layer is prepared by mixing three kinds of short-cut ceramic fibers with high silicon content and low oxygen content, so that the anti-deformation ceramic fiber layer has a higher elastic modulus. The multi-layer fiber structure of the fiber board can also improve the elastic modulus of the composite ceramic fiber board, thereby improving the anti-deformation ability of the composite ceramic fiber.

[0015] 2. In the present invention, by using ceramic fiber raw materials with low thermal expansion coefficient and excellent thermal shock resistance coefficient to prepare different fiber layers of the composite ceramic fiber board, the composite ceramic fiber board can have excellent high-temperature resistant and refractory properties while having a low thermal expansion coefficient and a high thermal shock resistance coefficient, ensuring the structural stability and service life of the ceramic fiber board, and enabling the composite ceramic fiber board to still maintain good performance in high-temperature environments and situations of rapid temperature change.

[0016] 3. In the present invention, by performing short-cut treatment on the raw materials of the anti-deformation ceramic fiber layer, the density of the anti-deformation ceramic fiber layer is higher than that of the high-temperature resistant refractory ceramic fiber layer. At the same time, the fiber content of the anti-deformation ceramic fiber layer is relatively large, resulting in a high density of the anti-deformation ceramic fiber layer. Therefore, the middle layer of the composite ceramic fiber board has a hard texture, excellent toughness, and compressive strength. At the same time, the three-layer fiber layer composite structure of the composite ceramic fiber can further improve the compressive strength of the ceramic fiber board.

[0017] 4. The composite ceramic fiber board of the present invention splices different fiber layers by means of wet pressing and then drying, so that the splicing between each fiber layer is firm, improving the splicing firmness of different fiber layers in the composite ceramic fiber board, and thus effectively reducing the problem of easy cracking at the splicing of different fiber layers. Detailed implementation manners

[0018] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Apparently, the described embodiments are only a part of the embodiments of the present invention, rather than all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0019] The present invention provides a composite ceramic fiber board with high temperature resistance, fire resistance and anti-deformation. The composite ceramic fiber board includes an anti-deformation ceramic fiber layer and high temperature resistant and fire resistant ceramic fiber layers arranged on both side surfaces of the anti-deformation ceramic fiber layer; Among them, in the present invention, both the high temperature resistant and fire resistant ceramic fiber layer and the anti-deformation ceramic fiber layer are made by drying the wet blanks of the ceramic fiber mixed slurry. The ceramic fiber mixed raw slurry includes mixed ceramic fibers, cationic organic binders, anionic inorganic binders and refractory fillers; In the present invention, the mixed ceramic fibers in the ceramic fiber mixed raw slurry of the high temperature resistant and fire resistant ceramic fiber layer include quartz fibers, zirconium silicate fibers and aluminum silicate fibers. The mixed ceramic fibers in the ceramic fiber mixed raw slurry of the anti-deformation ceramic fiber layer are chopped mixed ceramic fibers, and the chopped mixed ceramic fibers include aluminum silicate fibers, silicon carbide fibers, and alumina fibers.

[0020] In the present invention, the raw materials of the ceramic fiber mixed slurry of the high temperature resistant and fire resistant ceramic fiber layer include 50 parts to 65 parts of mixed ceramic fibers, 2.5 parts to 12 parts of cationic organic binders, 2 parts to 18 parts of anionic inorganic binders and 3 parts to 12 parts of refractory fillers by weight. The raw materials of the ceramic fiber mixed slurry of the anti-deformation ceramic fiber layer include 65 parts to 78 parts of mixed ceramic fibers, 2.5 parts to 12 parts of cationic organic binders, 2 parts to 18 parts of anionic inorganic binders and 3 parts to 12 parts of refractory fillers by weight.

[0021] In the present invention, the anionic inorganic binder is silica sol, the solid content of the silica sol is 8% to 35%, the cationic organic binder is pregelatinized starch, and the refractory filler is kaolin.

[0022] In the present invention, the mass ratio of the aluminum silicate fiber, silicon carbide fiber and alumina fiber is (2 - 3):(5 - 8):(4 - 5).

