Durable phosphate ceramic structures and their preparation
AssigneeArmstrong World Industries, Inc.
InventorsJeffery L. Barrall, Robert C. Garman
Life of this patent
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Abstract
Processes are described for producing strong, durable fiberous phosphate ceramic structures. Stronger fiberous phosphate ceramic structures can be produced by applying higher pressures during the reaction of phosphoric acid, a metal oxide selected from the group consisting of zinc oxide, calcium oxide, magnesium oxide, and aluminum oxide; and calcium silicate within a matrix of the fiber, or the fiber and a binder.
Claims33
A composition comprising a phosphate ceramic structure made by (A) contacting a compressible phosphatereactive substrate with an aqueous phosphoric acid solution, and (B) applying pressure to compact the compressible phosphate reactive substrate while a chemical reaction takes place in the substrate to form the phosphate ceramic structure, further providing that the said compressible phosphate reactive substrate comprises:
- calcium silicate;
- a metal oxide selected from the group consisting of:
- calcium oxide, aluminum oxide, zinc oxide, and magnesium oxide;
- and a nonreactive matrix of (1) fiber or (2) fiber and a binder wherein the fiber is present in an amount effective to make the substrate compressible.
A composition comprising a phosphate ceramic structure made by (A) contacting a compressible phosphatereactive substrate with an aqueous mixture of a solution of phosphoric acid and a metal oxide selected from the group consisting of:
- calcium oxide, aluminum oxide, zinc oxide, and magnesium oxide, and then applying pressure to compact the compressible phosphate reactive substrate while a chemical reaction takes place in the substrate to form the phosphate ceramic structure, further providing that the said compressible phosphate-reactive substrate comprises calcium silicate;
- and a non-reactive matrix of (1) fiber or (2) fiber and a binder, wherein the fiber is present in an amount effective to make the substrate compressible.
A composition useful for the preparation of a phosphate ceramic structure comprising:
- a compressible phosphate-reactive substrate which includes:
- a mixture of calcium silicate;
- a metal oxide selected from the group consisting of:
- calcium oxide, magnesium oxide, zinc oxide, and aluminum oxide;
- microcapsules containing an aqueous solution with phosphoric acid;
- and a non-reactive matrix of (a) fiber or (b) fiber and a binder.
A process for producing a strong, durable phosphate ceramic structure comprising (A) contacting a compressable phosphate-reactive substrate composition with an aqueous phosphoric acid solution;
- and (B) applying pressure to the phosphate reactive substrate in an amount effective to compact the substrate while a chemical reaction takes place in the substrate to form a phosphate ceramic structure, further providing that the said phosphate reactive substrate composition comprises calcium silicate;
- a metal oxide selected from the group consisting of:
- calcium oxide, aluminum oxide, zinc oxide and magnesium oxide;
- and a non-reactive matrix of fiber or fiber and a binder, wherein the fiber is present in an amount effective to make the substrate compressible.
A process for producing a strong, durable phosphate ceramic structure comprising (A) contacting a compressible phosphate-reactive substrate composition with an aqueous mixture of phosphoric acid and a metal oxide selected from the group consisting of:
- calcium oxide, aluminum oxide, zinc oxide, and magnesium oxide and (B) applying pressure to the compressible phosphate-reactive substrate in an amount effective to compact the substrate while a chemical reaction takes place in the substrate to form a phosphate ceramic structure;
- further providing, that the said compressible phosphate-reactive substrate composition comprises calcium silicate and a matrix of (1) fiber or (2) fiber and a binder wherein the fiber is present in an amount effective to make the substrate compressible.
Dependencies are inferred from the claim text.