US20160257613A2 - Extruded Lightweight Thermal Insulating Cement-Based Materials - Google Patents
Extruded Lightweight Thermal Insulating Cement-Based Materials Download PDFInfo
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- US20160257613A2 US20160257613A2 US14/785,968 US201414785968A US2016257613A2 US 20160257613 A2 US20160257613 A2 US 20160257613A2 US 201414785968 A US201414785968 A US 201414785968A US 2016257613 A2 US2016257613 A2 US 2016257613A2
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- 239000000463 material Substances 0.000 title claims abstract description 80
- 239000004568 cement Substances 0.000 claims abstract description 50
- 239000000203 mixture Substances 0.000 claims abstract description 42
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 36
- 239000000835 fiber Substances 0.000 claims abstract description 27
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 19
- 238000000518 rheometry Methods 0.000 claims abstract description 17
- 230000002787 reinforcement Effects 0.000 claims abstract description 15
- 239000002002 slurry Substances 0.000 claims description 55
- 239000008262 pumice Substances 0.000 claims description 43
- 238000000034 method Methods 0.000 claims description 35
- 229920002472 Starch Polymers 0.000 claims description 29
- VWDWKYIASSYTQR-UHFFFAOYSA-N sodium nitrate Chemical compound [Na+].[O-][N+]([O-])=O VWDWKYIASSYTQR-UHFFFAOYSA-N 0.000 claims description 26
- 239000005337 ground glass Substances 0.000 claims description 23
- 235000019698 starch Nutrition 0.000 claims description 23
- 239000011521 glass Substances 0.000 claims description 18
- 239000008107 starch Substances 0.000 claims description 14
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 12
- 239000004115 Sodium Silicate Substances 0.000 claims description 12
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 12
- 229910052911 sodium silicate Inorganic materials 0.000 claims description 12
- 239000004372 Polyvinyl alcohol Substances 0.000 claims description 10
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 10
- 150000004676 glycans Chemical class 0.000 claims description 9
- 229920001282 polysaccharide Polymers 0.000 claims description 9
- 239000005017 polysaccharide Substances 0.000 claims description 9
- 229920002678 cellulose Polymers 0.000 claims description 8
- 239000001913 cellulose Substances 0.000 claims description 8
- 239000004927 clay Substances 0.000 claims description 7
- 239000001856 Ethyl cellulose Substances 0.000 claims description 6
- ZZSNKZQZMQGXPY-UHFFFAOYSA-N Ethyl cellulose Chemical compound CCOCC1OC(OC)C(OCC)C(OCC)C1OC1C(O)C(O)C(OC)C(CO)O1 ZZSNKZQZMQGXPY-UHFFFAOYSA-N 0.000 claims description 6
- 229920000663 Hydroxyethyl cellulose Polymers 0.000 claims description 6
- 239000004354 Hydroxyethyl cellulose Substances 0.000 claims description 6
- 229920001479 Hydroxyethyl methyl cellulose Polymers 0.000 claims description 6
- 229920001249 ethyl cellulose Polymers 0.000 claims description 6
- 235000019325 ethyl cellulose Nutrition 0.000 claims description 6
- 239000010881 fly ash Substances 0.000 claims description 6
- 235000019447 hydroxyethyl cellulose Nutrition 0.000 claims description 6
- 229920000609 methyl cellulose Polymers 0.000 claims description 6
- 239000001923 methylcellulose Substances 0.000 claims description 6
- 238000002156 mixing Methods 0.000 claims description 6
- 229920001592 potato starch Polymers 0.000 claims description 6
- 239000011435 rock Substances 0.000 claims description 6
- 239000004576 sand Substances 0.000 claims description 6
- 229910021487 silica fume Inorganic materials 0.000 claims description 6
- 239000002893 slag Substances 0.000 claims description 6
- 239000001509 sodium citrate Substances 0.000 claims description 6
- NLJMYIDDQXHKNR-UHFFFAOYSA-K sodium citrate Chemical compound O.O.[Na+].[Na+].[Na+].[O-]C(=O)CC(O)(CC([O-])=O)C([O-])=O NLJMYIDDQXHKNR-UHFFFAOYSA-K 0.000 claims description 6
- 229940100445 wheat starch Drugs 0.000 claims description 6
- 229920003043 Cellulose fiber Polymers 0.000 claims description 5
- 239000003365 glass fiber Substances 0.000 claims description 5
- 238000004519 manufacturing process Methods 0.000 claims description 5
- 239000011368 organic material Substances 0.000 claims description 5
- 229920003023 plastic Polymers 0.000 claims description 5
- 239000004033 plastic Substances 0.000 claims description 5
- -1 polypropylene Polymers 0.000 claims description 5
- 102000004169 proteins and genes Human genes 0.000 claims description 5
- 108090000623 proteins and genes Proteins 0.000 claims description 5
- 238000001035 drying Methods 0.000 claims description 4
- 229920000945 Amylopectin Polymers 0.000 claims description 3
- 229920000856 Amylose Polymers 0.000 claims description 3
- 229920002134 Carboxymethyl cellulose Polymers 0.000 claims description 3
- 229920001353 Dextrin Polymers 0.000 claims description 3
- 239000004375 Dextrin Substances 0.000 claims description 3
- 229920002085 Dialdehyde starch Polymers 0.000 claims description 3
- 229910019142 PO4 Inorganic materials 0.000 claims description 3
- 150000001242 acetic acid derivatives Chemical class 0.000 claims description 3
