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
  • C04B28/02—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
  • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
  • C04B26/02—Macromolecular compounds

Definitions

• the invention relates to a method for the manufacture of insulating, porous, shaped articles and buildings and/or parts of buildings, made with such articles.More in particular the invention relates to a method for the manufacture of insulating, porous, shaped articles, such as flat plates, blocks or similar construction elements, which may be provided with chan ⁇ nels or hollow areas.
• the shaped articles have the disadvant- age that the bonded spheres will release from the shaped article by mechanical powers, which are for example the result of transportation and handling at the building- site as well as screwing and nailing, which may result in undesired modification of shape and weak spots in the articles.
• the present invention now has as an object to provide an improvement of this known method, whereby the product not only shows the advantages of the pro ⁇ ducts already known, but is also easier nailable and screwable and can be worked with customary hand-tools without bonded spheres releasing from the binder. Moreover the weight per unit of volume and the com- pressive strength may be adjusted as desired.
• the invention provides to that end a method for the manufacture if insulating, porous, shaped articles such as flat plates, blocks and other shaped articles, such as walls, floors or pre-shaped elements for buil- dings, which optionally may be provided with channels and or hollow areas, wherein hollow or partially hollow articles, such as polystyrene spheres, hollow spheres of glass or plastic, porous particles of ceramic mate ⁇ rial and other porous filling bodies are provided with an outer coating, consisting of a tacky substance, which adheres to the surface of the filling bodies, such as.
• bituminous and tar-like products resinous products, such as paint binders on a basis of natural or synthetic resins or polymers in initial state or in diluted or dissolved form or in the form of dispersions or emul ⁇ sions in water or other non-solvents for that.
• the tacky layer may also be applied as a mixture of the tar-like_ or bituminous or resinous products or polymers with a solution of soluble silicates, wherein the amount of silicate solution may amount up to 75%.
• the tacky layer is dusted by addition of powdery or finely granulated substances, for example cement, - lime, chalk, sand, talc, gypsum and other substances which do not interfere with the hardening of the binder later on, so that a mass is formed, consisting substan ⁇ tially of separate, coated spheres.
• powdery or finely granulated substances for example cement, - lime, chalk, sand, talc, gypsum and other substances which do not interfere with the hardening of the binder later on, so that a mass is formed, consisting substan ⁇ tially of separate, coated spheres.
• the coated spheres, thus obtained, are mixed with a binder, which may consist of material which in the course of time will harden by chemical or physical processes, such as mixtures of water with cement, gyp- sum, lime, sand, clay or mixtures thereof, or by resins or plastics of natural or synthetic type or mixtures, thereof with earlier mentioned binders, such as mixtu ⁇ res of sand and emulsions of polyvinylacetate, rubbers or solutions or emulsions of resins or polymers, which by drying or evaporation of the solvent, whether or not in combination with chemical reactions, form a mass that keeps in shape.
• a binder which may consist of material which in the course of time will harden by chemical or physical processes, such as mixtures of water with cement, gyp- sum, lime, sand, clay or mixtures thereof, or by resins or plastics of natural or synthetic type or mixtures, thereof with earlier mentioned binders, such as mixtu ⁇ res of sand and
• binders mentioned may be added both in mas ⁇ sive form as well as in foamed or beaten up form or volume increasing and weight lowering additives may be added thereto.
• the mixture of filling bodies and binder thus obtained is shaped to the desired articles by transfer of the not yet hardened mass into a mould and allowing this mass to harden or to harden partially, so that the articles can be released from the mould and can harden subsequently in free space.
• the mass may also be applied in unhardened state and be hardened at the eventual place of use. During the application of the unhardened mass into the mould or at the eventual place of use vibrating or shaking treatments may be applied or the mass may be transferred under pressure in order to obtain a better homogeneity of the eventual moulding piece.
• the articles obtained in this manner achieve a
• the articles which have been obtained after compression and vibration movements may be put to dry in self-supporting condition, without the necessity to keep them locked in moulds such as is the case for articles obtained according to the method described in European Patent Specification No.0031365.
• the compression and/or vibration treatment may be carried out in an apparatus of the type "Hydramat” as supplied by "Hess Maschinenfabrik KG” for compressing customary non-porous concrete blocks, the compressive force while carrying out the method according to the invention being substantially lower than the compressive force required for compressing customary concrete blocks.
• the tacky binder applied to the porous particles may be composed of a bituminous or tar-like product but also of other tacky substances such as solutions, sus ⁇ pensions or emulsions of polymers or resins of natural or synthetic origin.
• solutions are solutions of shellac in alcohol, emulsions of polyvinylacetate, which are used in the manufacture of latex-paint solu ⁇ tions of natural and synthetic resins, as are used in the preparation of paints and varnishes, as well as the paints and varnishes themselves, in as far as- they do not affect the porous articles or only to a very limit ⁇ ed extent.
• aqueous solutions of plastics or natural products may act as tacky binder as well.
• the binder may also be blended with a solution of soluble silicates of metals of the first main group of the periodic system, preferably a solution of sodium or potassium silicate, as these are known under the name waterglass, wherein the amount of waterglass may be up to 75 % of the weight of the total mixture with the tacky binder.
