CN101454148B - 支承绝热板 - Google Patents

支承绝热板 Download PDF

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Publication number
CN101454148B
CN101454148B CN2007800200190A CN200780020019A CN101454148B CN 101454148 B CN101454148 B CN 101454148B CN 2007800200190 A CN2007800200190 A CN 2007800200190A CN 200780020019 A CN200780020019 A CN 200780020019A CN 101454148 B CN101454148 B CN 101454148B
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colloidal
insulating product
plate
inorganic oxide
temperature
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CN101454148A (zh
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M·M·德索扎
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Unifrax I LLC
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Unifrax Corp
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00—Thermal insulation in general
    • F16L59/02—Shape or form of insulating materials, with or without coverings integral with the insulating materials
    • F16L59/026—Mattresses, mats, blankets or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B1/00—Layered products having a general shape other than plane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions
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Abstract

支承绝热板(41-45，51-55)包括胶态无机氧化物浸渍、挤压并干燥的耐高温无机纤维垫或板，板(41-45，51-55)具有高达至少约1000℃的使用温度，并在暴露于使用温度后保持机械完整性，板(41-45，51-55)具有大于或等于约500kg/m3的密度和至少约4900kPa(50kgf/cm2)的耐压力。

Description

支承绝热板
技术领域
提供绝热制品如支承绝热板和制造它们的方法。支承绝热板在一种实施方案中可用于防止热从熔化金属处理设备或其它设备中传导出来或进入。
发明背景
在熔化金属如钢或铝的加工中，金属处理装置如钢包(ladles)、鱼雷车(torpedo cars)、槽形浇道（trough runners)、中间罐(tundishes)和模具(molds)必须耐熔化金属、耐施加的机械应力和还避免系统过早热损失，从而熔化金属可在适宜温度下被输送到成型装置。