- 150000001412 amines Chemical class 0.000 claims description 3
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Inorganic materials [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 claims description 3
- ZOMBKNNSYQHRCA-UHFFFAOYSA-J calcium sulfate hemihydrate Chemical compound O.[Ca+2].[Ca+2].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O ZOMBKNNSYQHRCA-UHFFFAOYSA-J 0.000 claims description 3
- 229910002026 crystalline silica Inorganic materials 0.000 claims description 3
- 235000019425 dextrin Nutrition 0.000 claims description 3
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical class OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 claims description 3
- 229910021485 fumed silica Inorganic materials 0.000 claims description 3
- 229910052602 gypsum Inorganic materials 0.000 claims description 3
- 239000010440 gypsum Substances 0.000 claims description 3
- 239000011507 gypsum plaster Substances 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- 239000002245 particle Substances 0.000 claims description 3
- 239000010451 perlite Substances 0.000 claims description 3
- 235000019362 perlite Nutrition 0.000 claims description 3
- 239000010452 phosphate Substances 0.000 claims description 3
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 claims description 3
- 235000012239 silicon dioxide Nutrition 0.000 claims description 3
- 239000005995 Aluminium silicate Substances 0.000 claims description 2
- 235000012211 aluminium silicate Nutrition 0.000 claims description 2
- 238000005520 cutting process Methods 0.000 claims description 2
- 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 2
- 238000000465 moulding Methods 0.000 claims description 2
- 239000005871 repellent Substances 0.000 claims description 2
- 230000002940 repellent Effects 0.000 claims description 2
- 238000005507 spraying Methods 0.000 claims description 2
- 238000009966 trimming Methods 0.000 claims description 2
- 239000004743 Polypropylene Substances 0.000 claims 2
- 229920001155 polypropylene Polymers 0.000 claims 2
- 238000001816 cooling Methods 0.000 claims 1
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 6
- 239000002131 composite material Substances 0.000 description 4
- 229910000019 calcium carbonate Inorganic materials 0.000 description 3
- 238000001125 extrusion Methods 0.000 description 3
- 235000010344 sodium nitrate Nutrition 0.000 description 3
- 235000019886 MethocelTM Nutrition 0.000 description 2
- 239000004604 Blowing Agent Substances 0.000 description 1
- 239000011398 Portland cement Substances 0.000 description 1
- 238000007792 addition Methods 0.000 description 1
- 150000004645 aluminates Chemical class 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 239000011268 mixed slurry Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 150000004756 silanes Chemical class 0.000 description 1
- 239000004317 sodium nitrate Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000006467 substitution reaction 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
- 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
- C04B18/02—Agglomerated materials, e.g. artificial aggregates
- C04B18/027—Lightweight 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
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/04—Silica-rich materials; Silicates
- C04B14/14—Minerals of vulcanic origin
- C04B14/16—Minerals of vulcanic origin porous, e.g. pumice
-
- 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
- C04B28/02—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 hydraulic cements other than calcium sulfates
-
- 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
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/4505—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application
- C04B41/4535—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application applied as a solution, emulsion, dispersion or suspension
- C04B41/4543—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application applied as a solution, emulsion, dispersion or suspension by spraying, e.g. by atomising
-
- 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
- C04B2111/00129—Extrudable 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
- C04B2111/20—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
-
- 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
- C04B2201/30—Mortars, concrete or artificial stone characterised by specific physical values for heat transfer properties such as thermal insulation values, e.g. R-values
- C04B2201/32—Mortars, concrete or artificial stone characterised by specific physical values for heat transfer properties such as thermal insulation values, e.g. R-values for the thermal conductivity, e.g. K-factors
-
- 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
Definitions
- the present invention relates in general to cement-based materials, and more particularly to extruded lightweight thermal insulating cement-based materials.
- cement-based materials are generally produced using large amount of water to form a slurry that is too wet to extrude. Moreover, cement-based materials are generally not both lightweight and thermally insulating.
