CN117287980A - 隔热保温复合砖及其制备方法 - Google Patents
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- 238000009413 insulation Methods 0.000 claims description 24
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 19
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- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 claims description 8
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- RLQWHDODQVOVKU-UHFFFAOYSA-N tetrapotassium;silicate Chemical compound [K+].[K+].[K+].[K+].[O-][Si]([O-])([O-])[O-] RLQWHDODQVOVKU-UHFFFAOYSA-N 0.000 claims 1
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- NNHHDJVEYQHLHG-UHFFFAOYSA-N potassium silicate Chemical compound [K+].[K+].[O-][Si]([O-])=O NNHHDJVEYQHLHG-UHFFFAOYSA-N 0.000 description 1
- 235000019353 potassium silicate Nutrition 0.000 description 1
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
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Abstract
本发明公开了一种隔热保温复合砖及其制备方法,隔热保温复合砖包括隔热砖体和保温砖体;所述隔热砖体包括隔热体和镶嵌在所述隔热体中的空心球骨料,所述隔热砖体具有破坏表面,所述破坏表面露出所述空心球骨料的孔隙;所述保温砖体成型于所述破坏表面上,所述保温砖体的部分原料嵌入所述孔隙中。本发明的隔热保温复合砖具有轻质、便携使用以及保温隔热性能好等显著优点。
Description
技术领域
本发明涉及耐火新材料技术领域,更具体地,涉及一种隔热保温复合砖及其制备方法。
背景技术
节能降耗是低碳经济发展的方向,窑炉保温隔热是窑炉工业实现节能降耗的重要措施之一。根据窑炉的烧结要求,优化窑炉炉体结构设计,采用保温隔热性能好的耐火材料应用于窑炉的关键部位,是实现窑炉节能降耗的重要手段之一。
目前,窑炉炉墙结构从内到外依次包括耐火砖层、隔热砖层、保温砖层、保温板层和装饰面板层,其中,对窑炉的节能起关键作用的是隔热砖层和保温砖层,设计轻质、高强、热容小、热导率低的隔热保温砖体材料来代替传统的重质、热容大、吸热量大的材料,是实现窑炉节能降耗的发展方向。
中国专利CN210802035U公开了一种窑炉保温结构,其窑墙由内至外包括耐火砖、纳米保温材料及硅钙板,其纳米保温材料采用浇筑方式充填于耐火砖与硅钙板间。此方法虽然施工方法简单,但存在两方面的不足,首先,浇筑方式很难把纳米保温材料的保温特性优势展现出来,另窑炉后期炉墙、炉顶的修理带来很大困难,修理时纳米保温材料被破坏,浪费巨大。
发明内容
本发明的目的在于克服现有技术存在的上述缺陷,提供一种轻质、便携使用、且保温隔热性能好的隔热保温复合砖及其制备方法。
为实现上述目的,本发明的技术方案如下:
一种隔热保温复合砖,包括隔热砖体和保温砖体;
所述隔热砖体包括隔热体和镶嵌在所述隔热体中的空心球骨料,所述隔热砖体具有破坏表面,所述破坏表面露出所述空心球骨料的孔隙;
