Abstract A method of producing siliceous fiber containing composites which inhibit chloride ion stress corrosion of stainless steel. The method comprises the production of a siliceous fiber batt, the fibers of which form the reinforcing structure of the insulation material, but which fibers will not of themselves inhibit the chloride ion stress corrosion. Alkali metal silicates having an alkali metal to silicate ratio of between 3.75 and 7.5 to 1, and which inhibit the corrosion, are bonded to the skeletal structure of the fibers with a porous binder to both rigidify the fibers and retain the corrosion inhibiting material. In the preferred method of producing the composite, the alkali metal silicate and binder are incorporated with the fibers during the forming process, and the binder is, thereafter hardened to simultaneously form the rigid composite and secure the alkaline metal silicate to the structural skeleton of the fibers. In a less preferred arrangement, the fibers are bonded together with an organic binder, which is then cured, and a slurry of inorganic cementitious material, incorporating the alkali metal silicate, is sucked into the bonded fiber skeleton and hardened to produce the composite.
In the method of claim 1 wherein molten streams of siliceous material are injected into a stream of high velocity gases to attenuate the molten streams into fibers, and wherein the stream of fibers and gases is passed through a collection surface which retains the fibers on the collection surface in the form of a batt; the dispersing step wherein the particles of alkali metal silicate and binder forming material are injected into the gases from which the fibers are retained by the collection surface.
Claim 2
Dependent Claim
95 words
In the method of claim 1 wherein molten streams of siliceous material are injected into a stream of high vElocity gases to attenuate the molten streams into fibers, and wherein the stream of fibers and gases is passed through a collection surface which retains the fibers on the collection surface in the form of a batt; the dispersing step comprising wetting the fibers by injecting aqueous material into the high velocity stream of gases and fibers, and thereafter introducing the particles of alkali metal silicate into the stream on its way to the collection surface.
Claim 3
Dependent Claim
36 words
The method of claim 1 wherein the binder and alkali metal silicate are introduced dry to the gases on their way to the collection surface, followed by the step of applying water to the collected material.
Claim 4
Dependent Claim
38 words
The method of claim 3 wherein the fibers are wetted with an aqueous dispersion of an organic binder, followed by the step of hardening the organic binder to bond the particles of alkali metal silicate to the fibers.
Claim 5
Dependent Claim
34 words
The method of claim 5 followed by the step of impregnating the bonded fibers with a slurry of an inorganic binder material, and hardening the inorganic binder to produce a high temperature insulation material.
Claim 6
Dependent Claim
33 words
The method of claim 1 wherein the dispersing step includes forming a slurry comprising the particles of alkali metal silicate and an inorganic binder, and sucking the slurry into the batt of fibers.