Patent US4430108A successfully refreshed from Google Patents.
US4430108A
Expired / Lapsed
US
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Method for making foam glass from diatomaceous earth and fly ash
Assignee: DE MACEDO PEDRO BUARQUE
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Filing: 1982-09-14
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Granted: 1984-02-07
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Expires: 2002-09-14
Abstract
Abstract A method of making foam glass by impregnating diatomaceous earth, fly ash or mixtures thereof, and insoluble modifiers, if any, with at least one water soluble glass former in an amount expressed as its oxide of about 2.5 to 20 weight percent of the impregnated diatomaceous earth, fly ash or mixtures thereof; at least one water soluble flux in an amount expressed as its oxide of about 8 to 20 weight percent of the impregnated diatomaceous earth, fly ash or mixtures thereof; and at least one gas generator. The diatomaceous earth, fly ash or mixtures thereof is impregnated by mixing diatomaceous earth, fly ash or mixtures thereof and an impregnating solution comprising at least one water soluble glass former in an amount expressed as its oxide of about 3 to 14 weight percent; at least one water soluble flux in an amount expressed as its oxide of about 10 to 20 weight percent; at least one gas generator, and water in an amount of about 50 to 80 weight percent. Excess impregnating solution is removed and the impregnated diatomaceous earth, fly ash or mixtures thereof is heated to a sufficient temperature, generally about 720° to 1000° C., to cause foaming of the impregnated diatomaceous earth, fly ash or mixtures thereof. The foamed diatomaceous earth, fly ash or mixtures thereof is cooled and a foam glass body is thus formed.
Inventors
- 👤 Hamid Hojaji
- 👤 Pedro B. de Macedo
- 👤 Theodore A. Litovitz
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-07 06:39
CPC Classifications
C; C03; C03C; C03C11/00; C03C11/007; Y; Y10; Y10T; Y10T428/00; Y10T428/249921; Y10T428/249953; Y10T428/249967; Y10T428/249969
Claims Analysis
Total Claims: 58
Claim 1
Independent Claim
118 words
A process for making a foam glass body from diatomaceous earth, fly ash, volcanic ash and mixtures thereof comprising: (a) impregnating diatomaceous earth, fly ash, volcanic ash or a mixture thereof with an impregnating solution comprising at least one water soluble glass former, at least one water soluble flux, at least one water soluble carbohydrate gas generator, and water to form an impregnated material; (b) heating the impregnated material above the glass transition temperature of the impregnated material; (c) cooling the impregnated material; (d) pulverizing the cooled impregnated material; and (e) heating the pulverized impregnated material in an oxidizing atmosphere to a sufficient temperature to cause foaming of the impregnated material thereof thereby forming a foam glass body.
Claim 2
Dependent Claim
118 words
A process for making a foam glass body from diatomaceous earth, fly ash, volcanic ash and mixtures thereof comprising: (a) impregnating diatomaceous earth, fly ash, volcanic ash or a mixture thereof with an impregnating solution comprising at least one water soluble glass former, at least one water soluble flux, at least one water soluble carbohydrate gas generator, and water to form an impregnated material; (b) heating the impregnated material above the glass transition temperature of the impregnated material; (c) cooling the impregnated material; (d) pulverizing the cooled impregnated material; and (e) heating the pulverized impregnated material in an oxidizing atmosphere to a sufficient temperature to cause foaming of the impregnated material thereof thereby forming a foam glass body.
Claim 3
Dependent Claim
92 words
A process for making a foam glass body comprising: (a) heating diatomaceous earth, fly ash, wash ash or a mixture thereof to at least 500° C. to form a calcined material; (b) impregnating the calcined material with an impregnating solution comprising at least one water soluble glass former, at least one water soluble flux, at least one water soluble gas generator, and water; (c) heating the impregnated material to a sufficient temperature to cause foaming of the impregnated material thereby forming a foam glass body; and (d) cooling the foam glass body.
Claim 4
Dependent Claim
92 words
A process for making a foam glass body comprising: (a) heating diatomaceous earth, fly ash, wash ash or a mixture thereof to at least 500° C. to form a calcined material; (b) impregnating the calcined material with an impregnating solution comprising at least one water soluble glass former, at least one water soluble flux, at least one water soluble gas generator, and water; (c) heating the impregnated material to a sufficient temperature to cause foaming of the impregnated material thereby forming a foam glass body; and (d) cooling the foam glass body.
Claim 5
Dependent Claim
118 words
A process for making a foam glass body from diatomaceous earth or a mixture of diatomaceous earth and fly ash comprising: (a) forming a bed of diatomaceous earth or a mixture of diatomaceous earth and fly ash; (b) passing an impregnating solution through the bed to impregnate the diatomaceous earth or mixture of diatomaceous earth and fly ash and form an impregnated material, said impregnating solution comprising at least one water soluble glass former, at least one water soluble flux, at least one water soluble gas generator, and water; (c) heating the impregnated material to a sufficient temperature to cause foaming of the impregnated material thereby forming a foam glass body; and (d) cooling the foam glass body.
