CA3113656A1 - Closed cell geopolymer foam - Google Patents
Closed cell geopolymer foam Download PDFInfo
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- CA3113656A1 CA3113656A1 CA3113656A CA3113656A CA3113656A1 CA 3113656 A1 CA3113656 A1 CA 3113656A1 CA 3113656 A CA3113656 A CA 3113656A CA 3113656 A CA3113656 A CA 3113656A CA 3113656 A1 CA3113656 A1 CA 3113656A1
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
- C04B28/26—Silicates of the alkali metals
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/006—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing mineral polymers, e.g. geopolymers of the Davidovits type
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B18/04—Waste materials; Refuse
- C04B18/18—Waste materials; Refuse organic
- C04B18/24—Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper, cork
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B22/00—Use of inorganic materials as active ingredients for mortars, concrete or artificial stone, e.g. accelerators, shrinkage compensating agents
- C04B22/06—Oxides, Hydroxides
- C04B22/062—Oxides, Hydroxides of the alkali or alkaline-earth metals
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/10—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
- C04B2103/40—Surface-active agents, dispersants
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/40—Porous or lightweight materials
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P40/00—Technologies relating to the processing of minerals
- Y02P40/10—Production of cement, e.g. improving or optimising the production methods; Cement grinding
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Environmental & Geological Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Life Sciences & Earth Sciences (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Geology (AREA)
- Civil Engineering (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
Abstract
ABSTRACT CLOSED CELL GEOPOLYMER FOAM
The invention consists of a geopolymer foam comprising:
- from 50% to 90% by mass of pozzolanic material polymerized relative to the total mass of said foam;
- from 0.01% to 2%, by mass of the at least one surfactant relative to the total mass of said foam;
- from 1% to 20% by mass of fibers with lengths of between 5 and 1500 p.m relative to the total mass of said foam.
The invention also relates to the process for manufacturing said foam.
The invention also relates to a composition for manufacturing said foam.
The invention also relates to insulated or sealed doors, pipes and other supports upon which is applied, or upon which is comprised, said foam.
Finally, the invention relates to a kit comprising said composition for the manufacture of said foam, as well as a pozzolanic material.
Date Recue/Date Received 2021-03-30
The invention consists of a geopolymer foam comprising:
- from 50% to 90% by mass of pozzolanic material polymerized relative to the total mass of said foam;
- from 0.01% to 2%, by mass of the at least one surfactant relative to the total mass of said foam;
- from 1% to 20% by mass of fibers with lengths of between 5 and 1500 p.m relative to the total mass of said foam.
The invention also relates to the process for manufacturing said foam.
The invention also relates to a composition for manufacturing said foam.
The invention also relates to insulated or sealed doors, pipes and other supports upon which is applied, or upon which is comprised, said foam.
Finally, the invention relates to a kit comprising said composition for the manufacture of said foam, as well as a pozzolanic material.
Date Recue/Date Received 2021-03-30
Description
DESCRIPTION TITLE: CLOSED CELL GEOPOLYMER FOAM
[00011The invention belongs to the field of geopolymers and more particularly to that of mineral foams.
[00011The invention belongs to the field of geopolymers and more particularly to that of mineral foams.
[0002]The invention relates to an incombustible and thermally insulating mineral foam.
[0003 ]The invention also relates to the method for manufacturing said foam, as well as the intermediate composition designed to form the foam.
[00041The invention also relates to insulated or sealed doors or pipes and other supports upon which is applied, or upon which is comprised, said foam.
[0005]Finally, the invention relates to a kit comprising said intermediate composition as well as a pozzolanic material.
Prior art [0006]Geopolymer foams are known from the prior art. Geopolymer foams have many advantages, the main one being that instead of the carbon chain of conventional polymers, mineral material composed of silica and alumina is used. They are therefore inorganic polymers composed of mineral matter such as silica and alumina.
[0007]In the context of this invention, by geopolymer is meant an inorganic polymer essentially composed of units, silico-oxide (-Si-O-Si-0-), silico-aluminate (-Si-O-A1-0-), ferro-silico-aluminate (-Fe-O-Si-O-A1-0-) or aluminum-phosphate (-A1-0-P-0-), created by a process called g eopo lymeri zati on.
[0008]Geopolymers, by their nature, find applications in the field of construction, in particular for the manufacture of cements and concrete or even fire protection. These mineral foams are of particular interest due to their low density and their insulating and fire-resistant properties which make them suitable for use in the construction of walls, doors, insulation panels and may also be used to insulate, seal or repair pipes, furnaces and other systems subjected to high temperatures.
These latter uses imply that the foam forms and hardens quickly (in a few minutes to a few tens of minutes) so that it may be applied directly to the area to be isolated or sealed.
[0009]The incombustible mineral foams of the invention can in particular be prepared from an inorganic binder such as metakaolin, a natural pozzolanic material. The term -metakaolin" is understood to mean a thermally dehydroxylated kaolinite clay. In other words, it is a dehydroxylated alumina silicate of general composition Al2O3, 2Si02.
[000101It is known that one can prepare a geopolymer in the form of a mineral foam by mixing an inorganic binder with a so-called activation solution, most often comprising alkali metal hydroxides, then adding thereto an expanding agent which will form a gas in situ. The generation of gas will create gas bubbles in the liquid phase and form a foam, while the reaction of the inorganic binder with the activating solution most often accelerated by the addition of a hardener Date Recue/Date Received 2021-03-30 (for example a Ca2+ donor) causes rapid hardening, the result of polymerization, which then freezes the network of bubbles or the porosity. The product obtained is a rigid and porous foam.
[000111Geopolymer foams can also be made with an external gas supply unlike foams made by in situ gas generation. Generally speaking, foams with an external gas supply are made in two stages.
On the one hand, an aqueous foam is made from water and surfactants, on the other hand, a slurry of the inorganic binder is made. A foam is thus obtained resulting from the mixture of the slurry with the aqueous foam, which will gradually solidify over a relatively long period depending on the inorganic binder used. It is also possible to manufacture a geopolymer foam in a single step by mixing an inorganic binder with an activating solution to which foaming agents are added. Using different tools, a gas (for example air), is then introduced to the suspension obtained. The manufacture of foam using an external gas supply requires obtaining a very stable foam not only over time but also vis-à-vis the phenomena of coalescence or disappearance of bubbles or microbubbles of gas after injection and dispersion of the latter.
[000121FR3027023 discloses foams prepared from metakaolin, one or more natural or synthetic foaming agents of animal or plant origin. In particular, this application targets foaming agents of the protein type.
[000131W02015062860 discloses foams based on metakaolin and further comprising a surfactant.
The authors recommend the use of nonionic surfactants, such as alkyl polyglucosides for stabilization of the foam. A supply of gas is preferred over gas generation in situ. Fibers acting as fillers may be used in order to improve the mechanical stability of the hardened foam, these fibers preferably having a millimetric length of a maximum of 120 mm, particularly a maximum of 6 mm.
[0001410E102004006563 discloses organic/inorganic hybrid foams comprising surfactants. In particular, the surfactants are amine oxides and alkyl sulfates.
[000151US2015060720 or W02015062819 disclose methods of preparing a fast curing (less than minutes) inorganic foam. The blowing agent has the distinction of being scrap aluminum powder, which is a mixture of aluminum powder, aluminum nitride and aluminum oxide.
[000161W02018091482 discloses a metakaolin-based foam comprising the combination of 2 types of anionic and nonionic surfactants. The foam is formed by generating gas in situ. Fibers acting as fillers may be used, their lengths being less than 5 mm.
[000171W02017138913 discloses a composition of cement foam comprising a hydraulic cement, water, a foam-generating surfactant, a gas and stabilizing cellulose nanofibers (CNF) of a size between 35 and 10,000 nm. The CNFs are obtained by high-energy complex grinding methods and/or chemical or enzymatic pretreatments, as opposed to cellulose fibers of micrometric sizes Date Recue/Date Received 2021-03-30
[0003 ]The invention also relates to the method for manufacturing said foam, as well as the intermediate composition designed to form the foam.
[00041The invention also relates to insulated or sealed doors or pipes and other supports upon which is applied, or upon which is comprised, said foam.
[0005]Finally, the invention relates to a kit comprising said intermediate composition as well as a pozzolanic material.
Prior art [0006]Geopolymer foams are known from the prior art. Geopolymer foams have many advantages, the main one being that instead of the carbon chain of conventional polymers, mineral material composed of silica and alumina is used. They are therefore inorganic polymers composed of mineral matter such as silica and alumina.
[0007]In the context of this invention, by geopolymer is meant an inorganic polymer essentially composed of units, silico-oxide (-Si-O-Si-0-), silico-aluminate (-Si-O-A1-0-), ferro-silico-aluminate (-Fe-O-Si-O-A1-0-) or aluminum-phosphate (-A1-0-P-0-), created by a process called g eopo lymeri zati on.
[0008]Geopolymers, by their nature, find applications in the field of construction, in particular for the manufacture of cements and concrete or even fire protection. These mineral foams are of particular interest due to their low density and their insulating and fire-resistant properties which make them suitable for use in the construction of walls, doors, insulation panels and may also be used to insulate, seal or repair pipes, furnaces and other systems subjected to high temperatures.
These latter uses imply that the foam forms and hardens quickly (in a few minutes to a few tens of minutes) so that it may be applied directly to the area to be isolated or sealed.
[0009]The incombustible mineral foams of the invention can in particular be prepared from an inorganic binder such as metakaolin, a natural pozzolanic material. The term -metakaolin" is understood to mean a thermally dehydroxylated kaolinite clay. In other words, it is a dehydroxylated alumina silicate of general composition Al2O3, 2Si02.
[000101It is known that one can prepare a geopolymer in the form of a mineral foam by mixing an inorganic binder with a so-called activation solution, most often comprising alkali metal hydroxides, then adding thereto an expanding agent which will form a gas in situ. The generation of gas will create gas bubbles in the liquid phase and form a foam, while the reaction of the inorganic binder with the activating solution most often accelerated by the addition of a hardener Date Recue/Date Received 2021-03-30 (for example a Ca2+ donor) causes rapid hardening, the result of polymerization, which then freezes the network of bubbles or the porosity. The product obtained is a rigid and porous foam.
[000111Geopolymer foams can also be made with an external gas supply unlike foams made by in situ gas generation. Generally speaking, foams with an external gas supply are made in two stages.
