WO2004007394A1 - Thermally insulating moulded body and method of manufacture - Google Patents

Thermally insulating moulded body and method of manufacture Download PDF

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Publication number
WO2004007394A1
WO2004007394A1 PCT/GB2003/003117 GB0303117W WO2004007394A1 WO 2004007394 A1 WO2004007394 A1 WO 2004007394A1 GB 0303117 W GB0303117 W GB 0303117W WO 2004007394 A1 WO2004007394 A1 WO 2004007394A1
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WO
WIPO (PCT)
Prior art keywords
moulded body
weight percent
thermally insulating
dry
expanded vermiculite
Prior art date
Application number
PCT/GB2003/003117
Other languages
French (fr)
Inventor
Oras Khalid Abdul-Kader
Mark Daniel Mortimer
Baudevijn Van Gucht
Original Assignee
Microtherm International Limited
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
Priority claimed from GBGB0216588.4A external-priority patent/GB0216588D0/en
Priority claimed from GBGB0311623.3A external-priority patent/GB0311623D0/en
Application filed by Microtherm International Limited filed Critical Microtherm International Limited
Priority to AU2003280969A priority Critical patent/AU2003280969A1/en
Publication of WO2004007394A1 publication Critical patent/WO2004007394A1/en

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Classifications

    • 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
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/34—Compositions 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 cold phosphate binders
    • 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
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/24—Compositions 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
    • C04B28/26—Silicates of the alkali metals
    • 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
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/10—Compositions or ingredients thereof characterised by the absence or the very low content of a specific material
    • C04B2111/12—Absence of mineral fibres, e.g. asbestos

