EP2038116A2 - Fibre inorganique - Google Patents

Fibre inorganique

Info

Publication number
EP2038116A2
EP2038116A2 EP06786131A EP06786131A EP2038116A2 EP 2038116 A2 EP2038116 A2 EP 2038116A2 EP 06786131 A EP06786131 A EP 06786131A EP 06786131 A EP06786131 A EP 06786131A EP 2038116 A2 EP2038116 A2 EP 2038116A2
Authority
EP
European Patent Office
Prior art keywords
weight percent
fiber
calcia
alumina
less
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.)
Ceased
Application number
EP06786131A
Other languages
German (de)
English (en)
Other versions
EP2038116A4 (fr
Inventor
Bruce K. Zoitos
Michael J. Andrejcak
Paul M. Boymel
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.)
Unifrax 1 LLC
Original Assignee
Unifrax Corp
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 Unifrax Corp filed Critical Unifrax Corp
Publication of EP2038116A2 publication Critical patent/EP2038116A2/fr
Publication of EP2038116A4 publication Critical patent/EP2038116A4/fr
Ceased legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C13/00—Fibre or filament compositions
    • C03C13/06—Mineral fibres, e.g. slag wool, mineral wool, rock wool
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/62227—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products obtaining fibres
    • C04B35/62231—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products obtaining fibres based on oxide ceramics
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/62227—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products obtaining fibres
    • C04B35/62231—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products obtaining fibres based on oxide ceramics
    • C04B35/62236—Fibres based on aluminium oxide
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
    • C04B2235/3208—Calcium oxide or oxide-forming salts thereof, e.g. lime
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3231—Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
    • C04B2235/3244—Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/327—Iron group oxides, their mixed metal oxides, or oxide-forming salts thereof
    • C04B2235/3272—Iron oxides or oxide forming salts thereof, e.g. hematite, magnetite
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3418—Silicon oxide, silicic acids, or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/72—Products characterised by the absence or the low content of specific components, e.g. alkali metal free alumina ceramics
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
    • C04B2235/9669—Resistance against chemicals, e.g. against molten glass or molten salts
    • C04B2235/9692—Acid, alkali or halogen resistance

