CA1128257A - Self-hardening composition and composite therefrom - Google Patents
Self-hardening composition and composite therefromInfo
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- CA1128257A CA1128257A CA345,026A CA345026A CA1128257A CA 1128257 A CA1128257 A CA 1128257A CA 345026 A CA345026 A CA 345026A CA 1128257 A CA1128257 A CA 1128257A
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Abstract
ABSTRACT OF THE DISCLOSURE
A self-hardening composition consists essentially of 3-5% by weight of an alkaline earth metal chloride, 0.5-1.5%
by weight of calcium metasilicate, 0.5-1.5% by weight of sodium fluorosilicate, 30-40% by weight of sodium silicate, 0.02-0.04% by weight of aluminum silicate clay and water.
Composites made therefrom can include expanded aggregate material and/or reinforcing fibers, as extenders, or to impart control over the open curing time to preset requirements.
A self-hardening composition consists essentially of 3-5% by weight of an alkaline earth metal chloride, 0.5-1.5%
by weight of calcium metasilicate, 0.5-1.5% by weight of sodium fluorosilicate, 30-40% by weight of sodium silicate, 0.02-0.04% by weight of aluminum silicate clay and water.
Composites made therefrom can include expanded aggregate material and/or reinforcing fibers, as extenders, or to impart control over the open curing time to preset requirements.
Description
BACKGROUND OF T~lE INVENTION
Many adhesives and bonding compounds in pre.sen~ use are derived from pe-trocnemical or organic sources. These materials can emit toxic products or ignite in a fire, often resulting in ignition or degradation of particles bonded therewith to form further toxic products, exposure to which can be fatal in confined spaces.
Other bonding compounds adapted for composltions which will withstand extreme temperatures are kiln dried, fired or otherwise subjected to external heating to achieve satisfac-tory bonding, e.g., fired bricks, tiles, etc.
Vassilevsky et al, in U.S. Patent 3,483,006, describe a cold-curable cementitious composition composed of MgO or semi-calcined dolomite, magnesium sulfate, an alkaline earth metal chloride (XC12), an alkali metal silicate (Y2SiO3) and an alkali metal fluorosilicate (Y2SiF6). The cement comprises two complex substances: a Mg(Ca)-oxychloro-sulfate and the combination of XC12-Y2SiO3-Y2SiF6.
Gajardo et al tU.S. Patent 3,203,813) discloses an insulating material containing an aluminosilicate clay, a water-soluble alkali metal silicate, a foaming agent and an expanded siliceous inorganic aggregate, heated at 300-400F
to set the silicate.
Lyass et al (U.S. Patent 3,508,936) obtain a self-hardening mixture for foundry molds containing filler, sodium silicate as binder, dicalcium silicate as hardener, a foaming agent and an abietic resin to increase the strength of the mold.
, ~ '.
11~8Z~
Other references on siliceous cement or concrete products include:
3,138,471 Wygan-t 3,450,584 Petkus : 3,837,872 Conner 3,874,887 Dalmatov et al 4,030,939 Mallow OBJECT OF THE INVENTION
It is an object of the invention to provide a composi-tion for unsulating materials made by cold mixing variouscomponents to make a bonding compound that can be intermixed with particulate fillers such as expanded perlite, fiber gl~ss, mineral fibers or wools or diatomite to form a paste.
The paste can be molded, pressed or formed into structured products using conventional machines. The bonded products formed therefrom insulate against extremes of temperature but lose no bond strength and emit no toxic fumes when subjected to extreme heat or fires.
SUMMARY OF THE INVENTION
In a compositional aspect, this invention relates to ~ss~ ~;~/ly a self-hardening composition consistinglof 3-5% by weight of an alkaline earth metal chloride, 0.5-1.5% by weight of calcium metasilicate, 0.5-1.5% by weight of sodium fluoro-O ~
silicate, 30-40% by weight of sodium silicate, ~-4~r~ O- by weight of aluminum silicate clay and water.
