US20150060720A1 - Method for forming a quickly hardening, inorganic foam - Google Patents
Method for forming a quickly hardening, inorganic foam Download PDFInfo
- Publication number
- US20150060720A1 US20150060720A1 US14/394,811 US201314394811A US2015060720A1 US 20150060720 A1 US20150060720 A1 US 20150060720A1 US 201314394811 A US201314394811 A US 201314394811A US 2015060720 A1 US2015060720 A1 US 2015060720A1
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- United States
- Prior art keywords
- reactive powder
- weight
- aluminum
- accordance
- smaller
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000006260 foam Substances 0.000 title claims abstract description 48
- 238000000034 method Methods 0.000 title claims abstract description 29
- 239000000843 powder Substances 0.000 claims abstract description 56
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 48
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 29
- 230000008569 process Effects 0.000 claims abstract description 22
- 238000006243 chemical reaction Methods 0.000 claims abstract description 20
- PMHQVHHXPFUNSP-UHFFFAOYSA-M copper(1+);methylsulfanylmethane;bromide Chemical compound Br[Cu].CSC PMHQVHHXPFUNSP-UHFFFAOYSA-M 0.000 claims abstract description 20
- 229910052910 alkali metal silicate Inorganic materials 0.000 claims abstract description 16
- 239000007788 liquid Substances 0.000 claims abstract description 13
- 239000007787 solid Substances 0.000 claims abstract description 12
- 239000000470 constituent Substances 0.000 claims abstract description 11
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims abstract description 10
- 229910044991 metal oxide Inorganic materials 0.000 claims abstract description 3
- 150000004706 metal oxides Chemical class 0.000 claims abstract description 3
- 229910052814 silicon oxide Inorganic materials 0.000 claims abstract 2
- 229910052782 aluminium Inorganic materials 0.000 claims description 22
- 239000002245 particle Substances 0.000 claims description 16
- 239000004035 construction material Substances 0.000 claims description 13
- 229910052500 inorganic mineral Inorganic materials 0.000 claims description 12
- 239000011707 mineral Substances 0.000 claims description 12
- 239000000203 mixture Substances 0.000 claims description 12
- 239000000377 silicon dioxide Substances 0.000 claims description 12
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 12
- 229910052681 coesite Inorganic materials 0.000 claims description 10
- 229910052906 cristobalite Inorganic materials 0.000 claims description 10
- 229910052682 stishovite Inorganic materials 0.000 claims description 10
- 229910052905 tridymite Inorganic materials 0.000 claims description 10
- 238000002156 mixing Methods 0.000 claims description 6
- 239000002893 slag Substances 0.000 claims description 6
- 230000009970 fire resistant effect Effects 0.000 claims description 4
- -1 pozzolan Substances 0.000 claims description 4
- 239000004568 cement Substances 0.000 claims description 3
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 3
- 239000002557 mineral fiber Substances 0.000 claims description 3
- 238000005549 size reduction Methods 0.000 claims description 3
- 235000008733 Citrus aurantifolia Nutrition 0.000 claims description 2
- 235000011941 Tilia x europaea Nutrition 0.000 claims description 2
- 239000010881 fly ash Substances 0.000 claims description 2
- 239000003365 glass fiber Substances 0.000 claims description 2
- 239000010440 gypsum Substances 0.000 claims description 2
- 229910052602 gypsum Inorganic materials 0.000 claims description 2
- 239000004571 lime Substances 0.000 claims description 2
- 235000011837 pasties Nutrition 0.000 claims description 2
- 239000002994 raw material Substances 0.000 claims description 2
- 239000004576 sand Substances 0.000 claims description 2
- RLQWHDODQVOVKU-UHFFFAOYSA-N tetrapotassium;silicate Chemical compound [K+].[K+].[K+].[K+].[O-][Si]([O-])([O-])[O-] RLQWHDODQVOVKU-UHFFFAOYSA-N 0.000 claims description 2
- 239000006261 foam material Substances 0.000 claims 2
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 abstract description 10
- 235000019353 potassium silicate Nutrition 0.000 abstract description 7
- 230000015572 biosynthetic process Effects 0.000 description 14
- 230000004913 activation Effects 0.000 description 10
- 229910052593 corundum Inorganic materials 0.000 description 9
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 8
- 239000000243 solution Substances 0.000 description 8
- 238000004519 manufacturing process Methods 0.000 description 6
- 229910052751 metal Inorganic materials 0.000 description 6
