Patent US4530722A successfully refreshed from Google Patents.
US4530722A
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Binder and refractory compositions and methods
Assignee: Harborchem Inc
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Filing: 1983-08-22
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Granted: 1985-07-23
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Expires: 2003-08-22
Abstract
Abstract Binder, filler, and refractory compositions and methods of using and making these compositions are disclosed. The binder composition comprises colloidal silica, a liquid material containing Si-OH groups, a solvent which is capable of solubilizing the liquid material and the colloidal silica, and at least one aprotic, non-ionic, non-metallic, organic compound which contains at least one element selected from P, S, B and N and which stabilizes the binder composition against self-gelling. The liquid material and the colloidal silica are present in a ratio by weight of from about 10:1 to about 1:10 respectively. The liquid material has at least about 20% by weight SiO 2 . The colloidal silica contains at least about 15% by weight SiO 2 . The solvent and the organic compound are present in amounts so as to solubilize the liquid material and the colloidal silica, to provide a binder composition which is stable against self-gellation, and to provide a binder composition which gels to a single phase.
Inventors
- 👤 John R. Moore
- 👤 Stephen Maybaum
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-06 15:49
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/622; C04B35/626; C04B35/63; C04B35/6303; C04B35/6316; B; B22; B22C; B22C1/00; B22C1/16; B22C1/18; B22C1/183
Claims Analysis
Total Claims: 41
Claim 1
Independent Claim
164 words
A binder composition which is the result of combined ingredients comprising colloidal silica, a liquid material containing Si-OH groups, a solvent which is capable of solubilizing the liquid material and the colloidal silica, and at least one aprotic, non-ionic, non-metallic organic compound which contains at least one element selected from the group consisting of phosphorus, sulfur, boron, nitrogen, and mixtures thereof and which stabilizes the binder composition against self-gelling, wherein said colloidal silica and said liquid material are present in a ratio by weight of from about 1:12 to about 75:1 respectively, said liquid material has at least 20% by weight SiO 2 , and said colloidal silica contains at least about 15% by weight of SiO 2 , and wherein said solvent and said organic compound are present in amounts so as to solubilize the liquid material and the colloidal silica, to provide a binder composition which is stable against self-gellation, and to provide a binder composition which gels to a single phase.
Claim 2
Dependent Claim
164 words
A binder composition which is the result of combined ingredients comprising colloidal silica, a liquid material containing Si-OH groups, a solvent which is capable of solubilizing the liquid material and the colloidal silica, and at least one aprotic, non-ionic, non-metallic organic compound which contains at least one element selected from the group consisting of phosphorus, sulfur, boron, nitrogen, and mixtures thereof and which stabilizes the binder composition against self-gelling, wherein said colloidal silica and said liquid material are present in a ratio by weight of from about 1:12 to about 75:1 respectively, said liquid material has at least 20% by weight SiO 2 , and said colloidal silica contains at least about 15% by weight of SiO 2 , and wherein said solvent and said organic compound are present in amounts so as to solubilize the liquid material and the colloidal silica, to provide a binder composition which is stable against self-gellation, and to provide a binder composition which gels to a single phase.
Claim 3
Dependent Claim
59 words
A binder composition according to claim 1, comprising from about 2 to about 60% by weight of said liquid material containing Si-OH groups, from about 5 to about 55% by weight of said colloidal silica, from about 20 to about 50% by weight of said solvent, and from about 0.5 to about 50% by weight of said organic compound.
Claim 4
Dependent Claim
16 words
A binder composition according to claim 1, wherein said at least one organic compound contains phosphorus.
Claim 5
Dependent Claim
89 words
A binder composition according to claim 1, wherein said at least one organic compound is selected from the group consisting of fully esterified alkyl or aryl phosphate esters, fully esterified alkyl or aryl pyrophosphate esters, fully esterified alkyl or aryl phosphonate esters, fully esterified alkyl or aryl borate esters, fully esterified alkyl or aryl pyroborate esters, dialkyl or diaryl sulfoxides, N,N-dialkyl or diaryl alkanamides, and mixtures thereof, wherein said alkyl groups contain from 1 to 6 carbon atoms and said aryl groups contain from 6 to 8 carbon atoms.
Claim 6
Dependent Claim
34 words
A binder composition according to claim 1, wherein at least one organic compound is selected from the group consisting of dimethyl methyl phosphonate, triethyl phosphate, tributyl borate, dimethyl sulfoxide, dimethyl formamide and mixtures thereof.