~I~ZB~7 In a further compositional aspect o -this invention, self-hardening composites comprise 10-35% by weight o~ the foregoing composition, admixed with an expanded aggregate material or reinforcing fiber.
DETAIL~D DESCP~IPTION
"Alkaline earth metal chloride," as used in the speci-fication and claims, means MgCl2 or CaCl2 or a mixture thereof, preferably a 1:1 mixture thereof, represented by the formula CaC12.MgC12.
Calcium metasilicate is represented by the formula CaSiO3, whether in the d- (pseudowallastonite) or ~-(wollas-tonite) ~orm.
Sodium fluorosilicate, silicofluoride or hexafluorosili-cate is represented by the formula Na2SiF6.
"Aluminum silicate clay," as used in the specification and claims, includes non-expanding clays, of which kaolinite, halloysite, illite and attapulgite are exemplary. However, kaolin is preferred.
"Sodium silicate," as used in the specification and claims is generally represented by the formula Na2SiO3 and is also known as water glass or sodium metasilicate. Sodium silicate includes products having various ratios of Na2O:SiO2.
Typically, in the practice of this invention, sodium sili-cate is used in the form of a solution in which the SiO2:Na2O molar ratio is 1.65:3.9. Preferred sodium silicate with a specific gravity of 1.387 at ~99.3 per litre.
Solutions of sodium silicate used in the practice of this invention will contain about 30-40% of solids, i.e., solutions of above approximately 3~ Ba~ma will be ~sed.
Most preferably, the bonding compositions o this invention will contain 35-39% by weight of sodium silicate8. There-fore, sodium silicate solutions above approximately 39 Baumé will be used.
The self-hardening compositions of this invention are made by combining the solid ingredients, for example, with paddles or mechanically opposed rotating arms. To this is added sodium silicate solution. Mixing is continued until the product has an acceptable viscosity, preferably of the order of 26 centipoise at 68.4F. If the bonding composition is being used without fillers, the material is fabricated into the desired shape and permitted to set under ambient conditions. The time required for setting is dependent upon ambient temperature and open time required. Kule of thumb is 30 minutes at 60F ambient at which point the product has the following characteristics:
Conductivity is subject to fillers used and end product needs. As a rough guide, 25 m~ at 18 lb/ft3 will come out at 0.04-0.06 W/mC, or better. Low temperatures range down to minus 100C, or better, dependent upon known prior specifics. The bonded product has a hard rigid set and face. Natural color is pearl white. Crushing strength, '~ without any other additions apart from perlite and bonding compound, is 40 kg/in2. At the end of 1/3 hour, curing is complete as indicated by surface hardness.
Z~32~7 Because the compositlons of the inven~ion are sel-hardening, it will be understood that -the ingredients are mixed just prior to use. If desired, -the solid ingredients can be premixed and shipped dry. At the point of use, the solid ingredients can then be com~ined with sodium silicate solution.
In preferred embodiments, 10-35% by weight of the bond-ing composition is extended with an expanded aggregate material and10r reinforcing fiber material to provide fire-retardant lightweight air-curable composites.
"Expanded aggregate material," as used in the specifi-cation and claims, includes, but is not limited to, cellular perlite, vermiculite, cellular glass, expanded slag, -;
cellular diatomite and cellular pumice. ~owever, the fore-going are preferred, most preferably expanded or cellular perlite and cellular diatomite.
ReinfGrcing fibers include, but are not limited to, organic fibers and fiberglass. Fiberglass is preferred owi~g to resistance to combustion. Organic fibers include natural fibers such as cellulose and wood fibers and syn-; thetic fibers, e.g.~ from ~ to l~ inches in length.
In the practice of the invention, the filler being ; bonded is mixed with the cold sel~-hardening bonding composition to form a paste which is shaped by extrusion or pressing at 7-40 psi or higher pressures to the required shape, and predetermined product strength required.
