US4440865A
Expired / Lapsed
US
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Refractory compositions and method
Assignee: Individual
•
Filing: 1983-08-31
•
Granted: 1984-04-03
•
Expires: 2003-08-31
Abstract
Abstract Refractory compositions based upon alumina or aluminum silicate chemically bound by aluminum phosphate have a shelf life of three months to more than one year where the composition includes both liquid aluminum phosphate and phosphoric acid to form a portion of the aluminum phosphate binder in situ. In accordance with another embodiment of the present invention, increased strength is achieved by including alumina, and an aluminum silicate bearing material, such as clay, in the refractory composition to form the in situ aluminum phosphate bond from the reaction of phosphoric acid and aluminum silicate. The aluminum phosphate should be provided in the composition in an amount of about 5% to about 70% by weight of the bone dry composition and the phosphoric acid should be included in an amount in the range of about 1% to about 10% based on the weight of the bone dry composition to provide the surprisingly new and unexpected shelf life to the refractory composition. The aluminum phosphate and phosphoric acid together are particularly useful in a refractory ramming mix composition containing a heat insulator such as perlite, vermiculite, diatomaceous earth, expanded clay, flourspar, or an additive which is intended to be burned out to leave a void space at the intended use of the refractory, such as wood, flour, sawdust and the like.
Inventors
- 👤 Paul V. Salazar
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 18:26
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/66; C04B12/00; C04B12/02; C04B12/022; C04B28/00; C04B28/34; C04B28/346
Claims Analysis
Total Claims: 23
Claim 1
Independent Claim
34 words
A refractory composition having an increased shelf life comprising: ______________________________________
Aluminum phosphate 5-70%;
A refractory material selected
2-94%; and
from the group consisting of
alumina, aluminum silicate,
and mixtures thereof
Phosphoric acid 1-10%.
______________________________________
Claim 2
Dependent Claim
34 words
A refractory composition having an increased shelf life comprising: ______________________________________
Aluminum phosphate 5-70%;
A refractory material selected
2-94%; and
from the group consisting of
alumina, aluminum silicate,
and mixtures thereof
Phosphoric acid 1-10%.
______________________________________
Claim 3
Dependent Claim
18 words
The refractory composition of claim 1 comprising: ______________________________________
Aluminum phosphate 20-60%;
Alumina 20-60%; and
Phosphoric Acid 2-10%.
______________________________________
Claim 4
Dependent Claim
27 words
The refractory material of claim 1 further including water in the amount of 1-20% based upon the total weight of aluminum phosphate, refractory material and phosphoric acid.
Claim 5
Dependent Claim
50 words
The refractory composition of claim 1 comprising: ______________________________________
Aluminum phosphate 5-70%;
Alumina, aluminum silicate or
2-89%;
mixtures thereof
Phosphoric acid 1-10%;
An insulating material selected
5-60%
from the group consisting of
perlite, vermiculite, diatomaceous
earth, flourspar, wood flour, wood
dust, clay, ceramic fibers,
light weight grog, and expanded
shell.
______________________________________
Claim 6
Dependent Claim
22 words
The refractory composition of claim 4 wherein said insulating material is selected from the group consisting of perlite, vermiculite and diatomceous earth.
Claim 7
Dependent Claim
21 words
The refractory material of claim 1 comprising: ______________________________________
Aluminum phosphate 20-70%;
Alumina 20-77%;
Aluminum silicate 1-30%; and
Phosphoric acid 2-8%.
______________________________________
Claim 8
Dependent Claim
28 words
The refractory material of claim 6 comprising: ______________________________________
Aluminum phosphate 20-70%;
Alumina 20-75%;
Clay 1-30%;
Phosphoric acid 2-8%; and
Fibers burnable at or below
1-15%.
2000° F.
______________________________________
Claim 9
Dependent Claim
36 words
The refractory material of claim 1 comprising: ______________________________________
Aluminum phosphate 20-70%;
Alumina 20-63%;
Aluminum silicate 1-30%;
Phosphoric acid 1-10%; and
An insulating material selected
5-60%.
from the group consisting of
perlite, vermiculite and
diatomaceous earth
______________________________________
Claim 10
Dependent Claim
27 words
The refractory composition of claim 4 comprising: ______________________________________
Liquid aluminum phosphate
20-70%;
Alumina, aluminum silicate or
2-69%;
mixtures thereof
Phosphoric acid 1-10%; and
Expanded clay 10-60%.