- the present invention provides an extrudable lightweight thermal insulating cement-based material that is formed from a mixture that includes cement in the range of about 40 to 90% by wet weight percent, water in the range of about 10 to 60%, a lightweight expanded aggregate in the range of about 5 to 40% by wet weight percent, a secondary material (e.g., sand, rock, fly ash, slag, silica fume, calcium carbonate, etc.) in the range of about 0.1 to 50% by wet weight percent, a reinforcement fiber in the range of about 1 to 20% by wet weight percent, a rheology modifying agent in the range of about 0.5 to 10% by wet weight percent, and a retarder in the range of about 0.1 to 8% by dry weight percent.
- a secondary material e.g., sand, rock, fly ash, slag, silica fume, calcium carbonate, etc.
- the present invention provides a method for manufacturing an extrudable cement-based material by mixing a cement, a lightweight expanded aggregate, a secondary material, a reinforcement fiber, a rheology modifying agent and a retarder with water, extruding the mixture through a die using an extruder, and allowing the extruded mixture to set.
- the present invention provides a method of making the extrudable lightweight thermal insulating cement-based material (composite) by the following steps: (1) mixing about 40 to 90% Wt. wet cement with about 10 to 60% Wt. wet water; (2) blending the cement-water mixture with about 5 to 40% Wt. wet lightweight expanded aggregate, about 0.1 to 50% Wt. wet secondary material (e.g., sand, rock, fly ash, slag, silica fume, calcium carbonate, etc.), and about 1 to 20% Wt. wet reinforcement fiber; and (3) adding about 0.5 to 10% Wt. wet rheology modifying agent and about 0.1 to 8% Wt. wet retarder to the mixture.
- the resulting extrudable lightweight thermal insulating cement-based material can then be extruded and cured (e.g., allowed to sit, heating, steam, etc.).
- Ordinary Portland cement or aluminate cement in its wet state with water added before setting can be rheologically modified in to a clay-like material, which allows the use of the conventional clay production method known as extrusion.
- the cement-water mixture is blended with about 5-40 wt. % of lightweight expanded aggregate of the total wet volume.
- the preferred lightweight expanded aggregate is either expanded clay, Perlite, expanded glass, expanded pumice, or a combination thereof.
- the particle size of the lightweight expanded aggregate is either about 0-1 mm, 1-2 mm, 2-4 mm, 4-8 mm or a combination thereof.
- the cement-based lightweight thermal insulating composite with approx. 10-60 wt. % water of the total wet material and a suitable rheology modifying admixture is made to feel and behave similar to plastic clay.
- the material feels plastic/deformable to the touch and can be extruded similar to clay with the use of a clay extruder where the material is conveyed forward by an auger through a barrel and is formed continuously through a die into a final shape with form stability.
- the extruded material can have more or less form stability.
- the setting time can be retarded up to several hours with the use of small additions of suitable set retarders such as SodateTM (USG Product) or sodium citrate.
- SodateTM is a mixture of Plaster of Paris, sodium citrate and crystalline silica. Following extrusion, the material will within a few hours develop the final strength of the finished product.
- the product is either allowed to sit around for 28 days in a humid environment, or the strength development can be accelerated within 24-48 hours by heating either by its own internal heat development or by steam curing such as is conventional in the state-of-the-art.
- the present invention provides an extrudable cement-based material that is formed from a mixture that includes cement in the range of about 40 to 90% by dry weight percent, a secondary material in the range of about 0.1 to 50% by dry weight percent, a reinforcement fiber in the range of about 1 to 20% by dry weight percent, a rheology modifying agent in the range of about 0.5 to 10% by dry weight percent, a retarder in the range of about 0.1 to 8% by dry weight percent, a water in the range of 10 to 50% of a total wet material weight.
- the cement can be used as a binder with water in a composite composition in combination with a multitude of materials such as sand, gypsum, silica fume, fumed silica, fly ash, slag, rock, cellulose fiber, glass fiber, plastic fiber, polyvinyl alcohol (PVA) fiber, etc., or a combination thereof, which when rheologically modified can be extruded as described above.
- materials such as sand, gypsum, silica fume, fumed silica, fly ash, slag, rock, cellulose fiber, glass fiber, plastic fiber, polyvinyl alcohol (PVA) fiber, etc., or a combination thereof, which when rheologically modified can be extruded as described above.
- the rheology-modifying agents fall into the following categories: (1) polysaccharides and derivatives thereof, (2) proteins and derivatives thereof, and (3) synthetic organic materials. Polysaccharide rheology-modifying agents can be further subdivided into (a) cellulose-based materials and derivatives thereof, (b) starch-based materials and derivatives thereof, and (c) other polysaccharides.
- Suitable cellulose-based rheology-modifying agents include, for example, methylhydroxyethylcellulose (MHEC), hydroxymethylethylcellulose (HMEC), carboxymethylcellulose (CMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethylcellulose (HEC), hydroxyethylpropylcellulose (HEPC), or hydroxypropoylmethylcelluose (HPMC), etc.
