Plastic and nonmetallic article shaping or treating: processes – Pore forming in situ – Of inorganic materials
Patent
1997-09-29
1998-10-27
Derrington, James
Plastic and nonmetallic article shaping or treating: processes
Pore forming in situ
Of inorganic materials
264628, 264652, 501 85, C04B 3800, C04B 3808
Patent
active
058274570
ABSTRACT:
A method for manufacturing a lightweight foamed ceramic body from components comprising: (a) at least one expandable volcanic mineral; (b) at least one alkaline earth metal oxide, hydroxide, or carbonate, (c) at least one inorganic binder and (d) a foaming stabilizer, the method comprising: (1) sintering and expanding a mixture of components (a) to (d); (2) mixing the sintered and expanded material with water; (3) grinding the mixture of sintered and expanded material with water to form a ground mixture; (4) drying said ground mixture to form a dried mixture; (5) crushing said dried mixture to form a fine powder; (6) shaping said powder into a desired form to form a powder form; and (7) sintering said powder form. The ceramic material is preferably manufactured in a tunnel-type kiln. The resulting foamed ceramic is not only light in weight, but excellent in insulating properties due to its discrete cell of closed cellular structure. The foamed ceramic is useful in structural and building materials.
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