Manufacturing process and formula of ultra-high-strength inorganic fiberboard

Abstract

The invention relates to the technical field of inorganic fiberboards, and discloses a manufacturing process and formula of an ultrahigh-strength inorganic fiberboard, S1, raw material preparation and pretreatment: the inorganic fiberboard is prepared from the following raw materials in percentage by mass: 40-70% of reinforced fiber bundles; 15%-35% of a solid binder; 10%-30% of a flow promoter and a filler; 0.5%-3% of a coupling agent; s2, opening and mixing the fibers; and S3, paving by a dry method. According to the method, a traditional wet process is completely abandoned, water-saving, energy-saving and efficient green manufacturing is achieved, and the prepared inorganic fiberboard has extremely high strength and toughness and excellent fireproof performance and is suitable for the fields of buildings, aerospace, ships and the like which have harsh requirements for material performance.

Description

Technical Field

[0001] This invention relates to the field of inorganic fiberboard technology, and in particular to a manufacturing process and formula for ultra-high strength inorganic fiberboard. Background Technology

[0002] Traditional inorganic fiberboard generally suffers from poor toughness, low flexural strength, high density, and an inability to simultaneously achieve all the necessary properties such as water resistance, fire resistance, moisture resistance, and heat insulation. To improve its strength, methods such as increasing the density of the board or adding organic fibers (such as wood pulp or polymer fibers) are usually adopted, which leads to increased weight and cost of the board, or sacrifices its fire resistance and weather resistance.

[0003] Furthermore, its production method employs wet sheet forming or flow-through processes. This process suffers from drawbacks such as high water consumption, high drying energy consumption, the need for wastewater treatment, and the tendency for the boards to deform. In addition, the difficulty in controlling fiber dispersion during the wet process limits the production of high-fiber-content boards, resulting in a generally insufficient toughness in the products.

[0004] Therefore, improvements are needed. Summary of the Invention

[0005] The technical problem solved by this invention is to address the deficiencies in the prior art by providing a manufacturing process and formula for ultra-high strength inorganic fiberboard, thereby solving the problems mentioned in the background art.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: Manufacturing process of ultra-high strength inorganic fiberboard, S1: Raw material preparation and pretreatment. The inorganic fiberboard is composed of the following raw materials in the indicated mass fractions: 40%–70% reinforcing fiber bundles; 15%–35% solid binder; 10%–30% flow aids and fillers; 0.5%–3% coupling agent; the reinforcing fiber bundles are composed of two or three of the following: continuous basalt fibers, alkali-resistant glass fibers, and ceramic fibers with an average length of 20–50 mm; the solid binder is a thermoplastic solid polymer powder with a melting point or softening point between 80–180°C; the flow aids and fillers are composed of materials with a particle size of 200–1000 mesh. Spherical silica powder and / or quartz powder; coupling agent is silane coupling agent; S2: Fiber opening and mixing; a: The reinforcing fiber bundle is fed into the opening machine for preliminary opening, making it a loose fiber web; b: The opened fiber web, solid binder powder, flow aid and filler, and coupling agent are added to a high-speed mixing device; through mechanical stirring and airflow, the powder is uniformly adhered to the fiber surface, forming a "sand-on-sand" structure mixture; S3: Dry paving; The mixture is fed into a dry paving machine, and through airflow paving or mechanical paving, a uniform thickness and loose slab are formed on the steel strip or pad; Pre-compression: The loose slab is pre-compressed at room temperature with a pressure of 1-5. MPa, to pre-shape and transport it; hot pressing and curing: send the pre-pressed board into the hot press, and hot press for 5-15 minutes under the conditions of temperature 180-220℃ and pressure 10-25 MPa; cooling and post-processing: after the pressure is maintained, cool the mold with water to below 60℃, then release the pressure and remove the board, and cut it to length to obtain the high-strength inorganic fiberboard.

[0007] Furthermore, in step S1, the reinforcing fiber bundle is composed of basalt fiber, alkali-resistant glass fiber, and ceramic fiber, with the following weight ratio: basalt fiber: 30% to 50%; alkali-resistant glass fiber: 20% to 40%; ceramic fiber: 10% to 30%.

[0008] Furthermore, the solid binder is polyvinyl alcohol powder, polyester powder, or copolyamide powder.

