Refractory foam
AssigneeZYP Coatings, Inc.
InventorsCressie E. Holcombe, Jr., Patrick J. Ritt, William Brent Webb
Life of this patent
Estimating the term…
Abstract
A porous refractory in the K2O—SiO2—B2O3 system is formed by chemical direct foaming by heating to over 600° C., resulting in adherent black or white foam. The foam can function as highly porous thermal insulation, a high or low thermal emissivity surface, as a sealant for deteriorated refractory surfaces, as a filler for pockmarks/holes/gaps or as a bonding agent for parts with large gaps between them.
Claims16
A coating composition comprising:
- a mixture of potassium tetraborate tetrahydrate, ammonium pentaborate tetrahydrate, colloidal silica, water containing a cellulosic suspension agent which forms a black foam material when applied and heated to a temperature above 600° C.;
- and
- an additive comprising alumina fibers and hollow borosilicate spheres.
A process for forming a foam material on a ceramic or metal surface, or for repairing a refractory surface or for bonding to a refractory, ceramic, or metal surface of a part, by chemical direct foaming comprising the steps of:
- (i) applying to the surface a coating composition comprising a mixture of potassium tetraborate tetrahydrate, ammonium pentaborate tetrahydrate, colloidal silica, water containing a cellulosic suspension agent, and an additive comprising alumina fibers and hollow borosilicate spheres;
- and
- (ii) heating the composition to a temperature above 600° C., thus causing the composition to foam, forming a foam material.
A process for forming a foam material on a ceramic or metal surface, or for repairing a refractory surface or for bonding to a refractory, ceramic, or metal surface of a part, by chemical direct foaming comprising the steps of:
- (i) providing a coating composition comprising a mixture of potassium tetraborate tetrahydrate, ammonium pentaborate tetrahydrate, colloidal silica, and water containing a cellulosic suspension agent;
- (ii) applying the coating composition to a surface and drying at 300° C., forming a first layer;
- (iii) applying the coating composition to the first layer and drying at 300° C., forming a second layer;
- and
- (iv) heating the first layer and the second layer to a temperature of approximately 700° C., thus causing the composition to foam, forming a foam material.
Dependencies are inferred from the claim text.