[0023] The length of the chopped mixed ceramic fibers described in the present invention is 0.08 mm to 0.85 mm.

[0024] The mass ratio of the quartz fibers, zirconium silicate fibers and aluminum silicate fibers described in the present invention is (3 - 4):(2 - 4):(1 - 3).

[0025] The thickness of the deformation-resistant ceramic fiber layer in the present invention is 1 mm to 1.5 mm, and the thickness of the high-temperature resistant refractory ceramic fiber layer is 0.5 mm to 0.6 mm.

[0026] The present invention also provides a preparation method of a composite ceramic fiber board with high-temperature resistance, fire resistance and deformation resistance, comprising the following steps: Step S1: Weigh the mixed ceramic fibers, cationic organic binder and refractory filler of the high-temperature resistant refractory ceramic fiber layer according to parts by weight, mix the weighed raw materials with water and make a pulp, stir evenly, add an anionic inorganic binder for flocculation to obtain the flocculated mixed slurry A; Step S2: Weigh the chopped mixed ceramic fibers, cationic organic binder and refractory filler of the deformation-resistant ceramic fiber layer according to parts by weight, mix the weighed raw materials with water and make a pulp, stir evenly, add an anionic inorganic binder for flocculation to obtain the flocculated mixed slurry B; Step S3: Inject the bottom-layer mixed slurry A into a vertical forming mold and dehydrate it, inject the middle-layer mixed slurry B and dehydrate it, then inject the upper-layer mixed slurry A and dehydrate it, and then perform pressing to obtain a composite wet blank; Step S4: Dry the composite wet blank to obtain a composite ceramic fiber board.

[0027] Among them, in Step S1 and Step S2, the time for weighing the raw materials and mixing them with water to make a pulp is 6 min to 13 min.

[0028] In Step S3 and Step S4, the dehydration of the mixed slurry is vacuum filtration dehydration, the vacuum degree of dehydration is 0.03 MPa to 0.05 MPa, the dehydration time is 3 min to 7 min, the drying temperature is 95 °C to 120 °C, and the drying time is 8 h to 10 h.

[0029] In the present invention, by adding quartz fiber to the raw materials of the high-temperature resistant refractory ceramic fiber layer, the anti-deformation ability of the high-temperature resistant refractory ceramic fiber layer is better. Quartz fiber has extremely excellent low expansion coefficient and thermal shock resistance, good strength retention rate at high temperature, and stable size. Mixing quartz fiber with zirconium silicate fiber and aluminum silicate fiber to prepare the high-temperature resistant refractory ceramic fiber layer enables the outer fiber layer of this composite ceramic fiber board to have excellent high-temperature resistant refractory performance while also having excellent anti-deformation ability. The raw materials of the anti-deformation ceramic fiber layer located in the middle layer of this composite ceramic fiber board are aluminum silicate fiber, silicon carbide fiber, and alumina fiber. The mixed chopped fibers of these three ceramic fibers have a high silicon content and a low oxygen content, which enables this anti-deformation ceramic fiber layer to have a higher elastic modulus, thereby improving the anti-deformation ability of this composite ceramic fiber. The multi-layer fiber structure of this fiber board can also improve the elastic modulus of this composite ceramic fiber board, thereby further improving the anti-deformation ability of this ceramic fiber board.

[0030] In the present invention, before preparing the anti-deformation ceramic fiber layer, the raw material fibers are chopped, so that the density of this anti-deformation ceramic fiber layer is higher than that of the high-temperature resistant refractory ceramic fiber layer. At the same time, this anti-deformation ceramic fiber layer has a higher fiber content, resulting in a high density of this anti-deformation ceramic fiber layer, thereby enabling this anti-deformation ceramic fiber layer to have a hard texture, excellent toughness and compressive strength. The three-layer fiber layer composite structure of this composite ceramic fiber can also further improve the compressive strength of this ceramic fiber board.

[0031] In the present invention, different fiber layers of this composite ceramic fiber board are prepared by using ceramic fiber raw materials with excellent low expansion coefficient and thermal shock resistance coefficient, so that this composite ceramic fiber board can have excellent high-temperature resistant refractory performance while having a low thermal expansion coefficient and a high thermal shock resistance coefficient, ensuring the structural stability and service life of this ceramic fiber board, and enabling this composite ceramic fiber board to still maintain good performance in high-temperature environments and situations with rapid temperature changes.

