U.S. patent application number 14/374146 was filed with the patent office on 2015-02-05 for inorganic fibrous regularly shaped article and method for adjusting hardness thereof.
The applicant listed for this patent is NICHIAS CORPORATION. Invention is credited to Tomohiko Kishiki, Tetsuya Mihara, Hiroki Muramatsu, Ken Yonaiyama.
Application Number | 20150033986 14/374146 |
Document ID | / |
Family ID | 47469401 |
Filed Date | 2015-02-05 |
United States Patent
Application |
20150033986 |
Kind Code |
A1 |
Yonaiyama; Ken ; et
al. |
February 5, 2015 |
INORGANIC FIBROUS REGULARLY SHAPED ARTICLE AND METHOD FOR ADJUSTING
HARDNESS THEREOF
Abstract
An inorganic fibrous shaped product including organic fiber that
includes at least biosoluble inorganic fiber having the following
composition and an organic thickener, and including no colloidal
silica: [Composition] SiO.sub.2: 70 to 82 wt %; CaO: 10 to 29 wt %;
MgO: 1 wt % or less; Al.sub.2O.sub.3: less than 5 wt %; and the
total of SiO.sub.2, CaO, MgO and Al.sub.2O.sub.3 exceeds 98 wt
%.
Inventors: |
Yonaiyama; Ken; (Tokyo,
JP) ; Mihara; Tetsuya; (Tokyo, JP) ;
Muramatsu; Hiroki; (Tokyo, JP) ; Kishiki;
Tomohiko; (Tokyo, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NICHIAS CORPORATION |
Tokyo |
|
JP |
|
|
Family ID: |
47469401 |
Appl. No.: |
14/374146 |
Filed: |
December 4, 2012 |
PCT Filed: |
December 4, 2012 |
PCT NO: |
PCT/JP2012/007764 |
371 Date: |
July 23, 2014 |
Current U.S.
Class: |
106/287.17 ;
524/45 |
Current CPC
Class: |
C03C 25/321 20130101;
D21H 13/36 20130101; D21H 13/38 20130101; D04H 1/4209 20130101;
D01F 2/28 20130101; D21H 13/44 20130101; C03C 13/00 20130101; C03C
25/32 20130101; D04H 1/64 20130101 |
Class at
Publication: |
106/287.17 ;
524/45 |
International
Class: |
D01F 2/28 20060101
D01F002/28 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 24, 2012 |
JP |
2012-011705 |
Claims
1. An inorganic fibrous shaped product comprising organic fiber
that comprises at least biosoluble inorganic fiber having the
following composition and an organic thickener, comprising no
colloidal silica: [Composition] SiO.sub.2: 70 to 82 wt %; CaO: 10
to 29 wt %; MgO: 1 wt % or less; Al.sub.2O.sub.3: less than 5 wt %;
and the total SiO.sub.2, CaO, MgO and Al.sub.2O.sub.3 exceeds 98 wt
%.
2. The inorganic fibrous shaped product according to claim 1,
further comprising a fixing agent.
3. The inorganic fibrous shaped product according to claim 2,
wherein the fixing agent is one or more selected from sulfates,
nitrates, acetates and hydrochlorides of each of aluminum,
magnesium, calcium, sodium and potassium.
4. A method for adjusting the hardness of the surface of the
inorganic fibrous shaped product according to claim 1 wherein the
amount of at least one of an organic thickener and a fixing agent
is changed.
Description
TECHNICAL FIELD
[0001] The invention relates to an inorganic fibrous shaped product
that can be used as a sealing agent or a packing agent and a method
for adjusting the hardness thereof.
BACKGROUND ART
[0002] Inorganic fiber is light in weight, easy to handle, and has
excellent heat resistance. Therefore, inorganic fiber is used as a
heat-insulating sealing material, for example. On the other hand,
in recent years, a problem has been pointed out that inorganic
fiber is inhaled by a human body and the inhaled fiber invades the
lung. Therefore, biosoluble inorganic fiber that does not cause or
hardly cause problems even if inhaled by a human body has been
developed (Patent Documents 1 and 2, for example).
