Document R2JOYZYDX3Vzxd94Bg7Bq53V8

PLAINTIFF'S EXHIBIT GF-1566 ** /0/7/7/ ' W-b65 CALCIUM SILICATE THAmAL OSULATIOR KEOTCRCED WITH _______________CSLLUL06IC FIBERS_____________________ life' BAUfiWHMP OP THE 1RVIHTIM 1. Plaid of the Invention this Invention relates to hydrous ealclvn silicate Insulation for high tsnpsraturo uaa. Dm Insulation of this Invention la frss Iron asbestos or other Inorganic fibers such as glass. \ 2. Discussion of Prior Art She preparation and use of ealelta sillcats tbernal Insulation 10 naterlals la vall-kncsm and dsserlbsd In dstall In a nwbsr of prior art patents such as D.B. 2,(99,197, 2,716,070 and 9,5MjOfci process - Involves the reaction of Has and siliceous notarial niSnjtffiune of re inforcing fibers to alnlnlte cracking and fracture during aanufacture, shipping and uaa. Por the preparation of insulation suitable for high 15 temperature the prior art describes Inorganic fibers, such as asbestos and glass fibers which becone air-borne during fabrication, installation and use of tbs Insulation. U.8. 3,1*72,668 describee a stellar calclue silicate product except that the reinforcing means consist of Inorganic glass fibers coated with various resins. 20 Such Insulation la produced censercially today In largs quanti ties and used ter thereal Insulation of pipes, tanks, boilers and. tbs like. The ccnerdally available product generally contains 8-15% asbestos fiber and has a density of about 12-15 lbs. per cubic ft. lbs asbestos fiber le generally eaoelte, however cbryiotlle can be need alone, or In 25 coahlnetlon. although these prior art products have served well as Insulatlon naterlals, unfortunately In recent years such concern has developed oo the part or asdics! researchera over the part that Inorganic fibers^ such as asbestos and glass, nay play la tbs dsvslopaast of Inng cancer and aabestosls. As a result of developing sun own ewer Inergnnle fibers as a potential health hasard, legislation has baea Introduced la a aunbar of MICH07675 I itvhleh seek to Halt thi use of aatarlals containing Incc-genlc fibers Id certain appllcatlona. It la aa object of this invention to jrcrlde new claaa of high temperature insulating neterlale which eliminate tba health baxarda created hf ** use at Inorganic flbara. 5 samrr or the ntramai Id accardaaca vltb tbla Invention -there la prorlded a calclua silicate lneulatlcu for blgb temperature use, where the surface tempera tures of the Insulation are aalDtelned at about 100-200F, wherein all the Inorganic fibers eucb as aabestos and class ere replaced by eelluloslc 10 fibers aa defined ears fully hereinafter.- She jroduct of this Invention therefore* eliminates all queetlcna regarding health bexarde dae to I Inorganic fibers since tba resulting product is fibers. Also tba uaa of eellulosle fiber In place-ofj -reinforcing nsdia reduces the mar on processing i 15 cutting and fabricating tools employed tgr applicators. It le believed that this la the first tine that such ealluloelc reinforcing neterlele have been used In a high temperature calclua silicate insulating material, by high temperature, aa uaad In this Invention, la cent Insulating products suitable for uses wherein tba aurfaca tempera20 tures rang* from about 3$0 up to 1250^7 and tberafare sure designed to set tbe upper Unit. as'.ymj is3iync or the gmnew / Ibe novel eelelua silicate Insulating materials of.this lnren* tlon are prepared tgr nixing line, allies end tips eelluloslc'flbers Is aa V >' 25 aqueous nedlm to provide an aqueous line-silica slurry vhlch reacts to . 7r fops gal. mtar pressing, nerves excess eater and forces tbe material Into Its daaired shape. Ma eat product Is then autoclaved to produce a desired crystalline end product suitable far use In high teeparatore Insulating applications upon drying. 