- MHEC methylhydroxyethylcellulose
- HMEC carboxymethylcellulose
- MC methylcellulose
- EC ethylcellulose
- HEC hydroxyethylcellulose
- HEC hydroxyethylpropylcellulose
- HPMC hydroxypropoylmethylcelluose
- Suitable starch-based materials include, for example, wheat starch, pre-gelled wheat starch, potato starch, pre-gelled potato starch, amylopectin, amylose, seagel, starch acetates, starch hydroxyethyl ethers, ionic starches, long-chain alkylstarches, dextrins, amine starches, phosphate starches, and dialdehyde starches.
- the currently preferred rheology-modifying agent is methylhydroxypropylcellulose, examples of which are MethocelTM 240 and MethocelTM 240S, both of which are available from DOW Chemicals, USA.
- the finished lightweight thermal insulating cement-based composite will have densities in the range of about 0.2-1.0 g/cm3, compressive strengths in the range of about 0.5 MPa-10 MPa and heat conductance in the range of about 0.05-0.3 W/mK.
- compositional ranges of cement-based material can be:
- Component Wt. % Range of Wet Cement 40-90 Water 10-60 Lightweight expanded aggregate 5-40 Secondary material (e.g., sand, rock, 0.1-50 fly ash, slag, silica fume, calcium carbonate, etc.) Reinforcement fiber 1-20 Rheology modifying agent 0.5-10 Retarder 0.1-8
- the cement can be about 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89% or 90% by weight or other incremental percentage between.
- the water can be about 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50% 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59% or 60% by weight or other incremental percentage between.
- the lightweight expanded aggregate can be about 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39% or 40% by weight or other incremental percentage between.
- the secondary material can be about 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49% or 50% by weight or other incremental percentage between.
- the reinforcement fiber can be about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19% or 20% by weight or other incremental percentage between.
- the rheology modifying agent can be about 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1.0%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, 2.0%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%, 2.9%, 3.0%, 3.1%, 3.2%, 3.3%, 3.4%, 3.5%, 3.6%, 3.7%, 3.8%, 3.9%, 4.0%, 4.1%, 4.2%, 4.3%, 4.4%, 4.5%, 4.6%, 4.7%, 4.8%, 4.9%, 5.0%, 5.1%, 5.2%, 5.3%, 5.4%, 5.5%, 5.6%, 5.7%, 5.8%, 5.9%, 6.0%, 6.1%, 6.2%, 6.3%, 6.4%, 6.5%, 6.6%, 6.7%, 6.8%, 6.9%, 7.0%, 7.1%, 7.2%, 7.3%, 7.4%, 7.5%, 7.6%, 7.7%, 7.8%, 7.9%, 8.0%, 8.1%, 8.2%, 8.3%, 8.4%, 8.5%,
- the retarder can be about 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1.0%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, 2.0%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%, 2.9%, 3.0%, 3.1%, 3.2%, 3.3%, 3.4%, 3.5%, 3.6%, 3.7%, 3.8%, 3.9%, 4.0%, 4.1%, 4.2%, 4.3%, 4.4%, 4.5%, 4.6%, 4.7%, 4.8%, 4.9%, 5.0%, 5.1%, 5.2%, 5.3%, 5.4%, 5.5%, 5.6%, 5.7%, 5.8%, 5.9%, 6.0%, 6.1%, 6.2%, 6.3%, 6.4%, 6.5%, 6.6%, 6.7%, 6.8%, 6.9%, 7.0%, 7.1%, 7.2%, 7.3%, 7.4%, 7.5%, 7.6%, 7.7%, 7.8%, 7.9% or 8.0% by weight or other incremental percentage between.
- the present invention provides a method for manufacturing an extrudable lightweight thermal insulating cement-based material by mixing a cement, a lightweight expanded aggregate, a secondary material, a reinforcement fiber, a rheology modifying agent and a retarder with water, extruding the mixture through a die using an extruder, and allowing the extruded mixture to set (e.g., up to 2 to 3 hours, etc).
- Additional steps may include: (1) drying the extruded mixture; (2) curing the extruded mixture; (3) molding, cutting, trimming, sanding or routing the extruded mixture into a specified shape; and/or (4) spraying the extruded mixture with a water repellent.
- the surface of the finished product can be made water resistant with the use of silanes or surface coatings.
- the lightweight expanded glass or pumice aggregate can be made as follows:
- Aggregates are produced in conventional granulator by feeding about 1 part mixed slurry to 2.5 parts of ground pumice.
- the aggregate size can be tailored to set a maximum final aggregate size.
- the formed aggregates are dried in a conventional rotary drier.
