WO2008139180A1 - Method of forming an article - Google Patents
Method of forming an article Download PDFInfo
- Publication number
- WO2008139180A1 WO2008139180A1 PCT/GB2008/001644 GB2008001644W WO2008139180A1 WO 2008139180 A1 WO2008139180 A1 WO 2008139180A1 GB 2008001644 W GB2008001644 W GB 2008001644W WO 2008139180 A1 WO2008139180 A1 WO 2008139180A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- binder
- article
- clay
- mixed dispersion
- expanded
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Ceased
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/04—Silica-rich materials; Silicates
- C04B14/10—Clay
- C04B14/12—Expanded clay
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
- C04B28/04—Portland cements
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
- C04B28/06—Aluminous cements
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/34—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
Definitions
- the present application relates to methods of forming articles and in particular articles used for insulation, acoustic and fire protection purposes.
- a method of forming an article comprising wetting an expanded calcined clay with up to three times its own weight of water then combining the wetted clay with a binder in a mixed dispersion such that the mixed dispersion can be formed in a mould and set.
- the expanded calcined clay is Ultralite supplied by Ceramic Gas Products Limited.
- the expanded calcined clay is wetted in a granular or powered form (prill).
- wetted clay and binder are combined in a mechanical mixer.
- the expanded calcined clay has a bulk packing density of about 75 kilograms per cubic metre.
- the mixed dispersion is combined in proportions of 40% - 75% by volume expanded calcined clay and 25% - 60% by volume binder.
- additives are combined with the wetted expanded calcined clay and the binder at the combination stage in the mixed dispersion.
- additives may include colorants, fire inhibitors and other functional additives to alter and adjust the performance of the formed article.
- the mixed dispersion is poured into the mould or pressed into shapes defined by the mould.
- the mixed dispersion is set or cured to release the article from the mould. Possibly, the mixed dispersion is set or cured by an exothermic reaction.
- the article is dried by forced air drying and/or fired by varying a curing temperature.
- the binder is a Gypsum slurry. Possibly, the binder is up to 15% glass bonding by a glass bond material. Possibly, the binder is up to 80% of high alumina castable cement. Possibly, the binder is up to 30% refractory ball clay. Possibly, the binder is up to 30% colloidal silica. Possibly, the binder is up to 30% phosphate bonded cement. Possibly, the binder includes ethyl silicate bonding. Possibly, the article includes a chemically inert filler. Possibly, the binder includes Portland cement. Possibly, the binder includes polyvinyl acetate/cellulose.
- the article can be formed as boards, sheets, composite panels, tubes, seals and other solid or hollow shapes.
- the article is a component utilised for, but not limited to fire protection, insulation and noise reduction.
- An aspect of the present invention relates to combining a known expanded calcined clay with a binder in order to create a lightweight rigid article.
- An example given below of possible binder is Gypsum but others either alone or in combinations as described later could be used.
- the most desired and preferred expanded calcined clay is that sold under the trade name of Ultralite by Ceramic Gas Products Limited.
- the expanded calcined clay ensures that the eventual article is lightweight whilst the binder as indicated tends to bind the expanded calcined clay (Ultralight) material together to form the article.
- a combination of expanded calcined clay and a binder such as Gypsum ensures that the product allows the desired ranges of sizes and shapes to be achieved currently available with existing materials but with improved performance particularly in terms of integrity and possible surface powdering and erosion.
- an expanded calcinated clay and in particular Ultralite is utilised in order to create an article by the present method.
- the pore structure of the expanded calcinated clay ensures that the finally produced product has gained thermal properties and therefore can be used in relation to component articles utilised in insulation fire protection and acoustic applications.
- the expanded calcinated clay in accordance with the aspect of the present invention will have a bulk packing density in the order of 75 kilograms per cubic metre.
- Such calcinated clays are available as indicated and particularly under the trademark Ultralite.
- a method in which granules or powder of expanded calcinated clay are pre wetted with up to three times their own weight of water.
- This pre wetted expanded calcinated clay is then thoroughly mixed and dispersed with the binder such as a Gypsum slurry.
- the Gypsum slurry will eventually act as a binder within the article form.