[0003] According to applications, biosoluble inorganic fiber is not
only used as the raw material of textiles such as a rope, a yarn
and a cloth, but also secondarily processed to and used as a shaped
product such as a blanket, a board and a felt or an unshaped
product such as a coating material and mortar.
[0004] When a shaped product is used as a joint filler in a
heat-treatment apparatus, an industrial furnace or an incinerator,
a joint filler that fills a gap of refractory tiles,
heat-insulating bricks, shells and refractory mortars, a sealing
material, and a packing material, flexibility and cushion
properties are required such that construction of joints can be
conducted without forming gaps. When construction is carried out on
a curved surface or the like, since a shaped product is applied
after processing variously, in addition to flexibility, hardness is
required for the need of attaining working accuracy or dimensional
accuracy. As mentioned above, flexibility and hardness are required
according to applications. Further, in order not to be deformed
during use at high temperatures, it is preferred that a shaped
product have a small heat shrinkage.
[0005] A conventional shaped product such as a board contains an
inorganic binder (colloidal silica) in order to allow it to be
hard. However, if colloidal silica is contained, when a shaped
product is used at high temperatures, a problem arises that
strength is lowered or cushion properties are deteriorated due to
advancement in crystallization. Further, there is a problem that,
due to deterioration in flexibility, a shaped product cannot retain
its shape after construction, and as a result, it drops from the
location of construction or a gap is formed between the location of
construction and the shaped product.
RELATED ART DOCUMENTS
Patent Documents
[0006] Patent Document 1: JP-A-2001-270737 [0007] Patent Document
2: JP-T-2005-514318
SUMMARY OF THE INVENTION
[0008] An object of the invention is to provide an inorganic
fibrous shaped product that does not contain colloidal silica and
has various degrees of flexibility and hardness, and heat
resistance, and a method for adjusting the hardness thereof.
[0009] According to the invention, the following method for
adjusting the hardness of an inorganic fibrous shaped product can
be provided. [0010] 1. An inorganic fibrous shaped product
comprising organic fiber that comprises biosoluble inorganic fiber
having at least the following composition and an organic thickener,
and comprising no colloidal silica:
[Composition]
[0011] SiO.sub.2: 70 to 82 wt %;
[0012] CaO: 10 to 29 wt %;
[0013] MgO: 1 wt % or less;
[0014] Al.sub.2O.sub.3: less than 5 wt %; and
[0015] the total of SiO.sub.2, CaO, MgO and Al.sub.2O.sub.3 exceeds
98 wt %. [0016] 2. The inorganic fibrous shaped product according
to 1, further comprising a fixing agent. [0017] 3. The inorganic
fibrous shaped product according to 2, wherein the fixing agent is
one or more selected from sulfates, nitrates, acetates and
hydrochlorides of each of aluminum, magnesium, calcium, sodium and
potassium. [0018] 4. A method for adjusting the hardness of the
surface of the inorganic fibrous shaped product according to any of
1 to 3, wherein the amount of at least one of an organic thickener
and a fixing agent is changed.
[0019] According to the invention, it is possible to provide an
inorganic fibrous shaped product that does not contain colloidal
silica and has various degrees of flexibility and hardness, and
heat resistance, and to provide a method for adjusting the hardness
thereof.
MODE FOR CARRYING OUT THE INVENTION
[0020] The inorganic fibrous shaped product of the invention at
least comprises prescribed inorganic fiber (hereinafter may often
referred to as the "specific inorganic fiber") and an organic
thickener. The inorganic fibrous shaped product of the invention
does not contain colloidal silica. Further, the inorganic fibrous
shaped product of the invention does not have to contain a metal
alkoxide, a glass raw material composition (borosilicate glass,
frit 3249 (manufactured by Ferro Corporation: 3.5% CaO; 12.2% MgO;
28.9% B.sub.2O.sub.3; 13.3% Al.sub.2O.sub.3; and 42.1% SiO.sub.2)
or the like), a sol (alumina borate sol or the like), and an
inorganic binder such as an acid alumina phosphate does not have to
be contained. Further, a thermosetting resin such as a phenol resin
and an epoxy resin does not have to be contained.