- the dried aggregates together with about 30% finely ground kaolin are fed into a rotary kiln where it is heated between about 800-1400 degrees Celsius, during which process the granules expand to its final size of about 0-8 mm diameter and forms the light weight expanded aggregate.
- finer aggregates can be formed by following the granulator, feeding the finer aggregates directly in to a flash drier that heat the material above about 800 degrees Celsius and creates expanded aggregates in the size of about 0-1 mm.
- the finished lightweight expanded glass or pumice aggregate has a diameter of about 0-8 mm, a bulk density of about 0.10-0.50 g/cm3 and an effective density of about 0.10-0.8 g/cm3.
- the aggregates further have a compressive strength of about 0.5-5 MPa and are very good heat insulators with heat conductance of about 0.04-0.15 W/mK.
- compositional ranges of the expanded lightweight glass or pumice aggregate can be:
- Component Wt. % Range Slurry Ground glass or pumice 40-60 Water 40-60 Sodium silicate 3-15 NaNO 3 0.1-5
- the ground glass or pumice can be about 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59% or 60% by weight or other incremental percentage between.
- the water can be about 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59% or 60% by weight or other incremental percentage between.
- the sodium silicate can be about 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14% or 15% by weight or other incremental percentage between.
- the NaNO3 can be about 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 2%, 3%, 4% or 5% by weight or other incremental percentage between.
- the ground glass or pumice can be about 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84% or 85% by weight or other incremental percentage between.
- the slurry can be about 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49% or 50% by weight or other incremental percentage between.
- Component Wt. % Range Slurry Ground glass or pumice 40-60 Water 45-50 Sodium silicate 6-7 NaNO 3 0.9-1.1
- Component Wt. % Range Slurry Ground glass or pumice 40-60 Water 45-50 Sodium silicate 6-7 NaNO 3 0.9-1.1
- the ground glass or pumice can be about 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59% or 60% by weight or other incremental percentage between.
- the water can be about 45%, 46%, 47%, 48%, 49% or 50% by weight or other incremental percentage between.
- the sodium silicate can be about 6.0%, 6.1%, 6.2%, 6.3%, 6.4%, 6.5%, 6.6%, 6.7%, 6.8%, 6.9% or 7.0% by weight or other incremental percentage between.
- the NaNO3 can be about 0.9%, 1.0% or 1.1% by weight or other incremental percentage between.
- the words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.
- A, B, C, or combinations thereof refers to all permutations and combinations of the listed items preceding the term.
- A, B, C, or combinations thereof is intended to include at least one of: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB.
- compositions and/or methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of preferred embodiments, it may be apparent to those of skill in the art that variations may be applied to the compositions and/or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the invention as defined by the appended claims.
Abstract
Description
- This application claims priority to, and is the National Stage of International Application No. PCT/US2014/035277 filed on Apr. 24, 2014 and claims priority to U.S. Provisional Patent Application Ser. No. 61/815,308, filed on Apr. 24, 2013, U.S. Provisional Patent Application Ser. No. 61/815,328, filed on Apr. 24, 2013, U.S. Provisional Patent Application Ser. No. 61/815,332, filed on Apr. 24, 2013, and U.S. Provisional Patent Application Ser. No. 61/820,850, filed on May 8, 2013. The contents of both applications are hereby incorporated by reference herein in their entirety.
- The present invention relates in general to cement-based materials, and more particularly to extruded lightweight thermal insulating cement-based materials.
- Cement-based materials are generally produced using large amount of water to form a slurry that is too wet to extrude. Moreover, cement-based materials are generally not both lightweight and thermally insulating.
- The present invention provides an extrudable lightweight thermal insulating cement-based material that is formed from a mixture that includes cement in the range of about 40 to 90% by wet weight percent, water in the range of about 10 to 60%, a lightweight expanded aggregate in the range of about 5 to 40% by wet weight percent, a secondary material (e.g., sand, rock, fly ash, slag, silica fume, calcium carbonate, etc.) in the range of about 0.1 to 50% by wet weight percent, a reinforcement fiber in the range of about 1 to 20% by wet weight percent, a rheology modifying agent in the range of about 0.5 to 10% by wet weight percent, and a retarder in the range of about 0.1 to 8% by dry weight percent.
- In addition, the present invention provides a method for manufacturing an extrudable cement-based material by mixing a cement, a lightweight expanded aggregate, a secondary material, a reinforcement fiber, a rheology modifying agent and a retarder with water, extruding the mixture through a die using an extruder, and allowing the extruded mixture to set.