[0032] In the present invention, the splicing between fiber layers of this composite ceramic fiber board adopts the method of wet pressing and then drying. By drying the composite green body, the splicing of each fiber layer is made firm, thereby improving the splicing firmness of different fiber layers in this composite ceramic fiber board and effectively reducing the problem of easy cracking at the splicing of different fiber layers.

[0033] The features and properties of the present invention will be further described in detail below in conjunction with embodiments. Example 1

[0034] This embodiment provides a composite ceramic fiber board with high temperature resistance, fire resistance and anti-deformation. The composite ceramic fiber board includes an anti-deformation ceramic fiber layer and high temperature resistant and fire resistant ceramic fiber layers disposed on both surface sides of the anti-deformation ceramic fiber layer; Wherein, both the high temperature resistant and fire resistant ceramic fiber layer and the anti-deformation ceramic fiber layer are made by drying the wet blanks of the ceramic fiber mixture slurry. The ceramic fiber mixed stock slurry includes mixed ceramic fibers, cationic organic binders, anionic inorganic binders and refractory fillers; The mixed ceramic fibers in the ceramic fiber mixed stock slurry of the high temperature resistant and fire resistant ceramic fiber layer include quartz fibers, zirconium silicate fibers and aluminum silicate fibers. The mixed ceramic fibers in the ceramic fiber mixed stock slurry of the anti-deformation ceramic fiber layer are chopped mixed ceramic fibers. The chopped mixed ceramic fibers include aluminum silicate fibers, silicon carbide fibers and alumina fibers.

[0035] The raw materials of the ceramic fiber mixture slurry of the high temperature resistant and fire resistant ceramic fiber layer include, by weight, 50 parts of mixed ceramic fibers, 2.5 parts of cationic organic binders, 10 parts of anionic inorganic binders and 5 parts of refractory fillers. The raw materials of the ceramic fiber mixture slurry of the anti-deformation ceramic fiber layer include, by weight, 65 parts of mixed ceramic fibers, 2.5 parts of cationic organic binders, 3 parts of anionic inorganic binders and 5 parts of refractory fillers.

[0036] The anionic inorganic binder is silica sol, the solid content of the silica sol is 15%, the cationic organic binder is pregelatinized starch, and the refractory filler is kaolin.

[0037] The mass ratio of the aluminum silicate fibers, silicon carbide fibers and alumina fibers is 3:5:4.

[0038] The length of the chopped mixed ceramic fibers is 0.1 mm.

[0039] The mass ratio of the quartz fibers, zirconium silicate fibers and aluminum silicate fibers is 3:2:1.

[0040] The thickness of the anti-deformation ceramic fiber layer is 1 mm, and the thickness of the high temperature resistant and fire resistant ceramic fiber layer is 0.5 mm.

[0041] A preparation method of the composite ceramic fiber board with high temperature resistance, fire resistance and anti-deformation provided by this embodiment includes the following steps: Step S1: Weigh the mixed ceramic fibers, cationic organic binders and refractory fillers of the high temperature resistant and fire resistant ceramic fiber layer by weight, mix the weighed raw materials with water and beat them into a slurry, stir evenly, add the anionic inorganic binder for flocculation to obtain the flocculated mixed slurry A; Step S2: Weigh the chopped mixed ceramic fibers, cationic organic binder, and refractory filler of the anti-deformation ceramic fiber layer according to parts by weight, mix the weighed raw materials with water to make a pulp, stir evenly, and add an anionic inorganic binder for flocculation to obtain the flocculated mixed slurry B; Step S3: Inject the bottom mixed slurry A into the vertical forming mold and dehydrate it, then inject the middle mixed slurry B and dehydrate it, then inject the upper mixed slurry A and dehydrate it, and then press it to obtain a composite green body; Step S4: Dry the composite green body to obtain a composite ceramic fiber board.

[0042] Among them, in Step S1 and Step S2, the time for weighing the raw materials and mixing them with water to make a pulp is 8 min.

