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US4559244A
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US
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Composite refractory foams
Assignee: Stemcor Corp
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Filing: 1984-11-19
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Granted: 1985-12-17
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Expires: 2004-11-19
Abstract
Abstract Non-oxide refractory foams, possessing controlled permeability and uniformity, are prepared by impregnating an organic polymer foam material with a fluid, particulate slurry of a first refractory material, drying, applying to the dried, impregnated material a second refractory material which has a lower melting point than the first refractory material and thereafter heating, at a temperature sufficient to cause melt infiltration of the second refractory material into the impregnated material, thus producing inert and dimensionally stable composite refractory foams having broad utility as particulate filters or carriers.
Inventors
- 👤 Martin R. Kasprzyk
- 👤 Monika O. TenEyck
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-24 11:57
CPC Classifications
B; B22; B22F; B22F3/00; B22F3/10; B22F3/11; B22F3/1121; B22F3/1137; C; C04; C04B; C04B32/00; C04B32/005; C04B38/00; C04B38/06; C04B38/0615; C30; C30B; C30B31/00; C30B31/06; C30B31/16; C30B31/165; B22F2998/00; B22F2998/10
Claims Analysis
Total Claims: 34
Claim 1
Independent Claim
49 words
A composite refractory foam devoid of organic polymeric material, comprising a first particulated refractory material, open cellularly and interconnectingly arranged, having a second refractory material having a lower melting temperature than the first refractory material, melt infiltrated between at least a portion of the particles of first particulated material.
Claim 2
Dependent Claim
49 words
A composite refractory foam devoid of organic polymeric material, comprising a first particulated refractory material, open cellularly and interconnectingly arranged, having a second refractory material having a lower melting temperature than the first refractory material, melt infiltrated between at least a portion of the particles of first particulated material.
Claim 3
Dependent Claim
18 words
The composite foam of claim 1 wherein the first and the second refractory materials are non-oxide refractory materials.
Claim 4
Dependent Claim
22 words
The composite foam of claim 1 wherein the second refractory material has a melting temperature between 1200° C. and about 2300° C.
Claim 5
Dependent Claim
44 words
The composite foam of claim 1 wherein at a temperature where the second refractory material is a liquid and the first refractory material is a solid, the liquid refractory material wets the solid refractory material to a contact angle of less than 45 degrees.
Claim 6
Dependent Claim
18 words
Ihe composite foam of claim 1 having a cell size from about 2500 microns to about 50 microns.
Claim 7
Dependent Claim
31 words
The composite foam of claim 1 wherein the first particulated refractory is selected from the group consisting of SiC, molybdenum, carbon, boron, TiB 2 , MoSi 2 and B 4 C.
Claim 8
Dependent Claim
25 words
The composite foam of claim 1 wherein the second infiltrating refractory is selected from the group consisting of silicon, boron, titanium and MoSi 2 .
Claim 9
Dependent Claim
21 words
The composite foam of claim 1 wherein said first particulated material is silicon carbide and said second refractory material is silicon.
Claim 10
Dependent Claim
23 words
The composite foam of claim 1 wherein said first particulated material is silicon carbide and said second refractory material is MoSi 2 .
Claim 11
Dependent Claim
27 words
The composite foam of claim 1 wherein said first particulate material is selected from particulate graphite or B 4 C and said second refractory material is silicon.
Claim 12
Dependent Claim
30 words
The composite foam of claim 1 wherein the first particulated refractory material is selected from particulate SiC or B 4 C in a matrix of Silicon or MoSi 2 .
Claim 13
Dependent Claim
95 words
A process for the preparation of a composite refractory foam comprising impregnating an organic foam material with a fluid slurry of a first refractory material, drying, applying thereto a second refractory material having a lower melting point than the first refractory material, heating the thus treated foam material for a time and to a temperature sufficient to decompose the organic foam which heating is to at least the melting point of the second refractory material but less than that of the first refractory material and infiltrating said first refractory material with said second refractory material.