Many adhesives and bonding compounds in pre.sen~ use are derived from pe-trocnemical or organic sources. These materials can emit toxic products or ignite in a fire, often resulting in ignition or degradation of particles bonded therewith to form further toxic products, exposure to which can be fatal in confined spaces.
Other bonding compounds adapted for composltions which will withstand extreme temperatures are kiln dried, fired or otherwise subjected to external heating to achieve satisfac-tory bonding, e.g., fired bricks, tiles, etc.
Vassilevsky et al, in U.S. Patent 3,483,006, describe a cold-curable cementitious composition composed of MgO or semi-calcined dolomite, magnesium sulfate, an alkaline earth metal chloride (XC12), an alkali metal silicate (Y2SiO3) and an alkali metal fluorosilicate (Y2SiF6). The cement comprises two complex substances: a Mg(Ca)-oxychloro-sulfate and the combination of XC12-Y2SiO3-Y2SiF6.
Gajardo et al tU.S. Patent 3,203,813) discloses an insulating material containing an aluminosilicate clay, a water-soluble alkali metal silicate, a foaming agent and an expanded siliceous inorganic aggregate, heated at 300-400F
to set the silicate.
Lyass et al (U.S. Patent 3,508,936) obtain a self-hardening mixture for foundry molds containing filler, sodium silicate as binder, dicalcium silicate as hardener, a foaming agent and an abietic resin to increase the strength of the mold.
, ~ '.
11~8Z~
Other references on siliceous cement or concrete products include:
3,138,471 Wygan-t 3,450,584 Petkus : 3,837,872 Conner 3,874,887 Dalmatov et al 4,030,939 Mallow OBJECT OF THE INVENTION
It is an object of the invention to provide a composi-tion for unsulating materials made by cold mixing variouscomponents to make a bonding compound that can be intermixed with particulate fillers such as expanded perlite, fiber gl~ss, mineral fibers or wools or diatomite to form a paste.
The paste can be molded, pressed or formed into structured products using conventional machines. The bonded products formed therefrom insulate against extremes of temperature but lose no bond strength and emit no toxic fumes when subjected to extreme heat or fires.
SUMMARY OF THE INVENTION
In a compositional aspect, this invention relates to ~ss~ ~;~/ly a self-hardening composition consistinglof 3-5% by weight of an alkaline earth metal chloride, 0.5-1.5% by weight of calcium metasilicate, 0.5-1.5% by weight of sodium fluoro-O ~
silicate, 30-40% by weight of sodium silicate, ~-4~r~ O- by weight of aluminum silicate clay and water.
~I~ZB~7 In a further compositional aspect o -this invention, self-hardening composites comprise 10-35% by weight o~ the foregoing composition, admixed with an expanded aggregate material or reinforcing fiber.
DETAIL~D DESCP~IPTION
"Alkaline earth metal chloride," as used in the speci-fication and claims, means MgCl2 or CaCl2 or a mixture thereof, preferably a 1:1 mixture thereof, represented by the formula CaC12.MgC12.
Calcium metasilicate is represented by the formula CaSiO3, whether in the d- (pseudowallastonite) or ~-(wollas-tonite) ~orm.
Sodium fluorosilicate, silicofluoride or hexafluorosili-cate is represented by the formula Na2SiF6.
"Aluminum silicate clay," as used in the specification and claims, includes non-expanding clays, of which kaolinite, halloysite, illite and attapulgite are exemplary. However, kaolin is preferred.
"Sodium silicate," as used in the specification and claims is generally represented by the formula Na2SiO3 and is also known as water glass or sodium metasilicate. Sodium silicate includes products having various ratios of Na2O:SiO2.
Typically, in the practice of this invention, sodium sili-cate is used in the form of a solution in which the SiO2:Na2O molar ratio is 1.65:3.9. Preferred sodium silicate with a specific gravity of 1.387 at ~99.3 per litre.
Solutions of sodium silicate used in the practice of this invention will contain about 30-40% of solids, i.e., solutions of above approximately 3~ Ba~ma will be ~sed.