[0021] Organic thickeners include a natural thickener and its
derivative or a vinyl-based, vinylidene-based, polyester-based,
polyamide-based, polyether-based, polyglycol-based, polyvinyl
alcohol-based, polyalkylene oxide-based and polyacrylic acid-based
thickeners. Specific examples thereof include cellulose-based
thickeners such as CMC (carboxymethyl cellulose), MC (methyl
cellulose), albumin, casein, alginic acid, agar, starch,
polysaccharide, PVA (polyvinyl alcohol), PVB (polyvinyl butyral),
acrylic emulsion or the like. These may be used alone or in
combination of two or more. A polyacrylic acid-based thickener, a
cellulose-based thickener and starch are preferable. The shaped
product of the invention may contain an organic thickener in a
substantially un-molten state.
[0022] The inorganic fibrous shaped product of the invention may
further contain a fixing agent in order to allow an organic
thickener to be fixed to fibers. As examples of the fixing agent,
sulfates, nitrates, acetates and hydrochlorides of each of
aluminum, magnesium, calcium, sodium and potassium can be
given.
[0023] In order to allow flocs to be formed in a slurry, a
flocculant may be contained. A general-purpose flocculant may be
used, and the type and amount may appropriately be selected
according to the state of the resulting flocs. Flocculants are not
necessarily be contained.
[0024] The specific inorganic fiber used in the invention has the
following composition. The fiber having the following composition
has excellent biosolubility and fire resistance after heating.
[0025] SiO.sub.2: 66 to 82 wt %
[0026] CaO: 10 to 34 wt %
[0027] MgO: 3 wt % or less
[0028] Al.sub.2O.sub.3: 5 wt % or less
[0029] The total of SiO.sub.2, CaO, MgO and Al.sub.2O.sub.3 exceeds
98 wt %.
[0030] The following composition can preferably be exemplified.
[0031] SiO.sub.2: 66 to 82 wt % (it can be 68 to 80 wt %, 70 to 80
wt %, 71 to 80 wt % or 71 to 76 wt %, for example)
[0032] CaO: 10 to 34 wt % (it can be 20 to 30 wt % or 21 to 26 wt
%, for example) MgO: 3 wt % or less (it can be 1 wt % or less, for
example)
[0033] Al.sub.2O.sub.3: 5 wt % or less (it can be 3.5 wt % or less
or 3 wt % or less, or it can be 1 wt % or more or 2 wt % or more,
for example)
[0034] Other oxides: less than 2 wt %
[0035] If SiO.sub.2 is contained in the above-mentioned amount
range, the inorganic fiber has excellent heat resistance. If CaO
and MgO are contained in the above-mentioned amount range, the
inorganic fiber has excellent biosolubility before and after
heating.
[0036] The Al.sub.2O.sub.3 content can be 3.4 wt % or less or 3.0
wt % or less, for example, or it can be 1.1 wt % or more and 2.0 wt
% or more. The Al.sub.2O.sub.3 content is preferably 0 to 3 wt %,
more preferably 1 to 3 wt %. If Al.sub.2O.sub.3 is contained in
this amount range, a higher strength can be achieved.
[0037] The above-mentioned inorganic fiber may contain, as other
oxides, one or more selected from alkali metal oxides (K.sub.2O,
Na.sub.2O or the like), Fe.sub.2O.sub.3, ZrO.sub.2, P.sub.2O.sub.5,
B.sub.2O.sub.3, TiO.sub.2, MnO, R.sub.2O.sub.3 (R is selected from
Sc, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Y or a
mixture thereof) or the like. They need not be contained. The
content of each of other oxides may be less than 1.0 wt %, 0.2 wt %
or less or 0.1 wt % or less. As for the alkali metal oxide, the
content of each oxide may be less than 1.0 wt % or 0.2 wt % or
less, and the total of alkali metal oxides may be less than 1.0 wt
% or 0.2 wt % or less.
