DESC:FORM 2
The Patent Act 1970
(39 of 1970)
COMPLETE SPECIFICATION
(Section 10; rule 13)
Title of Invention

HYDROPHOBIC CALCIUM SILICATE BASED THERMAL INSULATION COVER AND PROCESS OF PREPARATION THEREOF

APPLICANT:
Varsha Refractories Pvt Ltd.
4, Ground Floor, Kailash Apartment, Near Old RTO building,
Tapsey Pandey Compound, R.P.Road, Behind Gurudev Hotel, Near D Mart, Kalyan West, 421301

The following Specification is complete specification to the provisional application 202321061517 filed on 13-09-2023 describes the invention.

FIELD OF THE INVENTION
[0001] The present invention relates to an insulating system that provides a shield from varied environmental conditions. More particularly, an insulating system that works as a guard against a broad range of environmental conditions, extreme physical condition along with providing a durable alternative that withstand extreme thermal and water resistance in an environment friendly means.

BACKGROUND OF THE INVENTION

[0002] High temperature insulation is a type of insulation where the insulation is specifically designed for extreme temperature. The insulation layer minimizes the transfer of thermal energy proceeding from hot components and thus prevents the nearby components from the damage caused as a result of extreme high temperature. The insulation provided to hot components increases the service life of the nearby components and also reduces the risk of damage caused as a result of extreme high temperature. In many manufacturing industries including oil refinery, ceramic, petroleum, glass, automobile a very high temperature is achieved during the process of manufacturing. The heated surface of combustion engine reaches up to 1000oC. The transfer of heat from hot combustion engine to nearby components create safety risk to worker working inside the industry.

[0003] In order to ensure the safety of the worker inside the manufacturing industry, a wide range of insulation layer is available commercially. The commercially available methods of insulation include mineral wool, fiberglass, and ceramic fiber. The ceramic fiber has low mechanical resistance and the fine particles of ceramic cause health risk to the worker working inside the industry. Fiberglass thermal insulation is cost effective but due to the fragile nature of the insulation layer the insulation layer does not withstand high mechanical pressure. Mineral wool insulation layer installation process is a complex process. If the layer is not installed and cut in an appropriate way it can result in danger to the worker working inside the industry. Many insulation process involves spraying of insulation material over the surface required. In such cases the spray is applied over the external surface only where the insulation is required. But, in high moisture geography the external insulation layer applied immediately absorbs moisture, retain water and causes difficulty in drying. A lot of research is done to solve the problem of high temperature thermal and water resistance.

[0004] US20170129813 the cited patent describes gypsum panel which includes two cover sheets, and a layer of gypsum core, the gypsum core is prepared from slurry of pregelatinized starch, stucco, and water, the panel shows thermal resistance of up to 850oC and the panel is added with siloxane to make it water resistant. The, stucco includes alpha calcium sulfate hemihydrate, beta calcium sulfate hemihydrate, water-soluble calcium sulfate anhydrite, starch, fibre, phosphate, foam, coversheet, and siloxane. A thermal resistance of up to 850oC is achieved. The method described is the complex one whereas, the thermal and water resistance is achieved by two layers of cover sheets and a layer of gypsum core. Thus, not applicable in cases where single layer of insulation is required.

[0005] US20190375685A1 the cited patent describes magnesium oxychloride cement (MOC) which includes magnesium oxide, magnesium chloride, water, filler coated with water repellent like silicone, silane and phosphate salt. The vermiculite added gives a heat resistance of 1100oC. The construction board prepared by MOC cement includes at least one metallic mesh/perforated thin metal sheet. The application of thermal and water-resistant cover is not applied at all places due to the presence of metal mesh/perforated thin metal sheet. Thus, the cited patent does not provide thermal and water resistance at places where the metallic mesh/perforated metal sheet cannot be applied in order to provide an insulation.