- 239000002184 metal Substances 0.000 description 6
- 238000007711 solidification Methods 0.000 description 6
- 230000008023 solidification Effects 0.000 description 6
- 229910001845 yogo sapphire Inorganic materials 0.000 description 6
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 4
- 239000007789 gas Substances 0.000 description 4
- 239000000047 product Substances 0.000 description 4
- KKCBUQHMOMHUOY-UHFFFAOYSA-N Na2O Inorganic materials [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 description 3
- 239000004115 Sodium Silicate Substances 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- 239000003513 alkali Substances 0.000 description 3
- 239000010431 corundum Substances 0.000 description 3
- 238000012216 screening Methods 0.000 description 3
- 229910052911 sodium silicate Inorganic materials 0.000 description 3
- 229910052596 spinel Inorganic materials 0.000 description 3
- 239000011029 spinel Substances 0.000 description 3
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- 238000004438 BET method Methods 0.000 description 2
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 2
- MHAJPDPJQMAIIY-UHFFFAOYSA-N Hydrogen peroxide Chemical compound OO MHAJPDPJQMAIIY-UHFFFAOYSA-N 0.000 description 2
- 238000002441 X-ray diffraction Methods 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- 150000008044 alkali metal hydroxides Chemical class 0.000 description 2
- 229910000272 alkali metal oxide Inorganic materials 0.000 description 2
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical class [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 229920000876 geopolymer Polymers 0.000 description 2
- 230000036571 hydration Effects 0.000 description 2
- 238000006703 hydration reaction Methods 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 239000011819 refractory material Substances 0.000 description 2
- 229910052594 sapphire Inorganic materials 0.000 description 2
- 229910002706 AlOOH Inorganic materials 0.000 description 1
- 235000002918 Fraxinus excelsior Nutrition 0.000 description 1
- AFCARXCZXQIEQB-UHFFFAOYSA-N N-[3-oxo-3-(2,4,6,7-tetrahydrotriazolo[4,5-c]pyridin-5-yl)propyl]-2-[[3-(trifluoromethoxy)phenyl]methylamino]pyrimidine-5-carboxamide Chemical compound O=C(CCNC(=O)C=1C=NC(=NC=1)NCC1=CC(=CC=C1)OC(F)(F)F)N1CC2=C(CC1)NN=N2 AFCARXCZXQIEQB-UHFFFAOYSA-N 0.000 description 1
- 239000003082 abrasive agent Substances 0.000 description 1
- 229910001854 alkali hydroxide Inorganic materials 0.000 description 1
- 229910052783 alkali metal Inorganic materials 0.000 description 1
- 150000004645 aluminates Chemical class 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 229940024545 aluminum hydroxide Drugs 0.000 description 1
- 229940024546 aluminum hydroxide gel Drugs 0.000 description 1
- ANBBXQWFNXMHLD-UHFFFAOYSA-N aluminum;sodium;oxygen(2-) Chemical compound [O-2].[O-2].[Na+].[Al+3] ANBBXQWFNXMHLD-UHFFFAOYSA-N 0.000 description 1
- SMYKVLBUSSNXMV-UHFFFAOYSA-K aluminum;trihydroxide;hydrate Chemical compound O.[OH-].[OH-].[OH-].[Al+3] SMYKVLBUSSNXMV-UHFFFAOYSA-K 0.000 description 1
- 239000002956 ash Substances 0.000 description 1
- 239000003637 basic solution Substances 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 150000003841 chloride salts Chemical class 0.000 description 1
- 239000004567 concrete Substances 0.000 description 1
- 238000007596 consolidation process Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000018044 dehydration Effects 0.000 description 1
- 238000006297 dehydration reaction Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 238000002309 gasification Methods 0.000 description 1
- XLYOFNOQVPJJNP-ZSJDYOACSA-N heavy water Substances [2H]O[2H] XLYOFNOQVPJJNP-ZSJDYOACSA-N 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 229910000069 nitrogen hydride Inorganic materials 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 230000035484 reaction time Effects 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 238000005488 sandblasting Methods 0.000 description 1
- 229910001388 sodium aluminate Inorganic materials 0.000 description 1
- 238000001179 sorption measurement Methods 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 1
- 239000013589 supplement Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
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
- C04B28/24—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
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/78—Heat insulating elements
-
- 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
- C04B38/02—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding chemical blowing agents
-