- Moreover, the present invention provides a method of making the extrudable lightweight thermal insulating cement-based material (composite) by the following steps: (1) mixing about 40 to 90% Wt. wet cement with about 10 to 60% Wt. wet water; (2) blending the cement-water mixture with about 5 to 40% Wt. wet lightweight expanded aggregate, about 0.1 to 50% Wt. wet secondary material (e.g., sand, rock, fly ash, slag, silica fume, calcium carbonate, etc.), and about 1 to 20% Wt. wet reinforcement fiber; and (3) adding about 0.5 to 10% Wt. wet rheology modifying agent and about 0.1 to 8% Wt. wet retarder to the mixture. The resulting extrudable lightweight thermal insulating cement-based material can then be extruded and cured (e.g., allowed to sit, heating, steam, etc.).
- For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures and in which:
- Not applicable.
- While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention.
- To facilitate the understanding of this invention, a number of terms are defined below. Terms defined herein have meanings as commonly understood by a person of ordinary skill in the areas relevant to the present invention. Terms such as “a”, “an,” and “the” are not intended to refer to only a singular entity, but include the general class of which a specific example may be used for illustration. The terminology herein is used to describe specific embodiments of the invention, but their usage does not delimit the invention, except as outlined in the claims.
- Ordinary Portland cement or aluminate cement in its wet state with water added before setting, can be rheologically modified in to a clay-like material, which allows the use of the conventional clay production method known as extrusion.
- To make the cement-water mixture lightweight, it is blended with about 5-40 wt. % of lightweight expanded aggregate of the total wet volume. The preferred lightweight expanded aggregate is either expanded clay, Perlite, expanded glass, expanded pumice, or a combination thereof. The particle size of the lightweight expanded aggregate is either about 0-1 mm, 1-2 mm, 2-4 mm, 4-8 mm or a combination thereof. A process for making the lightweight expanded glass or pumice aggregate will be described after the discussion regarding the lightweight thermal insulating cement-based material.
- For extrusion, the cement-based lightweight thermal insulating composite with approx. 10-60 wt. % water of the total wet material and a suitable rheology modifying admixture is made to feel and behave similar to plastic clay. The material feels plastic/deformable to the touch and can be extruded similar to clay with the use of a clay extruder where the material is conveyed forward by an auger through a barrel and is formed continuously through a die into a final shape with form stability.
- Depending on the water content and the amount of rheology modifying admixture, the extruded material can have more or less form stability.
- To allow enough time of the cement-based material to be extruded before setting (hardening), the setting time can be retarded up to several hours with the use of small additions of suitable set retarders such as Sodate™ (USG Product) or sodium citrate. Sodate™ is a mixture of Plaster of Paris, sodium citrate and crystalline silica. Following extrusion, the material will within a few hours develop the final strength of the finished product.
- To develop the final 28 days strength, the product is either allowed to sit around for 28 days in a humid environment, or the strength development can be accelerated within 24-48 hours by heating either by its own internal heat development or by steam curing such as is conventional in the state-of-the-art.
- As will be described below, the present invention provides an extrudable cement-based material that is formed from a mixture that includes cement in the range of about 40 to 90% by dry weight percent, a secondary material in the range of about 0.1 to 50% by dry weight percent, a reinforcement fiber in the range of about 1 to 20% by dry weight percent, a rheology modifying agent in the range of about 0.5 to 10% by dry weight percent, a retarder in the range of about 0.1 to 8% by dry weight percent, a water in the range of 10 to 50% of a total wet material weight.
- The cement can be used as a binder with water in a composite composition in combination with a multitude of materials such as sand, gypsum, silica fume, fumed silica, fly ash, slag, rock, cellulose fiber, glass fiber, plastic fiber, polyvinyl alcohol (PVA) fiber, etc., or a combination thereof, which when rheologically modified can be extruded as described above.
- The rheology-modifying agents fall into the following categories: (1) polysaccharides and derivatives thereof, (2) proteins and derivatives thereof, and (3) synthetic organic materials. Polysaccharide rheology-modifying agents can be further subdivided into (a) cellulose-based materials and derivatives thereof, (b) starch-based materials and derivatives thereof, and (c) other polysaccharides.
- Suitable cellulose-based rheology-modifying agents include, for example, methylhydroxyethylcellulose (MHEC), hydroxymethylethylcellulose (HMEC), carboxymethylcellulose (CMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethylcellulose (HEC), hydroxyethylpropylcellulose (HEPC), or hydroxypropoylmethylcelluose (HPMC), etc.
- Suitable starch-based materials include, for example, wheat starch, pre-gelled wheat starch, potato starch, pre-gelled potato starch, amylopectin, amylose, seagel, starch acetates, starch hydroxyethyl ethers, ionic starches, long-chain alkylstarches, dextrins, amine starches, phosphate starches, and dialdehyde starches.
- The currently preferred rheology-modifying agent is methylhydroxypropylcellulose, examples of which are Methocel™ 240 and Methocel™ 240S, both of which are available from DOW Chemicals, USA.