On the one hand, an aqueous foam is made from water and surfactants, on the other hand, a slurry of the inorganic binder is made. A foam is thus obtained resulting from the mixture of the slurry with the aqueous foam, which will gradually solidify over a relatively long period depending on the inorganic binder used. It is also possible to manufacture a geopolymer foam in a single step by mixing an inorganic binder with an activating solution to which foaming agents are added. Using different tools, a gas (for example air), is then introduced to the suspension obtained. The manufacture of foam using an external gas supply requires obtaining a very stable foam not only over time but also vis-à-vis the phenomena of coalescence or disappearance of bubbles or microbubbles of gas after injection and dispersion of the latter.
[000121FR3027023 discloses foams prepared from metakaolin, one or more natural or synthetic foaming agents of animal or plant origin. In particular, this application targets foaming agents of the protein type.
[000131W02015062860 discloses foams based on metakaolin and further comprising a surfactant.
The authors recommend the use of nonionic surfactants, such as alkyl polyglucosides for stabilization of the foam. A supply of gas is preferred over gas generation in situ. Fibers acting as fillers may be used in order to improve the mechanical stability of the hardened foam, these fibers preferably having a millimetric length of a maximum of 120 mm, particularly a maximum of 6 mm.
[0001410E102004006563 discloses organic/inorganic hybrid foams comprising surfactants. In particular, the surfactants are amine oxides and alkyl sulfates.
[000151US2015060720 or W02015062819 disclose methods of preparing a fast curing (less than minutes) inorganic foam. The blowing agent has the distinction of being scrap aluminum powder, which is a mixture of aluminum powder, aluminum nitride and aluminum oxide.
[000161W02018091482 discloses a metakaolin-based foam comprising the combination of 2 types of anionic and nonionic surfactants. The foam is formed by generating gas in situ. Fibers acting as fillers may be used, their lengths being less than 5 mm.
[000171W02017138913 discloses a composition of cement foam comprising a hydraulic cement, water, a foam-generating surfactant, a gas and stabilizing cellulose nanofibers (CNF) of a size between 35 and 10,000 nm. The CNFs are obtained by high-energy complex grinding methods and/or chemical or enzymatic pretreatments, as opposed to cellulose fibers of micrometric sizes Date Recue/Date Received 2021-03-30
3 obtained generally through wet grinding and selection that possess a simple morphology without crystallinity or ramification.
[000181The Prud'homme et al. Eur. Phys. J. Special Topics 224, 1725-1735 (2015) publication discusses the control of the porosity and thermal properties of geopolymer material either by modification of the formula or by adding additives, the second option being considered as the most promising. The influence of the additives on the mass of the samples is debated, figure 7 shows that the increase of the mass of the foam increases the thermal conductivity up until a certain point, and that the use of additives such as carbo fibers, cellulose fibers or starch increases the mass of the foam and also increases the thermal conductivity.
[000191W02017174560A1 discloses a geopolymer foam comprising cellulose nanofibers used for sound-absorbing applications. The disclosed foam possesses a majority of open cells due to the precise quantity of cellulose nanofibers.
The disadvantage of the mineral foams of the prior art is their open-cell nature resulting in high thermal conductivity. Open cells or pores are cells that are interconnected or have open binding channels. These open channels more or less connect the cells. The thermal conductivity of a foam is dependent on the porosity of the system and is therefore determined by the path of the air through the composition. The air path through an open cell foam is facilitated resulting in an increase in thermal conductivity.
[00020]The Applicant has surprisingly demonstrated that the use of micrometric lengths of fibers combined with the use of a specific amount of surfactants, gives mineral foam a perfectly stable closed-cell nature, and consequently a relatively low thermal conductivity.
[000211None of the abovementioned documents address the relationship between the size of the fibers and the foam cellularity, nor the means of obtaining the closed-cell mineral foams having a low thermal conductivity.
[00022]The properties of the foams according to the invention are as follows:
- incombustible foams;
- better control of foam mass;
- better control of cell density and size;
- better surface appearance (skin);
- reduced risk of cracks.
The incombustible mineral foams according to the invention may be used as fire barriers and comply with Al according to the "reaction to fire" and "resistance to fire"
standards, NF EN ISO
1182 and 1716 respectively. They have a thermal resistance up to at least 1200 C.
Date Recue/Date Received 2021-03-30
[000181The Prud'homme et al. Eur. Phys. J. Special Topics 224, 1725-1735 (2015) publication discusses the control of the porosity and thermal properties of geopolymer material either by modification of the formula or by adding additives, the second option being considered as the most promising. The influence of the additives on the mass of the samples is debated, figure 7 shows that the increase of the mass of the foam increases the thermal conductivity up until a certain point, and that the use of additives such as carbo fibers, cellulose fibers or starch increases the mass of the foam and also increases the thermal conductivity.
[000191W02017174560A1 discloses a geopolymer foam comprising cellulose nanofibers used for sound-absorbing applications. The disclosed foam possesses a majority of open cells due to the precise quantity of cellulose nanofibers.
The disadvantage of the mineral foams of the prior art is their open-cell nature resulting in high thermal conductivity. Open cells or pores are cells that are interconnected or have open binding channels. These open channels more or less connect the cells. The thermal conductivity of a foam is dependent on the porosity of the system and is therefore determined by the path of the air through the composition. The air path through an open cell foam is facilitated resulting in an increase in thermal conductivity.
[00020]The Applicant has surprisingly demonstrated that the use of micrometric lengths of fibers combined with the use of a specific amount of surfactants, gives mineral foam a perfectly stable closed-cell nature, and consequently a relatively low thermal conductivity.
[000211None of the abovementioned documents address the relationship between the size of the fibers and the foam cellularity, nor the means of obtaining the closed-cell mineral foams having a low thermal conductivity.
[00022]The properties of the foams according to the invention are as follows:
- incombustible foams;
- better control of foam mass;
- better control of cell density and size;
- better surface appearance (skin);
- reduced risk of cracks.
The incombustible mineral foams according to the invention may be used as fire barriers and comply with Al according to the "reaction to fire" and "resistance to fire"
standards, NF EN ISO
1182 and 1716 respectively. They have a thermal resistance up to at least 1200 C.
Date Recue/Date Received 2021-03-30
4 Description of the Figures [00023]Figure 1: Surface appearance of 3 samples of geopolymer foams respectively comprising from A to C no fibers, micrometric lengths of fibers, and millimetric lengths of fibers used as fillers.
Detailed Description of the Invention [00024]The invention consists of a geopolymer foam comprising:
- from 50% to 90% by mass of pozzolanic material polymerized relative to the total mass of said foam;
- from 0.01% to 2%, by mass of at least one surfactant relative to the total mass of said foam;
- from 1% to 20% by mass of fibers with lengths of between 5 and 1500 pm relative to the total mass of said foam.
[00025]The term -fibers" is understood to mean an element of elongated or extended shape. In the present application, the length of a fiber is considered to be of an average length.
[00026]"Polymerized pozzolanic material" is understood to be a geopolymer formed by the reaction of a pozzolanic material with an activating solution (e.g., a basic solution).
[000271In one embodiment, the geopolymer foam according to the invention is characterized in that the pozzolanic material is metakaolin.
[000281In one embodiment, the geopolymer foam according to the invention is characterized in that it comprises from 55% to 85% by mass of polymerized pozzolanic material relative to the total mass of said foam.
[000291In one embodiment, the geopolymer foam according to the invention is characterized in that it comprises from 60% to 80% by mass of polymerized pozzolanic material relative to the total mass of said foam.
[000301In one embodiment, the geopolymer foam according to the invention is characterized in that it comprises from 65% to 75% by mass of polymerized pozzolanic material relative to the total mass of said foam.
[000311In one embodiment, the geopolymer foam according to the invention is characterized in that it comprises from 0.01% to 1.5% by mass of at least one surfactant relative to the total mass of said foam.
[000321In one embodiment, the geopolymer foam according to the invention is characterized in that it comprises from 0.01% to 1% by mass of at least one surfactant relative to the total mass of said foam.
[00033]Preferably, the geopolymer foam according to the invention is characterized in that it comprises from 0.01 to 0.5% by mass of at least one surfactant relative to the total mass of said foam.
Date Recue/Date Received 2021-03-30
Detailed Description of the Invention [00024]The invention consists of a geopolymer foam comprising:
- from 50% to 90% by mass of pozzolanic material polymerized relative to the total mass of said foam;
- from 0.01% to 2%, by mass of at least one surfactant relative to the total mass of said foam;
- from 1% to 20% by mass of fibers with lengths of between 5 and 1500 pm relative to the total mass of said foam.
[00025]The term -fibers" is understood to mean an element of elongated or extended shape. In the present application, the length of a fiber is considered to be of an average length.
[00026]"Polymerized pozzolanic material" is understood to be a geopolymer formed by the reaction of a pozzolanic material with an activating solution (e.g., a basic solution).
[000271In one embodiment, the geopolymer foam according to the invention is characterized in that the pozzolanic material is metakaolin.
[000281In one embodiment, the geopolymer foam according to the invention is characterized in that it comprises from 55% to 85% by mass of polymerized pozzolanic material relative to the total mass of said foam.
[000291In one embodiment, the geopolymer foam according to the invention is characterized in that it comprises from 60% to 80% by mass of polymerized pozzolanic material relative to the total mass of said foam.
[000301In one embodiment, the geopolymer foam according to the invention is characterized in that it comprises from 65% to 75% by mass of polymerized pozzolanic material relative to the total mass of said foam.
[000311In one embodiment, the geopolymer foam according to the invention is characterized in that it comprises from 0.01% to 1.5% by mass of at least one surfactant relative to the total mass of said foam.
[000321In one embodiment, the geopolymer foam according to the invention is characterized in that it comprises from 0.01% to 1% by mass of at least one surfactant relative to the total mass of said foam.
[00033]Preferably, the geopolymer foam according to the invention is characterized in that it comprises from 0.01 to 0.5% by mass of at least one surfactant relative to the total mass of said foam.
Date Recue/Date Received 2021-03-30
5 [000341In one embodiment, the geopolymer foam according to the invention is characterized in that the at least one surfactant is selected from the group consisting of anionic surfactants, nonionic surfactants, and mixtures thereof.
[00035]The term -anionic surfactant" is intended to mean a surfactant which releases a negative charge in aqueous solution. The class of anionic surfactants is widely described in the literature.
[000361In one embodiment, the geopolymer foam according to the invention is characterized in that the at least one surfactant is selected from the group consisting of anionic surfactants, nonionic surfactants, and mixtures thereof.
