Non-combustible molding material

Claim 2

A non-combustible molding composition which is capable of hardening after being dehydrated to a mositure content of 5 to 50% by weight comprising, in aqueous dispersion: a. 100 parts by weight of a hydraulic inorganic mixture consisting of an inorganic substance composed predominantly of silica selected from the group consisting of quartz rock, silica sand, aplite, pottery stone, silicate terra alba, diaspore, diatomaceous earth, fly ash, perlite, obsidian perlite, pumice microballoon, foamed shale pumice, foamed clay and vermiculite; and an inorganic substance composed predominantly of calcium oxide selected from the group consisting of slaked lime, quick lime and calcium carbonate, the molar ratio of the inorganic substance composed predominantly of calcium oxide to the inorganic substance composed predominantly of silica being from 0.5 to 1.2; b. 10 to 200 parts by weight of mineral fibers selected from chrysotile asbestos, amosite asbestos, crocidolite asbestos, amphibole asbestos, tremolite asbestos, actinolite asbestos, rock wool, glass fiber and slag wool; and c. a substance selected from the group consisting of:

Claim 3

1 to 10 parts of sulfur; and 2. 1 to 10 parts of metal sulfide selected from the group consisting of potassium sulfide, tin sulfide, iron sulfide, copper sulfide, sodium sulfide, barium sulfide, cadmium sulfide, cobalt sulfide, lead sulfide and zinc sulfide.

Claim 4

1 to 10 parts of sulfur; and 2. 1 to 10 parts of metal sulfide selected from the group consisting of potassium sulfide, tin sulfide, iron sulfide, copper sulfide, sodium sulfide, barium sulfide, cadmium sulfide, cobalt sulfide, lead sulfide and zinc sulfide.

Claim 5

A water-hardened, non-combustible molded article comprising: a. 100 parts by weight of a hydraulic inorganic mixture consisting of an inorganic substance composed predominantly of silica selected from the group consisting of quartz rock, silica sand, aplite, pottery stone, silicate terra alba, diaspore, diatomaceous earth, fly ash, perlite, osidian perlite, pumice microballoon, foamed shale pumice, foamed clay and vermiculite; and an inorganic substance composed predominantly of calcium oxide selected from the group consisting of slaked lime, quick lime and calcium carbonate, the molar ratio of the inorganic substance composed predominantly of calcium oxide to the inorganic substance composed predominantly of silica being from 0.5 to 1.2; b. 10 to 200 parts by weight of mineral fibers selected from chrysotile asbestos, amosite asbestos, crocidolite asbestos, amphibole asbestos, tremolite asbestos, actinolite asbestos, rock wool, glass fiber and slag wool; and c. a substance selected from the group consisting of:

Claim 6

A water-hardened, non-combustible molded article comprising: a. 100 parts by weight of a hydraulic inorganic mixture consisting of an inorganic substance composed predominantly of silica selected from the group consisting of quartz rock, silica sand, aplite, pottery stone, silicate terra alba, diaspore, diatomaceous earth, fly ash, perlite, osidian perlite, pumice microballoon, foamed shale pumice, foamed clay and vermiculite; and an inorganic substance composed predominantly of calcium oxide selected from the group consisting of slaked lime, quick lime and calcium carbonate, the molar ratio of the inorganic substance composed predominantly of calcium oxide to the inorganic substance composed predominantly of silica being from 0.5 to 1.2; b. 10 to 200 parts by weight of mineral fibers selected from chrysotile asbestos, amosite asbestos, crocidolite asbestos, amphibole asbestos, tremolite asbestos, actinolite asbestos, rock wool, glass fiber and slag wool; and c. a substance selected from the group consisting of:

Claim 7

1 to 10 parts of sulfur; and 2. 1 to 10 parts of metal sulfide selected from the group consisting of potassium sulfide, tin sulfide, iron sulfide, copper sulfide, sodium sulfide, barium sulfide, cadmium sulfide, cobalt sulfide, lead sulfide and zinc sulfide.

Claim 8

1 to 10 parts of sulfur; and 2. 1 to 10 parts of metal sulfide selected from the group consisting of potassium sulfide, tin sulfide, iron sulfide, copper sulfide, sodium sulfide, barium sulfide, cadmium sulfide, cobalt sulfide, lead sulfide and zinc sulfide.

