CA1333953C - Heat resistant composition processable by vacuum forming - Google Patents

Heat resistant composition processable by vacuum forming

Info

Publication number
CA1333953C
CA1333953C CA000612311A CA612311A CA1333953C CA 1333953 C CA1333953 C CA 1333953C CA 000612311 A CA000612311 A CA 000612311A CA 612311 A CA612311 A CA 612311A CA 1333953 C CA1333953 C CA 1333953C
Authority
CA
Canada
Prior art keywords
composition
heat
vacuum forming
resistant
fibers
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA000612311A
Other languages
French (fr)
Inventor
Pierre Delvaux
Normand Lesmerises
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Cerminco Inc
Original Assignee
Ceram SNA Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ceram SNA Inc filed Critical Ceram SNA Inc
Priority to CA000612311A priority Critical patent/CA1333953C/en
Application granted granted Critical
Publication of CA1333953C publication Critical patent/CA1333953C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/24Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/14Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silica
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/632Organic additives
    • C04B35/636Polysaccharides or derivatives thereof
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/71Ceramic products containing macroscopic reinforcing agents
    • C04B35/78Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
    • C04B35/80Fibres, filaments, whiskers, platelets, or the like

Abstract

Disclosed is a heat-resistant composition particularly useful to produce heat-resistant boards, tubes, linings or similar articles, capable of resisting to a high temperature for a substantial period of time. The composition comprises from 30 to 70% by weight of a fibrous-like, synthetic forsterite obtained by calcination of chrysotile asbestos fibers at a temperature of from 650°C to 1450°C, the synthetic forsterite having an MgO:
SiO2 ratio lower than 1.1, a raw loose density of from 3 to 40 pcf, a thermal conductivity "k" factor of from 0.25 to 0.40 BTU. in/hr.°F.ft2 and a fusion point of from 1600 C to 1700°C. The composition also comprises colloidal silica as a binder. If desired, the composition may further comprise reinforcing fibers in such an amount as to give sufficient strength to the composition to make it operative depending on the intended use of the article produced therefrom.
This composition can be used in particular to produce fire proofing construction boards, heat-resistant seals or rollers, sleeves, casting molds or furnace insulating components.

Description

BACKGROUND OF THE INVENTION

a) Field of the invention ~ The present invention relates to a new heat-resistant composition particularly useful to produce heat-resistant boards, sleeves or linings capable of resisting to high temperatures for substantial periods of time. The invention also relates to the boards, sleeves, linings and similar articles obtained from such a composition by vacuum forming.

b) Brief description of the invention Canadian patent application serial number 577,693 filed on September 16, 1988 in the name of the same Applicant, discloses and claims a fibrous-like synthetic forsterite product which is particularly useful as an insulating material. This product which is presently offered for sale under the trademark FRITMAG and will be called as such hereinafter, is obtained by subjecting chrysotile asbestos fibers of any commercial grade, having an MgO: SiO2 ratio lower than 1:1, to calcination at a temperature of from 650 to 1450C.
FRITMAG has a raw loose density of from 3 to 40 pounds per cubic foot, a thermal conductivity K factor of from 0.25 to 0.40 BTU. in/hr.F.ft and a fusion point of about 1600 to 1700C. It possesses a somewhat fibrous structure ressembling that of the chrysotile asbestos fibers from which it derives, although this fibrous structure has shown to disappear upon rough manipulation, when subjected to pressure, or when mixed with other material. Then, the fibrous structure is lost but the product has and always retains a high insulating value , which is quite superior to granular forsterite, or similar to KAOWOOL ttrademark) or rockwool.
In the above-mentioned canadian patent application, it is mentioned that FRITMAG may be used as a substitute for asbestos, whenever a fibrous material to be used in bulk and having high insulating qualities is needed.
Indeed, FRITMAG is fibrous and has a loose density range substantially identical to asbestos. It also has high insulating properties and is devoided of all the undesirable health problems allegedly attributed to asbestos.
In the above-mentioned canadian patent application, it is also suggested to mix FRITMAG with an inert filler and a binder in order to form an insulating composition adapted to be shooted onto any surface to be insulated or to be moulded in the form of slabs for roof insulation.
However, no specific example of such a composition is given, except for a short reference made in the specification to a possible mixing with other materials, such as Portland cement. Similarly, no method of manufacturing slabs from such a composition is disclosed, although it is obvious that some of the methods presently used on an industrial scale to manufacture slabs may not be applicable if FRITMAG is part of the combination, because of the change of structure that has been noticed in this product when it is subjected to pressure or mixed with other materials.