30 Sha reaction of silica and Una to fan a hydratad calclua silicate la well-known and therefore tba general reaction condition* and -2- MICH07676 -------------------"1 xenetsnt. curc<r>*ratlons described Id the friar art can he utilised. Sea I for example U.S. 2,716,070 and/or U.8, 2,699,097- The preperetloc of tbs novel high temperature insulation of this invention require* certain re action conditions and ja mentions to Obtain optimum results in preparing an and product suitable for high tsmpai stive Insulating application. These reaction conditions and proportions conatltuto profaned embodiments of the subject invention. Therefore, although the solar ratio of lias to silica can gener ally fall rlthln a range of from about 1.0:1.0 to about 1.0:1.5, It baa 10 been found desirable la carrying out the preparation of theme1 insulating nstarlnla utilising tbs novel cellulosic reinforcing fibers of this Inven tion to employ a solar ratio of lint to silica of about JU0&.25 . The aaount of water employed in preparing the lea slurry baa been found to fall within a water to solids retloof 3:1 to 1$ about 20:1 . Optima results have been obtained with n water to solids rstlo of about 16:1 . In subjecting the line-sillcs fiber slurries of this invention to a predetermined Indurating tanparature and pressure to achieve complete reaction to tbe desired crystalline hydrous calcium silicate end product, 20 It Is preferred that the autoclave pressures range from about 12$ paig to about 175 paig and that pressure of about 150 paig be employed. 1 Tbe following examples core fully demonstrate the subject invention. In these example* all parts and percentage* shown are by weight. 29 BIWM 1 An aqueous mixture of ITT parts bleached sulfate wood pulp (j||hpitate J" eelluloeic pulps) end 1049 perts dlatomeceous earth Jolt hi COrefco hicallt*677_:L*e) Is prepared. This mixture, preheated to about 200r, end an aqueous mixture containing 699 parts of calclim hydroxide 30 at a temperature of about 150f is added to m v-ew containing sumdent eater, preheated to shout BxPr, to result in a water to solids ratio of abort 16:1 upon completion of said addition. Tbe -3- t MICH07677 i resulting slurry It maintained at a temperature of about 19O-200f for about cos hour undar continuous alow agitation at about b 1WK. Upon con* pletlon of this cycle, gslatlon ban occurred. Tbe galled .slurry la then deeatcred by uaa of a filter press to preside 12x36x1$ block and\Jxl pipe 5 covering noldad. These shaped places are tben Indurated In a high pressure staaa autodare at 150 palg far about flee boors. Thereafter tbe auto- clased products axe dried In a forced-draft hot air dryer, after which the products are trlaved end ready for packaging. "Rayofate J" la a ebealeal wood pulp prepared tgr digestion of wood 10 using tbe sulfate pPp<"g process. i ** Mined and refined by tbe Oeneral Befractorles Co. jtOrsffl^J.^ muout e "T The procedure of Bsanple 1 Is repeated In 4rraj^^n^^t with the-exception tbet Iff parte of enoelte asbestos (K grade) are utilised 15 In place of tbe bleached sulfate calluloalc pulp of Kxasple 1. Tbe following table demonstrates the results obtained with the two formulations and tbe relationship of each to currant federal Bpacif ications IB-1-523 (relating to the physical and strength characteristics Unite for high temperature insulation naterlals). 20 Table I (12" x 11/2" x 36" Block) Density - lbs./ft.3 Modulus - lbs./in.2 Bxaapls I 12.7 168 Exannle II 12.9 lho 13 nax. 35 nln. Impact - ft .lbs. 17 lk --- 25 Compareasl-se - (56 deformation) 230 lbe./ln. 186 -- 12VfiT. Soaking Beat LI--r Btelotaft W*ibt Lm* 30 k-factor g 500T naan 1.3 X.l 0.