Most preferably, the bonding compositions o this invention will contain 35-39% by weight of sodium silicate8. There-fore, sodium silicate solutions above approximately 39 Baumé will be used.
The self-hardening compositions of this invention are made by combining the solid ingredients, for example, with paddles or mechanically opposed rotating arms. To this is added sodium silicate solution. Mixing is continued until the product has an acceptable viscosity, preferably of the order of 26 centipoise at 68.4F. If the bonding composition is being used without fillers, the material is fabricated into the desired shape and permitted to set under ambient conditions. The time required for setting is dependent upon ambient temperature and open time required. Kule of thumb is 30 minutes at 60F ambient at which point the product has the following characteristics:
Conductivity is subject to fillers used and end product needs. As a rough guide, 25 m~ at 18 lb/ft3 will come out at 0.04-0.06 W/mC, or better. Low temperatures range down to minus 100C, or better, dependent upon known prior specifics. The bonded product has a hard rigid set and face. Natural color is pearl white. Crushing strength, '~ without any other additions apart from perlite and bonding compound, is 40 kg/in2. At the end of 1/3 hour, curing is complete as indicated by surface hardness.
Z~32~7 Because the compositlons of the inven~ion are sel-hardening, it will be understood that -the ingredients are mixed just prior to use. If desired, -the solid ingredients can be premixed and shipped dry. At the point of use, the solid ingredients can then be com~ined with sodium silicate solution.
In preferred embodiments, 10-35% by weight of the bond-ing composition is extended with an expanded aggregate material and10r reinforcing fiber material to provide fire-retardant lightweight air-curable composites.
"Expanded aggregate material," as used in the specifi-cation and claims, includes, but is not limited to, cellular perlite, vermiculite, cellular glass, expanded slag, -;
cellular diatomite and cellular pumice. ~owever, the fore-going are preferred, most preferably expanded or cellular perlite and cellular diatomite.
ReinfGrcing fibers include, but are not limited to, organic fibers and fiberglass. Fiberglass is preferred owi~g to resistance to combustion. Organic fibers include natural fibers such as cellulose and wood fibers and syn-; thetic fibers, e.g.~ from ~ to l~ inches in length.
In the practice of the invention, the filler being ; bonded is mixed with the cold sel~-hardening bonding composition to form a paste which is shaped by extrusion or pressing at 7-40 psi or higher pressures to the required shape, and predetermined product strength required.
2 ~ Z~ 7 Structured end products with densities of 10 to 39 lb/ft may be obtained in this fashion.
The expanded aggregate material used in the practice of this invention can have a particle size of from 150 microns to 4750 microns depending upon the specifications of structured end product requirement. However, material mesh of 2400-4750 microns is generally preferred. The density of the expanded aggregate materials can be from 2~ lb/ft3 (40-180 kg/m3), although aggregates having densities of 5~ lb/ft3 (90-180 kg/m3) are preferred.
Preferred sieve size of expanded perlite particles is 3000-6000 microns, with particle size (expanded) running from 3 mm to 7 mm.
Addition of inorganic viscosity increasing agents, - e.g., sodium silicate in solution at 1.387-4.864 pounds per U.S. gallon to the basic bonding compound up to a level of 10% by weight will extend curing time. The curing time can be decreased by the addition of up to 8% by weight of inorganic filler, e.g., kaolin, diatomatious earth, fine mica, vermiculite, talc, etc. to the self-hardening composition or composites made therefrom.
~` The process of mixing of the basic self-hardening bonding compound and curing the products through stacking ~ and shipping of structured end products is therefore -~; carried out without application of external heat for drying or curing.
It will be understood that the composite materials containing the self-hardening composition of this inven-tion can, while the composites are in the form of a paste of ~2~25~
the required density, be formed, pressed or molded undex varying pressures between sheets to for~ double- or single-faced lamînates. Either facing sheet o~ the thus-formed laminate is of metal, cardboard, plastic, iberglass, paper or any other material which will adhere to the com-posite material and which will dry and cure at ambiant temperature. Preferred laminates are those wherein the filler is fiberglass and the facing sheet is metal or fiberglass.
