High temperature lightweight thermal insulating cement and silica based materials
First Claim
Patent Images
1. An insulating material formed from a mixture comprising:
- a silica sand in an amount of 25 to 90% of weight wet;
water in an amount of 10 to 70% of weight wet;
a rheology-modifying agent in an amount of about 0.1 to 5.0% of a weight of the silica sand;
a pH increasing material in an amount of about 0.5 to 10% by weight of the water;
a foaming agent comprising an aluminum powder in an amount of 0.5% to 3.0% by weight of the silica sand or a surfactant in an amount of 0.05 to 2.0% by weight of the water; and
the insulating material having a maximum use temperature in a range of about 600 to 1000 degrees Celsius.
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Abstract
A high temperature lightweight thermal insulating material is formed from a mixture that includes cement or silica sand, water and a foaming agent. The foaming agent can be an aluminum powder or a surfactant. The insulating material has a maximum use temperature greater than about 600 degrees Celsius.
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Citations
22 Claims
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1. An insulating material formed from a mixture comprising:
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a silica sand in an amount of 25 to 90% of weight wet; water in an amount of 10 to 70% of weight wet; a rheology-modifying agent in an amount of about 0.1 to 5.0% of a weight of the silica sand; a pH increasing material in an amount of about 0.5 to 10% by weight of the water; a foaming agent comprising an aluminum powder in an amount of 0.5% to 3.0% by weight of the silica sand or a surfactant in an amount of 0.05 to 2.0% by weight of the water; and the insulating material having a maximum use temperature in a range of about 600 to 1000 degrees Celsius. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A method for manufacturing an insulating material comprising the steps of:
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mixing a silica sand in an amount of about 25 to 90% of weight wet with water in an amount of about 10 to 70% of weight wet; mixing a pH increasing material in an amount of about 0.5 to 10% by weight of the water with the sand-water mixture; foaming the sand-water mixture using a foaming agent comprising an aluminum powder in an amount of about 0.5 to 3.0% by weight of the silica sand, or a surfactant in an amount of about 0.05 to 2.0% by weight of the water; pouring the foamed sand-water mixture into a mold and allowing the foamed sand-water mixture to rise to form the insulating material; removing the insulating material from the mold; heat treating the insulating material; and the insulating material having a maximum use temperature of about 600 to 1000 degrees Celsius. - View Dependent Claims (9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21)
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22. A method for manufacturing an insulating material comprising the steps of:
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mixing a silica sand in an amount of about 25 to 90% of weight wet with water in an amount of about 10 to 70% of weight wet for about 1 to 5 minutes; mixing a pH increasing material in an amount of about 0.5 to 10% by weight of the water with the sand-water mixture for about 1 to 5 minutes; foaming the sand-water mixture using a foaming agent comprising an aluminum powder in an amount of about 0.5 to 3.0% by weight of the sand for about 5 seconds to a minute, or a surfactant in an amount of about 0.05 to 2.0% by weight of the water for about 1 to 10 minutes; pouring the foamed sand-water mixture into a mold and allowing the foamed sand-water mixture to rise to form the insulating material; removing the insulating material from the mold; heat treating the insulating material; and the insulating material having a maximum use temperature of about 600 to 1000 degrees Celsius, a density in the range of about 0.1 to 1.0 g/cm3, a thermal conductivity in the range of about 0.05 to 0.30 W/(m·
K), and a compressive strength in the range of about 30 to 3000 PSI (2.068 to 206.8 Bar).
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Specification