Compositions: ceramic – Ceramic compositions – Silicon compound containing
Patent
1996-07-01
2000-03-28
Bell, Mark L.
Compositions: ceramic
Ceramic compositions
Silicon compound containing
501133, 106638, 106816, C04B 3516
Patent
active
06043175&
DESCRIPTION:
BRIEF SUMMARY
FIELD OF THE INVENTION
This invention relates to the manufacture of silicon based binding compositions from silica. In particular, the invention relates to binding compositions which are prepared by the wet grinding of silica in an alkaline medium and products which may be prepared from the binding composition. In addition, this invention relates to the apparatus which may be used to prepare the binding composition.
BACKGROUND OF THE INVENTION
Ceramics may generally be defined as products manufactured by the action of heat on earthy raw materials in which silicon with its oxide and silicates occupy a predominant position. Various types of products are made from ceramics including structural clay products (such as brick, tile, terra cotta and glazed architectural brick); whitewares (such as dinnerware, chemical and electrical porcelain, sanitary ware and floor tile); glass products of all types; porcelain enamels; refractories; Portland cement, lime, plaster and gypsum products; abrasive materials such as fused alumina, silicon carbide and related products; and, aluminum silicate fibres.
Clay based ceramic products have become a staple in many areas of industry including the construction industry. In particular, structural clay products are used extensively in the construction of buildings.
Accordingly, one disadvantage of structural clay products is that an extensive amount of time is required to produce a single product. Further, large amounts of energy must be utilized during the baking process in the kiln. Typically, in order for a manufacturing plant to be economically efficient, kilns having a capacity to simultaneously bake a large quantity of bricks are required. In addition, manufacturing plants tend to be located near the source of the clay, thus increasing the cost of transporting the bricks to the construction site where they will be used.
More recently, silicate based material has been utilized to produce bricks. For example, calcium silicate bricks may be prepared by grinding lime together with sand to produce a lime-silica bonding adhesive, mixing this adhesive with sand, pressing the mixture of sand and bonding adhesive into a mold and baking the mixture in an autoclave. Calcium silicate bricks may be utilized in place of more conventional clay bricks in the construction industry.
One disadvantage with calcium silicate bricks is the amount of time required to produce a single brick. In addition, a large amount of processing equipment and power input is required to produce calcium silicate bricks.
Binding compositions have also been prepared by the wet grinding of sand in an alkaline medium. According to the method disclosed in U.S.S.R. Author's Priority Certificate No. 992487, sand is ground in a ball mill in an alkaline medium (pH 9.0-10.5) to produce a silica based binding composition. The feedstock is divided into three portions. The first portion, which comprises 50% of the feedstock of sand, is milled for 6 hours. In the presence of a waterglass having a pH of 10.5. The second portion, which comprises 25% of the initial feedstock, is then combined with the milled feedstock and the mixture is milled for 7 hours. The third portion, which comprises 25% of the initial feedstock, is added to this milled product and this mixture is then milled for an additional 12 hours. One disadvantage of this method is that each batch requires 24 hours of milling time. This reduces the potential throughput of the process. In addition, the lengthy grinding time increase the wear of the components of the ball mill and substantially decrease the lifetime of the ball mill. In addition, the product produced by this method may not have sufficient compressive strength for use in some applications.
SUMMARY OF THE INVENTION
According to the instant invention, a binding composition comprising silica is prepared by fractionating a silicon feedstock in the presence of an alkaline medium to produce fines that are substantially spherical in shape. The fines are surrounded by a layer of orthosilicic acid sol. Pref
REFERENCES:
patent: 20370 (1858-05-01), Rands
patent: 303708 (1884-08-01), Coles
patent: 2090578 (1937-08-01), Eppenbach
patent: 2492808 (1949-03-01), Marisic et al.
patent: 2741600 (1956-04-01), Allen
patent: 2856268 (1958-05-01), Young
patent: 2886466 (1959-05-01), Iler et al.
patent: 2992930 (1961-07-01), Wheeler et al.
patent: 3083167 (1963-03-01), Shannon
patent: 3103316 (1963-09-01), Schaal
patent: 3111278 (1963-11-01), Buschman
patent: 3215355 (1965-11-01), Shouvlin et al.
patent: 3434672 (1969-03-01), Guin
patent: 3459380 (1969-08-01), Kartman
patent: 3493182 (1970-02-01), Szegvari
patent: 3650977 (1972-03-01), Bobb
patent: 3652214 (1972-03-01), Aboutboul et al.
patent: 3709664 (1973-01-01), Krekeler et al.
patent: 3720532 (1973-03-01), Simpson et al.
patent: 3754952 (1973-08-01), Kirilishin et al.
patent: 3902673 (1975-09-01), Berggren
patent: 3920578 (1975-11-01), Yates
patent: 3930878 (1976-01-01), Mendoza
patent: 3933317 (1976-01-01), Rovere
patent: 3959174 (1976-05-01), Winyall et al.
patent: 4216113 (1980-08-01), Winyall
patent: 4256682 (1981-03-01), Denton
patent: 4336234 (1982-06-01), Leutner et al.
patent: 4457804 (1984-07-01), Reinhall
patent: 4576921 (1986-03-01), Lane
patent: 4624800 (1986-11-01), Sasaki et al.
patent: 4881348 (1989-11-01), Davis
patent: 4915870 (1990-04-01), Jones
patent: 4925647 (1990-05-01), Kirchhofer
patent: 4999325 (1991-03-01), Michael
patent: 5110769 (1992-05-01), Welsh et al.
patent: 5116535 (1992-05-01), Cochrane
patent: 5145692 (1992-09-01), Hereford
patent: 5221497 (1993-06-01), Watanabe et al.
patent: 5238518 (1993-08-01), Okubi et al.
"The Power of Particles" by Franz Frisch, Lufthansa Bordbuch Feb. 1993, pp. 54-57.
Patent Office, Application for Patent No. 375156, filed Mar. 6, 1931, Orazio Rebuffat, inventor; entitled: "Use of Colloidal Silica for the Egglomeration of Incoherent Material, With the Object of Forming Blocks of Refractory Materials and Mortars to be used in Joining Them Together".
Patent Office, Application For Patent No. 464,047, filed May 29, 1939, P. W. Jones and J. W. Swezey, applicants; "Method Of Making Artifical Structural Material and Product".
Application for Patent No. 58,079, Oct. 1891, entitled "Pulverizer", Estate of Y. W. Seaver, Department of Agriculture, Patent Branch, Boston, Massachusetts.
Kulev Gennady Ivanovich
Malinovski Leonid Glebovich
Miroevsky Piotr Ravelevich
Shvarev Ivan Pavloivich
Bell Mark L.
Sample David
VKVS Worldwide Corporation
LandOfFree
Method and apparatus for producing a silicon based binding compo does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Method and apparatus for producing a silicon based binding compo, we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Method and apparatus for producing a silicon based binding compo will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-1325894