[0038] The total content of SiO.sub.2, CaO, MgO and Al.sub.2O.sub.3
may exceed 99 wt %.
[0039] The fiber having the above-mentioned composition is
biosoluble. In general, biosoluble fiber is fiber having a
physiological saline dissolution ratio at 40.degree. C. of 1% or
more.
[0040] The physiological saline dissolution ratio is measured by
the following method, for example. Specifically, first, 1 g of the
sample obtained by pulverizing inorganic fibers to 200 meshes or
less and 150 mL of physiological saline are put in a conical flask
(volume: 300 mL). This flask is placed in an incubator of
40.degree. C., and a horizontal vibration (120 rpm) is continuously
applied for 50 hours. Thereafter, the concentration (mg/L) of each
element contained in a filtrate obtained by filtration is measured
by an ICP emission spectrometry apparatus. Based on the measured
concentration of each element and the content (wt %) of each
element in inorganic fiber before dissolution, the physiological
saline dissolution ratio (%) is calculated. That is, if the
measurement elements are silicon (Si), magnesium (Mg), calcium (Ca)
and aluminum (Al), the physiological saline dissolution ratio C(%)
is calculated in accordance with the following formula:
C(%)=[Amount of filtrate (L).times.(a1+a2+a3+a4).times.100]/[Weight
(mg) of inorganic fiber before
dissolution.times.(b1+b2+b3+b4)/100]. In this formula, a1, a2, a3
and a4 are respectively the measured concentration (mg/L) of
silicon, magnesium, calcium and aluminum and b1, b2, b3 and b4 are
respectively the content (wt %) of silicon, magnesium, calcium and
aluminum in the inorganic fiber before dissolution.
[0041] As the method for producing the above-mentioned inorganic
fiber, known methods such as the blowing method and the spinning
method can be mentioned.
[0042] The inorganic fibrous shaped product may contain other
inorganic fiber in addition to the above-mentioned specific
inorganic fiber. Among 100 parts by weight of the inorganic fiber,
the content of the specific inorganic fiber may be 50 wt % or more,
60 wt % or more, 80 wt % or more or 100 wt %.
[0043] Refractory fiber composed mainly of silica and alumina
(silica: 4 to 60 wt %, alumina: 40 to 96 wt %), rock wool (for
example, the SiO.sub.2 content is 30 to 50 mass %, the
Al.sub.2O.sub.3 content is 10 to 20 mass %, the MgO content is 1 to
10 mass %, the CaO content is 20 to 40 mass %, the Fe.sub.2O.sub.3
content is 0 to 3 mass % and the MnO content is 0 to 1 mass %),
carbon fiber, slag wool, glass wool, silica fiber, silicon carbide
fiber, boron nitride fiber, zirconia fiber, calcium silicate fiber,
and other natural mineral fiber can be given.
[0044] The inorganic fibrous shaped product may contain inorganic
powder, anti-foaming agents, pH-adjusting agents or the like.
[0045] The content of an organic thickener is normally 0.01 to 60
parts by weight, preferably 0.1 to 30 parts by weight, more
preferably 0.5 to 20 parts by weight, and further preferably 1 to
15 parts by weight, when the total content of all of the inorganic
fiber contained in the shaped product is taken as 100 parts by
weight. If the content of an organic thickener is 60 parts by
weight or more, dehydration forming becomes difficult. If the
shaped product is used at high temperatures, organic components may
cause a gas to be generated. Therefore, the content of an organic
thickener may be appropriately adjusted such that the inorganic
fibrous shaped product can exhibit its function or can satisfy
required properties according to applications.
[0046] A fixing agent may normally be contained in an amount of 0
to 10, preferably 0.5 to 10, and more preferably 1 to 7, if the
content of an organic thickener is taken as 1. In the shaped
product of the invention, a fixing agent is normally contained in
an amount of 0 to 20 parts by weight, preferably 0.01 to 15 parts
by weight, more preferably 0.5 to 10 parts by weight and further
preferably 1 to 10 parts by weight, if the total content of the
inorganic fiber is taken as 100 parts by weight. The total of an
organic thickener and a fixing agent is preferably 0.1 to 30 wt %,
preferably 1 to 20 wt %, preferably 1 to 15 wt % and preferably 1
to 10 wt %.