[0043] In Step S3 and Step S4, the dehydration of the mixed slurry is vacuum filtration dehydration, the vacuum degree of dehydration is 0.04 MPa, the dehydration time is 5 min, the drying temperature is 100 °C, and the drying time is 8 h. Example 2

[0044] This example provides a composite ceramic fiber board with high temperature resistance, fire resistance, and anti-deformation. The composite ceramic fiber board includes an anti-deformation ceramic fiber layer and high temperature resistant and fire resistant ceramic fiber layers provided on both side surfaces of the anti-deformation ceramic fiber layer; Among them, both the high temperature resistant and fire resistant ceramic fiber layer and the anti-deformation ceramic fiber layer are made by drying the green body of the ceramic fiber mixed slurry. The ceramic fiber mixed stock solution includes mixed ceramic fibers, cationic organic binders, anionic inorganic binders, and refractory fillers; The mixed ceramic fibers in the ceramic fiber mixed stock solution of the high temperature resistant and fire resistant ceramic fiber layer include quartz fibers, zirconium silicate fibers, and aluminum silicate fibers. The mixed ceramic fibers in the ceramic fiber mixed stock solution of the anti-deformation ceramic fiber layer are chopped mixed ceramic fibers, and the chopped mixed ceramic fibers include aluminum silicate fibers, silicon carbide fibers, and alumina fibers.

[0045] The raw materials of the ceramic fiber mixed slurry of the high temperature resistant and fire resistant ceramic fiber layer include 58 parts of mixed ceramic fibers, 3 parts of cationic organic binder, 5 parts of anionic inorganic binder, and 8 parts of refractory filler according to parts by weight. The raw materials of the ceramic fiber mixed slurry of the anti-deformation ceramic fiber layer include 67 parts of mixed ceramic fibers, 4 parts of cationic organic binder, 10 parts of anionic inorganic binder, and 6 parts of refractory filler according to parts by weight.

[0046] The anionic inorganic binder is silica sol, the solid content of the silica sol is 15%, the cationic organic binder is pregelatinized starch, and the refractory filler is kaolin.

[0047] The mass ratio of the aluminosilicate fiber, silicon carbide fiber and alumina fiber is 3:5:5.

[0048] The length of the chopped mixed ceramic fiber is 0.25 mm.

[0049] The mass ratio of the quartz fiber, zirconium silicate fiber and aluminosilicate fiber is 4:3:3.

[0050] The thickness of the deformation-proof ceramic fiber layer is 1.5 mm, and the thickness of the high-temperature resistant refractory ceramic fiber layer is 0.6 mm.

[0051] A preparation method of a high-temperature resistant, refractory and deformation-proof composite ceramic fiber board provided by this embodiment includes the following steps: Step S1: Weigh the mixed ceramic fiber, cationic organic binder and refractory filler of the high-temperature resistant refractory ceramic fiber layer according to parts by weight, mix the weighed raw materials with water to make a pulp, stir evenly, add an anionic inorganic binder for flocculation to obtain a flocculated mixed slurry A; Step S2: Weigh the chopped mixed ceramic fiber, cationic organic binder and refractory filler of the deformation-proof ceramic fiber layer according to parts by weight, mix the weighed raw materials with water to make a pulp, stir evenly, add an anionic inorganic binder for flocculation to obtain a flocculated mixed slurry B; Step S3: Inject the bottom-layer mixed slurry A into the vertical forming mold and then dehydrate it, inject the middle-layer mixed slurry B and dehydrate it, then inject the upper-layer mixed slurry A and dehydrate it, and then press it to obtain a composite wet blank; Step S4: Dry the composite wet blank to obtain a composite ceramic fiber board.

[0052] Among them, in Step S1 and Step S2, the time for weighing the raw materials and mixing them with water to make a pulp is 10 min.