Definitions

  • This invention relates to a thermally insulating moulded body and a method of manufacturing such a body.
  • this invention relates to a thermally insulating moulded body which finds application as a wall member, such as of ring form, in a radiant electric heater, particularly for a cooking appliance.
  • Radiant electric heaters are well known for use behind cooking surfaces, such as of glass-ceramic, in cooking appliances .
  • a heater typically comprises a dish- like support, such as of metal, in which is a base layer of thermal insulation material and one or more electric heating elements.
  • a wall member provided for this purpose must exhibit low thermal conductivity, adequate flexural strength and good electrical insulation properties. Furthermore, it is required to be inexpensive to manufacture .
  • moulded ring-shaped wall members in the form of bound ceramic fibre materials.
  • ceramic fibre materials are generally disadvantageous in that they are harmful if inhaled.
  • moulded ring-shaped wall members comprising expanded vermiculite and a suitable binder. Whilst relatively inexpensive to manufacture, such wall members are somewhat unsatisfactory in that they exhibit relatively high thermal conductivity.
  • moulded ring-shaped wall members comprising a mixture of expanded vermiculite, reinforcing fibres, a binder and microporous materials. Ring-shaped wall members of this composition, while exhibiting good performance, are somewhat expensive to manufacture .
  • a substantially fibre-free thermally insulating moulded body comprising a mixture of volatilised silica, expanded vermiculite and an inorganic binder.
  • a method of manufacturing a substantially fibre-free thermally insulating moulded body comprising forming a wet mixture comprising volatilised silica, expanded vermiculite and an aqueous solution of an inorganic binder, and compressing and drying the mixture to form a thermally insulating moulded body comprising a mixture of volatilised silica, expanded vermiculite and inorganic binder.
  • the thermally insulating moulded body may be used, for example as a wall member, such as of ring form, in a radiant electric heater.
  • the thermally insulating moulded body may be used as a base for an electric storage heater or in other applications where a moulded thermally insulating body is required.
  • the inorganic binder may be selected from an alkali metal silicate binder, such as sodium silicate or potassium silicate, preferably potassium silicate, and aluminium orthophosphate .
  • the dry thermally insulating moulded body may comprise:
  • the dry thermally insulating moulded body may comprise:
  • the thermally insulating moulded body may comprise:
  • the thermally insulating moulded body may comprise: a) 10 to 30 dry weight percent of volatilised silica; b) 40 to 70 dry weight percent of expanded vermiculite; and c) 10 to 14 dry weight percent of inorganic binder .
  • the thermally insulating body, and the mixture employed in the manufacture thereof, may optionally include an infra-red opacifier material, such as for scattering or absorbing infra-red radiation.
  • the infra-red opacifier material may be selected from rutile, ilmenite, titanium oxide, iron oxide, mixtures of titanium oxide and iron oxide, zirconium oxide, zirconium silicate, chromium oxide, silicon carbide and other materials of suitable refractive index and temperature stability as known to those skilled in the art.
  • the infra-red opacifier may be provided in an amount of between 0 and 40 percent by weight.
  • the volatilised silica may have a BET specific surface of less than 50 square metres per gram and preferably about 20 square metres per gram.
  • the mixture may be dried at a temperature of from room temperature to 300 degrees Celsius, after compressing.
  • the mixture may be compressed to a density (when dry) of between 600 and 1300 kilograms per cubic metre.
  • the present invention also provides a radiant electric heater provided with the thermally insulating moulded body.
  • the thermally insulating moulded body according to the present invention is adequately strong for use as a wall member, such as of ring form, in a radiant electric heater and also exhibits suitably low thermal conductivity and required electrical insulation properties for such application.
  • volatilised silica is a relatively inexpensive material, such moulded body is also inexpensive to manufacture.
  • Figure 1 is a perspective view of an embodiment of a substantially fibre-free thermally insulating moulded body according to the present invention, in the form of a ring-shaped wall member for a radiant electric heater;
  • Figure 2 is a plan view of a radiant electric heater provided with the thermally insulating moulded body of Figure 1;
  • Figure 3 is a cross-section through the heater of Figure 2.
  • a wet mixture was prepared comprising 20.4 per cent by weight of volatilised silica available from RW Silicium GmbH under the name RW-Fuller, 49.0 per cent by weight of Micron grade expanded vermiculite available from Hoben International, and 30.6 per cent wet weight of aqueous potassium silicate solution binder available from Ineos Chemicals under the name K66.
  • the volatilised silica has a nominal specific surface area of 20 m 2 /g.
  • the potassium silicate binder has the nominal composition 35 per cent by weight solids content and 65 per cent by weight water.
  • Micron grade exfoliated vermiculite has a particle size in a range from 0.1 mm to 3 mm.
  • the mixture was supplied to a moulding tool and compressed to a density of about 1000 kg/m 3 , then dried at 250 degrees Celsius after removal from the mould, to form a thermally insulating moulded body.
  • the resulting compressed and dried thermally insulating moulded body was nominally 25.5 per cent by dry weight of volatilised silica, 61.2 per cent by dry weight of expanded vermiculite and 13.3 per cent by dry weight of potassium silicate binder.
  • the ring-shaped thermally insulating moulded body 2 was tested using a three point bend strength apparatus known to a person skilled in the art.
  • the ring- shaped thermally insulating moulded body used for the test had an outer diameter of 164 mm, an inner diameter of 145 mm and a ring height of 13 mm.
  • the ring-shaped body was positioned on the two parallel bars of the three point bend apparatus (the bars being positioned 120 mm apart) and the third bar, parallel to the lower two and positioned equidistant between them, was brought down onto the ring-shaped body in such a way as to break the ring-shaped body.
  • the maximum force applied was recorded as about 55 N.