熔化金属处理装置因此包括与熔化金属直接接触的材料，如对熔化金属表现出优异非润湿特性的热面、致密和坚硬难熔材料。然后用一层高度绝热难熔材料支承这种材料，高度绝热难熔材料为装置提供冷面绝热。支承绝热材料的绝热性和强度越高，就越可制备更薄的支承绝热层以提供所需性能特性。较薄的支承绝热允许熔化金属处理装置尤其如钢包或鱼雷车有更大的金属容量。
概述
提供一种绝热制品，包括胶态无机氧化物浸渍的挤压并干燥的耐高温无机纤维垫(blanket)或板(board)，其中胶态无机氧化物为胶态无机氧化物与胶凝剂(gelling agent)的组合物;制品具有高达(up to)至少约1000℃的使用温度，并在暴露于使用温度后保持机械完整性(mechanical integrity)，制品具有大于或等于约500kg/m3的密度和至少约4900kPa(50kgf/cm2)的耐压力(compression resistance)。
在一些实施方案中，绝热制品在约700℃至约800℃的温度下具有小于或等于约0.45W/mK的热导率(thermal conductivity)。绝热制品可用作支承绝热板。
商业陶瓷纤维垫或板可用作原料，或者可以在用胶态无机氧化物溶液浸渍前，通过常规真空铸造(vacuum cast)法制备陶瓷纤维板。
本发明提供了以下技术方案：
1．一种绝热制品，包括胶态无机氧化物溶液组合物浸渍的挤压并干燥的耐高温无机纤维垫或板，其中胶态无机氧化物溶液组合物为胶态无机氧化物与胶凝剂的组合物；制品具有高达至少1000℃的使用温度，并在暴露于使用温度后保持机械完整性，制品具有大于500kg/m3的密度和至少4900kPa的耐压力，
其中胶凝剂包括无机盐或氧化物，和酸；
其中耐高温无机纤维包括陶瓷纤维、碱土金属硅酸盐纤维或其混合物中的至少一种；
其中胶态无机氧化物包括胶态二氧化硅、胶态氧化铝、胶态氧化锆、胶态氧化钛、胶态氧化铈或胶态氧化钇中的至少一种；
其中胶态无机氧化物溶液组合物包括胶态无机氧化物，0.01-10wt%无机盐或氧化物和0.01-10wt%酸的胶凝剂，和数量足以溶解胶凝剂的水，任选地该数量高达溶液组合物的70wt%，其中胶态无机氧化物溶液组合物包括30-100wt%的胶态无机氧化物，其中胶态无机氧化物溶液组合物的总重量是100wt%；
其中绝热制品包括20-80wt%的纤维和20-80wt%的胶态无机氧化物。
2．技术方案1的绝热制品，其中胶态无机氧化物溶液组合物为胶态二氧化硅与胶凝剂的组合物；制品具有大于或等于700kg/m3的密度和至少7800kPa的耐压力。
3．技术方案2的绝热制品，其中胶态无机氧化物溶液组合物包括胶态二氧化硅，0.01-10wt%无机盐或氧化物和0.01-10wt%酸的胶凝剂，和数量足以溶解胶凝剂的水，任选地该数量高达组合物的70wt%；其中胶态无机氧化物溶液组合物包括30-100wt%的胶态二氧化硅，其中胶态无机氧化物溶液组合物的总重量是100wt%。
4．技术方案3的绝热制品，其中制品具有大于或等于900kg/m3的密度、至少11800kPa的耐压力和在700到800℃的温度下小于或等于0.45W/mK的热导率。
5．技术方案3的绝热制品，包括30-80wt%的纤维和20-70wt%的胶态二氧化硅。
6．技术方案3的绝热制品，其中胶凝剂无机盐或氧化物包括醋酸铵、氯化钙、氯化镁或氧化镁中的至少一种，酸包括乙酸、盐酸或磷酸中的至少一种。
7．技术方案2的绝热制品，其中在用胶态无机氧化物溶液组合物首次浸渍后用至少胶态二氧化硅再次浸渍耐高温无机纤维垫或板，挤压和任选地干燥；制品具有大于或等于1100kg/m3的密度和至少29000kPa的耐压力。
8．技术方案7的绝热制品，包括20-60wt%的纤维和40-80wt%的胶态二氧化硅。
