Insulation material

Abstract

The method is for use with a substrate having a plurality of parallel channels extending therethrough. In the method, the steps comprise: filling a selected plurality of the channels with a granular material; and consolidating the granular material through heat. The selected plurality of channels is selected to produce a wall that separates the substrate into: a first portion having a first plurality of the parallel channels extending therethrough; and a second portion having a second plurality of the parallel channels extending therethrough.

1 . (canceled) 
     
     
         2 . (canceled) 
     
     
         3 . (canceled) 
     
     
         4 . (canceled) 
     
     
         5 . The insulating material of  claim 6  wherein said heat sensitive binder is selected from boric acid and anhydrous boron. 
     
     
         6 . A free flowing insulating material having a thermal conductivity of between about 0.8 and 1.8 BTU in/ft 2 ·hr ° F., wherein said material comprises: a) from about 65 to 85% by weight of fly-ash, b) from about 2 to 15% by weight of a heat sensitive binder; c) from 0 to 7% by weight of a non-wetting agent selected from the group consisting of calcium fluoride, magnesium fluoride and barium sulphate; d) from 0 to 10% by weight of a heat expandable material selected from the group consisting of vermiculite and graphite; and e) from 0 to 1% by weight of a dust suppressant, said insulating material having a flexural strength (CMOR) of at least about 200 psi. 
     
     
         7 . The insulating material of  claim 6  having a compressive strength (CCS) from about 200 to about 550 psi. 
     
     
         8 . The insulating material of  claim 6  having a thermal conductivity of less than about 1.0 BTU in/ft 2 ·hr·° F. and a CMOR of at least about 400 psi. 
     
     
         9 . The insulating material of  claim 6  having a moisture weight gain at 25° C. and relative humidity of 75% after 72 hours of less than 1.0%. 
     
     
         10 . The insulating material of  claim 9  having a moisture weight gain of less than 0.1%. 
     
     
         11 . (canceled) 
     
     
         12 . (canceled) 
     
     
         13 . The insulating material according to  claim 6 , wherein the granular material consists essentially of:
 from 65 to 85% by weight of fly-ash comprising cenospheres, and   from 15 to 35% by weight of a heat sensitive binder selected from the group consisting of boric acid and anhydrous boron oxide.   
     
     
         14 . The insulating material according to  claim 6 , wherein the material consists essentially of:
 about 80% by weight of said fly ash; and   about 20% by weight of said heat sensitive binder.   
     
     
         15 . The insulating material according to  claim 6 , wherein the heat sensitive binder is boric acid. 
     
     
         16 . The insulating material according to  claim 6 , wherein the granular material has a density of from 25 to 30 lb/ft 3 . 
     
     
         17 . The insulating material according to  claim 6 , wherein the granular material has a median particle size of approximately 50 microns and a particle size ranging from 10 to 160 microns. 
     
     
         18 . (canceled) 
     
     
         19 . A catalytic converter including the insulation material of  claim 6 . 
     
     
         20 . A molten metal processing apparatus comprised of the material of  claim 6 .