- a high speed mechanical mixer is utilised with paddles extending into a vat in which the expanded calcined clay and binder such as a Gypsum slurry are combined.
- additives may be used to facilitate flow and dispersion.
- additives may be added at this stage or at other times to provide particular functionality or performance to the article once formed.
- These additives may include fire suppressant materials to further enhance the thermal capabilities of the article once formed. It is important that all the additives as well as the binder and expanded clay are sufficiently dispersed and bonded together to form the article in use.
- the bonding procedure is achieved through a setting and/or curing stage.
- the mix may undergo an exothermic setting stage in a mould.
- a form of forced air drying may involve provision of higher than ambient temperatures, that is to say achieving a curing temperature, but normally will simply involve locating the set article within a dehumidifier arrangement in which a desiccant preferentially draws fluid from the set article in order to dry it.
- the bonding can be further strengthened by firing at elevated temperatures in a kiln.
- the expanded calcinated clay is arranged to be wetted with up to three times its own weight of water which is absorbed within the pore structure of the expanded calcined clay. After dehydration the pore structure is retained and will ensure that the article produced is of a lightweight nature. Furthermore, the pore dimensions in the article may be as small as 5 microns and so provide high energy insulation properties for the article formed above in accordance with aspects of the present invention as well as making it extremely lightweight.
- composition of the mixed dispersion will be in the ranges of 40% - 75% in volume expanded calcined clay with 25% - 60% in volume of a binder such as Gypsum.
- the composition of the article formed once set is sufficiently bound for constructional integrity.
- the articles will be components for but not limited to, fire protection, thermal insulation and noise reduction.
- the expanded calcined clay has unique properties as a result of its pore structures once set and dried. These pores may be as small as 5 microns and extend through the expanded calcined clay in order to give high heat energy insulation properties as well as a lightweight nature. It will be appreciated different levels of processing of the expanded calcined clay results in different bulk densities of the articles produced and, in accordance with aspects of the present invention this is controlled by varying the grain size of the manufactured material or article (prill).
- Articles formed in accordance with methods of aspects of the present invention typically as indicated are relatively lightweight and have high insulation properties.
- the binder such as gypsum is arranged to retain the expanded calcined clay structure within the article.
- a setting or curing procedure is achieved through an appropriate process such as an exothermic reaction of the binder such as Gypsum or cementaceous binder with the mixed dispersion.
- Relatively complex shapes can be manufactured by pouring or pressing the mixed dispersion into an appropriately shaped mould. It will be appreciated that the drying procedure to provide setting of the mixed dispersion will be tailored to particular mould shapes to ensure that the drying procedure does not cause cracking of the article as it dries.
- expanded calcined clay as indicated will be presented in granular or powder form (prill). By its nature this expanded calcined clay will absorb atmospheric moisture but generally will be receptive to pre wetting with as indicated by up to three times its own weight of water.
- the method in accordance with aspects of the present invention is provided in order to form an article which has enhanced properties. It will be appreciated that through use of the expanded calcinated clay articles can be made which withstand much higher temperatures or have other properties due to the additives to the expanded calcinated clay combined with a binder. Thus for example articles formed in accordance with aspects of the present invention combine expanded calcinated clay with a binder such as a Gypsum slurry will have a much higher temperature than Gypsum alone is capable of withstanding. The material is ideal for composite fire doors with a lighter weight and with greater heat resistance properties.
- the articles can be formed into a number of shapes including boards, sheets, composite panels, tubes, seals and other complex or simple solid and hollow shapes.
- a particular advantage with regard to aspects of the present invention is that the addition of expanded calcinated clay will provide an article which after manufacture is generally lighter or has more heat resistance or thermal insulation or acoustic insulation or fire retardancy than prior articles formed without expanded calcinated clay. It will be understood that the variation in these capabilities and properties will be dependent upon the proportions of expanded calcinated clay and the binder Aspects of the present invention provide for combination of the expanded calcinated clay with the following binder as alternatives to or combinations with each other or with gypsum:
- the glass bonding material as the binder in order to provide -and define porous filters or decorative shapes.
- the glass bonding material as a binder may constitute up to 15% by weight of the article.