9．技术方案1的绝热制品，包括胶态二氧化硅浸渍的真空铸造陶瓷纤维板，制品具有高达1300℃的使用温度，大于或等于700kg/m3的密度和至少6800kPa的耐压力。
10．技术方案9的绝热制品，其中真空铸造陶瓷纤维板在胶态二氧化硅浸渍前包括0.4-50wt%的高氧化铝纤维、4-90wt%的管状氧化铝，和0.01-0.2wt%的淀粉。
11．技术方案9的绝热制品，包括40-80wt%的纤维和20-60wt%的胶态二氧化硅。
12．技术方案9的绝热制品，其中真空铸造陶瓷纤维板由包括0.1-2wt%的铝硅酸盐纤维、0.01-1.25wt%的高氧化铝纤维和0.1-1.9wt%的无机致密剂的水浆液铸造，所述致密剂任选地为管状氧化铝，所述浆液还任选地包括淀粉和胶态二氧化硅。
13．技术方案9的绝热制品，具有在700到800℃的温度下小于或等于0.2W/mK的热导率。
14．技术方案1的绝热制品，其中耐高温无机纤维包括耐火陶瓷纤维、铝硅酸盐纤维、高氧化铝纤维、碱土金属硅酸盐纤维、铝二氧化硅氧化锆纤维或它们的混合物中的至少一种。
15．技术方案1的绝热制品，其中耐压力在整个制品上是基本均匀的。
16．技术方案2的绝热制品，其中绝热制品包括胶态二氧化硅浸渍的耐高温无机纤维垫，其任选地在挤压前，与胶态二氧化硅浸渍的真空铸造陶瓷纤维板接触在一起、挤压并干燥产生复合绝热制品。
17．技术方案1的绝热制品，其中绝热制品包括用于钢包、鱼雷车、槽形浇道或中间罐中至少一种的支承绝热板。
附图简述
图1为显示与对比产品相比的本发明支承绝热板的热导率对温度的图。
图2为显示与对比产品相比的本发明支承绝热板的线性收缩(linear shrinkage)对温度的图。
图3为显示一组对比产品支承板在温度暴露前和后的照片。
图4为显示根据实施例1(下文)制备的一组支承板在温度暴露前和后的照片。
图5为显示根据实施例3(下文)制备的一组支承板在温度暴露前和后的照片。
详细描述
与对比产品相比，本发明的支承绝热板能绝热直到1300℃，具有极高的耐压力，具有低热导率，和具有非常高的纯度。
通常，制备支承绝热板的方法包括用至少一种胶态无机氧化物如胶态二氧化硅、氧化铝和/或氧化锆浸渍绝热陶瓷纤维垫或板，将浸渍的垫或板放置在模具中并挤压浸渍的垫或板至所需厚度，在烘箱中干燥产生具有所需特性的干燥板，如果需要，切割干燥板至最终尺寸。
可根据下文公开的方法使用陶瓷纤维垫或板制造支承绝热板。
可使用已知的方法制造用于制造支承绝热板的陶瓷纤维垫或板，或可从商业上获取。合适的初始陶瓷垫和板目前可从UniRax I LLC(Niagara Falls，New York)以商标DURABLANKET和DURABOARD得到。
为了说明目的而不是限制，这类商业上可得到的陶瓷垫可包括陶瓷纤维，在一些实施方案中，具有约43-约47%的氧化铝含量和约53-约57%的二氧化硅含量，以重量计。在其它实施方案中，陶瓷垫可具有约29-约31%的氧化铝含量，约53-约55%的二氧化硅含量，和约15-约17%的氧化锆含量，以重量计。垫可具有大小约30-约1g2kg/m3的密度，在一些实施方案中，约64-约128kg/m3，和约1260℃-约1430℃的温度等级。
还是为了说明目的而不是限制，这类商业上可得到的陶瓷板可包括陶瓷纤维，在一些实施方案中，具有约42-约50%的氧化铝含量和约50-约58%的二氧化硅含量，以重量计。在其它实施方案中，陶瓷垫可具有约28-约32%的氧化铝含量，约52-约56%的二氧化硅含量，和约14-约18%的氧化锆含量，以重量计。板可具有大小约150-约350kg/m3的密度，约3-约10%的灼烧损失(LOI，loss on ignition)，和约1260℃的温度等级。
