US 4,833,025 AGranted

Method for applying a refractory layer on a surface and the layer produced thereby

AssigneeManville Corporation

InventorNicholas J. Rossi

Life of this patent

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Abstract

A process for applying an insulating bonded refractory fiber layer to a substrate such that the bonded refractory fiber will not delaminate form the substrate it is adhered to during thermal cycling. A pre-coat layer of refractory fiber coated with a binder containing potassium silicate, colloidal silica, kaolin clay, hydrated alumina, and optionally, Xanthan gum is applied to a substrate, preferably by spray application. Then a second insulating layer of refractory fiber coated with a binder containing either colloidal alumina, colloidal silica, colloidal zirconia, aluminum phosphates, or mixtures thereof is applied to the pre-coated substrate, preferably by spray application. Finally, the coated layers of bonded refactory fibers are cured. An article comprising a refractory layer bonded to a substrate produced by the foregoing process is also disclosed.

Claims9

Dependent claims

A process for producing a refractory layer on a substrate comprising in order the steps of:

(a) directing a first stream of refractory fibers toward the surface of a substrate;
(b) coating said first stream of refractory fibers with a liquid binder comprising about 25-35 wt% potassium silicate;
10-50 wt% colloidal silica;
4-8 wt% kaolin clay;
and 2-6 wt% hydrated alumina during said step of directing such that said refractory fibers adhere to to another and to said surface;
(c) directing a second stream of refractory fibers toward the refractory pre-coated substrate;
(d) coating said second stream of refractory fibers with a liquid binder comprising at least one material selected from the group consisting of colloidal silica, colloidal alumina, colloidal zirconia, and aluminum phosphates during the step of directing such that the refractory fibers adhere to one another and to the pre-coated surface;
and thereafter
(e) curing the layers of coated fibers.

6 more elements

Dependencies are inferred from the claim text.

Facts

Application: 07/165,064Filed 7 Mar 1988
Granted: 23 May 1989
Term ends: Not estimatedThe source records don’t support an estimate.

Classification9 codes

C04B 41/009
After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone: characterised by the material treated
C04B 28/26
Containing alkyl, ammonium or metal silicates; containing silica sols: silicates of the alkali metals
C04B 41/4596
Coating or impregnating , e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering…: with…
C04B 41/81
Of only ceramics: coating or impregnation