Classifications

• • 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
  • C04B28/34—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 cold phosphate binders
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F24—HEATING; RANGES; VENTILATING
  • F24C—DOMESTIC STOVES OR RANGES ; DETAILS OF DOMESTIC STOVES OR RANGES, OF GENERAL APPLICATION
  • F24C1/00—Stoves or ranges in which the fuel or energy supply is not restricted to solid fuel or to a type covered by a single one of the following groups F24C3/00 - F24C9/00; Stoves or ranges in which the type of fuel or energy supply is not specified
  • F24C1/08—Stoves or ranges in which the fuel or energy supply is not restricted to solid fuel or to a type covered by a single one of the following groups F24C3/00 - F24C9/00; Stoves or ranges in which the type of fuel or energy supply is not specified solely adapted for radiation heating
  • F24C1/10—Stoves or ranges in which the fuel or energy supply is not restricted to solid fuel or to a type covered by a single one of the following groups F24C3/00 - F24C9/00; Stoves or ranges in which the type of fuel or energy supply is not specified solely adapted for radiation heating with reflectors
  • F24C1/12—Stoves or ranges in which the fuel or energy supply is not restricted to solid fuel or to a type covered by a single one of the following groups F24C3/00 - F24C9/00; Stoves or ranges in which the type of fuel or energy supply is not specified solely adapted for radiation heating with reflectors of circular shape
• • 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
  • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
  • C04B2111/00482—Coating or impregnation materials