除了包括铝硅酸盐(RCF，aluminosilicate)纤维和/或铝氧化锆硅酸盐(AZS，alumino zirconia silicate)纤维的陶瓷纤维垫和板外，垫和板可替代或另外包括碱土金属硅酸盐(AES，alkaline earth silicate)纤维，如可从Unifrax I LLC以商标ISOFARX得到的那些，和/或高温陶瓷纤维，如高氧化铝纤维，如可从UniRax I LLC以商标FIBERMAX得到的那些。
可在商业上得到各种厚度和密度的陶瓷纤维垫和板。在一些实施方案中，使用陶瓷纤维垫或板制造厚度为完成的支承绝热板的厚度的约2-4倍的支承绝热板。在一种实施方案中，陶瓷纤维垫或板具有为完成的支承绝热板的厚度的约3.3倍的厚度，假定10磅(45N)基重垫。
根据使用它的应用以及它的热导率，改变支承绝热板的一般厚度。对于本文讨论的应用，一般厚度包括10、12、16和25mm，但可根据应用需要产生任何其它厚度。
初始陶瓷纤维垫或板可具有任何合适的宽度或长度，这取决于预定用途和可用加工设备的尺寸。在一些实施方案中，840mm的长度和220mm的宽度在经济上是合适的。在浸渍和干燥后，可切割致密化的绝热制品至商业上所需的尺寸。例如，对于熔化金属钢包应用，支承绝热板的典型尺寸为约416X101mm，但可制备任何合适尺寸。
可用于浸渍陶瓷纤维垫或板的胶态无机氧化物溶液组合物可包含至少一种胶态无机氧化物，如胶态二氧化硅、氧化铝、氧化锆、氧化钛、氧化铈和/或氧化钇。(在本文中，术语“溶液”意图包括包含胶态无机氧化物的浆液或分散体)。可使用商业上可得到的胶态无机氧化物配方，例如但不限于，可从Nalco Company(Naperville，Illinois)得到的包括40%固体的NALCO胶态二氧化硅。但是，也可使用其它等级的胶态二氧化硅，如30%固体含量或以下，或者大于40%固体含量。
胶态无机氧化物溶液组合物可包括约30-100wt%的胶态无机氧化物，如胶态二氧化硅。在一些实施方案中，胶态无机氧化物溶液可包括约50-约90%的胶态无机氧化物，如胶态二氧化硅，在其它实施方案中，包括约80-100%的胶态无机氧化物，如胶态二氧化硅。
胶态无机氧化物溶液的其它组分可包括胶凝剂和数量足以溶解胶凝剂的水。胶凝剂组分可包括促进胶态无机氧化物凝固或胶凝的无机盐或氧化物，例如在胶态二氧化硅的情况下，如醋酸铵、氯化钙、氯化镁、氧化镁等，和酸，如乙酸、盐酸、磷酸等。选择胶凝剂的类型和浓度使胶态悬浮液不稳定，并允许无机氧化物组分在耐高温纤维垫或板挤压过程中胶凝或凝固在适当位置。
可部分地通过胶凝剂的浓度控制胶凝时间，因为胶凝时间通常随温度增加而减少。无机盐或氧化物胶凝剂的数量可为溶液重量的约0.01-约10%。酸的数量可为约0.01-约10wt%。可部分地通过胶凝剂的浓度控制胶凝时间，因为胶凝时间随温度增加而减少。足以溶解胶凝剂的水的数量可为溶液的0-约70%。
胶态无机氧化物溶液可另外包括着色剂，在一些实施方案中，数量为约0.01wt%-约10wt%，如能使最终产品靠颜色区分。
在制造支承板绝热制品的过程中，可用胶态二氧化硅溶液浸渍未处理的绝热垫或板至饱和点。
可在约5到约100吨(40-900kN)的压力下挤压浸渍的垫或板。在一些实施方案中，可以使用约20到约40吨(180-360kN)的压力。本领域的技术人员无需过多实验就可根据需要改变压力获得浸渍垫或板所需的性质。可使用用于挤压陶瓷绝热板的任何常规压机。已知当挤压陶瓷绝热板时使用模具。模具形状和尺寸可根据挤压绝热板的所需尺寸来变化。
在一种实施方案中，将浸渍的垫或板放置到模具内并挤压至其最终厚度。可将浸渍的垫或板在压机中保持约1到约120分钟的时间。在另一种实施方案中，浸渍的垫或板被挤压约1到约5分钟的时间。
可在温度为约40℃到约350℃的烘箱中干燥挤压的垫或板。在另一种实施方案中，可使用约80℃到约150℃的温度。