Claim 9

A process for producing a noncombustible molded article, which comprises: i. mixing uniformly a molding composition consisting essentially of a. 100 parts by weight of a hydraulic inorganic mixture consisting of an inorganic substance composed predominantly of silica selected from the group consisting of quartz rock, silica sand, aplite, pottery stone, silicate terra alba, diaspore, diatomaceous earth, fly ash, perlite, obsidian perlite, pumice microballoon, foamed shale pumice, foamed clay and vermiculite; and an inorganic substance composed predominantly of calcium oxide selected from the group consisting of slaked lime, quick lime and calcium carbonate, the molar ratio of the inorganic substance composed predominantly of calcium oxide to the inorganic substance composed predominantly of silica being from 0.5 to 1.2; b. 10 to 200 parts by weight of mineral fibers selected from chrysotile asbestos, amosite asbestos, crocidolite asbestos, amphibole asbestos, tremolite asbestos, actinolite asbestos, rock wool, glass fiber and slag wool; c. a substance selected from the group consisting of: 1. 1 to 10 parts of sulfur; and 2. 1 to 10 parts of metal sulfide selected from the group consisting of potassium sulfide, tin sulfide, iron sulfide, copper sulfide, sodium sulfide, barium sulfide, cadmium sulfide, cobalt sulfide, lead sulfide or zinc sulfide; and d. 300 to 2000 parts by weight per 100 parts by weight of the total amount of components (a), (b) and (c), of water, ii. molding the mixture so obtained, iii. dehydrating the molded article at a pressure of at least 50 kg/cm 2 to a moisture content of 5 to 50% by weight, and iv. heating the molded article at a temperature of 150° C to 210° C and at a vapor pressure of 5 to 20 atmospheres to harden it.

Claim 10

A process for producing a noncombustible molded article, which comprises: i. mixing uniformly a molding composition consisting essentially of a. 100 parts by weight of a hydraulic inorganic mixture consisting of an inorganic substance composed predominantly of silica selected from the group consisting of quartz rock, silica sand, aplite, pottery stone, silicate terra alba, diaspore, diatomaceous earth, fly ash, perlite, obsidian perlite, pumice microballoon, foamed shale pumice, foamed clay and vermiculite; and an inorganic substance composed predominantly of calcium oxide selected from the group consisting of slaked lime, quick lime and calcium carbonate, the molar ratio of the inorganic substance composed predominantly of calcium oxide to the inorganic substance composed predominantly of silica being from 0.5 to 1.2; b. 10 to 200 parts by weight of mineral fibers selected from chrysotile asbestos, amosite asbestos, crocidolite asbestos, amphibole asbestos, tremolite asbestos, actinolite asbestos, rock wool, glass fiber and slag wool; c. a substance selected from the group consisting of: 1. 1 to 10 parts of sulfur; and 2. 1 to 10 parts of metal sulfide selected from the group consisting of potassium sulfide, tin sulfide, iron sulfide, copper sulfide, sodium sulfide, barium sulfide, cadmium sulfide, cobalt sulfide, lead sulfide or zinc sulfide; and d. 300 to 2000 parts by weight per 100 parts by weight of the total amount of components (a), (b) and (c), of water, ii. molding the mixture so obtained, iii. dehydrating the molded article at a pressure of at least 50 kg/cm 2 to a moisture content of 5 to 50% by weight, and iv. heating the molded article at a temperature of 150° C to 210° C and at a vapor pressure of 5 to 20 atmospheres to harden it.

Claim 11

The process of claim 3, wherein there is added to said molding composition a reaction promotor selected from the group consisting of sodium hydroxide, potassium hydroxide, lithium hydroxide, and alumina.

Claim 12

The process of claim 3, wherein said hardening is performed by heating the molded article at 60 - 90° C. at atmospheric pressure for 5 to 10 hours, and then heating it in an autoclave for 5 to 20 hours at 150 - 210° C. and 5 to 20 atmospheres.

Claim 13

The process of claim 3, wherein there is added to said molding composition an organic heat-decomposable blowing agent which is decomposed at 150° to 250° C and selected from the group consisting of dinitrosopentamethylene tetramine, 1,1'-azodicarbonamide, benzenesulfonyl hydrazide, benzenesulfonyl hydrazide derivatives, 4,4'-hydroxybisbenzene-sulfonyl hydrazide, para-toluene-sulfonazide, and toluenesulfonyl hydrazide.

Claim 14

A composition according to claim 1, wherein (a) is a hydraulic mixture of quartz rock and slaked lime, and (b) is chysotile asbestos.

Claim 15

An article according to claim 2, wherein (a) is a hydraulic mixture of quartz rock and slaked lime, and (b) is chysotile asbestos.

Claim 16

A process according to claim 3, wherein (a) is a hydraulic mixture of quartz rock and slaked lime, and (b) is chysotile asbestos.

Claim 17

A process according to claim 4, wherein the reaction promotor is sodium hydroxide.