US4735756A
Expired / Lapsed
US
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Method for producing light-weight molded articles containing ceramic fibers
Assignee: Didier Werke AG
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Filing: 1985-09-19
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Granted: 1988-04-05
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Expires: 2005-09-19
Abstract
Abstract Method for the production of light-weight molded articles wherein, in a first embodiment, a dispersion of ceramic fibers is flocculated with a cationic flocculating agent, a dispersion of finely divided refractory material and inorganic bonding agent is flocculated with an anionic flocculating agent, the flocculated dispersions are mixed together, and following settling of the mixture and optional removal of excess liquid, the mixture is filled into molds, converted by dewatering into molded articles, and dried. According to a second embodiment, a dispersion of ceramic fibers is flocculated with a cationic flocculating agent, finely divided refractory material and inorganic bonding agent which may be stirred in with water are added to this flocculated dispersion, an aqueous solution of an anionic flocculating agent is mixed into this mixture, and following settling of the mixture and optional removal of excess liquid, the mixture is filled into molds, converted by dewatering into molded articles, and dried.
Inventors
- 👤 Miroslav Rausch
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 18:54
CPC Classifications
C; C04; C04B; C04B30/00; C04B30/02; C04B28/00; C04B28/34; C04B33/00; C04B33/02; C04B33/13; C04B33/132; C04B33/138; C04B33/30; C04B33/36; C04B35/00; C04B35/01; C04B35/10; C04B35/111; C04B35/117; C04B35/622; C04B35/626; C04B35/62605; C04B35/62625; C04B35/6263; C04B35/63; C04B35/632; C04B35/71; C04B35/78; C04B35/80; C04B2103/00; C04B2103/0068; C04B2103/008; C04B2111/00; C04B2111/00474; C04B2111/0087; C04B2235/00; C04B2235/02; C04B2235/50; C04B2235/52; C04B2235/5208; C04B2235/5212; C04B2235/5216; C04B2235/522; C04B2235/5228; C04B2235/60; C04B2235/606; C04B2235/608; Y; Y02; Y02P; Y02P40/00; Y02P40/60
Claims Analysis
Total Claims: 22
Claim 1
Independent Claim
114 words
A method for producing a light-weight molded article, which comprises: flocculating a first aqueous dispersion containing ceramic fibers with a cationic flocculating agent to produce a first flocculated dispersion, flocculating a second aqueous dispersion containing refractory material having a particle size of not more than 0.09 mm and an inorganic bonding agent with an anionic flocculating agent to produce a second flocculated dispersion, mixing said first and second flocculated dispersions with each other to produce a mixture of said dispersions, allowing said mixture to settle, introducing the settled mixture into a screen mold, removing excess water from the mixture in said screen mold to form a molded article, and further drying said molded article.
Claim 2
Independent Claim
114 words
A method for producing a light-weight molded article, which comprises: flocculating a first aqueous dispersion containing ceramic fibers with a cationic flocculating agent to produce a first flocculated dispersion, flocculating a second aqueous dispersion containing refractory material having a particle size of not more than 0.09 mm and an inorganic bonding agent with an anionic flocculating agent to produce a second flocculated dispersion, mixing said first and second flocculated dispersions with each other to produce a mixture of said dispersions, allowing said mixture to settle, introducing the settled mixture into a screen mold, removing excess water from the mixture in said screen mold to form a molded article, and further drying said molded article.
Claim 3
Dependent Claim
13 words
The method according to claim 1, wherein said refractory material is a dross.
Claim 4
Dependent Claim
27 words
The method according to claim 1, which further comprises removing some of the excess liquid from said settled mixture before introducing said mixture into said screen mold.
Claim 5
Dependent Claim
14 words
The method according to claim 1, which further comprises calcining said dried molded article.
Claim 6
Dependent Claim
39 words
The method according to claim 1, wherein said light-weight molded article contains 2-25% by weight of said ceramic fibers and 75-98% by weight of said refractory material based on the combined weight of said ceramic fibers and refractory material.
Claim 7
Dependent Claim
28 words
The method according to claim 5, wherein the amount of said ceramic fibers is 5-17% by weight and the amount of said refractory material is 83-95% by weight.
Claim 8
Dependent Claim
39 words
The method according the claim 1, which further comprises introducing an aqueous solution of said anionic flocculating agent into said screeen mold to the extent of 1 - 10 cm deep before introducing said mixture into said screen mold,
Claim 9
Dependent Claim
30 words
The method according to claim 1, wherein said first aqueous dispersion contains less than 0.3% by weight of said ceramic fibers based on the weight of said first aqueous dispersion.
Claim 10
Dependent Claim
17 words
The method according to claim 8, wherein the amount of said ceramic fibers is 0.08-0.2% by weight.
Claim 11
Dependent Claim
29 words
The method according to claim 1, wherein said second aqueous dispersion further contains 0.5-3.5% by weight of ceramic or organic fibers based on the weight of said refractory material.
Claim 12
Independent Claim
103 words
A method for producing a light-weight molded article, which comprises: flocculating an aqueous dispersion containing ceramic fibers with a cationic flocculating agent to produce a flocculated dispersion, adding refractory material having a particle size of not more than 0.09 mm and an inorganic bonding agent to said flocculated dispersion to produce a first mixture, adding an anionic flocculating agent to said first mixture to produce a second mixture, allowing said second mixture to settle, introducing the settled mixture into a screen mold, removing excess water from the mixture in said screen mold to form a molded article, and further drying said molded article.
Claim 13
Independent Claim
103 words
A method for producing a light-weight molded article, which comprises: flocculating an aqueous dispersion containing ceramic fibers with a cationic flocculating agent to produce a flocculated dispersion, adding refractory material having a particle size of not more than 0.09 mm and an inorganic bonding agent to said flocculated dispersion to produce a first mixture, adding an anionic flocculating agent to said first mixture to produce a second mixture, allowing said second mixture to settle, introducing the settled mixture into a screen mold, removing excess water from the mixture in said screen mold to form a molded article, and further drying said molded article.
Claim 14
Dependent Claim
13 words
The method according to claim 11, wherein said refractory material is a dross.
Claim 15
Dependent Claim
27 words
The method according to claim 11, which further comprises removing some of the excess liquid from said settled mixture before introducing said mixture into said screen mold.
Claim 16
Dependent Claim
14 words
The method according to claim 11, which further comprises calcining said dried molded article.
Claim 17
Dependent Claim
39 words
The method according to claim 11, wherein said light-weight molded article contains 2-25% by weight of said ceramic fibers and 75-98% by weight of said refractory material based on the combined weight of said ceramic fibers and refractory material.
Claim 18
Dependent Claim
28 words
The method according to claim 15, wherein the amount of said ceramic fibers is 5-17% by weight and the amount of said refractory material is 83-95% by weight.
Claim 19
Dependent Claim
37 words
The method according to claim 11, which further comprises introducing an aqueous solution of said anionic flocculating agent into said screen mold to the extent of 1-10 cm deep before introducing said mixture into said screen mold.
Claim 20
Dependent Claim
28 words
The method according to claim 11, wherein said aqueous dispersion contains less than 0.3% by weight of said ceramic fibers based on the weight of said aqueous dispersion.
Claim 21
Dependent Claim
17 words
The method according to claim 18, wherein the amount of said ceramic fibers is 0.08-0.2% by weight.
Claim 22
Dependent Claim
31 words
The method according to claim 11, which further comprises mixing said refractory material and inorganic bonding agent with water before adding said refractory material and bonding agent to said flocculated dispersion.
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