在一些实施方案中，在约80℃到约150℃的温度下干燥挤压的垫或板约2到约6分钟的时间。在另一种实施方案中，在约40℃到约350℃的温度下干燥挤压的垫或板约10分钟到约1小时的时间。
实施例1
在制备支承绝热板的示例性实施方案中，用胶态二氧化硅浸渍标准耐火陶瓷纤维垫或板。这通过使初始垫或板与胶态二氧化硅溶液接触使得其被完全浸泡来实现。在一种实施方案中，用由约98.2%的胶态二氧化硅(Nalco，40%固体)、约0.81%醋酸铵和约0.18%乙酸的胶凝剂和足以溶解醋酸铵的约0.81%的水组成的胶态二氧化硅溶液浸渍陶瓷纤维垫。
在用胶态二氧化硅浸渍陶瓷纤维垫或板后，将浸渍的垫或板放到模具内并使用25吨(220kN)工业压机挤压至其最终厚度。可使用常规方法进行这种操作。允许浸渍胶态二氧化硅溶液的胶凝发生。
可将胶态二氧化硅浸渍的陶瓷纤维垫或板挤压成厚度为初始垫或板厚度大约25%到大约50%的板。在一种实施方案中，将胶态二氧化硅浸渍的垫或板挤压成厚度为初始陶瓷纤维垫或板厚度大约30%的板。
可在挤压操作中回收部分胶态二氧化硅溶液，并且如果胶凝还未发生的话，就循环回到浸渍浴。
干燥挤压的板，然后切割至支承绝热板制品的所需尺寸。切割陶瓷绝热板的常规方法是众所周知的，可使用这些方法中的任何一个，包括但不限于使用圆锯、带锯等。
被切割至400mmX100mm尺寸和10-16mm厚度的最终支承绝热板具有约900到约1000kg/m3的密度和约11800kPa(120kgf/cm2)的耐压力。
通过热丝法DIN50146测量的支承绝热板的热导率显示在图1中，在约750℃下为约0.38W/mK。如图2中所示，在约1200℃的温度下，绝热板具有约5.5%的线性收缩。这些绝热板具有高达约1200℃的使用温度。
实施例2
在另一个示例性实施方案中，陶瓷纤维垫或板具有为完成的支承绝热板的厚度3.3倍的厚度。同样，用胶态二氧化硅浸渍标准耐火陶瓷纤维垫或板，在一种实施方案中，使得其被完全浸泡。在一种实施方案中，用由约98.2%的胶态二氧化硅(Nalco，40%固体)、约0.81%醋酸铵和约0.18%乙酸的胶凝剂和足以溶解醋酸铵的约0.81%的水组成的胶态二氧化硅溶液浸渍陶瓷纤维垫。
在用胶态二氧化硅浸渍陶瓷纤维垫或板后，将浸渍的垫或板放到模具内并挤压至其最终厚度。干燥挤压的板，然后切割至支承绝热板制品的所需尺寸，400mmX100mm尺寸和10-16mm厚度。
在切割后，用胶态二氧化硅溶液再次浸渍绝热板，在这种实施方案申，胶态二氧化硅溶液在约50wt%的水中包括约50wt%的胶态二氧化硅(Nalco，40%固体)。然后干燥再次浸渍的绝热板得到支承绝热制品，其具有约1100到约1250kg/m3的密度和高达约49000kPa(500kgf/cm2)的耐压力。
作为使用商业陶瓷纤维板作为原料的替代方案，可在用胶态无机氧化物溶液浸渍前通过常规真空铸造方法制备陶瓷纤维板。为了说明目的而不是限制，可由约0.1-约2%的标准RCF铝硅酸盐纤维、约0.01-约1.25%的高氧化铝纤维(如可从Unifrax I LLC得到的FIBERMAX纤维)和无机致密剂如约0.1-约1.9%的管状氧化铝(都为重量百分比)的水溶液或浆液制备真空铸造陶瓷纤维板。可存在通常用于制造真空铸造板的常规数量的淀粉和胶态无机氧化物如胶态二氧化硅。
实施例3
在一种示例性实施方案中，使用陶瓷纤维板制造支承绝热板，即真空铸造陶瓷纤维板，其中由具有以下组成的溶液真空铸造板:约97.54%的水;约0.10%的FIBERMAX高氧化铝纤维;约1%的HP标准RCF(铝硅酸盐)纤维;约1%的管状氧化铝;约0.08%的淀粉;和约0.28%的胶态二氧化硅。
用于制造绝热板的陶瓷纤维真空铸造板具有为完成的支承绝热板的厚度近2倍(约1.9倍)的厚度。
