Bonding of thermal tile insulation
First Claim
1. A method for coupling a first porous insulation member to a second porous insulation member, each of the first and second porous insulation members being formed of a fibrous, low-density silica-based material, the method comprising the steps of:
- providing a ceramic/organic thermal setting binder having a thermal set organic binder and a ceramic binder selected from a group of binders consisting of glass and ceramic;
applying the ceramic/organic thermal setting binder between a pair of mating surfaces formed into the first and second porous insulation members;
heating the first and second porous insulation members to a first predetermined temperature to cause the thermal set ceramic/organic binder to distribute the binder through a joint formed by the mating surfaces of the first and second porous insulation members and thereafter cure the organic binder to form a bonded joint;
heating the bonded first and second porous insulation members to a second predetermined temperature to burn out the thermal set organic binder; and
firing the bonded first and second porous insulation members at a third predetermined temperature to cause the ceramic binder to fixedly couple the mating surfaces of the first and second porous insulation members to one another.
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Accused Products
Abstract
An insulative body having first and second porous insulation members and a ceramic binder. Each of the first and second porous insulation members is formed of a fibrous, low-density silica-based material and cooperatively defines a joint. The ceramic binder is disposed between a pair of mating surfaces that form the joint. The ceramic binder couples the first and second porous insulation members together. A method for bonding insulative bodies to one another through the use of an ceramic/organic thermal setting binder is also provided.
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Citations
16 Claims
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1. A method for coupling a first porous insulation member to a second porous insulation member, each of the first and second porous insulation members being formed of a fibrous, low-density silica-based material, the method comprising the steps of:
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providing a ceramic/organic thermal setting binder having a thermal set organic binder and a ceramic binder selected from a group of binders consisting of glass and ceramic;
applying the ceramic/organic thermal setting binder between a pair of mating surfaces formed into the first and second porous insulation members;
heating the first and second porous insulation members to a first predetermined temperature to cause the thermal set ceramic/organic binder to distribute the binder through a joint formed by the mating surfaces of the first and second porous insulation members and thereafter cure the organic binder to form a bonded joint;
heating the bonded first and second porous insulation members to a second predetermined temperature to burn out the thermal set organic binder; and
firing the bonded first and second porous insulation members at a third predetermined temperature to cause the ceramic binder to fixedly couple the mating surfaces of the first and second porous insulation members to one another. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
providing a surface hardening agent in a liquid carrier;
applying the surface hardening agent to at least one of the pair of mating surfaces; and
curing the surface hardening agent that has been applied to the at least one of the mating surfaces.
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3. The method of claim 2, wherein the surface hardening agent is selected from a group of surface hardening agents consisting of silica sol and alumina sol.
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4. The method of claim 3, wherein before the step of applying the surface hardening agent, the method further comprises the steps of:
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providing a pore-obstructing material;
applying the pore-obstructing material to the at least one of the mating surfaces to thereby limit a depth with which the surface hardening agent is permitted to penetrate.
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5. The method of claim 4, wherein the pore-obstructing material is selected from a group of pore-obstructing materials consisting of cordierite and mullite.
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6. The method of claim 1, wherein before the step of applying the ceramic/organic thermal setting binder, the method includes the steps of:
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providing a solvent; and
employing the solvent to, adjust a viscosity of the ceramic/organic thermal setting binder.
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7. The method of claim 1, wherein the first predetermined temperature is about 180°
- F. to about 400°
F.
- F. to about 400°
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8. The method of claim 1, wherein the second predetermined temperature is about 800°
- F. to about 1000°
F.
- F. to about 1000°
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9. The method of claim 1, wherein the third predetermined temperature is about 1200°
- F. to about 2400°
F.
- F. to about 2400°
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10. The method of claim 1, wherein before the step of providing the ceramic/organic thermal setting binder, the method includes the step of mitering an end portion of each of the first and second porous insulation members.
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11. The method of claim 10, wherein the ceramic binder includes aluminum oxide and silica.
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12. The method of claim 1, wherein the ceramic binder includes about 0 percent by weight to about 90 percent by weight of aluminum oxide and about 100 percent by weight to about 10 percent by weight of silica.
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13. The method of claim 12, wherein the ceramic binder includes about 83 percent by weight of aluminum oxide and about 16 percent by weight of silica.
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14. The method of claim 12, wherein the ceramic/organic thermal setting binder includes about 90 percent by weight of the ceramic binder and about 10 percent by weight of an epoxy.
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15. The method of claim 1, wherein the ceramic/organic thermal setting binder includes about 90 percent by weight of glass and about 10 percent by weight of acrylic.
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16. The method of claim 1, wherein the ceramic/organic thermal setting binder includes about 95 percent by weight of glass and about 5 percent by weight of ethocellulose.
Specification