Compositions: coating or plastic – Coating or plastic compositions – Alkali metal silicate containing
Reexamination Certificate
2000-01-18
2002-07-16
Marcantoni, Paul (Department: 1755)
Compositions: coating or plastic
Coating or plastic compositions
Alkali metal silicate containing
C106S602000, C501S106000, C501S107000
Reexamination Certificate
active
06419737
ABSTRACT:
FIELD OF THE INVENTION
The present invention is related to a cementitious polymeric matrix comprising silica aluminous materials having high mechanical properties and high temperature resistance properties.
The present invention is also related to a method of realisation of such a cementitious polymeric matrix comprising silica aluminous materials.
BACKGROUND OF THE INVENTION
Heat and fire resistance silica products traditionally have been prepared by energy-intensive methods that require costly high consumption of energy and carefully regulated chemical formulation, pre-heating, firing and cooling cycles to achieve reproducible quality products. Various calcium aluminate and calcined alumino cement and refractory moulding products have been produced, but none of these has achieved the combined of fast curing, high adhesive bonding qualities, low material accessibility, together with good mechanical, thermal and chemical properties.
Aims of the Present Invention
Thus, a need exists for a product that combines the above qualities with simplicity of use so as to preclude any special skill or training to accommodate the product to various uses.
A first aim of the present invention is to suggest a new product which combines properties of high mechanical resistance with high temperature resistance on the same product.
A further aim of the present invention is to suggest a product having low material cost.
A further aim of the present invention is to suggest a realisation method of such a product which has a simplicity of use so as to preclude any special skill or training to accommodate the product to various uses.
Other advantages and properties of the invention related to the product or to the method of realisation will be described hereunder in the description.
Main Characteristics of the Present Invention
The present invention relates to an alumino silicate polymer (ASP) matrix which could meet all the above-mentioned requirements.
The product of the present invention comprises two major components, which are:
a liquid component form of alkali metal silicate aqueous solution of formula M
2
O.RSiO
2
.XH
2
O, in which:
M is an alkali metal monovalent cation such as K
+
or Na
+
;
R is designated to be the molar ratio of SiO
2
/M
2
O range comprised between 0.5/1 and 9/1; and
X is the amount of water comprised between 30 and 70 wt %;
a powder component form which comprises at least:
silico-aluminous reactive raw materials composed of Al
6
Si
2
O
13
and Al
2
O
3
.4 SiO
2
with a relative proportion ranging from 40 to 60 wt %, the particle size of both components ranging from 50 to 70 microns.
According to a first preferred embodiment, the preferred powder component further comprises:
zirconium silicate flour having a particle size ranging from 50 to 70 microns, the ratio of the zirconium silicate flour being comprised between 1 and 25 wt % of the powder component.
According to another preferred embodiment, the powder component further comprises:
pulverised raw materials being a combination of two major components which are:
beauxite component having 80 wt % Al
2
O
3
alumino content and having maximum grain size of 500 microns,
chamosite component having 40 wt % Al
2
O
3
alumino content and having an average grain size comprised between 60 and 100 microns and being of the formula such as ((Fe,Al,Mg)
6
(SiAl)
4
O10(OH)
8
), the combination of beauxite chamosite components wave ratio ranging from 1/1 to 1/2 and being preferably around 1/2.
Preferably, the ratio of the raw material being comprised between 1 and 25 wt % of the powder component. Alkali metal silicate solution used in the present invention is prepared by direct reaction of alkali metal hydroxide, water (H
2
O) and precipitated silica (SiO
2
) through exothermic reactions. This solution can also be prepared in situ.
The required amount of the components which are mixed and the rheology of the (ASP) matrix can be adapted to various processing techniques by the eventual addition of some other filler materials.
Thus the ASP matrix can be:
a semi-dry friable material, which can be compacted statically or dynamically into its final shape. The shape can be handled without mould prior to hardening;
a plastic paste showing cohesion which can be calendered and compacted by rolling or which can be extruded through a die, similar to classical brick making;
a liquid suspension of particles, which can be casted or injected in a moule.
After shaping, an increase in temperature (below 100° C.) as initial curing is required to accelerate the initial setting, and then stored for another several days as post curing, so finishing the hardening reaction within a few days leading to following advantageous properties:
the environmental aspects are very positive such as low temperature processing, low cost raw materials, availability of raw materials together with the recycling of waste products;
high mechanical strength, for instance, compressive strength between 40 MPA to 100 MPA (depending on formulation), and hardness above 8 Mohs;
the most important properties of alumino-silicate polymer (ASP) materials are surely the absolute fire resistance, thermal and chemical resistance, as well as durability against weathering. It can be worked on by means of nailing, screwing, sawing and drilling, non conductivity together with the other two main properties.
The use of widely available raw materials and simple implementation techniques for the obtention of cheap and durable building materials.
The origin of the raw materials is mineral, more precisely silicate materials which are dominantly present in the earth's crust under the shape, for instance of clays or weathered materials rocks. Several types of pozzolanic materials are very suited, but also industrial waste products such as by-product pozzolans can be used.
Alumino-silicate (ASP) binding composition is always in a two components system having a powder component form from mineral origin, and a liquid component form which consisting of inorganic catalysts in solution (usually in water). When the components are mixed together, the catalysts break down the structure of the powder component, and subsequently build up an excellent cementitious polymeric structure through polymerisation or polycondensation or poly aggregation reactions. The structure of (ASP) materials is however totally inorganic polymers. The emphasis of the present invention has been placed on the development of material systems which do react at low temperatures and at atmospheric pressure, and which do lead to solid ceramic like end-products.
The cementitious property of ASP materials is attributed to the formation of:
Alkali metal tri aluminate (M
6
Al
6
O
12
)
Alkali metal tri silicate (M
6
Si
8
O
19
)
Alkali metal di silicate (M
2
Si
2
O
5
)
In this way, the additives are used to obtain materials with typical ceramic properties, in contrast with the traditional high temperature thermal processing route.
This permits saving in energy and processing cost and offers technological advantages and open new horizon towards excellent building materials. Many traditional building materials (i.e. some organic polymer materials and other mineral base fibres), are moving from restriction towards ban, because they are recognised as extremely toxic materials or to be source of cancer. Thus, a need exists to find a replacement for those traditional banded building materials with emphasis on health and economic grounds.
The superior properties of the products of the present invention can be described as the combination of the following requirements:
1. High mechanical strength both in wet and dry conditions
2. High heat and fire resistance
3. Incombustibility
4. Extremely non-conductivity
5. High chemical resistance
6. Excellent water resistance
7. Low coefficient of thermal expansion
8. Low level of firing contraction
9. Low material cost together with simplicity of use
The present invention of alumino-silicate polymer (ASP) matrix seems to meet all these requirements.
Although the specific properties of the alumino-sil
H.T.B.S. Corporation B.V.
Knobbe Martens Olson & Bear LLP
Marcantoni Paul
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