WO2008139180A1 - Procédé de façonnage d'un article - Google Patents

Procédé de façonnage d'un article Download PDF

Info

Publication number
WO2008139180A1
WO2008139180A1 PCT/GB2008/001644 GB2008001644W WO2008139180A1 WO 2008139180 A1 WO2008139180 A1 WO 2008139180A1 GB 2008001644 W GB2008001644 W GB 2008001644W WO 2008139180 A1 WO2008139180 A1 WO 2008139180A1
Authority
WO
WIPO (PCT)
Prior art keywords
binder
article
clay
mixed dispersion
expanded
Prior art date
Application number
PCT/GB2008/001644
Other languages
English (en)
Inventor
David Ronald Mandley
Andrew Christopher Clark
Original Assignee
Ceramic Gas Products Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Ceramic Gas Products Ltd filed Critical Ceramic Gas Products Ltd
Priority to GB0921488.3A priority Critical patent/GB2463186B/en
Publication of WO2008139180A1 publication Critical patent/WO2008139180A1/fr

Links

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
    • 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
    • C04B14/10—Clay
    • C04B14/12—Expanded clay
    • 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
    • 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
    • C04B28/04—Portland cements
    • 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
    • C04B28/06—Aluminous cements
    • 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
    • C04B28/14—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 calcium sulfate cements
    • 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
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/34—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders
    • 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