[0053] In Step S3 and Step S4, the dehydration of the mixed slurry is vacuum filtration dehydration, the vacuum degree of dehydration is 00.05 MPa, the dehydration time is 3 min, the drying temperature is 120 °C, and the drying time is 8 h. Example Three

[0054] This embodiment provides a high-temperature resistant, refractory and deformation-proof composite ceramic fiber board, which includes a deformation-proof ceramic fiber layer and high-temperature resistant refractory ceramic fiber layers arranged on both side surfaces of the deformation-proof ceramic fiber layer; Among them, both the high-temperature resistant refractory ceramic fiber layer and the deformation-proof ceramic fiber layer are made after drying the wet blanks of the ceramic fiber mixed slurry, and the ceramic fiber mixed raw slurry includes mixed ceramic fiber, cationic organic binder, anionic inorganic binder and refractory filler; The mixed ceramic fibers in the ceramic fiber mixed stock solution of the high-temperature resistant refractory ceramic fiber layer include quartz fibers, zirconium silicate fibers, and aluminum silicate fibers. The mixed ceramic fibers in the ceramic fiber mixed stock solution of the anti-deformation ceramic fiber layer are chopped mixed ceramic fibers, and the chopped mixed ceramic fibers include aluminum silicate fibers, silicon carbide fibers, and alumina fibers.

[0055] The raw materials of the ceramic fiber mixed slurry of the high-temperature resistant refractory ceramic fiber layer include 62 parts by weight of mixed ceramic fibers, 6 parts of cationic organic binder, 12 parts of anionic inorganic binder, and 7 parts of refractory filler. The raw materials of the ceramic fiber mixed slurry of the anti-deformation ceramic fiber layer include 72 parts by weight of mixed ceramic fibers, 5 parts of cationic organic binder, 5 parts of anionic inorganic binder, and 10 parts of refractory filler.

[0056] The anionic inorganic binder is silica sol, the solid content of the silica sol is 25%, the cationic organic binder is pregelatinized starch, and the refractory filler is kaolin.

[0057] The mass ratio of the aluminum silicate fibers, silicon carbide fibers, and alumina fibers is 3:7:5.

[0058] The length of the chopped mixed ceramic fibers is 0.7 mm.

[0059] The mass ratio of the quartz fibers, zirconium silicate fibers, and aluminum silicate fibers is 3:2:1.

[0060] The thickness of the anti-deformation ceramic fiber layer is 1.3 mm, and the thickness of the high-temperature resistant refractory ceramic fiber layer is 0.6 mm.

[0061] A preparation method of a high-temperature resistant, refractory, and anti-deformation composite ceramic fiber board provided in this embodiment includes the following steps: Step S1: Weigh the mixed ceramic fibers, cationic organic binder, and refractory filler of the high-temperature resistant refractory ceramic fiber layer according to the parts by weight, mix the weighed raw materials with water and beat them into a slurry, stir evenly, add the anionic inorganic binder for flocculation to obtain the flocculated mixed slurry A; Step S2: Weigh the chopped mixed ceramic fibers, cationic organic binder, and refractory filler of the anti-deformation ceramic fiber layer according to the parts by weight, mix the weighed raw materials with water and beat them into a slurry, stir evenly, add the anionic inorganic binder for flocculation to obtain the flocculated mixed slurry B; Step S3: Inject the bottom-layer mixed slurry A into the vertical forming mold and dehydrate it, then inject the middle-layer mixed slurry B and dehydrate it, then inject the upper-layer mixed slurry A and dehydrate it, and then press it to obtain a composite green blank; Step S4: Dry the composite green blank to obtain a composite ceramic fiber board.

[0062] Among them, in steps S1 and S2, the time for weighing the raw materials and mixing them with water for pulping is 9 minutes.

[0063] In steps S3 and S4, the dehydration of the mixed slurry is vacuum filtration dehydration. The vacuum degree of dehydration is 0.05 MPa, the dehydration time is 4 minutes, the drying temperature is 110 °C, and the drying time is 9 hours.

[0064] Comparative Example 1: This comparative example provides a ceramic fiber board. The mixed ceramic fibers in the ceramic fiber mixed stock solution of the ceramic fiber layer include quartz fibers, zirconium silicate fibers, and aluminum silicate fibers. The raw materials of the mixed ceramic fiber slurry include 50 parts of mixed ceramic fibers, 2.5 parts of cationic organic binder, 10 parts of anionic inorganic binder, and 5 parts of refractory filler by weight.

