US4604318A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Composition and process for forming inorganic resins and resulting product
Assignee: USG Interiors LLC
•
Filing: 1984-10-01
•
Granted: 1986-08-05
•
Expires: 2004-10-01
Abstract
Abstract Compositions and processes for forming inorganic resins, including articles of manufacture incorporating these resins are disclosed. the inorganic resins are characterized by their strength, nonflammability, dimensional stability, resistance to organic and inorganic chemicals, to heat and to abrasion and their adaptability to being formed into noncellular or cellular forms. The resins are formed by reacting a liquid component A containing an aluminum phosphate or a magnesium phosphate and a liquid component B containing a source of magnesium oxide, such as magnesia, and/or wollastonite and an essentially non-reactive phosphate dispersing agent. Various fillers may be incorporated and a blowing agent may be added to form a cellular resin.
Inventors
- 👤 William L. Prior
- 👤 William C. Sargeant
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 13:09
CPC Classifications
C; C04; C04B; C04B28/00; C04B28/34; C04B30/00; C04B30/02; C04B2111/00; C04B2111/00034; C04B2111/00129; Y; Y02; Y02W; Y02W30/00; Y02W30/50; Y02W30/91; Y10; Y10T; Y10T442/00; Y10T442/20; Y10T442/2221; Y10T442/2549; Y10T442/2566; Y10T442/2574
Claims Analysis
Total Claims: 64
Claim 1
Independent Claim
115 words
A process for forming an inorganic resin comprising: (a) forming a liquid component A comprising an aqueous solution of an aluminum phosphate, a magnesium phosphate or a mixture thereof having a viscosity ranging between about 700 and about 10,000 centipoises; (b) forming a separate liquid component B comprising an aqueous vehicle, a phosphate-reactive material selected from the group consisting of wollastonite, a source of magnesium oxide or mixtures thereof, and an essentially nonreactive phosphate dispersing agent, said component B having a viscosity permitting it to be rapidly and thoroughly mixed with component A; and (c) mixing said components A and B to form a slurry which reacts exothermically to set up as an inorganic resin.
Claim 2
Dependent Claim
115 words
A process for forming an inorganic resin comprising: (a) forming a liquid component A comprising an aqueous solution of an aluminum phosphate, a magnesium phosphate or a mixture thereof having a viscosity ranging between about 700 and about 10,000 centipoises; (b) forming a separate liquid component B comprising an aqueous vehicle, a phosphate-reactive material selected from the group consisting of wollastonite, a source of magnesium oxide or mixtures thereof, and an essentially nonreactive phosphate dispersing agent, said component B having a viscosity permitting it to be rapidly and thoroughly mixed with component A; and (c) mixing said components A and B to form a slurry which reacts exothermically to set up as an inorganic resin.
Claim 3
Dependent Claim
26 words
A process in acordance with claim 1 including the step of forming said resin into a structure of predetermined size and configuration before it sets up.
Claim 4
Dependent Claim
24 words
A process in accordance with claim 2 wherein said step of forming the resin into said structure comprises molding, casting, or extruding said resin.
Claim 5
Dependent Claim
36 words
A process in accordance with claim 1 wherein said component A includes an inert, low water-demand filler in an amount up to about 50% by weight of the total weight of said components A and B.
Claim 6
Dependent Claim
37 words
A process in accordance with claim 1 wherein said component A includes finely divided acicular wollastonite having an aspect ratio of at least about 10% by weight of the total weight of said components A and B.
Claim 7
Dependent Claim
40 words
A process in accordance with claim 1 wherein said component A, component B or both includes a water-repellant surfactant in a total amount between about 0.2% and 5% by weight of the total weight of said components A and B.
Claim 8
Dependent Claim
35 words
A process in accordance with claim 1 wherein the amount of said aqueous solution of component A ranges between about 20% and about 70% by weight of the total weight of components A and B.
Claim 9
Dependent Claim
24 words
A process in accordance with claim 1 wherein said component A has a solids content ranging between about 20 and about 70 weight percent.
Claim 10
Dependent Claim
48 words
A process in acordance with claim 1 wherein said reactive wollastonite is a finely divided acicular wollastonite material having an aspect ratio of less than about 10:1 and a surface area of at least about 1.0 m 2 /gm and is present in said components A and B.
Claim 11
Dependent Claim
23 words
A process in accordance with claim 1 wherein said non-reacting dispersing agent of said component B is a polyphosphate in an aqueous solution.