[0009] Furthermore, the inorganic fiberboard is composed of the following raw materials in the indicated mass fractions: 40%–70% reinforcing fiber bundles; 15%–35% solid binder; 10%–30% flow aids and fillers; 0.5%–3% coupling agent; the reinforcing fiber bundles are composed of two or three of the following: continuous basalt fibers, alkali-resistant glass fibers, and ceramic fibers with an average length of 20–50 mm; the solid binder is a thermoplastic solid polymer powder with a melting point or softening point between 80–180 °C; the flow aids and fillers are spherical silica powder and / or quartz powder with a particle size of 200–1000 mesh; and the coupling agent is a silane coupling agent.

[0010] Furthermore, the reinforcing fiber bundle is composed of basalt fiber, alkali-resistant glass fiber and ceramic fiber, with the following weight ratio: basalt fiber: 30% to 50%; alkali-resistant glass fiber: 20% to 40%; ceramic fiber: 10% to 30%.

[0011] Furthermore, the solid binder is polyvinyl alcohol powder, polyester powder, or copolyamide powder.

[0012] Compared with the prior art, the beneficial effects of the present invention are as follows: Offering comprehensive performance: Utilizing continuous basalt fiber, glass fiber, and ceramic fiber with high aspect ratios as the reinforcing skeleton, thermoplastic solid polymer powder as the binder, and spherical powder fillers, a "sand-in-sand" structure mixture is formed through fiber opening and dry mixing. This mixture is then dry-laid, pre-compressed, and cured under high temperature and pressure in one step. By leveraging the high strength and modulus of basalt fiber, the toughness of alkali-resistant glass fiber, and the high-temperature resistance of ceramic fiber, these three elements complement each other to form a multi-scale, multi-functional reinforcement system. This achieves high flexural strength and toughness while maintaining the low density and lightweight characteristics of the board.

[0013] Combining fire resistance, water resistance, and thermal insulation: The entire product is made of inorganic fibers and fillers, fundamentally ensuring excellent fire resistance and high-temperature resistance. The solid binder forms a dense structure after hot pressing, which, combined with a hydrophobic coupling agent, significantly improves the board's moisture and water resistance. The loose fiber structure and inorganic materials themselves also endow the board with good thermal insulation properties.

[0014] Dry production process: The dry production process completely avoids the problems of high water consumption and large amount of industrial wastewater that need to be treated in the traditional wet papermaking process, and realizes green and clean production. The drying part and drying process, which are extremely energy-intensive in the wet process, are eliminated. The main energy consumption is concentrated in the short hot pressing process, and the overall production energy consumption is greatly reduced. Detailed Implementation

[0015] In view of the technical problems described in the background art, a manufacturing process for ultra-high strength inorganic fiberboard is provided. S1: Raw material preparation and pretreatment. The inorganic fiberboard is composed of the following raw materials in the indicated mass fractions: 40%–70% reinforcing fiber bundles; 15%–35% solid binder; 10%–30% flow aids and fillers; 0.5%–3% coupling agent. The reinforcing fiber bundles consist of two or three of the following: continuous basalt fibers, alkali-resistant glass fibers, and ceramic fibers with an average length of 20–50 mm. The solid binder is a thermoplastic solid polymer powder with a melting or softening point between 80–180°C. The flow aids and fillers are spherical silica powder and / or quartz powder with a particle size of 200–1000 mesh. The coupling agent is a silane coupling agent. S2: Fiber Opening and Mixing; a: The reinforcing fiber bundles are fed into an opening machine for initial opening, making them into a loose fiber web; b: The opened fiber web, solid binder powder, flow aid and filler, and coupling agent are added to a high-speed mixing device; through mechanical stirring and airflow, the powder is uniformly adhered to the fiber surface, forming a "sand-on-sand" structure mixture; S3: Dry Laying; The mixture is fed into a dry laying machine, and through airflow laying or mechanical laying, a uniform thickness and loose slab are formed on the steel strip or pad; Pre-compression: The loose slab is pre-compressed at room temperature with a pressure of 1-5. MPa, to pre-shape and transport it; hot pressing and curing: send the pre-pressed board into the hot press, and hot press for 5-15 minutes under the conditions of temperature 180-220℃ and pressure 10-25 MPa; cooling and post-processing: after the pressure is maintained, cool the mold with water to below 60℃, then release the pressure and remove the board, and cut it to length to obtain the high-strength inorganic fiberboard.

[0016] As a preferred implementation method, in step S1, the reinforcing fiber bundle is composed of basalt fiber, alkali-resistant glass fiber and ceramic fiber, with the following weight ratio: basalt fiber: 30% to 50%; alkali-resistant glass fiber: 20% to 40%; ceramic fiber: 10% to 30%.

[0017] As a preferred implementation method, the solid binder is polyvinyl alcohol powder, polyester powder or copolyamide powder.

