Method of manufacturing a molten metal-resistant ceramic fiber composition
First Claim
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1. A method for producing a molten metal-resistant ceramic fiber composition, comprising the steps of:
- providing a frit of CaO, Al2 O3, and B2 O3 ;
providing a low temperature organic binder;
mixing the low temperature organic binder with the frit;
providing alumino-silicate ceramic fibers having an average mean diameter of about 1.2 microns;
mixing the binder-frit mixture with the fibers;
adding water to the binder-frit-fiber mixture;
forming the binder-frit-fiber mixture into a desired shape;
drying the binder-frit-fiber mixture; and
firing the binder-frit-fiber mixture to oxidize the binder and melt the frit.
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Abstract
A method of manufacturing a molten metal-resisting ceramic fiber composition includes mixing ceramic fibers, a frit, ceramic additives, a low temperature binder, and water. The mixture is formed into a desired shape, preferably by being extruded through a die. The shaped mixture is baked at low temperature, and then is fired at high temperature. During firing, the low temperature binder is oxidized and the frit is melted so as to substantially coat the fibers and fuse them into a porous matrix.
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Citations
32 Claims
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1. A method for producing a molten metal-resistant ceramic fiber composition, comprising the steps of:
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providing a frit of CaO, Al2 O3, and B2 O3 ; providing a low temperature organic binder; mixing the low temperature organic binder with the frit; providing alumino-silicate ceramic fibers having an average mean diameter of about 1.2 microns; mixing the binder-frit mixture with the fibers; adding water to the binder-frit-fiber mixture; forming the binder-frit-fiber mixture into a desired shape; drying the binder-frit-fiber mixture; and firing the binder-frit-fiber mixture to oxidize the binder and melt the frit. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 19)
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12. A method for producing a molten metal-resistant ceramic fiber composition, comprising the steps of:
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providing a frit of CaO, Al2 O3, and B2 O3 ; providing a low temperature organic binder selected from the group consisting of hydroxypropyl methylcellulose and methylcellulose ether; mixing the low temperature organic binder with the frit; providing alumino-silicate fibers having an average means diameter of about 1.2 microns; mixing the binder-frit mixture with the aluminosilicate fibers; adding water to the binder-frit-binder mixture; extruding the binder-frit-fiber mixture into a desired shape; drying the binder-frit-fiber mixture; and firing the binder-frit-fiber mixture to oxidize the binder and melt the frit. - View Dependent Claims (13, 14, 15, 16, 17, 18, 20)
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21. A method for producing a molten metal-resistant ceramic fiber composition, compromising the steps of:
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providing a frit of CaO, Al2 O3, and B2 O3 ; providing a low temperature organic binder; mixing the low temperature organic binder with the frit; providing alumino-silicate ceramic fibers; Adding water to the binder-frit-fiber mixture mixing the binder-frit-fiber mixture; forming the binder-frit-fiber mixture into a desired shape; drying the binder-frit-fiber mixture; firing the binder-frit-fiber mixture at about 1050°
C. for about 2 hours to oxidize the binder and melt the frit; andcooling the binder-frit-fiber mixture from about 1050°
C. to about 25°
C. over a period of about 6 hours. - View Dependent Claims (22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32)
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Specification