Definitions

  • the present application relates to methods of forming articles and in particular articles used for insulation, acoustic and fire protection purposes.
  • a method of forming an article comprising wetting an expanded calcined clay with up to three times its own weight of water then combining the wetted clay with a binder in a mixed dispersion such that the mixed dispersion can be formed in a mould and set.
  • the expanded calcined clay is Ultralite supplied by Ceramic Gas Products Limited.
  • the expanded calcined clay is wetted in a granular or powered form (prill).
  • wetted clay and binder are combined in a mechanical mixer.
  • the expanded calcined clay has a bulk packing density of about 75 kilograms per cubic metre.
  • the mixed dispersion is combined in proportions of 40% - 75% by volume expanded calcined clay and 25% - 60% by volume binder.
  • additives are combined with the wetted expanded calcined clay and the binder at the combination stage in the mixed dispersion.
  • additives may include colorants, fire inhibitors and other functional additives to alter and adjust the performance of the formed article.
  • the mixed dispersion is poured into the mould or pressed into shapes defined by the mould.
  • the mixed dispersion is set or cured to release the article from the mould. Possibly, the mixed dispersion is set or cured by an exothermic reaction.
  • the article is dried by forced air drying and/or fired by varying a curing temperature.
  • the binder is a Gypsum slurry. Possibly, the binder is up to 15% glass bonding by a glass bond material. Possibly, the binder is up to 80% of high alumina castable cement. Possibly, the binder is up to 30% refractory ball clay. Possibly, the binder is up to 30% colloidal silica. Possibly, the binder is up to 30% phosphate bonded cement. Possibly, the binder includes ethyl silicate bonding. Possibly, the article includes a chemically inert filler. Possibly, the binder includes Portland cement. Possibly, the binder includes polyvinyl acetate/cellulose.
  • the article can be formed as boards, sheets, composite panels, tubes, seals and other solid or hollow shapes.
  • the article is a component utilised for, but not limited to fire protection, insulation and noise reduction.
  • An aspect of the present invention relates to combining a known expanded calcined clay with a binder in order to create a lightweight rigid article.
  • An example given below of possible binder is Gypsum but others either alone or in combinations as described later could be used.
  • the most desired and preferred expanded calcined clay is that sold under the trade name of Ultralite by Ceramic Gas Products Limited.
  • the expanded calcined clay ensures that the eventual article is lightweight whilst the binder as indicated tends to bind the expanded calcined clay (Ultralight) material together to form the article.
  • a combination of expanded calcined clay and a binder such as Gypsum ensures that the product allows the desired ranges of sizes and shapes to be achieved currently available with existing materials but with improved performance particularly in terms of integrity and possible surface powdering and erosion.
  • an expanded calcinated clay and in particular Ultralite is utilised in order to create an article by the present method.
  • the pore structure of the expanded calcinated clay ensures that the finally produced product has gained thermal properties and therefore can be used in relation to component articles utilised in insulation fire protection and acoustic applications.
  • the expanded calcinated clay in accordance with the aspect of the present invention will have a bulk packing density in the order of 75 kilograms per cubic metre.
  • Such calcinated clays are available as indicated and particularly under the trademark Ultralite.
  • a method in which granules or powder of expanded calcinated clay are pre wetted with up to three times their own weight of water.
  • This pre wetted expanded calcinated clay is then thoroughly mixed and dispersed with the binder such as a Gypsum slurry.
  • the Gypsum slurry will eventually act as a binder within the article form.
  • a high speed mechanical mixer is utilised with paddles extending into a vat in which the expanded calcined clay and binder such as a Gypsum slurry are combined.
  • additives may be used to facilitate flow and dispersion.
  • additives may be added at this stage or at other times to provide particular functionality or performance to the article once formed.
  • These additives may include fire suppressant materials to further enhance the thermal capabilities of the article once formed. It is important that all the additives as well as the binder and expanded clay are sufficiently dispersed and bonded together to form the article in use.
  • the bonding procedure is achieved through a setting and/or curing stage.
  • the mix may undergo an exothermic setting stage in a mould.
  • a form of forced air drying may involve provision of higher than ambient temperatures, that is to say achieving a curing temperature, but normally will simply involve locating the set article within a dehumidifier arrangement in which a desiccant preferentially draws fluid from the set article in order to dry it.
  • the bonding can be further strengthened by firing at elevated temperatures in a kiln.
  • the expanded calcinated clay is arranged to be wetted with up to three times its own weight of water which is absorbed within the pore structure of the expanded calcined clay. After dehydration the pore structure is retained and will ensure that the article produced is of a lightweight nature. Furthermore, the pore dimensions in the article may be as small as 5 microns and so provide high energy insulation properties for the article formed above in accordance with aspects of the present invention as well as making it extremely lightweight.
  • composition of the mixed dispersion will be in the ranges of 40% - 75% in volume expanded calcined clay with 25% - 60% in volume of a binder such as Gypsum.
  • the composition of the article formed once set is sufficiently bound for constructional integrity.
  • the articles will be components for but not limited to, fire protection, thermal insulation and noise reduction.
  • the expanded calcined clay has unique properties as a result of its pore structures once set and dried. These pores may be as small as 5 microns and extend through the expanded calcined clay in order to give high heat energy insulation properties as well as a lightweight nature. It will be appreciated different levels of processing of the expanded calcined clay results in different bulk densities of the articles produced and, in accordance with aspects of the present invention this is controlled by varying the grain size of the manufactured material or article (prill).
  • Articles formed in accordance with methods of aspects of the present invention typically as indicated are relatively lightweight and have high insulation properties.
  • the binder such as gypsum is arranged to retain the expanded calcined clay structure within the article.
  • a setting or curing procedure is achieved through an appropriate process such as an exothermic reaction of the binder such as Gypsum or cementaceous binder with the mixed dispersion.
  • Relatively complex shapes can be manufactured by pouring or pressing the mixed dispersion into an appropriately shaped mould. It will be appreciated that the drying procedure to provide setting of the mixed dispersion will be tailored to particular mould shapes to ensure that the drying procedure does not cause cracking of the article as it dries.
  • expanded calcined clay as indicated will be presented in granular or powder form (prill). By its nature this expanded calcined clay will absorb atmospheric moisture but generally will be receptive to pre wetting with as indicated by up to three times its own weight of water.
  • the method in accordance with aspects of the present invention is provided in order to form an article which has enhanced properties. It will be appreciated that through use of the expanded calcinated clay articles can be made which withstand much higher temperatures or have other properties due to the additives to the expanded calcinated clay combined with a binder. Thus for example articles formed in accordance with aspects of the present invention combine expanded calcinated clay with a binder such as a Gypsum slurry will have a much higher temperature than Gypsum alone is capable of withstanding. The material is ideal for composite fire doors with a lighter weight and with greater heat resistance properties.
  • the articles can be formed into a number of shapes including boards, sheets, composite panels, tubes, seals and other complex or simple solid and hollow shapes.
  • a particular advantage with regard to aspects of the present invention is that the addition of expanded calcinated clay will provide an article which after manufacture is generally lighter or has more heat resistance or thermal insulation or acoustic insulation or fire retardancy than prior articles formed without expanded calcinated clay. It will be understood that the variation in these capabilities and properties will be dependent upon the proportions of expanded calcinated clay and the binder Aspects of the present invention provide for combination of the expanded calcinated clay with the following binder as alternatives to or combinations with each other or with gypsum:
  • the glass bonding material as the binder in order to provide -and define porous filters or decorative shapes.
  • the glass bonding material as a binder may constitute up to 15% by weight of the article.
  • Provision of ethyl silicate bonding as the binder will provide refractories and in particular refractory crucibles along with other formed shapes which have a reduced weight in comparison with similar articles formed by prior techniques. A reduced weight will enhance capability with regard to safer manual handling in use.
  • Provision of polyvinyl acetate (PVA) and/or cellulose as a binder within the article will adjust heat resistance and thermal insulating effects when the article in the form of a powder is incorporated within paints for the construction industry.
  • Articles in accordance with aspects of the present invention may be provided as a powder which can then be considered a chemically inert filler for plastic components to reduce weight and increase fire resistance. It will also be understood that a powder formed in accordance with aspects of the present invention may be added to ordinary Portland cement or concrete products to reduce their weight.
  • additives may be included within the mixed dispersion of expanded calcined clay and binder in order to facilitate mixing and distribution.
  • these additives may add colour or be a fire retardant or other functional additive to retain and adjust the components once formed and set in accordance with the aspects of the present invention.
  • the degree of variation in the weight and functionality of the article can be controlled by the amount of pre wetting of the expanded calcined clay in accordance with the aspects of the present invention. It will be appreciated that care must be taken with respect to the pre wetting and mixing procedure such that the lightweight nature of the article produced is retained.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Dispersion Chemistry (AREA)
  • Civil Engineering (AREA)
  • Building Environments (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Preparation Of Clay, And Manufacture Of Mixtures Containing Clay Or Cement (AREA)