[0065] The anionic inorganic binder is silica sol, the solid content of the silica sol is 15%, the cationic organic binder is pregelatinized starch, and the refractory filler is kaolin.

[0066] The mass ratio of quartz fiber, zirconium silicate fiber, and aluminum silicate fiber is 3:2:1.

[0067] The thickness of the ceramic fiber layer is 2 mm.

[0068] A comparative example provided by the present invention: A preparation method of a high-temperature resistant, fireproof, and deformation-resistant composite ceramic fiber board includes the following steps: Step S1: Weigh the mixed ceramic fibers, cationic organic binder, and refractory filler of the ceramic fiber board by weight, mix the weighed raw materials with water for pulping, stir evenly, and add an anionic inorganic binder for flocculation to obtain a flocculated mixed slurry. Step S2: Inject the bottom layer of the mixed slurry into a vertical forming mold for dehydration, and then press it to obtain a green body. Step S3: Dry the green body to obtain a ceramic fiber board.

[0069] Among them, in step S1, the time for weighing the raw materials and mixing them with water for pulping is 8 minutes.

[0070] In steps S2 and S3, the dehydration of the mixed slurry is vacuum filtration dehydration. The vacuum degree of dehydration is 0.04 MPa, the dehydration time is 5 minutes, the drying temperature is 100 °C, and the drying time is 8 hours.

[0071] The differences between the ceramic fiber board of this comparative example and its preparation method and those of Example 1 are that the ceramic fiber board of this comparative example has a single-layer ceramic fiber structure. The ceramic fiber mixing slurry of the single-layer ceramic fiber board has the same raw materials and raw material weight ratios as those of the high-temperature resistant refractory ceramic fiber layer in Example 1, and there is no pressing of multiple layers of slurries. The rest are the same as those in Example 1.

[0072] Comparative Example 2: This comparative example provides a high-temperature resistant, refractory and deformation-resistant composite ceramic fiber board, which includes a deformation-resistant ceramic fiber layer and high-temperature resistant refractory ceramic fiber layers arranged on both surface sides of the deformation-resistant ceramic fiber layer; Among them, both the high-temperature resistant refractory ceramic fiber layer and the deformation-resistant ceramic fiber layer are made after drying the wet blanks of the ceramic fiber mixing slurry. The ceramic fiber mixed raw slurry of the high-temperature resistant refractory ceramic fiber layer includes mixed ceramic fibers, cationic organic binders, anionic inorganic binders, and refractory fillers. The ceramic fiber mixed raw slurry of the deformation-resistant ceramic fiber layer includes aluminum silicate ceramic fibers, cationic organic binders, anionic inorganic binders, and refractory fillers.

[0073] The mixed ceramic fibers in the ceramic fiber mixed raw slurry of the high-temperature resistant refractory ceramic fiber layer include quartz fibers, zirconium silicate fibers, and aluminum silicate fibers. The aluminum silicate ceramic fibers in the ceramic fiber mixed raw slurry of the deformation-resistant ceramic fiber layer are chopped ceramic fibers.

[0074] The raw materials of the ceramic fiber mixing slurry of the high-temperature resistant refractory ceramic fiber layer include 50 parts by weight of mixed ceramic fibers, 2.5 parts of cationic organic binders, 10 parts of anionic inorganic binders, and 5 parts of refractory fillers. The raw materials of the ceramic fiber mixing slurry of the deformation-resistant ceramic fiber layer include 65 parts by weight of aluminum silicate ceramic fibers, 2.5 parts of cationic organic binders, 3 parts of anionic inorganic binders, and 5 parts of refractory fillers.

[0075] The anionic inorganic binder is silica sol, the solid content of the silica sol is 15%, the cationic organic binder is pre-gelatinized starch, and the refractory filler is kaolin.

[0076] The length of the chopped mixed ceramic fibers is 0.1 mm.

[0077] The mass ratio of quartz fibers, zirconium silicate fibers, and aluminum silicate fibers is 3:2:1.

[0078] The thickness of the deformation-resistant ceramic fiber layer is 1 mm, and the thickness of the high-temperature resistant refractory ceramic fiber layer is 0.5 mm.

