Microfibrous composition comprising siliceous spicules of spongiaria, processes and equipment for obtaining them

Abstract: A microfibrous composition is described, particularly used for heat and sound insulation, which comprises an amount of siliceous spicules of spongiaria ranging from 70% to 99% by weight, based on the total weight of the composition. Further, the process and equipment designed to obtain said microfibrous composition are described. (end of abstract)

Agent: Alston & Bird LLP - Charlotte, NC, US
Inventor: Oswaldo Fritzons Junior
USPTO Applicaton #: #20070200083 - Class: 252062000 (USPTO)
Related Patent Categories: Compositions, Heat Or Sound Insulating

Microfibrous composition comprising siliceous spicules of spongiaria, processes and equipment for obtaining them description/claims

The Patent Description & Claims data below is from USPTO Patent Application 20070200083, Microfibrous composition comprising siliceous spicules of spongiaria, processes and equipment for obtaining them.

Brief Patent Description - Full Patent Description - Patent Application Claims

[0001] This application claims priority of Brazilian patent application No. P10304176-0, the disclosure thereof being hereby incorporated by reference.

[0002] The present invention relates to a composition of microfibrous texture essentially comprising siliceous spicules of spongiaria, as well as processes and equipment for obtaining them. Said microfibrous composition may be used, among other uses, for thermal insulation. The techniques involved in the making of it are related to the ceramic industrial sector and the sector of manufacturing artifacts for civil architecture.

[0003] Description of the Prior Art

[0004] Bodies composed by fibers, for example from animal hair, are mostly good thermal insulators. So, various products constituted by natural fibers are utilized. In the animal kingdom there are sheep wool, furs from rabbit and other animals. In the vegetable kingdom, there are wooden fibers, from which paper and cardboard are made, and other, such as cotton fibers to make various fabrics. In the mineral kingdom, there are products such as chrysotile, ordinarily called amianthus.

[0005] Various fibrous synthetic products have arisen and are good products for heat and sound insulation. Among them, polymeric fibers such as nylon and polyesters stand out. In a field of use for insulation designed for higher temperatures, glass fibers, "rock wools", calcium silicate fibers and also the so-called "ceramic fibers" have appeared.

[0006] In addition to the fibrous form, there are also insulants having high porosity, such as corks of vegetable origin, expanded polystyrene and polyurethane, besides kaolin-based and/or diatomite-based insulants.

[0007] Focusing now on the filed of high-temperature fibrous insulators, it can be noticed that amianthus is a very interesting product, but there is today serious restrictions to the use thereof, mainly due to questions of salubriousness. Since this product is expected to go out of the market, only the above-mentioned synthetic fibers will be left.

[0008] The glass fibers are relatively noble products and may be long, continuous or short filaments, of great chemical and physical homogeneity. They resist up to 800.degree. C. and are commercialized in webs, being relatively expensive.

[0009] The calcium silicate fibers are less expensive fibers, but are intended to be used at temperature no higher than 600.degree. C. They are also sold in webs or as semi-rigid aggregate products.

[0010] The "rock wools" are products derived from the basaltic rock melting. They sand temperatures around 800.degree. C. and are cheaper than glass fibers. They are commercialized in webs or in semi-rigid pieces. Such products today are often used in domestic and industrial ovens such as bakeries and also in insulation of solar heater.

[0011] The "ceramic fibers" are more refractive having types which stand temperatures from 1.250.degree. C. to 1.400.degree. C., being some of them able to stand even higher temperatures. They have, generally, silico-aluminous to aluminous composition, and their refractoriness increases according to the amount of aluminum comprised therein. There is also the pure silica fiber with good refractory properties. The costs of the manufacturing theses fibers depend on their deterioration resistance under high temperatures. Generally, all types of this fiber have good thermal insulation properties. However, theses fibers, under high temperatures, deteriorate by melting or get fragile by recristalization mainly of christobalite in the glass mass. The ceramic fibers are commercialized in long fibers constituting webs, or then, in short fibers, generally, aggregated by resin binding components constituting semi-rigid products.

[0012] Ceramic fibers exhibit, as a restriction to its use, low compression strength or bending strength, even in the so-called "rigid" products, and a high linear retraction of up to 8%, found in the first burning at temperatures of continuous use. In addition, such products are quite expensive with respect to other high-temperature insulators.