所述保温砖体成型于所述破坏表面上,所述保温砖体的部分原料嵌入所述孔隙中。
本发明还提供了一种上述隔热保温复合砖的制备方法,包括以下过程:
将所述隔热体的原料和所述空心球骨料用结合剂混合后制成隔热砖胚体;
对所述隔热砖胚体进行烧结,使所述隔热体的原料发生反应生成所述隔热体,所述空心球骨料镶嵌在所述隔热体的网格中,得到所述隔热砖体;
对所述隔热砖体的一表面进行破坏处理,得到破坏表面;
将所述保温砖体的原料混合后,得到保温砖混合料;
将所述保温砖混合料压制到所述破坏表面上,使部分所述保温砖混合料嵌入到露出的所述孔隙中,得到所述隔热保温复合砖。
实施本发明实施例,将具有如下有益效果:
本发明实施例通过形成具有空心球骨料的隔热砖体,一方面降低复合砖的比重,另一方面,以破坏表面为保温砖体的成型模具,使保温砖体的部分原料能嵌入破坏表面露出的空心球骨料的孔隙内,形成交叉网络的复合砖结构,增强保温砖体与隔热砖体的结合力,使复合砖形成一整体,相比单独的隔热砖体和保温砖体,不仅大大增强了使用的便捷性,而且隔热砖体和保温砖体的复合界面也增强了隔热和保温效果。
具体实施方式
下面将结合本发明实施例,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
本发明公开了一种隔热保温复合砖,其特征在于,包括隔热砖体和保温砖体;隔热砖体包括隔热体和镶嵌在隔热体中的空心球骨料,隔热砖体具有破坏表面,破坏表面露出空心球骨料的孔隙;保温砖体成型于破坏表面上,保温砖体的部分原料嵌入孔隙中。
上述技术方案中,通过形成具有空心球骨料的隔热砖体,一方面降低复合砖的比重,另一方面,以破坏表面为保温砖体的成型模具,使保温砖体的部分原料能嵌入破坏表面露出的空心球骨料的孔隙内,形成交叉网络的复合砖结构,增强保温砖体与隔热砖体的结合力,使复合砖形成一整体,相比单独的隔热砖体和保温砖体,不仅大大增强了使用的便捷性,而且隔热砖体和保温砖体的复合界面也增强了隔热和保温效果。
在上述技术方案中,隔热砖体为空心砖体,内部的孔隙具有热传导慢、热容小的优点。
在一具体实施例中,保温砖体的热导率小于气体的热导率;或者保温砖体的热导率与气体的热导率相当。在本具体实施例中,保温砖体的保温原理是:降低热量的热导率,避免热量传输到外部。在本发明中,隔热砖体和保温砖体在复合界面处紧密连接,能增强保温效果。
在一具体实施例中,保温砖体的热导率为0.02W·m-1·K-1~0.042W·m-1·K-1。
在一具体实施例中,保温砖体的原料以气相二氧化硅为主体材料,其热导率极低,接近真空热导率,掺杂增强粉末和增强纤维来提高保温砖体的强度和硬度,同时,增强纤维的掺杂还能提高保温砖体内部的孔隙率,降低保温砖体的热导率。具体的,保温砖体的原料包括以下质量份数的各组分:
65份~75份的气相二氧化硅、10份~20份的增强粉末、10份~20份的增强纤维,以及外加质量为气相二氧化硅、增强粉末和增强纤维的总质量的15%~25%的粘结剂水溶液。
增强粉末可以包括碳化硅粉末和/或二氧化硅微粉,增强纤维可以包括硅酸棉纤维、莫来石纤维、玻璃纤维等中的一种或两种以上,粘结剂水溶液包括硅酸钠水溶液和/或硅酸钾水溶液。
在一具体实施例中,保温砖体的原料包括以下质量份数的各组分:
65份~75份的气相二氧化硅、10份~20份的碳化硅粉末、10份~20份的硅酸棉纤维,以及外加质量为气相二氧化硅、碳化硅粉末和硅酸棉纤维的总质量的15%~25%的粘结剂水溶液。
上述组分及其配比使得保温砖体的热导率为0.02W·m-1·K-1~0.042W·m-1·K-1,与气体的热导率相当,能够提供优异的保温性能,且其密度为0.25g/cm3~0.32g/cm3,质量较轻,且复合界面温度≤1000℃时,窑墙外表面的温升≤30℃,保温隔热性能优异。
在一具体实施例中,保温砖体的制备方法包括以下过程:
1)将保温砖体的原料混合后,得到保温砖混合料。
具体的,在一具体实施例中,将气相二氧化硅、碳化硅粉末、硅酸棉纤维和硅酸钠水溶液混合后得到保温砖混合料。
2)将保温砖混合料压制到破坏表面上,使部分保温砖混合料嵌入到露出的孔隙中,得到隔热保温复合砖。