SUMMARY OF THE INVENTION
The present invention derives from further studies that have been conducted on FRITMAG since it was first synthetized.
In accordance with the present invention, it has been found that heat-resistant boards, sleeves, linings and, more generally, any kind of heat-resistant articles capable of resisting to very high temperatures over substantial periods of time can be produced from a new heat-resistant composition processable by vacuum forming and consisting of an aqueous suspension containing from 1 to 10% by weight of a mixture comprising from 30 to 70% by weight of FRITMAG, the balance consisting mainly of colloidal silica as a binder.
The heat-resistant composition according to the invention may also comprise reinforcing fibers preferably selected from the group consisting of cellulose, glasswool, refractory fibers such as ceramic fibers, rockwool and their mixtures, in such an amount as to give sufficient strength, especially tensile strength, to the composition to make the article produced therefrom operative depending on its intended use.
In accordance with the invention, it has also been surprisingly found that the vacuum forming method commonly used for manufacturing heat-resistant boards, sleeves, linings or articles of any specific shape from any heat-resistant composition can also be used with success if use is made of the heat-resistant composition according to the invention as defined hereinabove as starting material. This vacuum forming method which is also used industrially worldwidely, basically consists in subjecting to vacuum an aqueous suspension containing from 1 to 10% by weight of solids. This vacuum forming method is particularly useful to produce boards, sleeves or any hollow shaped articles.
Surprisingly, it has been found that FRITMAG can effectively be used as a substitute for asbestos to produce boards, sleeves or hollow articles through such a vacuum forming method. As a matter of fact, it has been found that FRITMAG behaves as asbestos when subjected to vacuum and gives heat-resistant sleeves, boards or hollow articles 1 333q53 that can be subjected to very high temperatures over substantial periods of time and behave as effectively as any similar article made from "standard asbestos composition", such as the one presently sold as MILLBOARD.
As aforesaid, the composition according to the invention may further comprise reinforcing fibers.
Advantageously, the amount of reinforcing fibers may be adjusted at will, so as to give sufficient strength, especially tensile strength, to the resulting article to make it operative depending on its intended use. This amount of fibers added to the composition may be very small. Indeed, the addition of such reinforcing fiber is not required by any of the manufacturing methods mentioned hereinabove, but exclusively by the desiderata of the consumer.
Of course, the kind of fibers incorporated into the composition depends on the intended use of the boards, sleeves or heat-resistant articles produced from the composition. As a binder, use is made of colloidal silica like the one sold under the trademark LUDOX. If desired, additional binders such as starch may be used together with colloidal silica.
As aforesaid, the vacuum forming method may be used to produce boards and sleeves. It may also be used to produce other hollow articles of more complicated shape, such as casting molds, furnace insulating components and the like.
The composition according to the invention may further comprise inert fillers and additives known per se in this very specific field. Examples of such additives are siliceous dust, quartz, crushed stones, kaolin, blast furnace slag, etc.

EXAMPLE 1:

Plates of 30 cm X 30 cm having a thickness of 0.3 cm were produced by vacuum forming, using the composition given hereinafter as starting material.

FRITMAG 10.0 kg FIBERFRAX~ 4.0 kg Starch (EMPRESO ~ 0.8 kg LUDOX HSR-40 2.8 kg More particularly, the plates were prepared as follows.

Starch previously dissolved into water were added into the process water. FRITMAG and reinforcing fibers of trademark FIBERFARX and LUDOX HS-40 were subsequently added in this order. The concentration of solid in the process water was kept to about 3% and the elements were mixed for a period of time of 5 to 10 minutes prior to being subjected to vacuum forming .
The mixture was then subjected to vacuum forming to produce the requested plates. The resulting plates were compressed to have a volumic weight of 1.25g/cm3 and were dried at 105C for 24 hours.
The tensile and bending strengths of these plates are given in Table I and are compared with the mechanical properties of similar plates obtained from a commercial asbestos-containing MILLBOARD.
After heating at 8 hours at 1000C, the resulting plates kept about 80% of their mechanical properties. In contrast, the plates obtained from the asbestos-containing MILLBOARD were reduced to dust after heating at 800 C for 5 hours.

TABLE I

Volume Bending Tensile weight strength strength gr/cm MPa MPa Composition according to the invention 1.25 4.5 2.6 Asbestos-containing MILLBOARD
(comparative) 0.90 5.6 3.0 EXAMPLE 2:

Cylindrical sleeves having a length of 35 cm, an internal diameter of 10 cm and an external diameter of 14 cm were produced by vacuum forming, starting from the compositions given in Table II hereinafter. Each of the compositions was processed as disclosed in Example hereinabove, prior to being subjected to vacuum forming.

The resulting sleeves were dried for 24 hours at 105C.