[0018] Example 1: In this example, the reinforcing fiber bundle is composed of basalt fiber, alkali-resistant glass fiber and ceramic fiber.

[0019] The mass fraction of the raw material components is: The reinforcing fiber bundle comprises 55% by mass, including 25% by mass basalt fiber, 20% by mass alkali-resistant glass fiber, and 10% by mass ceramic fiber. The lengths of the basalt fiber, alkali-resistant glass fiber, and ceramic fiber can be selected according to implementation requirements, such as any size like 20mm, 30mm, 40mm, or 50mm, without any limitation.

[0020] A 25% by mass solid binder may be selected from polyvinyl alcohol powder, polyester powder or copolyamide powder; in this embodiment, polyvinyl alcohol powder is selected.

[0021] 19% by mass of flow aids and fillers, such as 15% by mass of spherical silica powder (600 mesh) and 4% by mass of quartz powder (800 mesh). The particle size can be selected according to actual production needs.

[0022] A 1% mass fraction of coupling agent, which is a silane coupling agent.

[0023] The reinforcing fiber bundles are fed into the opening machine, and the appropriate operating parameters are adjusted to perform preliminary opening, resulting in a fluffy and dispersed fiber web.

[0024] The opened fiber web, along with solid binder powder, flow aids, fillers, and coupling agents, is added to a high-speed mixing device. Through mechanical stirring and airflow, the powder adheres evenly to the fiber surface, forming a "sand-on-sand" structure in the mixture. This step is crucial for ensuring the uniformity of dry paving.

[0025] Dry paving: The mixture is fed into a dry paving machine, and a uniform and fluffy slab is formed on the steel strip or base plate through air-jet paving or mechanical paving.

[0026] Pre-pressing: The loose slab is pre-pressed at room temperature with a pressure of 1-5 MPa to initially shape it and facilitate transport.

[0027] Hot-press curing: The pre-pressed slab is fed into a hot press and hot-pressed for 5-15 minutes at a temperature of 180-220℃ and a pressure of 10-25 MPa. During this process, the solid binder melts and flows, fully wetting the fibers, and forms a dense three-dimensional network structure with the fibers and fillers under pressure.

[0028] Cooling and post-processing: After the pressure holding is completed, the mold is cooled with water to below 60°C, then the pressure is released and the board is removed. After being cut to length, the high-strength inorganic fiberboard is obtained.

[0029] Example 2: In this example, the reinforcing fiber bundle is composed of basalt fiber, alkali-resistant glass fiber and ceramic fiber.

[0030] The mass fraction of the raw material components is: The reinforcing fiber bundle comprises 65% by mass, including 35% by mass basalt fiber, 25% by mass alkali-resistant glass fiber, and 5% by mass ceramic fiber. The lengths of the basalt fiber, alkali-resistant glass fiber, and ceramic fiber can be selected according to implementation requirements, such as any size like 20mm, 30mm, 40mm, or 50mm, without any limitation.

[0031] A 20% by mass fraction of solid binder may be selected from polyvinyl alcohol powder, polyester powder or copolyamide powder; in this embodiment, polyvinyl alcohol powder is selected.

[0032] 14.2% by mass of flow aids and fillers, such as 12% by mass of spherical silica powder (400 mesh) and 2.4% by mass of quartz powder (800 mesh). The particle size can be selected according to actual production needs.

[0033] A 0.8% mass fraction coupling agent, which is a silane coupling agent.

[0034] The reinforcing fiber bundles are fed into the opening machine, and the appropriate operating parameters are adjusted to perform preliminary opening, resulting in a fluffy and dispersed fiber web.

[0035] The reinforcing fiber bundles are fed into the opening machine, and the appropriate operating parameters are adjusted to perform preliminary opening, resulting in a fluffy and dispersed fiber web.

[0036] The opened fiber web, along with solid binder powder, flow aids, fillers, and coupling agents, is added to a high-speed mixing device. Through mechanical stirring and airflow, the powder adheres evenly to the fiber surface, forming a "sand-on-sand" structure in the mixture. This step is crucial for ensuring the uniformity of dry paving.

[0037] Dry paving: The mixture is fed into a dry paving machine, and a uniform and fluffy slab is formed on the steel strip or base plate through air-jet paving or mechanical paving.

[0038] Pre-pressing: The loose slab is pre-pressed at room temperature with a pressure of 1-5 MPa to initially shape it and facilitate transport.