Claim 7
Dependent Claim
18 words
A binder composition according to claim 4, wherein said at least one organic compound comprises dimethyl methyl phosphonate.
Claim 8
Dependent Claim
18 words
A binder composition according to claim 1, wherein said liquid material containing Si-OH groups comprises hydrated alkyl silicate.
Claim 9
Dependent Claim
17 words
A binder composition according to claim 7, wherein said hydrated alkyl silicate is a hydrated ethyl silicate.
Claim 10
Dependent Claim
15 words
A binder composition according to claim 1, wherein said solvent is a water-miscible organic solvent.
Claim 11
Dependent Claim
102 words
A binder composition according to claim 1, comprising from about 5 to about 40% by weight of ethyl silicate that has been hydrated, said ethyl silicate containing from about 28% to about 60% by weight of SiO 2 ; from about 5 to about 40% by weight acidic colloidal silica containing from about 15 to about 60% by weight of SiO 2 ; from about 0.5 to about 12% by weight of dimethyl methyl phosphonate; and from about 20 to about 55% by weight of a solvent selected from diethylene glycol monoethyl ether, propylene glycol monomethyl ether, or propylene glycol monopropyl ether.
Claim 12
Dependent Claim
171 words
A refractory composition comprising refractory particles and a binder composition, wherein said binder composition is the result of combined ingredients comprising colloidal silica, a liquid material containing Si-OH groups, a solvent which is capable of solubilizing the liquid material and the colloidal silica, and at least one aprotic, non-ionic, non-metallic, organic compound which contains at least one element from the group consisting of phosphorus, sulfur, boron, nitrogen, and mixtures thereof and which stabilizes the binder composition against self-gelling, wherein said colloidal silica and said liquid material are present in a ratio by weight from about 1:12 to about 75:1 respectively, said liquid material contains at least about 20% by weight SiO 2 , and said colloidal silica contains at least 15% by weight of SiO 2 , and wherein said solvent and said organic compound are present in amount sufficient to solubilize the liquid material and the colloidal silica, to provide a binder composition which is stable against self-gellation, and to provide a binder composition which gels to a single phase.
Claim 13
Dependent Claim
171 words
A refractory composition comprising refractory particles and a binder composition, wherein said binder composition is the result of combined ingredients comprising colloidal silica, a liquid material containing Si-OH groups, a solvent which is capable of solubilizing the liquid material and the colloidal silica, and at least one aprotic, non-ionic, non-metallic, organic compound which contains at least one element from the group consisting of phosphorus, sulfur, boron, nitrogen, and mixtures thereof and which stabilizes the binder composition against self-gelling, wherein said colloidal silica and said liquid material are present in a ratio by weight from about 1:12 to about 75:1 respectively, said liquid material contains at least about 20% by weight SiO 2 , and said colloidal silica contains at least 15% by weight of SiO 2 , and wherein said solvent and said organic compound are present in amount sufficient to solubilize the liquid material and the colloidal silica, to provide a binder composition which is stable against self-gellation, and to provide a binder composition which gels to a single phase.
Claim 14
Dependent Claim
63 words
A refractory composition according to claim 11, wherein said binder composition comprises from about 2 to about 60% by weight of said liquid material containing Si-OH groups, from about 5 to about 55% by weight of said colloidal silica, from about 20 to about 50% by weight of said solvent, and from about 0.5 to about 50% by weight of said organic compound.
Claim 15
Dependent Claim
31 words
A refractory composition according to claim 11, wherein said refractory particles are selected from the group consisting of zircon, alumina, aluminosilicates, MgO, olivine, silica flour, fused quartz, graphite and mixtures thereof.
Claim 16
Dependent Claim
16 words
A refractory composition according to claim 11, wherein said at least one organic compound contains P.
Claim 17
Dependent Claim
89 words
A refractory composition according to claim 11, wherein said at least one organic compound is selected from the group consisting of fully esterified alkyl or aryl phosphate esters, fully esterified alkyl or aryl pyrophosphate esters, fully esterified alkyl or aryl phosphonate esters, fully esterified alkyl or aryl borate esters, fully esterified alkyl or aryl pyroborate esters, dialkyl or diaryl sulfoxides, N,N-dialkyl or diaryl alkanamides, and mixtures thereof, wherein said alkyl groups contain from 1 to 6 carbon atoms and said aryl groups contain from 6 to 8 carbon atoms.