- The finished lightweight thermal insulating cement-based composite will have densities in the range of about 0.2-1.0 g/cm3, compressive strengths in the range of about 0.5 MPa-10 MPa and heat conductance in the range of about 0.05-0.3 W/mK.
- In one embodiment of the present invention, the compositional ranges of cement-based material can be:
-
Component Wt. % Range of Wet Cement 40-90 Water 10-60 Lightweight expanded aggregate 5-40 Secondary material (e.g., sand, rock, 0.1-50 fly ash, slag, silica fume, calcium carbonate, etc.) Reinforcement fiber 1-20 Rheology modifying agent 0.5-10 Retarder 0.1-8 - The cement can be about 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89% or 90% by weight or other incremental percentage between.
- The water can be about 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50% 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59% or 60% by weight or other incremental percentage between.
- The lightweight expanded aggregate can be about 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39% or 40% by weight or other incremental percentage between.
- The secondary material can be about 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49% or 50% by weight or other incremental percentage between.
- The reinforcement fiber can be about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19% or 20% by weight or other incremental percentage between.
- The rheology modifying agent can be about 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1.0%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, 2.0%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%, 2.9%, 3.0%, 3.1%, 3.2%, 3.3%, 3.4%, 3.5%, 3.6%, 3.7%, 3.8%, 3.9%, 4.0%, 4.1%, 4.2%, 4.3%, 4.4%, 4.5%, 4.6%, 4.7%, 4.8%, 4.9%, 5.0%, 5.1%, 5.2%, 5.3%, 5.4%, 5.5%, 5.6%, 5.7%, 5.8%, 5.9%, 6.0%, 6.1%, 6.2%, 6.3%, 6.4%, 6.5%, 6.6%, 6.7%, 6.8%, 6.9%, 7.0%, 7.1%, 7.2%, 7.3%, 7.4%, 7.5%, 7.6%, 7.7%, 7.8%, 7.9%, 8.0%, 8.1%, 8.2%, 8.3%, 8.4%, 8.5%, 8.6%, 8.7%, 8.8%, 8.9%, 9.0%, 9.1%, 9.2%, 9.3%, 9.4%, 9.5%, 9.6%, 9.7%, 9.8%, 9.9%, 10.0% by weight or other incremental percentage between.
- The retarder can be about 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1.0%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, 2.0%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%, 2.9%, 3.0%, 3.1%, 3.2%, 3.3%, 3.4%, 3.5%, 3.6%, 3.7%, 3.8%, 3.9%, 4.0%, 4.1%, 4.2%, 4.3%, 4.4%, 4.5%, 4.6%, 4.7%, 4.8%, 4.9%, 5.0%, 5.1%, 5.2%, 5.3%, 5.4%, 5.5%, 5.6%, 5.7%, 5.8%, 5.9%, 6.0%, 6.1%, 6.2%, 6.3%, 6.4%, 6.5%, 6.6%, 6.7%, 6.8%, 6.9%, 7.0%, 7.1%, 7.2%, 7.3%, 7.4%, 7.5%, 7.6%, 7.7%, 7.8%, 7.9% or 8.0% by weight or other incremental percentage between.
- In addition, the present invention provides a method for manufacturing an extrudable lightweight thermal insulating cement-based material by mixing a cement, a lightweight expanded aggregate, a secondary material, a reinforcement fiber, a rheology modifying agent and a retarder with water, extruding the mixture through a die using an extruder, and allowing the extruded mixture to set (e.g., up to 2 to 3 hours, etc).
- Additional steps may include: (1) drying the extruded mixture; (2) curing the extruded mixture; (3) molding, cutting, trimming, sanding or routing the extruded mixture into a specified shape; and/or (4) spraying the extruded mixture with a water repellent.
- Following setting and drying of the finished product, the surface of the finished product can be made water resistant with the use of silanes or surface coatings.
- Making the lightweight expanded aggregate from glass or pumice will now be described. The lightweight expanded glass or pumice aggregate can be made as follows:
- 1) Grind glass or pumice in a ball mill to produce ground material predominantly less than about 100 microns.
- 2) Mix the ground material with about 45-50% water to produce a slurry.
- 3) Add about 6-7% sodium silicate (substitution ratio of 2.5) to the slurry.
- 4) Add about 1% sodium nitrate (NaNO3) to the slurry. This later acts as a blowing agent.
- 5) Aggregates are produced in conventional granulator by feeding about 1 part mixed slurry to 2.5 parts of ground pumice. By varying the amount of water in the slurry and the ratio of ground pumice to the slurry, the aggregate size can be tailored to set a maximum final aggregate size.
- 6) Following, the formed aggregates are dried in a conventional rotary drier.
- 7) Following, the dried aggregates together with about 30% finely ground kaolin are fed into a rotary kiln where it is heated between about 800-1400 degrees Celsius, during which process the granules expand to its final size of about 0-8 mm diameter and forms the light weight expanded aggregate.