• the powdery substance is preferably added at the end of the blending operation whereby the powder ' particles will adhere to the tacky binder and thus will form a layer on the surface of the porous part ⁇ icles.
• the hardening binder may be added completely or partially during the first blending or may be added completely or partially after the first blend ⁇ ing. If required the hardening binder may be pre-mixed with water and possibly other additives such as foam ⁇ ing agents, stabilizers, dyes, promotors, retardants, and other components such as known from the process- ing of concrete and which are required to achieve the desired properties of the hardening binder.
• additives such as foam ⁇ ing agents, stabilizers, dyes, promotors, retardants, and other components such as known from the process- ing of concrete and which are required to achieve the desired properties of the hardening binder.
• a proteinaceous concentrate such as available from the firm SK at Trostberg, may be used, while the concentrate may be added in concen- trated or diluted form, but other customary foaming agents and surface active compounds may be used as well, apart from foaming or beaten up resins. he addi ⁇ tion may be carried out with known dosing apparatus.
• the invention will now be elucidated in more detail starting from one of the possible formulations in this case on the basis of coated spheres of expand ⁇ ed polystyrene foam, wherein the coating consists of a bituminous product, waterglass and cement, whereas the hardening binder consists of a mixture of foamed concrete.
• hese may consist for example of polystyrene. hese spheres may have a diameter of 0.5 to 15 mm, more in particular a diame- ter of 3 to 5 mm and a specific weight of 10 to 15 kg per cubic meter.
• the lower side of the converging lower end (2) of the silo is a small rectangular dis ⁇ charge opening, under which a helical screw conveyor is present in a cylindrical housing (3) , directly connected with said discharge opening, the conveyor being driven by an electromotor, which either as such or of which a transmission driving gear is gradually variable in number of revolutions within a broad range of velocities from standstill, in order to drive the helical screw conveyor with a variable, accurately adjustable velocity.
• the helical screw conveyor emerges into a suction-duct (4) of an exhauster (5) , of which the blade-wheel has rounded off blades, allowing the spheres to pass without
• he exhauster (5) blows the spheres through a conduit (6) towards a silo (7) , provided with a suitable air outlet, for example a fine-meshed sieve plate, mounted in the upper side, so that the air coming from the exhauster can escape readily.
• a suitable air outlet for example a fine-meshed sieve plate
• the spheres fall from silo (7) into a first compounding mill (8) , consisting preferably of a trough with two horizontal shafts, running parallel to each other, each provided with radially extending pins, which are each time displaced with respect to adjacent pins somewhat in the direction of the circum ⁇ ference, so that their free ends show a helical course around the shaft.
• Compounding mill (8) has for example a length of 4 meters and the mutual distances of the pins on each shaft are for example 10 cm.
• the pins on the two shafts overlap each other so that on rotation of the shafts in opposite direction the pins will pass each other at short distance and the pins in ' the area between the shafts will move in a downward direction ' .
• the ends of the pins will move close to the wall of the trough of compounding mill (8) .
• the pins occupy about three threads around the shaft.Similar compound- ing mills are known in essence. he shafts rotate with a velocity of at most 200 rotations per hour.A supply apparatus for the tacky substances or a mixture of the tacky substance and the solution of the soluble sili ⁇ cate emerges at about 90 cm from the discharge opening of silo (7), delivering in an accurately dosed manner a quantity of the tacky substance to the porous parti ⁇ cles in compounder (8) .Compounding takes place over a part of the path in compounder (8) , whereafter an amount of powdery substance is brought into the co - pounding mill from a bunker (13) at (12) by means of a cell-wheel.Shortly before the addition of the powdery substance the porous particles tightly adhere to each other by the tacky substance or a mixture of the tacky substance and the soluble silicate, which is at the surface of
• the total residence time of the spheres in the compounder (8) amounts to 2 to 6 minutes, with in the initial 3 meters only porous particles and the tacky liquid or a mixture thereof with the soluble silicate being mixed in the compounder and in the last meter of the com- pounder (8) the powdery substances being present as well.
• the pins (10) on shafts (9) do not or hardly provide any conveyance themselves in axial direction of the compounder (8) .
• the conveyance thus takes place mainly by displacement of the material present in the compounder by freshly supplied material.
• the spheres clot together the powdery substance can not or hardly reach the spheres which have not yet been mixed adequately_with the tacky substance by flowing upstream
• the hardening binder in this example cement
• Belt (16) conveys the porous particles, in this example polystyrene foam spheres, to a secon compound ⁇ ing mill (17) , which has the same construction as compounder (8) , but may be shorter than the latter, for example 3 meters and with pins covering 2 ⁇ threads.At a short distance from the inlet water and in this example a proteinaceous foaming agent are
• a mixture as meant in the example described above may consist of 20 kg polystyrene foam spheres with dimensions as described, about 6 kg tacky substan ⁇ ce, or for example 5 kg tacky substance and 10 kg of waterglass, 50 kg powdery substance such as cement or a mixture of sand and cement, 50 kg hardening binder for example cement, 45 kg water and in this example about 3 kg of protein-concentrate as foaming agent.
• the powdery substance and the hardening binder may consist of different compounds but may also consist of the same compound.
• Additives may also be added to the hardening binder so as for example sand, pebbles and other par- tides, which increase the volume.