`> 1.5 9-5 0.50 ' 2.0 12.0 0.60 It can be seen from Sable 1 that the test material (Kxampls I) MICH07678 <*^m^** tiiK8urd co reiki product. The tact Material ae thei equiranoirts of 19-1>523 is all roapacts except far lose la velpht aftar anatlng beat at 1250f, vbleb la to be expected alaea the orpanic eelluloale fiber baa laaa tsoperators raalotaaee than asbestos fiber. This high loaa la anight la not dacnnd significant considering tba goad K-fectar values obtained. The important shrinkage eharaetarlatlc la not affected tp tba uae of eelluloale fiber. It la alao obvloua from i erarlnation of tba Modulus, coepreaalre and lepaet data tbat tba teat aaterlal baa excellent, and ear* tbaa adequate, strength ebaraeterlatlea 10 for shlpplag and installation requirementa, baaed on extensive field exper ience with tba ataadard product. la order to evaluate ln-eemee performance, ai propertlea waa aada aftar soaking beat conditioning In :i at $00, 750, 1000 aad 12$0r for alx hours. Thie detail 15 la tabla II. Table II Ixanple I 5ooy. Modulus - lbo./in. 2 20 5% Compressive - lbs./in.2 229 T$0r. Fxemple II 72 236 Modulus 3 J.3 Compressive 2lB 190 iooor. 5 k6 Compressive 202 236 mtpr. 6 28 Compressive 200 19b 30 Tbe results Indicate a substantial drop-off In modulus, but tba eowpreaalvn strength at Jt deformation la essentially unchangad, and equal, -5- rtrs>'~i'iu II~ aafoak- --la - s *i >- - MICH07679 throughout tbs temperature usage range. Ibe Insulation products of this Invention In all jase - . , a Depressive strength at 55 deformation of at least 175 pal ef. tr soaking beat conditioning at 1250F for six bours. Baaed on Industry experience, strength rsgulramants, as neasurad by aodulua, are aucb greater during shipping and Installation than after Installation. In tag event. It la nia practice to apply enough thick ness of Insulation to provide an outer lnaulatloo surface tenperature not arraadlai 150f, eo that beat loaa Is nlnlmJaad and paraoonal are protected froa aevara horns. Tbls praetlca 1U always result in tbs mtar portion 10 of the Insulation maintaining Its Initial strength characteristics since It la subjected to temperatures of 350*375? during tbe autoclaving and drying operations la manufacture. Vo further establish performance, 12* x C'l%*andLpe covering aade with celluloslc fiber In accordance with Xzampie'^^M'epplied to 15 c section of 12" pipe operating at a temperature of 6l5? In a power housa. Periodic Inspection of this Installation Indicates satisfactory perforaanee. Surface temparaturo of the Insulation la apjraxlaately 125P* Similar results have bean- obtained with pipes operating at 1000F and 1200P. In preparing the novel reinforced celluloslc fiber Insulating 20 materials of this Invention, It baa bean found that eelluloelc fibers which are free from Impurities that Interfere with tbe gelation reaction of tbe line and allies must be employed. It le preferred that tbe cellu loslc fibers have been refined to result la substantial fraadoa from lignins, wood augera and other Impurities that Interfera with tbe forma 25 tion of hydrous calcium silicate. Ixamplee of these celluloslc materials are rhanlral wood pulps aucb as blaaebed or unhlaaebed sulfata or sulfite Jgap.. It la preferred that tbe eelluloelc fibrous aaterlsls ba present In as anoint ranging froa about 5 to JOg of tbe total wight of tbe solids 30 content. Optima results have been obtained In tbe ores of about 10-155 eelluloelc content, which results in an end product having s density Cpcf) of about 12.5 end e compressive strength of about 230 (pal) at 55 detona tion. -6- MICH07680 I CUPS: I 1. A thermal Insulation sultablr for aa a; taaperature's up to 12502 comprising a body alaesnt sssantlally consisting of the reaction products of cslrlia hydroxide and sUleaous aatarlal together with 5 reinforcing cellulose fibers, the celluloslc fiber content of said body being free about 55 to about 305 bjr might of tbs total weight thereof. 2. Tbs composition of claim 1 whereIs aald fiber content'lb 105 '.to 155 and tbs compressire strength at $5 information of aald elenant la at 10 least 175 pel after soaking bant conditioning at 12502 for alx hours. 3. Tbs composition of claim 2 wherein said siliceous material la i dlatonaeeous earth with an BlOg contest of nt least 6b5._a 4. The product of claim 3 baring a temperature reeletaS^Bsh that a thickness of Insulation 2 1/2 lncbss thick applied toWfcarfece bested 15 to approximately 6l5F results In a surface taeparcturc not exceeding 150with no appreciable cracking of the outar surface of anld Insulation. -7MICH07681