[00037]The term ``nonionic surfactant" is understood to mean a surfactant whose molecules have no net charge. The class of nonionic surfactants is widely described in the literature.
[0003 811n one embodiment, the geopolymer foam according to the invention is characterized in that the nonionic surfactants are selected from alkyl polyglucosides (D-glucopyranose, oligomers, alkyl glucosides).
[000391In one embodiment, the geopolymer foam according to the invention is characterized in that the nonionic surfactants are selected from alkyl polyglucosides (D-glucopyranose, oligomers, alkyl glucosides).
[00040]The term -alkyl-poly-glucoside" is understood to mean a nonionic surfactant having the formula: H-(C6H1005) m-O-R1, in which (C6H1005) is a glucose unit and R1 is a C6-C22 alkyl group, preferably C8-C16 and C8-C10, and m is a positive integer between 1 and 10, l< m < 10.
[000411In one embodiment, the alkyl polyglucosides are those marketed by the company SEPPIC, such as SIMULSOL SL8 (D-glucopyranose, oligomers, decyl octyl glycosides, 01-36, CE: 500-200-1), or SIMULSOL SL 826 (D-glucopyranose, oligomers, decyl octyl glycosides, 01-2119488530-36, CE: 500-200-1, D-Glucopyranose, oligomeric, C10-16 (even numbered)-alkyl glycosides, 01-2119489418-23, CE: 600-975-8, (2-methoxymethylethoxy) propanol, 012119450011-60, CE:
252-104-2, dodecan-l-ol, 01-2119485976-15, EC: 203-982-0) or SIMULSOL SL26 (D-Glucopyranose, oligomeric, C10-16 (even numbered) alkyl glycosides, 01-2119489418-23, CE:
600-975-8) or mixtures thereof.
[000421In one embodiment, the alkyl polyglucosides SIMULSOL SL 8, SL 826 and SL26 are in preferential ratios of 50: 50 for the couple SL8: SL826 and 50: 2.5: 47.5 for that of SL8: SL26:
SL826.
[000431In one embodiment, the geopolymer foam according to the invention is characterized in that it comprises from 1% to 17% by mass of fibers with lengths of between 5 and 1500 gm relative to the total mass of said foam.
Date Recue/Date Received 2021-03-30
[00035]The term -anionic surfactant" is intended to mean a surfactant which releases a negative charge in aqueous solution. The class of anionic surfactants is widely described in the literature.
[000361In one embodiment, the geopolymer foam according to the invention is characterized in that the at least one surfactant is selected from the group consisting of anionic surfactants, nonionic surfactants, and mixtures thereof.
[00037]The term ``nonionic surfactant" is understood to mean a surfactant whose molecules have no net charge. The class of nonionic surfactants is widely described in the literature.
[0003 811n one embodiment, the geopolymer foam according to the invention is characterized in that the nonionic surfactants are selected from alkyl polyglucosides (D-glucopyranose, oligomers, alkyl glucosides).
[000391In one embodiment, the geopolymer foam according to the invention is characterized in that the nonionic surfactants are selected from alkyl polyglucosides (D-glucopyranose, oligomers, alkyl glucosides).
[00040]The term -alkyl-poly-glucoside" is understood to mean a nonionic surfactant having the formula: H-(C6H1005) m-O-R1, in which (C6H1005) is a glucose unit and R1 is a C6-C22 alkyl group, preferably C8-C16 and C8-C10, and m is a positive integer between 1 and 10, l< m < 10.
[000411In one embodiment, the alkyl polyglucosides are those marketed by the company SEPPIC, such as SIMULSOL SL8 (D-glucopyranose, oligomers, decyl octyl glycosides, 01-36, CE: 500-200-1), or SIMULSOL SL 826 (D-glucopyranose, oligomers, decyl octyl glycosides, 01-2119488530-36, CE: 500-200-1, D-Glucopyranose, oligomeric, C10-16 (even numbered)-alkyl glycosides, 01-2119489418-23, CE: 600-975-8, (2-methoxymethylethoxy) propanol, 012119450011-60, CE:
252-104-2, dodecan-l-ol, 01-2119485976-15, EC: 203-982-0) or SIMULSOL SL26 (D-Glucopyranose, oligomeric, C10-16 (even numbered) alkyl glycosides, 01-2119489418-23, CE:
600-975-8) or mixtures thereof.
[000421In one embodiment, the alkyl polyglucosides SIMULSOL SL 8, SL 826 and SL26 are in preferential ratios of 50: 50 for the couple SL8: SL826 and 50: 2.5: 47.5 for that of SL8: SL26:
SL826.
[000431In one embodiment, the geopolymer foam according to the invention is characterized in that it comprises from 1% to 17% by mass of fibers with lengths of between 5 and 1500 gm relative to the total mass of said foam.
Date Recue/Date Received 2021-03-30
6 [000441In one embodiment, the geopolymer foam according to the invention is characterized in that it comprises from 1% to 15% by mass of fibers with lengths of between 5 and 1500 gm relative to the total mass of said foam.
[00045] In one embodiment, the geopolymer foam according to the invention is characterized in that it comprises from 1% to 12% by mass of fibers with lengths of between 5 and 1500 gm relative to the total mass of said foam.
[000461In one embodiment, the geopolymer foam according to the invention is characterized in that the fibers have lengths between 5 and 1000 pm.
[000471In one embodiment, the geopolymer foam according to the invention is characterized in that the fibers have lengths between 10 and 800 pm.
[000481In one embodiment, the geopolymer foam according to the invention is characterized in that the fibers have lengths between 5 and 50 pm.
[000491In one embodiment, the geopolymer foam according to the invention is characterized in that the fibers have lengths between 10 and 40 pm.
[000501In one embodiment, the geopolymer foam according to the invention is characterized in that the fibers have lengths between 15 and 30 pm.
[0005 liln one embodiment, the geopolymer foam according to the invention is characterized in that the fibers are selected from the group consisting of plant fibers, animal fibers, mineral fibers, semi-synthetic fibers, polymeric fibers.
[000521In one embodiment, the geopolymer foam according to the invention is characterized in that the fibers are not cellulose nanofibers (CNF).
[00053] In one embodiment, the geopolymer foam according to the invention is characterized in that the fibers do not have dimensions in the nanometer range. This is understood to mean that no fiber has an average length of less than 1 gm.
[000541In one embodiment, the geopolymer foam according to the invention is characterized in that the fibers are cellulose fibers.
[00055]Preferably, the cellulose fibers possess at least one of the following characteristics:
- They are made from paper pulp, made from wood from renewable resources.
- They have an average diameter of approximately 25 pm.
- They have an apparent mass between 20 and 250 g/L.
- They are resistant to temperatures of up to 150 C, briefly up to approximately 200 C.
- They have a high absorption and retention of liquid media.
- They have a high traction resistance.
- They are insoluble in water and oil and are not comparable to cellulose derivatives soluble in water such as carboxymethyl cellulose (CMC).
Date Recue/Date Received 2021-03-30
[00045] In one embodiment, the geopolymer foam according to the invention is characterized in that it comprises from 1% to 12% by mass of fibers with lengths of between 5 and 1500 gm relative to the total mass of said foam.
[000461In one embodiment, the geopolymer foam according to the invention is characterized in that the fibers have lengths between 5 and 1000 pm.
[000471In one embodiment, the geopolymer foam according to the invention is characterized in that the fibers have lengths between 10 and 800 pm.
[000481In one embodiment, the geopolymer foam according to the invention is characterized in that the fibers have lengths between 5 and 50 pm.
[000491In one embodiment, the geopolymer foam according to the invention is characterized in that the fibers have lengths between 10 and 40 pm.
[000501In one embodiment, the geopolymer foam according to the invention is characterized in that the fibers have lengths between 15 and 30 pm.
[0005 liln one embodiment, the geopolymer foam according to the invention is characterized in that the fibers are selected from the group consisting of plant fibers, animal fibers, mineral fibers, semi-synthetic fibers, polymeric fibers.
[000521In one embodiment, the geopolymer foam according to the invention is characterized in that the fibers are not cellulose nanofibers (CNF).
[00053] In one embodiment, the geopolymer foam according to the invention is characterized in that the fibers do not have dimensions in the nanometer range. This is understood to mean that no fiber has an average length of less than 1 gm.
[000541In one embodiment, the geopolymer foam according to the invention is characterized in that the fibers are cellulose fibers.
[00055]Preferably, the cellulose fibers possess at least one of the following characteristics:
- They are made from paper pulp, made from wood from renewable resources.
- They have an average diameter of approximately 25 pm.
- They have an apparent mass between 20 and 250 g/L.
- They are resistant to temperatures of up to 150 C, briefly up to approximately 200 C.
- They have a high absorption and retention of liquid media.
- They have a high traction resistance.
- They are insoluble in water and oil and are not comparable to cellulose derivatives soluble in water such as carboxymethyl cellulose (CMC).
Date Recue/Date Received 2021-03-30
7 - They are inert to acids and alkalis in a range of pH values from 4 to 12.
[00056] The use of micrometric lengths of fibers contributes significantly to increasing the density of the cells or pores, as well as the stability of the foam in its liquid phase before curing.
[000571In one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises at least one hydrophobic agent.
[000581In one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 1% to 20% by mass of at least one hydrophobic agent relative to the total mass of said foam.
[000591In one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 1% to 15% by mass of at least one hydrophobic agent relative to the total mass of said foam.
[00060]In one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 1% to 10% by mass of at least one hydrophobic agent relative to the total mass of said foam.
[00061]In one embodiment, the geopolymer foam according to the invention is characterized in that the at least one hydrophobic agent is selected from the group consisting of siliconates, silanes, siloxanes and mixtures thereof.
[000621In one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises at least one thickener.
[00063]The term "thickener" is understood to mean a substance intended to modulate/increase the viscosity of a composition.
[000641In one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 1 to 25% by mass of at least one thickener relative to the total mass of said foam.
[000651In one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 1 to 20% by mass of at least one thickener relative to the total mass of said foam.
[000661In one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 1 to 15% by mass of at least one thickener relative to the total mass of said foam.
[000671In one embodiment, the foam is characterized in that the at least one thickener is selected from the group consisting of chemically modified water-soluble starches such as pre-frozen starch, salts of carboxymethylated starches and adipates of acetylated distarch, galactomannans such as guar gum, xanthan gum, mineral fillers such as kaolinite clays, cellulose derivatives such as methyl ethyl cellulose, and mixtures thereof.
