US 6,183,852 B2 · Refractory fibrous ceramic insulation and process of making same

Abstract

A fibrous ceramic mat is molded from a slurry of ceramic fibers and/or ceramic microparticles and/or a metal. The mat is impregnated with a sol prior to drying. A catalyst for the sol is introduced into the mat to cause the sol to gel. The sol-gel binder forms bonds so that the mat is dimensionally stabilized. The mat is dried to produce the desired ceramic insulation that has preferably a consistent microstructure and a fully gelled sol-gel binder through its entire thickness. If we use a metal, it corrodes (i.e., oxidizes) or otherwise reacts to form a refractory binder that augments the sol and reduces the need to infuse sol incrementally to achieve strength. Using metal powder significantly reduces the cost of manufacture.

Claims10

Dependent claims

A process for forming a ceramic insulation comprising the steps of:

(a) forming a slurry of (i) ceramic fibers, microparticles, or mixtures thereof;
(ii) optionally, fugitive microparticles;
and (iii) a metal;
(b) molding the slurry to form a soft felt mat having a thickness;
(c) converting the metal in the mat to a ceramic to form bonds between the ceramic fibers, microparticles, and mixtures thereof;
(d) impregnating the mat with a sol prior to drying the mat;
(e) gelling the sol to form a sol-gel to form bonds between the ceramic fibers, microparticles, and mixtures thereof so that the mat is dimensionally stabilized;
and
(f) drying the mat to produce the ceramic insulation.

6 more elements

Dependencies are inferred from the claim text.

Facts

Application

08/209,847Filed 11 Mar 1994 · continuation in part

Priority

15 Sep 1992

Granted

6 Feb 2001

Term ends

Not estimatedThe source records don’t support an estimate.

Classification26 codes

C04B 41/009
After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone: characterised by the material treated
C04B 14/24
Glass ; Devitrified glass: porous, e.g. foamed glass
C04B 28/005
Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic…
C04B 30/02
Compositions for artificial stone, not containing binders: containing fibrous materials

Refractory fibrous ceramic insulation and process of making same

Life of this patent

Refractory fibrous ceramic insulation and process of making same

Life of this patent

Abstract

Claims10