[0047] The organic fibrous shaped product may be configured such
that the total content of the inorganic fiber and the organic
thickener (if organic powder and/or a fixing agent are contained,
the total content of the inorganic fiber, the organic thickener,
the inorganic powder and the fixing agent) becomes 90 wt % or more,
95 wt % or more, 98 wt % or more, 99 wt % or more or 100 wt %.
[0048] The inorganic fibrous shaped product is preferably in the
shape of a fabric such as a felt or in the shape of a flexible
sheet. The shaped product such as a felt can be used as a single
body without the need of scattering, applying or stacking other
materials on the surface thereof. The shaped product having
flexibility or cushion properties can change its form easily, and
therefore, can be pushed into a gap between joints easily, for
example. The thickness is not particularly restricted, but is
normally 5 mm or more, preferably 10 to 50 mm.
[0049] The hardness and flexural strength of the inorganic fibrous
shaped product of the invention can be appropriately adjusted
according to applications by changing the amount of an organic
thickener and/or a fixing agent. With an increase in the amount of
an organic thickener and a fixing agent, the organic fibrous shaped
product has higher hardness.
[0050] The surface hardness of the inorganic fibrous shaped product
in the normal state (unheated) varies depending on the application,
but is normally 1 to 60.degree.. The method for measuring the
surface hardness is described in the Examples.
[0051] Further, a flexural strength in the normal state of 0.03 to
0.6 Mpa is preferable since the handling properties and the working
accuracy of the inorganic fibrous shaped product are improved. The
method for measuring the flexural strength is described in the
Examples.
[0052] The heat shrinkage of the inorganic fibrous shaped product
after heating at 1100.degree. C. for 24 hours is preferably 2% or
less, more preferably 1% or less. The heat shrinkage can be further
lowered by using the above-mentioned specific inorganic fiber
having a low heat shrinkage and by appropriately combining an
organic thickener and a fixing agent. The method for measuring the
heat shrinkage is described in the Examples.
[0053] The shaped product can be produced by a known method such as
dehydration forming or the like. For example, it can be produced by
a method in which a raw material containing the inorganic fiber and
an organic thickener and a dispersion medium are mixed to form a
slurry, the slurry is flown in a die to conduct forming, and the
formed product is dried. Drying is preferably conducted at a
temperature that is not higher than the melting temperature. The
shaped product of the invention can be produced by using a used
shaped product. However, since it is difficult to control the
amount of an organic substance, normally, a used shaped product is
not used. If the amount of an organic substance is large, a large
amount of gas is generated when heating.
[0054] When dehydration forming is conducted, a slurry is produced
by mixing components with a solvent. The amount of a solvent is
normally 1000 to 100000 parts by weight, preferably 1500 to 80000
parts by weight, and further preferably 2000 to 60000 parts by
weight, when the total amount of all inorganic fiber contained in
the shaped product is taken as 100 parts by weight.
[0055] Normally, water is used as the solvent. A polar organic
solvent may be used, or may be added partially, but water is
preferable as the solvent. As for water, one that is normally used
on the industrial basis may be used, and examples of usable water
include distilled water, ion exchange water, tap water, groundwater
and industrial water.
EXAMPLES
Examples 1 to 16
(1) Production of Felt
[0056] Inorganic fiber A comprising 73 mass % of SiO.sub.2, 24 mass
% of CaO, 0.3 mass % of MgO and 2 mass % of Al.sub.2O.sub.3 and an
organic thickener selected from CMC (organic thickener), starch
(organic thickener) and an acrylic emulsion (organic thickener)
were mixed with water in amounts shown in Tables 1 to 3, whereby a
raw material slurry was prepared. As for CMC or starch, the
concentration of solid matters had been adjusted to 0.5 to 5% in
advance, and CMC or starch was added in the state where it was
fully dissolved or swollen in water.