- Provision of ethyl silicate bonding as the binder will provide refractories and in particular refractory crucibles along with other formed shapes which have a reduced weight in comparison with similar articles formed by prior techniques. A reduced weight will enhance capability with regard to safer manual handling in use.
- Provision of polyvinyl acetate (PVA) and/or cellulose as a binder within the article will adjust heat resistance and thermal insulating effects when the article in the form of a powder is incorporated within paints for the construction industry.
- Articles in accordance with aspects of the present invention may be provided as a powder which can then be considered a chemically inert filler for plastic components to reduce weight and increase fire resistance. It will also be understood that a powder formed in accordance with aspects of the present invention may be added to ordinary Portland cement or concrete products to reduce their weight.
- additives may be included within the mixed dispersion of expanded calcined clay and binder in order to facilitate mixing and distribution.
- these additives may add colour or be a fire retardant or other functional additive to retain and adjust the components once formed and set in accordance with the aspects of the present invention.
- the degree of variation in the weight and functionality of the article can be controlled by the amount of pre wetting of the expanded calcined clay in accordance with the aspects of the present invention. It will be appreciated that care must be taken with respect to the pre wetting and mixing procedure such that the lightweight nature of the article produced is retained.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Structural Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Dispersion Chemistry (AREA)
- Civil Engineering (AREA)
- Building Environments (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
- Preparation Of Clay, And Manufacture Of Mixtures Containing Clay Or Cement (AREA)
Abstract
A method of forming an article, the method comprising wetting an expanded calcined clay with up to three times its own weight of water then combining the wetted clay with a binder in a mixed dispersion such that the mixed dispersion can be formed in a mould and set.
Description
Method of forming an article
The present application relates to methods of forming articles and in particular articles used for insulation, acoustic and fire protection purposes.
It will be appreciated that there is a requirement for relatively rigid lightweight board, components and composites for use in a wide variety of installations and structures. Provision of articles having good thermal and fire resistant properties are particularly useful in buildings and structures.
In accordance with aspects of the present invention there is provided a method of forming an article, the method comprising wetting an expanded calcined clay with up to three times its own weight of water then combining the wetted clay with a binder in a mixed dispersion such that the mixed dispersion can be formed in a mould and set.
Typically, the expanded calcined clay is Ultralite supplied by Ceramic Gas Products Limited. Generally, the expanded calcined clay is wetted in a granular or powered form (prill).
Typically, the wetted clay and binder are combined in a mechanical mixer.
Generally, the expanded calcined clay has a bulk packing density of about 75 kilograms per cubic metre.
Typically, the mixed dispersion is combined in proportions of 40% - 75% by volume expanded calcined clay and 25% - 60% by volume binder.
Possibly, further additives are combined with the wetted expanded calcined clay and the binder at the combination stage in the mixed dispersion.
Such additives may include colorants, fire inhibitors and other functional additives to alter and adjust the performance of the formed article.
Generally, the mixed dispersion is poured into the mould or pressed into shapes defined by the mould.
Generally, the mixed dispersion is set or cured to release the article from the mould. Possibly, the mixed dispersion is set or cured by an exothermic reaction. The article is dried by forced air drying and/or fired by varying a curing temperature.
Possibly, the binder is a Gypsum slurry. Possibly, the binder is up to 15% glass bonding by a glass bond material. Possibly, the binder is up to 80% of high alumina castable cement. Possibly, the binder is up to 30% refractory ball clay. Possibly, the binder is up to 30% colloidal silica. Possibly, the binder is up to 30% phosphate bonded cement. Possibly, the binder includes ethyl silicate bonding. Possibly, the article includes a chemically inert filler. Possibly, the binder includes Portland cement. Possibly, the binder includes polyvinyl acetate/cellulose.
Generally, the article can be formed as boards, sheets, composite panels, tubes, seals and other solid or hollow shapes.
Also in accordance with aspects of the present invention is provided an article formed in accordance with the above method.
Typically the article is a component utilised for, but not limited to fire protection, insulation and noise reduction.
There is a requirement to provide a relatively rigid but lightweight article in a form of a board or shaped component for use in a wide range of industries and products. These articles can be in a variety of shapes and
sizes depending upon a particular interoperability requirement and effects necessary in a particular structure. Generally with such articles there is a desire to produce components which have a consistent shape but which are relatively cheap to manufacture.