Date Recue/Date Received 2021-03-30
[00056] The use of micrometric lengths of fibers contributes significantly to increasing the density of the cells or pores, as well as the stability of the foam in its liquid phase before curing.
[000571In one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises at least one hydrophobic agent.
[000581In one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 1% to 20% by mass of at least one hydrophobic agent relative to the total mass of said foam.
[000591In one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 1% to 15% by mass of at least one hydrophobic agent relative to the total mass of said foam.
[00060]In one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 1% to 10% by mass of at least one hydrophobic agent relative to the total mass of said foam.
[00061]In one embodiment, the geopolymer foam according to the invention is characterized in that the at least one hydrophobic agent is selected from the group consisting of siliconates, silanes, siloxanes and mixtures thereof.
[000621In one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises at least one thickener.
[00063]The term "thickener" is understood to mean a substance intended to modulate/increase the viscosity of a composition.
[000641In one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 1 to 25% by mass of at least one thickener relative to the total mass of said foam.
[000651In one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 1 to 20% by mass of at least one thickener relative to the total mass of said foam.
[000661In one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 1 to 15% by mass of at least one thickener relative to the total mass of said foam.
[000671In one embodiment, the foam is characterized in that the at least one thickener is selected from the group consisting of chemically modified water-soluble starches such as pre-frozen starch, salts of carboxymethylated starches and adipates of acetylated distarch, galactomannans such as guar gum, xanthan gum, mineral fillers such as kaolinite clays, cellulose derivatives such as methyl ethyl cellulose, and mixtures thereof.
Date Recue/Date Received 2021-03-30
8 [00068]The term -kaolinite" is understood to be a hydrated alumina silicate constituting one of the main clay minerals and forming the essential element of kaolin.
[0006911n one embodiment the at least one thickener is a mineral filler.
[00070]Mineral fillers are used to improve the mechanical characteristics, the refractory properties, as well as the material price of mineral foams. Preferably the inorganic filler is kaolinite clay as it is used to produce metakaolin and it does not react under the action of the activating solution under the conditions of foam manufacturing procedures.
[0007 liln one embodiment the at least one thickener is a chemically modified starch.
[00072]Preferably the chemically modified starch is a pre-frozen starch.
[0007311n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises at least one protein or a mixture of animal or plant proteins selected from the group consisting of albumin, keratin hydrolysates such as extracts of keratin from animal hooves and/or horns, and mixtures thereof.
[0007411n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 0.1% to 10% by mass of the at least one protein or a mixture of animal or plant proteins selected from the group consisting of albumin, keratin hydrolysates such as extracts of keratin from animal hooves and/or horns, and mixtures thereof, relative to the total mass of said foam.
[0007511n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 0.1% to 7% by mass of the at least one protein or a mixture of animal or plant proteins selected from the group consisting of albumin, keratin hydrolysates such as extracts of keratin from animal hooves and/or horns, and mixtures thereof, relative to the total mass of said foam.
[0007611n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 0.1% to 5% by mass of the at least one protein or a mixture of animal or plant proteins selected from the group consisting of albumin, keratin hydrolysates such as extracts of keratin from animal hooves and/or horns, and mixtures thereof, relative to the total mass of said foam.
[00077]Preferably the at least one protein or mixture of animal or vegetable proteins are keratin hydrolysates.
[00078]The use of keratin hydrolysates facilitates the entrainment of air during the manufacture of the foam and provides a lubricating effect which allows better flow of the foam at densities less than or equal to 200 Kg/m3.
[0007911n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises at least one pH buffer.
Date Recue/Date Received 2021-03-30
[0006911n one embodiment the at least one thickener is a mineral filler.
[00070]Mineral fillers are used to improve the mechanical characteristics, the refractory properties, as well as the material price of mineral foams. Preferably the inorganic filler is kaolinite clay as it is used to produce metakaolin and it does not react under the action of the activating solution under the conditions of foam manufacturing procedures.
[0007 liln one embodiment the at least one thickener is a chemically modified starch.
[00072]Preferably the chemically modified starch is a pre-frozen starch.
[0007311n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises at least one protein or a mixture of animal or plant proteins selected from the group consisting of albumin, keratin hydrolysates such as extracts of keratin from animal hooves and/or horns, and mixtures thereof.
[0007411n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 0.1% to 10% by mass of the at least one protein or a mixture of animal or plant proteins selected from the group consisting of albumin, keratin hydrolysates such as extracts of keratin from animal hooves and/or horns, and mixtures thereof, relative to the total mass of said foam.
[0007511n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 0.1% to 7% by mass of the at least one protein or a mixture of animal or plant proteins selected from the group consisting of albumin, keratin hydrolysates such as extracts of keratin from animal hooves and/or horns, and mixtures thereof, relative to the total mass of said foam.
[0007611n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 0.1% to 5% by mass of the at least one protein or a mixture of animal or plant proteins selected from the group consisting of albumin, keratin hydrolysates such as extracts of keratin from animal hooves and/or horns, and mixtures thereof, relative to the total mass of said foam.
[00077]Preferably the at least one protein or mixture of animal or vegetable proteins are keratin hydrolysates.
[00078]The use of keratin hydrolysates facilitates the entrainment of air during the manufacture of the foam and provides a lubricating effect which allows better flow of the foam at densities less than or equal to 200 Kg/m3.
[0007911n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises at least one pH buffer.
Date Recue/Date Received 2021-03-30
9 [0008011n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 0,1% to 15% by mass of at least one pH buffer relative to the total mass of said foam.
[000811In one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 0,1% to 10% by mass of at least one pH buffer relative to the total mass of said foam.
[0008211n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 0.1% to 7% by mass of at least one pH buffer relative to the total mass of said foam.
[0008311n one embodiment, the geopolymer foam according to the invention is characterized in that it comprises at least one pH buffer, selected from the group consisting of monocalcium phosphate, bicalcium phosphate, citric acid, citrate, gamma butyrolactone esters, glyceryl triacetate, glycerol and mixtures thereof.
[0008411n one embodiment, the geopolymer foam according to the invention is characterized in that the at least one pH buffer is bi-calcium phosphate.
[0008511n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises at least one set-accelerator.
[0008611n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 0.1% to 8% by mass of at least one set-accelerator relative to the total mass of said foam.
[0008711n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 0.1% to 6% by mass of at least set-accelerator relative to the total mass of said foam.
[0008811n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 0.1% to 4% by mass of at least one set-accelerator relative to the total mass of said foam.
[0008911n one embodiment, the geopolymer foam according to the invention is characterized in that it comprises at least one set-accelerator selected from the group consisting of Portland cement, plaster of Paris, calcium hydroxide, hydrated lime, and mixtures thereof.
[0009011n one embodiment, the geopolymer foam according to the invention is characterized in that the at least one set-accelerator is hydrated lime.
[00091]The addition of a set-accelerator allows the foam produced at the exit of the machine to solidify in less than an hour to half an hour, thus freezing the distribution of gas microbubbles, i.e., cells or pores, this being a determining factor for obtaining good thermal insulation properties.
Date Recue/Date Received 2021-03-30
[000811In one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 0,1% to 10% by mass of at least one pH buffer relative to the total mass of said foam.
[0008211n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 0.1% to 7% by mass of at least one pH buffer relative to the total mass of said foam.
[0008311n one embodiment, the geopolymer foam according to the invention is characterized in that it comprises at least one pH buffer, selected from the group consisting of monocalcium phosphate, bicalcium phosphate, citric acid, citrate, gamma butyrolactone esters, glyceryl triacetate, glycerol and mixtures thereof.
[0008411n one embodiment, the geopolymer foam according to the invention is characterized in that the at least one pH buffer is bi-calcium phosphate.
[0008511n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises at least one set-accelerator.
[0008611n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 0.1% to 8% by mass of at least one set-accelerator relative to the total mass of said foam.
[0008711n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 0.1% to 6% by mass of at least set-accelerator relative to the total mass of said foam.
[0008811n one embodiment, the geopolymer foam according to the invention is characterized in that it further comprises from 0.1% to 4% by mass of at least one set-accelerator relative to the total mass of said foam.
[0008911n one embodiment, the geopolymer foam according to the invention is characterized in that it comprises at least one set-accelerator selected from the group consisting of Portland cement, plaster of Paris, calcium hydroxide, hydrated lime, and mixtures thereof.
[0009011n one embodiment, the geopolymer foam according to the invention is characterized in that the at least one set-accelerator is hydrated lime.
[00091]The addition of a set-accelerator allows the foam produced at the exit of the machine to solidify in less than an hour to half an hour, thus freezing the distribution of gas microbubbles, i.e., cells or pores, this being a determining factor for obtaining good thermal insulation properties.
Date Recue/Date Received 2021-03-30
10 [000921In one embodiment, the geopolymer foam according to the invention is characterized in that the thermal conductivity is between 0.025 and 0.05 W.m-2.K.
[000931In one embodiment, the geopolymer foam according to the invention is characterized in that its density is between 80 and 300 Kg/m3.
[000941In one embodiment, the geopolymer foam according to the invention is characterized in that its density is between 100 and 150 Kg/m3.
[000951In one embodiment, the foam according to the invention is characterized in that it has a thermal resistance greater than 900 C, preferably greater than 1000 C and even more preferably up to at least 1200 C.
[00096]The invention also relates to any support such as for example a fire door, an insulating panel, a furnace, a pipe, which comprises or upon which is affixed an incombustible inorganic foam as defined above. The support on which is affixed a non-combustible inorganic foam as defined above can be made of any material selected from organic, inorganic or metallic materials, such as for example a wooden board, a brick or a metal beam.
[00097]The invention also relates to a process for preparing a geopolymer foam comprising the following steps:
a) Place in contact within an aqueous solution, O at least one pozzolanic material, O an activation solution comprising at least one soluble metal hydroxide, O at least one silicate, O at least one surfactant, O fibers with lengths of between 5 and 1500 gm.
b) Mix by stirring and obtaining a suspension, c) Introduction of a gas, d) Hardening.
[000981In one embodiment, the process for preparing a geopolymer foam is characterized in that the at least one soluble metal hydroxide is an alkali metal hydroxide.
[00099]Preferably, the at least one alkali metal hydroxide is selected from the group consisting of sodium hydroxide and potassium hydroxide, alone or in combination.
[0001001In one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of the at least one surfactant relative to the total mass of the suspension obtained in step b) is between 0.03% and 0.6%.
[0001011In one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of the at least one surfactant relative to the total mass of the suspension obtained in step b) is between 0.03% and 0.45%.
