Calcium silicate insulating material containing alumina silica microspheres

Abstract

An asbestos free, calcium silicate insulating material suitable for use in the casting of molten non-ferrous metals, and suitable for use in applications where a fire resistant, heat insulating, electrical insulating, and corrosion resistant material is desirable. The calcium silicate insulating material is produced by combining lime, a siliceous component, alumina silica microspheres, wollastonite and organic fibrous material in the presence of water to form a slurry. The slurry is then placed under steam pressure, to react the lime, siliceous component and water, dried, and heat treated if necessary.

What is claimed is:  
     
         1 . A calcium silicate insulating material formed from a mixture, in the presence of water, comprising: 12 to 40 weight percent lime, 12 to 40 weight percent of siliceous component and up to 70 weight percent alumina silica microspheres.  
     
     
         2 . A calcium silicate insulation material as in  claim 1 , wherein said mixture further comprises up to 10 weight percent organic fiber.  
     
     
         3 . A calcium silicate insulation material as in  claim 1 , wherein said mixture further comprises up to 70 weight percent wollastonite.  
     
     
         4 . A calcium silicate insulation material as in  claim 2 , wherein said mixture further comprises up to 70 weight percent wollastonite.  
     
     
         5 . A calcium silicate insulating material as in  claim 2 , wherein the amount of said lime of said mixture is 14 to 20 weight percent, the amount of said siliceous component of said mixture is 14 to 20 weight percent, the amount of said alumina silica microspheres of said mixture is 52 to 68 weight percent, and the amount of said organic fiber is 4 to 8 weight percent .  
     
     
         6 . A calcium silicate insulating material as in  claim 4 , wherein the amount of said lime of said mixture is 14 to 20 weight percent, the amount of said siliceous component of said mixture is 14 to 20 weight percent, the amount of said alumina silica microspheres of said mixture is 10 to 30 weight percent, the amount of said wollastonite is 30 to 50 weight percent and the amount of said organic fiber is 4 to 8 weight percent.  
     
     
         7 . An insulating material as in claims  1  through  6 , wherein said lime and said siliceous component have reacted to form a predominantly tobermorite phase calcium silicate hydrate matrix.  
     
     
         8 . An insulating material as in claims  1  through  6 , wherein said lime and said siliceous component have reacted to form a predominantly xonotlite phase calcium silicate hydrate matrix.  
     
     
         9 . A method for producing a calcium silicate type insulating material, including the steps of: 
 a. molding a shape from an aqueous slurry of a mixture comprising: 12 to 40 weight percent lime, 12 to 40 weight percent siliceous component, up to 70 weight percent alumina silica microspheres, 0 to 70 weight percent wollastonite, and 0 to 10 weight percent organic fiber;    b. curing said shape in an atmosphere of steam at sufficiently elevated pressure for sufficient time to cause the lime, siliceous component, and water to form a calcium silicate hydrate matrix.    c. drying said shape to remove excess water.    
     
     
         10 . A method for producing a calcium silicate type insulating material as in  claim 9 , wherein the amount of said lime of said mixture is 14 to 20 weight percent, the amount of said siliceous component of said mixture is 14 to 20 weight percent, the amount of said alumina silica microspheres of said mixture is 10 to 30 weight percent, the amount of said wollastonite of said mixture is 30 to 50 weight percent, and the amount of said organic fiber of said mixture is 4 to 8 weight percent.  
     
     
         11 . A method for producing a calcium silicate type insulating material as in  claim 10 , further comprising the step of heat treating said shape to above 500 degrees Fahrenheit.  
     
     
         12 . A method for producing a calcium silicate type insulating material as in  claim 10 , wherein the amount of said pressure utilized and the duration of said time employed in the curing step (b) result in a predominantly tobermorite phase of said calcium silicate hydrate matrix.  
     
     
         13 . A method for producing a calcium silicate type insulating material as in  claim 10 , wherein the amount of said pressure utilized and the duration of said time employed in the curing step (b) result in a predominantly xonotlite phase of said calcium silicate hydrate matrix.  
     
     
         14 . A method for producing a calcium silicate type insulating material as in  claim 12 , further comprising the step of heat treating said shape to above 500 degrees Fahrenheit.  
     
     
         15 . A method for producing a calcium silicate type insulating material, including the steps of: 
 a. combining an aqueous slurry from a mixture comprising: 12 to 40 weight percent lime, 12 to 40 weight percent siliceous component, up to 70 weight percent alumina silica microspheres, 0 to 70 weight percent wollastonite, and 0 to 10 weight percent organic fiber;    b. reacting said aqueous slurry in an atmosphere of steam at sufficiently elevated pressure for sufficient time to cause the lime, siliceous component, and water to form a calcium silicate hydrate matrix;    c. molding said slurry into a shape;    d. drying said shape to remove excess water.    
     
     
         16 . A method for producing a calcium silicate type insulating material as in  claim 15 , wherein the amount of said pressure utilized and the duration of said time employed in the reacting step (b) result in a predominantly xonotlite phase of said calcium silicate hydrate matrix.  
     
     
         17 . A method for producing a calcium silicate type insulating material as in  claim 15 , wherein the amount of said lime of said mixture is 14 to 20 weight percent, the amount of said siliceous component of said mixture is 14 to 20 weight percent, the amount of said alumina silica microspheres of said mixture is 10 to 30 weight percent, the amount of said wollastonite of said mixture is 30 to 50 weight percent, and the amount of said organic fiber of said mixture is 4 to 8 weight percent.  
     
     
         18 . A method for producing a calcium silicate type insulating material as in  claim 17 , wherein the amount of said pressure utilized and the duration of said time employed in the reacting step (b) result in a predominantly xonotlite phase of said calcium silicate hydrate matrix.