US 11,702,372 B2
Thermal insulation
Farid Modarresifar, Merseyside (GB)
Assigned to Thermal Ceramics UK Limited, Merseyside (GB)
Filed by Thermal Ceramics UK Limited, Merseyside (GB)
Filed on Oct. 21, 2021, as Appl. No. 17/507,008.
Claims priority of application No. 2016878 (GB), filed on Oct. 23, 2020; application No. 2017916 (GB), filed on Nov. 13, 2020; application No. 2103109 (GB), filed on Mar. 5, 2021; and application No. 2109437 (GB), filed on Jun. 30, 2021.
Prior Publication US 2022/0127757 A1, Apr. 28, 2022
Int. Cl. C03C 13/06 (2006.01); C04B 35/622 (2006.01); C04B 37/00 (2006.01); C01B 33/24 (2006.01); F27D 1/00 (2006.01); D01F 9/08 (2006.01); E04B 1/78 (2006.01); D01D 1/04 (2006.01); D01D 5/08 (2006.01)
CPC C04B 37/001 (2013.01) [C01B 33/24 (2013.01); C03C 13/06 (2013.01); C04B 35/62227 (2013.01); D01D 1/04 (2013.01); D01D 5/08 (2013.01); D01F 9/08 (2013.01); E04B 1/78 (2013.01); F27D 1/0003 (2013.01); C01P 2002/52 (2013.01); C01P 2002/60 (2013.01); C01P 2004/03 (2013.01); C01P 2006/32 (2013.01); C01P 2006/37 (2013.01); C04B 2237/341 (2013.01); D10B 2101/02 (2013.01)] 26 Claims
OG exemplary drawing
 
1. A process for the manufacture of inorganic fibres comprising:
(a) selecting a composition and proportion of each of the following raw materials:
(i) silica sand;
(ii) lime, said lime comprising at least 0.10 wt % magnesia; and
(iii) optional additives comprising a source of oxides or non-oxides of one or more of the lanthanides series of elements, Li, Na, K, Sr, Sn, Ba, Cr, Fe, Zn, Y, Zr, Hf, Ca, B, P or combinations thereof;
(b) mixing the silica sand; lime; and optional additives to form a mixture;
(c) melting the mixture in a furnace;
(d) shaping the molten mixture into inorganic fibres,
wherein the raw material selection comprises composition selection and proportion selection of the raw materials to obtain an inorganic fibre composition comprising a range of from 61.0 wt % to 70.8 wt % silica; at least 0.10 wt % and less than 2.0 wt % magnesia; less than 2.0% incidental impurities; and no more than 2.0 wt % of metal oxides and/or metal non-oxides derived from said optional additives; with calcia providing the balance up to 100 wt %; and wherein the inorganic fibre composition comprises no more than 0.80 wt % Al2O3 derived from the incidental impurities and/or the optional additives; and
wherein the composition selection and proportion selection of the raw materials is configured so the amount of magnesia in the fibre composition is sufficient to inhibit the formation of surface crystallite grains upon heat treatment at 1100° C. for 24 hours, said surface crystallite grains comprise an average crystallite size in a range of from 0.0 to 0.90 μm.