Method of making lightweight refractory composition and articles using foamed colloidal silica binder
AssigneeMagneco/Metrel, Inc.
InventorDominic Pautler
Life of this patent
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Abstract
A foamed colloidal silica binder having a total porosity of about 50% to about 95% by volume can be used to make porous refractory compositions and refractory articles having a porosity of about 25% to about 75% by volume. The foamed colloidal silica binder endures mixing with refractory ingredients to form the porous refractory composition, casting the refractory composition into a refractory shape, and drying the shape to form to refractory article, without significant collapsing of the foam. The resulting lightweight refractory articles are useful in a wide variety of insulating and weight-reducing applications.
Claims30
A method of making a porous refractory composition, comprising the steps of:
- a) providing a synthetic, non-protein foaming agent;
- b) providing an aqueous colloidal silica binder;
- c) providing a solid refractory component exclusive of the colloidal silica binder;
- d) mixing the synthetic, non-protein foaming agent with the aqueous colloidal silica binder to yield a foamed colloidal silica binder;
- and
- e) mixing the foamed colloidal silica binder with the solid refractory component to form the porous refractory composition.
A method of making a porous refractory composition, comprising the steps of:
- providing a foamed colloidal silica binder having a total porosity of about 50% to about 95% by volume and a total pore volume of about 0.75 to about 15.0 grams/cm3;
- providing a solid refractory component exclusive of the foamed colloidal silica binder;
- and
- mixing about 3% to about 50% by weight of the foamed colloidal silica binder with about 50% to about 97% by weight of the solid refractory component to form the porous refractory composition;
- wherein the foamed colloidal silica binder includes about 20% to about 70% by weight colloidal silica particles, about 30% to about 80% by weight water, and a synthetic non-protein foaming agent present in a weight ratio to the water of about 1:25 to about 1:1500.
A method of making a porous refractory article, comprising the steps of:
- providing a porous refractory composition including about 3% to about 50% by weight of a foamed colloidal silica binder and about 50% to about 97% by weight a solid refractory component exclusive of the foamed colloidal silica binder;
- casting the porous refractory composition to a mold or substrate;
- and
- drying the porous refractory composition to form the porous refractory article;
- wherein the foamed colloidal silica binder includes colloidal silica particles and a synthetic non-protein foaming agent and has a total porosity of about 50% to about 95% by volume;
- and
- the porous refractory article has a total porosity of about 25% to about 75% by volume.
Dependencies are inferred from the claim text.