  • the ring-shaped thermally insulating moulded body also exhibits adequately low thermal conductivity of about 0.252 W/mK at 100 degrees Celsius, and about 0.285 W/mK at 180 degrees Celsius measured by means of cylindrical cell thermal conductivity apparatus known to a person skilled in the art.
  • a wet mixture was prepared using the same materials as those in Example 1 comprising 20.4 per cent by weight of volatilised silica, 54.1 per cent by weight of expanded vermiculite and 25.5 per cent wet weight of potassium silicate solution binder.
  • the mixture was compressed to a density of about 1000 kg/m 3 , and dried in accordance with the methods described in Example 1.
  • the resulting compressed and dried thermally insulating moulded body was nominally 24.5 per cent by dry weight of volatilised silica, 64.8 per cent by dry weight of expanded vermiculite and 10.7 per cent by dry weight of potassium silicate binder.
  • the thermally insulating moulded body, in ring form was tested for strength in accordance with the procedure described in Example 1.
  • the maximum force applied to break the ring-shaped body was about 44 N.
  • the ring- shaped body also exhibits adequately low thermal conductivity of about 0.201 W/mK at a mean temperature of 100 degrees Celsius, and about 0.222 W/mK at a mean temperature of 180 degrees Celsius.
  • a wet mixture was prepared using the same materials as those in Example 1 comprising 40.0 per cent by weight of volatilised silica, 30.0 per cent by weight of expanded vermiculite and 30.0 per cent wet weight of potassium silicate solution binder.
  • the mixture was compressed to a density of nominally 1000 kg/m 3 , and dried in accordance with the methods described in Example 1.
  • the resulting compressed and dried thermally insulating moulded body was nominally 49.7 per cent by dry weight of volatilised silica, 37.3 per cent by dry weight of expanded vermiculite and 13.0 per cent by dry weight of potassium silicate binder.
  • the thermally insulating moulded body, in ring form, tested as described in Example 1 required a maximum breaking force of about 89 N. It also exhibits adequately low thermal conductivity of about 0.254 W/mK at a mean temperature of 200 degrees Celsius.
  • a wet mixture was prepared using the same materials as those in Example 1 comprising 60.0 per cent by weight of volatilised silica, 20.0 per cent by weight of expanded vermiculite and 20.0 per cent wet weight of potassium silicate solution binder.
  • the mixture was compressed to a density of nominally 1000 kg/m 3 , and dried in accordance with the methods described in Example 1.
  • the resulting compressed and dried thermally insulating moulded body was nominally 69.0 per cent by dry weight of volatilised silica, 23.0 per cent by dry weight of expanded vermiculite and 8.0 per cent by dry weight of potassium silicate binder.
  • the thermally insulating moulded body, in ring form, tested as described in Example 1 required a maximum breaking force of about 33 N. It also exhibits adequately low thermal conductivity of about 0.238 W/mK at a mean temperature of 200 degrees Celsius.
  • a wet mixture was prepared using the same materials as those in Example 1 comprising 40.0 per cent by weight of volatilised silica, 20.0 per cent by weight of expanded vermiculite, 20.0 per cent wet weight of potassium silicate solution binder, and 20.0 per cent by weight of infrared opacifier in the form of rutile (titanium oxide) , available from Eggerding Group, Amsterdam.
  • rutile titanium oxide
  • the rutile has a mean particle size of 1.6 micron as measured using a Fischer sizer.
  • the mixture was compressed to a nominal density of 1000 kg/m 3 and dried in accordance with the methods described in Example 1.
  • the resulting compressed and dried thermally insulating moulded body was nominally 46.0 per cent by dry weight of volatilised silica, 23.0 per cent by dry weight of expanded vermiculite, 23.0 per cent by dry weight of rutile and 8.0 per cent by dry weight of potassium silicate binder.
  • the thermally insulating moulded body, in ring form, tested as described in Example 1 required a maximum breaking force of about 33 N. It also exhibits adequately low thermal conductivity of about 0.211 W/mK at a mean temperature of 200 degrees Celsius.
  • a wet mixture was prepared using the same materials as those in Example 5 comprising 30.0 per cent by weight of volatilised silica, 25.0 per cent by weight of expanded vermiculite, 25.0 per cent wet weight of potassium silicate solution binder, and 20.0 per cent by weight of rutile.
  • the mixture was compressed to a nominal density of 1000 kg/m 3 and dried in accordance with the methods described in Example 1.
  • the resulting compressed and dried thermally insulating moulded body was nominally 35.8 per cent by dry weight of volatilised silica, 29.9 per cent by dry weight of expanded vermiculite, 23.9 per cent by dry weight of rutile and 10.4 per cent by dry weight of potassium silicate binder.
  • the thermally insulating moulded body, in ring form, tested as described in Example 1 required a maximum breaking force of about 18 N. It also exhibits adequately low thermal conductivity of about 0.213 W/mK at a mean temperature of 200 degrees Celsius.
  • a wet mixture was prepared using the same materials as those in Example 5 comprising 15.0 per cent by weight of volatilised silica, 35.0 per cent by weight of expanded vermiculite, 30.0 per cent wet weight of potassium silicate solution binder, and 20.0 per cent by weight of rutile.
  • the mixture was compressed to a nominal density of 1000 kg/m 3 and dried in accordance with the methods described in Example 1.
  • the resulting compressed and dried thermally insulating moulded body was nominally 18.6 per cent by dry weight of volatilised silica, 43.5 per cent by dry weight of expanded vermiculite, 24.8 per cent by dry weight of rutile and 13.1 per cent by dry weight of potassium silicate binder.
  • the thermally insulating moulded body, in ring form, tested as described in Example 1 required a maximum breaking force of about 32 N. It also exhibits adequately low thermal conductivity of about 0.217 W/mK at a mean temperature of 200 degrees Celsius.
  • a wet mixture was prepared using the same materials as those in Example 5 comprising 15.0 per cent by weight of volatilised silica, 50.0 per cent by weight of expanded vermiculite, 25.0 per cent wet weight of potassium silicate solution binder, and 10.0 per cent by weight of rutile.
  • the mixture was compressed to a nominal density of 1000 kg/m 3 and dried in accordance with the methods described in Example 1.
  • the resulting compressed and dried thermally insulating moulded body was nominally 17.9 per cent by dry weight of volatilised silica, 59.7 per cent by dry weight of expanded vermiculite, 11.9 per cent by dry weight of rutile and 10.5 per cent by dry weight of potassium silicate binder.