~ 33~ 3 TABLE II

COMPOSITION
A B C
Starch (kg) 0. 37 0.370.37 FRITMA ~ (kg) 3.68 4.655.56 Rock Wool (kg) 2.83 1.860.95 LUDOX HS-4 ~ (kg) 1. 30 1.301.30 Water (liters) 163.00 163.00 163.00 The volumic weight of the sleeves produced from compositions A, B and C were equal to 18, 20 and 36 pcf respectively.

EXAMPLE 3:

Cylindrical sleeves similar to those disclosed in Example 2 were produced by vacuum forming, using, as starting materials, compositions given in Table III
hereinafter. The sleeves were dried for 24 hours at 105 C.
The volumic weight of the sleeves produced from compositions D, E and F were equal to 12, 20 and 19 pcf respectively.

TABLE III

COMPOSITION
D E F

Starch (kg) 0. 37 0.37 0.37 FRITMA ~ (kg) ---- 4. 65 -----Rock Wool (kg) 6.51 1.86 Fibers (MANVILLE
No. 6)~ (kg) ---- ____ 6.51 LUDOX HS-4 ~ (kg) 1.30 1.30 1.30 Water (liters) 163.00 163.00 163.00 The sleeves that were so obtained were hermatically closed at their bottom and aluminum was casted in molded form at a temperature about 800C inside the same. A temperature sensor was placed into the aluminum to follow the evolution of the temperature. The result of these tests are reported in Table IV.

TABLE IV

VARIATION OF THE ALUMINUM TEMPERATURE INSIDE THE SLEEVES

Time (in minute) COMPOSITION

D E F
C C C
2.5 673 750 750 5.0 657 725 715 7.5 650 700 680 10.0 650 675 660 12.5 650 660 650 15.0 650 650 650 20.0 649 650 650 25.0 648 650 650 1 333~3 As can be noted, the sleeves made from composition E had a behaviour that was equal to or slightly better than the the behaviour of the sleeves made from composition F. Both of these sleeves had undergone very small degradation after complete cooling of the aluminum.
The sleeves made from composition E (i.e. from the composition containing FRITMAG) had a behaviour much superior to the sleeves made from composition D. The sleeves made from this composition D underwent substantial degradation after cooling of the aluminum.

Claims (11)

1. A heat-resistant composition processable by vacuum forming to produce articles capable of resisting to high temperatures for substantial periods of time, said composition consisting of an aqueous suspension containing from 1 to 10% by weight of a mixture comprising:
- from 30 to 70% by weight of a fibrous-like, synthetic forsterite obtained by calcination of chrysotile asbestos fibers at a temperature of from 650°C to 1450°C, said synthetic forsterite having an MgO: Sio2 ratio lower than 1.1, a raw loose density of from 3 to 40 pcf, a thermal conductivity "k" factor of from 0.25 to 0.40 BTU.
in/hr.°F.ft2 and a fusion point of from 1600° to 1700°C; and - colloidal silica as a binder.
2. The composition of claim 1, further comprising starch as an additional binder in the mixture.
3. The composition of claim 1, further comprising:
- reinforcing fiber present in the mixture in such an amount as to give sufficient strength to said composition to make it operative depending on the intended use of the article produced therefrom.
4. The composition of claim 3, wherein said reinforcing fibers are selected from the group consisting of cellulose, glasswool, refractory fibers, rockwool and their mixtures.
5. The composition of claim 2, further comprising:
- reinforcing fibers present in the mixture in such an amount as to give sufficient strength to said composition to make it operative depending on the intended use of the article produced therefrom.
6. A heat-resistant board obtained by vacuum forming of the composition of claim 4.
7. A heat-resistant board obtained by vacuum forming of the composition of claim 5.
8. A heat-resistant sleeve obtained by vacuum forming of the composition of claim 4.
9. A heat-resistant sleeve obtained by vacuum forming of the composition of claim 5.
10. A heat-resistant lining obtained by vacuum forming of the composition of claim 4.
11. A heat-resistant lining obtained by vacuum forming of the composition of claim 5.
CA000612311A 1989-09-21 1989-09-21 Heat resistant composition processable by vacuum forming Expired - Fee Related CA1333953C (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA000612311A CA1333953C (en) 1989-09-21 1989-09-21 Heat resistant composition processable by vacuum forming

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA000612311A CA1333953C (en) 1989-09-21 1989-09-21 Heat resistant composition processable by vacuum forming

Publications (1)

Publication Number Publication Date
CA1333953C true CA1333953C (en) 1995-01-17

Family

ID=4140640

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000612311A Expired - Fee Related CA1333953C (en) 1989-09-21 1989-09-21 Heat resistant composition processable by vacuum forming

Country Status (1)

Country Link
CA (1) CA1333953C (en)

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