Definitions

  • a high temperature resistant inorganic fiber useful as a thermal, electrical, or acoustical insulating material which has a use temperature of HOO 0 C or greater.
  • the high temperature resistant inorganic fiber is easily manufacturable, exhibits low shrinkage after prolonged exposure to the use temperature, retains good mechanical strength after exposure to the use temperature, and is soluble in physiological fluids.
  • the insulation material industry has determined that it is desirable to utilize fibers in thermal and acoustical insulating applications, which are not durable in physiological fluids, that is, fiber compositions which exhibit a low biopersistence. While candidate materials have been proposed, the use temperature limit of these materials have not been high enough to accommodate many of the applications to which high temperature resistant fibers, including vitreous fibers and ceramic fibers, are applied. Many compositions within the synthetic vitreous fiber family of materials have been proposed which are non-durable or decomposable in a physiological medium.
  • the high temperature resistant fibers should also exhibit minimal linear shrinkage at expected exposure temperatures, and after prolonged or continuous exposure to the expected use temperatures, in order to provide effective thermal protection to the article being insulated.
  • temperature resistance as expressed by shrinkage characteristics that are important in fibers that are used in insulation, it is also required that the fibers have mechanical strength characteristics during and following exposure to the use or service temperature, that will permit the fiber to maintain its structural integrity and insulating characteristics in use.
  • an improved inorganic fiber composition that is readily manufacturable from a fiberizable melt of desired ingredients, which exhibits low shrinkage during and after exposure to service temperatures of HOO 0 C or greater, which exhibits low brittleness after exposure to the expected use temperatures, and which maintains mechanical integrity after exposure to use temperatures of HOO 0 C or greater.
  • a high temperature resistant inorganic fiber that is useful as a thermal, electrical or acoustical insulating material is provided.
  • the inorganic fiber has a use temperature of HOO 0 C and greater.
  • the high temperature resistant inorganic is fiber is easily manufacturable from a melt of fiber ingredients, exhibits low linear shrinkage, retains good mechanical strength and integrity after exposure to the use temperature, and yet is soluble in physiological fluids.
  • At least 90 weight percent of the inorganic fiber comprises the fiberization product of greater than 50 weight percent calcia and greater than 0 to less than 50 weight percent alumina.
  • Also provided is a process for the production of an inorganic fiber the process comprises forming a melt with ingredients comprising calcia and alumina, and producing fibers from the melt, wherein the ingredients comprise, in total, at least 90 weight percent of said ingredients comprise greater than 50 weight percent calcia and greater than 0 to less than 50 weight percent alumina.
  • thermo insulation article comprises inorganic fibers comprising a fiberization product, wherein at least 90 weight percent of the fiberization product comprises greater than 50 weight percent calcia and greater than 0 to less than 50 weight percent alumina.
  • a method of insulating an article comprises disposing on, in, near or around the article, a thermal insulation material comprising inorganic fibers comprising a fiberization product, wherein at least 90 weight percent of the fiberization product comprises greater than 50 weight percent calcia and greater than 0 to less than 50 weight percent alumina.
  • FIG. 1 is a scanning electron micrograph of a calcium-aluminate fiber comprising the fiberization product of about 65 weight percent alumina and about 33 weight percent calcia.
  • FIG. 2 is a scanning electron micrograph of a calcium-aluminate fiber comprising the fiberization product of about 55.8 weight percent alumina and about 42.1 weight percent calcia.
  • FIG. 3 is a scanning electron micrograph of a calcium-aluminate fiber comprising the fiberization product of about 43.5 weight percent alumina and about 53 weight percent calcia.
  • FIG. 4 is a viscosity vs. temperature curve for a calcium-aluminate fiber melt chemistry comprising about 55.8 weight percent alumina and about 42.1 weight percent calcia.
  • FIGS. 5A-5C are photographs of refractory ceramic fiber thermal insulation blankets after exposure to a Na ⁇ O flux.
  • FIGS. 6A-6D are photographs of thermal insulation blankets comprising calcium-aluminate fibers after exposure to a Na2 ⁇ flux.
  • the inorganic fiber that is useful as a thermal, electrical, and acoustical insulation material is provided.
  • the inorganic fiber has a continuous service or use temperature of 1100 0 C or greater.
  • the vitreous inorganic fiber has a continuous service or use temperature of 1260°C or greater.
  • the inorganic fiber is non-durable in physiological fluids.
  • nondurable in physiological fluids it is meant that the inorganic fiber at least partially dissolves or decomposes in such fluids, such as simulated lung fluid, during in vitro tests.
  • the inorganic vitreous fiber also exhibits a linear shrinkage, as determined by the test method described below, of less than about 5 percent in response to exposure to a use temperature of 126O 0 C for 24 hours.
  • the inorganic fiber possesses a very low biopersistence in physiological fluids, and good linear shrinkage properties.
  • the low shrinkage, high temperature resistant inorganic fiber comprises the fiberization product of a melt containing calcia and alumina as the primary constituents.
  • the inorganic fiber comprising the fiberization product of calcia and alumina is referred to as a "calcium-aluminate" fiber.
  • At least 90 weight percent of the calcium-aluminate fiber comprises the fiberization product of greater than 50 weight percent calcia and greater than 0 to less than 50 weight percent alumina.
  • At least 90 weight percent of the calcium-aluminate fiber comprises the fiberization product of greater than 50 to about 60 weight percent calcia and from about 40 to less than 50 weight percent alumina.