DESCRIPTION OF PREFERRED EMBODI~IENTS
With respect to the self-hardening composi-tion of this invention, the most preferred embodiment is that wherein the alkaline earth metal chloride is CaC12.MgC12, the aluminum silicate clay is kaolin, the amount of sodium silicate is 35-39% by weight and the molar ratio Na20:SiO2 is 1:1.65-3.9.
Of the composites prepared in accordance with the invention, one which is particularly preferred is that wherein the expanded aggregate material is cellular perlite, vermiculite, cellular glass, expanded slag, cellular diatomite or cellular pumice. Another particularly preferred composite contains both one of the foregoing types of aggregate and a reinforcing filler selected from fiberglass or mineral fiber.
Without further elaboration, it is believed that one s~illed in the art can, using the preceding description, utilize the present invention to its fullest exten-t. The ~LZ~;~5~
following preferred specific embodiments are, therefore, to be construed as merely illustrative and not limitative of the remainder of the disclosure in any way whatsoever.
In the following examples, the temperatures are set forth uncorrected in degrees celsius; unless otherwise indicated, all parts and percentages are by weight.
PREPARATION OF SELF-HARDE~ING COMPOSITION
The following dry ingredients were mixed together by a rotary mixer:
~/O by weight Magnesium Calcium Chloride-CaC12:MgC12 4 ; Calcium Metasilicate-CaSiO3 Sodium Fluorosilicate Kaolin 1/32 To the resulting dry mix was added 93 31/32% by weight of commercial sodium silicate solution (40.5 Baume, Na2O:SiO2 ratio 1:1.65-3.9.). The mixture was stirred to a viscosity of 26 centipoise.
;.
/o by weight Expanded Perlite Particles 63-90 Bonding Compound of Example 1 10-37 The particles to be bonded were first dry mixed together by mechanically opposed rotating arms and then mixed with the bonding compound in the cold state. The resulting mass was stirred to a paste, which was shaped by application of pressure from 15-38 psi into structural products.
_ g_ 1~2~ 7 V!o by welght Fibers (Organic) 68-84 Diatomite 5-~7 Bonding Compound of Example 123-35 The composite was mixed as in Example 2 and pressed at 17 psi to obtain structural products, which cured at ambient conditions within 1-3 hours to a produc~ having the following characteristics: pearl white colored rigid board with perlite particles shape clearly visible.
Capable to be handled and used, and, when tapped with finger~
gives a resonant solid sound.
/o by weight Expanded Perlite Particles 25-56 Organic Fibers 32-45 Bonding Compound of Example l18-29 A composite material was obtained as in Example 2.
/O by weight Expanded Perlite Particles 60-85 Fiberglass 5-12 Bonding Compound of Example 110-34 Composite material obtained as in Example 2 had the following characteristics: a rigid lightweight (17-22 lb/ft3) dry-faced core material that had high thermal insulation qualities. Non-hygroscopic with free moisture content maximum 0.5%. Appearance: pearl white. Softening point:
900-1100C, 1600-2000F. Fusion point: 1280-1350 C, 2300-2450F. Products structured from Examples L, 2, 3, 5, 6, 7 were inert. Some unlaminated core material was made from Example 5, in accordance with the present inven-tion, in the form o dry panels with a specific densi~y o:E
27 lb/ft3 (432 kg/m3) in 1.0 meter lengths as cold mixed formed and cured panels. These panels were used to form a dry board encasement fire protection cover for a structural steel column and was submitted to a time and temperature test curve of: British Standard 476, part 8 (1972~ in the following categories:
Dry panels encasement at 50 mm (2 inches) thick with no laminates either side:
Stability: 12~ min Re-load: Satisfied Fire resistance: 120 min Dry panels encasement at 25 mm (1 inch) thick with no ` laminates either side:
- Stability: 60 min ;~
Re-load: Satisfied ~` Fire resistance: 60 min Further tests showed that the foregoing panels were com-pletely incombustible and non-toxic when submitted to furnace temperatures of 2,000F for extended periods and not subject to loss of bond when direct flame in the same temperature range was applied to any face of the material for extended periods.
