REFRACTORY COATING MATERIAL CONTAINING LOW BIOPERSISTENT FIBERS AND METHOD FOR MAKING THE SAME

• US 20170349769A1
• Filed: 05/23/2017
• Published: 12/07/2017
• Est. Priority Date: 06/06/2016
• Status: Active Grant

• Current Assignee: Unifrax I LLC (ASP Unifrax Holdings, Inc.)
• Original Assignee: Unifrax I LLC (ASP Unifrax Holdings, Inc.)
• Inventors: GEISE, Matthew R., DE SOUZA, Mauricio Munhoz
• Granted Patent: US 10,487,224 B2
• Time in Patent Office: Days
• CPC Class Codes: C08K 7/02 Fibres or whiskers
• CPC Class Codes: C09D 133/26 Homopolymers or copolymers of acrylamide or methacrylamide
• CPC Class Codes: C09D 5/00 Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced electrically insulating plastics, resins or waxes H01B3/30; Filling pastes
• CPC Class Codes: C09D 7/00 Features of coating compositions, not provided for in group C09D5/00 driers C09F9/00; Processes for incorporating ingredients in coating compositions
• CPC Class Codes: C09D 7/43 Thickening agents
• CPC Class Codes: C09D 7/61 inorganic
• CPC Class Codes: C09D 7/70 characterised by shape, e.g. fibres, flakes or microspheres
• CPC Class Codes: C23C 14/12 Organic material

Abstract

A refractory coating material that can be used to coat a wide variety of surfaces or substrates to provide thermal and mechanical protection. The refractory coating material can withstand exposure to use temperatures of about 1500° C. and greater, yet the fibers contained therein exhibit low biopersistence in physiological fluids such as simulated lung fluid. Also disclosed are methods for making and utilizing the refractory coating material.

Claims

1. A refractory coating material comprising low biopersistent inorganic fibers, at least one organic binder, at least one inorganic binder, at least one silica-containing compound, optionally a gelling agent, and further optionally a thickening agent, wherein the at least one inorganic binder comprises colloidal inorganic oxide.

2. The refractory coating material of claim 1, wherein the coating material is substantially free of alumina.

3. The refractory coating material of claim 1, comprising about 5 to about 70 weight percent low biopersistent fibers, about 0.1 to about 7.5 weight percent organic binder, an inorganic binder comprising about 2 to about 50 weight percent colloidal inorganic oxide, about 30 to about 85 weight percent silica-containing compound other than colloidal silica, and optionally about 0.1 to about 3.0 weight percent thickening agent.

4. The refractory coating material of claim 3, comprising about 27 to about 42 weight percent low biopersistent fibers, about 1.0 to about 3.5 weight percent organic binder, an inorganic binder comprising about 7 to about 25 weight percent colloidal inorganic oxide, about 40 to about 55 weight percent silica-containing compound other than colloidal silica and optionally about 0.1 to about 0.5 weight percent thickening agent.

5. The refractory coating material of claim 1, wherein the low biopersistent inorganic fibers comprise magnesia-silicate fibers comprising the fiberization product of at least from about 60 to about 90 weight percent silica, and from greater than 0 to about 35 weight percent magnesia.

6. The refractory coating material of claim 1, wherein the low biopersistent fibers comprise calcia-magnesia-silicate fibers comprising the fiberization product of at least from about 45 to about 90 weight percent silica, from greater than 0 to about 45 weight percent calcia, and from greater than 0 to about 35 weight percent magnesia.

7. The refractory coating material of claim 1, wherein the colloidal inorganic oxide comprises colloidal silica, colloidal zirconia, colloidal titania, colloidal ceria, colloidal yttria and/or combinations thereof.

8. The refractory coating material of claim 1, wherein the colloidal inorganic oxide comprises colloidal silica.

9. The refractory coating material of claim 1, wherein the gelling agent comprises ammonium acetate, calcium chloride, magnesium chloride, magnesium oxide or combinations thereof.

10. The refractory coating material of claim 1, wherein the at least one silica-containing compound comprises at least one of amorphous or crystalline silicon dioxide powder.

11. The refractory coating material of claim 10, wherein the at least one silica-containing compound comprises amorphous silica.

12. The refractory coating material of claim 10, wherein the amorphous silica is biogenic.

13. The refractory coating material of claim 12, wherein the amorphous silica comprises rice hull ash, oat bran ash, wheat chaff ash and/or combinations thereof.

14. The refractory coating material of claim 10, wherein the at least one silica-containing compound comprises quartz.

15. The refractory coating material of claim 1, wherein the thickening agent comprises bentonite clay, magnesium aluminum silicate and/or combinations thereof.

16. The refractory coating material of claim 1, wherein the organic binder comprises natural resins, synthetic resins, starch and/or combinations thereof.

17. The refractory coating material of claim 16, wherein the organic binder comprises a polyacrylamide-containing polymer.

18. The refractory coating material of claim 1, wherein the refractory coating material is formed from an aqueous slurry comprising by weight about 3 to about 60% low biopersistent fibers, about 0.1 to about 6.5% organic binder, about 5 to about 50% colloidal silica, about 5 to about 65% silica-containing compound other than colloidal silica, about 0.1 to about 3% thickening agent, and about 5 to about 65% water.

19. The refractory coating material of claim 1, wherein the refractory coating material is formed from an aqueous slurry comprising by weight about 12 to about 25% low biopersistent fibers, about 0.3 to about 2.5% organic binder, about 10 to about 25% colloidal silica, about 15 to about 30% silica-containing compound other than colloidal silica, about 0.1 to about 0.5% thickening agent, and about 27 to about 35% water.

20. A process for producing the refractory coating material of claim 1, comprising preparing an aqueous slurry comprising the low biopersistent inorganic fibers with the at least one organic binder, the at least one colloidal inorganic oxide, the at least one silica-containing compound, optionally the gelling agent, and further optionally the thickening agent.

21. A method of utilizing the refractory coating material of claim 1, comprising coating a surface or substrate with a material comprising the low biopersistent inorganic fibers, the at least one organic binder, the at least one colloidal inorganic oxide, the at least one silica-containing compound, optionally the gelling agent, and further optionally the thickening agent.