Claim 6
Dependent Claim
118 words
A process for making a foam glass body from diatomaceous earth or a mixture of diatomaceous earth and fly ash comprising: (a) forming a bed of diatomaceous earth or a mixture of diatomaceous earth and fly ash; (b) passing an impregnating solution through the bed to impregnate the diatomaceous earth or mixture of diatomaceous earth and fly ash and form an impregnated material, said impregnating solution comprising at least one water soluble glass former, at least one water soluble flux, at least one water soluble gas generator, and water; (c) heating the impregnated material to a sufficient temperature to cause foaming of the impregnated material thereby forming a foam glass body; and (d) cooling the foam glass body.
Claim 7
Dependent Claim
16 words
The process of claims 1, 2 or 3, wherein the diatomaceous earth is calcined diatomaceous earth.
Claim 8
Dependent Claim
16 words
The process of claims 1, 2 or 3, wherein the diatomaceous earth is flux-calcined diatomaceous earth.
Claim 9
Dependent Claim
16 words
The process of claims 1, 2 or 3, wherein the fly ash is calcined fly ash.
Claim 10
Dependent Claim
41 words
The process of claims 1, 2, or 3, wherein the impregnated material is dried to a water content less than about 5 weight percent, pulverized to a particle size less than 1 mm, and placed in a mold prior to heating.
Claim 11
Dependent Claim
22 words
The process of claims 1, 2 or 3, wherein the impregnated solution is at a temperature of about 50° to 100° C.
Claim 12
Dependent Claim
20 words
The process of claims 1, 2 or 3, wherein the temperature which causes foaming is about 720° to 1000° C.
Claim 13
Dependent Claim
30 words
The process of claim 1 wherein the impregnated material is heated to about 800° to 1100° C. and the pulverized impregnated material is heated to about 800° to 1000° C.
Claim 14
Dependent Claim
62 words
The process of claims 2 or 3, wherein step (c) is conducted by a first heating to a temperature of about 350° to 600° C. for a sufficient period of time to sinter the impregnated material, and a second heating of the sintered material to a temperature of about 720° to 900° C. for sufficient time to stabilize the foam glass body.
Claim 15
Dependent Claim
25 words
The process of claim 11, wherein the first heating and second heating are at a heating rate of about 10° to 80° C. per minute.
Claim 16
Dependent Claim
32 words
The method of claim 3, wherein the impregnating solution is passed through the bed by continuously introducing impregnating solution at a point below the bed at sufficient velocity to fluidize the bed.
Claim 17
Dependent Claim
12 words
The method of claim 13, wherein the impregnating solution is continuously recycled.
Claim 18
Dependent Claim
21 words
The process of claim 3, wherein a gas is passed upwardly through the bed and impregnating solution to fluidize the bed.
Claim 19
Dependent Claim
10 words
The process of claim 15, wherein the gas is air.
Claim 20
Dependent Claim
60 words
The process of claims 1, 2, or 3, wherein the impregnating solution contains water soluble glass former in an amount expressed as its oxide of about 3 to 14 weight percent, water soluble flux in an amount expressed as its oxide of about 10 to 20 weight percent, and water in an amount of about 50 to 80 weight percent.
Claim 21
Dependent Claim
37 words
The process of claim 17, wherein the water soluble glass former is a member of the group consisting of a boron oxide containing compound, a silicon oxide containing compound, a phosphorus oxide containing compound and mixtures thereof.
Claim 22
Dependent Claim
26 words
The process of claim 18, wherein the boron oxide containing compound is selected from the group consisting of boric acid, alkali metal borate, and mixtures thereof.
Claim 23
Dependent Claim
13 words
The process of claim 19, wherein the alkali metal borate is sodium borate.
Claim 24
Dependent Claim
16 words
The process of claim 18, wherein the silicon oxide containing compound is an alkali metal silicate.
Claim 25
Dependent Claim
22 words
The process of claim 21, wherein the alkali metal silicate is selected from the group consisting of sodium silicate and potassium silicate.
Claim 26
Dependent Claim
16 words
The process of claim 18, wherein the phosphorus oxide containing compound is an alkali metal phosphate.
Claim 27
Dependent Claim
22 words
The process of claim 23, wherein the alkali metal phosphate is selected from the group consisting of sodium phosphate and potassium phosphate.
Claim 28
Dependent Claim
15 words
The process of claim 17, wherein the water soluble flux is an alkali metal flux.
