Plastic and nonmetallic article shaping or treating: processes – Pore forming in situ – Of inorganic materials
Reexamination Certificate
2000-04-27
2001-06-26
Fiorilla, Christopher A. (Department: 1731)
Plastic and nonmetallic article shaping or treating: processes
Pore forming in situ
Of inorganic materials
C264S101000, C264S621000
Reexamination Certificate
active
06251316
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of producing solid articles of clay foam to be used in building and products obtained therefrom.
2. Description of Related Art
The need to lighten parts of buildings, such as main walls, curtain walls, partition walls and ceilings, and to give them the required insulating, deadening properties has brought to the manufacturing of hollow materials such as hollow clay tiles, hollow clay blocks, plaster board and the like that do not fully solve the problems.
Such parts of buildings may also be made of synthetic foam materials such as polystyrene, polyurethane, etc., combining light weight and good deadening, insulating properties. The problem of inflammability of such materials has been recently solved so that they can presently be used in building as panels, especially covering panels. However, the problem of their poor mechanical resistance to compressive stress has not been solved so far and their use as carrying structure is excluded.
In an attempt to foam materials inherently provided with mechanical strength, incombustibility, and easy mouldability such as clay, gases or substances developing gases have been put therein using raw clay as starting material.
However, such attempts have not provided satisfactory results so far both as far as the moulding of a homogeneously foamed mass and mouldability and mechanical strength thereof is concerned.
SUMMARY OF THE INVENTION
A method of providing a solid article of clay foam to be used in building, including the steps of:
a) providing baked clay which has been ground to form clay particles;
b) providing a water solution of a salt of silicic acid;
c) mixing the clay particles and the water solution to form a fluid mass;
d) dividing the fluid mass into a first portion and a second portion and placing each portion in a separate first and second container, respectively;
e) adding formaldehyde to the first portion in the first container in an amount of 5-15% by weight of the first portion and thoroughly stirring;
f) adding hydrogen peroxide to the second portion in the second container in an amount of about of 5-15% by weight of the second and thoroughly stirring;
g) sucking the fluid mass in the first and second containers into a sealed vacuum reactor and mixing thoroughly to form a reaction mixture wherein the silicic acid salt is caused to harden and gel thus forming a porous, solid mass; and
h) transferring the porous, solid mass to a mold to dry, thus forming the desired clay foam solid article.
REFERENCES:
patent: 3409450 (1968-11-01), Weber
patent: 3673290 (1972-06-01), Brubaker et al.
patent: 5151228 (1992-09-01), Vahlbrauk
DeLio & Peterson LLC
Fiorilla Christopher A.
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