  • At least 90 weight percent of the calcium-aluminate fiber comprises the fiberization product comprising greater than 50 to about 80 weight percent calcia and about 20 to less than 50 weight percent alumina.
  • At least 90 weight percent of the calcium-aluminate fiber comprises the fiberization product of about 60 to about 80 weight percent calcia and about 20 to about 40 weight percent alumina. According to further embodiments, at least 90 weight percent of the calcium-aluminate fiber comprises the fiberization product of greater than 50 to about 70 weight percent calcia and about 30 to less than 50 weight percent alumina.
  • the raw materials for the melt may be obtained from any suitable source capable of supplying the required chemistry and purity.
  • suitable sources of calcium oxide include calcium-aluminate cement having a desired ratio of CaO/AkCb, lime, limestone, and quicklime.
  • suitable sources of alumina are those having the required purity and which may be blended as needed with the CaO-bearing materials to achieve the desired chemistry.
  • the calcium-aluminate fiber may contain up to about 10 weight percent of impurities.
  • impurities may include iron oxides. If iron oxide impurities are present in the fiberization melt from the starting raw materials, they are usually present in an amount of about 1 weight percent or less, calculated as Fe2 ⁇ 3.
  • the impurities in the calcium-aluminate fiber may include up to 10 percent by weight of silica impurity, based on the total weight of the fiber. However, in certain embodiments the calcium-aluminate fibers may contain less than about 5 weight percent silica, or even as low as about 2 weight percent silica or less.
  • Linear shrinkage of an inorganic fiber is a good measure of a fiber's high temperature resistance or of its performance at a particular continuous service or use temperature.
  • the calcium-aluminate fibers exhibit a linear shrinkage after exposure to a service temperature of 126O 0 C for 24 hours of 5 percent or less.
  • the calcium-aluminate fibers are useful for thermal insulating applications at continuous service or operating temperatures of at least 126O 0 C or greater.
  • it has been found that the calcium-aluminate fibers do not melt until they are exposed to a temperature of 132O 0 C or greater.
  • a method for preparing a low shrinkage, high temperature resistant, non- durable calcium-aluminate fiber having a use temperature of at least 1100°C or greater is also provided.
  • the method of forming the calcium-aluminate fiber includes forming a material melt of ingredients comprising calcia and alumina, and forming fibers from the melt of ingredients.
  • the calcium-aluminate fibers may be produced from the melt of ingredients by standard melt spinning or fiber blowing techniques.
  • the method of forming the calcium- aluminate fiber includes forming a material melt of ingredients where at least 90 weight percent of the ingredients comprise, in total, greater than 50 weight percent calcia and greater than 0 to less than 50 weight percent alumina, and forming fibers from the melt of ingredients. It is understood that not each ingredient of the material melt must possess this calcia: alumina ratio, or any of the other calcia: alumina ratios described herein. Rather, the total amount of calcia and alumina contained in the material melt of ingredients comprises this ratio, or any of the calcia: alumina ratios described herein. Thus, in this embodiment, and the embodiments that follow, each ingredient need not have calcia and alumina in the disclosed ranges, but that total of such ingredients should comprise the disclosed ranges.
  • the method of forming the calcium- aluminate fiber includes forming a material melt of ingredients where at least 90 weight percent of the ingredients comprise, in total, greater than 50 to about 60 weight percent calcia and from about 40 to less than 50 weight percent alumina, and forming fibers from the melt of ingredients.
  • the method of forming the calcium- aluminate fiber includes forming a material melt of ingredients where at least 90 weight percent of the ingredients comprise, in total, about greater than 50 to about 80 weight percent calcia and about 20 to less than 50 weight percent alumina.
  • the method of forming the calcium- aluminate fiber includes forming a material melt of ingredients where at least 90 weight percent of the ingredients comprise, in total, about 60 to about 80 weight percent calcia and about 20 to about 40 weight percent alumina.
  • the method of forming the calcium- aluminate fiber includes forming a material melt of ingredients where at least 90 weight percent of the ingredient comprise, in total, greater than 50 to about 70 weight percent calcia and about 30 to less than 50 weight percent alumina.
  • the viscosity of the material melt of ingredients may optionally be controlled by the presence of viscosity modifiers, in an amount sufficient to provide the fiberization required for the desired applications.
  • the viscosity modifiers may be present in the raw materials which supply the main components of the melt, or may, at least in part, be separately added. Desired particle size of the raw materials is determined by furnacing conditions, including furnace size, pour rate, melt temperature, residence time, and the like.
  • the calcium-aluminate fiber may be prepared by fiber blowing or fiber spinning techniques.
  • a suitable fiber blowing technique includes the steps of mixing the starting raw materials containing calcia and alumina together to form a material mixture of ingredients, introducing the material mixture of ingredients into a suitable vessel or container, melting the material mixture of ingredients for discharge through a suitable nozzle, and blowing a high pressure gas onto the discharged flow of molten material mixture of ingredients to form the calcium-aluminate fibers.
  • a suitable fiber spinning technique includes the steps of mixing the starting raw materials containing calcia and alumina together to form a material mixture of ingredients, introducing the material mixture of ingredients into a suitable vessel or container, melting the material mixture of ingredients for discharge through a suitable nozzle onto spinning wheels. The molten stream then cascades over the wheels, coating the wheels and being thrown off through centripetal forces, thereby forming fibers.
  • a method of insulating an article using a thermal insulation material containing the calcium-aluminate fibers is also provided.