[0057] In Tables 1 to 3, as for the amount of components other than
the inorganic fiber, the amount is indicated in terms of part by
weight when the amount of the inorganic fiber A is taken as 100
parts by weight. Water was used in an amount of 3000 parts by
weight when the amount of the inorganic fiber A is taken as 100
parts by weight.
[0058] This raw material slurry was flown in a forming die in which
a net was provided in the bottom part thereof. The water contained
in the raw material slurry was sucked and removed through the net
of the forming die. Thereafter, the dehydrated raw material was
dried by heating in a drier, whereby felts each having a thickness
of 25 mm were obtained.
(2) Evaluation of Felt
[0059] The following evaluation was conducted for the resulting
felts. The results are shown in Tables 1 to 3.
(i) Heat Shrinkage
[0060] A sample (length: 150 mm, width: 50 mm) taken out from the
felt was fired at 1100.degree. C. for 24 hours. Before and after
the firing, the length in the longitudinal direction was measured,
and the heat shrinkage was obtained according to the following
formula:
[(Measured value before heating-Measured value after
heating)/Measured value before heating].times.100
(ii) Flexural Strength
[0061] For a sample (length: 150 mm, width: 50 mm) taken out from
the felt, the breaking load thereof was measured by using a
three-point bending testing machine (Tensilon). The flexural
strength was calculated according to the following formula:
Bending strength (MPa)={3.times.maximum load (N).times.distance
(mm) between the centers of support rolls}/{2.times.width (mm) of
insulating material.times.(thickness (mm) of insulating
material).sup.2}
(iii) Hardness
[0062] The pressure surface of an Asker Durometer Type C was
brought in contact with the surface of the felt that was held
horizontally such that the indenter point of the durometer became
vertical to the felt surface. The scale of the durometer was
immediately read. An average value of measurement values at 5
locations was taken as the hardness)(.degree.) of the test
piece.
TABLE-US-00001 TABLE 1 Example 1 Example 2 Example 3 Example 4
Example 5 Example 6 Inorganic fiber Inorganic fiber A 100 100 100
100 100 100 Organic thickener CMC 1 3 5 7 10 15 Starch Acrylic
emulsion Fixing agent Aluminum sulfate Heat shrinkage 1100.degree.
C. .times. 24 hr 0.20 0.00 0.60 0.40 0.5 0.4 Flexural strength
Unheated 0.03 0.02 0.04 0.07 0.1 0.2 Hardness Surface 3 15 23 25 35
50
TABLE-US-00002 TABLE 2 Example Example Example 7 Example 8 Example
9 10 11 Inorganic fiber Inorganic fiber A 100 100 100 100 100
Organic thickener CMC 5 5 5 5 5 Starch 1 3 5 7 10 Acrylic emulsion
Fixing agent Aluminum sulfate Heat shrinkage 1100.degree. C.
.times. 24 hr 1.6 1.2 1.2 1.4 1.5 Flexural strength Unheated 0.04
0.05 0.03 0.05 0.06 Hardness Surface 5 6 11 13 15
TABLE-US-00003 TABLE 3 Example Example Example Example Example 12
13 14 15 16 Inorganic fiber Inorganic fiber A 100 100 100 100 100
Organic thickener CMC 5 5 5 5 5 Starch Acrylic emulsion 1 3 5 7 10
Fixing agent Aluminum sulfate Heat shrinkage 1100.degree. C.
.times. 24 hr 1.2 1.2 1.2 1.2 0.6 Flexural strength Unheated 0.05
0.13 0.17 0.2 0.24 Hardness Surface 8 12 28 32 40
Comparative Examples 1 to 3
[0063] The components shown in Table 4 were mixed in amounts shown
in Table 4. The mixture was subjected to dehydration forming to
produce formed bodies (board) each having a thickness of 25 mm.
Evaluation was conducted in the same manner as in Example 1. The
results are shown in Table 4.
[0064] The inorganic fiber B comprises 53 mass % of SiO.sub.2 and
47 mass % of Al.sub.2O.sub.3.
