US3928047A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Artificial stone and method for making the stone from a coal byproduct
Assignee: Individual
•
Filing: 1974-07-10
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Granted: 1975-12-23
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Expires: 1994-07-10
Abstract
Abstract Solid coal combustion products, fly ash, mine tailings or the like coal byproducts are melted after their composition is adjusted to contain 40-60% SiO2; 15-40% trivalent oxides, mainly those of iron and aluminum; and 11-35% mono- and divalent oxides. After melting at 1,350*-1,500*C until the melt is substantially fined, the material is molded at 1,200*-1,400*C, then is crystallized between 900* and 1,300*C and then the crystallized object is cooled. The product contains a feldspar which is either 55-75% labradorite or 50-70% plagioclase, also 4-20% monoclinic and rhombic pyroxenes, and 2-25% oxides mainly having a spinel structure and ferric oxide modifications. Depending on the starting composition and the heat treatment that is employed, different crystal associations are obtained some of which are more useful as architectural paneling and the like, while others are more useful as items with good chemical durability.
Inventors
- 👤 Laszlo Kapolyi
- 👤 Imre Kubovits
- 👤 Ferenc Kaszanitzky
- 👤 Szabo
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-07 15:25
CPC Classifications
C; C04; C04B; C04B33/00; C04B33/02; C04B33/025; C03; C03C; C03C10/00; C03C10/0063; C04B32/00; C04B32/005; C04B35/00; C04B35/01; C04B35/14; Y; Y10; Y10S; Y10S106/00; Y10S106/01
Claims Analysis
Total Claims: 9
Claim 1
Independent Claim
169 words
A PROCESS FOR MAKING ARTIFICIAL STONE WHICH COMPRISES: A. ADJUSTING THE COMPOSITION OF A COAL BYPRODUCT HAVING A MELTING POINT NOT HIGHER THAN APPROXIMATELY 1500*C, WITH AT LEAST ONE CHEMICAL INGREDIENT WHICH CONTAINS, EXPRESSED AS AN OXIDE, AT LEAST ONE MEMBER SELECTED FROM THE GROUP CONSISTING OF SIO2, A120, FE203, FE0, MN0 CA0, MG0, NA20, AND K20, TO OBTAIN A STARTING COMPOSITION WHICH IS CONTAINED WITHIN THE AREA DEMARCATED WITH BOLD LINES IN THE PHASE DIAGRAM OF FIG. 1 AND IS DEFINED BY CORNER POINTS MARKED WITH THE LETTERS FROM A TO H; B. MELTING THE STARTING COMPOSITION BETWEEN ABOUT 1,350*C AND ABOUT 1,500*C UNTIL THE CONTAINED GASES ARE SUBSTANTIALLY REMOVED FROM THE MELT; C. FORMING THE RESULTING MELT INTO OBJECTS AT A TEMPERATURE BETWEEN ABOUT 1,200*C AND ABOUT 1,400*C; THEN WITHOUT THE NEED FOR REHEATING D. CRYSTALLIZING THE FORMED OBJECT AT A TEMPERATURE BETWEEN ABOUT 900*C AND ABOUT 1,300*C FOR A PERIOD OF FROM ABOUT 0.5 HOUR TO ABOUT 6 HOURS; AND C. COOLING THE RESULTING CRYSTALLIZED OBJECT.
Claim 2
Dependent Claim
169 words
A PROCESS FOR MAKING ARTIFICIAL STONE WHICH COMPRISES: A. ADJUSTING THE COMPOSITION OF A COAL BYPRODUCT HAVING A MELTING POINT NOT HIGHER THAN APPROXIMATELY 1500*C, WITH AT LEAST ONE CHEMICAL INGREDIENT WHICH CONTAINS, EXPRESSED AS AN OXIDE, AT LEAST ONE MEMBER SELECTED FROM THE GROUP CONSISTING OF SIO2, A120, FE203, FE0, MN0 CA0, MG0, NA20, AND K20, TO OBTAIN A STARTING COMPOSITION WHICH IS CONTAINED WITHIN THE AREA DEMARCATED WITH BOLD LINES IN THE PHASE DIAGRAM OF FIG. 1 AND IS DEFINED BY CORNER POINTS MARKED WITH THE LETTERS FROM A TO H; B. MELTING THE STARTING COMPOSITION BETWEEN ABOUT 1,350*C AND ABOUT 1,500*C UNTIL THE CONTAINED GASES ARE SUBSTANTIALLY REMOVED FROM THE MELT; C. FORMING THE RESULTING MELT INTO OBJECTS AT A TEMPERATURE BETWEEN ABOUT 1,200*C AND ABOUT 1,400*C; THEN WITHOUT THE NEED FOR REHEATING D. CRYSTALLIZING THE FORMED OBJECT AT A TEMPERATURE BETWEEN ABOUT 900*C AND ABOUT 1,300*C FOR A PERIOD OF FROM ABOUT 0.5 HOUR TO ABOUT 6 HOURS; AND C. COOLING THE RESULTING CRYSTALLIZED OBJECT.
Claim 3
Dependent Claim
84 words
The process of claim 1, wherein the starting composition contains (a) from about 45% to about 60% SiO2; (b) from about 15% to about 40% trivalent oxides from among said chemical ingredients, at least 40% of said trivalent oxides being Fe2O3; and (c) from about 15% to about 35% mono-and-divalent oxides from among said chemical ingredients, from about 10% to about 20% of said mono-and-divalent oxides being divalent oxides, and from about 1% to about 5% of said mono-and-divalent oxides being monovalent alkali oxides.
Claim 4
Dependent Claim
51 words
The process of claim 1, wherein (a) the SiO2 content of the starting composition is from about 40% to about 50%; and (b) the starting composition contains from about 20% to about 40% trivalent oxides from among said chemical ingredients, at least 55% of said preceeding trivalent oxides being Al2 O3.
Claim 5
Dependent Claim
48 words
The process of claim 3, wherein (a) the starting composition is melted between about 1,400*C and about 1,500*C; (b) the melt is formed at a temperature between about 1,300*C and about 1, 400*C; and (c) the crystallizing is carried out at temperatures between about 1,150*C and about 1,300*C.
Claim 6
Dependent Claim
23 words
The process of claim 4, wherein said crystallizing is carried out during a period of between about 0.5 hours and about 2 hours.
Claim 7
Dependent Claim
20 words
The process of claim 1, wherein the combustible content of the coal byproduct is utilized in said step of melting.
Claim 8
Dependent Claim
43 words
The process of claim 4, wherein the chemical ingredient used to adjust the composition of the coal byproduct, is one or more of the following ankerite, siderite, limestone, dolomite, magnesium carbonate ore, bauxite, red mud, wehrlite, phonolite, granite, aplite, tuff, marl, and sandstone.
Claim 9
Dependent Claim
9 words
The product made with the process of claim 1.
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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) | 1978-12-22 | 1979-06-23 | 1979-12-23 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-12-22 | 1983-06-23 | 1983-12-23 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-12-22 | 1987-06-23 | 1987-12-23 | $7700.00 | Window Closed / Lapsed |