  • the thermally insulating moulded body, in ring form, tested as described in Example 1 required a maximum breaking force of about 25 N. It also exhibits adequately low thermal conductivity of about 0.264 W/mK at a mean temperature of 200 degrees Celsius.
  • a wet mixture was prepared comprising 25.0 per cent by weight of volatilised silica available from RW Silicium GmbH under the name RW-Fuller Ql, 30.0 per cent by weight of Special grade expanded vermiculite available from Hoben International, 15.0 per cent by weight of infrared opacifier in the form of rutile (titanium oxide) , available from Eggerding Group, Amsterdam, and 30.0 per cent wet weight of aqueous potassium silicate solution binder available from Ineos Chemicals under the name K66.
  • the Ql volatilised silica has a nominal specific surface area of 20 m 2 /g.
  • the mixture was compressed to a nominal density of 1000 kg/m 3 and dried in accordance with the methods described in Example 1.
  • the resulting compressed and dried thermally insulating moulded body was nominally 31.1 per cent by dry weight of volatilised silica, 37.3 per cent by dry weight of expanded vermiculite, 18.6 per cent by dry weight of rutile and 13.0 per cent by dry weight of potassium silicate binder.
  • the thermally insulating moulded body, in ring form, tested as described in Example 1 required a maximum breaking force of about 78 N. It also exhibits adequately low thermal conductivity of about 0.253 W/mK at a mean temperature of 200 degrees Celsius.
  • a wet mixture was prepared comprising 22.0 per cent by weight of volatilised silica available from RW Silicium GmbH under the name RW-Fuller Ql, 35.0 per cent by weight of Special grade expanded vermiculite available from Hoben International, 17.0 per cent by weight of infrared opacifier in the form of zircon (zirconium silicate) , available from Eggerding Group, Amsterdam, and 26.0 per cent wet weight of aqueous potassium silicate solution binder available from Ineos Chemicals under the name K66.
  • the mixture was compressed to a nominal density of 1000 kkgg//mm 33 aanndd ddrriied in accordance with the methods described in Example 1.
  • the resulting compressed and dried thermally insulating moulded body was nominally 26.5 per cent by dry weight of volatilised silica, 42.0 per cent by dry weight of expanded vermiculite, 20.5 per cent by dry weight of zircon and 11.0 per cent by dry weight of potassium silicate binder.
  • the thermally insulating moulded body, in ring form, tested as described in Example 1 required a maximum breaking force of about 40 N. It also exhibits adequately low thermal conductivity of about 0.236 W/mK at a mean temperature of 200 degrees Celsius.
  • a wet mixture was prepared using the same materials as those in Example 10 comprising 25.0 per cent by weight of volatilised silica available from RW Silicium GmbH under the name RW-Fuller Ql, 32.0 per cent by weight of Special grade expanded vermiculite available from Hoben International, 16.0 per cent by weight of infrared opacifier in the form of zircon, and 27.0 per cent wet weight of potassium silicate solution.
  • the mixture was compressed to a nominal density of 1000 kg/m 3 and dried in accordance with the methods described in Example 1.
  • the resulting compressed and dried thermally insulating moulded body was nominally 30.3 per cent by dry weight of volatilised silica, 38.8 per cent by dry weight of expanded vermiculite, 19.4 per cent by dry weight of zircon and 11.5 per cent by dry weight of potassium silicate binder.
  • the thermally insulating moulded body, in ring form, tested as described in Example 1 required a maximum breaking force of about 50 N. It also exhibits adequately low thermal conductivity of about 0.246 W/mK at a mean temperature of 200 degrees Celsius.
  • a wet mixture was prepared comprising 45.0 per cent by weight of volatilised silica available from RW Silicium GmbH under the name RW-Fuller Ql, 25.0 per cent by weight of Micron grade expanded vermiculite available from Hoben International, and 30.0 per cent wet weight of aqueous potassium silicate solution binder available from Ineos Chemicals under the name K66.
  • the mixture was compressed to a nominal density of 1000 kg/m 3 and dried in accordance with the methods described in Example 1.
  • the resulting compressed and dried thermally insulating moulded body was nominally 55.9 per cent by dry weight of volatilised silica, 31.1 per cent by dry weight of expanded vermiculite and 13.0 per cent by dry weight of potassium silicate binder.
  • the thermally insulating moulded body, in ring form, tested as described in Example 1 required a maximum breaking force of about 98 N. It also exhibits adequately low thermal conductivity of about 0.219 W/mK at a mean temperature of 200 degrees Celsius.
  • thermally insulating moulded bodies described in Examples 1 to 12 can be used, for example as a wall member, in a radiant electric heater.
  • the thermally insulating moulded body is of ring- shape as denoted by reference numeral 2 in Figure 1, and is arranged for insertion as a wall member in a radiant electric heater 4 , as shown in Figures 2 and 3.
  • the radiant electric heater 4 is arranged for location in a cooking appliance underneath a cooking surface 6, such as of glass-ceramic, and comprises a metal dish-like support 8 in which an electric heating element 10 is supported on a base layer 12 of thermal insulation material, which may be well-known microporous insulation material.
  • the ring- shaped thermally insulating moulded body 2 according to the present invention is located around the periphery of the heater 4, against the rim of the metal dish-like support 8 and contacts the underside of the cooking surface 6.
  • the electric heater 4 is also provided with a known form of temperature-responsive device 14 and also a terminal block 16 for connecting the heating element 10 to a power supply.
  • thermally insulating moulded bodies described in Examples 1 to 12 can be used, for example as a base, for an electric storage heater or other applications where a moulded thermally insulating body is required.
  • a drying temperature of 250 degrees Celsius is described in Examples 1 to 12 to form a thermally insulating moulded body. It should be understood that such drying can be effected at room temperature, or at an elevated temperature of up to about 300 degrees Celsius, and can be carried out before or after removing the moulded body from the moulding tool .
  • Examples 1 to 12 are described as being compressed to about 100 0 kilograms per cubic metre the mixtures may be compressed to a range of densities (when dry) , for example between 600 and 1300 kilograms per cubic metre.