Claim 18
Dependent Claim
35 words
A refractory composition according to claim 11, wherein said at least one organic compound is selected from the group consisting of dimethyl methyl phosphonate, triethyl phosphate, tributyl borate, dimethyl sulfoxide, dimethyl formamide and mixtures thereof.
Claim 19
Dependent Claim
18 words
A refractory composition according to claim 11, wherein said at least one organic compound comprises dimethyl methyl phosphonate.
Claim 20
Dependent Claim
19 words
A refractory composition according to claim 11, wherein said liquid material containing Si-OH groups is a hydrated ethyl silicate.
Claim 21
Dependent Claim
104 words
A refractory composition according to claim 11, wherein said binder composition comprises from about 5 to about 40% by weight of ethyl silicate that has been hydrated, said ethyl silicate containing from about 28% to about 60% by weight SiO 2 ; from about 5 to about 40% by weight acidic colloidal silica containing from about 15 to about 60% by weight SiO 2 ; from about 0.5 to about 12% by weight of dimethyl methyl phosphonate; and from about 20 to about 55% by weight of a solvent selected from diethylene glycol monoethyl ether, propylene glycol monomethyl ether, or propylene glycol monopropyl ether.
Claim 22
Dependent Claim
20 words
A refractory composition according to claim 11, which has been gelled in a predetermined shape to form a refractory shape.
Claim 23
Dependent Claim
24 words
A refractory composition according to claim 11, which has been applied to a porous material and then gelled to form a porous refractory foam.
Claim 24
Dependent Claim
170 words
A process for preparing a binder composition comprising the steps of providing a reaction mixture comprising acid, a silicate ester which is capable of being hydrolyzed to liquid materials containing Si-OH groups, and a solvent which solubilizes the silicate ester and which also will solubilize colloidal silica sol; and adding an aqueous based colloidal silica sol to the reaction mixture at a rate sufficient to hydrate the silicate ester without gelling the resulting binder composition, wherein the water present in the colloidal silica sol provides substantially all of the water to hydrate the silicate ester and wherein the acid is present in an amount sufficient to catalyze the hydration reaction and to provide a final pH of from about 1 to about 3 for the resulting binder composition; and adding to the reaction mixture at least one aprotic, non-ionic, non-metallic, organic compound which contains at least one element selected from the group consisting of phosphorus, sulfur, boron, nitrogen, and mixtures thereof and which stabilizes the resulting binder composition against self-gelling.
Claim 25
Dependent Claim
170 words
A process for preparing a binder composition comprising the steps of providing a reaction mixture comprising acid, a silicate ester which is capable of being hydrolyzed to liquid materials containing Si-OH groups, and a solvent which solubilizes the silicate ester and which also will solubilize colloidal silica sol; and adding an aqueous based colloidal silica sol to the reaction mixture at a rate sufficient to hydrate the silicate ester without gelling the resulting binder composition, wherein the water present in the colloidal silica sol provides substantially all of the water to hydrate the silicate ester and wherein the acid is present in an amount sufficient to catalyze the hydration reaction and to provide a final pH of from about 1 to about 3 for the resulting binder composition; and adding to the reaction mixture at least one aprotic, non-ionic, non-metallic, organic compound which contains at least one element selected from the group consisting of phosphorus, sulfur, boron, nitrogen, and mixtures thereof and which stabilizes the resulting binder composition against self-gelling.
Claim 26
Dependent Claim
24 words
A process according to claim 22, wherein the organic compound is added to the reaction mixture prior to addition of the colloidal silica sol.
Claim 27
Dependent Claim
26 words
A process according to claim 22, wherein in forming the reaction mixture the acid is added to a mixture comprising the silicate ester and the solvent.
Claim 28
Dependent Claim
111 words
A process according to claim 22, wherein said colloidal silica is added to the mixture in an amount to provide a ratio by weight of said colloidal silica to said liquid material of from about 1:12 to about 75:1, said liquid material has at least 20% by weight SiO 2 , and said colloidal silica contains at least about 15% by weight of SiO 2 , and wherein said solvent and said organic compound are present in amounts so as to solubilize the liquid material and the colloidal silica, to provide a binder composition which is stable against self-gellation, and to provide a binder composition which gels to a single phase.
