Density-Gradient Inorganic Fiber Molded Body for Wind Erosion
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Solution Overview
Problem
Conventional inorganic fiber molded bodies suffer from issues such as fiber and particulate matter scattering, environmental pollution, and poor thermal and mechanical shock resistance, especially when exposed to high temperatures or mechanical stress, limiting their effectiveness as heat-insulating materials in industrial furnaces.
Innovation Solution
An inorganic fiber molded body with a structured density gradient, comprising high-fiber and low-fiber density regions, is produced by impregnating an inorganic sol into an aggregate of inorganic fibers and subjecting it to controlled drying, which enhances thermal, mechanical, and wind erosion resistance while minimizing surface particulate matter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional dehydration molding process is used to produce inorganic fiber molded bodies, then the molded bodies can be produced with relatively light weight and easy processing, but they suffer from occurrence of cracks and fiber scattering on the surface due to mechanical shock and thermal shock
Solution Approach 1:
The patent changes the density distribution parameter of the inorganic fiber molded body by controlling the particle size distribution of inorganic particles. By using a specific mixture of fine particles (0.1-10 μm) and coarse particles (10-100 μm) in defined proportions, the molded body achieves optimized packing density and structural integrity that prevents crack formation and fiber scattering while maintaining ease of processing
Solution Approach 2:
The patent creates a composite structure within the inorganic fiber molded body by combining inorganic fibers with a dual-component particle system (fine and coarse particles). This composite arrangement allows the fine particles to fill gaps and bind fibers while coarse particles provide structural framework, resulting in improved resistance to mechanical and thermal shocks without compromising manufacturability
2Weight of moving object
If inorganic fibers with diameter not more than 3 μm are used to achieve light weight, then the molded bodies become lighter, but fiber scattering and harmful cristobalite formation increase at high temperatures
Solution Approach 1:
The patent controls the particle size parameter by using a bimodal distribution with fine particles (0.1-10 μm) and coarse particles (10-100 μm). This parameter optimization allows the use of lightweight inorganic fibers while the fine particles act as binders to prevent fiber scattering and the coarse particles provide thermal stability to suppress cristobalite formation at high temperatures
Solution Approach 2:
The patent introduces fine inorganic particles as an intermediary substance that binds the lightweight inorganic fibers together. This intermediary material prevents the fibers from scattering at high temperatures while the specific size range and proportion of fine particles ensure they do not promote harmful cristobalite formation, thus enabling use of light-weight fibers without the associated harmful effects
3Reliability
If aggregate of inorganic fibers subjected to needling treatment is used to achieve high thermal shock resistance, then thermal shock resistance improves, but the material suffers from wind erosion and fiber scattering under high wind blow speed conditions
Solution Approach 1:
The patent optimizes the particle size distribution parameter by combining fine particles (0.1-10 μm) and coarse particles (10-100 μm) in specific proportions. The fine particles create a dense matrix that binds fibers effectively for thermal shock resistance, while the coarse particles provide a rugged outer structure that resists wind erosion, thus resolving the contradiction between thermal shock resistance and wind erosion resistance
4Reliability
If glass layer coating is applied to prevent fiber scattering, then fiber scattering is reduced, but the glass layer peels off or cracks due to thermal expansion at high temperatures
Solution Approach 1:
The patent extracts the coating function from a separate glass layer application and integrates it into the bulk structure by incorporating fine inorganic particles (0.1-10 μm) throughout the molded body during manufacturing. These fine particles form a stable binding matrix that prevents fiber scattering inherently, eliminating the need for a separate glass coating that would peel or crack due to thermal expansion differences
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting inorganic fiber molded body is lightweight, resistant to thermal and mechanical shocks, and exhibits improved wind erosion resistance, making it suitable for various heat-insulating applications without significant fiber or particulate matter scattering.
Implementation Method 1
impregnating an inorganic sol into an aggregate of inorganic fibers
Implementation Method 2
subjecting it to suction dehydration
Data Source
AI summary
The inorganic fiber molded body of the present invention is characterized in that the molded body has an extremely light weight, and is free from problems such as scattering of fibers and particulate matters from a surface thereof and environmental pollution such as generation of harmful gases. In addition, the present invention provides an inorganic fiber molded body that is excellent in not only thermal shock resistance and mechanical shock resistance but also a high-speed wind erosion resistance, well-balanced in properties and can be used in the applications of various heat-insulating materials. The present invention relates to an inorganic fiber molded body comprising inorganic fibers and inorganic binder particles and having at least one set of a high-fiber density region and a low-fiber density region, in which a ratio of a content of the binder particles in the high-fiber density region to a content of the binder particles in the low-fiber density region as measured by a predetermined method is 0.5:1 to 5:1; and a number-average particle diameter and the number of the inorganic binder particles on an outermost surface of the molded body as measured by a predetermined method are 20 to 35 μm and less than 15, respectively.