Definitions

• This invention relates generally to bonded aggregate structures and their production and to improved building (wall, floor and ceiling) panel structures and the like laminated with bonded aggregate and methods for their production.
• Bonded aggregate structures are well known for refractory purposes (e.g., 3,285,758) and for outdoor load-bearing and road repair use (e.g., 4,059,455).
• the mixtures used for forming the known structures require a high content of ammonium phosphate components.
• Such use is impractical and even hazardous for many purposes, particularly indoors or at building sites where good ventilation is unavailable to remove the high concentration of gaseous ammonia generated by the bonding reaction. It is therefore an object of the present invention to provide bonded aggregate structures and means for their production which avoid the disadvantages of the prior art structures and processes.
• the invention in one aspect is in bonded aggregate structures obtained at ambient temperature by establishing a workable aggregate mixture which undergoes an exothermic reaction, working the mixture into a predetermined form prior to setting, and allowing the worked form to set into a rigid structure.
• the workable mixtures of the invention are constituted with magnesium oxide, silicate, aggregate and aluminum phosphate acidic solution; optionally with compatible structural fibers such as glass fibers and filaments. While the quality and proportions of the components are not particularly critical, the weight ratio of silicate (a typical silicate being mullite) to acidic solution (expressed as 50% solution with a weight ratio P 2 O 5 : Al 2 O 3 of about 4 ) suitably is from about 3:2 to about 4:1, the weight ratio of magnesium oxide to (silicate (i.e., mullite) is from about 1:7 to about 1:10, and the quantity of acidic solution relative to the total mixture is sufficient prior to setting to impart lubricity (that is, smoothness and uniformity) to the mixture.
• silicate a typical silicate being mullite
• acidic solution expressed as 50% solution with a weight ratio P 2 O 5 : Al 2 O 3 of about 4
• the weight ratio of magnesium oxide to (silicate (i.e., mullite) is from about 1:7
• the setting time of the mixture can be varied as desired. By increasing the relative proportion of silicate the setting time is increased.
• a workable mixture of the invention constituted with magnesium oxide, silicate (such as silicate sand or aluminum silicate), light weight aggregates such as vermiculite, perlite or glass beads and aqueous mono aluminum phosphate acidic solution, may be combined to form a light weight, low density material used for insulating purposes.
• the weight ratio of magnesium oxide to the mono aluminum phosphate acidic solution is approximately 3:1.
• This light weight mixture may be expanded for insulating purposes by adding a carbonate to the mixture.
• Various carbonates such as dolomite, magnesium carbonate, caffeine carbonate and sodium carbonate may be used at a weight ratio of carbonate to magnesium oxide from 3:1 to 4:1.
• By adding as much as 40 to 60% of the carbonate material to the mixture an expansion of up to ten times the original volume of the mixture can be achieved, thereby reducing the weight of the end product to as low as 7 to 10 pounds per square foot.
• either aluminum salt of commercial stearic acid or zinc salt of commercial stearic acid (commonly referred to as aluminum stearate and zinc stearate, respectively) may be added to the above mixture.
• the weight ratio of the aluminum stearate or zinc stearate to magnesium oxide under these circumstances is approximately 1:99.
• the magnesium oxide used is a dry dead-burned particulate magnesia.
• a typical chemical analysis and mesh size for magnesia may be the following:
• the aggregate is any suitable siliceous aggregate or mixture of such aggregates having an average density ranging from light to heavy depending on the intended use.
• the size range of the aggregate is not critical and suitably may be from under 1/16 inch to over 1/2 inch.
• Examples of aggregate materials are cellular and non-cellular materials such as sand, stone, refractory aggregates, silica aggregates and rare earth materials, peagravel, expanded per lite and vermiculite, volcanic glass, volcanic ash, pumice, glass beads and the like.
• the use of cellular, low density aggregate is preferred, the density for strength and low weight advantage preferably being in the range from about 5 to about 15 pounds per cubic foot.
• aqueous mono aluminum phosphate acidic solution can be varied in concentration and amount used such that it is equivalent for purposes of imparting lubricity to an aluminum phosphate, 50% solution, technical grade, having the following typical properties:
• Al 2 O 3 /P 2 O 5 0.24 AlPO 4 : 19.0%
• Silicate Loss at 110°C: 48-50% Miscibility w/water Total Silicate is a dry sandy powder found naturally or synthetically produced. Although any silicate may be used in this mixture, metallic silicates such as aluminum silicate or magnesium silicate are employed for applications requiring some heat reflectivity.
• silicate an aluminum silicate known as mullite, has the following typical analysis:
• a variety of carbonate compounds may be used to expand the light weight material in the mixture of the second embodiment.
• One carbonate commonly used, dolomite has the following typical analysis:
• Formul a CaMg ( CO 3 ) 2 Calcium Carbonate (CaCO 3 ) 54.4% Magnesium Carbonate (MgCO 3 ) 44.5
• An advantage of the instant mixtures is that they can be established under cold weather conditions.
• the reaction which takes place upon mixing the components is exothermic.
• the setting time varies depending on the relative quantities of the components. For example, the setting time of the mixture is about 4 to 6 minutes when the weight ratio
• MgO: aluminum s i l icate is 9 : 1 and can be extended correspondingly as this ratio is decreased.
• the setting time of the light weight material of the second mixture may be reduced to an a lmost instantaneous s et by increasing the content of magnesium oxide to as high as
• the dry and wet components Prior to mixing, the dry and wet components are kept separately. For purposes of mixing, the components are then brought together in any suitable way to provide a uniform workable mixture.
• the dry components of the mixture magnes ium oxide, s i l icate and aggregate, can be formulated in a single package or lot separate from the acidic solution. The latter, contained in an appropriate quantity as a single unit package or lot, can then be combined with the dry components at the site of mixing and forming.
• the resulting mixture while still workable is then placed, shaped, compacted, etc., by conventional means, into a suitable form or cast, and allowed to set until rigid, for purposes of repair, retrofitting or construction.
• the form used can be a cavity or break in a road surface or bridge, a specially made construction form, a building template or modular form, an open space within a wall or floor or ceiling, the wall surfaces of a chimney or furnace, a panel adapted to receive a covering laminate or layer of settable material, or other similar form.
• a conventional mixing spray gun is used to apply the components of the mixture to the supporting structure.
• the various components of the mixture may be applied with as little as fifteen pounds of pressure using the spray gun.
• the mono aluminum phosphate acidic solution is kept in a separate chamber in the spray gun and is not combined with the other ingredients until each of the other ingredients and the mono aluminum phosphate acidic solution are simultaneously emitted from the tip of the spray gun.
• the use of the mixing spray gun allows for easy, controlled application of the quick drying mixture since the mixture does not begin to set until it is sprayed toward the surface of the supporting structure.