[0006] US7700505 the cited patent describes gypsum board and it comprises calcium sulfate including anhydrous calcium sulfate, semi hydrated calcium sulfate in alpha/beta crystalline form. The fire-resistant additives added are gypsum board, vermiculite, clay, colloidal silica, colloidal alumina and shows thermal resistance. The water-resistant additives give water repellent properties. The cited patent document explains about a gypsum board have one mat facer which includes water resistant agent covered inner and outer ply, one gypsum core. The cited patent describes a board to provide thermal and water resistance. The cited patent is not applicable where insulation by means of board is not possible. Thus, high thermal, and water resistance to various manufacturing units is not possible with the cited patent.

[0007] US011267935B2 the cited patent describes about a polyurethane which shows water as well as thermal resistance. The polyurethane is added with fillers calcium carbonate, silica, aluminium trihydrate, calcium hydrate, and antimony trioxide. The polyurethane prepared by the cited patent provides water and heat resistance. The heat resistance of up to 110oF (43OC) is shown by the cited patent. Thus, a high temperature heat resistance along with water resistance is not provided by the cited invention.

[0008] US005399397A the cited patent shows that the synthetic calcium silicate is produced by the reaction of diatomaceous earth and lime. The synthetic calcium silicate is substantially free of adsorbed water and chemically-bound water. A specified quantity of getter material is mixed with the quantity of synthetic calcium silicate. The synthetic calcium silicate absorbs moisture or atmospheric constituent. The cited patent describes about synthetic calcium silicate, the synthetic calcium silicate absorbs moisture. The cited patent does not provide high temperature and water resistance thus not suitable where high temperature resistance and water repellent properties are required.

[0009] Thus, there is a need to develop a product that provide water resistant, high temperature insulation along with ease of installation. The ease of installation is provided by making a water-resistant thermal insulation product that does not absorb water in high moisture geography thereby prevents damage of product.

OBJECTS OF THE INVENTION

[0010] Some of the objects of the present invention, which at least one embodiment herein satisfies, are as listed herein below.

[0011] An object of the present invention is to overcome the drawbacks, limitations of conventionally available water-resistant materials.

[0012] Yet another object of the present invention is to provide an efficient hydrophobic cover that does not absorb water during application, thus prevents the damage of cover caused due to absorption of water.

[0013] Yet another object of the present invention is to provide an insulation cover that ensures high temperature resistance and water resistance without causing harm to the environment thus provides an insulation cover in an eco-friendly manner.

[0014] Yet another object of the present invention to provide a water resistant and high temperature insulation cover without causing much loss of water thus limits the loss of natural resources during the process.

[0015] Yet another object of the present invention to provide a finished water resistant and high temperature insulation cover that ensures ease of installation to the user thus saves the time of installation of the user.

[0016] Yet another object of the present invention is to provide an effective thermal resistance cover that is hydrophobic thus prevents the product from damage due to heat and water.

[0017] Yet another object of the present invention is to provide a cover which prevents damage from water as well as heat thus prevents the use of multiple covers applied by the user.

[0018] Yet another object of the present invention is to provide uniform hydrophobic and thermal insulation cover that does not cause damage to the product due to uneven insulation.

[0019] Yet another object of the present invention is to reduce the damage caused to the cover during the process of installation thus provide an economic yet effective alternative to the user.

SUMMARY OF THE INVENTION

[0020] The present invention generally relates to a hydrophobic calcium silicate based thermal insulation cover that restricts the damage caused due to moisture and high temperature along with providing ease of installation to the user. The invention ensures that the thermal, water-resistant cover is achieved by an environmentally friendly means by limiting the loss of natural resources.