在一具体实施例中,隔热体可以为莫来石、刚玉莫来石、刚玉等中的一种或两种以上;上述隔热体为高铝材料,具有质量轻、强度高、耐火/隔热性能佳、热导率低、热容小的优异性能,可以直接与火焰接触。
空心球骨料可以包括氧化铝空心球骨料和/或莫来石空心球骨料等,空心球骨料能降低隔热砖体的整体密度。
在一具体实施例中,隔热砖体的原料包括以下质量份数的各组分:
60份~70份的氧化铝空心球骨料、8份~20份的活性氧化铝、5份~10份的硅微粉,外加质量为氧化铝空心球骨料、活性氧化铝、硅微粉的总质量的10%~15%的造孔剂和质量为氧化铝空心球骨料、活性氧化铝、硅微粉的总质量的4~8%的结合剂。
在一具体实施例中,造孔剂包括有机聚轻球,在烧结过程中转化为气体,控制隔热砖体的比重。
在一具体实施例中,结合剂为有机结合剂。
在一具体实施例中,隔热砖体的制备方法包括以下过程:
1)将隔热体的原料和空心球骨料用结合剂混合后制成隔热砖胚体。
在上述技术方案中,具体的,隔热体的原料包括活性氧化铝和硅微粉,将氧化铝空心球骨料、造孔剂、活性氧化铝、硅微粉和结合剂湿混后制成隔热砖胚体。
2)对隔热砖胚体进行烧结,使隔热体的原料发生反应生成隔热体,空心球骨料镶嵌在隔热体的晶体网格中,得到隔热砖体。
在上述技术方案中,活性氧化铝和硅微粉发生反应生成莫来石晶型的隔热体,氧化铝空心球镶嵌在莫来石的晶体网格中。
本发明采用烧结工艺制成隔热体,提高隔热砖体整体的强度、硬度和高温稳定性。
得到隔热砖体后,对隔热砖体的一表面进行破坏处理,露出空心球骨料的孔隙,得到破坏表面,然后在破坏表面直接成型保温砖体,使保温砖体的部分原料嵌入孔隙内,增强保温砖体和隔热砖体直接的结合强度,使二者成为一整体,不仅便于窑炉的施工及维修,而且二者复合界面处的保温性能更佳。
在上述各实施例中,隔热砖体的厚度为100毫米~150毫米,优选114毫米,保温砖体的厚度为25毫米~120毫米,优选为100毫米。
以下为具体实施例。
表1给出了各实施例的隔热砖体和保温砖体的组分及其含量。
表1:各实施例的隔热砖体和保温砖体的组分及其含量
隔热保温复合砖的制备方法,包括以下过程:
1)将隔热砖体的各原料均匀混炼后,振动成型,得到隔热砖胚体。
2)将隔热砖胚体在1550℃下进行烧结,形成隔热砖体。
3)对隔热砖体的一表面进行破坏处理,得到破坏表面。
4)将保温砖体的各原料均匀混炼后,得到保温砖混合料,将保温砖混合料涂覆在破坏表面上,然后低压压制形成保温砖体,从而得到隔热保温复合砖。
对比例D1:
对比例D1与实施例1相比区别仅在于:保温砖体采用硅酸棉纤维板,将硅酸棉纤维板与未破坏表面的隔热砖体紧密连接。
对比例D2
对比例D2与实施例4相比区别仅在于:保温砖体采用硅酸棉纤维板,将硅酸棉纤维板与未破坏表面的隔热砖体紧密连接。
对比例D3
对比例D3与实施例7相比区别仅在于:保温砖体采用硅酸棉纤维板,将硅酸棉纤维板与未破坏表面的隔热砖体紧密连接。
表1中各实施例和对比例制得的隔热保温复合砖的性能指标如表2所示,其中,外表温度是指保温砖体外表面的温度,热流密度是指保温砖体内的热流密度。
表2:各实施例和对比例的隔热保温复合砖的性能指标
从表2可以看到:本发明的隔热砖体的密度为1.0~1.2g/cm3,导热系数为0.55-0.88W·m-1·k-1,常温抗压强度大于8Mpa;保温砖体的密度为0.25~0.32g/cm3,导热系数为:0.02-0.042W·m-1·k-1,与空气导热系数相当。将本发明与对比例D1~D3相比,当隔热砖体的高温面温度为1050℃时,本发明复合界面温度明显高于对比例D1~D3,本发明保温砖体内的热流密度明显低于对比例D1~D3,本发明的保温砖体外表面的温升明显小于对比例D1~D3,说明本发明复合砖的保温效果相比现有技术更好。
另,本发明的复合砖的隔热砖体和保温砖体之间的粘结力强,在运输、堆砌窑墙以及破碎窑墙进行修理时,隔热砖体和保温砖体均不会分离,使用方便。若不破坏表面,直接在隔热砖体上压制保温砖体,则保温砖体和隔热砖体之间的粘结强度较弱,二者易分离,尤其在破碎窑墙进行修理时,会导致保温砖体大面积脱落,以及在停窑一段时间后再开窑,温差导致的热胀冷缩也会使保温砖体易脱落。