  • the method of insulating an article includes disposing on, in, near, or around the article to be insulated, a thermal insulation material that contains calcium-aluminate fibers.
  • the calcium-aluminate fibers included in the thermal insulation material are those in which at least 90 weight percent of the fiber comprises the fiberization product of greater than 50 weight percent calcia and greater than 0 to less than 50 weight percent alumina.
  • the calcium-aluminate fibers included in the thermal insulation material are those fibers in which at least 90 weight percent of the fiber comprises the fiberization product of greater than 50 to about 60 weight percent calcia and from about 40 to less than 50 weight percent alumina.
  • the calcium-aluminate fibers included in the thermal insulation material are those fibers in which at least 90 weight percent of the fiber comprises the fiberization product comprising about greater than 50 to about 80 weight percent calcia and about 20 to less than 50 weight percent alumina.
  • the calcium-aluminate fibers included in the thermal insulation material are those fibers in which at least 90 weight percent of the fiber comprises the fiberization product of about 60 to about 80 weight percent calcia and about 20 to about 40 weight percent alumina.
  • the calcium-aluminate fibers included in the thermal insulation material are those fibers in which at least 90 weight percent of the fiber comprises the fiberization product of greater than 50 to about 70 weight percent calcia and about 30 to less than 50 weight percent alumina.
  • Thermal insulation containing the calcium-aluminate fibers may be utilized in thermal insulation applications as a replacement for standard mineral wool or alumino-silicate refractory ceramic fiber. Thermal insulation material containing the calcium-aluminate fibers may be utilized for thermal insulation applications that require resistance of HOO 0 C or greater. Moreover, thermal insulation material containing the calcium-aluminate fibers may be utilized for thermal insulation applications that require resistance up to about 126O 0 C. Without limitation, thermal insulation containing the calcium-aluminate fibers may be utilized to thermally insulate heating vessels, such as furnaces, in the chemical processing, petroleum processing, ceramic processing, glass processing, metals production and processing industries, or in the automotive, aerospace, appliance, and fire protection industries.
  • the calcium-aluminate fibers may be provided in the form of bulk fibers. Additionally, the calcium-aluminate fibers may be incorporated into a wide variety of acoustical, electrical, or thermal insulation articles or products. Without limitation, for example, the calcium-aluminate fibers may be processed into high temperature resistant fiber containing blankets, including needled and stitched blankets, boards, braids, cloths, expanding papers, non-expanding papers, fabrics, felts, cast shapes, modules, bonded modules, mats, packings, ropes, tapes, sleeving, vacuum cast shapes, woven textiles, workable compositions, including high temperature resistant caulks, cements, coatings, mortars, pumpable compositions, putties, and moldable compositions.
  • high temperature resistant caulks including high temperature resistant caulks, cements, coatings, mortars, pumpable compositions, putties, and moldable compositions.
  • the flux resistance of the calcium-aluminate fibers was evaluated.
  • the term "fluxing” describes a reaction in which a relatively minor component (the flux) acts to drastically lower the melting point of a second material.
  • the fluxing process can significantly compromise the integrity of a thermal insulation material.
  • a flux may be present in the fuel that is used to fire the kiln.
  • Two common fluxes encountered in high temperature resistant kiln insulation applications are Na2 ⁇ and KiO, which are very damaging to refractory ceramic fiber.
  • the flux test is designed to test the aggressiveness of an impurity (the flux) toward the fiber at elevated temperatures. Briefly, a 1 gram sample of a powdered flux is piled in a 1 square inch area on the surface of fiber blanket. The assembly is then heated to 126O 0 C (or the desired test temperature) and held for 24 hours. Following the heating, the flux attack on the blanket is determined by visual inspection. Fluxing attack results in melting of the fiber which is in contact with the fluxing agent. The degree of attack can be assess by the amount of fiber which is melted. The results of the flux testing is reported in Table I:
  • Comparative Examples Cl and C2 represent commercially available alumina-zirconia-silica fiber blanket
  • Comparative Example C3 represents a commercially available alumino-silicate ceramic fiber blanket.
  • the results indicate that the commercially available alumina-zirconia-silica and alumino- silicate blankets were attacked by the Na2 ⁇ flux, thereby compromising the integrity of the insulation.
  • the fiber refractory ceramic fiber material blankets of the comparative examples the 1 square inch of blanket which had been in contact with the flux had melted.
  • no flux attack was observed for insulation blankets manufactured from the calcium-aluminate fibers.
  • the inorganic fiber compositions, method for producing the inorganic fiber composition, the various inorganic fiber containing articles, and method of insulating articles are not limited to the embodiments described above, but include all variations, modifications, and equivalent embodiments.
  • the embodiments that are disclosed separately are not necessarily in the alternative, as the various embodiments of the invention may be combined to provide the desired characteristics. Therefore, the inorganic fiber, fiber containing articles, and methods for preparing the fiber and using the fiber as thermal insulation should not be limited to any single embodiment, but rather construed in breadth and scope in accordance with the recitation of the attached claims.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Structural Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • General Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Inorganic Fibers (AREA)
  • Glass Compositions (AREA)
  • Porous Artificial Stone Or Porous Ceramic Products (AREA)
  • Compounds Of Alkaline-Earth Elements, Aluminum Or Rare-Earth Metals (AREA)