Abstract

A substantially fibre-free thermally insulating moulded body (2) and a method of manufacturing the same comprising a mixture of volatilised silica, expanded vermiculite and an inorganic binder.

Description

THERMALLY INSULATING MOULDED BODY AND METHOD OF
MANUFACTURE
This invention relates to a thermally insulating moulded body and a method of manufacturing such a body.
In particular, this invention relates to a thermally insulating moulded body which finds application as a wall member, such as of ring form, in a radiant electric heater, particularly for a cooking appliance.
Radiant electric heaters are well known for use behind cooking surfaces, such as of glass-ceramic, in cooking appliances . Such a heater typically comprises a dish- like support, such as of metal, in which is a base layer of thermal insulation material and one or more electric heating elements. It is known to provide one or more wall members of ring form in the heater, around the periphery of the heater and/or as an inner wall separating adjacent heating zones of the heater. The wall member or members usually rest on the base layer of the heater and contact the underside of the cooking surface.
A wall member provided for this purpose must exhibit low thermal conductivity, adequate flexural strength and good electrical insulation properties. Furthermore, it is required to be inexpensive to manufacture .
It is known to provide moulded ring-shaped wall members in the form of bound ceramic fibre materials. However, such ceramic fibre materials are generally disadvantageous in that they are harmful if inhaled. It is also known to provide moulded ring-shaped wall members comprising expanded vermiculite and a suitable binder. Whilst relatively inexpensive to manufacture, such wall members are somewhat unsatisfactory in that they exhibit relatively high thermal conductivity.
It is also known to provide moulded ring-shaped wall members comprising a mixture of expanded vermiculite, reinforcing fibres, a binder and microporous materials. Ring-shaped wall members of this composition, while exhibiting good performance, are somewhat expensive to manufacture .
It is an object of the present invention to overcome or minimise these problems .
According to one aspect of the present invention there is provided a substantially fibre-free thermally insulating moulded body comprising a mixture of volatilised silica, expanded vermiculite and an inorganic binder.
According to another aspect of the present invention there is provided a method of manufacturing a substantially fibre-free thermally insulating moulded body, the method comprising forming a wet mixture comprising volatilised silica, expanded vermiculite and an aqueous solution of an inorganic binder, and compressing and drying the mixture to form a thermally insulating moulded body comprising a mixture of volatilised silica, expanded vermiculite and inorganic binder.
The thermally insulating moulded body may be used, for example as a wall member, such as of ring form, in a radiant electric heater. Alternatively, the thermally insulating moulded body may be used as a base for an electric storage heater or in other applications where a moulded thermally insulating body is required.
The inorganic binder may be selected from an alkali metal silicate binder, such as sodium silicate or potassium silicate, preferably potassium silicate, and aluminium orthophosphate .
The dry thermally insulating moulded body may comprise:
a) 10 to 70 weight percent of volatilised silica; b) 10 to 70 weight percent of expanded vermiculite; and c) 3 to 20 weight percent of inorganic binder.
The dry thermally insulating moulded body may comprise:
a) 10 to 70 weight percent of volatilised silica; b) 20 to 70 weight percent of expanded vermiculite; and c) 5 to 14 weight percent of inorganic binder.
The thermally insulating moulded body may comprise:
a) 10 to 56 dry weight percent of volatilised silica; b) 30 to 70 dry weight percent of expanded vermiculite; and c) 10 to 14 dry weight percent of inorganic binder.
The thermally insulating moulded body may comprise: a) 10 to 30 dry weight percent of volatilised silica; b) 40 to 70 dry weight percent of expanded vermiculite; and c) 10 to 14 dry weight percent of inorganic binder .
The thermally insulating body, and the mixture employed in the manufacture thereof, may optionally include an infra-red opacifier material, such as for scattering or absorbing infra-red radiation. The infra-red opacifier material may be selected from rutile, ilmenite, titanium oxide, iron oxide, mixtures of titanium oxide and iron oxide, zirconium oxide, zirconium silicate, chromium oxide, silicon carbide and other materials of suitable refractive index and temperature stability as known to those skilled in the art.
The infra-red opacifier may be provided in an amount of between 0 and 40 percent by weight.
The volatilised silica may have a BET specific surface of less than 50 square metres per gram and preferably about 20 square metres per gram.
The mixture may be dried at a temperature of from room temperature to 300 degrees Celsius, after compressing.
The mixture may be compressed to a density (when dry) of between 600 and 1300 kilograms per cubic metre.
The present invention also provides a radiant electric heater provided with the thermally insulating moulded body. In spite of being fibre-free, the thermally insulating moulded body according to the present invention is adequately strong for use as a wall member, such as of ring form, in a radiant electric heater and also exhibits suitably low thermal conductivity and required electrical insulation properties for such application. By virtue of being fibre-free, and also because volatilised silica is a relatively inexpensive material, such moulded body is also inexpensive to manufacture.
For a better understanding of the present invention and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings in which:
Figure 1 is a perspective view of an embodiment of a substantially fibre-free thermally insulating moulded body according to the present invention, in the form of a ring-shaped wall member for a radiant electric heater;
Figure 2 is a plan view of a radiant electric heater provided with the thermally insulating moulded body of Figure 1; and
Figure 3 is a cross-section through the heater of Figure 2.
EXAMPLE 1
A wet mixture was prepared comprising 20.4 per cent by weight of volatilised silica available from RW Silicium GmbH under the name RW-Fuller, 49.0 per cent by weight of Micron grade expanded vermiculite available from Hoben International, and 30.6 per cent wet weight of aqueous potassium silicate solution binder available from Ineos Chemicals under the name K66.
The volatilised silica has a nominal specific surface area of 20 m2/g.
The potassium silicate binder has the nominal composition 35 per cent by weight solids content and 65 per cent by weight water.
Micron grade exfoliated vermiculite has a particle size in a range from 0.1 mm to 3 mm.
The mixture was supplied to a moulding tool and compressed to a density of about 1000 kg/m3, then dried at 250 degrees Celsius after removal from the mould, to form a thermally insulating moulded body.
