High temperature calcium silicate insulation

Patent metadata

Field	Value
Publication number	US-10494304-B2
Application number	US-201715602850-A
Country	US
Kind code	B2
Filing date	May 23, 2017
Priority date	Apr 16, 2015
Publication date	Dec 3, 2019
Grant date	Dec 3, 2019

Abstract

A calcium silicate insulation product includes a calcium silicate hydrate matrix that is predominantly but not substantially all xonotlite, for example 51-90 weight percent xonotlite and 10-49 weight percent tobermorite. The insulation product also contains wollastonite, and may include fines of lime and silica and reinforcing carbon fibers. A method of producing the insulation product includes providing the components of the insulation as dry solids, blending the dry solids with water to form a slurry, filter pressing the slurry to form a pressed shape, and curing the pressed shape under steam pressure only until the desired proportions of xonotlite and tobermorite are achieved in the calcium silicate hydrate matrix.

First claim

What is claimed is:

1. An insulating material, comprising:
a calcium silicate hydrate matrix having 51-90 weight percent xonotlite and 10-49 weight percent tobermorite; and
wollastonite;
wherein the weight of wollastonite in the insulating material is 25-200 percent of the combined weights of the xonotlite and tobermorite;
and wherein the insulating material is formed into a substantially uniform rigid body.

2. The insulating material of claim 1 , wherein the calcium silicate hydrate matrix has 62-81 weight percent xonotlite and 19-38 weight percent tobermorite.

3. The insulating material of claim 1 , wherein the calcium silicate hydrate matrix has 66-76 weight percent xonotlite and 24-34 weight percent tobermorite.

4. The insulating material of claim 1 , further comprising carbon reinforcing fibers, wherein the insulating material has a flexural strength of at least 1300 lb/in 2 .

5. The insulating material of claim 4 , wherein the insulating material has a flexural strength of at least 1400 lb/in 2 .

6. The insulating material of claim 4 , wherein the insulating material has a flexural strength of at least 1500 lb/in 2 .

7. The insulating material of claim 1 , wherein the insulating material has a compressive strength of at least 2600 lb/in 2 .

8. The insulating material of claim 1 , wherein the insulating material has a compressive strength of at least 3200 lb/in 2 .

9. The insulating material of claim 1 , wherein the density of the insulating material is less than 55 lb/ft 3 .

10. The insulating material of claim 1 , wherein the insulating material has a linear shrinkage in length of less than 0.5 percent at 1380° F.

11. The insulating material of claim 1 , wherein the insulating material has a linear shrinkage in length of less than 0.4 percent at 1380° F.

12. The insulating material of claim 11 , wherein the insulating material has a linear shrinkage in thickness of less than 0.90 percent at 1380° F.

13. The insulating material of claim 1 , further comprising carbon fibers and fines of lime and silica, wherein the insulating material has:
a flexural strength of at least 1300 lb/in 2 ;
a compressive strength of at least 2600 lb/in 2 ; and
a density of less than 55 lb/ft 3 .

14. The insulating material of claim 1 , further comprising carbon fibers and fines of lime and silica, wherein the insulating material has:
a flexural strength of at least 1500 lb/in 2 ;
a compressive strength of at least 3200 lb/in 2 ; and
a density of less than 55 lb/ft 3 .

15. The insulating material of claim 1 , wherein the weight of wollastonite in the insulating material is 50-175 percent of the combined weights of the xonotlite and tobermorite.

16. The insulating material of claim 1 , wherein the weight of wollastonite in the insulating material is 120-160 percent of the combined weights of the xonotlite and tobermorite.

17. A method of making an insulating material, the method comprising:
providing as dry solids
10-20 weight percent previously-prepared xonotlite,
15-25 weight percent lime,
15-25 weight percent silica, and
35-55 weight percent wollastonite;

blending the dry solids with water to form a slurry;
filter pressing the slurry to form a pressed shape; and
curing the resulting pressed shape under steam pressure only until the resulting composition includes, in addition to the wollastonite and any residual lime and silica, a calcium silicate hydrate matrix having 51-90 weight percent xonotlite and 10-49 weight percent tobermorite.

18. The method of claim 17 , comprising curing the resulting pressed shape under steam pressure only until the resulting composition includes, in addition to the wollastonite and any residual lime and silica, a calcium silicate hydrate matrix having 62-81 weight percent xonotlite and 19-38 weight percent tobermorite.

19. The method of claim 17 , comprising curing the resulting pressed shape under steam pressure only until the resulting composition includes, in addition to the wollastonite and any residual lime and silica, a calcium silicate hydrate matrix having 66-76 weight percent xonotlite and 24-34 weight percent tobermorite.

20. The method of claim 17 , wherein curing the resulting pressed shape under steam pressure comprises curing the resulting pressed shape under saturated steam at 12-18 bar for 5 to 8 hours.

Assignees

• Johns Manville

Inventors

• Kulprathipanja Ames
• Dolin Rick Lee
• Camp Noel

Classifications

• C04B28/188 Primary

  the Ca-silicates being present in the starting mixture · CPC title

• C04B2111/28

  Fire resistance, i.e. materials resistant to accidental fires or high temperatures · CPC title

• C04B14/386

  Carbon (carbon nanotubes C04B14/026) · CPC title

• C04B14/062

  Microsilica, e.g. colloïdal silica (preparing microsilica slurries or suspensions C04B18/148) · CPC title

• C04B40/024

  Steam hardening, e.g. in an autoclave · CPC title