______________________________________
Claim 11
Dependent Claim
29 words
A refractory composition having an increased shelf life comprising: ______________________________________
Liquid aluminum phosphate
5-70%;
Alumina, aluminum silicate or
2-93%;
mixtures thereof
Phosphoric acid 1-10%; and
Expanded clay 1-30%.
______________________________________
Claim 12
Dependent Claim
29 words
A refractory composition having an increased shelf life comprising: ______________________________________
Liquid aluminum phosphate
5-70%;
Alumina, aluminum silicate or
2-93%;
mixtures thereof
Phosphoric acid 1-10%; and
Expanded clay 1-30%.
______________________________________
Claim 13
Dependent Claim
27 words
The refractory composition of claim 10 comprising: ______________________________________
Liquid aluminum phosphate
10-50%;
Alumina, aluminum silicate or
20-84%;
mixtures thereof
Phosphoric acid 1-10%; and
Expanded clay 5-20%.
______________________________________
Claim 14
Dependent Claim
43 words
The refractory composition of claim 11 comprising: ______________________________________
Liquid aluminum phosphate
10-30%;
Alumina 2-93%;
Phosphoric acid 1-10%; and
Expanded clay 5-20%,
______________________________________ wherein 20-60% by weight of said alumina is alumina ground to -325 mesh and 40-80% of said alumina is bubble alumina.
Claim 15
Dependent Claim
13 words
The refractory composition of claim 12 wherein said bubble alumina is calcined alumina.
Claim 16
Dependent Claim
13 words
The refractory composition of claim 12 wherein said clay is a montmorillonite clay.
Claim 17
Dependent Claim
11 words
The refractory composition of claim 11 wherein said clay is bentonite.
Claim 18
Dependent Claim
27 words
The refractory composition of claim 11 further including water in an amount of 1-20% based upon the total weight of aluminum phosphate, alumina, phosphoric acid and clay.
Claim 19
Dependent Claim
40 words
A refractory furnace lining disposed against an interior furnace wall or interior furnace conduit comprising: ______________________________________
Aluminum phosphate 3-70%
A refractory material selected
2-94%; and
from the group consisting of
alumina, aluminum silicate,
and mixtures thereof
Phosphoric acid 1-10%.
______________________________________
Claim 20
Dependent Claim
40 words
A refractory furnace lining disposed against an interior furnace wall or interior furnace conduit comprising: ______________________________________
Aluminum phosphate 3-70%
A refractory material selected
2-94%; and
from the group consisting of
alumina, aluminum silicate,
and mixtures thereof
Phosphoric acid 1-10%.
______________________________________
Claim 21
Dependent Claim
48 words
The refractory furnace lining disposed against an interior furnace wall or interior furnace conduit of claim 17 comprising: ______________________________________
Aluminum phosphate 20-70%;
Alumina, aluminum silicate or
2-64%;
mixtures thereof
Clay 5-60%; and
An insulating material selected
10-60%.
from the group consisting of
perlite, vermiculite, and
diatomaceous earth
______________________________________
Claim 22
Dependent Claim
17 words
The article of claim 17 comprising: ______________________________________
Aluminum phosphate 20-60%;
Alumina 20-60%; and
Phosphoric Acid 2-10%.
______________________________________
Claim 23
Dependent Claim
55 words
The article of claim 17 comprising: ______________________________________
Aluminum phosphate 5-70%;
Alumina, aluminum silicate or
2-89%;
mixtures thereof
Phosphoric acid 1-10%; and
An insulating material selected
5-60%.
from the group consisting of
perlite, vermiculite, diatomaceous
earth, flourspar, wood flour, wood
dust, clay, ceramic fibers, fibers
burnable below 3000° F., light
weight grog, and expanded shell
______________________________________
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1987-04-03 | 1987-10-03 | 1988-04-03 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-04-03 | 1991-10-03 | 1992-04-03 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-04-03 | 1995-10-03 | 1996-04-03 | $7700.00 | Window Closed / Lapsed |