The resulting compressed and dried thermally insulating moulded body was nominally 25.5 per cent by dry weight of volatilised silica, 61.2 per cent by dry weight of expanded vermiculite and 13.3 per cent by dry weight of potassium silicate binder.
An indication of the flexural strength of a ring-shaped thermally insulating moulded body 2 was obtained by measuring the maximum force required to break the ring- shaped body. The ring-shaped thermally insulating moulded body was tested using a three point bend strength apparatus known to a person skilled in the art. The ring- shaped thermally insulating moulded body used for the test had an outer diameter of 164 mm, an inner diameter of 145 mm and a ring height of 13 mm. The ring-shaped body was positioned on the two parallel bars of the three point bend apparatus (the bars being positioned 120 mm apart) and the third bar, parallel to the lower two and positioned equidistant between them, was brought down onto the ring-shaped body in such a way as to break the ring-shaped body. The maximum force applied was recorded as about 55 N. The ring-shaped thermally insulating moulded body also exhibits adequately low thermal conductivity of about 0.252 W/mK at 100 degrees Celsius, and about 0.285 W/mK at 180 degrees Celsius measured by means of cylindrical cell thermal conductivity apparatus known to a person skilled in the art.
EXAMPLE 2
A wet mixture was prepared using the same materials as those in Example 1 comprising 20.4 per cent by weight of volatilised silica, 54.1 per cent by weight of expanded vermiculite and 25.5 per cent wet weight of potassium silicate solution binder.
The mixture was compressed to a density of about 1000 kg/m3, and dried in accordance with the methods described in Example 1.
The resulting compressed and dried thermally insulating moulded body was nominally 24.5 per cent by dry weight of volatilised silica, 64.8 per cent by dry weight of expanded vermiculite and 10.7 per cent by dry weight of potassium silicate binder.
The thermally insulating moulded body, in ring form was tested for strength in accordance with the procedure described in Example 1. The maximum force applied to break the ring-shaped body was about 44 N. The ring- shaped body also exhibits adequately low thermal conductivity of about 0.201 W/mK at a mean temperature of 100 degrees Celsius, and about 0.222 W/mK at a mean temperature of 180 degrees Celsius.
EXAMPLE 3
A wet mixture was prepared using the same materials as those in Example 1 comprising 40.0 per cent by weight of volatilised silica, 30.0 per cent by weight of expanded vermiculite and 30.0 per cent wet weight of potassium silicate solution binder.
The mixture was compressed to a density of nominally 1000 kg/m3, and dried in accordance with the methods described in Example 1.
The resulting compressed and dried thermally insulating moulded body was nominally 49.7 per cent by dry weight of volatilised silica, 37.3 per cent by dry weight of expanded vermiculite and 13.0 per cent by dry weight of potassium silicate binder.
The thermally insulating moulded body, in ring form, tested as described in Example 1 required a maximum breaking force of about 89 N. It also exhibits adequately low thermal conductivity of about 0.254 W/mK at a mean temperature of 200 degrees Celsius.
EXAMPLE 4
A wet mixture was prepared using the same materials as those in Example 1 comprising 60.0 per cent by weight of volatilised silica, 20.0 per cent by weight of expanded vermiculite and 20.0 per cent wet weight of potassium silicate solution binder. The mixture was compressed to a density of nominally 1000 kg/m3, and dried in accordance with the methods described in Example 1.
The resulting compressed and dried thermally insulating moulded body was nominally 69.0 per cent by dry weight of volatilised silica, 23.0 per cent by dry weight of expanded vermiculite and 8.0 per cent by dry weight of potassium silicate binder.
The thermally insulating moulded body, in ring form, tested as described in Example 1 required a maximum breaking force of about 33 N. It also exhibits adequately low thermal conductivity of about 0.238 W/mK at a mean temperature of 200 degrees Celsius.
EXAMPLE 5
A wet mixture was prepared using the same materials as those in Example 1 comprising 40.0 per cent by weight of volatilised silica, 20.0 per cent by weight of expanded vermiculite, 20.0 per cent wet weight of potassium silicate solution binder, and 20.0 per cent by weight of infrared opacifier in the form of rutile (titanium oxide) , available from Eggerding Group, Amsterdam.
The rutile has a mean particle size of 1.6 micron as measured using a Fischer sizer.
The mixture was compressed to a nominal density of 1000 kg/m3 and dried in accordance with the methods described in Example 1.
The resulting compressed and dried thermally insulating moulded body was nominally 46.0 per cent by dry weight of volatilised silica, 23.0 per cent by dry weight of expanded vermiculite, 23.0 per cent by dry weight of rutile and 8.0 per cent by dry weight of potassium silicate binder.
The thermally insulating moulded body, in ring form, tested as described in Example 1 required a maximum breaking force of about 33 N. It also exhibits adequately low thermal conductivity of about 0.211 W/mK at a mean temperature of 200 degrees Celsius.
EXAMPLE 6
A wet mixture was prepared using the same materials as those in Example 5 comprising 30.0 per cent by weight of volatilised silica, 25.0 per cent by weight of expanded vermiculite, 25.0 per cent wet weight of potassium silicate solution binder, and 20.0 per cent by weight of rutile.
The mixture was compressed to a nominal density of 1000 kg/m3 and dried in accordance with the methods described in Example 1.
The resulting compressed and dried thermally insulating moulded body was nominally 35.8 per cent by dry weight of volatilised silica, 29.9 per cent by dry weight of expanded vermiculite, 23.9 per cent by dry weight of rutile and 10.4 per cent by dry weight of potassium silicate binder.
The thermally insulating moulded body, in ring form, tested as described in Example 1 required a maximum breaking force of about 18 N. It also exhibits adequately low thermal conductivity of about 0.213 W/mK at a mean temperature of 200 degrees Celsius.
EXAMPLE 7
A wet mixture was prepared using the same materials as those in Example 5 comprising 15.0 per cent by weight of volatilised silica, 35.0 per cent by weight of expanded vermiculite, 30.0 per cent wet weight of potassium silicate solution binder, and 20.0 per cent by weight of rutile.
The mixture was compressed to a nominal density of 1000 kg/m3 and dried in accordance with the methods described in Example 1.
The resulting compressed and dried thermally insulating moulded body was nominally 18.6 per cent by dry weight of volatilised silica, 43.5 per cent by dry weight of expanded vermiculite, 24.8 per cent by dry weight of rutile and 13.1 per cent by dry weight of potassium silicate binder.
The thermally insulating moulded body, in ring form, tested as described in Example 1 required a maximum breaking force of about 32 N. It also exhibits adequately low thermal conductivity of about 0.217 W/mK at a mean temperature of 200 degrees Celsius.
EXAMPLE 8
A wet mixture was prepared using the same materials as those in Example 5 comprising 15.0 per cent by weight of volatilised silica, 50.0 per cent by weight of expanded vermiculite, 25.0 per cent wet weight of potassium silicate solution binder, and 10.0 per cent by weight of rutile.
