Manufacturing method of ceramic body with excellent adiabatic capacity

• US 20070072761A1
• Filed: 06/17/2004
• Published: 03/29/2007
• Est. Priority Date: 10/07/2003
• Status: Abandoned Application

• Current Assignee: Kyung Dong Ceratech Co., Ltd.
• Original Assignee: Kyung Dong Ceratech Co., Ltd.
• Inventors: Lee, Hong-Jae, Yu, Gi-Hong
• Application Number:
  US10/574,718
• Publication Number:
  US 20070072761A1
• Time in Patent Office: Days
• US Class Current: 501/80
• CPC Class Codes: C04B 2111/28 Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• CPC Class Codes: C04B 35/00 Shaped ceramic products characterised by their composition porous ceramic products C04B38/00; ceramic articles characterised by particular shape, see the relevant classes, e.g. linings for casting ladles, tundishes, cups or the like B22D41/02; ceramic substrates for microelectronic semi-conductors H01L23/15; Ceramics compositions containing free metal bonded to carbides, diamond, oxides, borides, nitrides, silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides or sulfides other than as macroscopic reinforcing agents C22C; shaping of ceramics B28B; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products chemical preparation of powders of inorganic compounds C01; infiltration of sintered ceramic preforms with molten metal C04B41/51
• CPC Class Codes: C04B 38/0615 the burned-out substance being a monolitic element having approximately the same dimensions as the final article, e.g. a porous polyurethane sheet or a prepreg obtained by bonding together resin particles C04B38/0022 takes precedence

Abstract

The present invention relates to a porous ceramic body with excellent thermal insulation property. The inventive method comprises: an impregnation step in which a polymer sponge having a three-dimensional porous network structure with open cells is immersed in an inorganic adhesive, such that the polymer sponge is completely impregnated with the inorganic adhesive; a dewatering step in which the inorganic adhesive is partially removed from the polymer sponge impregnated with the inorganic adhesive, such that the polymer sponge contains the inorganic adhesive at a amount selected according to the desired density of the porous ceramic body; and a drying step in which the polymer sponge from which the inorganic adhesive had been partially removed in the dewatering step is dried so as to cure the inorganic adhesive.

Claims

1. A method for preparing a porous ceramic body with excellent thermal insulation property, the method comprising:

an impregnation step in which a polymer sponge having a three-dimensional porous network structure with open cells is immersed in an inorganic adhesive, such that the polymer sponge is completely impregnated with the inorganic adhesive;

a dewatering step in which the inorganic adhesive is partially removed from the polymer sponge impregnated with the inorganic adhesive, such that the polymer sponge contains the inorganic adhesive at an amount selected according to the desired density of the porous ceramic body; and

a drying step in which the polymer sponge from which the inorganic adhesive had been partially removed in the dewatering step is dried so as to cure the inorganic adhesive.

2. The method of claim 1, which additionally comprises the step of introducing a gaseous or solid curing agent into the pores of the polymer sponge, before the drying step but after the dewatering step.

3. The method of claim 1, wherein, at the impregnation step, the polymer sponge is immersed in the inorganic adhesive after mixing the inorganic adhesive with a solid or liquid curing agent.

4. The method of any one of claims 1 to 3, wherein the impregnating, dewatering and drying steps are performed repeatedly several times.

5. The method of any one of claims 1 to 3, wherein the inorganic adhesive is at least one selected from the group consisting of silicates and modified silicates, including sodium silicate, potassium silicate and lithium silicate, sol compounds, including silica sol and alumina sol, and phosphate adhesives, including aluminum phosphate and modified aluminum phosphate.

6. The method of any one of claims 1 to 3, wherein, at the impregnation step, the polymer sponge is immersed in the inorganic adhesive after mixing the inorganic adhesive with a surfactant.

7. The method of any one of claims 1 to 3, wherein, at the impregnation step, the polymer sponge is immersed in the inorganic adhesive after mixing the inorganic adhesive with at least one selected from silane coupling agents and organic adhesives.

8. The method of any one of claims 1 to 3, wherein, at the impregnation step, the polymer sponge is immersed in the inorganic adhesive after mixing the inorganic adhesive with at least one selected from sodium silicofluoride and magnesium sulfate.

9. The method of any one of claims 1 to 3, wherein, at the impregnation step, the polymer sponge is immersed in the inorganic adhesive after mixing the inorganic adhesive with a water repellant.

10. The method of any one of claims 1 to 3, wherein, at the impregnation step, the polymer sponge is immersed in the inorganic adhesive after mixing the inorganic adhesive with at least one selected from the group consisting of aluminum hydroxide, magnesium hydroxide, antimony compounds, boric acid, borax, phosphoric acid, phosphate, phosphorus-based and halogen-based flame retardants, and thermosetting resins.

11. The method of claim 2 or 3, wherein the impregnation and curing step are performed repeatedly several times such that the inorganic adhesive is impregnated again into the polymer sponge.

12. A porous ceramic body with excellent thermal insulation property, which is prepared by the method of any one of claims 1 to 3.