Claim 12
Dependent Claim
87 words
A process in accordance with claim 1 wherein at least one of said components A or B includes a water-repellant surfactant; wherein said component B includes a blowing agent capable of releasing a gas by reaction, decomposition or vaporization in said slurry; and wherein said dispersing agent is one which does not raise the pH of said slurry above 10, whereby, when said components A and B are mixed, said blowing agent releases said gas to cause said slurry to set up into a cellular inorganic resin.
Claim 13
Dependent Claim
35 words
A process in accordance with claim 11 wherein said blowing agent is calcium carbonate in an amount ranging between about 0.2% and about 15% by weight of the total weight of components A and B.
Claim 14
Dependent Claim
35 words
A process in accordance with claim 12 wherein said blowing agent is calcium carbonate in an amount ranging between about 0.25 and about 15% by weight of the total weight of components A and B.
Claim 15
Dependent Claim
52 words
A process in accordance with claim 1 wherein at least one of said components A or B includes a water-repellant surfactant and said process includes the step of introducing an inert gas under pressure into said slurry during said mixing step thereby causing said slurry to set-up as a celluar inorganic resin.
Claim 16
Dependent Claim
39 words
A process in accordance with claim 1 wherein the weight ratio of said mono aluminum phosphate, mono magnesium phosphate or mixture thereof of component A to said phosphate-reactive constituent of component B ranges between about 50/50 and about 65/35.
Claim 17
Dependent Claim
32 words
A process in accordance with claim 1 including the step of adjusting and maintaining the temperatures of components A and B to 15.5° C. or lower prior to said step of mixing.
Claim 18
Independent Claim
113 words
A method of manufacturing a resin cement having having extended shelf life comprising adjusting the viscosity of an aqueous solution of an aluminum phosphate, or an aqueous solution of a magnesium phosphate or mixtures thereof to a viscosity of about 700 to about 10,000 centipoises, to form component A; combining a phosphate-reactive wollastonite and/or a source of phosphate-reactive magnesium oxide with a phosphate dispersing agent essentially unreactive with component A to form component B in essentially dry form and maintaining component B separated from component A to obtain a desired shelf life until immediately prior to use; and adding water and combining components A and B to form said resin cement by reaction.
Claim 19
Independent Claim
113 words
A method of manufacturing a resin cement having having extended shelf life comprising adjusting the viscosity of an aqueous solution of an aluminum phosphate, or an aqueous solution of a magnesium phosphate or mixtures thereof to a viscosity of about 700 to about 10,000 centipoises, to form component A; combining a phosphate-reactive wollastonite and/or a source of phosphate-reactive magnesium oxide with a phosphate dispersing agent essentially unreactive with component A to form component B in essentially dry form and maintaining component B separated from component A to obtain a desired shelf life until immediately prior to use; and adding water and combining components A and B to form said resin cement by reaction.
Claim 20
Independent Claim
130 words
A method of manufacturing a resin article comprising: mixing two components A and B to form a mixture undergoing exothermic reaction; directing the mixture toward a support surface capable of supporting said mixture until the reaction is completed; wherein component A comprises an aqueous solution of an aluminum phosphate, a magnesium phosphate or mixtures thereof having a viscosity ranging between about 700 and about 10,000 centipoises; and wherein component B comprises an aqueous vehicle; a phosphate-reactive constituent comprising wollastonite, or a source of magnesium oxide or mixtures thereof, and an essentially nonreactive phosphate dispersing agent; said component B having a viscosity permitting it to be rapidly and thoroughly mixed with component A, thereby to form a slurry which reacts exothermically to form an inorganic resin article on said support surface.
Claim 21
Independent Claim
130 words
A method of manufacturing a resin article comprising: mixing two components A and B to form a mixture undergoing exothermic reaction; directing the mixture toward a support surface capable of supporting said mixture until the reaction is completed; wherein component A comprises an aqueous solution of an aluminum phosphate, a magnesium phosphate or mixtures thereof having a viscosity ranging between about 700 and about 10,000 centipoises; and wherein component B comprises an aqueous vehicle; a phosphate-reactive constituent comprising wollastonite, or a source of magnesium oxide or mixtures thereof, and an essentially nonreactive phosphate dispersing agent; said component B having a viscosity permitting it to be rapidly and thoroughly mixed with component A, thereby to form a slurry which reacts exothermically to form an inorganic resin article on said support surface.
Claim 22
Dependent Claim
30 words
The method of claim 18 wherein said support surface comprises a fiberglass mat and said mixture impregnates at least an upper surface of said mat to form a fiber-reinforced article.
Claim 23
Dependent Claim
25 words
The method of claim 18 wherein said support surface comprises a fiberboard and said resin cement adheres to said fiberboard to form a composite article.
Claim 24
Dependent Claim
9 words
The product made by the process of claim 19.