The roregoing examples relate to a rigid dry-formed panel, bu~, by the very nature of complete compounds and aggregates and by the very low psi pressures required to form a desired end product, it is possible to press and mold ~l~2i~
to any shape that is capable to be so produced from existing plant and equipment with a modification being made to the feed and pressure applied in order to retain the ~nown a~d natural insulation qualities and geodetic streng~hs tha~
are found in pre-expanded perlite particles of all grade sizes.
Composites containing up to 55% of fiberglass (see Example 4) had better load-bearing characteristics and higher shear strength than those of Example 2.
Composites of the following compositions are prepared as in Example 2:
/~ by weight Expanded Perlite Particles: Large grade 63-74 Kaolin 4-7 Glass Fibers: one-inch long 1-5 Bonding Compound of Example 1 10-28 The products were structured as core materials having a nominal density of 15-28 lb/ft3, and laminated on each face with aluminum foil, air-laid fiberglass sheeting, etc.
Bonding material was made as in Example l from the following:
/O by wei~ht Magnesium Chloride 4 Calciu~ Metasilicate].
Sodium Fluorosilicate Kaolin 1/32 - To this dry mixture was added sodium silicate solu~ion, ~l~282~
40-42Be, the combination mixed to a viscosity of 26 centipoise .
Bonding material was formulated with expanded illers and/or fibrous fillers as in Examples 2-7. The behavior o products was similar.
The preceding examples can be repeated with similar success by substituting the generically or specifically described reactants and/or operating conditions of this invention for those used in the preceding examples.
From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention, andt without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions.
`: ;
~ -13-
The expanded aggregate material used in the practice of this invention can have a particle size of from 150 microns to 4750 microns depending upon the specifications of structured end product requirement. However, material mesh of 2400-4750 microns is generally preferred. The density of the expanded aggregate materials can be from 2~ lb/ft3 (40-180 kg/m3), although aggregates having densities of 5~ lb/ft3 (90-180 kg/m3) are preferred.
Preferred sieve size of expanded perlite particles is 3000-6000 microns, with particle size (expanded) running from 3 mm to 7 mm.
Addition of inorganic viscosity increasing agents, - e.g., sodium silicate in solution at 1.387-4.864 pounds per U.S. gallon to the basic bonding compound up to a level of 10% by weight will extend curing time. The curing time can be decreased by the addition of up to 8% by weight of inorganic filler, e.g., kaolin, diatomatious earth, fine mica, vermiculite, talc, etc. to the self-hardening composition or composites made therefrom.
~` The process of mixing of the basic self-hardening bonding compound and curing the products through stacking ~ and shipping of structured end products is therefore -~; carried out without application of external heat for drying or curing.
It will be understood that the composite materials containing the self-hardening composition of this inven-tion can, while the composites are in the form of a paste of ~2~25~
the required density, be formed, pressed or molded undex varying pressures between sheets to for~ double- or single-faced lamînates. Either facing sheet o~ the thus-formed laminate is of metal, cardboard, plastic, iberglass, paper or any other material which will adhere to the com-posite material and which will dry and cure at ambiant temperature. Preferred laminates are those wherein the filler is fiberglass and the facing sheet is metal or fiberglass.
DESCRIPTION OF PREFERRED EMBODI~IENTS
With respect to the self-hardening composi-tion of this invention, the most preferred embodiment is that wherein the alkaline earth metal chloride is CaC12.MgC12, the aluminum silicate clay is kaolin, the amount of sodium silicate is 35-39% by weight and the molar ratio Na20:SiO2 is 1:1.65-3.9.