Claim 14
Dependent Claim
95 words
A process for the preparation of a composite refractory foam comprising impregnating an organic foam material with a fluid slurry of a first refractory material, drying, applying thereto a second refractory material having a lower melting point than the first refractory material, heating the thus treated foam material for a time and to a temperature sufficient to decompose the organic foam which heating is to at least the melting point of the second refractory material but less than that of the first refractory material and infiltrating said first refractory material with said second refractory material.
Claim 15
Dependent Claim
26 words
The process of claim 12, wherein the organic foam is heat compression set to a predetermined thickness prior to impregnation with a slurry of refractory material.
Claim 16
Dependent Claim
44 words
The process of claim 12 wherein at a temperature where the second refractory material is a liquid and the first refractory material is a solid, the liquid refractory material wets the solid refractory material to a contact angle of less than about 45 degrees.
Claim 17
Dependent Claim
19 words
The process of claim 12 wherein the impregnated organic foam material is treated to expel fluids prior to drying.
Claim 18
Dependent Claim
17 words
The process of claim 15 wherein said material is treated to expel fluids by squeezing or rolling.
Claim 19
Dependent Claim
20 words
The process of claim 12 wherein said heating is to a tempcrature from about 1200° C. to about 2300° C.
Claim 20
Dependent Claim
14 words
The process of claim 12 wherein the organic foam is compressed prior to impregnation.
Claim 21
Dependent Claim
22 words
The process of claim 12 wherein the cell size of the organic foam is from about 2500 microns to about 50 microns.
Claim 22
Dependent Claim
20 words
The process of claim 12 wherein the organic foam has from about 10 to about 500 pores per linear inch.
Claim 23
Dependent Claim
13 words
The process of claim 12 wherein the fluid slurry is an aqueous slurry.
Claim 24
Dependent Claim
21 words
The process of claim 12 wherein said fluid slurry contains from about 10 to about 80 parts by weight refractory material.
Claim 25
Dependent Claim
26 words
The process of claim 12 wherein said infiltrating refractory is applied by coating the surface of the dried impregnated foam with a dry particulate refractory material.
Claim 26
Dependent Claim
21 words
The process of claim 23 wherein said infiltrating particulate material has an average particle size of about 20 microns or more.
Claim 27
Dependent Claim
17 words
The process of claim 12, wherein the impregnating and the infiltrating refractory materials are non-oxide refractory materials.
Claim 28
Dependent Claim
29 words
The process of claim 12 wherein the impregnating refractory material is at least one of SiC, B 4 C, boron, MoSi 2 , molybdenum, carbon and TiB 2 .
Claim 29
Dependent Claim
22 words
The process of claim 12 wherein the infiltrating refractory material is at least one of silicon, boron, titanium and MoSi 2 .
Claim 30
Dependent Claim
29 words
The process of claim 12 wherein the organic foam is at least one selected from the group consisting of cellulosics, polystyrenes, polyethylenes, polypropylenes, polyvinyl chlorides, latexes, acrylics and polyurethanes.
Claim 31
Dependent Claim
11 words
The process of claim 12 wherein the organic foam is polyurethane.
Claim 32
Dependent Claim
47 words
The process of claim 12 wherein the organic foam material is a polyurethane foam having a cell size of from about 2500 microns to about 50 microns, the fluid slurry is an aqueous slurry, and the impregnated organic material is treated to expel fluids prior to drying.
Claim 33
Dependent Claim
9 words
The product found by the process of claim 12.
Claim 34
Dependent Claim
9 words
The product found by the process of claim 30.
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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) | 1988-12-16 | 1989-06-17 | 1989-12-17 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1992-12-16 | 1993-06-17 | 1993-12-17 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1996-12-16 | 1997-06-17 | 1997-12-17 | $7700.00 | Window Closed / Lapsed |