- 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
- C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
- C04B40/0028—Aspects relating to the mixing step of the mortar preparation
- C04B40/0039—Premixtures of ingredients
- C04B40/0042—Powdery mixtures
-
- 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
- C04B2111/00034—Physico-chemical characteristics of the mixtures
- C04B2111/00215—Mortar or concrete mixtures defined by their oxide composition
-
- 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
- C04B2111/00551—Refractory coatings, e.g. for tamping
-
- 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
- C04B2111/00663—Uses not provided for elsewhere in C04B2111/00 as filling material for cavities or the like
-
- 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
- C04B2111/52—Sound-insulating materials
-
- 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
- C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
- C04B2201/20—Mortars, concrete or artificial stone characterised by specific physical values for the density
-
- 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
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
-
- 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]
Definitions
- the invention relates to a process for forming a rapid-hardening inorganic foam based on the reaction of two components:
- the invention further relates to a reactive powder for the preparation of a rapid-hardening inorganic foam by reaction with an alkaline activation solution.
- Inorganic foam (mineral foam) is used as a thermally insulating, fire-resistant lightweight construction material. Rapid hardening of the foam is of advantage in the filling up of hollows in wall constructions, in the production of insulating boards, and in the repair of the thermal insulation of industrial furnaces. In on-site processing it is advantageous to use a formula that requires mixing of only two components whenever possible. For thermal insulations of industrial furnaces the inorganic foam must be built up of components which offer high temperature resistance.
- reactive solids containing SiO 2 and Al 2 O 3 in sufficient amount and in reactive form (ashes, active clays, meta kaolin, pozzolans, slags, etc.),
- alkaline activation solution that contains (apart from water) alkali hydroxides, alkali silicates, alkali aluminates, alkali carbonates and alkali sulphates, either singly or in combinations thereof, and
- U.S. Pat. No. 3,396,112 describes a process of preparing inorganic foams by reacting water with a particulate mixture of aluminum and a dry, water-soluble alkali metal silicate, the particles of the mixture having a particle size of less than 10 mesh (2 mm), and the water content constituting from 30 to 75 weight percent of the total mixture.
- the weight ratio of the alkali metal silicate to the aluminum is from 15:1 to 1:9, and the alkali metal silicate has an alkali metal oxide to silica ratio of 2:1 to 1:4.
- U.S. Pat. No. 3,784,385 concerns the production of a refractory gas concrete having a thermal resistance up to 1,200° C., consisting of five components:
- a finely ground filler in the form of a chrome-aluminum slag, in a weight percentage of 22 to 32 percent relative to the total weight when mixed with the binder,
- European Patent EP 1 180 504 B1 concerns a pore-forming, solidification-accelerating additive for binding agent-building materials, containing 50-90% Al 2 O 3 , 4-20% MgO, 0.5-15% SiO 2 , 0.1-5% aluminum nitride, 0.1-10% metallic aluminum, 0.1-15% loss on ignition, and the main mineral constituents in the form of corundum ( ⁇ -Al 2 O 3 ) and spinel (MgO ⁇ Al 2 O 3 ), wherein the metallic aluminum particles are enveloped by mineral transition modifications from aluminum hydroxide (Al 2 O 3 ⁇ 3H 2 O) to ⁇ -Al 2 O 3 , and wherein the powder has a particle size of at least 90% smaller than 500 ⁇ m and a specific surface of at least 10 m 2 /g.
- This additive is produced from a residue from the treatment of aluminum salt slag, by thermal dehydration and activation within a temperature range of 400-1000° C.
- 450 g of “SEROX TK750” powder, thermally activated at 750° C., with a specific surface area of 45 m 2 /g and a content of metallic aluminum of 3%) was mixed for about 1 minute with 400 g of liquid water glass. After a few minutes, the formation of gas in the paste began, resulting in the formation of foam and an increase in volume, connected with an increase of temperature to 76° C. After a reaction time of 10 minutes the body was hardened so as to be mechanically stable, having a bulk density of 0.63 g/cm 3 .