[0039] Hot-press curing: The pre-pressed slab is fed into a hot press and hot-pressed for 5-15 minutes at a temperature of 180-220℃ and a pressure of 10-25 MPa. During this process, the solid binder melts and flows, fully wetting the fibers, and forms a dense three-dimensional network structure with the fibers and fillers under pressure.

[0040] Cooling and post-processing: After the pressure holding is completed, the mold is cooled with water to below 60°C, then the pressure is released and the board is removed. After being cut to length, the high-strength inorganic fiberboard is obtained.

[0041] Example 3: In this example, the reinforcing fiber bundle is composed of alkali-resistant glass fiber and ceramic fiber.

[0042] The reinforcing fiber bundle comprises 45% by mass, including 25% by mass alkali-resistant glass fiber and 20% by mass ceramic fiber. The lengths of the alkali-resistant glass fiber and ceramic fiber can be selected according to implementation requirements, such as any size like 20mm, 30mm, 40mm, or 50mm, without limitation.

[0043] A 30% by mass solid binder may be selected from polyvinyl alcohol powder, polyester powder or copolyamide powder; in this embodiment, polyvinyl alcohol powder is selected.

[0044] 24% by mass of flow aids and fillers, such as 15% by mass of spherical silica powder (400 mesh) and 9% by mass of quartz powder (600 mesh). The particle size can be selected according to actual production needs.

[0045] A 1% mass fraction of coupling agent, which is a silane coupling agent.

[0046] The reinforcing fiber bundles are fed into the opening machine, and the appropriate operating parameters are adjusted to perform preliminary opening, resulting in a fluffy and dispersed fiber web.

[0047] The reinforcing fiber bundles are fed into the opening machine, and the appropriate operating parameters are adjusted to perform preliminary opening, resulting in a fluffy and dispersed fiber web.

[0048] The opened fiber web, along with solid binder powder, flow aids, fillers, and coupling agents, is added to a high-speed mixing device. Through mechanical stirring and airflow, the powder adheres evenly to the fiber surface, forming a "sand-on-sand" structure in the mixture. This step is crucial for ensuring the uniformity of dry paving.

[0049] Dry paving: The mixture is fed into a dry paving machine, and a uniform and fluffy slab is formed on the steel strip or base plate through air-jet paving or mechanical paving.

[0050] Pre-pressing: The loose slab is pre-pressed at room temperature with a pressure of 1-5 MPa to initially shape it and facilitate transport.

[0051] Hot-press curing: The pre-pressed slab is fed into a hot press and hot-pressed for 5-15 minutes at a temperature of 180-220℃ and a pressure of 10-25 MPa. During this process, the solid binder melts and flows, fully wetting the fibers, and forms a dense three-dimensional network structure with the fibers and fillers under pressure.

[0052] Cooling and post-processing: After the pressure holding is completed, the mold is cooled with water to below 60°C, then the pressure is released and the board is removed. After being cut to length, the high-strength inorganic fiberboard is obtained.

[0053] The following is a specific formulation for an ultra-high strength inorganic fiberboard, comprising the following raw materials by mass fraction: 40%–70% reinforcing fiber bundles; 15%–35% solid binder; 10%–30% flow aids and fillers; and 0.5%–3% coupling agent. The reinforcing fiber bundles consist of two or three of the following: continuous basalt fibers, alkali-resistant glass fibers, and ceramic fibers with an average length of 20–50 mm. The solid binder is a thermoplastic solid polymer powder with a melting or softening point between 80–180°C. The flow aids and fillers are spherical silica powder and / or quartz powder with a particle size of 200–1000 mesh. The coupling agent is a silane coupling agent.

[0054] Preferably, the reinforcing fiber bundle is composed of basalt fiber, alkali-resistant glass fiber and ceramic fiber, with the following weight ratio: basalt fiber: 30% to 50%; alkali-resistant glass fiber: 20% to 40%; ceramic fiber: 10% to 30%.

[0055] Preferably, the solid binder is polyvinyl alcohol powder, polyester powder, or copolyamide powder.

[0056] The above technical solution has at least the following beneficial effects.

[0057] 1. Using continuous basalt fiber, glass fiber, and ceramic fiber with a high aspect ratio as the reinforcing skeleton, thermoplastic solid polymer powder as the binder, and spherical powder filler, a "sand-in-sand" structure mixture is formed through fiber opening and dry mixing. This mixture is then formed in one step through dry laying, pre-compression, and high-temperature, high-pressure hot pressing curing. Utilizing the high strength and high modulus of basalt fiber, the toughness of alkali-resistant glass fiber, and the high-temperature resistance of ceramic fiber, the complementary advantages of these three materials form a multi-scale, multi-functional reinforcement system. This achieves high flexural strength and toughness while maintaining the low density and lightweight characteristics of the board.