TABLE-US-00004 TABLE 4 Com. Ex. Com. Ex. Com. Ex. 1 2 3 Inorganic
fiber Inorganic fiber A 100 100 Inorganic fiber B 100 Organic
thickener CMC Starch 3 4.5 4.5 Inorganic binder Colloidal silica 10
5 5 Fixing agent Aluminum sulfate Flocculant 2 0.5 0.5 Heat
shrinkage 1100.degree. C. .times. 24 hr 1.00 3 2.1 Flexural
strength Unheated 0.80 0.5 0.5 Hardness Surface 55 50 50
Examples 17 to 36
[0065] The components shown in Tables 5 and 6 were mixed in amounts
shown in Tables 5 and 6. Felts each having a thickness of 25 mm
were produced and evaluated in the same manner as in Example 1. The
results are shown in Tables 5 and 6.
TABLE-US-00005 TABLE 5 Example Example Example Example Example
Example Example Example 17 18 19 20 21 22 23 24 Inorganic fiber
Inorganic fiber A 100 100 100 100 100 100 100 100 Organic thickener
CMC 5 5 5 5 5 5 5 5 Starch Acrylic emulsion Fixing agent Aluminum
sulfate 0 0.25 0.5 1 2 3 4 5 Heat shrinkage 1100.degree. C. .times.
24 hr 1.02 1.05 0.79 0.82 0.59 0.61 0.68 0.77 Flexural strength
Unheated 0.03 0.06 0.07 0.07 0.21 0.25 0.38 0.4 Hardness Surface 4
6 8 9 35 32 33 45 Example Example Example Example Example Example
Example Example 25 26 27 28 29 30 31 32 Inorganic fiber Inorganic
fiber A 100 100 100 100 100 100 100 100 Organic thickener CMC 3 3 3
3 1 1 1 1 Starch Acrylic emulsion Fixing agent Aluminum sulfate 1.8
4 6 7 0.5 1 2 3 Heat shrinkage 1100.degree. C. .times. 24 hr 0.58
1.13 0.60 0.62 -0.27 0.25 0.73 0.67 Flexural strength Unheated 0.19
0.33 0.47 0.50 0.02 0.03 0.04 0.04 Hardness Surface 23 35 40 48 2 1
4 5
TABLE-US-00006 TABLE 6 Example Example Example Example Composition
33 34 35 36 Inorganic fiber Inorganic fiber A 100 100 100 100
Organic thickener CMC 5 5 5 3 Starch Acrylic emulsion Fixing agent
Aluminum nitrate 1 2 3 2 Heat shrinkage 1100.degree. C. .times. 24
hr 0.76 0.78 0.73 0.89 Flexural strength Unheated 0.12 0.31 0.49
0.14 Hardness Surface 19 38 45 21
[0066] From Tables 1 to 6, it can be understood that the felts of
the Examples can have appropriate values of heat shrinkage,
flexural strength and hardness without using an inorganic binder.
The heat shrinkage of the felts is equivalent to or smaller than
that of the boards, and the flexural strength (flexibility) of the
felts is equivalent to or smaller than that of the boards. Further,
it can be understood that the hardness of the felt can be increased
to a level that is equal to that of the board by increasing the
amount of an organic thickener or the amount of a fixing agent and
an organic thickener.
INDUSTRIAL APPLICABILITY
[0067] The inorganic fibrous shaped product of the invention can be
used in various applications as a joint filler in a heat treatment
apparatus, an industrial kiln or an incinerator; a joint filler
that fills a gap of refractory tiles, heat-insulting bricks, shells
and refractory mortars, a sealing material, a packing material, a
heat insulating material or an alternative to asbestos.
[0068] Although only some exemplary embodiments and/or examples of
this invention have been described in detail above, those skilled
in the art will readily appreciate that many modifications are
possible 2 0 in the exemplary embodiments and/or examples without
materially departing from the novel teachings and advantages of
this invention. Accordingly, all such modifications are intended to
be included within the scope of this invention.
[0069] The documents described in this specification and the
Japanese application specification claiming priority under the
Paris Convention are incorporated herein by reference in its
entirety.
* * * * *