초록 ▼

Provided is a lightweight, fibrous thermal insulation panel including high temperature resistant biosoluble inorganic fibers, expanded perlite, binder, and optionally conventional high temperature resistant inorganic fibers. Further provided is a method for preparing a lightweight, fibrous high temp

Provided is a lightweight, fibrous thermal insulation panel including high temperature resistant biosoluble inorganic fibers, expanded perlite, binder, and optionally conventional high temperature resistant inorganic fibers. Further provided is a method for preparing a lightweight, fibrous high temperature thermal insulation panel including: (a) providing an aqueous slurry comprising from about 15% to about 90% high temperature resistant biosoluble inorganic fibers, from about 10% to about 80% expanded perlite, at least one of from 0% to about 50% organic binder or from 0% to about 20% inorganic binder by weight, and optionally from 0% to about 70% conventional high temperature resistant fibers; (b) forming the lightweight, fibrous thermal insulation panel by depositing the said aqueous slurry onto a substrate; (c) partially dewatering the slurry on the substrate to form a fibrous layer; and (d) drying the fibrous layer to a moisture content of no greater than about 5% by weight.

대표청구항 ▼

1. A lightweight, fibrous high temperature thermal insulation panel comprising high temperature resistant biosoluble inorganic fibers, expanded perlite, binder, and optionally conventional high temperature resistant inorganic fibers; wherein the panel is rigid; the panel density is from about 60 kg/