[0021] In an aspect of the present invention a water-resistant thermal insulation cover comprises a slurry includes an inorganic hydroxide compound, an oxide and water, a reinforcing material includes paper pulp, mineral wool, glass, steel, bamboo, natural fibers, and multiple water-repellent chemical(s) including saturated monobasic acid, fatty acid and siloxane, the slurry is uniformly mixed and then cooked to form a block of desired dimensions, the reinforcing material is added to the cooked slurry to provide strength, stiffness, prevents deformation of the block, the water-repellent chemical(s) are added to ensure water-repellent property at inner as well as outer side of the block to obtain water resistant thermal insulation cover that provides heat resistance up to 1100OC.

[0022] Yet another aspect of the present invention, a hydrophobic calcium silicate based thermal insulation cover and its process of manufacturing involves mixing of an inorganic hydroxide compound and a metalloid oxide in a pit tank, water is added in pit tank and mixed with the inorganic hydroxide compound and the metalloid oxide appropriately, the mixture is stirred from top for uniform mixing, slurry is transferred to digester for cooking, the cooked slurry is transferred to blow down vessel (BDV), multiple reinforcing materials are added to blow down vessel (BDV) from a pulper, then stirring in blow down vessel (BDV) is performed for uniform mixing of mixture, then multiple water-repellent chemical(s) are added in blow down vessel (BDV) and are mixed uniformly, then the slurry is transferred to holding tank, a required quantity of the slurry is taken into slurry tank as per thickness and size of mold, the mold is pressed to form a block of desired thickness and size, the block is dried in drying oven and cut into required size to obtain water resistant thermal insulation cover.

[0023] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS:

[0024] The illustrated embodiments of the subject matter will be understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter of present invention.

[0025] Figure 1: Describes the process flow of preparation, packaging and dispatch of hydrophobic calcium silicate based thermal insulation cover.

[0026] A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION OF THE INVENTION

[0027] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit, and scope of the present disclosure as defined by the appended claims.

[0028] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details. Embodiments of this disclosure relates to the field of speech analysis and, more specifically, to systems and methods for enactment of visual speech using neural network. Also addresses challenges related to background noise, voice denoising, lip movements, and spectrogram processing, resulting in improved speech quality and intelligibility in various visual settings.

[0029] If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.

[0030] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.

[0031] The present invention relates to a hydrophobic calcium silicate based thermal insulation cover that provides insulation along with minimizing the harm caused by moisture and high temperatures while offering user-friendly installation. It achieves a thermal, water-resistant covering through eco-friendly methods, reducing the depletion of natural resources.

[0032] A water-resistant thermal insulation cover includes a slurry 302 of an inorganic hydroxide compound, an oxide and water. The oxide includes a metalloid. In a preferred embodiment the inorganic hydroxide compound is preferably calcium hydroxide. The slurry is added with a reinforcing material. The reinforcing material includes paper pulp, mineral wool, glass, steel, bamboo, and natural fibers. In a preferred embodiment mineral wool is 9.7% to 12.5%kg, the glass is 1.4%-4.1%kg, and the paper pulp is 1.6%-2%kg.

[0033] The slurry is added with multiple water-repellent chemical(s) including saturated monobasic acid, fatty acid and siloxane. The slurry 302 is uniformly mixed and then cooked to form a block 101 of desired dimensions. The reinforcing material is added to the cooked slurry 302 to provide strength, stiffness, and prevents deformation of the block 101.

[0034] The water-repellent chemical(s) are added to ensure water-repellent property at inner as well as outer side of block 101 to obtain water resistant thermal insulation cover that provides heat resistance up to 1100OC. In a preferred embodiment metalloid oxide includes boron oxide and silicon oxide.

[0035] The water-resistant thermal insulation cover exhibits bulk density of 290 kg/m3, flexural strength of 680 kN/m2, linear shrinkage strength of 0.9%.

Process of preparing water-resistant thermal insulation cover

[0036] The process of preparing water-resistant thermal insulation cover 100 includes various steps: initially an inorganic hydroxide compound and a metalloid oxide is collected in a pit tank. Water is added in pit tank and mixing of inorganic hydroxide compound, the metalloid oxide and water is performed. The water is added in 2.7 to 3 times Liter quantity to appropriately blend hydrated lime and silica in pit tank. Approximately 6 to 7 times liters water is added in slurry preparation vessel (SPV) 300 / mixing cone tank 200. In a preferred embodiment inorganic hydroxide compound includes calcium hydroxide, magnesium hydroxide, and sodium hydroxide compound.