Of the composites prepared in accordance with the invention, one which is particularly preferred is that wherein the expanded aggregate material is cellular perlite, vermiculite, cellular glass, expanded slag, cellular diatomite or cellular pumice. Another particularly preferred composite contains both one of the foregoing types of aggregate and a reinforcing filler selected from fiberglass or mineral fiber.
Without further elaboration, it is believed that one s~illed in the art can, using the preceding description, utilize the present invention to its fullest exten-t. The ~LZ~;~5~
following preferred specific embodiments are, therefore, to be construed as merely illustrative and not limitative of the remainder of the disclosure in any way whatsoever.
In the following examples, the temperatures are set forth uncorrected in degrees celsius; unless otherwise indicated, all parts and percentages are by weight.
PREPARATION OF SELF-HARDE~ING COMPOSITION
The following dry ingredients were mixed together by a rotary mixer:
~/O by weight Magnesium Calcium Chloride-CaC12:MgC12 4 ; Calcium Metasilicate-CaSiO3 Sodium Fluorosilicate Kaolin 1/32 To the resulting dry mix was added 93 31/32% by weight of commercial sodium silicate solution (40.5 Baume, Na2O:SiO2 ratio 1:1.65-3.9.). The mixture was stirred to a viscosity of 26 centipoise.
;.
/o by weight Expanded Perlite Particles 63-90 Bonding Compound of Example 1 10-37 The particles to be bonded were first dry mixed together by mechanically opposed rotating arms and then mixed with the bonding compound in the cold state. The resulting mass was stirred to a paste, which was shaped by application of pressure from 15-38 psi into structural products.
_ g_ 1~2~ 7 V!o by welght Fibers (Organic) 68-84 Diatomite 5-~7 Bonding Compound of Example 123-35 The composite was mixed as in Example 2 and pressed at 17 psi to obtain structural products, which cured at ambient conditions within 1-3 hours to a produc~ having the following characteristics: pearl white colored rigid board with perlite particles shape clearly visible.
Capable to be handled and used, and, when tapped with finger~
gives a resonant solid sound.
/o by weight Expanded Perlite Particles 25-56 Organic Fibers 32-45 Bonding Compound of Example l18-29 A composite material was obtained as in Example 2.
/O by weight Expanded Perlite Particles 60-85 Fiberglass 5-12 Bonding Compound of Example 110-34 Composite material obtained as in Example 2 had the following characteristics: a rigid lightweight (17-22 lb/ft3) dry-faced core material that had high thermal insulation qualities. Non-hygroscopic with free moisture content maximum 0.5%. Appearance: pearl white. Softening point:
900-1100C, 1600-2000F. Fusion point: 1280-1350 C, 2300-2450F. Products structured from Examples L, 2, 3, 5, 6, 7 were inert. Some unlaminated core material was made from Example 5, in accordance with the present inven-tion, in the form o dry panels with a specific densi~y o:E
27 lb/ft3 (432 kg/m3) in 1.0 meter lengths as cold mixed formed and cured panels. These panels were used to form a dry board encasement fire protection cover for a structural steel column and was submitted to a time and temperature test curve of: British Standard 476, part 8 (1972~ in the following categories:
Dry panels encasement at 50 mm (2 inches) thick with no laminates either side:
Stability: 12~ min Re-load: Satisfied Fire resistance: 120 min Dry panels encasement at 25 mm (1 inch) thick with no ` laminates either side:
- Stability: 60 min ;~
Re-load: Satisfied ~` Fire resistance: 60 min Further tests showed that the foregoing panels were com-pletely incombustible and non-toxic when submitted to furnace temperatures of 2,000F for extended periods and not subject to loss of bond when direct flame in the same temperature range was applied to any face of the material for extended periods.
The roregoing examples relate to a rigid dry-formed panel, bu~, by the very nature of complete compounds and aggregates and by the very low psi pressures required to form a desired end product, it is possible to press and mold ~l~2i~
to any shape that is capable to be so produced from existing plant and equipment with a modification being made to the feed and pressure applied in order to retain the ~nown a~d natural insulation qualities and geodetic streng~hs tha~
are found in pre-expanded perlite particles of all grade sizes.