用由约80%胶态二氧化硅(Nalco，40%固体)、约18.53%水、约0.1%着色剂以及约1.25%醋酸铵和约0.25%乙酸的胶凝剂组成的胶态二氧化硅溶液浸渍真空铸造板。在这种实施方案中，需要较低密度材料。
在用胶态二氧化硅浸渍真空铸造陶瓷纤维板后，将浸渍的板放置到模具内并挤压至其最终厚度(60吨压力-530kN)。干燥挤压的板，然后切割至支承绝热板制品的所需尺寸，400mm×100mm尺寸和10-16mm厚度。这些支承绝热制品具有约700到约800kg/m3的密度和约7800kPa(80kgf/cm2)的耐压力。
通过热丝法DIN50146测量的支承绝热板的热导率显示在图1中，在约750℃下为约0.25W/mK。如图2中所示，在约1300℃的温度下，支承绝热板具有仅仅约2%的线性收缩。这些支承绝热板具有高达约1300℃的使用温度。
在一种实施方案中，实施例1和实施例3的浸渍制品，如陶瓷垫和真空铸造陶瓷板，任选地在挤压前，可以在一起接触，挤压并干燥，产生复合支承绝热制品。
在一些实施方案中，胶态氧化铝和/或胶态氧化锆可与胶态二氧化硅一起使用或取代它。
图1为显示通过热丝法DIN50146测量的单位为W/mK的热导率与单位为℃的温度的关系的图。该图显示了三个单独样品组的数据。第一样品组包括按照实施例1描述的方法制备的本发明的支承绝热板。图1显示第一样品组的数据为连接一系列正方形的线。第二样品组包括按照实施例3描述的方法制备的本发明的支承绝热板。图1显示第二样品组的数据为连接一系列三角形的线。第三样品组包括对比的商业产品。图1显示第三样品组的数据为连接一系列钻石形的线。
图1的图说明，对于所有取样温度，对比产品的热导率都高于按照实施例1描述的方法制备的本发明的支承绝热板或按照实施例3描述的方法制备的本发明的支承绝热板的热导率。因此，与对比产品相比，本发明的支承绝热板为较好的绝热体。图还表明，对于所有取样温度，按照实施例1描述的方法制备的本发明的支承绝热板的热导率高于按照实施例3描述的方法制备的本发明的支承绝热板的热导率。也就是说，按照实施例3描述的方法制备的本发明的支承绝热板是试验的三种支承板中最好的绝热体。
图2为显示单位为无因次的线性收缩百分率与单位为℃的温度的关系图。该图显示了三个独立样品组的数据。第一样品组包括按照实施例1描述的方法制备的本发明的支承绝热板。图2显示第一样品组的数据为连接一系列钻石形的线。第二样品组包括按照实施例3描述的方法制备的本发明的支承绝热板。图2显示第二样品组的数据为连接一系列正方形的线。第三样品组为对比产品。图2显示第三样品组的数据为连接一系列三角形的线。
图3显示板31-35;图4显示板41-45;图5显示板51-55。图3中的板31-35全部为对比产品板。图4中的板41-45全部按照实施例1中的实施方案制备。图5中的板51-55全部按照实施例3中的实施方案制备。
在图3-5中，板31、41和51为对照板，仅仅暴露于环境温度。板32、42和52暴露于1000℃温度。板33、43和53暴露于1100℃温度。板34、44和54暴露于1200℃温度，板35、45和55暴露于1300℃温度。
在图3中，板31为具有光滑、低上光度(glaze finish)的浅黄色;板32为具有光滑、低上光度的浅橙色;板33为具有低上光度的红棕色。板33还比对照板(板31)显著小;板34为具有起伏、高上光度的棕色;板34还比对照板(板31)显著小;板35为具有粗糙表面和具有低上光度的暗棕色;板35小于对照板。
在图4中，板41为具有光滑、低上光表面的灰白色。板42、43、44和45外观上与板1各自类似。板42、43、44和45中都没有在暴露于高温后表现出明显的颜色、表面结构、表面光泽或尺寸变化，表现出耐高温和耐收缩性。