Claim 25
Dependent Claim
9 words
The product made by the process of claim 20.
Claim 26
Dependent Claim
51 words
An inorganic resin composition comprising a liquid component A comprising an aqueous solution of an aluminum phosphate, a magnesium phosphate or mixtures thereof; an aqueous vehicle; a phosphate-reactive material selected from the group consisting of a source of magnesium oxide, wollastonite, and mixtures thereof; and an essentially nonreactive phosphate dispersing agent.
Claim 27
Dependent Claim
51 words
An inorganic resin composition comprising a liquid component A comprising an aqueous solution of an aluminum phosphate, a magnesium phosphate or mixtures thereof; an aqueous vehicle; a phosphate-reactive material selected from the group consisting of a source of magnesium oxide, wollastonite, and mixtures thereof; and an essentially nonreactive phosphate dispersing agent.
Claim 28
Dependent Claim
27 words
The composition of claim 23 including an inert, low water-demand filler in an amount up to about 50% by weight of the total weight of said composition.
Claim 29
Dependent Claim
11 words
The composition of claim 24 wherein said inert filler is silica.
Claim 30
Dependent Claim
17 words
The composition of claim 24 wherein at least a portion of said filler comprises preformed cellular material.
Claim 31
Dependent Claim
22 words
The composition of claim 24 wherein at least a portion of said filler comprises a finely divided chemically hydrated water releasing agent.
Claim 32
Dependent Claim
69 words
The composition of claim 23 divided into two components for mixing to form an inorganic resin including a liquid component A comprising an aqueous solution of an aluminum phosphate and/or a magnesium phosphate; and a liquid component B comprising an aqueous vehicle; a source of phosphate-reactive material selected from the group consisting of a source of magnesium oxide, wollastonite and mixtures thereof; and an essentially non-reactive phosphate dispersing agent.
Claim 33
Dependent Claim
62 words
The two-component composition of claim 28 wherein said component A includes wollastonite substantially unreactive with said aluminum phosphate or said magnesium phosphate over the time required to formulate said component A and to mix it with said component B, the quantity of said unreactive wollastonite amounting up to about 10% by weight of the total weight of said components A and B.
Claim 34
Dependent Claim
38 words
The two-component composition of claim 29 wherein said substantially unreactive wollastonite is a finely divided acicular material having an aspect ratio of at least about 15:1 and a surface area of less than about 1.0 m 2 /gm.
Claim 35
Dependent Claim
28 words
The composition of claim 23 including a water-repellent surfactant in a total amount between about 0.2% and about 5% by weight of the total weight of said composition.
Claim 36
Dependent Claim
23 words
The composition of claim 31 wherein said water-repellant surfactant is a hydrophobic fumed silica, a titanate, a silicone, a wax, or a stearate.
Claim 37
Dependent Claim
14 words
The composition of claim 32 wherein said water-repellant surfactant is a hydrophobic fumed silica.
Claim 38
Dependent Claim
12 words
The composition of claim 23 wherein said phosphate is mono aluminum phosphate.
Claim 39
Dependent Claim
32 words
The two-component composition of claim 28 wherein said component A includes mono aluminum phosphate and/or mono magnesium phosphate, and has a solids content ranging between about 20 and about 70 weight percent.
Claim 40
Dependent Claim
34 words
The two-component composition of claim 28 wherein the amount of said aqueous solution of component A ranges between about 20% and about 70% by weight of the total weight of components A and B.
Claim 41
Dependent Claim
61 words
The composition of claim 13 wherein said source of phosphate reactive material is finely divided acicular wollastonite having as aspect ratio of less than about 10:1 and a surface area of at least about 1.0 m 2 /gm and is present in said composition in an amount of up to about 40% by weight of the total weight of said composition.
Claim 42
Dependent Claim
13 words
The composition of claim 23 wherein said non-reactive dispersing agent is a polyphosphate.
Claim 43
Dependent Claim
45 words
The composition of claim 23 including a water-repellant surfactant and a blowing agent capable of releasing a gas by reaction, decomposition or vaporization in said composition; and wherein said dispersing agent is one which does not raise the pH of said composition above about 10.
Claim 44
Dependent Claim
31 words
The composition of claim 39 wherein said blowing agent is calcium carbonate in an amount ranging between about 0.2% and about 15% by weight of the total weight of said composition.
Claim 45
Dependent Claim
32 words
The two-component composition of claim 28 wherein the weight ratio of said aqueous solution of component A to said phosphate reactive material of component B ranges between about 50/50 and about 65/35.
