US4558016A
Expired / Lapsed
US
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Ceramic fiber reinforced refractory
Assignee: ExxonMobil Technology and Engineering Co
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Filing: 1980-08-18
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Granted: 1985-12-10
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Expires: 2000-08-18
Abstract
Abstract A reinforced refractory product having increased tensile strength is provided comprising a refractory material such as a phosphate bonded castable refractory having distributed therein ceramic fibers in yarn form consisting of roved bundles of filaments. A method of distributing the ceramic fibers in the refractory is also provided wherein a mix of water and refractory material matrix is first formed and thereafter the fibers are added. Such method substantially reduced the risk of fiber damage during incorporation of the fiber in the matrix.
Inventors
- 👤 Stanley O. Bronson
- 👤 John R. Peterson
- 👤 Edward B. Schumacher
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 07:55
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/71; C04B35/78; C04B35/80; C04B35/01; C04B35/447; C04B35/622; C04B35/626; C04B35/62605; C04B35/62625; C04B35/6263; C04B35/628; C04B35/62844; C04B35/63; C04B35/6303; C04B35/6306; C04B35/66; C04B2235/00; C04B2235/02; C04B2235/50; C04B2235/52; C04B2235/5208; C04B2235/5216; C04B2235/522; C04B2235/5228; C04B2235/5264; C04B2235/60; C04B2235/61; C04B2235/70; C04B2235/96
Claims Analysis
Total Claims: 34
Claim 1
Independent Claim
50 words
A reinforced refractory product comprising a refractory material having ceramic fibers in yarn form in an approximate percentage by weight of the total in a range from 0.25 to 1.0 distributed therein, said fibers being in yarn form for the purpose of enhancing the modulus of rupture of said product.
Claim 2
Dependent Claim
50 words
A reinforced refractory product comprising a refractory material having ceramic fibers in yarn form in an approximate percentage by weight of the total in a range from 0.25 to 1.0 distributed therein, said fibers being in yarn form for the purpose of enhancing the modulus of rupture of said product.
Claim 3
Dependent Claim
15 words
The product of claim 1 wherein said refractory material is a phosphate bonded castable refractory.
Claim 4
Dependent Claim
15 words
The product of claim 1 wherein said ceramic fibers are comprised of an alumina-boria-silicate composition.
Claim 5
Dependent Claim
19 words
The product of claim 3 wherein said ceramic fibers comprise 62% alumina, 14% boria and 24% silica by weight.
Claim 6
Dependent Claim
24 words
The product of claim 1 wherein said ceramic fibers are comprised of filaments having a filament tensile strength of at least about 250,000 p.s.i.
Claim 7
Dependent Claim
16 words
The product of claim 5 wherein said filaments have an average diameter of about 11 microns.
Claim 8
Dependent Claim
15 words
The product of claim 1 wherein said fibers are sized with an organic polymeric material.
Claim 9
Dependent Claim
12 words
The product of claim 7 wherein sadi organic polymeric material is polytetrafluoroethylene.
Claim 10
Dependent Claim
48 words
A reinforced refractory product of enhanced modulus of rupture at temperatures of between approximately 1000° F. to 1600° F., comprising a phosphate-bonded castable refractory having ceramic fibers in yarn form distributed therein in an approximate percentage by weight of the total in a range from 0.25 to 1.0.
Claim 11
Dependent Claim
48 words
A reinforced refractory product of enhanced modulus of rupture at temperatures of between approximately 1000° F. to 1600° F., comprising a phosphate-bonded castable refractory having ceramic fibers in yarn form distributed therein in an approximate percentage by weight of the total in a range from 0.25 to 1.0.
Claim 12
Dependent Claim
14 words
The product of claim 9 wherein said fibers are comprised of an alumina-boria-silicate composition.
Claim 13
Dependent Claim
16 words
The product of claim 10 wherein said fiber comprises 62% alumina, 14% boria and 24% silicate.
Claim 14
Dependent Claim
18 words
The product of claim 9 wherein said yarn formed of said ceramic fibers comprises roved bundles of filaments.
Claim 15
Dependent Claim
16 words
The product of claim 12 wherein said filaments have an average diameter of about 11 microns.
Claim 16
Dependent Claim
18 words
The product of claim 12 wherein said filaments have a tensile strength of at least about 250,000 p.s.i.
Claim 17
Dependent Claim
16 words
The product of claim 9 wherein said ceramic fibers in yarn form are sized with polytetrafluoroethylene.