[0037] Stirring 301 of the mixture is performed, stirring 301 is performed from top to ensure uniform mixing. Now, the slurry 302 is transferred to a digester 400 for cooking. The cooking is performed at 187 to 205OC temperature, 12 to 18 Kg/cm2 pressure and then cooking is performed for 2 to 5 Hrs. In a preferred embodiment the cooking is performed at 192 to 200 OC.

[0038] The cooked slurry 302 is transferred to blow down vessel (BDV) 500. After that multiple reinforcing materials are added to blow down vessel (BDV) 500 from a pulper. In a preferred embodiment the reinforcing materials are paper pulp, mineral wool, glass fibers and natural fibers. Then stirring is performed in blow down vessel (BDV) 500 for uniform mixing. After mixing water-repellent chemical(s) are added in blow down vessel (BDV) 500 and are mixed inside the vessel.

[0039] In a preferred embodiment the water-repellent chemical(s) include 4 to 6% w/w Silicate acid and siloxane. The water-repellent chemical(s) are saturated monobasic acid / fatty acid and siloxane in 50:50 ratio. In a preferred embodiment the water-repellent chemicals are allowed to mix for 12 to 16 minutes. Now, the slurry is transferred to holding tank 600. To prepare a mold the required quantity of slurry 302 is collected into slurry tank 801 as per mold thickness and size. The slurry passes through slurry line 700.
[0040] To prepare a mold, a mold is pressed to form a block 101 of desired thickness and size. For the preparation of mold cake formation press 800 is used. The mold is pressed at 75 to 90 kg/cm2 pressure. Block 101 is dried in oven. The block 101 passes through conveyer 900 for drying. The block 101 is dried at temperature 180 to 200OC. After drying, cutting of block 101 is performed as per required size to obtain water resistant thermal insulation cover. Drying is performed in a multilayer dryer 1000. The cutting process is performed in a cutting machine 1100. After cutting the block 101 is packed via stretch wrap 1200. Once the packing is done, the block 101 is stacked for storage 1300. After that the block 101 is dispatched 1400 for selling. To ensure minimal effect on natural resources and reduce the industrial effluents, the present process re-utilizes wastewater to reduce water pollution caused by industrial effluents and restrict use of water consumption required for the process.

[0041] In a preferred embodiment of the present invention the quantity of lime and silica used is in accordance with the actual percentage of -OH ions in hydrated lime and the percentage of silica available in the raw materials. Firstly, the raw materials are tested and based on the purity of raw material quantity is varied to obtain 45% kg of 100% pure hydrated lime and 40% kg of 100% pure silica The raw materials used are commercially available silica and hydrated lime from RA enterprise and limelight respectively. During the manufacturing process water is used for charging hydrated lime and silica. Initially silica is charged and then hydrated lime is charged. The process of charging hydrated lime and silica all the raw materials are kept in dry powder form.

[0042] In an embodiment of the present invention a total of 10 times the weight of raw materials liters of water is used in the process of preparation of water-resistant thermal insulation cover. Initially approximately 3 times liters of water is added for the preparation of slurry of lime and silica, whereas the remaining 7 times liters of water is added to slurry along with reinforcing material. In a preferred embodiment the reinforce material used is 11% of mineral wool, 2.8%kg of chopped glass and 1.8%kg paper pulp.

[0043] In a preferred embodiment of the present invention the plurality of water-repellent chemical(s) includes MB 100 WB Silicate Acid(5% w/w) and WR05 WB Siloxane (5% w/w). Here, MB 100 WB (5% w/w) exhibits efficient water repellent properties. It shows water repellent effect when used with calcium silicate without altering other properties like porosity, density and durability of Calcium Silicate.