Abstract

L'invention concerne des fibres inorganiques contenant du calcium et de l'alumine en tant que principaux composants de fibre. L'invention concerne également des procédés consistant à préparer les fibres inorganiques et à isoler thermiquement des articles au moyen d'une isolation thermique comprenant les fibres inorganiques. Les fibres résistent à des températures de 1100 °C et plus, ainsi qu'aux attaques de flux.
EP06786131A 2006-06-30 2006-06-30 Fibre inorganique Ceased EP2038116A4 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2006/025840 WO2008005008A2 (fr) 2006-06-30 2006-06-30 Fibre inorganique

Publications (2)

Publication Number Publication Date
EP2038116A2 true EP2038116A2 (fr) 2009-03-25
EP2038116A4 EP2038116A4 (fr) 2010-05-05

Family

ID=38895042

Family Applications (1)

Application Number Title Priority Date Filing Date
EP06786131A Ceased EP2038116A4 (fr) 2006-06-30 2006-06-30 Fibre inorganique

Country Status (7)

Country Link
EP (1) EP2038116A4 (fr)
JP (1) JP5162584B2 (fr)
CN (1) CN101528623B (fr)
AU (1) AU2006345730B2 (fr)
BR (1) BRPI0621848A2 (fr)
MX (1) MX2008016366A (fr)
WO (1) WO2008005008A2 (fr)

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JP6105478B2 (ja) * 2010-11-16 2017-03-29 ユニフラックス ワン リミテッド ライアビリティ カンパニー 無機繊維
JP5856541B2 (ja) * 2012-06-07 2016-02-09 ニチアス株式会社 生理食塩水に可溶なＡｌ−Ｃａ系無機繊維及びその組成物
JP2014141367A (ja) * 2013-01-23 2014-08-07 Nichias Corp 生体溶解性無機繊維及びその組成物
BR112020007143A2 (pt) 2017-10-10 2020-09-24 Unifrax I Llc fibra inorgânica com baixa biopersistência isenta de sílica cristalina

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0586797A1 (fr) 1992-08-26 1994-03-16 Didier-Werke Ag Fibre inorganique

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
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AU2006345730B2 (en) 2011-11-03
WO2008005008A2 (fr) 2008-01-10
JP5162584B2 (ja) 2013-03-13
AU2006345730A1 (en) 2008-01-10
JP2009542927A (ja) 2009-12-03
CN101528623A (zh) 2009-09-09
CN101528623B (zh) 2013-09-25
WO2008005008A3 (fr) 2009-04-30
EP2038116A4 (fr) 2010-05-05
MX2008016366A (es) 2009-02-23

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