The mixture was compressed to a nominal density of 1000 kg/m3 and dried in accordance with the methods described in Example 1.
The resulting compressed and dried thermally insulating moulded body was nominally 17.9 per cent by dry weight of volatilised silica, 59.7 per cent by dry weight of expanded vermiculite, 11.9 per cent by dry weight of rutile and 10.5 per cent by dry weight of potassium silicate binder.
The thermally insulating moulded body, in ring form, tested as described in Example 1 required a maximum breaking force of about 25 N. It also exhibits adequately low thermal conductivity of about 0.264 W/mK at a mean temperature of 200 degrees Celsius.
EXAMPLE 9
A wet mixture was prepared comprising 25.0 per cent by weight of volatilised silica available from RW Silicium GmbH under the name RW-Fuller Ql, 30.0 per cent by weight of Special grade expanded vermiculite available from Hoben International, 15.0 per cent by weight of infrared opacifier in the form of rutile (titanium oxide) , available from Eggerding Group, Amsterdam, and 30.0 per cent wet weight of aqueous potassium silicate solution binder available from Ineos Chemicals under the name K66.
The Ql volatilised silica has a nominal specific surface area of 20 m2/g. The mixture was compressed to a nominal density of 1000 kg/m3 and dried in accordance with the methods described in Example 1.
The resulting compressed and dried thermally insulating moulded body was nominally 31.1 per cent by dry weight of volatilised silica, 37.3 per cent by dry weight of expanded vermiculite, 18.6 per cent by dry weight of rutile and 13.0 per cent by dry weight of potassium silicate binder.
The thermally insulating moulded body, in ring form, tested as described in Example 1 required a maximum breaking force of about 78 N. It also exhibits adequately low thermal conductivity of about 0.253 W/mK at a mean temperature of 200 degrees Celsius.
EXAMPLE 10
A wet mixture was prepared comprising 22.0 per cent by weight of volatilised silica available from RW Silicium GmbH under the name RW-Fuller Ql, 35.0 per cent by weight of Special grade expanded vermiculite available from Hoben International, 17.0 per cent by weight of infrared opacifier in the form of zircon (zirconium silicate) , available from Eggerding Group, Amsterdam, and 26.0 per cent wet weight of aqueous potassium silicate solution binder available from Ineos Chemicals under the name K66.
The mixture was compressed to a nominal density of 1000 kkgg//mm33 aanndd ddrriied in accordance with the methods described in Example 1.
The resulting compressed and dried thermally insulating moulded body was nominally 26.5 per cent by dry weight of volatilised silica, 42.0 per cent by dry weight of expanded vermiculite, 20.5 per cent by dry weight of zircon and 11.0 per cent by dry weight of potassium silicate binder.
The thermally insulating moulded body, in ring form, tested as described in Example 1 required a maximum breaking force of about 40 N. It also exhibits adequately low thermal conductivity of about 0.236 W/mK at a mean temperature of 200 degrees Celsius.
EXAMPLE 11
A wet mixture was prepared using the same materials as those in Example 10 comprising 25.0 per cent by weight of volatilised silica available from RW Silicium GmbH under the name RW-Fuller Ql, 32.0 per cent by weight of Special grade expanded vermiculite available from Hoben International, 16.0 per cent by weight of infrared opacifier in the form of zircon, and 27.0 per cent wet weight of potassium silicate solution.
The mixture was compressed to a nominal density of 1000 kg/m3 and dried in accordance with the methods described in Example 1.
The resulting compressed and dried thermally insulating moulded body was nominally 30.3 per cent by dry weight of volatilised silica, 38.8 per cent by dry weight of expanded vermiculite, 19.4 per cent by dry weight of zircon and 11.5 per cent by dry weight of potassium silicate binder.
The thermally insulating moulded body, in ring form, tested as described in Example 1 required a maximum breaking force of about 50 N. It also exhibits adequately low thermal conductivity of about 0.246 W/mK at a mean temperature of 200 degrees Celsius.
EXAMPLE 12
A wet mixture was prepared comprising 45.0 per cent by weight of volatilised silica available from RW Silicium GmbH under the name RW-Fuller Ql, 25.0 per cent by weight of Micron grade expanded vermiculite available from Hoben International, and 30.0 per cent wet weight of aqueous potassium silicate solution binder available from Ineos Chemicals under the name K66.
The mixture was compressed to a nominal density of 1000 kg/m3 and dried in accordance with the methods described in Example 1.
The resulting compressed and dried thermally insulating moulded body was nominally 55.9 per cent by dry weight of volatilised silica, 31.1 per cent by dry weight of expanded vermiculite and 13.0 per cent by dry weight of potassium silicate binder.
The thermally insulating moulded body, in ring form, tested as described in Example 1 required a maximum breaking force of about 98 N. It also exhibits adequately low thermal conductivity of about 0.219 W/mK at a mean temperature of 200 degrees Celsius.
It should be understood that the thermally insulating moulded bodies described in Examples 1 to 12 can be used, for example as a wall member, in a radiant electric heater. The thermally insulating moulded body is of ring- shape as denoted by reference numeral 2 in Figure 1, and is arranged for insertion as a wall member in a radiant electric heater 4 , as shown in Figures 2 and 3. The radiant electric heater 4 is arranged for location in a cooking appliance underneath a cooking surface 6, such as of glass-ceramic, and comprises a metal dish-like support 8 in which an electric heating element 10 is supported on a base layer 12 of thermal insulation material, which may be well-known microporous insulation material. The ring- shaped thermally insulating moulded body 2 according to the present invention is located around the periphery of the heater 4, against the rim of the metal dish-like support 8 and contacts the underside of the cooking surface 6.
The electric heater 4 is also provided with a known form of temperature-responsive device 14 and also a terminal block 16 for connecting the heating element 10 to a power supply.
It should also be understood that the thermally insulating moulded bodies described in Examples 1 to 12 can be used, for example as a base, for an electric storage heater or other applications where a moulded thermally insulating body is required.
A drying temperature of 250 degrees Celsius is described in Examples 1 to 12 to form a thermally insulating moulded body. It should be understood that such drying can be effected at room temperature, or at an elevated temperature of up to about 300 degrees Celsius, and can be carried out before or after removing the moulded body from the moulding tool .
It should be appreciated that although the mixtures in Examples 1 to 12 are described as being compressed to about 1000 kilograms per cubic metre the mixtures may be compressed to a range of densities (when dry) , for example between 600 and 1300 kilograms per cubic metre.

