CA2489689A1 - Isotropic pitch-based materials for thermal insulation - Google Patents

Isotropic pitch-based materials for thermal insulation Download PDF

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Publication number
CA2489689A1
CA2489689A1 CA 2489689 CA2489689A CA2489689A1 CA 2489689 A1 CA2489689 A1 CA 2489689A1 CA 2489689 CA2489689 CA 2489689 CA 2489689 A CA2489689 A CA 2489689A CA 2489689 A1 CA2489689 A1 CA 2489689A1
Authority
CA
Canada
Prior art keywords
mixture
sugar
binder
preform
weight
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
CA 2489689
Other languages
French (fr)
Other versions
CA2489689C (en
Inventor
Charles C. Chiu
Irwin Charles Lewis
Ching-Feng Chang
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.)
Graftech International Holdings Inc
Original Assignee
Ucar Carbon Company Inc.
Charles C. Chiu
Irwin Charles Lewis
Ching-Feng Chang
Graftech International Holdings 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 Ucar Carbon Company Inc., Charles C. Chiu, Irwin Charles Lewis, Ching-Feng Chang, Graftech International Holdings Inc. filed Critical Ucar Carbon Company Inc.
Publication of CA2489689A1 publication Critical patent/CA2489689A1/en
Application granted granted Critical
Publication of CA2489689C publication Critical patent/CA2489689C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/632—Organic additives
    • C04B35/636—Polysaccharides or derivatives thereof
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/71—Ceramic products containing macroscopic reinforcing agents
    • C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
    • C04B35/80—Fibres, filaments, whiskers, platelets, or the like
    • C04B35/83—Carbon fibres in a carbon matrix
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D1/00—Casings; Linings; Walls; Roofs
    • F27D1/0003—Linings or walls
    • F27D1/0006—Linings or walls formed from bricks or layers with a particular composition or specific characteristics
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/526—Fibers characterised by the length of the fibers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/74—Physical characteristics
    • C04B2235/77—Density
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
    • C04B2235/9607—Thermal properties, e.g. thermal expansion coefficient
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/249928—Fiber embedded in a ceramic, glass, or carbon matrix
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y10T428/249942—Fibers are aligned substantially parallel
    • Y10T428/249945—Carbon or carbonaceous fiber
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • Y10T428/254—Polymeric or resinous material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/28—Web or sheet containing structurally defined element or component and having an adhesive outermost layer
    • Y10T428/2813—Heat or solvent activated or sealable
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Ceramic Products (AREA)
  • Working-Up Tar And Pitch (AREA)
  • Inorganic Fibers (AREA)
  • Thermal Insulation (AREA)
  • Furnace Housings, Linings, Walls, And Ceilings (AREA)
  • Nonwoven Fabrics (AREA)
  • Carbon And Carbon Compounds (AREA)

Abstract

Insulation materials suited to high temperature applications, such as the insulation of furnaces, are formed from a mixture of pitch carbon fibers, su ch as isotropic pitch carbon fibers, and a binder comprising a solution of suga r in water. The sugar solution is preferably at a concentration of from 20-60 % sucrose to yield a low density material having high flexural strength and lo w thermal conductivity when carbonized to a temperature of about 1800 ~C.</SDO AB>

Claims (20)