当使用单独制备的隔热砖体和保温砖体时,可以采取两种方式进行施工,一种是使用粘合剂将隔热砖体和保温砖体相粘结,但是粘合剂层会蓄热,不仅浪费能效,而且增加墙的厚度和比重;另一种是浇注,但是,浇筑很难将保温材料的保温特性优势充分展现出来。
以上所述实施例仅表达了本发明的几种实施方式,其描述较为具体和详细,但并不能因此而理解为对申请专利范围的限制。应当指出的是,对于本领域的普通技术人员来说,在不脱离本发明构思的前提下,还可以做出若干变形和改进,这些都属于本发明的保护范围。因此,本发明专利的保护范围应以所附权利要求为准。
Claims (8)
1.一种隔热保温复合砖,其特征在于,包括隔热砖体和保温砖体;
所述隔热砖体包括隔热体和镶嵌在所述隔热体中的空心球骨料,所述隔热砖体具有破坏表面,所述破坏表面露出所述空心球骨料的孔隙;
所述保温砖体成型于所述破坏表面上,所述保温砖体的部分原料嵌入所述孔隙中;
其中,所述保温砖体的原料包括以下质量份数的各组分:
65份~75份的气相二氧化硅、10份~20份的增强粉末、10份~20份的增强纤维,以及外加质量为所述气相二氧化硅、所述增强粉末和所述增强纤维的总质量的15%~25%的粘结剂水溶液;
所述增强粉末包括碳化硅粉末和/或二氧化硅微粉中的一种或两种以上;
所述增强纤维包括硅酸棉纤维、莫来石纤维、玻璃纤维中的一种或两种以上;
所述粘结剂水溶液包括硅酸钠水溶液和/或硅酸钾水溶液。
2.根据权利要求1所述的隔热保温复合砖,其特征在于,保温砖体的原料包括以下质量份数的各组分:
65份~75份的气相二氧化硅、10份~20份的碳化硅粉末、10份~20份的硅酸棉纤维,以及外加质量为所述气相二氧化硅、所述碳化硅粉末和所述硅酸棉纤维的总质量的15%~25%的粘结剂水溶液。
3.根据权利要求1~2中任意一项所述的隔热保温复合砖,其特征在于,所述保温砖体的制备方法包括:
将所述保温砖体的原料混合后,得到保温砖混合料;
将所述保温砖混合料压制到所述破坏表面上,使部分所述保温砖混合料嵌入到露出的所述孔隙中,得到所述隔热保温复合砖。
4.根据权利要求1~2中任意一项所述的隔热保温复合砖,其特征在于,所述隔热体为莫来石、刚玉莫来石、刚玉中的一种或两种以上;
所述空心球骨料包括氧化铝空心球骨料和/或莫来石空心球骨料。
5.根据权利要求1~2中任意一项所述的隔热保温复合砖,其特征在于,所述隔热砖体的原料包括以下质量份数的各组分:
60份~70份的氧化铝空心球骨料、8份~25份的活性氧化铝、5份~15份的硅微粉,外加质量为所述氧化铝空心球骨料、所述活性氧化铝、所述硅微粉的总质量的10%~15%的造孔剂和质量为所述氧化铝空心球骨料、所述活性氧化铝、所述硅微粉的总质量的4~8%的结合剂。
6.根据权利要求1所述的隔热保温复合砖,其特征在于,所述隔热砖体的制备方法包括以下过程:
将所述隔热体的原料和所述空心球骨料用结合剂混合后制成隔热砖胚体;
对所述隔热砖胚体进行烧结,使所述隔热体的原料发生反应生成所述隔热体,所述空心球骨料镶嵌在所述隔热体的网格中,得到所述隔热砖体。
7.根据权利要求1所述的隔热保温复合砖,其特征在于,
所述隔热砖体的厚度为100毫米-150毫米;
所述保温砖体的厚度为25毫米-120毫米。
8.一种如权利要求1~7中任意一项所述的隔热保温复合砖的制备方法,其特征在于,包括以下过程:
将所述隔热体的原料和所述空心球骨料用结合剂混合后制成隔热砖胚体;
对所述隔热砖胚体进行烧结,使所述隔热体的原料发生反应生成所述隔热体,所述空心球骨料镶嵌在所述隔热体的网格中,得到所述隔热砖体;
对所述隔热砖体的一表面进行破坏处理,得到破坏表面;
将所述保温砖体的原料混合后,得到保温砖混合料;
将所述保温砖混合料压制到所述破坏表面上,使部分所述保温砖混合料嵌入到露出的所述孔隙中,得到所述隔热保温复合砖。
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