- European patent application publication EP 0 576 254 A2 concerns a reactive non-metallic product with 7-25% aluminum nitride and 2-8% aluminum, which is produced by treating aluminum dross and aluminum salt slag by washing out the chlorides (page 2, lines 53-55). A possible use of this product for the production of refractories or abrasives is described, but not for the formation of inorganic foam.
- the mineral foam should have constituents which offer a high fire resistance.
- a further object of the present invention is the provision of a reactive powder for the formation of a rapid-hardening inorganic foam.
- the object is achieved by a process of forming a rapid-hardening inorganic foam based on the reaction of two components:
- the object is further achieved by a reactive powder for the forming of a rapid-hardening mineral foam by reaction with an alkaline activation solution, wherein the reactive powder comprises the essential constituents:
- inorganic foams or lightweight construction materials which can be obtained by the above process, preferably a thermally insulating and/or fire-resistant lightweight construction material.
- the process according to the present invention can, preferably, be carried out at room temperature, the room temperature generally being in the range from 15° C. to 30° C., more particularly from 18° C. to 25° C.
- a powder according to the invention having structure-building as well as gas-forming properties, can be obtained, for example, in the recovery of aluminum from aluminum dross by mechanical crushing and classifying in the form of grain size fractions of less than 1 mm, having the lowest content of aluminum, for example in the form of the screenings “CAI-ALON S-D” and the filter dust “CAI-ALON B-H,” (manufacturer: Cast Aluminum Industries, Dubai, United Arab Emirates; Table 1).
- the aforementioned powders of the present invention exhibit a BET surface area of 2.2 and 3.4 m 2 /g, respectively.
- a powder may be used that has been recovered from aluminum dross, preferably a powder recovered from aluminum dross by mechanical size reduction and classification (particularly by screening, filtration or air classification)
- the BET surface area (specific surface area) of the reactive powder according to the present invention is preferably smaller than 10 m 2 /g, more preferably smaller than 7.5 m 2 /g, more particularly smaller than 5 m 2 /g.
- BET surface area is determined according to ISO 9277 (1995), which replaces DIN 66131 (ISO 9277:1995; “Determination of the specific surface area of solids by gas adsorption using the BET method”).
- the reactive powder and the alkaline activation solution can of course also be used in combination with further mineral raw materials, such as metakaolin, fly ash, slag, pozzolan, cement, lime, gypsum, sand, glass fibers, mineral fibers, if necessary adding further alkaline activation solution or water in an amount necessary for adjusting the consistency of the mixture to give a pasty consistency.
- further mineral raw materials such as metakaolin, fly ash, slag, pozzolan, cement, lime, gypsum, sand, glass fibers, mineral fibers
- the present invention further relates to an inorganic foam or lightweight construction material that can be manufactured, or has been manufactured, using the process according to the present invention. More particularly, this foam or material is a thermally insulating or/and fire-resistant lightweight construction material.
- the inorganic foam or lightweight construction material according to the present invention may also be present in the form of finished parts made therefrom, particularly insulating boards.