Claim 46
Dependent Claim
27 words
The composition of claim 23 wherein the weight ratio of said aqueous solution of phosphate to the aluminum phosphate-reactive constituent ranges between about 20/80 and about 70/30.
Claim 47
Dependent Claim
48 words
The composition of claim 23 including up to about 50% by total weight of an inert, low-water demand filler, up to about 10% by weight of wollastonite substantially unreactive with said aluminum phosphate or said magnesium phosphate, and up to about 5% by weight of a water-repellent surfactant.
Claim 48
Dependent Claim
43 words
The composition of claim 43 including up to about 15% by weight of a blowing agent capable of releasing a gas by reaction, decomposition or vaporization, said blowing agent being one which does not raise the pH of said composition above about 10.
Claim 49
Dependent Claim
58 words
The two-component composition of claim 28 wherein the amount of said aqueous solution of component A ranges between about 20% and about 70% by weight of the total weight of said components A and B; and said aqueous solution of aluminum phosphate and/or magnesium phosphate has a solids content ranging between about 20 and about 70 weight percent.
Claim 50
Dependent Claim
49 words
An inorganic resin formed by the reaction upon mixing of a composition comprising water; aluminum phosphate, or a magnesium phosphate or a mixture thereof; a phosphate-reactive material selected from the group consisting of a source of magnesium oxide, wollastonite and mixtures thereof; and an essentially non-reactive phosphate dispensing agent.
Claim 51
Dependent Claim
49 words
An inorganic resin formed by the reaction upon mixing of a composition comprising water; aluminum phosphate, or a magnesium phosphate or a mixture thereof; a phosphate-reactive material selected from the group consisting of a source of magnesium oxide, wollastonite and mixtures thereof; and an essentially non-reactive phosphate dispensing agent.
Claim 52
Dependent Claim
13 words
An inorganic resin in accordance with claim 46 including a low water-demand filler.
Claim 53
Dependent Claim
17 words
An inorganic resin in accordance with claim 47 wherein said filler is silica added in component A.
Claim 54
Dependent Claim
27 words
An inorganic resin in accordance with claim 46 wherein said phosphate-reactive material comprises finely divided acicular woolastonite having an aspect ratio of about 5:1 in component B.
Claim 55
Dependent Claim
28 words
An inorganic resin in accordance with claim 46 including wollastonite having an aspect ratio of at least 15:1 and wollastonite having an aspect ratio of less than 10:1.
Claim 56
Dependent Claim
11 words
An inorganic resin in accordance with claim 46 in cellular form.
Claim 57
Dependent Claim
27 words
An inorganic resin in accordance with claim 51 wherein the cells of said resin are formed by adding a surfactant and a blowing agent to the composition.
Claim 58
Dependent Claim
22 words
An inorganic resin in accordance with claim 51 wherein said surfactant is fumed hydrophobic silica and said blowing agent is calcium carbonate.
Claim 59
Dependent Claim
29 words
An inorganic resin in accordance with claim 51 wherein the cells of said resin are formed by introducing an inert gas under pressure during said mixing of said composition.
Claim 60
Dependent Claim
21 words
An inorganic resin in accordance with claim 51 wherein the cells of said resin range from ultrafine to medium in size.
Claim 61
Dependent Claim
44 words
A resin cement composition comprising an aluminum phosphate, or a magnesium phosphate, or mixtures thereof; a phosphate reactive material selected from the group consisting of a source of magnesium oxide, a phosphate reactive wollastonite, and mixtures thereof; and an essentially non-reactive phosphate dispersing agent.
Claim 62
Dependent Claim
44 words
A resin cement composition comprising an aluminum phosphate, or a magnesium phosphate, or mixtures thereof; a phosphate reactive material selected from the group consisting of a source of magnesium oxide, a phosphate reactive wollastonite, and mixtures thereof; and an essentially non-reactive phosphate dispersing agent.
Claim 63
Dependent Claim
33 words
The composition of claim 56 wherein said phosphate comprises mono aluminum phosphate and the dispersing agent is selected from the group consisting of sodium tripolyphosphate, sodium hexa-metaphosphate, sodium acid pyrophosphate, and mixtures thereof.
Claim 64
Dependent Claim
33 words
The composition of claim 56 wherein said phosphate is mono magnesium phosphate and the dispersing agent is selected from the group consisting of dipotassium phosphate, tripotassium phosphate, tripolyphosphate, tetrapotassium phosphate, and mixtures thereof.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1989-08-04 | 1990-02-03 | 1990-08-05 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-08-04 | 1994-02-03 | 1994-08-05 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1997-08-04 | 1998-02-03 | 1998-08-05 | $7700.00 | Window Closed / Lapsed |