Abstract

L'invention porte sur un procédé de façonnage d'un article. Ce procédé comprend l'humidification d'une argile calcinée expansée avec jusqu'à trois fois sa propre masse d'eau, puis la combinaison de l'argile humidifiée avec un liant dans une dispersion mélangée de telle sorte que la dispersion mélangée peut être façonnée dans un moule et durcie.
PCT/GB2008/001644 2007-05-11 2008-05-12 Procédé de façonnage d'un article WO2008139180A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB0921488.3A GB2463186B (en) 2007-05-11 2008-05-12 Method of forming an article

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0709046.7 2007-05-11
GBGB0709046.7A GB0709046D0 (en) 2007-05-11 2007-05-11 Method of forming an article

Publications (1)

Publication Number Publication Date
WO2008139180A1 true WO2008139180A1 (fr) 2008-11-20

Family

ID=38219211

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB2008/001644 WO2008139180A1 (fr) 2007-05-11 2008-05-12 Procédé de façonnage d'un article

Country Status (2)

Country Link
GB (2) GB0709046D0 (fr)
WO (1) WO2008139180A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AT513933A1 (de) * 2013-02-12 2014-08-15 Horst Wustinger Verfahren für das Verbinden von Körnern aus geblähtem Vulkanglas
BE1022709B1 (nl) * 2015-02-11 2016-08-22 JAAMANN Albert Christiaan R. Bouwblok voor constructies
CN108503305A (zh) * 2018-04-04 2018-09-07 袁亮久 一种耐火保温的轻质防水发泡水泥填充材料及发泡方法
AT520113A1 (de) * 2017-07-11 2019-01-15 Dullinger Heinz Verfahren für das Herstellen eines Ziegels

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1446498A (fr) * 1965-06-12 1966-07-22 Perfectionnement à la fabrication de panneaux industriels pour le bâtiment
DE1930478A1 (de) * 1968-06-19 1970-01-02 Artmann Dipl Ing Paul Leichtbaustoff,insbesondere Leichtbeton,und Verfahren zu dessen Herstellung
DD83531A5 (de) * 1969-06-03 1971-07-20 Paul Dipl Ing Artmann Leichtbaustoff, insbesondere Leichtbeton, und Verfahren zu seiner Herstellung
WO1992007714A1 (fr) * 1990-10-25 1992-05-14 Erik Arne Kristoffer Westin Composition a plusieurs constituants destinee a un systeme de plancher en solives, et procede de fabrication
GB2265144A (en) * 1992-03-11 1993-09-22 Yen Hui Shan Preformed cellular composite wall
DE19643367A1 (de) * 1996-10-09 1998-04-16 Witega Angewandte Werkstoff Forschung Gemeinnuetzige Gmbh Adlershof Hochdämmfähiger konstruktiver Leichtbeton für die monolithische Massivbauweise und Verfahren zur Herstellung der Leichtbetonmischung
DE10116141A1 (de) * 2001-09-07 2003-03-27 Liapor Gmbh & Co Kg Verfahren zur Herstellung eines hochporösen Körpers
WO2004069766A1 (fr) * 2003-02-08 2004-08-19 Technical Lightweight Composites Ltd Matieres composites
FR2882551A1 (fr) * 2005-02-25 2006-09-01 Lero Soc Civ Ile Composition pour materiau de construction destinee a etre mise en forme : en moules, en coffrage de chantier, en coffrage du pre-fabrication