[0079] The preparation method of a high-temperature resistant, refractory and deformation-resistant composite ceramic fiber board provided by this comparative example includes the following steps: Step S1: Weigh the mixed ceramic fibers, cationic organic binder, and refractory filler of the high-temperature resistant refractory ceramic fiber layer according to parts by weight. Mix the weighed raw materials with water to make a slurry, stir evenly, add an anionic inorganic binder for flocculation to obtain the flocculated mixed slurry A; Step S2: Weigh the chopped ceramic fibers, cationic organic binder, and refractory filler of the anti-deformation ceramic fiber layer according to parts by weight. Mix the weighed raw materials with water to make a slurry, stir evenly, add an anionic inorganic binder for flocculation to obtain the flocculated mixed slurry B; Step S3: Inject the bottom-layer mixed slurry A into the vertical forming mold and dehydrate it, then inject the middle-layer mixed slurry B and dehydrate it, then inject the upper-layer mixed slurry A and dehydrate it, and then press it to obtain a composite green body; Step S4: Dry the composite green body to obtain a composite ceramic fiber board.

[0080] Among them, in Step S1 and Step S2, the time for weighing the raw materials and mixing them with water to make a slurry is 8 min.

[0081] In Step S3 and Step S4, the dehydration of the mixed slurry is vacuum filtration dehydration, the vacuum degree of dehydration is 0.04 MPa, the dehydration time is 5 min, the drying temperature is 100 °C, and the drying time is 8 h.

[0082] The difference between the ceramic fiber board and its preparation method of this comparative example and those of Example 1 is that the raw materials of the anti-deformation ceramic fiber layer of the composite ceramic fiber board of this comparative example do not use chopped mixed ceramic fibers, and only use aluminum silicate fibers as the fiber raw material of the ceramic fibers, and the rest are the same as those in Example 1.

[0083] In the above examples and comparative examples, the weight ratios of various fiber raw materials are as follows in the table: ; Performance test: Refer to the method of GB / T13480-2014 to test the compressive strength performance of the ceramic fiber board samples obtained in the examples and comparative examples, and conduct a refractory performance test experiment on the ceramic fiber board samples prepared in the examples and comparative examples according to GB / T9978. This experiment mainly focuses on the compressive strength and refractory duration of the ceramic fiber board.

[0084] The results of the performance test are as follows in the table: ; Combined with the above examples and comparative examples, and analyzed in combination with the test results: Through the comparison between Examples 1 to 3 and Comparative Example 1, the refractory performance of the ceramic fiber board samples in Examples 1 to 3 is significantly better than that of the ceramic fiber board samples in Comparative Example 1; By comparing Examples 1 to 3 with Comparative Example 2, the compressive strength of the ceramic fiber board samples in Examples 1 to 3 is superior to that of the ceramic fiber board samples in Comparative Example 2.

[0085] For those skilled in the art, it is obvious that the present invention is not limited to the details of the above exemplary embodiments, and the present invention can be implemented in other specific forms without departing from the spirit or basic characteristics of the present invention. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-restrictive. The scope of the present invention is defined by the appended claims rather than the above description. Therefore, all changes falling within the meaning and scope of the equivalent elements of the claims are intended to be included in the present invention.

Claims

1. A composite ceramic fiber board with high temperature resistance, fire resistance and anti-deformation, characterized in that, The composite ceramic fiber board includes a deformation-proof ceramic fiber layer and high-temperature resistant refractory ceramic fiber layers disposed on both side surfaces of the deformation-proof ceramic fiber layer; Both the high-temperature resistant refractory ceramic fiber layer and the deformation-proof ceramic fiber layer are made by drying wet blanks of ceramic fiber mixture slurries. The ceramic fiber mixed original slurry includes mixed ceramic fibers, cationic organic binders, anionic inorganic binders, and refractory fillers; The mixed ceramic fibers in the ceramic fiber mixed original slurry of the high-temperature resistant refractory ceramic fiber layer include quartz fibers, zirconium silicate fibers, and aluminum silicate fibers. The mixed ceramic fibers in the ceramic fiber mixed original slurry of the deformation-proof ceramic fiber layer are chopped mixed ceramic fibers. The chopped mixed ceramic fibers include aluminum silicate fibers, silicon carbide fibers, and alumina fibers.