Claim 29
Dependent Claim
26 words
The process of claim 25, wherein the alkali metal of the alkali metal flux is selected from the group consisting of sodium, potassium, and mixtures thereof.
Claim 30
Dependent Claim
15 words
The process of claim 17, wherein the gas generator is a carbon oxide gas generator.
Claim 31
Dependent Claim
26 words
The process of claims 2 or 3, wherein the carbon oxide gas generator is selected from the group consisting of carbonates, bicarbonates, carbohydrates, and mixtures thereof.
Claim 32
Dependent Claim
18 words
The process of claim 1, wherein the carbohydrate is selected from the group consisting of sugar and glycerin.
Claim 33
Dependent Claim
45 words
The process of claims 1, 2, or 3, wherein the impregnated material contains modifiers selected from the group consisting of volcanic ash, petalite, perlite, sand, silica dust, clays, refractory slags, gypsum, talc, glass powder, refractory fibrous material, naturally occurring minerals and oxides, and mixtures thereof.
Claim 34
Dependent Claim
11 words
The process of claim 30, wherein the modifier is volcanic ash.
Claim 35
Dependent Claim
23 words
The process of claims 1, 2 or 3, wherein the diatomaceous earth has a median pore size of about 1.5 to 22 microns.
Claim 36
Dependent Claim
118 words
The process of claims 1, 2 or 3, wherein the water soluble glass former is selected from the group consisting of boric acid, alkali metal borates and mixtures thereof, in an amount expressed as boron oxide of about 4 to 9 weight percent of the solution, the flux is selected from the group consisting of alkali metal carbonates, alkali metal bicarbonates, alkali metal borates, alkali metal silicates, alkali metal phosphates and mixtures thereof in an amount expressed as alkali metal oxide of about 12 to 16 weight percent of the impregnating solution, the gas generator is a carbon oxide gas generator, and water is present in an amount of about 55 to 70 weight percent of the solution.
Claim 37
Dependent Claim
103 words
The process of claims 1, 2 or 3, wherein the water soluble glass former is an alkali metal silicate in an amount expressed as silicon oxide of about 5 to 11 weight percent of the solution, the flux is an alkali metal carbonate, alkali metal bicarbonate, alkali metal borate, alkali metal silicate, alkali metal phosphate, or mixture thereof in an amount expressed as alkali metal oxide of about 12 to 19 weight percent of the impregnating solution, the gas generator is a carbon oxide gas generator, and water is present in an amount of about 55 to 70 weight percent of the solution.
Claim 38
Dependent Claim
147 words
The process of claims 1, 2 or 3, wherein the water soluble glass former is a mixture of an alkali metal silicate and a boron oxide containing compound selected from the group consisting of boric acid, alkali metal borates, and mixtures thereof, in an amount expressed as their oxide of about 5 to 14 weight percent of the solution, the boron oxide containing compound being present in solution in an amount expressed as boron oxide greater than about 0.5 weight percent, the flux is alkali metal carbonate, alkali metal bicarbonate, alkali metal borate, alkali metal silicate, alkali metal phosphate, or mixture thereof in an amount expressed as alkali metal oxide of about 12 to 19 weight percent of the impregnating solution, the gas generator is a carbon oxide gas generator, and water is present in an amount of about 55 to 70 weight percent of the solution.
Claim 39
Dependent Claim
142 words
The process of claims 1, 2 or 3, wherein the water soluble glass former is a mixture of an alkali metal silicate and a phosphorus oxide containing compound selected from the group consisting of alkali metal phosphates in an amount expressed as their oxide of about 5 to 14 weight percent of the solution, the phosphorus oxide containing compound being present in solution in an amount expressed as phosphorus oxide greater than about 0.5 weight percent, the flux is alkali metal carbonate, alkali metal bicarbonate, alkali metal borate, alkali metal silicate, alkali metal phosphate, or mixture thereof in an amount expressed as alkali metal oxide of about 12 to 19 weight percent of the impregnating solution, the gas generator is a carbon oxide gas generator, and water is present in an amount of about 55 to 70 weight percent of the solution.
Claim 40
Dependent Claim
20 words
The process of claims 1, 2 or 3, wherein the impregnating solution is maintained at a pH greater than 11.
Claim 41
Dependent Claim
34 words
The process of claims 1, 2 or 3, wherein the diatomaceous earth is selected from the group consisting of calcined diatomaceous earth and flux-calcined diatomaceous earth and the fly ash is calcined fly ash.
Claim 42
Dependent Claim
34 words
The process of claim 3, wherein excess impregnating solution is removed from the bed of impregnated diatomaceous earth or mixture of diatomaceous earth and fly ash by applying a pressure differential across the bed.
