Fired construction shapes and process and binder therefor

Claim 2

A process for producing a soda lime glass physically bonded structural product comprising the steps of: a. forming a moldable, thioxtropic particulate composition of low porosity and high packing density by mixing: 1. particulate inorganic inert aggregate; 2. from 8 to 35 weight per cent finely divided waste soda lime glass whose particles have a size of less than 80 mesh;

Claim 3

ball clay in an amount of at least 2 weight per cent and sufficient to render the mixture thioxtropic; and 4. water in an amount not greater than 20 weight per cent to make said mixture moldable, the particle size of said aggregate being greater than the particle size of said finely divided waste soda lime glass and the particle size distribution of said aggregate and said finely divided glass being such that the mixture thereof contains 15 to 35 weight per cent of particles whose size is less than 80 mesh; b. forming said mixture into a predetermined shape; c. drying, then firing said shaped mixture at a temperature below 1900°F and sufficient to soften said finely divided soda lime glass and allow it to flow around and physically bond to said particulate aggregate substantially without chemical reaction; and d. cooling said fired shape.

Claim 4

ball clay in an amount of at least 2 weight per cent and sufficient to render the mixture thioxtropic; and 4. water in an amount not greater than 20 weight per cent to make said mixture moldable, the particle size of said aggregate being greater than the particle size of said finely divided waste soda lime glass and the particle size distribution of said aggregate and said finely divided glass being such that the mixture thereof contains 15 to 35 weight per cent of particles whose size is less than 80 mesh; b. forming said mixture into a predetermined shape; c. drying, then firing said shaped mixture at a temperature below 1900°F and sufficient to soften said finely divided soda lime glass and allow it to flow around and physically bond to said particulate aggregate substantially without chemical reaction; and d. cooling said fired shape.

Claim 5

A process according to claim 1 wherein the porosity of said composition after cooling is between 2 and 20%.

Claim 6

A process according to claim 1 in which said particulate inert aggregate comprises particulate waste material.

Claim 7

A process according to claim 1 wherein soda lime glass comprises from about 8 to 94 weight per cent of said particulate composition, provided no more than 35 per cent of said composition is finely divided soda lime glass.

Claim 8

A process according to claim 1 wherein said finely divided soda lime glass comprises from about 15 to 25 weight per cent of said particulate composition.

Claim 9

A process according to claim 1 wherein said ball clay comprises from about 2 to about 10 weight per cent of said particulate composition.

Claim 10

A binder composition comprising finely divided soda lime glass, having a particle size not greater than 80 mesh, in admixture with from about 0.1 to about 1.25 parts by weight of ball clay per part of finely divided soda lime glass.

Claim 11

A binder composition comprising finely divided soda lime glass, having a particle size not greater than 80 mesh, in admixture with from about 0.1 to about 1.25 parts by weight of ball clay per part of finely divided soda lime glass.

Claim 12

A fired, soda lime glass physically bonded structural product of low porosity produced in accordance with the process of claim 1.

Claim 13

A process for producing soda lime glass physically bonded structural clay products comprising the steps of: a. forming into a predetermined shape a particulate composition of low porosity from inert aggregate particles, including a clay dispersant, 15 to 25 weight per cent finely divided waste soda lime glass, 2 to 10 weight per cent ball clay and 3 to 15 weight per cent water; b. drying, then firing said shaped particulate composition for from 45 minutes to 4 hours at a temperature below 1900°F and sufficient to soften said soda lime glass and allow it to flow around and physically bond to said inert aggregate particles substantially without chemical reaction; and c. cooling said shaped particulate composition.

Claim 14

A process for producing soda lime glass physically bonded structural clay products comprising the steps of: a. forming into a predetermined shape a particulate composition of low porosity from inert aggregate particles, including a clay dispersant, 15 to 25 weight per cent finely divided waste soda lime glass, 2 to 10 weight per cent ball clay and 3 to 15 weight per cent water; b. drying, then firing said shaped particulate composition for from 45 minutes to 4 hours at a temperature below 1900°F and sufficient to soften said soda lime glass and allow it to flow around and physically bond to said inert aggregate particles substantially without chemical reaction; and c. cooling said shaped particulate composition.

Claim 15

A fired, soda lime glass physically bonded structural clay product of low porosity comprising: a. a mass of randomly distributed inert aggregate particles; b. a binder of randomly distributed soda lime glass coating said aggregate particles and physically bonding said product together and comprising 15 to 25 weight per cent of said product; and c. an admixture of ball clay comprising 2 to 10 weight per cent of said product; said product being of relatively maximum packing density to provide tensile strength and durability.

Claim 16

A fired, soda lime glass physically bonded structural clay product of low porosity comprising: a. a mass of randomly distributed inert aggregate particles; b. a binder of randomly distributed soda lime glass coating said aggregate particles and physically bonding said product together and comprising 15 to 25 weight per cent of said product; and c. an admixture of ball clay comprising 2 to 10 weight per cent of said product; said product being of relatively maximum packing density to provide tensile strength and durability.