Conditioned colloidal silica post impregnant to prevent binder migration in the production of insulation articles comprising randomly oriented refractory fibers

• US 4,332,852 A
• Filed: 12/03/1979
• Issued: 06/01/1982
• Est. Priority Date: 03/29/1978
• Status: Expired due to Term

• Current Assignee: Unifrax Corporation (ASP Unifrax Holdings, Inc.)
• Original Assignee: Kennecott Corporation (Alcan)
• Inventors: Korklan, Harris J., Greany, John K.
• Primary Examiner(s): Cannon, James C.
• Application Number:
  US06/099,374
• Time in Patent Office: 911 Days
• Field of Search: 162/135, 162/181 C, 264/86, 264/87, 264/128, 428/331, 428/340, 428/372, 428/378, 428/920, 428/921
• US Class Current: 428/331
• CPC Class Codes: C04B 28/24 containing alkyl, ammonium or metal silicates; containing silica sols reaction mixtures resulting in mineral polymers C04B28/006; polymeric reaction products of alkali metal silicates with isocyanates C08G18/3895
• CPC Class Codes: Y10S 428/92 Fire or heat protection feature
• CPC Class Codes: Y10S 428/921 Fire or flameproofing
• CPC Class Codes: Y10T 428/259 Silicic material
• CPC Class Codes: Y10T 428/27 Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.]
• CPC Class Codes: Y10T 428/2927 including structurally defined particulate matter
• CPC Class Codes: Y10T 428/2938 Coating on discrete and individual rods, strands or filaments

Abstract

An inorganic refractory insulation article comprising randomly oriented refractory fibers retained by dried colloidal silica uniformly distributed throughout the article and containing from about 0.001 to about 1.5 percent by weight of the article of aluminum chlorhydrate. The invention further comprises the process for making the article by forming a fiber mat from a fiber slurry, impregnating the mat with a conditioned colloidal silica composition comprising colloidal silica, acid, aluminum chlorhydrate and water and drying the mat to form the article.

Claims

1. An inorganic refractory insulation article comprising randomly oriented refractory fibers retained by dried colloidal silica uniformly distributed throughout the article and from about 0.001 to about 1.5 weight percent of aluminum chlorhydrate.

2. The article of claim 1 wherein said article is a board and wherein said board has a density of from about 0.4 to about 0.6 gms/cc, contains from about 30 to about 50 weight percent fiber, from about 10 to about 45 weight percent dried colloidal silica, from about 0.001 to about 1.5 weight aluminum chlorhydrate and the balance being a filler selected from the group consisting of colloidal clay, ground silica having an average particle size of smaller than about 200 mesh, and mixtures thereof.