An aspect of the present invention relates to combining a known expanded calcined clay with a binder in order to create a lightweight rigid article. An example given below of possible binder is Gypsum but others either alone or in combinations as described later could be used. The most desired and preferred expanded calcined clay is that sold under the trade name of Ultralite by Ceramic Gas Products Limited. The expanded calcined clay ensures that the eventual article is lightweight whilst the binder as indicated tends to bind the expanded calcined clay (Ultralight) material together to form the article. A combination of expanded calcined clay and a binder such as Gypsum for example ensures that the product allows the desired ranges of sizes and shapes to be achieved currently available with existing materials but with improved performance particularly in terms of integrity and possible surface powdering and erosion.
In accordance with aspects of the present invention as indicated an expanded calcinated clay and in particular Ultralite is utilised in order to create an article by the present method. The pore structure of the expanded calcinated clay ensures that the finally produced product has gained thermal properties and therefore can be used in relation to component articles utilised in insulation fire protection and acoustic applications. Typically, the expanded calcinated clay in accordance with the aspect of the present invention will have a bulk packing density in the order of 75 kilograms per cubic metre. Such calcinated clays are available as indicated and particularly under the trademark Ultralite.
In accordance with aspects of the present invention a method is provided in which granules or powder of expanded calcinated clay are pre
wetted with up to three times their own weight of water. This pre wetted expanded calcinated clay is then thoroughly mixed and dispersed with the binder such as a Gypsum slurry. The Gypsum slurry will eventually act as a binder within the article form. In order to achieve good dispersion and mixing of the expanded calcinated clay once wetted with the binder such as a Gypsum slurry normally a high speed mechanical mixer is utilised with paddles extending into a vat in which the expanded calcined clay and binder such as a Gypsum slurry are combined.
In order to facilitate mixing then pouring of the mixed dispersion of expanded calcinated clay and the binder such as a Gypsum slurry additives may be used to facilitate flow and dispersion. Furthermore, additives may be added at this stage or at other times to provide particular functionality or performance to the article once formed. These additives may include fire suppressant materials to further enhance the thermal capabilities of the article once formed. It is important that all the additives as well as the binder and expanded clay are sufficiently dispersed and bonded together to form the article in use.
The bonding procedure is achieved through a setting and/or curing stage. Thus, the mix may undergo an exothermic setting stage in a mould. Although it is possible to dry the article within the mould by using normal natural drying more typically and practically the article is removed from the mould after setting and a form of forced air drying is provided. This forced air drying may involve provision of higher than ambient temperatures, that is to say achieving a curing temperature, but normally will simply involve locating the set article within a dehumidifier arrangement in which a desiccant preferentially draws fluid from the set article in order to dry it.The bonding can be further strengthened by firing at elevated temperatures in a kiln.
As indicated above the expanded calcinated clay is arranged to be wetted with up to three times its own weight of water which is absorbed within
the pore structure of the expanded calcined clay. After dehydration the pore structure is retained and will ensure that the article produced is of a lightweight nature. Furthermore, the pore dimensions in the article may be as small as 5 microns and so provide high energy insulation properties for the article formed above in accordance with aspects of the present invention as well as making it extremely lightweight.
The composition of the mixed dispersion will be in the ranges of 40% - 75% in volume expanded calcined clay with 25% - 60% in volume of a binder such as Gypsum. The composition of the article formed once set is sufficiently bound for constructional integrity. Typically, the articles will be components for but not limited to, fire protection, thermal insulation and noise reduction.
As indicated the expanded calcined clay has unique properties as a result of its pore structures once set and dried. These pores may be as small as 5 microns and extend through the expanded calcined clay in order to give high heat energy insulation properties as well as a lightweight nature. It will be appreciated different levels of processing of the expanded calcined clay results in different bulk densities of the articles produced and, in accordance with aspects of the present invention this is controlled by varying the grain size of the manufactured material or article (prill).
Articles formed in accordance with methods of aspects of the present invention typically as indicated are relatively lightweight and have high insulation properties. The binder such as gypsum is arranged to retain the expanded calcined clay structure within the article. Once in the mould a setting or curing procedure is achieved through an appropriate process such as an exothermic reaction of the binder such as Gypsum or cementaceous binder with the mixed dispersion.