[0044] In a preferred embodiment of the present invention the water is re-used to reduce industrial waste and ensure minimal impact on natural resources. The slurry is prepared in a colloidal state which is coagulated and is dewatered using a filter hydraulic press to separate solid contents from the water. The wastewater is allowed to settle and both the sludge and water are reused separately in batch preparation in a cyclic process. The steam that is vented out from the pressure vessels is used in reaction vessels are passed through heat exchangers to heat up the raw water before it is fed into the boiler and the cooled down steam is also reused for a new batch preparation.

[0045] In an embodiment of the present invention the process of drying of each block requires approximately 24 to 30 hours in multilayer dryer based on the environmental conditions and ambient temperature. The water-resistant thermal insulation cover exhibits thermal conductivity up to 1100OC and linear shrinkage. Water-resistance is determined by water soak test which showed moisture resistance, density, flexural strength, linear shrinkage, thermal conductivity.

Test Result: 1

S. No Sample Description Dimension
Thick Width Length
(In mm) (In mm) (In mm)
Number of covers manufactured
1. Sample 1 135 150 600 1900
2. Sample 2 50 150 600 976
3. Sample 3 25 150 600 2000

Test Result: 2
S. No Particulars Specified Values Results
1. Temperature Max Service Deg. C 1100°C 1100°C 1100°C
2. Bulk Density kg/m3 280 -320 290 280 - 320 290
3. Compressive Strength reduction in thickness % 4 (max) 2.75
3.1 Dry Under load 345 kN/m2 after 24 hrs heat soak
3.2 Dry Under load 415 kN/m2 3 (max) 2.90
3.3 Wet (After immersion in water for 18 hrs) underload 170 kN/ m2 4 (max) 3.10
4. Flexural Strength/ Cold Crushing Strength kN/ m2 600 (min) 680
5. Moisture Content % max 5.00 (max) 4.10
6. Alkalinity pH 8.00-11.0 8.4
7. Heat Soaking at 1050oC for 24 Hrs
7.1 Linear Shrinkage (length) % 1.3 (max) 0.9
7.2 Loss in Mass 10 (max) 5.4
7.3 Compressive Strength reduction in thickness underload 345 kN/m2 5% (max) 2.90
8. Thermal Conductivity at mean temperature W/m-k
300°C Mean Temp 0.076 (max) 0.070
400°C Mean Temp 0.090 (max) 0.082
500°C Mean Temp 0.098 (max) 0.089
550°C Mean Temp 0.110 (max) 0.105
9. Max dimensional tolerance in length /width / thickness -1.5, +3 mm

[0046] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are comprised to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF INVENTION