[0058] 2. The use of entirely inorganic fibers and fillers fundamentally ensures the product's excellent fire resistance and high-temperature resistance. The solid binder forms a dense structure after hot pressing, which, combined with a hydrophobic coupling agent, significantly improves the board's moisture and water resistance. The loose fiber structure and inorganic materials themselves also endow the board with good thermal insulation properties.

[0059] 3. The use of a completely dry production method completely avoids the problems of high water consumption and large amounts of industrial wastewater that need to be treated in the traditional wet papermaking process, thus achieving green and clean production; it eliminates the drying part and drying process that are extremely energy-intensive in the wet process, and the main energy consumption is concentrated in the short hot pressing process, which greatly reduces the overall production energy consumption.

[0060] The above does not limit the technical scope of the present invention in any way. Any modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the technical scope of the present invention.

Claims

1. A manufacturing process for ultra-high strength inorganic fiberboard, characterized in that, S1: Raw material preparation and pretreatment. Inorganic fiberboard is composed of the following raw materials by mass fraction: 40%–70% of the fiber bundles are reinforced; 15%–35% solid binder; 10%–30% flow aids and fillers; 0.5%–3% coupling agent; The reinforcing fiber bundle is composed of two or three of the following: continuous basalt fibers, alkali-resistant glass fibers, and ceramic fibers with an average length of 20-50 mm. The solid binder is a thermoplastic solid polymer powder with a melting point or softening point between 80-180℃; The flow aid and filler are spherical silica powder and / or quartz powder with a particle size of 200-1000 mesh; The coupling agent is a silane coupling agent; S2: Fiber opening and mixing; a: The reinforcing fiber bundles are fed into the opening machine for initial opening, so that they become a fluffy fiber web; b: The opened fiber web, solid binder powder, flow aid and filler, and coupling agent are added together into a high-speed mixing device; through mechanical stirring and airflow, the powder is evenly adhered to the fiber surface to form a mixture with a "sand-on-sand" structure. S3: Dry paving; The mixture is fed into a dry paving machine, and through air-jet paving or mechanical paving, a slab of uniform thickness and loose texture is formed on the steel strip or base plate. Pre-pressing: The loose slab is pre-pressed at room temperature with a pressure of 1-5 MPa to initially shape it for transportation; Hot pressing curing: The pre-pressed slab is fed into a hot press and hot-pressed for 5-15 minutes at a temperature of 180-220℃ and a pressure of 10-25 MPa. Cooling and post-processing: After the pressure holding is completed, the mold is cooled with water to below 60°C, then the pressure is released and the board is removed. After cutting to length, high-strength inorganic fiberboard is obtained.

2. The manufacturing process for ultra-high strength inorganic fiberboard according to claim 1, characterized in that: In step S1, the reinforcing fiber bundles consist of basalt fibers, alkali-resistant glass fibers, and ceramic fibers, with the following weight ratio range: Basalt fiber: 30%–50%; Alkali-resistant glass fiber: 20%–40%; Ceramic fiber: 10%–30%.

3. The manufacturing process for ultra-high strength inorganic fiberboard according to claim 1, characterized in that: The solid binder is polyvinyl alcohol powder, polyester powder, or copolyamide powder.

4. The ultra-high strength inorganic fiberboard formulation of claim 1, wherein, Inorganic fiberboard is composed of the following raw materials by mass fraction: 40%–70% of the fiber bundles are reinforced; 15%–35% solid binder; 10%–30% flow aids and fillers; 0.5%–3% coupling agent; The reinforcing fiber bundle is composed of two or three of the following: continuous basalt fibers, alkali-resistant glass fibers, and ceramic fibers with an average length of 20-50 mm. The solid binder is a thermoplastic solid polymer powder with a melting point or softening point between 80-180℃; The flow aid and filler are spherical silica powder and / or quartz powder with a particle size of 200-1000 mesh; The coupling agent is a silane coupling agent.

5. The ultra-high strength inorganic fiberboard formulation according to claim 4, characterized in that: The reinforcing fiber bundles are composed of basalt fibers, alkali-resistant glass fibers, and ceramic fibers, with the following weight ratio range: Basalt fiber: 30%–50%; Alkali-resistant glass fiber: 20%–40%; Ceramic fiber: 10%–30%.

6. The ultra-high strength inorganic fiberboard formulation according to claim 4, characterized in that: The solid binder is polyvinyl alcohol powder, polyester powder, or copolyamide powder.