- the mineral composition of the formed foam bodies still contained some residual metallic aluminum, but no aluminum nitride, and that, hence, the aluminum nitride had reacted virtually completely, in contrast to the metallic aluminum.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Structural Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- General Chemical & Material Sciences (AREA)
- Inorganic Chemistry (AREA)
- Acoustics & Sound (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
- Glass Compositions (AREA)
- Porous Artificial Stone Or Porous Ceramic Products (AREA)
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE102012007396.8 | 2012-04-16 | ||
| DE201210007396 DE102012007396B3 (de) | 2012-04-16 | 2012-04-16 | Verfahren zur Bildung eines schnell erhärtenden, anorganischen Schaums und reaktives Pulver zur Bildung eines schnell erhärtenden Mineralschaums |
| PCT/IB2013/000869 WO2013156852A1 (de) | 2012-04-16 | 2013-04-08 | Verfahren zur bildung eines schnell erhärtenden, anorganischen schaums |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| US20150060720A1 true US20150060720A1 (en) | 2015-03-05 |
Family
ID=48465012
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US14/394,811 Abandoned US20150060720A1 (en) | 2012-04-16 | 2013-04-08 | Method for forming a quickly hardening, inorganic foam |
Country Status (7)
Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2016534964A (ja) * | 2013-10-31 | 2016-11-10 | コンストラクション リサーチ アンド テクノロジー ゲーエムベーハーＣｏｎｓｔｒｕｃｔｉｏｎ Ｒｅｓｅａｒｃｈ ＆ Ｔｅｃｈｎｏｌｏｇｙ ＧｍｂＨ | アルミニウムドロスを含む自己発泡性ジオポリマー組成物 |
| WO2018091482A1 (fr) | 2016-11-17 | 2018-05-24 | Isolfeu-Creation | Mousse geopolymere aux proprietes ameliorees |
| WO2019058280A1 (en) | 2017-09-20 | 2019-03-28 | Johnson & Johnson Consumer Inc. | SYSTEM AND METHOD FOR BEHAVIORAL COACHING OF CAREGIVER |
| WO2021111011A1 (fr) | 2019-12-05 | 2021-06-10 | Isolfeu-Creation | Mousse géopolymère a cellules fermees |
| US11479512B2 (en) * | 2016-12-23 | 2022-10-25 | Nu-Rock Corporation S.A.R.L. | Process and apparatus for producing a shaped article |
| US11673834B2 (en) | 2019-12-05 | 2023-06-13 | Isolfeu-Creation | Closed cell geopolymer foam |
| WO2023176491A1 (ja) * | 2022-03-18 | 2023-09-21 | 日東電工株式会社 | 積層体 |
Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP2868637A1 (de) | 2013-10-31 | 2015-05-06 | Construction Research & Technology GmbH | Geopolymerschaum-Formulierung |
| EP2868826A1 (de) | 2013-10-31 | 2015-05-06 | Basf Se | Betonelement umfassend einen Schallabsorber |
| CN103787631A (zh) * | 2013-12-26 | 2014-05-14 | 青岛中科菲力工程技术研发有限公司 | 耐火保温砂浆 |
| CN110759655B (zh) * | 2017-06-26 | 2021-11-05 | 苏州大学 | 一种工业废弃物基地质聚合物 |
| CN109731574A (zh) * | 2018-06-29 | 2019-05-10 | 光大水务（深圳）有限公司 | 一种催化剂复合载体、基于该载体的催化剂及催化剂的制备方法 |
| CN117326829B (zh) * | 2023-09-21 | 2024-05-14 | 河海大学 | 一种具有单向排列微孔的无机聚合物隔热板制备方法 |
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| US6132574A (en) * | 1997-05-30 | 2000-10-17 | Aluminium-Salzschalcke Aufbereitungs Gmbh | Bottom lining for electrolytic cells and process for its manufacture |
| US20020124776A1 (en) * | 2000-08-15 | 2002-09-12 | Reinhard Feige | Porosifying, solidification-accelerating additive for binding agent building materials, and process of producing |
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| US3396112A (en) * | 1965-06-11 | 1968-08-06 | Ashland Oil Inc | Process of preparing inorganic foams from alkali metal silicates and aluminum |
| US3784385A (en) * | 1972-02-18 | 1974-01-08 | A Tarasova | Method of preparing mix for producing refractory gas concrete and the product obtained thereby |
| US4133691A (en) * | 1978-01-18 | 1979-01-09 | W. R. Grace & Co. | Process for preparing inorganic foam materials |
| NO175303C (no) * | 1986-09-16 | 1994-09-28 | Lanxide Technology Co Ltd | Framgangsmåte for tilvirkning av et fast keramisk skum- eller svampformig legeme |