1. A method of forming a thermal insulation material comprising:
combining carbon-containing fibers, which include pitch-based carbon fibers, with a binder which includes a soluble sugar to form a mixture forming the mixture into a solid preform having a general shape of the thermal insulation material; and heating the preform to a sufficient temperature to carbonize the preform and form the thermal insulation material.
2. The method of claim 1, wherein the carbon-containing fibers include isotropic pitch carbon fibers.
3. The method of claim 1, wherein the carbon-containing fibers include at least 80% by weight of isotropic pitch carbon fibers.
4. The method of claim 1, wherein the binder is an aqueous sugar solution which includes from about 15 to about 80% by weight sugar.
5. The method of claim 1, wherein the sugar is selected from the group consisting of sucrose, fructose, dextrose, maltose, mannose glucose, galactose, UDP-galactose, and xylose, their soluble polysaccaride equivalents, and combinations thereof.
6. The method of claim 1, wherein the sugar includes sucrose.
7. The method of claim 6, wherein the binder includes from about 20 % by weight to about 60% by weight sugar.
8. The method of claim 7, wherein the binder includes about 45%
by weight to about 60% by weight sucrose.
9. The method of claim 1, wherein the mixture includes about 20-80 parts fiber and 80-20 parts sugar.
10. The method of claim 1, wherein the step of forming includes:
filtering the mixture to remove excess binder.
11. The method of claim 1, wherein the step of heating includes heating the preform to a temperature of at least 900°C.
12. The method of claim 11, wherein the step of heating includes heating the preform to a temperature of about 1800°C.
13. The method of claim 1, wherein the fibers have an average length of less than about 800 micrometers.
14. The method of claim 1, wherein the carbonized preform has a density of from about 0.1 to about 0.4 g/cm3.
15. An insulation material formed by the method of claim 1.
16. A low density thermal insulation article formed from a mixture of isotropic pitch carbon fibers and a sugar binder which has been heated to a sufficient temperature to carbonize the mixture, the article having a density of from about 0.1 to about 0.4 g/cm3.
17. The article of claim 16, wherein the article has a thermal conductivity of less than about 0.4 W/m°.K.
18. The article of claim 16, wherein the fibers have an average length of from about 400 to about 800 micrometers.
19. A method of providing thermal insulation for a high temperature radiant heat source comprising:
forming a self supporting insulation member having a thermal conductivity of less than about 0.4 W/m°.K, including:
filtering a mixture which includes isotropic pitch carbon fibers and an aqueous sugar solution, heating the filtered mixture to a temperature of at least 900°C to form the member; and positioning the insulation member adjacent the high temperature radiant heat source to insulate the heat source.
20. The method of claim 19, wherein the insulation member is in the shape of a board having a thickness of less than about 10 cm.
CA 2489689 2002-06-28 2003-06-27 Isotropic pitch-based materials for thermal insulation Expired - Fee Related CA2489689C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US10/184,850 2002-06-28
US10/184,850 US6800364B2 (en) 2002-06-28 2002-06-28 Isotropic pitch-based materials for thermal insulation
PCT/US2003/020560 WO2004003279A1 (en) 2002-06-28 2003-06-27 Isotropic pitch-based materials for thermal insulation

Publications (2)

Publication Number Publication Date
CA2489689A1 true CA2489689A1 (en) 2004-01-08
CA2489689C CA2489689C (en) 2012-09-04

Family

ID=29999244

Family Applications (1)

Application Number Title Priority Date Filing Date
CA 2489689 Expired - Fee Related CA2489689C (en) 2002-06-28 2003-06-27 Isotropic pitch-based materials for thermal insulation

Country Status (7)

Country Link
US (3) US6800364B2 (en)
EP (2) EP1518016B1 (en)
AT (1) ATE547549T1 (en)
AU (1) AU2003248760A1 (en)
CA (1) CA2489689C (en)
MX (1) MXPA04012730A (en)
WO (1) WO2004003279A1 (en)

Families Citing this family (10)

* Cited by examiner, † Cited by third party
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US20060239889A1 (en) * 2001-09-28 2006-10-26 Lewis Irwin C Sugar additive blend useful as a binder or impregnant for carbon products
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US20040067316A1 (en) * 2002-10-04 2004-04-08 Paul Gray Method for processing silicon-carbide materials using organic film formers
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US10603867B1 (en) 2011-05-24 2020-03-31 Enevate Corporation Carbon fibers and methods of producing the same
KR20140001698U (en) * 2011-06-24 2014-03-21 그라프텍 인터내셔널 홀딩스 인코포레이티드 Thermal insulation assembly
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KR20210024740A (en) * 2019-08-26 2021-03-08 현대자동차주식회사 A composite fiber web excellent in heat resistance and sound absorption and a method for manufacturing the same
GB2591249A (en) 2020-01-22 2021-07-28 Mersen Scotland Holytown Ltd Thermal insulation materials suitable for use at high temperatures, and process for making said materials

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Also Published As

Publication number Publication date
WO2004003279A1 (en) 2004-01-08
US7150837B2 (en) 2006-12-19
US20040005446A1 (en) 2004-01-08
ATE547549T1 (en) 2012-03-15
EP1518016B1 (en) 2012-02-29
US6800364B2 (en) 2004-10-05
AU2003248760A1 (en) 2004-01-19
EP1518016A4 (en) 2008-10-29
USRE42775E1 (en) 2011-10-04
CA2489689C (en) 2012-09-04
EP1518016A1 (en) 2005-03-30
US20050029487A1 (en) 2005-02-10
EP2280107A1 (en) 2011-02-02
MXPA04012730A (en) 2005-03-23

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