[0047] The advantages of cover of present invention includes:
1. Lightweight high temperature as high as 1100?
2. It shows water resistance
3. Shows significant mechanical strength
4. It has low shrinkage
5. Covers exhibit low thermal conductivity
6. Exhibits high thermal stability
7. Applicable in various industries including construction, ceramics, cement, chemical, glass, metal industries – Aluminum, Copper, galvanizing, passive fire protection, petrochemical, sugar, textile and many other industries.
,CLAIMS:WE CLAIM:
1. A water-resistant thermal insulation cover characterized in that comprises:
i) a slurry 302 includes an inorganic hydroxide compound, an oxide and water;
ii) a reinforcing material includes paper pulp, mineral wool, glass, steel, bamboo, natural fibers; and
iii) a plurality of water-repellent chemical(s) includes saturated monobasic acid, fatty acid and siloxane
wherein said slurry 302 is uniformly mixed and then cooked to form a block 101 of desired dimensions, said reinforcing material is added to said cooked slurry 302 to provide strength, stiffness, prevents deformation of said block 101, said water-repellent chemical(s) are added to ensure water-repellent property at inner as well as outer side of said block 101 to obtain water resistant thermal insulation cover that provides heat resistance up to 1100OC.
2. The water-resistant thermal insulation cover as claimed in claim 2 wherein, said mineral wool is 9.7% to 12.5%kg, said glass is 1.4 – 4.1%kg, said paper pulp is 1.6-2%kg.
3. The water-resistant thermal insulation cover as claimed in claim 1 wherein, said oxide includes a metalloid.
4. The water-resistant thermal insulation cover as claimed in claim 1, wherein said cover exhibits bulk density of 290 kg/m3, flexural strength of 680 kN/m2, linear shrinkage strength of 0.9%.
5. A process of preparing water-resistant thermal insulation cover comprises:
i. An inorganic hydroxide compound and a metalloid oxide in a pit tank;
ii. Adding water in pit tank and mixing said inorganic hydroxide compound, said metalloid oxide and water appropriately;
iii. Stirring the mixture of step ii, said stirring 301 is performed from top for uniform mixing;
iv. Transferring slurry 302 to digester 400 for cooking;
v. Transferring cooked slurry 302 to blow down vessel (BDV) 500;
vi. Adding reinforcing materials to blow down vessel (BDV) 500 from a pulper;
vii. Stirring blow down vessel (BDV) 500 for uniform mixing;
viii. Adding plurality of water-repellent chemical(s) in blow down vessel (BDV) 500 and allowing it to mix;
ix. Transferring slurry to holding tank 600;
x. Taking the required quantity of said slurry 302 into slurry tank 801 as per mold thickness and size;
xi. Pressing said mold to form a block of desired thickness and size;
xii. Drying said block 101 in drying Oven; and
xiii. Cutting said block 101 as per required size to obtain water resistant thermal insulation cover.

6. The process of preparing water resistant thermal insulation cover as claimed in claim 6 wherein, said water is added in 2.5 to 3 times Liter quantity to appropriately blend hydrated lime and silica in pit tank.
7. The process of preparing water resistant thermal insulation cover as claimed in claim 6 wherein, said water is 7-7.5 times liters added in slurry preparation vessel (SPV) 300 / mixing cone tank 200.
8. The process of preparing water resistant thermal insulation cover as claimed in claim 6 wherein, said cooking of step iv is performed at 187 to 205 OC temperature and 12 to 18 Kg/cm2 pressure will be maintained then cooking for 2 to 5 Hrs.
9. The process of preparing water resistant thermal insulation cover as claimed in claim 9 wherein, said cooking is preferably performed at 192 to 200 OC.
10. The water-resistant thermal insulation cover and process of preparing as claimed in claim 1 and 6 wherein, said reinforcing material is preferably paper pulp, mineral wool, glass fibers and natural fibers.
11. The water-resistant thermal insulation cover as claimed in claim 1 wherein, said metalloid oxide preferably includes boron oxide and silicon oxide.
12. The water-resistant thermal insulation cover and process of preparing as claimed in claim 1 and 6 wherein, said inorganic hydroxide compound includes calcium hydroxide, magnesium hydroxide, sodium hydroxide compound.
13. The water-resistant thermal insulation cover and process of preparing as claimed in claim 1 and 6 wherein, said water-repellent chemical(s) include 4 to 6% w/w Silicate acid and siloxane, said water-repellent chemical(s) are saturated monobasic acid / fatty acid and siloxane in 50:50 ratio, said chemicals are allowed to mix for 12 to 16 minutes.
14. The process of preparing water resistant thermal insulation cover as claimed in claim 6 wherein, said mold is pressed at 75 to 90 kg/cm2 pressure.
15. The process of preparing water resistant thermal insulation cover as claimed in claim 6 wherein, said block 101 is dried at temperature 180 to 200OC.
16. The process of preparing water resistant thermal insulation cover as claimed in claim 6 wherein, said process re-utilizes wastewater to reduce industrial effluents and water consumption.
Dated this 13th March 2024