| US4814300A (en) * | 1987-12-02 | 1989-03-21 | The Duriron Company, Inc. | Porous ceramic shapes, compositions for the preparation thereof, and method for producing same |
| CA2098776A1 (en) * | 1992-06-22 | 1993-12-23 | Richard D. Lindsay | Reactive non-metallic product recovered from dross |
| DE10300170B9 (de) * | 2003-01-08 | 2005-04-21 | Aluminium-Salzschlacke Aufbereitungs Gmbh | Verfahren zur Herstellung von hochtonerdehaltigem Rohstoff |
| DE10335232A1 (de) * | 2003-08-01 | 2005-02-24 | Giesemann, Herbert, Dipl.-Ing. | Hochfeuerfester anorganischer Schaumstoffkörper |
-
2012
- 2012-04-16 DE DE201210007396 patent/DE102012007396B3/de not_active Expired - Fee Related
-
2013
- 2013-04-08 EP EP13779012.7A patent/EP2838868B1/de not_active Not-in-force
- 2013-04-08 US US14/394,811 patent/US20150060720A1/en not_active Abandoned
- 2013-04-08 CN CN201380020185.6A patent/CN104395263B/zh not_active Expired - Fee Related
- 2013-04-08 WO PCT/IB2013/000869 patent/WO2013156852A1/de active Application Filing
- 2013-04-08 AU AU2013250885A patent/AU2013250885B2/en not_active Ceased
- 2013-04-08 IN IN8592DEN2014 patent/IN2014DN08592A/en unknown
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| Publication number | Priority date | Publication date | Assignee | Title |
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| US6132574A (en) * | 1997-05-30 | 2000-10-17 | Aluminium-Salzschalcke Aufbereitungs Gmbh | Bottom lining for electrolytic cells and process for its manufacture |
| US20020124776A1 (en) * | 2000-08-15 | 2002-09-12 | Reinhard Feige | Porosifying, solidification-accelerating additive for binding agent building materials, and process of producing |
Non-Patent Citations (1)
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| "Perlite/Silicate COmposite for High Temperature Insulation and Formed Shapes". The Schundler Company. 03-27-2009. https://web.archive.org/web/20090327061825/http://schundler.com/composites.htm * |
Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2016534964A (ja) * | 2013-10-31 | 2016-11-10 | コンストラクション リサーチ アンド テクノロジー ゲーエムベーハーＣｏｎｓｔｒｕｃｔｉｏｎ Ｒｅｓｅａｒｃｈ ＆ Ｔｅｃｈｎｏｌｏｇｙ ＧｍｂＨ | アルミニウムドロスを含む自己発泡性ジオポリマー組成物 |
| WO2018091482A1 (fr) | 2016-11-17 | 2018-05-24 | Isolfeu-Creation | Mousse geopolymere aux proprietes ameliorees |
| US11479512B2 (en) * | 2016-12-23 | 2022-10-25 | Nu-Rock Corporation S.A.R.L. | Process and apparatus for producing a shaped article |
| WO2019058280A1 (en) | 2017-09-20 | 2019-03-28 | Johnson & Johnson Consumer Inc. | SYSTEM AND METHOD FOR BEHAVIORAL COACHING OF CAREGIVER |
| WO2021111011A1 (fr) | 2019-12-05 | 2021-06-10 | Isolfeu-Creation | Mousse géopolymère a cellules fermees |
| FR3104153A1 (fr) | 2019-12-05 | 2021-06-11 | Isolfeu | Mousse géopolymère a cellules fermees |
| US11673834B2 (en) | 2019-12-05 | 2023-06-13 | Isolfeu-Creation | Closed cell geopolymer foam |
| WO2023176491A1 (ja) * | 2022-03-18 | 2023-09-21 | 日東電工株式会社 | 積層体 |
| JP2023137849A (ja) * | 2022-03-18 | 2023-09-29 | 日東電工株式会社 | 積層体 |
Also Published As
| Publication number | Publication date |
|---|---|
| EP2838868A4 (de) | 2015-12-02 |
| IN2014DN08592A (enrdf_load_stackoverflow) | 2015-05-22 |
| CN104395263A (zh) | 2015-03-04 |
| AU2013250885B2 (en) | 2015-11-19 |
| AU2013250885A1 (en) | 2014-10-30 |
| WO2013156852A1 (de) | 2013-10-24 |
| DE102012007396B3 (de) | 2013-06-13 |
| EP2838868B1 (de) | 2016-09-07 |
| EP2838868A1 (de) | 2015-02-25 |
| CN104395263B (zh) | 2016-09-07 |
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Owner name: CAST ALUMINIUM INDUSTRIES, UNITED ARAB EMIRATES Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:FEIGE, REINHARD;AHMED, WAHEED;NAZIR, MUHAMMAD KASHIF;SIGNING DATES FROM 20141016 TO 20141029;REEL/FRAME:034683/0378 |
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