- 8) Upon exiting the rotary kiln as last steps the aggregates are cooled and then sieved to divide the aggregate into different end use size ranges such as 0-2 mm, 2-4 mm and 4-8 mm
- 9) Alternatively finer aggregates can be formed by following the granulator, feeding the finer aggregates directly in to a flash drier that heat the material above about 800 degrees Celsius and creates expanded aggregates in the size of about 0-1 mm.
- The finished lightweight expanded glass or pumice aggregate has a diameter of about 0-8 mm, a bulk density of about 0.10-0.50 g/cm3 and an effective density of about 0.10-0.8 g/cm3. The aggregates further have a compressive strength of about 0.5-5 MPa and are very good heat insulators with heat conductance of about 0.04-0.15 W/mK.
- In one embodiment of the present invention, the compositional ranges of the expanded lightweight glass or pumice aggregate can be:
-
Component Wt. % Range Slurry: Ground glass or pumice 40-60 Water 40-60 Sodium silicate 3-15 NaNO3 0.1-5 For granulator: Ground glass or pumice 50-85 Slurry 15-50 - For the slurry, the ground glass or pumice can be about 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59% or 60% by weight or other incremental percentage between.
- For the slurry, the water can be about 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59% or 60% by weight or other incremental percentage between.
- For the slurry, the sodium silicate can be about 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14% or 15% by weight or other incremental percentage between.
- For the slurry, the NaNO3 can be about 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 2%, 3%, 4% or 5% by weight or other incremental percentage between.
- For the granulator, the ground glass or pumice can be about 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84% or 85% by weight or other incremental percentage between.
- For the granulator, the slurry can be about 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49% or 50% by weight or other incremental percentage between.
- In another embodiment of the present invention the compositional ranges of the expanded lightweight glass or pumice aggregate can be:
-
Component Wt. % Range Slurry: Ground glass or pumice 40-60 Water 45-50 Sodium silicate 6-7 NaNO3 0.9-1.1 For granulator: 1 part slurry to 2.5 parts ground glass or pumice - For the slurry, the ground glass or pumice can be about 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59% or 60% by weight or other incremental percentage between.
- For the slurry, the water can be about 45%, 46%, 47%, 48%, 49% or 50% by weight or other incremental percentage between.
- For the slurry, the sodium silicate can be about 6.0%, 6.1%, 6.2%, 6.3%, 6.4%, 6.5%, 6.6%, 6.7%, 6.8%, 6.9% or 7.0% by weight or other incremental percentage between.
- For the slurry, the NaNO3 can be about 0.9%, 1.0% or 1.1% by weight or other incremental percentage between.
- It may be understood that particular embodiments described herein are shown by way of illustration and not as limitations of the invention. The principal features of this invention can be employed in various embodiments without departing from the scope of the invention. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this invention and are covered by the claims.
- All publications, patents and patent applications mentioned in the specification are indicative of the level of skill of those skilled in the art to which this invention pertains. All publications, patents and patent applications are herein incorporated by reference to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference.
- The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims and/or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” The use of the term “or” in the claims is used to mean “and/or” unless explicitly indicated to refer to alternatives only or the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and “and/or.” Throughout this application, the term “about” is used to indicate that a value includes the inherent variation of error for the device, the method being employed to determine the value, or the variation that exists among the study subjects.
- As used in this specification and claim(s), the words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.
- The term “or combinations thereof” as used herein refers to all permutations and combinations of the listed items preceding the term. For example, “A, B, C, or combinations thereof” is intended to include at least one of: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB.
- Continuing with this example, expressly included are combinations that contain repeats of one or more item or term, such as BB, AAA, AB, BBC, AAABCCCC, CBBAAA, CABABB, and so forth. The skilled artisan will understand that typically there is no limit on the number of items or terms in any combination, unless otherwise apparent from the context.
- All of the compositions and/or methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of preferred embodiments, it may be apparent to those of skill in the art that variations may be applied to the compositions and/or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the invention as defined by the appended claims.
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US20160068435A1 (en) | 2016-03-10 |
US20200002227A1 (en) | 2020-01-02 |
US10414692B2 (en) | 2019-09-17 |
CA2909983A1 (en) | 2014-10-30 |
CN111003958A (en) | 2020-04-14 |
WO2014176414A1 (en) | 2014-10-30 |
US11142480B2 (en) | 2021-10-12 |
HK1221453A1 (en) | 2017-06-02 |
CA2909983C (en) | 2019-11-12 |
EP2989059B8 (en) | 2021-11-24 |
EP2989059B1 (en) | 2021-10-06 |
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CN105473529A (en) | 2016-04-06 |
WO2014176414A9 (en) | 2015-04-09 |
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