Patent US3847634A successfully refreshed from Google Patents.
US3847634A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Synthetic lightweight building material
Assignee: Individual
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Filing: 1973-03-12
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Granted: 1974-11-12
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Expires: 1993-03-12
Abstract
Abstract A synthetic lightweight building material suitable for use as aggregate, building blocks, bricks, facing masonry such as tile, and lightweight decorative stone, is prepared by mixing gypsum by-products from phosphoric or hydrofluoric acid manufacture containing traces of impurities with lime and a soluble silicate with sufficient water to form a slurry which is then molded and allowed to set to form such concrete structures or, if desired, crushed into rock aggregate for the manufacture of such structures. The slurry contains a mixture by weight of solids of 2 to 10 percent lime and 1 to 25 percent silica, the latter being in the form of either a soluble silica powder or a colloidal dispersion of silica sol with sufficient water to form the slurry. The remainder of the mixture comprising, as an essential constituent, calcium sulfate provided by the gypsum by-product.
Inventors
- 👤 R Vickery
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 22:09
CPC Classifications
C; C04; C04B; C04B28/00; C04B28/18; C04B28/182; C04B2111/00; C04B2111/40
Claims Analysis
Total Claims: 11
Claim 1
Independent Claim
103 words
A SYNTHETIC LIGHTWEIGHT BUILDING MATERIAL COMPOSITION HAVING A COMPRESSIVE STRENGTH OF ABOUT 3,000 TO 5,000 POUNDS PER SQUARE INCH CONSISTING ESSENTIALLY OF 1 TO 25 PERCENT BY WEIGHT PARTICULATE SILICEOUS MATERIAL AND 2 TO 10 PERCENT BY WEIGHT LIME, THE REMAINDER COMPRISING A GYPSUM-TYPE RESIDUE SELECTED FROM THE GROUP CONSISTING OF PHOSPHOGYPSUM AND FLUOROGYPSUM, SAID RESIDUE CONTAINING OF PHOSPHOGYPSUM AND ENT CALCIUM SULFATE, SAID COMPOSITION BEING COMBINED WITH SUFFICIENT WATER TO FORM A SLURRY WHEREIN THE SILICA CONSTITUENT OF SAID SILICEOUS MATERIAL REACTS TO FORM COMPLEX CALCIUM SILICATES FOR PRODUCING CALCIUM SILICATE CRYSTALS WHICH ACT AS A BINDER UPON OBTAINING A HYDRAULIC SET.
Claim 2
Dependent Claim
103 words
A SYNTHETIC LIGHTWEIGHT BUILDING MATERIAL COMPOSITION HAVING A COMPRESSIVE STRENGTH OF ABOUT 3,000 TO 5,000 POUNDS PER SQUARE INCH CONSISTING ESSENTIALLY OF 1 TO 25 PERCENT BY WEIGHT PARTICULATE SILICEOUS MATERIAL AND 2 TO 10 PERCENT BY WEIGHT LIME, THE REMAINDER COMPRISING A GYPSUM-TYPE RESIDUE SELECTED FROM THE GROUP CONSISTING OF PHOSPHOGYPSUM AND FLUOROGYPSUM, SAID RESIDUE CONTAINING OF PHOSPHOGYPSUM AND ENT CALCIUM SULFATE, SAID COMPOSITION BEING COMBINED WITH SUFFICIENT WATER TO FORM A SLURRY WHEREIN THE SILICA CONSTITUENT OF SAID SILICEOUS MATERIAL REACTS TO FORM COMPLEX CALCIUM SILICATES FOR PRODUCING CALCIUM SILICATE CRYSTALS WHICH ACT AS A BINDER UPON OBTAINING A HYDRAULIC SET.
Claim 3
Dependent Claim
24 words
The material composition according to claim 1 wherein said gypsum-type residues include one or more impurities from a group consisting of aluminum and fluorine.
Claim 4
Dependent Claim
22 words
The material composition according to claim 2 wherein said gypsum-type residue is dehydrated at at least 120*C for at least 2 hours.
Claim 5
Dependent Claim
24 words
The material composition according to claim 2 wherein said particulate siliceous material is combined in the form of an aqueous colloidal dispersion of silicate.
Claim 6
Dependent Claim
30 words
The material composition according to claim 2 wherein said particulate siliceous material is combined in the form of dry silicate powder having a particulate size of 65 mesh or smaller.
Claim 7
Dependent Claim
23 words
The material composition according to claim 1 wherein said calcium silicate crystals have a matrix form similar to that of thaumassite and xonotlite.
Claim 8
Dependent Claim
20 words
The material composition according to claim 1 consisting essentially of 1 to 10 percent by weight of said siliceous material.
Claim 9
Dependent Claim
19 words
The material composition according to claim 7 consisting essentially of 3 to 5 percent by weight of said lime.
Claim 10
Dependent Claim
20 words
The material composition according to claim 8 consisting essentially of 2 to 7 percent by weight of said siliceous material.
Claim 11
Dependent Claim
36 words
The material composition according to claim 1 wherein said slurry upon obtaining a hydraulic set has a density of 1.6 and provides said compressive strength within the range of 3,000 to 5,000 pounds per square inch.
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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) | 1977-11-11 | 1978-05-13 | 1978-11-12 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1981-11-11 | 1982-05-13 | 1982-11-12 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1985-11-11 | 1986-05-13 | 1986-11-12 | $7700.00 | Window Closed / Lapsed |