Claims

1. A substantially fibre-free thermally insulating moulded body (2) characterised by comprising a mixture of volatilised silica, expanded vermiculite and an inorganic binder.
2. A moulded body as claimed in claim 1, characterised in that the inorganic binder is selected from an alkali metal silicate binder and aluminium orthophosphate .
3. A moulded body as claimed in claim 2, characterised in that the alkali metal silicate binder is sodium silicate.
4. A moulded body as claimed in claim 2, characterised in that the alkali metal silicate binder is potassium silicate.
5. A moulded body as claimed in any preceding claim, characterised in that the dry thermally insulating moulded body comprises :
a) 10 to 70 weight percent of volatilised silica; b) 10 to 70 weight percent of expanded vermiculite; and c) 3 to 20 weight percent of inorganic binder.
6. A moulded body as claimed in claim 5, characterised in that the dry thermally insulating moulded body comprises : a) 10 to 70 weight percent of volatilised silica; b) 20 to 70 weight percent of expanded vermiculite; and c) 5 to 14 weight percent of inorganic binder.
7. A moulded body as claimed in claim 6, characterised in that the dry thermally insulating moulded body comprises : a) 10 to 56 dry weight percent of volatilised silica; b) 30 to 70 dry weight percent of expanded vermiculite; and c) 10 to 14 dry weight percent of inorganic binder.
8. A moulded body as claimed in claim 7, characterised in that the dry thermally insulating moulded body comprises : a) 10 to 30 dry weight percent of volatilised silica; b) 40 to 70 dry weight percent of expanded vermiculite; and c) 10 to 14 dry weight percent of inorganic binder.
9. A moulded body as claimed in any preceding claim, characterised in that the thermally insulating body includes an infra-red opacifier material.
10. A moulded body as claimed in claim 9, characterised in that the infra-red opacifier material is selected from rutile, ilmenite, titanium oxide, iron oxide, mixtures of titanium oxide and iron oxide, zirconium oxide, zirconium silicate, chromium oxide, and silicon carbide.
11. A moulded body as claimed in claim 9 or 10, characterised in that the infra-red opacifier is provided in an amount of between 0 and 40 percent by weight.
12. A moulded body as claimed in any preceding claim, characterised in that the volatilised silica has a BET specific surface of less than 50 square metres per gram.
13. A moulded body as claimed in claim 12, characterised in that the volatilised silica has a BET specific surface of about 20 square metres per gram.
14. A moulded body as claimed in any preceding claim, characterised in that the mixture is dried at a temperature of from room temperature to 300 degrees Celsius.
15. A moulded body as claimed in any preceding claim, characterised in that the mixture is compressed to a dry density of between 600 and 1300 kilograms per cubic metre .
16. A radiant electric heater (4) characterised by being provided with a substantially fibre-free thermally insulating moulded body (2) as claimed in any preceding claim.
17. A method of manufacturing a substantially fibre-free thermally insulating moulded body (2) , characterised in that the method comprises forming a wet mixture comprising volatilised silica, expanded vermiculite and an aqueous solution of an inorganic binder, and compressing and drying the mixture to form a thermally insulating moulded body comprising a mixture of volatilised silica, expanded vermiculite and inorganic binder.
18. A method according to claim 17, characterised in that the inorganic binder is selected from an alkali metal silicate binder and aluminium orthophosphate .
19. A method according to claim 18, characterised in that the alkali metal silicate binder is sodium silicate.
20. A method according to claim 18, characterised in that the alkali metal silicate binder is potassium silicate.
21. A method according to any one of claims 17 to 20, characterised in that the dry thermally insulating moulded body comprises:
a) 10 to 70 weight percent of volatilised silica; b) 10 to 70 weight percent of expanded vermiculite; and c) 3 to 20 weight percent of inorganic binder.
22. A method according to claim 21, characterised in that the dry thermally insulating moulded body comprises a) 10 to 70 weight percent of volatilised silica; b) 20 to 70 weight percent of expanded vermiculite; and c) 5 to 14 weight percent of inorganic binder.
23. A method according to claim 22, characterised in that the dry thermally insulating moulded body comprises: a) 10 to 56 dry weight percent of volatilised silica; b) 30 to 70 dry weight percent of expanded vermiculite; and c) 10 to 14 dry weight percent of inorganic binder.
24. A method according to claim 23, characterised in that the dry thermally insulating moulded body comprises: a) 10 to 30 dry weight percent of volatilised silica; b) 40 to 70 dry weight percent of expanded vermiculite; and c) 10 to 14 dry weight percent of inorganic binder.
25. A method according to any one of claims 17 to 24, characterised in that the thermally insulating body includes an infra-red opacifier material.
26. A method according to claim 25, characterised in that the infra-red opacifier material is selected from rutile, ilmenite, titanium oxide, iron oxide, mixtures of titanium oxide and iron oxide, zirconium oxide, zirconium silicate, chromium oxide, silicon carbide and other materials of suitable refractive index and temperature stability.
27. A method according to claim 25 or 26, characterised in that the infra-red opacifier is provided in an amount of between 0 and 40 percent by weight.
28. A method according to any one of claims 17 to 27, characterised in that the volatilised silica has a BET specific surface of less than 50 square metres per gram.
29. A method according to claim 28, characterised in that the volatilised silica has a BET specific surface of about 20 square metres per gram.
30. A method according to any one of claims 17 to 29, characterised in that the mixture is dried at a temperature of from room temperature to 300 degrees Celsius.
31. A method according to any one of claims 17 to 30, characterised in that the mixture is compressed to a dry density of between 600 and 1300 kilograms per cubic metre.
32. A radiant electric heater (4) characterised by being provided with a substantially fibre-free thermally insulating moulded body (2) manufactured by a method according to any one of claims 17 to 31.
PCT/GB2003/003117 2002-07-17 2003-07-16 Thermally insulating moulded body and method of manufacture WO2004007394A1 (en)

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GBGB0216588.4A GB0216588D0 (en) 2002-07-17 2002-07-17 Thermally insulating moulded body and method of manufacture
GB0216588.4 2002-07-17
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GB0311623.3 2003-05-21

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108203289A (en) * 2016-12-16 2018-06-26 淄博悦卡电器科技有限公司 A kind of vermiculite and the compound heat-barrier material of nano-powder
US10450229B2 (en) * 2015-09-23 2019-10-22 Vermikorea Co., Ltd. Slim vermiculite board for construction finishing
WO2022265520A1 (en) * 2021-06-18 2022-12-22 Ophiolite As Heat refractive insulation material

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JPS5520275A (en) * 1978-08-02 1980-02-13 Towa Taika Kogyo Kk Nonhydrous* heat generating* self curing refractory lining material
WO1993021126A1 (en) * 1992-04-11 1993-10-28 Hüls Troisdorf Aktiengesellschaft Low-density inorganic moulding and process for producing it
DE19809590A1 (en) * 1998-03-06 1999-09-23 Viessmann Werke Kg Refractory moulding especially for insulation lining of low temperature boiler closures and combustion chamber floors
FR2814740A1 (en) * 2000-10-03 2002-04-05 2M2F INSULATING REACTIVE MINERAL LOAD
DE10065075A1 (en) * 2000-12-23 2002-06-27 Sepp Zeug Mixture used in the production of molded parts contains vermiculite, phosphate binder, water, highly dispersed metal oxide, clay, and a combination of inorganic silicates
EP1236704A1 (en) * 2001-02-19 2002-09-04 Microtherm International Limited Base for an electric heater and method of manufacture

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JPS5520275A (en) * 1978-08-02 1980-02-13 Towa Taika Kogyo Kk Nonhydrous* heat generating* self curing refractory lining material
WO1993021126A1 (en) * 1992-04-11 1993-10-28 Hüls Troisdorf Aktiengesellschaft Low-density inorganic moulding and process for producing it
DE19809590A1 (en) * 1998-03-06 1999-09-23 Viessmann Werke Kg Refractory moulding especially for insulation lining of low temperature boiler closures and combustion chamber floors
FR2814740A1 (en) * 2000-10-03 2002-04-05 2M2F INSULATING REACTIVE MINERAL LOAD
DE10065075A1 (en) * 2000-12-23 2002-06-27 Sepp Zeug Mixture used in the production of molded parts contains vermiculite, phosphate binder, water, highly dispersed metal oxide, clay, and a combination of inorganic silicates
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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10450229B2 (en) * 2015-09-23 2019-10-22 Vermikorea Co., Ltd. Slim vermiculite board for construction finishing
CN108203289A (en) * 2016-12-16 2018-06-26 淄博悦卡电器科技有限公司 A kind of vermiculite and the compound heat-barrier material of nano-powder
WO2022265520A1 (en) * 2021-06-18 2022-12-22 Ophiolite As Heat refractive insulation material

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