COPPER VERMICULITE THERMAL COATING

• US 20060105656A1
• Filed: 11/01/2005
• Published: 05/18/2006
• Est. Priority Date: 11/01/2004
• Status: Abandoned Application

• Current Assignee: The Thermo-Tec High Performance Automotive Incorporated
• Original Assignee: The Thermo-Tec High Performance Automotive Incorporated
• Inventors: White, James E.
• Application Number:
  US11/163,823
• Publication Number:
  US 20060105656A1
• Time in Patent Office: Days
• US Class Current: 442/131
• CPC Class Codes: F01N 13/14 having thermal insulation exhaust manifolds F01N13/102
• CPC Class Codes: F01N 13/16 Selection of particular materials
• CPC Class Codes: F01N 2310/14 Wire mesh fabric, woven glass cloth or the like
• CPC Class Codes: Y10T 442/259 Coating or impregnation provides protection from radiation [e.g., U.V., visible light, I.R., micscheme-change-itemave, high energy particle, etc.] or heat retention thru radiation absorption
• CPC Class Codes: Y10T 442/2926 Coated or impregnated inorganic fiber fabric
• CPC Class Codes: Y10T 442/2992 Coated or impregnated glass fiber fabric

Abstract

An improved insulating material and method is provided by a vermiculite and copper coating. The coating may be used in a variety of applications including on a thermal fabric such as a porous fiberglass fabric made of texturized yarn. The coating fuses with the fiberglass fabric at elevated temperatures. The coating allows improved dispersion of heat over that of prior art vermiculite coated fiberglass fabric.

Claims

1. A refractory coating comprising vermiculite and copper.

2. The coating of claim 1 wherein the refractory coating is generally about 9 parts vermiculite and 1 part copper.

3. The coating of claim 1, wherein the copper is provided as particles generally in a size range of 28-35 microns.

4. An insulating material comprising:

a base fabric; and

a refractory coating comprising vermiculite and at least one material having a thermal conductivity coefficient of at least 50 (W/m K) at about 1000 K, the refractory coating formed on the surface and interstices of the fabric, the refractory coating being capable of fusing with the base fabric at elevated temperatures above 750 degrees F.

5. The material of claim 4 wherein the at least one material having a thermal conductivity coefficient of at least 50 (W/m K) at about 1000 K is copper.

6. The material of claim 4 wherein the base fabric is a porous fiberglass fabric made from a texturized fiberglass yarn.

7. The material of claim 5 wherein the refractory coating is generally about 9 parts vermiculite and 1 part copper.

8. The material of claim 5 wherein the refractory coating is provided as a dispersion.

9. The material of claim 5, wherein the copper of the refractory coating is provided as particles generally in a size range of 28-35 microns.

10. The material of claim 5, wherein the refractory coating comprising at least 10% copper particles generally in a size range of 28-35 microns.

17. The method of claim 10 wherein the step of providing a fabric comprises the step of providing a porous fiberglass fabric made from a texturized fiberglass yarn.

18. The method of claim 10 wherein the step of:

providing a vermiculite and copper dispersion utilizes copper particles generally in a size range of 28-35 microns.

19. The method of claim 10 further comprising the step of:

wrapping the coated fabric around a pipe.

20. The method of claim 18 further comprising the step of:

subjecting the pipe and the coated fabric to elevated temperatures above 750 degrees F. wherein the vermiculite and copper coating fuses with the fabric.

11. A method of manufacturing an insulating material comprising the steps of:

providing a fabric;

providing a vermiculite and copper dispersion;

immersing the fabric in the vermiculite and copper dispersion; and

drying the coated fabric.

12. The method of claim 11 further comprising the step of:

subjecting the coated fabric to elevated temperatures above 750 degrees F. wherein the vermiculite and copper coating fuses with the fabric.

13. The method of claim 11 wherein the step of providing a vermiculite and copper dispersion comprises the step of:

forming a dispersion generally comprising 9 parts vermiculite to every 1 part copper.

14. The method of claim 11 further comprising the step of:

controlling the fabric to coating ratio during the impregnation of the vermiculite and copper coating using metering rolls or high-pressure roll pads to ensure proper impregnation and add-on of the coating.

15. The method of claim 11 further comprising the step of:

applying an overspray in the form of a specially formulated binder to the fabric prior to the step of immersing the fabric in the vermiculite and copper dispersion, the overspray providing retention of the bulk property of the fabric.

16. The method of claim 11 wherein the step of drying the coated fabric is accomplished by subjecting the fabric to a source of infrared heat or forced dry air at about 250 degrees F.