Composites containing up to 55% of fiberglass (see Example 4) had better load-bearing characteristics and higher shear strength than those of Example 2.
Composites of the following compositions are prepared as in Example 2:
/~ by weight Expanded Perlite Particles: Large grade 63-74 Kaolin 4-7 Glass Fibers: one-inch long 1-5 Bonding Compound of Example 1 10-28 The products were structured as core materials having a nominal density of 15-28 lb/ft3, and laminated on each face with aluminum foil, air-laid fiberglass sheeting, etc.
Bonding material was made as in Example l from the following:
/O by wei~ht Magnesium Chloride 4 Calciu~ Metasilicate].
Sodium Fluorosilicate Kaolin 1/32 - To this dry mixture was added sodium silicate solu~ion, ~l~282~
40-42Be, the combination mixed to a viscosity of 26 centipoise .
Bonding material was formulated with expanded illers and/or fibrous fillers as in Examples 2-7. The behavior o products was similar.
The preceding examples can be repeated with similar success by substituting the generically or specifically described reactants and/or operating conditions of this invention for those used in the preceding examples.
From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention, andt without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions.
`: ;
~ -13-
Claims (11)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A self-hardening composition consisting essentially of 3-5% by weight of an alkaline earth metal chloride, 0.5-1.5% by weight of calcium metasilicate, 0.5-1.5% by weight of sodium fluorosilicate, 30-40% by weight of sodium silicate, 0.02-0.04% by weight of aluminum silicate clay and water.
2. The composition of claim 1, wherein the alkaline earth metal chloride is CaC12 MgC12.
3. The composition of cIaim 1, wherein the aluminum silicate clay is kaolin.
4. The composition of claim 1, wherein the amount of sodium silicate is 35-39% by weight.
5. The composition of claim 4, wherein the ratio Na20:Si02 is 1:1.65-3.9.
6. The composition of claim 1, wherein the alkaline earth metal chloride is CaC12 MgC12, the aluminum silicate clay is kaolin, the amount of sodium silicate is 35-39% by weight, and the molar ratio Na20:Si02 is 1:1.65-3.9.
7. A self-hardening composite material comprising 10-35% by weight of the composition of claim 1, admixed with an expanded aggregate material or reinforcing fibers.
8. A laminate comprising a composite of claim 7, firmly adhered to a facing sheet.
9. The composite material of claim 7, wherein the expanded aggregate material is cellular perlite, vermiculite, cellular glass, expanded slag, cellular diatomite, or cellular pumice.
10. The composite of claim 7, wherein the reinforcing fiber is fiberglass or mineral fibers.
11. The composite of claim 8, wherein the reinforcing fiber is fiberglass or mineral fiber and the expanded cellular aggregate material is cellular perlite, vermiculite, cellular glass, expanded slag, cellular diatomite, or cellular pumice.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA345,026A CA1128257A (en) | 1980-02-04 | 1980-02-04 | Self-hardening composition and composite therefrom |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA345,026A CA1128257A (en) | 1980-02-04 | 1980-02-04 | Self-hardening composition and composite therefrom |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1128257A true CA1128257A (en) | 1982-07-27 |
Family
ID=4116174
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA345,026A Expired CA1128257A (en) | 1980-02-04 | 1980-02-04 | Self-hardening composition and composite therefrom |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1128257A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US10370624B2 (en) | 2015-12-28 | 2019-08-06 | Colgate-Palmolive Company | Dishwashing pastes |
-
1980
- 1980-02-04 CA CA345,026A patent/CA1128257A/en not_active Expired
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US10370624B2 (en) | 2015-12-28 | 2019-08-06 | Colgate-Palmolive Company | Dishwashing pastes |
| US10745652B2 (en) | 2015-12-28 | 2020-08-18 | Colgate-Palmolive Company | Dishwashing pastes |
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