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Publication number Priority date Publication date Assignee Title
GB1456641A (en) * 1973-10-29 1976-11-24 Ici Ltd Composite foamed polyurethane material
SU1761728A1 (ru) * 1990-07-31 1992-09-15 Центральный межведомственный институт повышения квалификации руководящих работников и специалистов строительства Керамзитобетонна смесь
DE19831295A1 (de) * 1998-07-13 2000-01-20 Hubert Koertge Leichtbeton für Fertighauselemente und Verfahren zu seiner Herstellung

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1446498A (fr) * 1965-06-12 1966-07-22 Perfectionnement à la fabrication de panneaux industriels pour le bâtiment
DE1930478A1 (de) * 1968-06-19 1970-01-02 Artmann Dipl Ing Paul Leichtbaustoff,insbesondere Leichtbeton,und Verfahren zu dessen Herstellung
DD83531A5 (de) * 1969-06-03 1971-07-20 Paul Dipl Ing Artmann Leichtbaustoff, insbesondere Leichtbeton, und Verfahren zu seiner Herstellung
WO1992007714A1 (fr) * 1990-10-25 1992-05-14 Erik Arne Kristoffer Westin Composition a plusieurs constituants destinee a un systeme de plancher en solives, et procede de fabrication
GB2265144A (en) * 1992-03-11 1993-09-22 Yen Hui Shan Preformed cellular composite wall
DE19643367A1 (de) * 1996-10-09 1998-04-16 Witega Angewandte Werkstoff Forschung Gemeinnuetzige Gmbh Adlershof Hochdämmfähiger konstruktiver Leichtbeton für die monolithische Massivbauweise und Verfahren zur Herstellung der Leichtbetonmischung
DE10116141A1 (de) * 2001-09-07 2003-03-27 Liapor Gmbh & Co Kg Verfahren zur Herstellung eines hochporösen Körpers
WO2004069766A1 (fr) * 2003-02-08 2004-08-19 Technical Lightweight Composites Ltd Matieres composites
FR2882551A1 (fr) * 2005-02-25 2006-09-01 Lero Soc Civ Ile Composition pour materiau de construction destinee a etre mise en forme : en moules, en coffrage de chantier, en coffrage du pre-fabrication

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* Cited by examiner, † Cited by third party
Title
CHEMICAL ABSTRACTS, vol. 111, no. 2, 10 July 1989, Columbus, Ohio, US; abstract no. 11711, GUSEV, B. V.; MUSTAFIN, Y. I.; DIDENKO, E.A.: "Control of the preparation of concrete mixes" page 282; XP002496847 *
GUSEV, B. V.; MUSTAFIN, Y. I,, DIDENKO, E. A.: "Control of the preparation of concrete mixes", STROIT. MATER. KONSTR., vol. 4, 1988, Russ *

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AT513933A1 (de) * 2013-02-12 2014-08-15 Horst Wustinger Verfahren für das Verbinden von Körnern aus geblähtem Vulkanglas
BE1022709B1 (nl) * 2015-02-11 2016-08-22 JAAMANN Albert Christiaan R. Bouwblok voor constructies
BE1022783B1 (nl) * 2015-02-11 2016-09-02 Albert Christiaan R JAAMANN Bouwelement voor constructies
AT520113A1 (de) * 2017-07-11 2019-01-15 Dullinger Heinz Verfahren für das Herstellen eines Ziegels
AT520113B1 (de) * 2017-07-11 2019-06-15 Dullinger Heinz Verfahren für das Herstellen eines Ziegels
CN108503305A (zh) * 2018-04-04 2018-09-07 袁亮久 一种耐火保温的轻质防水发泡水泥填充材料及发泡方法

Also Published As

Publication number Publication date
GB2463186B (en) 2013-02-20
GB0921488D0 (en) 2010-01-20
GB2463186A (en) 2010-03-10
GB0709046D0 (en) 2007-06-20

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