Light weight ceramic aggregates made by agglomerating ceramic fibers
AssigneeUnifrax I LLC
InventorJens DECKER
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Abstract
A method of agglomerating bulk ceramic fibers includes mixing the bulk ceramic fibers with water to form wet fibers; mixing the wet fibers with a binder including an organic binder and/or an inorganic binder to form agglomerates; and drying the agglomerates. The agglomerates may be mixed with additional binders and fillers to form an insulating mix that may be used to insulate a furnace or other heat source. A foaming nozzle may be used for the application of agglomerates. A foaming agent and water are air atomized within the foaming nozzle and the resulting foam is mixed into pneumatically conveyed agglomerates, which result results in a lightweight refractory material layer on a target substrate.
Claims20
A method, comprising:
- mixing bulk ceramic fibers with water to form wet fibers;
- mixing the wet fibers with a binder comprising an organic binder and/or an inorganic binder to form agglomerates;
- and
- drying the agglomerates.
A material for refractory light weight concretes or fire-proofing concretes, comprising:
- agglomerates produced by mixing bulk ceramic fibers with water to form wet fibers;
- mixing the wet fibers with a binder comprising an organic binder and/or an inorganic binder to form the agglomerates;
- and drying the agglomerates;
- and
- an additional binder comprising calcium aluminate cement, Portland cement, phosphate salts, colloidal silica, colloidal alumina, liquid aluminum phosphate, phosphoric acid, or combinations thereof.
A foaming nozzle for installing lightweight refractory materials, the foaming nozzle comprising:
- an inlet, wherein the inlet is configured to receive a foaming agent and water admixture;
- an air valve, wherein the air valve is configured to supply atomizing air to the foaming nozzle;
- a foaming tube, the foaming tube containing metal wool;
- and
- a water distribution body, wherein the water distribution body is configured to be fluidly coupled with a spray nozzle of a gunning machine.
Dependencies are inferred from the claim text.