Date Recue/Date Received 2021-03-30
[000931In one embodiment, the geopolymer foam according to the invention is characterized in that its density is between 80 and 300 Kg/m3.
[000941In one embodiment, the geopolymer foam according to the invention is characterized in that its density is between 100 and 150 Kg/m3.
[000951In one embodiment, the foam according to the invention is characterized in that it has a thermal resistance greater than 900 C, preferably greater than 1000 C and even more preferably up to at least 1200 C.
[00096]The invention also relates to any support such as for example a fire door, an insulating panel, a furnace, a pipe, which comprises or upon which is affixed an incombustible inorganic foam as defined above. The support on which is affixed a non-combustible inorganic foam as defined above can be made of any material selected from organic, inorganic or metallic materials, such as for example a wooden board, a brick or a metal beam.
[00097]The invention also relates to a process for preparing a geopolymer foam comprising the following steps:
a) Place in contact within an aqueous solution, O at least one pozzolanic material, O an activation solution comprising at least one soluble metal hydroxide, O at least one silicate, O at least one surfactant, O fibers with lengths of between 5 and 1500 gm.
b) Mix by stirring and obtaining a suspension, c) Introduction of a gas, d) Hardening.
[000981In one embodiment, the process for preparing a geopolymer foam is characterized in that the at least one soluble metal hydroxide is an alkali metal hydroxide.
[00099]Preferably, the at least one alkali metal hydroxide is selected from the group consisting of sodium hydroxide and potassium hydroxide, alone or in combination.
[0001001In one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of the at least one surfactant relative to the total mass of the suspension obtained in step b) is between 0.03% and 0.6%.
[0001011In one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of the at least one surfactant relative to the total mass of the suspension obtained in step b) is between 0.03% and 0.45%.
Date Recue/Date Received 2021-03-30
11 [0001021In one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of the at least one surfactant relative to the total mass of the suspension obtained in step b) is between 0.03% and 0.3%.
[0001031Preferably, in one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of the at least one surfactant relative to the total mass of the suspension obtained in step b) is between 0.03 and 0.15%.
[0001041In one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of fibers with lengths of between 5 and 1500 gm relative to the total mass of the suspension obtained in step b) is between 1% and 10%.
[0001051In one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of fibers with lengths of between 5 and 1500 gm relative to the total mass of the suspension obtained in step b) is between 1% and 8%.
[0001061In one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of fibers with lengths of between 5 and 1500 gm relative to the total mass of the suspension obtained in step b) is between 2% and 7%.
[0001071In one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of fibers with lengths of between 5 and 1500 gm relative to the total mass of the suspension obtained in step b) is between 3% and 6%.
[0001081In one embodiment, the process for preparing a geopolymer foam is characterized in that the fibers have lengths between 5 and 1000 gm.
[0001091In one embodiment, the process for preparing a geopolymer foam is characterized in that the fibers have lengths between 10 and 800 gm.
[00011011n one embodiment, the process for preparing a geopolymer foam is characterized in that the fibers have a diameter of between 5 and 50 gm.
[00011111n one embodiment, the process for preparing a geopolymer foam is characterized in that the fibers have a diameter of between 10 and 40 gm.
[0001121In one embodiment, the process for preparing a geopolymer foam is characterized in that the fibers have a diameter of between 15 and 30 gm.
[0001131In one embodiment, the process for preparing a geopolymer foam is characterized in that the fibers are cellulose fibers.
[0001141In one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of the pozzolanic material relative to the total mass of the suspension obtained in step b) is between 20% and 60%.
Date Recue/Date Received 2021-03-30
[0001031Preferably, in one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of the at least one surfactant relative to the total mass of the suspension obtained in step b) is between 0.03 and 0.15%.
[0001041In one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of fibers with lengths of between 5 and 1500 gm relative to the total mass of the suspension obtained in step b) is between 1% and 10%.
[0001051In one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of fibers with lengths of between 5 and 1500 gm relative to the total mass of the suspension obtained in step b) is between 1% and 8%.
[0001061In one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of fibers with lengths of between 5 and 1500 gm relative to the total mass of the suspension obtained in step b) is between 2% and 7%.
[0001071In one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of fibers with lengths of between 5 and 1500 gm relative to the total mass of the suspension obtained in step b) is between 3% and 6%.
[0001081In one embodiment, the process for preparing a geopolymer foam is characterized in that the fibers have lengths between 5 and 1000 gm.
[0001091In one embodiment, the process for preparing a geopolymer foam is characterized in that the fibers have lengths between 10 and 800 gm.
[00011011n one embodiment, the process for preparing a geopolymer foam is characterized in that the fibers have a diameter of between 5 and 50 gm.
[00011111n one embodiment, the process for preparing a geopolymer foam is characterized in that the fibers have a diameter of between 10 and 40 gm.
[0001121In one embodiment, the process for preparing a geopolymer foam is characterized in that the fibers have a diameter of between 15 and 30 gm.
[0001131In one embodiment, the process for preparing a geopolymer foam is characterized in that the fibers are cellulose fibers.
[0001141In one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of the pozzolanic material relative to the total mass of the suspension obtained in step b) is between 20% and 60%.
Date Recue/Date Received 2021-03-30
12 [00011511n one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of the pozzolanic material relative to the total mass of the suspension obtained in step b) is between 25% and 55%.
[00011611n one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of the pozzolanic material relative to the total mass of the suspension obtained in step b) is between 30% and 50%.
[00011711n one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of the pozzolanic material relative to the total mass of the suspension obtained in step b) is between 35% and 45%.
[00011811n one embodiment, the process for preparing a geopolymer foam is characterized in that in step a), the pozzolanic material is metakaolin.
[00011911n one embodiment, the process for preparing a geopolymer foam is characterized in that in step a) at least one hydrophobic agent is added.
[00012011n one embodiment, the process for preparing a geopolymer foam is characterized in that in step a) at least one hydrophobic agent from 2% to 10% by mass relative to the total mass of the suspension obtained in step b) is added.
[00012111n one embodiment, the process for preparing a geopolymer foam is characterized in that in step a) at least one hydrophobic agent from 2% to 8% by mass relative to the total mass of the suspension obtained in step b) is added.
[00012211n one embodiment, the process for preparing a geopolymer foam is characterized in that in step a) at least one hydrophobic agent from 2% to 6% by mass relative to the total mass of the suspension obtained in step b) is added.
[0001231In one embodiment, the process for preparing a geopolymer foam is characterized in that in step a) at least one thickener from 1% to 10% by mass relative to the total mass of the suspension obtained in step b) is added.
[00012411n one embodiment, the process for preparing a geopolymer foam is characterized in that in step a) at least one thickener is added.
[00012511n one embodiment, the process for preparing a geopolymer foam is characterized in that in step a) at least one thickener from 1% to 8% by mass relative to the total mass of the suspension obtained in step b) is added.
[00012611n one embodiment, the process for preparing a geopolymer foam is characterized in that in step a) at least one thickener from 3 to 7% by mass relative to the total mass of the suspension obtained in step b) is added.
[00012711n one embodiment, the process for preparing a geopolymer foam is characterized in that in step b) the stirring is carried out using a deflocculating disc dispenser.
Date Recue/Date Received 2021-03-30
[00011611n one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of the pozzolanic material relative to the total mass of the suspension obtained in step b) is between 30% and 50%.
[00011711n one embodiment, the process for preparing a geopolymer foam is characterized in that the amount of the pozzolanic material relative to the total mass of the suspension obtained in step b) is between 35% and 45%.
[00011811n one embodiment, the process for preparing a geopolymer foam is characterized in that in step a), the pozzolanic material is metakaolin.
[00011911n one embodiment, the process for preparing a geopolymer foam is characterized in that in step a) at least one hydrophobic agent is added.
[00012011n one embodiment, the process for preparing a geopolymer foam is characterized in that in step a) at least one hydrophobic agent from 2% to 10% by mass relative to the total mass of the suspension obtained in step b) is added.
[00012111n one embodiment, the process for preparing a geopolymer foam is characterized in that in step a) at least one hydrophobic agent from 2% to 8% by mass relative to the total mass of the suspension obtained in step b) is added.
[00012211n one embodiment, the process for preparing a geopolymer foam is characterized in that in step a) at least one hydrophobic agent from 2% to 6% by mass relative to the total mass of the suspension obtained in step b) is added.
[0001231In one embodiment, the process for preparing a geopolymer foam is characterized in that in step a) at least one thickener from 1% to 10% by mass relative to the total mass of the suspension obtained in step b) is added.
[00012411n one embodiment, the process for preparing a geopolymer foam is characterized in that in step a) at least one thickener is added.
[00012511n one embodiment, the process for preparing a geopolymer foam is characterized in that in step a) at least one thickener from 1% to 8% by mass relative to the total mass of the suspension obtained in step b) is added.
[00012611n one embodiment, the process for preparing a geopolymer foam is characterized in that in step a) at least one thickener from 3 to 7% by mass relative to the total mass of the suspension obtained in step b) is added.
[00012711n one embodiment, the process for preparing a geopolymer foam is characterized in that in step b) the stirring is carried out using a deflocculating disc dispenser.
Date Recue/Date Received 2021-03-30
13 [0001281The stirring speed is adapted based on the dimensions of the disc and the tank.
[00012911n one embodiment, the process for preparing a geopolymer foam is characterized in that between step b) and c) at least one protein or a mixture of animal or plant proteins selected from the group consisting of albumin, keratin hydrolysates such as extracts of keratin from animal hooves and/or horns, and mixtures thereof is added.
[00013011n one embodiment, the process for preparing a geopolymer foam is characterized in that between step b) and c) between 0.1% to 4% by mass of at least one protein or one mixture of animal or vegetable proteins selected from the group consisting of albumin, keratin hydrolysates such as extracts of keratin from animal hooves and/or horns, and mixtures thereof, relative to the total mass of the suspension obtained in step b) is added.
[00013 On one embodiment, the process for preparing a geopolymer foam is characterized in that between step b) and c) between 0.1% to 3% by mass of at least one protein or one mixture of animal or vegetable proteins selected from the group consisting of albumin, keratin hydrolysates such as extracts of keratin from animal hooves and/or horns, and mixtures thereof, relative to the total mass of the suspension obtained in step b) is added.
[00013211n one embodiment, the process for preparing a geopolymer foam is characterized in that between step b) and c) between 0.1% to 2% by mass of at least one protein or one mixture of animal or vegetable proteins selected from the group consisting of albumin, keratin hydrolysates such as extracts of keratin from animal hooves and/or horns, and mixtures thereof, relative to the total mass of the suspension obtained in step b) is added.