• the spray gun For mixtures which employ heavier aggregate, such as stone, the spray gun must be used at a pressure of up to 150 pounds. It will be appreciated by those skilled in the art that the use of the spray gun greatly increases the efficiency of application, particularly in the case of a lightwieght mixture which may set up almost instantaneously.
• the instant bonded aggregate structures are non-ammoniacal so that during mixing, forming and setting no special precautions need be taken to vent the area of ammonia fumes.
• the formulations are temperature insensitive, can be made to have high early strength, and given the benefit of the present teaching, can be adjusted within wide limits to suit the particular requirements of each job.
• the formulation can be varied for setting to a fast or slow rock-hard set by varying the content of silicate or magnesium oxide; for low density (less than about 15 pounds per cubic foot) or high density (more than about
• a good high density, load bearing ceramic material having early high strength can be made with the following components:
• Magnesium oxide 7-10 Silicate (mixture of sand and 60-65 aluminum silicate)
• the silicate mixture composition is varied depending on the function to be served. For road repair, or other purposes not requiring a heat reflective surface, little or no silicate other than sand is required. If a heat reflective surface is desired, higher contents of an additional silicate such as aluminum silicate is used.
• One preferred aspect of the invention is a method of improving the energy efficiency of a room panel or zone-confining panel having a facing surface and an energy-transmissive backing surface.
• the terms room panel and zone-confining panel as used herein are meant to include wall, floor or ceiling members of buildings; work-station panels, dividers, carrels, stalls, booths, etc.; radiant heat panels, fire walls and false ceilings, panel and wall members of stationary objects such as hoods, stoves, furnaces, vats, boilers, animal shelters, brooders, silos, storage tanks, processing chambers; and the like.
• the method of improving the energy efficiency of such panels includes the steps of laminating the backing surface, and allowing the thus laminated mixture or cover to set until hard and thereby become rigidly attached to the backing surface.
• Energy efficiency is realized in that panels laminated according to the invention become heatinsulative, especially panels that are laminated with mixtures containing cellular aggregates such as glass beads, expanded perlite, etc. In the latter case, the K-factor of the resulting bonded aggregate cover is comparable to that of the cellular aggregates per se.
• the cover When the cover includes a mix of cellular and noncellular aggregate, certain advantages are seen such as enhanced heat content or capacity whereby the cover has a so-called flywheel effect with respect to retention of heat or energy level over prolonged periods, which serves to avoid precipitious changes in temperature within the confines of the covered panel or panel enclosure.
• the cover also serves as an acoustical insulator. It will be realized that the cover for the panel can be varied in its coverage of the panel and its thickness. Thus, the cover will ordinarily be completely co-extensive with the panel.
• the cover can be uniform or non-uniform in thickness, as desired.
• conventional anchoring means can be used such as lathing strips, fingers, tie rods, perforations, and the like, spaced at intervals on the panel.
• a preferred panel embodiment of the invention is an overhead or ceiling panel member and preferably a radiant heat panel, laminated according to the method of the invention.
• a preferred method embodiment comprises the step of anchoring the laminated mixture to the radiant heat panel by spray-gun application of the various components of the desired mixture directly onto the surface of the panel.
• Figure 1 is a view showing the facing surface
• Figure 2 is a cross-sectional view of the panel taken on line 2-2 of Figure 1 showing the panel and its cover of laminated bonded aggregate structure .
• the radiant heat panel 10 has an exposed surface 11 and a congruent backing surface 12 to the latter of which a bonded aggregate 13 is attached.
• the attachment is favored and prevented from latera l dis lodgement by mold forming relief means or sunk relief anchor means 14.
• a support system 20, suspended from overhead as from the ceil ing (not shown) of a building or room by a cable or chain 21 attached to the panel is used to maintain the panel 10 steady at a predetermined position above the floor for purposes of heating the space within the room.
• Further cable segments 22 support a reflector 23 which in turn by attachment to cable segments 24 and mounting base 24a support a gas burner 25 and pilot 26.
• the latter burner and pilot unit is serviced by a temperature control ler 30, gas supp ly l ine 31, and burner and pi lot lines 32 and 33.
• the panel 10 is 23 gauge steel, 4 feet in diameter with one foot center-tocenter radial sacing of the circumferential anchor means
• the bonded aggregate cover 13 is about 1-2 inches thick.
• the heating unit uses a burner rated at 15, 000 BTU. Air temperature control is adj ustable from 78 to 110 degrees F. In a preferred procedure, the backing surface
• the composition of the mixture of silicate and glass beads is varied depending on the desired rate of setting and strength.
• Silicate typically comprises 10-40% of the silicate-glass mixture.
• the dry ingredients are first mixed and placed into one chamber of a conventional mixing spray gun. A small amount of clay (less than about 5% by weight is preferably added to the dry ingredients to provide lubricity.
• the mono aluminum phosphate acidic solution is placed into a second chamber in the gun. The mono aluminum phosphate acidic solution then combines with the dry ingredients as each of these components is emitted from the tip of the spray gun during application.
• the setting time can be varied from nearly instantaneous (within one minute) to eight minutes.
• the laminated panel can be used immediately for radiating heat.
• the savings in energy usage typically is 20 to 50% or more.
• the increased efficiency is seen by the fact that heat losses are minimized such that to maintain a given temperature, the burner unit is activated substantially less frequencly than with prior art uncoated heater panels.
• the lamination according to the invention can be advantageously done using a conventional panel 10 which lacks the relief shaped anchor means 14.
• the facing surface 11 of the cover 13 can be coated with a suitable light or heat reflective paint or similar coating.
• the radiant heat panels of the invention are preferred for animal shelters, especially for brooder radiant heat panels used, for example, in raising chicks.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Structural Engineering (AREA)
• Inorganic Chemistry (AREA)
• Materials Engineering (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Organic Chemistry (AREA)
• Combustion & Propulsion (AREA)
• Mechanical Engineering (AREA)
• General Engineering & Computer Science (AREA)
• Building Environments (AREA)
• Curing Cements, Concrete, And Artificial Stone (AREA)
• Laminated Bodies (AREA)

Applications Claiming Priority (2)

Publications (2)

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Family Applications (1)

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Citations (5)

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• 1984
  • 1984-07-18 JP JP50294084A patent/JPS60501898A/ja active Pending
  • 1984-07-18 AU AU32139/84A patent/AU3213984A/en not_active Abandoned
  • 1984-07-18 WO PCT/US1984/001114 patent/WO1985000586A1/en not_active Application Discontinuation
  • 1984-07-18 BR BR8406990A patent/BR8406990A/pt unknown
  • 1984-07-18 EP EP19840902977 patent/EP0151175A4/de not_active Withdrawn
  • 1984-07-23 CA CA000459475A patent/CA1249610A/en not_active Expired

Patent Citations (5)

Non-Patent Citations (1)

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