US3844804A
Expired / Lapsed
US
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Silicate foam structures and method of preparation
Assignee: GAF Corp
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Filing: 1972-01-03
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Granted: 1974-10-29
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Expires: 1992-01-03
Abstract
Abstract A liquid silicate reactant, such as phosphoric acid, is absorbed in an amorphous reactant carrier, preferably calcium containing, to form a dry premix composition that is blended with an aqueous alkali metal silicate to form a moldable silicate mix. This mix is heated in a mold at a temperature sufficient to cause the removal of water therefrom, with small water gas bubbles being formed within and throughout the mix to produce a lightweight multicellular foam structure. The reactant and calcium ions are slowly leached from the carrier for reaction with the silicate during the foaming process, improving the water-insolubility and firmness characteristics of the resulting foamed structure. The rate of leaching is sufficiently slow, however, so as not to cause premature and rapid reaction with the silicate tending to reduce expansion of the structure. As a result, a low density foamed structure having a density of from about 3 to about 15, preferably less than 10, lbs/ft3 is obtained. The aqueous alkali metal silicate preferably comprises a combination of sodium silicate and potassium silicate, with the potassium silicate comprising from about 5 percent to about 10 percent by weight based on the total weight of alkali metal silicate employed.
Inventors
- 👤 J Horai
- 👤 C Sheeler
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 01:29
CPC Classifications
C; C04; C04B; C04B28/00; C04B28/24; C04B28/26; C04B35/00; C04B35/01; C04B35/16
Claims Analysis
Total Claims: 31
Claim 1
Independent Claim
144 words
A METHOD FOR PREPARING A FOAMED SILICATE STRUCTURE COMPRISING: A. PREMIXING A HIGHLY ABSORBENT, AMORPHOUS LIGHTWEIGHT REACTANT CARRIER WITH A LIQUID AGENT REACTIVE WITH SILICATE TO IMPROVE THE WATER-SOLUBILITY AND FIRMNESS OF SAID SILICATE UPON FOAMING THEREOF, SAID CARRIER AND SAID AGNET BEING MIXED IN PROPORTIONS SUCH THAT SAID AGENT IS ESSENTIALLY TOTALLY ABSORBED BY THE REACTANT CARRIER, RESULTING IN AN ESSENTIALLY DRY PREMIX COMPOSITION; B. MIXING SAID DRY PREMIX COMPOSITION WITH AN AQUEOUS ALKALI METAL SILICATE HAVING A TOTAL SOLIDS CONTENT OF FROM ABOUT 35 PERCENT TO ABOUT 55 PERCENT BY WEIGHT TO FORM A MOLDABLE SILICATE MIX; C. HEATING SAID MOLDABLE SILICATE MIX IN A MOLD AT A TEMPERATURE SUFFICIENT TO CAUSE THE WATER CONTENT OF THE MIX TO BE RAPIDLY REMOVED THEREFROM, SMALL WATER VAPOR GAS BUBBLES BEING FORMED WITHIN AND THROUGHOUT THE MIX TO PRODUCE A LIGHTWEIGHT, MULTI-CELLULAR FOAM STRUCTURE.
Claim 2
Independent Claim
144 words
A METHOD FOR PREPARING A FOAMED SILICATE STRUCTURE COMPRISING: A. PREMIXING A HIGHLY ABSORBENT, AMORPHOUS LIGHTWEIGHT REACTANT CARRIER WITH A LIQUID AGENT REACTIVE WITH SILICATE TO IMPROVE THE WATER-SOLUBILITY AND FIRMNESS OF SAID SILICATE UPON FOAMING THEREOF, SAID CARRIER AND SAID AGNET BEING MIXED IN PROPORTIONS SUCH THAT SAID AGENT IS ESSENTIALLY TOTALLY ABSORBED BY THE REACTANT CARRIER, RESULTING IN AN ESSENTIALLY DRY PREMIX COMPOSITION; B. MIXING SAID DRY PREMIX COMPOSITION WITH AN AQUEOUS ALKALI METAL SILICATE HAVING A TOTAL SOLIDS CONTENT OF FROM ABOUT 35 PERCENT TO ABOUT 55 PERCENT BY WEIGHT TO FORM A MOLDABLE SILICATE MIX; C. HEATING SAID MOLDABLE SILICATE MIX IN A MOLD AT A TEMPERATURE SUFFICIENT TO CAUSE THE WATER CONTENT OF THE MIX TO BE RAPIDLY REMOVED THEREFROM, SMALL WATER VAPOR GAS BUBBLES BEING FORMED WITHIN AND THROUGHOUT THE MIX TO PRODUCE A LIGHTWEIGHT, MULTI-CELLULAR FOAM STRUCTURE.
Claim 3
Dependent Claim
19 words
The process of claim 1 and including cooling the foamed silicate structure prior to removal thereof from said mold.
Claim 4
Dependent Claim
14 words
The process of claim 1 in which said alkali metal silicate comprises sodium silicate.
Claim 5
Dependent Claim
17 words
The process of claim 3 in which said alkali metal silicate comprises sodium silicate and potassium silicate.
Claim 6
Dependent Claim
48 words
The process of claim 4 in which said potassium silicate comprises from about 5 percent to about 10 percent by weight based on the total weight of alkali metal silicate employed, whereby the strength, dimensional stability, water insolubility and non-hygroscopic character of the foamed silicate structure are enhanced.
Claim 7
Dependent Claim
29 words
The process of claim 5 in which said amorphous carrier comprises silica containing from about 5 percent to about 25 percent by weight of an alkaline earth metal salt.
Claim 8
Dependent Claim
12 words
The process of claim 6 in which said salt is calcium oxide.