Claim 18
Dependent Claim
44 words
A reinforced refractory product comprising a phosphate-bonded castable refractory having ceramic fibers distributed therein, said fibers being a yarn comprised of roved bundles of filaments of an alumina-boria-silicate composition in approximate percent by weight of the total in a range from 0.25 to 1.0.
Claim 19
Dependent Claim
44 words
A reinforced refractory product comprising a phosphate-bonded castable refractory having ceramic fibers distributed therein, said fibers being a yarn comprised of roved bundles of filaments of an alumina-boria-silicate composition in approximate percent by weight of the total in a range from 0.25 to 1.0.
Claim 20
Dependent Claim
18 words
The product of claim 16 wherein said fibers are comprised of 62% alumina, 14% boria and 24% silica.
Claim 21
Dependent Claim
19 words
The product of claim 16 wherein said filaments have a filament tensile strength of at least about 250,000 p.s.i.
Claim 22
Dependent Claim
15 words
The product of claim 16 wherein said filaments have an average diameter of 11 microns.
Claim 23
Dependent Claim
12 words
The product of claim 16 wherein said fibers are sized with polytetrafluoroethylene.
Claim 24
Independent Claim
63 words
A method of forming a product of ceramic fibers in yarn form in a refractory material, comprising the steps of: (a) forming a mix of a refractory matrix and water; and (b) blending said ceramic fibers in yarn form in approximate percentage by weight of the total in a range from 0.25 to 1.0, with said mix until said fibers are dispersed therein.
Claim 25
Independent Claim
63 words
A method of forming a product of ceramic fibers in yarn form in a refractory material, comprising the steps of: (a) forming a mix of a refractory matrix and water; and (b) blending said ceramic fibers in yarn form in approximate percentage by weight of the total in a range from 0.25 to 1.0, with said mix until said fibers are dispersed therein.
Claim 26
Dependent Claim
15 words
The method of claim 21 wherein said refractory material is a phosphate bonded castable refractory.
Claim 27
Independent Claim
73 words
A method of forming a product of enhanced modulus of rupture comprising ceramic fibers in yarn form in a refractory material, comprising the steps of: (a) adding water to a refractory matrix to form a mix having a plastic consistency; and (b) adding and blending said ceramic fibers in yarn form in approximate weight of the total in a range from 0.25 to 1.0, with said mix until said fibers are dispersed therein.
Claim 28
Independent Claim
73 words
A method of forming a product of enhanced modulus of rupture comprising ceramic fibers in yarn form in a refractory material, comprising the steps of: (a) adding water to a refractory matrix to form a mix having a plastic consistency; and (b) adding and blending said ceramic fibers in yarn form in approximate weight of the total in a range from 0.25 to 1.0, with said mix until said fibers are dispersed therein.
Claim 29
Dependent Claim
15 words
The method of claim 23 wherein said refractory material is a phosphate bonded castable refractory.
Claim 30
Dependent Claim
18 words
The method of claim 24 wherein said blending step is performed about two minutes after adding said water.
Claim 31
Dependent Claim
16 words
The method of claim 24 wherein said blending occurs for one minute after adding said fibers.
Claim 32
Independent Claim
92 words
A method of forming a product of enhanced modulus of rupture comprising ceramic fibers in yarn form in a refractory material, comprising the steps of: (a) adding a quantity of water to a refractory matrix with water sufficient to form a mix having a plastic consistency; (b) adding said ceramic fibers in yarn form in an approximate percentage by weight of the total in a range from 0.25 to 1.0, to said mix about two minutes after adding said water; and (c) blending said fibers with said mix for about one minute.
Claim 33
Independent Claim
92 words
A method of forming a product of enhanced modulus of rupture comprising ceramic fibers in yarn form in a refractory material, comprising the steps of: (a) adding a quantity of water to a refractory matrix with water sufficient to form a mix having a plastic consistency; (b) adding said ceramic fibers in yarn form in an approximate percentage by weight of the total in a range from 0.25 to 1.0, to said mix about two minutes after adding said water; and (c) blending said fibers with said mix for about one minute.
Claim 34
Dependent Claim
14 words
The method of claim 27 wherein said refractory is a phosphate bonded castable refractory.
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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) | 1988-12-09 | 1989-06-10 | 1989-12-10 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1992-12-09 | 1993-06-10 | 1993-12-10 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1996-12-09 | 1997-06-10 | 1997-12-10 | $7700.00 | Window Closed / Lapsed |