2. A high-temperature resistant, fireproof and deformation-proof composite ceramic fiber board according to claim 1, characterized in that: The raw materials of the ceramic fiber mixture slurry of the high-temperature resistant refractory ceramic fiber layer include, by weight, 50 parts to 65 parts of mixed ceramic fibers, 2.5 parts to 12 parts of cationic organic binders, 2 parts to 18 parts of anionic inorganic binders, and 3 parts to 12 parts of refractory fillers. The raw materials of the ceramic fiber mixture slurry of the deformation-proof ceramic fiber layer include, by weight, 65 parts to 78 parts of mixed ceramic fibers, 2.5 parts to 12 parts of cationic organic binders, 2 parts to 18 parts of anionic inorganic binders, and 3 parts to 12 parts of refractory fillers.

3. A composite ceramic fiber board with high temperature resistance, fire resistance and anti-deformation according to claim 1, characterized in that: The anionic inorganic binder is silica sol, the solid content of the silica sol is 8% to 35%, the cationic organic binder is pre-gelatinized starch, and the refractory filler is kaolin.

4. A composite ceramic fiber board with high temperature resistance, fire resistance and anti-deformation, as described in claim 1, characterized in that: The mass ratio of the aluminum silicate fibers, silicon carbide fibers, and alumina fibers is (2 to 3):(5 to 8):(4 to 5).

5. A composite ceramic fiber board with high temperature resistance, fire resistance and anti-deformation, as described in claim 1, characterized in that: The length of the chopped mixed ceramic fibers is 0.08 mm to 0.85 mm.

6. The composite ceramic fiber board with high temperature resistance, fire resistance and anti-deformation according to claim 1, characterized in that: The mass ratio of the quartz fibers, zirconium silicate fibers, and aluminum silicate fibers is (3 to 4):(2 to 4):(1 to 3).

7. A composite ceramic fiber board with high temperature resistance, fire resistance and anti-deformation, characterized in that: The thickness of the deformation-proof ceramic fiber layer is 1 mm to 1.5 mm, and the thickness of the high-temperature resistant refractory ceramic fiber layer is 0.5 mm to 0.6 mm.

8. A preparation method of a composite ceramic fiber board with high temperature resistance, fire resistance and anti-deformation. According to any one of claims 1-7, a composite ceramic fiber board with high temperature resistance, fire resistance and anti-deformation, characterized in that, It includes the following steps: Step S1: Weigh the mixed ceramic fibers, cationic organic binders, and refractory fillers of the high-temperature resistant refractory ceramic fiber layer by weight, mix the weighed raw materials with water for beating, stir evenly, and add an anionic inorganic binder for flocculation to obtain a flocculated mixed slurry A; Step S2: Weigh the chopped mixed ceramic fibers, cationic organic binders, and refractory fillers of the deformation-proof ceramic fiber layer by weight, mix the weighed raw materials with water for beating, stir evenly, and add an anionic inorganic binder for flocculation to obtain a flocculated mixed slurry B; Step S3: Inject the bottom mixed slurry A into a vertical forming mold for dehydration, inject the middle mixed slurry B for dehydration, then inject the upper mixed slurry A and dehydrate, and then perform pressing to obtain a composite wet blank; Step S4: Dry the composite wet blank to obtain a composite ceramic fiber board.

9. The preparation method of a composite ceramic fiber board with high temperature resistance, fire resistance and anti-deformation according to claim 8, characterized in that: In Step S1 and Step S2, the time for weighing the raw materials and mixing them with water for beating is 6 min to 13 min.

10. The preparation method of a composite ceramic fiber board with high temperature resistance, fire resistance and anti-deformation according to claim 8, characterized in that: In steps S3 and S4, the dehydration of the mixed slurry is vacuum filtration dehydration, the vacuum degree of dehydration is 0.03 MPa to 0.05 MPa, the dehydration time is 3 min to 7 min, the drying temperature is 95 °C to 120 °C, and the drying time is 8 h to 10 h.