Claims
- 1. A noncombustible fibrous paper comprising:
(a) a dominant amount by weight of aluminosilicate refractory fibers, said fibers being substantially from 1 micron to 35 microns in width and from 1 cm to 15 cm in length; and (b) from 0.2% to 4% by weight of a polymeric binder distributed throughout the paper, said paper being structurally stable when in direct contact with a flame at a very high temperature up to about 1400° C.
- 2. A noncombustible paper as in claim I wherein the very high temperature is from about 1000° C. to 1400° C.
- 3. A noncombustible paper as in claim 1 wherein the dominant amount is from 90 to 99.8% by weight.
- 4. A noncombustible paper as in claim 1 wherein the dominant amount is from 70% to 99.8% by weight and further comprising an effective amount of a second noncombustible material.
- 5. A noncombustible paper as in claim 1 wherein the polymeric binder is a vinyl acetate/ethylene copolymer emulsion.
- 6. A noncombustible paper as in claim 1 further comprising from 0.1% to 5% by weight of a textile filler.
- 7. A noncombustible paper as in claim 6 wherein the textile filler is a viscose fiber.
- 8. A noncombustible paper as in claim 1 further comprising an effective amount of a second binder.
- 9. A noncombustible paper as in claim 8 wherein the second binder is applied as a coating.
- 10. A noncombustible paper as in claim 8 wherein the coating is a copolymer emulsion.
- 11. A noncombustible paper as in claim 10 wherein the copolymer emulsion is a vinyl acetate/ethylene copolymer emulsion.
- 12. A noncombustible paper as in claim 1 further comprising from 0.2% to 5% by weight of silicic acid aquagel.
- 13. A noncombustible paper as in claim 12 wherein the silicic acid aquagel is dehydrated during processing of the paper and becomes an amorphous adhesive.
- 14. A noncombustible paper as in claim 1 wherein said paper is structurally stable when exposed to a continuous flame having temperatures of at least 1200° C. without substantial disintegration.
- 15. A noncombustible paper as in claim 1 wherein the aluminosilicate refractory fibers are comprised of from 30% to 70% silica by weight and from 70% to 30% by weight alumina.
- 16. A noncombustible paper as in claim 15 wherein the silica and the alumina are present in substantially equal proportions by weight.
- 17. A noncombustible paper as in claim 1 further comprising from 0.1% to 3% of one or more mineral oxide by weight.
- 18. A noncombustible paper as in claim 1 wherein the paper has a density from about 180 to 240 kg/M3.
- 19. A noncombustible paper as in claim 1 wherein the paper is from 0.3 mm to 3.0 mm in thickness.
- 20. A method of making a noncombustible paper comprising:
(a) pulping aluminosilicate refractory fibers; (b) adding an effective amount of a polymeric binder forming a continuous pulp; (c) pressing the continuous pulp; and (d) dehydrating the continuous pulp. such that a mat paper is formed that is structurally stable at a very high temperature when in direct contact with a flame.
- 21. A method as in claim 20 wherein the very high temperature is from about 1000° C. to 1400° C.
- 22. A method as in claim 20 wherein the polymeric binder is a vinyl acetate/ethylene copolymer emulsion.
- 23. A method as in claim 20 comprising the step of coating the paper with a polymeric coating.
- 24. A method as in claim 20 wherein the polymer coating is a vinyl acetate/ethylene copolymer emulsion.
- 25. A method as in claim 20 further comprising the step of adding an effective amount of a textile filler.
- 26. A method as in claim 25 wherein the textile filler is a viscose fiber.
- 27. A method as in claim 20 further comprising the step of adding an effective amount of silicic acid aquagel.
- 28. A method as in claim 20 further comprising the step of cleaning the aluminosilicate refractory fibers after pulping.
- 29. A method as in claim 20 further comprising the preliminary step selecting low granule-content aluminosilicate fibers.
- 30. A method as in claim 20 wherein the aluminosilicate refractory fibers are comprised of from 30% to 70% silica by weight and from 70% to 30% by weight alumina.
- 31. A method as in claim 20 further comprising the preliminary step of extruding aluminosilicate to form textile fibers having a predetermined dimension.
- 32. A method as in claim 31 wherein the predetermined dimension is from 1 micron to 35 microns in width and from 1 cm to 15 cm in length.
RELATED APPLICATIONS
[0001] The present application is a divisional of U.S. application Ser. No. 09/835,069 filed Apr. 13, 2001.
Divisions (1)
|
Number |
Date |
Country |
Parent |
09835069 |
Apr 2001 |
US |
Child |
10355609 |
Jan 2003 |
US |