在图5中，板51为具有光滑、低光泽表面的灰白色。板52、53、54和55外观上在颜色、表面结构和表面光泽方面类似。板52、53和54尺寸类似于板51。板55比板51稍微小。板52-55表现出耐高温性和相当大的耐收缩性。
当由陶瓷纤维垫或板生产并用胶态二氧化硅溶液浸渍时，本发明的完成的支承绝热板的组成通常可包括约30到约80wt%的纤维，和约20到约70wt%的胶态二氧化硅。当用胶态二氧化硅再次浸渍已浸渍并干燥的陶瓷垫或板时，完成的支承绝热板可包括约20到约60wt%的纤维，和约40到约80wt%的胶态二氧化硅。当按照实施例3中描述的方法真空铸造初始陶瓷板时，完成的支承绝热板可包括约40到约80wt%的纤维，和约20到约60wt%的胶态二氧化硅。在用胶态二氧化硅浸渍前，真空铸造陶瓷纤维板可包括约0.4到约50wt%的高氧化铝纤维，约4到约90wt%的管状氧化铝，约0.01到约0.2wt%的淀粉，和任选地包括胶态二氧化硅。
当由陶瓷纤维垫或板生产并用胶态二氧化硅溶液浸渍时，完成的支承绝热板通常在约900℃到约1100℃的温度下具有约2到约6%的线性收缩百分率。当按照实施例3中描述的方法真空铸造初始陶瓷板时，完成的支承绝热板在约900℃到约1100℃的温度下可具有约0.1到约2%的线性收缩百分率。
实施例4、5和6
按照实施例1、2和3的过程制备绝热板，它们的性质分别记载下面的表中分别作为实施例4、5和6。
实施例4 实施例5 实施例6
耐压力kPa(kgf/cm2) 16700(170) 31400(320) 7000(71)
线性收缩1000℃ 3-4％ 3-4％ 0.5-2％
密度(kg/m3) 900-1000 1000-1200 800-1000
热导率（W/mK，800℃) 0.37 --- 0.20
通过上述制造方法生产的支承绝热板可具有约700到约1250千克每立方米(kg/m3)或更大的密度。对于钢包，讨论的绝热板的耐压力一般在7800-11800kPa(80-120kgf/cm2)的范围内。对于鱼雷车，讨论的绝热板的耐压力为至少20000kPa(200kgf/cm2)。
本发明的支承绝热板的非常低的热导率允许使用较薄的难熔衬里，如在熔化金属钢包或鱼雷车中，以便增加钢包或鱼雷车用于其预定应用的有用体积。讨论的支承绝热板显著降低了熔化金属处理装置的冷面温度，以及减少了设备的热损失。
基本上无机的支承绝热板可由高纯度原料如无机纤维、无机纤维垫或板和胶态无机氧化物组合物生产。相对于对比的包含约5%氧化铁的现有技术产品，商业上可用原料的纯度为讨论的支承绝热板提供了基本无铁的优点(在一些实施方案中，远远小于1%铁)。讨论的支承绝热板因此不在高温下与它接触的耐火材料反应。
应认识到，本文描述的实施方案仅仅是示例性的，在不脱离本发明的精神和范围的情况下，本领域技术人员可作出变化和改进。所有这类变化和改进都打算包括在如上文所述的本发明范围内。另外，公开的所有实施方案不必然在替换方案中，因为可组合本发明的各种实施方案提供所需结果。

Claims (17)

1.一种绝热制品，包括胶态无机氧化物溶液组合物浸渍的挤压并干燥的耐高温无机纤维垫或板，其中胶态无机氧化物溶液组合物为胶态无机氧化物与胶凝剂的组合物；制品具有高达至少1000℃的使用温度，并在暴露于使用温度后保持机械完整性，制品具有大于500kg/m3的密度和至少4900kPa的耐压力，
其中胶凝剂包括无机盐或氧化物，和酸；
其中耐高温无机纤维包括陶瓷纤维、碱土金属硅酸盐纤维或其混合物中的至少一种；
其中胶态无机氧化物包括胶态二氧化硅、胶态氧化铝、胶态氧化锆、胶态氧化钛、胶态氧化铈或胶态氧化钇中的至少一种；
其中胶态无机氧化物溶液组合物包括胶态无机氧化物，0.01-10wt%无机盐或氧化物和0.01-10wt%酸的胶凝剂，和数量足以溶解胶凝剂的水，任选地该数量高达溶液组合物的70wt%，其中胶态无机氧化物溶液组合物包括30-100wt%的胶态无机氧化物，其中胶态无机氧化物溶液组合物的总重量是100wt%；
