CA2437191A1 - Compression molded inorganic fiber articles, and methods and compositions used in molding same - Google Patents

Compression molded inorganic fiber articles, and methods and compositions used in molding same Download PDF

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Publication number
CA2437191A1
CA2437191A1 CA002437191A CA2437191A CA2437191A1 CA 2437191 A1 CA2437191 A1 CA 2437191A1 CA 002437191 A CA002437191 A CA 002437191A CA 2437191 A CA2437191 A CA 2437191A CA 2437191 A1 CA2437191 A1 CA 2437191A1
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CA
Canada
Prior art keywords
article
composition
fireplace
molding
inorganic
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002437191A
Other languages
French (fr)
Other versions
CA2437191C (en
Inventor
David Charles Lyons
Ted Victor Schroeder
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
HNI Technologies Inc
Original Assignee
Hon Technology Inc.
David Charles Lyons
Ted Victor Schroeder
Hni Technologies Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hon Technology Inc., David Charles Lyons, Ted Victor Schroeder, Hni Technologies Inc. filed Critical Hon Technology Inc.
Publication of CA2437191A1 publication Critical patent/CA2437191A1/en
Application granted granted Critical
Publication of CA2437191C publication Critical patent/CA2437191C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/24Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24BDOMESTIC STOVES OR RANGES FOR SOLID FUELS; IMPLEMENTS FOR USE IN CONNECTION WITH STOVES OR RANGES
    • F24B1/00Stoves or ranges
    • F24B1/18Stoves with open fires, e.g. fireplaces
    • F24B1/1808Simulated fireplaces
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24CDOMESTIC STOVES OR RANGES ; DETAILS OF DOMESTIC STOVES OR RANGES, OF GENERAL APPLICATION
    • F24C3/00Stoves or ranges for gaseous fuels
    • F24C3/002Stoves
    • F24C3/006Stoves simulating flames
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20Resistance against chemical, physical or biological attack
    • C04B2111/28Fire resistance, i.e. materials resistant to accidental fires or high temperatures

Abstract

A method of forming articles made of an inorganic fiber material using compression molding. In one respect, a method of forming an article, wherein the method includes providing a molding composition comprising inorganic fiber and an inorganic binder, and compression molding the molding composition into the article. In another respect, the method including providing a molding composition comprising inorganic fibers and binder, and compression molding the molding composition into the article, wherein at least 75% by weight of the molded article is inorganic material. In some embodiments the cured binder is capable of withstanding temperatures of at least (315 ~C) without significant degradation or deterioration due to heat. Articles made by the use of such methods and a molding composition for use in compression molding an article are also included.

Claims (39)

1. ~A method of forming as article, the method comprising:
providing a molding composition comprising a manufactured inorganic fiber and an inorganic binder;
compression molding the molding composition into the article; and heating the molding composition during the compression molding.
2. ~The method of claim 1, wherein the molding composition comprises the inorganic fiber, the inorganic binder, and a carrier solvent,
3. ~The method of claim 1, wherein the inorganic fiber includes glass fiber, ceramic fiber, refractory ceramic fiber, mineral fiber, or mixtures thereof.
4. ~The method of claim 1, wherein the inorganic fiber further comprises chopped fiber glass.
5. ~The method of claim 1, wherein the inorganic binder comprises silica, sodium, calcium, and magnesium based binders, or mixtures thereof.
6. ~The method of claim 1, wherein the inorganic binder comprises colloidal silica.
7. ~The method of claim 2, wherein the carrier solvent comprises water.
8. ~The method of claim 2, wherein the molding composition has a moisture content in the range of 20 to 35% by weight of the total composition.
9. ~The method of claim 2, wherein the molding composition has a moisture content in the range of 25 to 27% by weight of the total composition.
10. The method of claim 1, wherein the article is an article for use in a fireplace assembly, a grill assembly, a campfire assembly, or a burner assembly.
11. The method of claim 10, wherein the article is a combustion chamber for a fireplace, a fireplace box, a fireplace door, a fireplace surround, a fireplace log a fireplace burner ar a fireplace refractory member.
12. A method of forming an article, the method comprising;
providing a molding composition comprising inorganic fiber and a binder, wherein the inorganic fiber includes glass fiber, ceramic fiber, refractory ceramic fiber, ar mineral wool;
compression molding the molding composition into the article, wherein at least 75% by weight of the molded article is inorganic material; and heating the molding composition during the compression molding.
13. The method of claim 12, wherein at least 90% by weight of the molded article is inorganic material.
14. The method of claim 12, wherein at least 95% by weight of the molded article is inorganic material.
15. A method of forming an article, the method comprising:
providing a molding composition comprising inorganic fiber and a binder, wherein the inorganic fiber includes glass fiber ceramic fiber refractery ceramic fiber, or mineral wool;
compression molding the molding composition into the article such that the binder cures; and hearing the molding composition during the compression molding;
wherein the cured binder is capable of withstanding temperatures of at least 600° F without significant degradation or deterioration due to heat.
16. The method of claim 15, wherein the cured binder is capable of withstanding temperatures of at least 800° F without significant degradation or deterioration due to heat.
17. The method of claim 15, wherein the binder comprises an inorganic binder,
18. The method of claim 15, wherein the article is a combustion chamber for a fireplace, fireplace box, a fireplace door, a fireplace surround, a fireplace log, a fireplace burner or a fireplace refractory member.
19. A method of forming an article, the method comprising:
providing a molding composition comprising inorganic fiber and a binder, wherein the inorganic fiber includes glass fiber, ceramic fiber, refractory ceramic fiber, or mineral wool;
compression molding the molding composition into the article; and heating the molding composition during the compression molding;
wherein the article is capable of withstanding temperatures of at least 600° F
without significant degradation or deterioration due to heat.
20. The method of claim 19, wherein the article is capable of withstanding temperatures of at lease 500° F without significant degradation or deterioration due to heat.
21. The method of claim 19, wherein the article is a combustion chamber for a fireplace, a fireplace box, a fireplace door, a fireplace surround, a fireplace log, a fireplace burner or a fireplace refractory member.
22. The method of claim 19, wherein the binder comprises an inorganic binder.
23. An article made by the method of compression molding of claim 1.
24. An article made by the method of compression molding of claim 12.
25. An article made by the method of compression molding of claim 15.
26. An article made by the method of compression molding of claim 19.
27. An article comprising a monolithic combustion chamber enclosure including at least 3 panels, wherein the article is compression molded.
28. An article comprising a monolithic firebox including at least 3 panels, wherein the article is compression molded.
29. An article comprising a monolithic gas burner panel, wherein the article is compression molded.
30. An molding composition for use in compression molding an article, said composition comprising:

in the range of 25 % or less by wt. inorganic fiber, wherein the inorganic fiber includes glass fiber, ceramic fiber, refractory ceramic fiber, or mineral wool;
in the range of 10 to 40 % by wt, binder;
in the range of 15 to 45 % by wt, carrier solvent; and in the range of 0 to 70 % by wt. additional additives.
31. The composition of claim 30, wherein the binder is an inorganic binder.
32. The composition of claim 30, wherein the additional additives includes an inorganic filler, and the inorganic filler is in the range of 15 to 70 % by weight of the total composition.
33. The composition of claim 30, wherein the additional additives includes an organic polymer, and the organic polymer is in the range of 0.1 to 0.5 by weight of the total composition.
34. The composition of claim 33, wherein the organic polymer is an acrylic polymer.
35. The composition of claim 33, wherein the organic polymer act as a molding thickener to help the composition hold shape when it is being molded.
36. The composition of claim 30, wherein the carrier solvent is water,
37. The composition of claim 35, wherein the composition has a moisture content in the range of 20 to 35% by weight of the total composition.
38. The composition of claim 37, wherein the composition has a moisture content 23 to 30% by weight of the total composition.
39. The composition of claim 38, wherein the composition has a moisture content in the range of 25 to 27% by weight of the total composition.
CA2437191A 2001-02-08 2002-01-17 Compression molded inorganic fiber articles, and methods and compositions used in molding same Expired - Fee Related CA2437191C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US09/781,148 2001-02-08
US09/781,148 US7098269B2 (en) 2001-02-08 2001-02-08 Compression molded inorganic fiber articles, and methods and compositions used in molding same
PCT/US2002/003906 WO2002062723A2 (en) 2001-02-08 2002-01-17 Compression molded inorganic fiber articles, and methods and compositions used in molding same

Publications (2)

Publication Number Publication Date
CA2437191A1 true CA2437191A1 (en) 2002-08-15
CA2437191C CA2437191C (en) 2012-03-20

Family

ID=25121838

Family Applications (1)

Application Number Title Priority Date Filing Date
CA2437191A Expired - Fee Related CA2437191C (en) 2001-02-08 2002-01-17 Compression molded inorganic fiber articles, and methods and compositions used in molding same

Country Status (6)

Country Link
US (4) US7098269B2 (en)
EP (1) EP1399395A2 (en)
JP (1) JP2004525055A (en)
AU (1) AU2002242143B2 (en)
CA (1) CA2437191C (en)
WO (1) WO2002062723A2 (en)

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Also Published As

Publication number Publication date
CA2437191C (en) 2012-03-20
EP1399395A2 (en) 2004-03-24
AU2002242143B2 (en) 2008-01-03
US20030049575A1 (en) 2003-03-13
WO2002062723A3 (en) 2003-02-06
US7470729B2 (en) 2008-12-30
US7098269B2 (en) 2006-08-29
JP2004525055A (en) 2004-08-19
US20050165160A1 (en) 2005-07-28
US20050119397A1 (en) 2005-06-02
US20030039933A1 (en) 2003-02-27
WO2002062723A2 (en) 2002-08-15

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