[0001331In one embodiment, the process for preparing a geopolymer foam is characterized in that between step b) and c) at least one set-accelerator is added.
[00013411n one embodiment, the process for preparing a geopolymer foam is characterized in that between step b) and c) at least one set-accelerator from 0.1% to 4% by mass relative to the total mass of the suspension obtained in step b) is added.
[00013511n one embodiment, the process for preparing a geopolymer foam is characterized in that between step b) and c) at least one set-accelerator from 0.1% to 3% by mass relative to the total mass of the suspension obtained in step b) is added.
[00013611n one embodiment, the process for preparing a geopolymer foam is characterized in that between step b) and c) at least one set-accelerator from 0.1% to 2% by mass relative to the total mass of the suspension obtained in step b) is added.
[00013711n one embodiment, the process for preparing a geopolymer foam is characterized in that between step b) and c) the at least one set-accelerator is hydrated lime.
[0001381The term -gas" is understood to mean any body which is in the state of an expandable and compressible fluid (gaseous state) under normal temperature and pressure conditions.
Date Recue/Date Received 2021-03-30
[00012911n one embodiment, the process for preparing a geopolymer foam is characterized in that between step b) and c) at least one protein or a mixture of animal or plant proteins selected from the group consisting of albumin, keratin hydrolysates such as extracts of keratin from animal hooves and/or horns, and mixtures thereof is added.
[00013011n one embodiment, the process for preparing a geopolymer foam is characterized in that between step b) and c) between 0.1% to 4% by mass of at least one protein or one mixture of animal or vegetable proteins selected from the group consisting of albumin, keratin hydrolysates such as extracts of keratin from animal hooves and/or horns, and mixtures thereof, relative to the total mass of the suspension obtained in step b) is added.
[00013 On one embodiment, the process for preparing a geopolymer foam is characterized in that between step b) and c) between 0.1% to 3% by mass of at least one protein or one mixture of animal or vegetable proteins selected from the group consisting of albumin, keratin hydrolysates such as extracts of keratin from animal hooves and/or horns, and mixtures thereof, relative to the total mass of the suspension obtained in step b) is added.
[00013211n one embodiment, the process for preparing a geopolymer foam is characterized in that between step b) and c) between 0.1% to 2% by mass of at least one protein or one mixture of animal or vegetable proteins selected from the group consisting of albumin, keratin hydrolysates such as extracts of keratin from animal hooves and/or horns, and mixtures thereof, relative to the total mass of the suspension obtained in step b) is added.
[0001331In one embodiment, the process for preparing a geopolymer foam is characterized in that between step b) and c) at least one set-accelerator is added.
[00013411n one embodiment, the process for preparing a geopolymer foam is characterized in that between step b) and c) at least one set-accelerator from 0.1% to 4% by mass relative to the total mass of the suspension obtained in step b) is added.
[00013511n one embodiment, the process for preparing a geopolymer foam is characterized in that between step b) and c) at least one set-accelerator from 0.1% to 3% by mass relative to the total mass of the suspension obtained in step b) is added.
[00013611n one embodiment, the process for preparing a geopolymer foam is characterized in that between step b) and c) at least one set-accelerator from 0.1% to 2% by mass relative to the total mass of the suspension obtained in step b) is added.
[00013711n one embodiment, the process for preparing a geopolymer foam is characterized in that between step b) and c) the at least one set-accelerator is hydrated lime.
[0001381The term -gas" is understood to mean any body which is in the state of an expandable and compressible fluid (gaseous state) under normal temperature and pressure conditions.
Date Recue/Date Received 2021-03-30
14 [00013911n one embodiment, the process for preparing a geopolymer foam is characterized in that in step c), the gas is air.
[00014011n one embodiment, the process for preparing a geopolymer foam is characterized in that in step c) the introduction of gas is carried out using an expansion machine.
[0001411The use of an expansion machine, also called an aerator/mixer, with a dynamic or static expansion unit, preferably dynamic, ensures control over the definition of the densities of the foam, the density and the size of the cells present in it through flow controls, which are desirable characteristics for non-combustible foams according to industrial applications.
[0001421The invention also relates to a composition for the preparation of a geopolymer foam comprising:
- an alkaline activation solution comprising at least one soluble metal hydroxide, - at least one silicate;
- at least one surfactant, - fibers with lengths of between 5 and 1500 gm.
[00014311n one embodiment, the composition for preparing a geopolymer foam is characterized in that the at least one soluble metal hydroxide is an alkali metal hydroxide.
[000144]Preferably, the at least one alkali metal hydroxide is selected from the group consisting of sodium hydroxide and potassium hydroxide, alone or in combination.
[00014511n one embodiment, the composition for preparing a geopolymer foam is characterized in that it comprises at least one surfactant from 0.03% to 0.6% by mass relative to the total mass of said composition.
[00014611n one embodiment, the composition for preparing a geopolymer foam is characterized in that it comprises at least one surfactant from 0.03% to 0.45% by mass relative to the total mass of said composition.
[00014711n one embodiment, the composition for preparing a geopolymer foam is characterized in that it comprises at least one surfactant from 0.03% to 0.3% by mass relative to the total mass of said composition.
[00014811n one embodiment, the composition for the preparation of a geopolymer foam is characterized in that the at least one surfactant is selected from the group consisting of nonionic alkyl polyglucoside surfactants.
[00014911n one embodiment, the composition for preparing a geopolymer foam is characterized in that it comprises fibers with lengths of between 5 and 1500 pm from 1% to 10% by mass relative to the total mass of said composition.
Date Recue/Date Received 2021-03-30
[00014011n one embodiment, the process for preparing a geopolymer foam is characterized in that in step c) the introduction of gas is carried out using an expansion machine.
[0001411The use of an expansion machine, also called an aerator/mixer, with a dynamic or static expansion unit, preferably dynamic, ensures control over the definition of the densities of the foam, the density and the size of the cells present in it through flow controls, which are desirable characteristics for non-combustible foams according to industrial applications.
[0001421The invention also relates to a composition for the preparation of a geopolymer foam comprising:
- an alkaline activation solution comprising at least one soluble metal hydroxide, - at least one silicate;
- at least one surfactant, - fibers with lengths of between 5 and 1500 gm.
[00014311n one embodiment, the composition for preparing a geopolymer foam is characterized in that the at least one soluble metal hydroxide is an alkali metal hydroxide.
[000144]Preferably, the at least one alkali metal hydroxide is selected from the group consisting of sodium hydroxide and potassium hydroxide, alone or in combination.
[00014511n one embodiment, the composition for preparing a geopolymer foam is characterized in that it comprises at least one surfactant from 0.03% to 0.6% by mass relative to the total mass of said composition.
[00014611n one embodiment, the composition for preparing a geopolymer foam is characterized in that it comprises at least one surfactant from 0.03% to 0.45% by mass relative to the total mass of said composition.
[00014711n one embodiment, the composition for preparing a geopolymer foam is characterized in that it comprises at least one surfactant from 0.03% to 0.3% by mass relative to the total mass of said composition.
[00014811n one embodiment, the composition for the preparation of a geopolymer foam is characterized in that the at least one surfactant is selected from the group consisting of nonionic alkyl polyglucoside surfactants.
[00014911n one embodiment, the composition for preparing a geopolymer foam is characterized in that it comprises fibers with lengths of between 5 and 1500 pm from 1% to 10% by mass relative to the total mass of said composition.
Date Recue/Date Received 2021-03-30
15 [00015011n one embodiment, the composition for preparing a geopolymer foam is characterized in that it comprises fibers with lengths of between 5 and 1500 pm from 1% to 8% by mass relative to the total mass of said composition.
[00015111n one embodiment, the composition for preparing a geopolymer foam is characterized in that it comprises fibers with lengths of between 5 and 1500 pm from 2% to 7% by mass relative to the total mass of said composition.
[0001521In one embodiment, the composition for preparing a geopolymer foam is characterized in that it comprises fibers with lengths of between 5 and 1500 pm from 3% to 6% by mass relative to the total mass of said composition.
[00015311n one embodiment, the composition for preparing a geopolymer foam is characterized in that the fibers have lengths between 5 and 1000 gm.
[00015411n one embodiment, the composition for preparing a geopolymer foam is characterized in that the fibers have lengths between 10 and 800 gm.
[00015511n one embodiment, the composition for preparing a geopolymer foam is characterized in that the fibers have a diameter of between 5 and 50 gm.
[00015611n one embodiment, the composition for preparing a geopolymer foam is characterized in that the fibers have a diameter of between 10 and 40 gm.
[0001571In one embodiment, the composition for preparing a geopolymer foam is characterized in that the fibers have a diameter of between 15 and 30 gm.
[00015811n one embodiment, the composition for preparing a geopolymer foam is characterized in that the fibers are cellulose fibers.
[00015911n one embodiment, the composition for preparing a geopolymer foam is characterized in that it further comprises at least one hydrophobic agent.
[00016011n one embodiment, the composition for preparing a geopolymer foam is characterized in that it further comprises at least one hydrophobic agent from 2% to 10% by mass relative to the total mass of said composition.
[00016111n one embodiment, the composition for preparing a geopolymer foam is characterized in that it comprises at least one hydrophobic agent from 2% to 8% by mass relative to the total mass of said composition.
[0001621In one embodiment, the composition for preparing a geopolymer foam is characterized in that it further comprises at least one hydrophobic agent from 2% to 6% by mass relative to the total mass of said composition.
[00016311n one embodiment, the geopolymer foam according to the invention is characterized in that the at least one hydrophobic agent is selected from the group consisting of siliconates, silanes, siloxanes and mixtures thereof.
Date Recue/Date Received 2021-03-30
[00015111n one embodiment, the composition for preparing a geopolymer foam is characterized in that it comprises fibers with lengths of between 5 and 1500 pm from 2% to 7% by mass relative to the total mass of said composition.
[0001521In one embodiment, the composition for preparing a geopolymer foam is characterized in that it comprises fibers with lengths of between 5 and 1500 pm from 3% to 6% by mass relative to the total mass of said composition.
[00015311n one embodiment, the composition for preparing a geopolymer foam is characterized in that the fibers have lengths between 5 and 1000 gm.
[00015411n one embodiment, the composition for preparing a geopolymer foam is characterized in that the fibers have lengths between 10 and 800 gm.
[00015511n one embodiment, the composition for preparing a geopolymer foam is characterized in that the fibers have a diameter of between 5 and 50 gm.