Landscapes

• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Materials Engineering (AREA)
• Structural Engineering (AREA)
• Organic Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Inorganic Chemistry (AREA)
• Curing Cements, Concrete, And Artificial Stone (AREA)
• Building Environments (AREA)
• Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
• Laminated Bodies (AREA)
• Insulating Bodies (AREA)

Priority Applications (3)

Applications Claiming Priority (2)

Publications (1)

Family

ID=19843934

Family Applications (1)

Country Status (12)

Cited By (3)

Families Citing this family (1)

Citations (4)

• 1984
  • 1984-05-10 NL NL8401498A patent/NL8401498A/nl not_active Application Discontinuation
• 1985
  • 1985-05-06 IL IL75097A patent/IL75097A0/xx unknown
  • 1985-05-07 ZA ZA853443A patent/ZA853443B/xx unknown
  • 1985-05-08 GR GR851118A patent/GR851118B/el unknown
  • 1985-05-09 EP EP85902173A patent/EP0181367A1/en not_active Withdrawn
  • 1985-05-09 AU AU43534/85A patent/AU4353485A/en not_active Abandoned
  • 1985-05-09 WO PCT/NL1985/000018 patent/WO1985005351A1/en not_active Application Discontinuation
  • 1985-05-09 JP JP60502136A patent/JPS61502330A/ja active Pending
  • 1985-05-09 BR BR8506722A patent/BR8506722A/pt unknown
  • 1985-05-10 ES ES543042A patent/ES8608458A1/es not_active Expired
• 1986
  • 1986-01-07 FI FI860056A patent/FI860056A/fi not_active Application Discontinuation
  • 1986-01-08 NO NO860052A patent/NO860052L/no unknown

Patent Citations (4)

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