Insulating material containing pitch based graphite fiber

Claim 2

An insulating material comprising about: a. 15 to 40 weight percent lime; b. 15 to 40 weight percent siliceous component; c. 15 to 50 weight percent wollastonite; d. 0 to 15 weight percent inorganic fiber to provide green strength; and e. 0.5 to 15 weight percent organic fiber wherein 1.5 to 5 weight percent is pitch base graphitic fiber.

Claim 3

An insulating material comprising about: a. 20 to 35 weight percent lime; b. 20 to 35 weight percent siliceous component; c. 20 to 45 weight percent wollastonite; d. 0 to 12 weight percent inorganic fiber to provide green strength; and e. 0.5 to 12 weight percent organic fiber wherein 0.5 to 4 weight percent is pitch base graphitic fiber.

Claim 4

An insulating material comprising about: a. 20 to 35 weight percent lime; b. 20 to 35 weight percent siliceous component; c. 20 to 45 weight percent wollastonite; d. 0 to 12 weight percent inorganic fiber to provide green strength; and e. 0.5 to 12 weight percent organic fiber wherein 0.5 to 4 weight percent is pitch base graphitic fiber.

Claim 5

An insulating material suitable for use in continuous molten metal casting comprising about: a. 28 to 32 weight percent lime; b. 23 to 32 weight percent siliceous component; c. 35 to 40 weight percent wollastonite; d. 1 to 7 weight percent inorganic fiber to provide green strength; and e. 0.5 to 8 weight percent organic fiber wherein 0.5 to 3 weight percent is pitch base graphitic fiber.

Claim 6

An insulating material suitable for use in continuous molten metal casting comprising about: a. 28 to 32 weight percent lime; b. 23 to 32 weight percent siliceous component; c. 35 to 40 weight percent wollastonite; d. 1 to 7 weight percent inorganic fiber to provide green strength; and e. 0.5 to 8 weight percent organic fiber wherein 0.5 to 3 weight percent is pitch base graphitic fiber.

Claim 7

An insulating material as claimed in claim 1 wherein said material is substantially asbestos-free.

Claim 8

An insulating material as claimed in claim 1 wherein the siliceous component includes 2-20 weight percent colloidal silica.

Claim 9

An insulating material as claimed in claim 1 wherein the siliceous component includes 5 to 17 weight percent colloidal silica.

Claim 10

An insulating material as claimed in claim 1 wherein the siliceous component includes 8 to 15 weight percent colloidal silica.

Claim 11

An insulating material as claimed in claim 1 further comprising 5 to 25 weight percent of a member selected from the group consisting of vermiculite, mica, spodumene and lithium aluminate.

Claim 12

An insulating material as claimed in claim 1 further comprising 5 to 15 weight percent vermiculite.

Claim 13

An insulating material as claimed in claim 1 further comprising 8 to 13 weight percent vermiculite.

Claim 14

An insulating material as claimed in claim 1 wherein said material is made by mixing a mixture comprising 15-40 weight percent lime, 15-40 weight percent siliceous component, 15-50 weight percent wollastonite, 0 to 15 weight percent inorganic fiber and 0.5 to 15 weight percent organic fiber wherein 0.5 to 5 weight percent is pitch based graphitic fiber with water to form an aqueous slurry; molding the aqueous slurry into a wet shape; expelling water from the wet shape; heating the wet shape in the presence of steam; and drying the wet shape to remove free water.

Claim 15

An insulating material as claimed in claim 11 wherein said material has a matrix comprising calcium silicate hydrate.

Claim 16

An insulating material as claimed in claim 11 wherein said material has a matrix comprising predominately tobormorite.

Claim 17

An asbestos-free insulating material consisting essentially of about: a. 15 to 40 weight percent lime; b. 15 to 40 weight percent siliceous component of which 2-20 weight percent is colloidal silica; c. 15 to 50 weight percent wollastonite; d. 0 to 15 weight percent inorganic fiber to provide green strength; and e. 0.5 to 15 weight percent organic fiber wherein 0.5 to 5 weight percent is pitch based graphite fiber.

Claim 18

An asbestos-free insulating material consisting essentially of about: a. 15 to 40 weight percent lime; b. 15 to 40 weight percent siliceous component of which 2-20 weight percent is colloidal silica; c. 15 to 50 weight percent wollastonite; d. 0 to 15 weight percent inorganic fiber to provide green strength; and e. 0.5 to 15 weight percent organic fiber wherein 0.5 to 5 weight percent is pitch based graphite fiber.

Claim 19

An asbestos-free insulating material made by the steps of: a. Mixing a mixture comprising about 15 to 40 weight percent lime, about 15 to 40 weight percent silica, about 15 to 50 weight percent wollastonite, 0 to 15 weight percent inorganic fiber, and 0.5 to 15 weight percent organic fiber wherein 0.5 to 5 weight percent is pitch based graphitic fiber with water to form an aqueous slurry; b. Molding the aqueous slurry into a wet shape; c. Expelling water from the wet shape; d. Heating the wet shape above 170° C. in the presence of steam; e. Drying the wet shape to remove free water; and f. Subjecting the dried wet shape to a heat treating cycle wherein the temperature is raised over at least an 18 hour period from about 200° C. to about 500° C.

Claim 20

An asbestos-free insulating material made by the steps of: a. Mixing a mixture comprising about 15 to 40 weight percent lime, about 15 to 40 weight percent silica, about 15 to 50 weight percent wollastonite, 0 to 15 weight percent inorganic fiber, and 0.5 to 15 weight percent organic fiber wherein 0.5 to 5 weight percent is pitch based graphitic fiber with water to form an aqueous slurry; b. Molding the aqueous slurry into a wet shape; c. Expelling water from the wet shape; d. Heating the wet shape above 170° C. in the presence of steam; e. Drying the wet shape to remove free water; and f. Subjecting the dried wet shape to a heat treating cycle wherein the temperature is raised over at least an 18 hour period from about 200° C. to about 500° C.