[00015611n one embodiment, the composition for preparing a geopolymer foam is characterized in that the fibers have a diameter of between 10 and 40 gm.
[0001571In one embodiment, the composition for preparing a geopolymer foam is characterized in that the fibers have a diameter of between 15 and 30 gm.
[00015811n one embodiment, the composition for preparing a geopolymer foam is characterized in that the fibers are cellulose fibers.
[00015911n one embodiment, the composition for preparing a geopolymer foam is characterized in that it further comprises at least one hydrophobic agent.
[00016011n one embodiment, the composition for preparing a geopolymer foam is characterized in that it further comprises at least one hydrophobic agent from 2% to 10% by mass relative to the total mass of said composition.
[00016111n one embodiment, the composition for preparing a geopolymer foam is characterized in that it comprises at least one hydrophobic agent from 2% to 8% by mass relative to the total mass of said composition.
[0001621In one embodiment, the composition for preparing a geopolymer foam is characterized in that it further comprises at least one hydrophobic agent from 2% to 6% by mass relative to the total mass of said composition.
[00016311n one embodiment, the geopolymer foam according to the invention is characterized in that the at least one hydrophobic agent is selected from the group consisting of siliconates, silanes, siloxanes and mixtures thereof.
Date Recue/Date Received 2021-03-30
16 [0001641The invention also relates to the use of a composition for the preparation of a geopolymer foam as described above.
[000165] The invention also relates to a kit comprising:
- a composition for the preparation of a geopolymer foam as described above;
- a pozzolanic material.
[00016611n one embodiment, the kit according to the invention is characterized in that the pozzolanic material is metakaolin.
The different elements of the kit are not in contact with each other for an extemporaneous preparation of geopolymer mineral foam.
Date Recue/Date Received 2021-03-30
[000165] The invention also relates to a kit comprising:
- a composition for the preparation of a geopolymer foam as described above;
- a pozzolanic material.
[00016611n one embodiment, the kit according to the invention is characterized in that the pozzolanic material is metakaolin.
The different elements of the kit are not in contact with each other for an extemporaneous preparation of geopolymer mineral foam.
Date Recue/Date Received 2021-03-30
17 Examples [000167]Example 1: Composition for the preparation of a geopolymer foam according to the invention:
% of dry material Components s Pozzolanic 1 Metakaolin 26.05 Material 2A Sodium Hydroxide 4.66 Activation ___________________________________________ Solution 2B Sodium Silicate 10.98 Hydrophobic Agent Potassium Methyl 3 Silicone 4.02 Nonionic Surfactant Alkyl Polyglucoside 4 SFT 5L8 0.034 Nonionic Surfactant Alkyl Polyglucoside 5L826 0.034 Powdered Egg 6 Albumin Fraction 0.74 7 Kaolinitic Clays 5.21 pH Buffer 8 CaHPO4 2.61 Cellulose fibers of a length of 18 or 40 gm TECHNOCEL 10 or 9 40 1.49 Cellulose fibers of a Other length of 150gm Components 10 TECHNOCEL 90-2 1.49 Date Recue/Date Received 2021-03-30
% of dry material Components s Pozzolanic 1 Metakaolin 26.05 Material 2A Sodium Hydroxide 4.66 Activation ___________________________________________ Solution 2B Sodium Silicate 10.98 Hydrophobic Agent Potassium Methyl 3 Silicone 4.02 Nonionic Surfactant Alkyl Polyglucoside 4 SFT 5L8 0.034 Nonionic Surfactant Alkyl Polyglucoside 5L826 0.034 Powdered Egg 6 Albumin Fraction 0.74 7 Kaolinitic Clays 5.21 pH Buffer 8 CaHPO4 2.61 Cellulose fibers of a length of 18 or 40 gm TECHNOCEL 10 or 9 40 1.49 Cellulose fibers of a Other length of 150gm Components 10 TECHNOCEL 90-2 1.49 Date Recue/Date Received 2021-03-30
18 Cellulose fibers of a length of 500 and 700 Ilm 11 and 1000 0.74 12 Keratin Hy drolysate 1.19 Hydrated Lime 13 Ca(OH)2 1.12 EAU Total 39.63%
[000168]Table 1: Composition for the preparation of a geopolymer foam according to the invention with a 100% basic Na activating solution.
[000169] Example 2: Composition for the preparation of a geopolymer foam according to the invention:
% of dry Components materials Pozzolanic 1 Metakaolin 25.69 Material ____________________________________________ 2A Potassium Hydroxide 6.17 Activation __________________________________________ Solution 2B Sodium Silicate 4.46 2C Potassium Silicate .. 6.31 Other 3 Hydrophobic Agent Components Potassium Methyl Silicone 4.08 4 Nonionic Surfactant Alkyl Polyglucoside SFT 5L8 0.034 Nonionic Surfactant Alkyl Polyglucoside 5L826 0.034 6 Powdered Egg Albumin Fraction 0.76 7 Kaolinitic Clays 6.04 8 pH Buffer CaHPO4 1.13 Date Recue/Date Received 2021-03-30
[000168]Table 1: Composition for the preparation of a geopolymer foam according to the invention with a 100% basic Na activating solution.
[000169] Example 2: Composition for the preparation of a geopolymer foam according to the invention:
% of dry Components materials Pozzolanic 1 Metakaolin 25.69 Material ____________________________________________ 2A Potassium Hydroxide 6.17 Activation __________________________________________ Solution 2B Sodium Silicate 4.46 2C Potassium Silicate .. 6.31 Other 3 Hydrophobic Agent Components Potassium Methyl Silicone 4.08 4 Nonionic Surfactant Alkyl Polyglucoside SFT 5L8 0.034 Nonionic Surfactant Alkyl Polyglucoside 5L826 0.034 6 Powdered Egg Albumin Fraction 0.76 7 Kaolinitic Clays 6.04 8 pH Buffer CaHPO4 1.13 Date Recue/Date Received 2021-03-30
19 9 Cellulose fibers of a length of 18 or 40 gm TECHNOCEL 10 or 40 1.51 Cellulose fibers of a length of 150 gm TECHNOCEL 90-2 1.51 11 Cellulose fibers of a length of 500 and 700 gm TECHNOCEL 300 and 1000 0.76 12 Keratin hydrolysate 1.21 13 Hydrated Lime Ca(OH)2 1.13 EAU Total 39.17%
[000170]Table 2: Composition for the preparation of a geopolymer foam according to the invention with a K based basic activating solution.
[000171]Example 3: Manufacture of a geopolymer foam according to the invention.
[0001721Manufacturing the cream:
[0001731Liquid components (2A, 2B, 2C, 3, 4, 5) are mixed, solid components (1, 6, 7) and fibers (9, 10, 11) are added and stirred with a deflocculating disc dispenser at 1000-1500 rpm for approximately 25 minutes. The temperature of the mixture is maintained at 18-
[000170]Table 2: Composition for the preparation of a geopolymer foam according to the invention with a K based basic activating solution.
[000171]Example 3: Manufacture of a geopolymer foam according to the invention.
[0001721Manufacturing the cream:
[0001731Liquid components (2A, 2B, 2C, 3, 4, 5) are mixed, solid components (1, 6, 7) and fibers (9, 10, 11) are added and stirred with a deflocculating disc dispenser at 1000-1500 rpm for approximately 25 minutes. The temperature of the mixture is maintained at 18-
20 C.
[0001741Manufacturing the foam:
[0001751The component 8 is added and mixed for 1 min under the same conditions, then components 12, 13, as well as water QSP are mixed for one minute. The cream may then be aerated using an expansion machine. The air and cream flow rates and the speed of the expansion unit are adjusted to obtain the final foam upon leaving the machine.
[000176]Example 4: Comparative test between a geopolymer foam according to the invention with and without fibers, as well as with a geopolymer foam disclosed in W02018091482.
[0001771A simplified geopolymer foam composition was carried out to demonstrate the effect of the presence or absence of micrometric sized fibers on the texture of the geopolymer foam.
[0001781The composition of the 3 samples tested is summarized in the following Table 3:
Date Recue/Date Received 2021-03-30 Components % of dry materials Metakaolin 26.72 K based activating solution 17.61 Hydrophobic Agent 4.25 Surfactants 0.07 EAU Total 51.35%
[000179] Table 3: composition of samples tested.
[000180]Three portions of the above composition weighing 200 g or 230 ml are poured into 3 separate 1L beakers.
[0001811No addition is made to a first beaker A.
[0001821In a second beaker B, 4.33% by mass of fibers having a length of 18 pm relative to the total mass of the composition is added. 99.5% of these fibers are less than 32 gm in length.
[0001831In a third beaker C, 4.33% of millimetric fibers is added. In particular, these millimetric fibers are used as fillers in the composition of the geopolymer foam disclosed in W02018091482.
80% of the millimetric fibers added have a length of between 800 pm and 2.5 mm.
[0001841The various fibers added to beakers B and C are mixed by stirring for 3 minutes and then the mixture is left to stand for 10 minutes before being stirred again for one minute at low speed.
[0001851The foams are then produced using a kitchen mixer with 5 speeds, in the following sequence:
- 30 seconds at speed 1 (the lowest speed);
- 2 minutes and 30 seconds at speed 4.
The same operating mode is applied to the 3 mixtures, A, B and C.
[0001861The 3 samples are then left to stand for solidification.
[0001871Results:
[0001881At T = 2 hours, a change in surface appearance is observed in sample A
as well as in sample C. No change is observed in sample B.
[0001891At T = 5 hours, the samples are completely solidified. A marked and clear porosity is observed in samples A and C, while sample B has a homogeneous appearance with fine porosity.
[000190]The appearance of the 3 different samples is illustrated in Figure 1.
[000191]These observations demonstrate that the use of fibers of micrometric sizes in a geopolymer foam composition confers upon it the nature of a closed cell or pore after solidification.
Date Recue/Date Received 2021-03-30
[0001741Manufacturing the foam:
[0001751The component 8 is added and mixed for 1 min under the same conditions, then components 12, 13, as well as water QSP are mixed for one minute. The cream may then be aerated using an expansion machine. The air and cream flow rates and the speed of the expansion unit are adjusted to obtain the final foam upon leaving the machine.
[000176]Example 4: Comparative test between a geopolymer foam according to the invention with and without fibers, as well as with a geopolymer foam disclosed in W02018091482.
[0001771A simplified geopolymer foam composition was carried out to demonstrate the effect of the presence or absence of micrometric sized fibers on the texture of the geopolymer foam.