其中绝热制品包括20-80wt%的纤维和20-80wt%的胶态无机氧化物。
2.权利要求1的绝热制品，其中胶态无机氧化物溶液组合物为胶态二氧化硅与胶凝剂的组合物；制品具有大于或等于700kg/m3的密度和至少7800kPa的耐压力。
3.权利要求2的绝热制品，其中胶态无机氧化物溶液组合物包括胶态二氧化硅，0.01-10wt%无机盐或氧化物和0.01-10wt%酸的胶凝剂，和数量足以溶解胶凝剂的水，任选地该数量高达组合物的70wt%；其中胶态无机氧化物溶液组合物包括30-100wt%的胶态二氧化硅，其中胶态无机氧化物溶液组合物的总重量是100wt%。
4.权利要求3的绝热制品，其中制品具有大于或等于900kg/m3的密度、至少11800kPa的耐压力和在700到800℃的温度下小于或等于0.45W/mK的热导率。
5.权利要求3的绝热制品，包括30-80wt%的纤维和20-70wt%的胶态二氧化硅。
6.权利要求3的绝热制品，其中胶凝剂无机盐或氧化物包括醋酸铵、氯化钙、氯化镁或氧化镁中的至少一种，酸包括乙酸、盐酸或磷酸中的至少一种。
7.权利要求2的绝热制品，其中在用胶态无机氧化物溶液组合物首次浸渍后用至少胶态二氧化硅再次浸渍耐高温无机纤维垫或板，挤压和任选地干燥；制品具有大于或等于1100kg/m3的密度和至少29000kPa的耐压力。
8.权利要求7的绝热制品，包括20-60wt%的纤维和40-80wt%的胶态二氧化硅。
9.权利要求1的绝热制品，包括胶态二氧化硅浸渍的真空铸造陶瓷纤维板，制品具有高达1300℃的使用温度，大于或等于700kg/m3的密度和至少6800kPa的耐压力。
10.权利要求9的绝热制品，其中真空铸造陶瓷纤维板在胶态二氧化硅浸渍前包括0.4-50wt%的高氧化铝纤维、4-90wt%的管状氧化铝，和0.01-0.2wt%的淀粉。
11.权利要求9的绝热制品，包括40-80wt%的纤维和20-60wt%的胶态二氧化硅。
12.权利要求9的绝热制品，其中真空铸造陶瓷纤维板由包括0.1-2wt%的铝硅酸盐纤维、0.01-1.25wt%的高氧化铝纤维和0.1-1.9wt%的无机致密剂的水浆液铸造，所述致密剂任选地为管状氧化铝，所述浆液还任选地包括淀粉和胶态二氧化硅。
13.权利要求9的绝热制品，具有在700到800℃的温度下小于或等于0.2W/mK的热导率。
14.权利要求1的绝热制品，其中耐高温无机纤维包括耐火陶瓷纤维、铝硅酸盐纤维、高氧化铝纤维、碱土金属硅酸盐纤维、铝二氧化硅氧化锆纤维或它们的混合物中的至少一种。
15.权利要求1的绝热制品，其中耐压力在整个制品上是基本均匀的。
16.权利要求2的绝热制品，其中绝热制品包括胶态二氧化硅浸渍的耐高温无机纤维垫，其任选地在挤压前，与胶态二氧化硅浸渍的真空铸造陶瓷纤维板接触在一起、挤压并干燥产生复合绝热制品。
17.权利要求1的绝热制品，其中绝热制品包括用于钢包、鱼雷车、槽形浇道或中间罐中至少一种的支承绝热板。
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BRPI0712442A2 (pt) 2012-06-12
RU2467877C2 (ru) 2012-11-27
US20070281565A1 (en) 2007-12-06
EP2021169A4 (en) 2011-10-05
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US7413797B2 (en) 2008-08-19
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