Claim 29
Dependent Claim
62 words
A process according to claim 25, wherein the resulting composition comprises from about 2 to about 60% by weight of said liquid material containing Si-OH groups, from about 5 to about 55% by weight of said colloidal silica, from about 20 to about 50% by weight of said solvent, and from about 0.5 to about 50% by weight of said organic compound.
Claim 30
Dependent Claim
15 words
A process according to claim 25, wherein said at least one organic compound contains phosphorus.
Claim 31
Dependent Claim
85 words
A process according to claim 25, wherein said at least one organic compound is selected from the group consisting of fully esterified alkyl or aryl phosphate esters, fully esterified alkyl or aryl pyrophosphate esters, fully esterified alkyl or aryl phosphonate esters, fully esterified alkyl or aryl borate esters, fully esterified alkyl or aryl pyroborate esters, dialkyl or diaryl sulfoxides, N,N-dialkyl or diaryl alkanamide, wherein said alkyl groups contain from 1 to 6 carbon atoms and said aryl groups contain from 6 to 8 carbon atoms.
Claim 32
Dependent Claim
40 words
A process according to claim 25, wherein the silicate ester is an alkyl silicate, the solvent is selected from the group consisting of diethylene glycol monoethyl ether and propylene glycol monomethyl ether, and the organic compound is dimethyl methyl phosphonate.
Claim 33
Dependent Claim
26 words
A process according to claim 23, wherein the temperature during the addition of the colloidal silica sol is maintained from about 15° to about 31° C.
Claim 34
Dependent Claim
26 words
A binder composition according to claim 1, wherein the ratio of said colloidal silica and said liquid material is from about 1:10 to about 10:1, respectively.
Claim 35
Dependent Claim
59 words
A binder composition according to claim 1, comprising from about 1 to about 60% by weight of said liquid material containing Si-OH groups, from about 5 to about 75% by weight of said colloidal silica, from about 10 to about 93.5% by weight of said solvent, and from about 0.5 to about 50% by weight of said organic compound.
Claim 36
Dependent Claim
102 words
A binder composition according to claim 1, comprising from about 2 to about 40% by weight of ethyl silicate that has been hydrated, said ethyl silicate containing from about 28% to about 60% by weight of SiO 2 ; from about 5 to about 60% by weight acidic colloidal silica containing from about 15 to about 60% by weight of SiO 2 ; from about 1 to about 20% by weight of dimethyl methyl phosphonate; and from about 20 to about 60% by weight of a solvent selected from diethylene glycol monoethyl ether, propylene glycol monomethyl ether, or propylene glycol monopropyl ether.
Claim 37
Dependent Claim
26 words
A refractory composition according to claim 11, wherein the ratio of said colloidal silica and said liquid material is from about 1:10 to about 10:1, respectively.
Claim 38
Dependent Claim
59 words
A refractory composition according to claim 11, comprising from about 1 to about 60% by weight of said liquid material containing Si-OH groups, from about 5 to about 75% by weight of said colloidal silica, from about 10 to about 93.5% by weight of said solvent, and from about 0.5 to about 50% by weight of said organic compound.
Claim 39
Dependent Claim
102 words
A refractory composition according to claim 11, comprising from about 2 to about 40% by weight of ethyl silicate that has been hydrated, said ethyl silicate containing from about 28% to about 60% by weight of SiO 2 ; from about 5 to about 60% by weight acidic colloidal silica containing from about 15 to about 60% by weight of SiO 2 ; from about 5 to about 20% by weight of dimethyl methyl phosphonate; and from about 20 to about 60% by weight of a solvent selected from diethylene glycol monoethyl ether, propylene glycol monomethyl ether, or propylene glycol monopropyl ether.
Claim 40
Dependent Claim
25 words
A process according to claim 25, wherein the ratio of said colloidal silica and said liquid material is from about 1:10 to about 10:1, respectively.
Claim 41
Dependent Claim
62 words
A process according to claim 25, wherein the binder composition comprises from about 1 to about 60% by weight of said liquid material containing Si-OH groups, from about 5 to about 75% by weight of said colloidal silica, from about 10 to about 93.5% by weight of said solvent, and from about 0.5 to about 50% by weight of said organic compound.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1988-07-22 | 1989-01-21 | 1989-07-23 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1992-07-22 | 1993-01-21 | 1993-07-23 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1996-07-22 | 1997-01-21 | 1997-07-23 | $7700.00 | Window Closed / Lapsed |