Claim 43
Dependent Claim
165 words
A process for making a foam glass body from diatomaceous earth, fly ash or a mixture thereof comprising: (a) impregnating diatomaceous earth, fly ash or a mixture thereof using an impregnating solution comprising at least one water soluble glass former selected from the group consisting of boron oxide containing compound, and a mixture of a boron oxide containing compound and a silicon oxide containing compound, in an amount expressed as their oxide of about 3 to 20 weight percent, at least one water soluble alkali metal flux, in an amount expressed as alkali oxide of about 10 to 20 weight percent, at least one water soluble gas generator, and water in an amount of about 50 to 80 weight percent; (b) heating the impregnated diatomaceous earth, fly ash or mixture thereof to a sufficient temperature to cause foaming of the impregnated diatomaceous earth, fly ash or mixture thereof, thereby forming a foam glass body; and (c) cooling the foam glass body having a surface glaze.
Claim 44
Dependent Claim
165 words
A process for making a foam glass body from diatomaceous earth, fly ash or a mixture thereof comprising: (a) impregnating diatomaceous earth, fly ash or a mixture thereof using an impregnating solution comprising at least one water soluble glass former selected from the group consisting of boron oxide containing compound, and a mixture of a boron oxide containing compound and a silicon oxide containing compound, in an amount expressed as their oxide of about 3 to 20 weight percent, at least one water soluble alkali metal flux, in an amount expressed as alkali oxide of about 10 to 20 weight percent, at least one water soluble gas generator, and water in an amount of about 50 to 80 weight percent; (b) heating the impregnated diatomaceous earth, fly ash or mixture thereof to a sufficient temperature to cause foaming of the impregnated diatomaceous earth, fly ash or mixture thereof, thereby forming a foam glass body; and (c) cooling the foam glass body having a surface glaze.
Claim 45
Dependent Claim
78 words
The process of claim 40, wherein the boron oxide containing compound is present in an amount of about 4 to 9 weight percent, the alkali metal flux is present in an amount of between about 12 to 16 weight percent, the gas generator is carbon oxide gas generator and is present in an amount expressed as carbon of about 1.5 to 3.5 weight percent, and water is present in an amount of about 55 to 70 weight percent.
Claim 46
Dependent Claim
109 words
The process of claim 40, wherein the mixture of silicon oxide containing compound and boron oxide containing compound are present in solution in an amount of about 5 to 14 weight percent, the alkali metal flux is present in solution in an amount of about 12 to 19 weight percent, the gas generator is a carbon dioxide gas generator and is present in solution in an amount expressed as carbon of about 1.5 to 3.5 weight percent, and water is present in an amount of about 55 to 70 weight percent, said boron oxide containing compound being present in solution in an amount greater than about 0.5 weight percent.
Claim 47
Dependent Claim
24 words
The process of claim 42, wherein said boron oxide containing compound is present in solution in an amount greater than about 1 weight percent.
Claim 48
Dependent Claim
38 words
The process of claims 40, 41 or 42, wherein the boron oxide containing compound is selected from the group consisting of boric acid and alkali metal borates, and the silicon oxide containing compound is an alkali metal silicate.
Claim 49
Dependent Claim
22 words
The process of claim 44, wherein the alkali metal of the alkali metal borate and alkali metal silicate is sodium or potassium.
Claim 50
Dependent Claim
24 words
The process of claim 41, wherein the alkali metal flux is selected from the group consisting of alkali metal carbonates and alkali metal bicarbonates.
Claim 51
Dependent Claim
17 words
The process of claim 42, wherein the alkali metal flux is at least one alkali metal carbonate.
Claim 52
Dependent Claim
21 words
The process of claim 47, wherein the alkali metal is selected from the group consisting of sodium, potassium, and mixtures thereof.
Claim 53
Dependent Claim
15 words
The process of claim 40, wherein the gas generator is a carbon oxide gas generator.
Claim 54
Dependent Claim
24 words
The process of claim 49, wherein the carbon oxide gas generator is selected from the group consisting of carbonates, bicarbonates, carbohydrates, and mixtures thereof.
Claim 55
Dependent Claim
18 words
The process of claim 50, wherein the carbohydrate is selected from the group consisting of sugar and glycerin.
Claim 56
Dependent Claim
24 words
The process of claim 50, wherein the carbonate is selected from the group consisting of sodium carbonate, potassium carbonate, sodium bicarbonate, and potassium bicarbonate.
Claim 57
Dependent Claim
26 words
The process of claim 40, wherein the diatomaceous earth is selected from the group consisting of natural diatomaceous earth, calcined diatomaceous earth, and flux-calcined diatomaceous earth.
Claim 58
Dependent Claim
35 words
The process of claim 1 wherein heating step (b) is performed in the presence of a reducing agent in an amount sufficient to substantially inhibit oxidation of said at least one water soluble gas generator.
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