[0001781The composition of the 3 samples tested is summarized in the following Table 3:
Date Recue/Date Received 2021-03-30 Components % of dry materials Metakaolin 26.72 K based activating solution 17.61 Hydrophobic Agent 4.25 Surfactants 0.07 EAU Total 51.35%
[000179] Table 3: composition of samples tested.
[000180]Three portions of the above composition weighing 200 g or 230 ml are poured into 3 separate 1L beakers.
[0001811No addition is made to a first beaker A.
[0001821In a second beaker B, 4.33% by mass of fibers having a length of 18 pm relative to the total mass of the composition is added. 99.5% of these fibers are less than 32 gm in length.
[0001831In a third beaker C, 4.33% of millimetric fibers is added. In particular, these millimetric fibers are used as fillers in the composition of the geopolymer foam disclosed in W02018091482.
80% of the millimetric fibers added have a length of between 800 pm and 2.5 mm.
[0001841The various fibers added to beakers B and C are mixed by stirring for 3 minutes and then the mixture is left to stand for 10 minutes before being stirred again for one minute at low speed.
[0001851The foams are then produced using a kitchen mixer with 5 speeds, in the following sequence:
- 30 seconds at speed 1 (the lowest speed);
- 2 minutes and 30 seconds at speed 4.
The same operating mode is applied to the 3 mixtures, A, B and C.
[0001861The 3 samples are then left to stand for solidification.
[0001871Results:
[0001881At T = 2 hours, a change in surface appearance is observed in sample A
as well as in sample C. No change is observed in sample B.
[0001891At T = 5 hours, the samples are completely solidified. A marked and clear porosity is observed in samples A and C, while sample B has a homogeneous appearance with fine porosity.
[000190]The appearance of the 3 different samples is illustrated in Figure 1.
[000191]These observations demonstrate that the use of fibers of micrometric sizes in a geopolymer foam composition confers upon it the nature of a closed cell or pore after solidification.
Date Recue/Date Received 2021-03-30
21 [0001921Example 5: Comparative test between a foam according to the invention and a foam disclosed in W02018091482 [00019210ne sample of each foam is available in the form of cylindrical stoppers of approximately 800 ml. The samples have similar densities (approximately 250 Kg/m3).
[000194] Each of the 2 samples was placed in a large container filled with water. Each container are sized to allow free movement of the sample and its complete immersion. The samples are placed on water and left for 5 min. The immersion height of each sample in water is measured and expressed as a percentage of the total height of the latter.
[0001951The samples are then removed from the water and placed on an inclined plane so as to drain out the water trapped in their porosities for a period of 2 hours.
[0001961The samples are weighed before testing and after draining, the increase in weight as compared to the initial weight is expressed as a percentage.
[000197] Case of the foam sample disclosed in W02018091482:
= Immersion height after 5 min. = 75 to 80%, the sample gradually sinks.
= Weight increase after draining = 81%
[000198] Case of the foam sample according to the invention = Immersion height after 5 min = 10-15%, the immersion depth remains unchanged, the sample floats.
= Weight increase after draining = 0.9%
[000199] These observations demonstrate that the foam according to the invention has a majority of closed cells unlike the foam disclosed in W02018091482, the porosity of which is open.
Date Recue/Date Received 2021-03-30
[000194] Each of the 2 samples was placed in a large container filled with water. Each container are sized to allow free movement of the sample and its complete immersion. The samples are placed on water and left for 5 min. The immersion height of each sample in water is measured and expressed as a percentage of the total height of the latter.
[0001951The samples are then removed from the water and placed on an inclined plane so as to drain out the water trapped in their porosities for a period of 2 hours.
[0001961The samples are weighed before testing and after draining, the increase in weight as compared to the initial weight is expressed as a percentage.
[000197] Case of the foam sample disclosed in W02018091482:
= Immersion height after 5 min. = 75 to 80%, the sample gradually sinks.
= Weight increase after draining = 81%
[000198] Case of the foam sample according to the invention = Immersion height after 5 min = 10-15%, the immersion depth remains unchanged, the sample floats.
= Weight increase after draining = 0.9%
[000199] These observations demonstrate that the foam according to the invention has a majority of closed cells unlike the foam disclosed in W02018091482, the porosity of which is open.
Date Recue/Date Received 2021-03-30
Claims (5)
1. Geopolymer foam comprising:
- from 50% to 90% by mass of pozzolanic material polymerized relative to the total mass of said foam;
- from 0.01% to 2%, by mass of at least one surfactant relative to the total mass of said foam;
- from 1% to 20% by mass of fibers with lengths of between 5 and 1500 pm relative to the total mass of said foam.
- from 50% to 90% by mass of pozzolanic material polymerized relative to the total mass of said foam;
- from 0.01% to 2%, by mass of at least one surfactant relative to the total mass of said foam;
- from 1% to 20% by mass of fibers with lengths of between 5 and 1500 pm relative to the total mass of said foam.
2. Geopolymer foam according to claim 1 characterized in that the pozzolanic material is metakaolin.
3. Process for the preparation of a geopolymer foam comprising the following steps:
a) Place in contact within an aqueous solution, O at least one pozzolanic material, O an activation solution comprising at least one soluble metal hydroxide, O at least one silicate, O at least one surfactant, O fibers with lengths of between 5 and 1500 gm.
b) Mix by stirring and obtaining a suspension, c) Introduction of a gas, d) Hardening.
a) Place in contact within an aqueous solution, O at least one pozzolanic material, O an activation solution comprising at least one soluble metal hydroxide, O at least one silicate, O at least one surfactant, O fibers with lengths of between 5 and 1500 gm.
b) Mix by stirring and obtaining a suspension, c) Introduction of a gas, d) Hardening.
4. Process for the preparation of a geopolymer foam according to claim 3 characterized in that the amount of the at least one surfactant relative to the total mass of the suspension obtained in step b) is between 0.03% and 0.6%.
5. Process for the preparation of a geopolymer foam according to either of claims 3 and 4, characterized in that the amount of fibers with lengths of between 5 and 1500 gm relative to the total mass of the suspension obtained in step b) is between 1% and 10%.
Date Recue/Date Received 2021-03-30
Date Recue/Date Received 2021-03-30
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| FR19/13833 | 2019-12-05 | ||
| FR1913833A FR3104153B1 (en) | 2019-12-05 | 2019-12-05 | CLOSED CELL GEOPOLYMER FOAM |
| PCT/EP2020/084954 WO2021111011A1 (en) | 2019-12-05 | 2020-12-07 | Closed cell geopolymer foam |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA3113656A1 true CA3113656A1 (en) | 2021-06-05 |
Family
ID=76206810
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA3113656A Pending CA3113656A1 (en) | 2019-12-05 | 2020-12-07 | Closed cell geopolymer foam |
Country Status (4)
| Country | Link |
|---|---|
| US (1) | US11673834B2 (en) |
| EP (1) | EP4069655A1 (en) |
| CA (1) | CA3113656A1 (en) |
| MX (1) | MX2021003102A (en) |
Family Cites Families (14)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2659963B1 (en) | 1990-03-20 | 1994-01-14 | Cordi Geopolymere Sa | COATINGS MO, FO, IN GEOPOLYMERIC MATERIALS INTENDED FOR THERMAL PROTECTION, AND PROCESSES FOR OBTAINING SAME. |
| FR2680194B1 (en) | 1991-08-09 | 1998-08-28 | Poudres & Explosifs Ste Nale | PROCESS FOR THERMAL INSULATION OF A CONSTRUCTION ELEMENT. |
| DE102004006563A1 (en) | 2004-02-10 | 2005-09-01 | Aksys Gmbh | Inorganic-organic hybrid foam, is formed by mixing inorganic reactive components, a hardener, a foaming agent, a silicon compound and a tenside, followed by hardening |
| GB0911633D0 (en) | 2009-07-06 | 2009-08-12 | Banah Uk Ltd | Geopolymeric structural building units and methods of manufacture thereof |
| US20140005302A1 (en) | 2010-10-14 | 2014-01-02 | Tnemec Company, Inc. | Geopolymer and epoxy simultaneous interpenetrating polymer network composition, and methods for the same |
| DE102012007396B3 (en) | 2012-04-16 | 2013-06-13 | Cast Aluminium Industries | Forming a rapid setting-inorganic foam, comprises reacting a powder comprising oxides and nitrides of aluminum and metallic aluminum with an alkali metal silicate (water glass) to form a paste, and forming a foam body by exothermic reaction |
| EP2868638A1 (en) | 2013-10-31 | 2015-05-06 | Construction Research & Technology GmbH | Self-foaming geopolymer composition containing aluminum dross |
| EP2868637A1 (en) | 2013-10-31 | 2015-05-06 | Construction Research & Technology GmbH | Geopolymer foam formulation |
| BE1021769B1 (en) | 2013-12-06 | 2016-01-15 | S.A.Lhoist Recherche Et Developpement | BINDER COMPOSITION FOR PERFORATED MORTAR AND COATING. |
| BE1021808B1 (en) | 2013-12-06 | 2016-01-19 | S.A. Lhoist Recherche Et Developpement | BINDER COMPOSITION FOR MORTARS, BEDS AND LIGHT COATINGS WITH VEGETABLE AGGREGATES OR BIO SOURCES. |
| FR3027023B1 (en) | 2014-10-09 | 2019-04-26 | Glaztec'h | NEW POROUS MINERAL RIGID FOAMS AND USES THEREOF |
| US10766813B2 (en) | 2016-02-08 | 2020-09-08 | Halliburton Energy Services, Inc. | Nanocellulose foam stabilizing additive |
| CA3019760A1 (en) | 2016-04-07 | 2017-10-12 | Construction Research & Technology Gmbh | Geopolymer foam formulation |
| FR3058719B1 (en) | 2016-11-17 | 2018-12-07 | Isolfeu-Creation | GEOPOLYMER FOAM WITH IMPROVED PROPERTIES |
-
2020
- 2020-12-07 EP EP20817374.0A patent/EP4069655A1/en active Pending
- 2020-12-07 MX MX2021003102A patent/MX2021003102A/en unknown
- 2020-12-07 US US17/269,122 patent/US11673834B2/en active Active
- 2020-12-07 CA CA3113656A patent/CA3113656A1/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| MX2021003102A (en) | 2021-09-14 |
| US11673834B2 (en) | 2023-06-13 |
| EP4069655A1 (en) | 2022-10-12 |
| US20220119314A1 (en) | 2022-04-21 |
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