1. A lightweight, fibrous high temperature thermal insulation panel comprising high temperature resistant biosoluble inorganic fibers, expanded perlite, binder, and optionally conventional high temperature resistant inorganic fibers; wherein the panel is rigid; the panel density is from about 60 kg/m3 to about 160 kg/m3; and the panel comprises from 0% to about 70% by weight mineral wool, from about 10% to about 80% by weight expanded perlite, from about 15% to about 90% by weight magnesium silicate fiber, and from greater than 0% to about 50% by weight acrylic latex binder by weight. 2. The lightweight, fibrous high temperature thermal insulation panel of claim 1, wherein the panel comprises from 0% to about 70% by weight mineral wool, from about 10% to about 80% by weight expanded perlite, from about 15% to about 90% by weight magnesium silicate fiber, and from greater than 0% to about 6% by weight acrylic latex binder by weight. 3. The lightweight, fibrous high temperature thermal insulation panel of claim 2, comprising, by weight: mineral wool in an amount of from 0% to about 40%;expanded perlite in an amount of from about 20% to about 60%;magnesium silicate fiber in an amount of from about 30% to about 70%;acrylic latex binder in an amount of from about 2% about 4%; andpolyvinyl alcohol in an amount of from 0% to about 1%. 4. The lightweight, fibrous high temperature thermal insulation panel of claim 1, wherein the conventional high temperature resistant inorganic fibers comprise at least one of refractory ceramic fibers, mineral wool fibers, leached glass silica fibers, fiberglass, glass fibers or mixtures thereof. 5. The lightweight, fibrous high temperature thermal insulation panel of claim 4, wherein the ceramic fibers comprise alumina-silica fibers. 6. The lightweight, fibrous high temperature thermal insulation panel of claim 5, wherein the alumina-silica fibers comprise the fiberization product of from about 45 to about 75 weight percent alumina and from about 25 to about 55 weight percent silica. 7. The lightweight, fibrous high temperature thermal insulation panel of claim 4, wherein the mineral wool fibers comprise at least one of rock wool fibers, slag wool fibers or glass wool fibers. 8. A lightweight, fibrous high temperature thermal insulation panel comprising high temperature resistant biosoluble inorganic fibers, expanded perlite, binder, and optionally conventional high temperature resistant inorganic fibers; wherein the panel is rigid; the panel density is from about 60 kg/m3 to about 160 kg/m3; and wherein the high temperature resistant biosoluble fibers comprise at least one of alkaline earth silicate fibers, calcia-aluminate fibers, potassia-calcia-aluminate fibers, potassia-alumina-silicate fibers, or sodia-alumina-silicate fibers. 9. The lightweight, fibrous high temperature thermal insulation panel of claim 8, wherein the alkaline earth silicate fibers comprise at least one of calcium-magnesia-silicate fibers or magnesium-silicate fibers. 10. The lightweight, fibrous high temperature thermal insulation panel of claim 8, wherein the binder comprises an organic binder comprising from about 1% to about 10% acrylic latex by weight. 11. The lightweight, fibrous high temperature thermal insulation panel of claim 10, wherein the organic binder comprises from about 1% to about 5% acrylic latex by weight. 12. The lightweight, fibrous high temperature thermal insulation panel of claim 8, wherein the binder comprises up to 5% organic binder fibers by weight. 13. The lightweight, fibrous high temperature thermal insulation panel of claim 1, wherein the expanded perlite has a density in the range of from about 30 kg/m3 to about 150 kg/m3. 14. The lightweight, fibrous high temperature thermal insulation panel of claim 1, wherein the expanded perlite has a density in the range of from about 55 kg/m3 to about 146 kg/m3. 15. The lightweight, fibrous high temperature thermal insulation panel of claim 1, produced by a wet forming process. 16. The lightweight, fibrous high temperature thermal insulation panel of claim 15, wherein the wet forming process is a paper-making process. 17. The lightweight, fibrous high temperature thermal insulation panel of claim 15, wherein the wet forming process is a vacuum forming process. 18. The lightweight, fibrous high temperature thermal insulation panel of claim 1 having a density of from about 72 kg/m3 to about 96 kg/m3. 19. The lightweight, fibrous high temperature thermal insulation panel of claim 1 having a basis weight of from about 500 gsm to about 6,000 gsm. 20. A method for preparing a lightweight, fibrous high temperature thermal insulation panel comprising: (a) providing an aqueous slurry comprising from about 15% to about 90% high temperature resistant biosoluble inorganic fibers, wherein the high temperature resistant biosoluble fibers comprise at least one of alkaline earth silicate fibers, calcia-aluminate fibers, potassia-calcia-aluminate fibers, potassia-alumina-silicate fibers, or sodia-alumina-silicate fibers,from about 10% to about 80% expanded perlite,binder comprising at least one of from 0% to about 50% organic binder or from 0% to about 20% inorganic binder by weight, and optionally from 0% to about 70% conventional high temperature resistant fibers;(b) forming the lightweight, fibrous thermal insulation panel by depositing the said aqueous slurry onto a substrate;(c) partially dewatering the slurry on the substrate to form a fibrous layer;(d) drying the fibrous layer to a moisture content of no greater than about 5% by weight; wherein the dried fibrous thermal insulation panel is rigid; and wherein the panel density is from about 60 kg/m3 to about 160 kg/m3. 21. The method of claim 20 wherein the binder is at least one of from greater than 0% to about 6% organic binder or from greater than 0% to about 20% inorganic binder by weight, wherein the insulation panel is non-combustible. 22. The method of claim 20 wherein the aqueous slurry further comprises at least one of dispersing agents, retention aids, flocculating agents, dyes, pigments, antioxidants, surfactants, water repellents, fillers or fire retardants. 23. The method of claim 20 further comprising applying a vacuum pressure differential to the slurry on the substrate to remove water from the slurry. 24. A method for preparing a lightweight, fibrous high temperature thermal insulation panel comprising providing an aqueous slurry comprising high temperature resistant biosoluble inorganic fibers, expanded perlite, organic and/or inorganic binder, and optionally conventional high temperature resistant inorganic fibers, and depositing the aqueous slurry onto a substrate, partially dewatering the slurry on the substrate to form a fibrous layer, and drying the fibrous layer to a moisture content of no greater than about 0.5% by weight, wherein the dried fibrous thermal insulation panel is rigid; wherein the panel density is from about 60 kg/m3 to about 160 kg/m3; and wherein the high temperature resistant biosoluble fibers comprise at least one of alkaline earth silicate fibers, calcia-aluminate fibers, notassia-calcia-aluminate fibers, potassia-alumina-silicate fibers, or sodia-alumina-silicate fibers. 25. The lightweight, fibrous high temperature thermal insulation panel of claim 8 wherein the panel comprises from about 15% to about 90% high temperature resistant biosoluble inorganic fibers, from about 10% to about 80% perlite, from greater than 0% to about 50% organic binder, and optionally from 0% to about 70% conventional high temperature resistant inorganic fibers by weight. 26. The lightweight, fibrous high temperature thermal insulation panel of claim 8 wherein the binder comprises from 0% to about 6% organic binder and/or from 0% to about 20% inorganic binder by weight, wherein the insulation panel is non-combustible. 27. The lightweight, fibrous high temperature thermal insulation panel of claim 8, wherein the conventional high temperature resistant inorganic fibers comprise at least one of refractory ceramic fibers, mineral wool fibers, leached glass silica fibers, fiberglass, glass fibers or mixtures thereof. 28. The lightweight, fibrous high temperature thermal insulation panel of claim 27, wherein the ceramic fibers comprise alumina-silica fibers. 29. The lightweight, fibrous high temperature thermal insulation panel of claim 28, wherein the alumina-silica fibers comprise the fiberization product of from about 45 to about 75 weight percent alumina and from about 25 to about 55 weight percent silica. 30. The lightweight, fibrous high temperature thermal insulation panel of claim 8, wherein the expanded perlite has a density in the range of from about 30 kg/m3 to about 150 kg/m3. 31. The lightweight, fibrous high temperature thermal insulation panel of claim 8, wherein the expanded perlite has a density in the range of from about 55 kg/m3 to about 146 kg/m3. 32. The lightweight, fibrous high temperature thermal insulation panel of claim 8, produced by a wet forming process. 33. The lightweight, fibrous high temperature thermal insulation panel of claim 32, wherein the wet forming process is a paper-making process. 34. The lightweight, fibrous high temperature thermal insulation panel of claim 32, wherein the wet forming process is a vacuum forming process. 35. The lightweight, fibrous high temperature thermal insulation panel of claim 8 having a density of from about 72 kg/m3 to about 96 kg/m3. 36. The lightweight, fibrous high temperature thermal insulation panel of claim 8 having a basis weight of from about 500 gsm to about 6,000 gsm.