Compression molded inorganic fiber articles, and methods and compositions used in molding same
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B22C-001/18
B22C-001/16
출원번호
US-0034336
(2005-01-11)
등록번호
US-7470729
(2008-12-30)
발명자
/ 주소
Lyons,David Charles
Schroeder,Ted Victor
출원인 / 주소
HNI Technologies Inc.
대리인 / 주소
Faegre & Benson LLP
인용정보
피인용 횟수 :
1인용 특허 :
45
초록▼
A method of forming articles made of an inorganic fiber material using compression molding. In one respect, a method of forming an article, wherein the method includes providing a molding composition comprising inorganic fiber and an inorganic binder, and compression molding the molding composition
A method of forming articles made of an inorganic fiber material using compression molding. In one respect, a method of forming an article, wherein the method includes providing a molding composition comprising inorganic fiber and an inorganic binder, and compression molding the molding composition into the article. In another respect, the method including providing a molding composition comprising inorganic fibers and a binder, and compression molding the molding composition into the article, wherein at least 75% by weight of the molded article is inorganic material. In some embodiments the cured binder is capable of withstanding temperatures of at least 600�� F. without significant degradation or deterioration due to heat. Articles made by the use of such methods and a molding composition for use in compression molding an article are also included.
대표청구항▼
We claim: 1. A method of forming an article, the method comprising: providing a molding composition comprising inorganic fiber and a binder suspended in an aqueous solution, wherein the composition is in the range of about 15% to 45% by wt. water; and compression molding the molding composition int
We claim: 1. A method of forming an article, the method comprising: providing a molding composition comprising inorganic fiber and a binder suspended in an aqueous solution, wherein the composition is in the range of about 15% to 45% by wt. water; and compression molding the molding composition into the article with compression and heat sufficient to remove at least a portion of the aqueous solution, wherein the article is capable of withstanding temperatures of at least 600�� F. without significant degradation or deterioration due to heat. 2. The method of claim 1, wherein the article is capable of withstanding temperatures of at least 800�� F. without significant degradation or deterioration due to heat. 3. The method of claim 1, wherein the article is a combustion chamber for a fireplace, a fireplace box, a fireplace door, a fireplace surround, a fireplace log, a fireplace burner or a fireplace refractory member. 4. The method of claim 1, wherein the binder comprises an inorganic binder. 5. The method of claim 4, wherein the molding composition comprises the inorganic fiber, the inorganic binder, a carrier solvent comprising the aqueous solution, and additional additives, wherein at least a portion of the inorganic binder is suspended in at least a portion of the carrier solvent, wherein the composition is less than 25% by wt. inorganic fiber, wherein the composition is in the range of about 15 to 35% by wt. inorganic binder, wherein the composition is in the range of about 15 to 45% by wt. carrier solvent, and wherein the composition is in the range of about 0 to 70% by wt. additional solid additives. 6. A method of forming an article, the method comprising: providing a molding composition comprising an inorganic fiber, an inorganic binder, a carrier solvent, and additional additives, wherein at least a portion of the inorganic binder is suspended in at least a portion of the carrier solvent, wherein the composition is less than 25% by wt. inorganic fiber, wherein the composition is in the range of about 15 to 35% by wt. inorganic binder, wherein the composition is in the range of about 15 to 45% by wt. carrier solvent, and wherein the composition is in the range of about 0 to 70% by wt. additional solid additives; and compression molding the molding composition into the article. 7. The method of claim 6, wherein the inorganic fiber comprises glass fibers, ceramic fibers, refractory fibers, refractory ceramic fibers, mineral fibers, or mixtures thereof. 8. The method of claim 7, wherein the inorganic fiber comprises chopped fiber glass. 9. The method of claim 6, wherein the inorganic binder comprises a silica, based binder. 10. The method of claim 9, wherein the inorganic binder comprises colloidal silica. 11. The method of claim 6, wherein the carrier solvent comprises water. 12. The method of claim 6, wherein the molding composition has a moisture content in the range of 20 to 35% by weight of the total composition. 13. The method of claim 6, wherein the article is an article for use in a fireplace assembly, a grill assembly, a campfire assembly, or a burner assembly. 14. The method of claim 6, wherein the article is a combustion chamber for a fireplace, a fireplace box, a fireplace door, a fireplace surround, a fireplace log, a fireplace burner or a fireplace refractory member. 15. The method of claim 6, wherein the inorganic binder is capable of withstanding temperatures of at least 600�� F. without significant degradation or deterioration due to heat. 16. The method of claim 15, wherein the inorganic binder is capable of withstanding temperatures of at least 800�� F. without significant degradation or deterioration due to heat. 17. The method of claim 6, wherein the composition is less than 10% by wt. inorganic fiber. 18. The method of claim 17, wherein the composition is less than 5% by wt. inorganic fiber. 19. The method of claim 6, wherein the composition is in the range of about 20 to 30% by wt. inorganic binder. 20. The method of claim 6, wherein the composition is in the range of about 20 to 40% by wt. carrier solvent. 21. The method of claim 20, wherein the composition is in the range of about 25 to 35% by wt. carrier solvent. 22. A method of forming an article, the method comprising: providing a molding composition comprising an inorganic fiber, a binder, a carrier solvent, and additional additives, wherein the composition is less than 25% by wt. inorganic fiber, wherein the composition is in the range of about 15% to 45% by wt. carrier solvent, and wherein substantially all of the inorganic fiber comprises a fiber length of about 1/16 of an inch to 2 inches; and compression molding the molding composition into the article. 23. The method of claim 22, wherein the substantially all of the inorganic fiber comprises a diameter in a range of 1 micron to 30 microns.
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