[0013] The microfibrous composition of the present invention comprises siliceous spicules of spongiaria (explained in greater detail later) and often look like synthetic products constituted by short ceramic fibers.

[0014] Siliceous spicules of spongiaria are cylindrical microneedles with length on the order of 500 .mu.m, thickness on the order of 10 .mu.m, essentially composed of silica. Such spicules can be qualified as fibers or microfibers due to said dimensions. Such terminology will be used hereinafter, in this context.

[0015] Said siliceous spicules of spongiaria are parts remaining from skeletons of colonies of certain organisms that are scientifically called sponges. Sponges are minute animals of aquatic life, which form colonies called spongiaria. Cyclically, the colonies die, releasing the spicules that are dispersed in the aquatic medium, settling on the beds of lakes or sea, and are then fossilized. This process, which occurs after tens or hundreds of years in the same biological medium, enables the formation of expressive deposits of these materials.

[0016] Important concentrations of spicules of sponges are found in sedimentary extracts of specific geological environments, always mixed with clays, sands and other materials predominantly of aquatic organic origin. Rocks rich in these materials receive the geological name "spongilites", being ordinarily known, in Brazil, as "barro de po de mico" or simply "mico" which corresponds to their appearance similar to fine hairs.

[0017] Ceramic products derived from materials constituted by siliceous spicules of spongiaria are widely known. By way of clarification, the following is reported: [0018] a) since before Brazil was discovered, certain indigenous tribes had already used materials derived from sponges in ceramic craftwork for making highly resistant pots intended for cooking food; [0019] b) in Brazil a pottery industry exists since centuries ago, which is based specifically on these materials. At present, it is estimated that in this country about 50,000 families make a living in this activity, scattered in small communities, some of them with over 5,000 inhabitants, always located near of around natural deposits; [0020] c) the ceramic pieces, made from these materials, being preferably bricks, are characterized by their high strength, their heat-insulation properties and some refractoriness; by virtue of these properties, they are used in civil architecture, in making ceramic furnaces, barbecues and charcoal-industry furnaces, among other possibilities. They are ordinarily known as "tijolos de mico" or "tijolos de po de mico"; [0021] d) the formulations used, for example, for making ceramic pieces are most varied, depending upon the availability of ores at the place or at the moment. So, according to the place or time, the production of pieces varies much from pieces very rich in microfibers with up to about 50% (by weight) to pieces very poor in microfibers with from 5% to 10%. Clays and sands, which occur close to the microfibers in ores, constitute the rest of the formulations, with few exceptions. These natural concentrations of microfibers of spongiaria are not sufficient for providing pieces with excellent heat and sound insulation properties.

[0022] Microfibers are considered the strong point of these materials. So, products having the useful properties, optimized from microfibers were developed, thus obtaining levels of industrial conformity that meet the present-day specific requirements. In order to achieve the results known today, the following steps were necessary: [0023] a--development of technology for beneficiation of ores leading to the separation of microfibers; [0024] b--multiple assays on formulations and development and optimization thereof; [0025] c--systematic studies involving the shaping of pieces and technical characterization of the microfibrous compositions obtained on laboratory scale; and [0026] d--development of technology for shaping and manufacturing artifacts on an industrial-production scale.

[0027] With the study of these materials over these years, it has been possible to obtain much purer concentrates thereof, that is to say, exhibiting high concentrations of spicules. With these concentrates, high-quality insulating pieces with the help of industrial shaping techniques can be made, which are also the object of the present invention.

OBJECTIVES OF THE INVENTION

[0028] An objective of the present invention is to provide a microfibrous composition comprising siliceous spicules of spongiaria, the amount thereof ranging from 70% to 99% by weight, based on the total weight of the composition. This amount is much higher than that already obtained in the prior art, and resulting in relevant improvements of the physico-chemical properties inherent in the pieces made with this composition.

[0029] Another objective of the present invention is to provide the processes and the respective equipment for obtaining the microfibrous composition aimed at.

BRIEF DESCRIPTION OF THE INVENTION

[0030] The objectives of the present invention are achieved by means of a microfibrous composition, particularly used for heat insulation and sound insulation, characterized by comprising an amount of siliceous spicules of spongiaria ranging from 70% to 99% by weight, based on the total weight of the composition.

Brief Patent Description - Full Patent Description - Patent Application Claims
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