Claim 9
Dependent Claim
30 words
The process of claim 5 in which said liquid agent is taken from the group consisting of concentrated phosphoric acid, hydrochloric acid, aluminum chloride, ammonium chloride and aluminum sulfate solution.
Claim 10
Dependent Claim
44 words
The process of claim 1 in which the carrier comprises silica, and said silica and said liquid agent are mixed in a weight ratio of 4 parts silica and from 1 to 2 parts of said liquid reactant to form said dry premix composition.
Claim 11
Dependent Claim
44 words
The process of claim 8 in which the carrier comprises silica and said silica and said liquid agent are mixed in a weight ratio of 4 parts silica and from 1 to 2 parts of said liquid agent to form said dry premix composition.
Claim 12
Dependent Claim
46 words
The process of claim 10 in which said dry premix composition and said alkali metal silicates are blended in a weight ratio of about 10 parts of said dry premix to about 85 to about 95 parts of said silicates to form said moldable silicate mix.
Claim 13
Dependent Claim
13 words
The process of claim 8 in which said liquid agent comprises phosphoric acid.
Claim 14
Dependent Claim
13 words
The process of claim 11 in which said liquid agent comprises phosphoric acid.
Claim 15
Dependent Claim
15 words
The process of claim 13 in which said phosphoric acid comprises 85.5 percent phosphoric acid.
Claim 16
Dependent Claim
48 words
The process of claim 1 in which said moldable silicate mix is heated at an air temperature of from about 212*F to about 900*F for a period of time sufficient to permit water to be vaporized from the body of the mix, thus forming the desired foamed structure.
Claim 17
Dependent Claim
30 words
The process of claim 15 in which said moldable mix is heated by high-frequency electronic heating, said temperature not exceeding about 240*F, the time of heating not exceeding 15 minutes.
Claim 18
Dependent Claim
48 words
The process of claim 5 in which said moldable silicate mix is heated at an air temperature of from about 212*F to about 900*F for a period of time sufficient to permit water to be vaporized from the body of the mix, thus forming the desired foam structure.
Claim 19
Dependent Claim
16 words
The process of claim 17 in which said temperature is from about 220*F to about 800*F.
Claim 20
Dependent Claim
30 words
The process of claim 18 in which said liquid agent is taken from the group consisting of concentrated phosphoric acid, hydrochloric acid, aluminum chloride, ammonium chloride and aluminum sulfate solution.
Claim 21
Dependent Claim
15 words
The process of claim 19 in which said liquid agent comprises 85.5 percent phosphoric acid.
Claim 22
Dependent Claim
79 words
The process of claim 20 in which the carrier comprises silica and said silica and said liquid agent are mixed in the proportions of about 4 parts silica and from 1 to 2 parts phosphoric acid by weight to form said dry premix, said premix and alkali metal silicates being blended in a weight ratio of about 10 parts of said dry premix to about 85 to about 95 parts of said silicates to form said moldable silicate mix.
Claim 23
Dependent Claim
103 words
A moldable silicate mix composition comprising: a. an aqueous alkali metal silicate having a total solids content of from about 35 percent to about 55 percent by weight; and b. a dry premix composition comprising a mixture of a highly absorbent, amorphous, lightweight carrier comprising amorphous silica containing from about 5 percent to about 25 percent by weight of an alkaline earth metal salt and a liquid agent reactive with silicate to improve the water insolubility and firmness of said silicate upon foaming thereof, said liquid agent being present in an amount such that said agent is essentially totally absorbed by the carrier.
Claim 24
Dependent Claim
103 words
A moldable silicate mix composition comprising: a. an aqueous alkali metal silicate having a total solids content of from about 35 percent to about 55 percent by weight; and b. a dry premix composition comprising a mixture of a highly absorbent, amorphous, lightweight carrier comprising amorphous silica containing from about 5 percent to about 25 percent by weight of an alkaline earth metal salt and a liquid agent reactive with silicate to improve the water insolubility and firmness of said silicate upon foaming thereof, said liquid agent being present in an amount such that said agent is essentially totally absorbed by the carrier.
Claim 25
Dependent Claim
14 words
The composition of claim 22 in which said alkali metal silicate comprises sodium silicate.
Claim 26
Dependent Claim
17 words
The composition of claim 23 in which said alkali metal silicate comprises sodium silicate and potassium silicate.
Claim 27
Dependent Claim
48 words
The composition of claim 24 in which said potassium silicate comprises from about 5 percent to about 10 percent by weight based on the total weight of alkali metal silicate employed, whereby the strength, dimensional stability, water insolubility and non-hygroscopic character of the foamed silicate structure are enhanced.
Claim 28
Dependent Claim
13 words
The composition of claim 25 in which said metal salt is calcium oxide.
Claim 29
Dependent Claim
30 words
The composition of claim 25 in which said liquid agent is taken from the group consisting of concentrated phosphoric acid, hydrochloric acid, aluminum chloride, ammonium chloride and aluminum sulfate solution.
Claim 30
Dependent Claim
71 words
The composition of claim 27 in which said amorphous silica carrier and said liquid agent are employed in a weight ratio of 4 parts silica and 1 to 2 parts of said liquid agent to form said dry premix and said dry premix and said aLkali metal silicate are employed in a weight ratio of about 10 parts of said premix to about 85 to about 95 parts of said silicates.
Claim 31
Dependent Claim
13 words
The composition of claim 28 in which said liquid agent comprises phosphoric acid.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1977-10-28 | 1978-04-29 | 1978-10-29 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1981-10-28 | 1982-04-29 | 1982-10-29 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1985-10-28 | 1986-04-29 | 1986-10-29 | $7700.00 | Window Closed / Lapsed |