Relatively complex shapes can be manufactured by pouring or pressing the mixed dispersion into an appropriately shaped mould. It will be appreciated that the drying procedure to provide setting of the mixed dispersion will be tailored to particular mould shapes to ensure that the drying procedure does not cause cracking of the article as it dries.
Typically, expanded calcined clay as indicated will be presented in granular or powder form (prill). By its nature this expanded calcined clay will absorb atmospheric moisture but generally will be receptive to pre wetting with as indicated by up to three times its own weight of water.
The method in accordance with aspects of the present invention is provided in order to form an article which has enhanced properties. It will be appreciated that through use of the expanded calcinated clay articles can be made which withstand much higher temperatures or have other properties due to the additives to the expanded calcinated clay combined with a binder. Thus for example articles formed in accordance with aspects of the present invention combine expanded calcinated clay with a binder such as a Gypsum slurry will have a much higher temperature than Gypsum alone is capable of withstanding. The material is ideal for composite fire doors with a lighter weight and with greater heat resistance properties.
The articles can be formed into a number of shapes including boards, sheets, composite panels, tubes, seals and other complex or simple solid and hollow shapes. Furthermore, a particular advantage with regard to aspects of the present invention is that the addition of expanded calcinated clay will provide an article which after manufacture is generally lighter or has more heat resistance or thermal insulation or acoustic insulation or fire retardancy than prior articles formed without expanded calcinated clay. It will be understood that the variation in these capabilities and properties will be dependent upon the proportions of expanded calcinated clay and the binder
Aspects of the present invention provide for combination of the expanded calcinated clay with the following binder as alternatives to or combinations with each other or with gypsum:
a) Glass bonding material as the binder in order to provide -and define porous filters or decorative shapes. The glass bonding material as a binder may constitute up to 15% by weight of the article.
b) Inclusion of up to 80% by weight of a high alumina castable cement as the binder. Provision of such high alumina castable cement will provide an article which allows formation of refractory shapes.
c) Inclusion of up to 30% refractory ball clay as the binder will improve the refractory properties of an article formed in accordance with aspects of the present invention.
d) Inclusion of up to 30% colloidal silica as the binder to improve resilience qualities of an article formed in accordance with aspects of the present invention.
e) Provision of up to 30% phosphate bonded cement as the binder in order to adjust the strength and capabilities of the formed article in accordance with aspects of the present invention.
f) Provision of ethyl silicate bonding as the binder will provide refractories and in particular refractory crucibles along with other formed shapes which have a reduced weight in comparison with similar articles formed by prior techniques. A reduced weight will enhance capability with regard to safer manual handling in use.
g) Provision of polyvinyl acetate (PVA) and/or cellulose as a binder within the article will adjust heat resistance and thermal insulating effects when the article in the form of a powder is incorporated within paints for the construction industry. h) Provision of up to 80% of a ceramic fibre as a binder in order to import heat resistace to vacuum formed shapes for example investment casting crucibles and gas fire logs/shapes.
As described above with regard to the main example given in accordance with aspects of the present invention provision of a Gypsum slurry as the binder will increase heat resistance and impart acoustic insulation within an article formed in accordance with aspects of the present invention.
Articles in accordance with aspects of the present invention may be provided as a powder which can then be considered a chemically inert filler for plastic components to reduce weight and increase fire resistance. It will also be understood that a powder formed in accordance with aspects of the present invention may be added to ordinary Portland cement or concrete products to reduce their weight.
Modifications and alterations to the aspects of the present invention will be appreciated by those skilled of the art. Thus, for example, as indicated above additives may be included within the mixed dispersion of expanded calcined clay and binder in order to facilitate mixing and distribution. Furthermore, these additives may add colour or be a fire retardant or other functional additive to retain and adjust the components once formed and set in accordance with the aspects of the present invention. Furthermore, the degree of variation in the weight and functionality of the article can be controlled by the amount of pre wetting of the expanded calcined clay in accordance with the aspects of the present invention.
It will be appreciated that care must be taken with respect to the pre wetting and mixing procedure such that the lightweight nature of the article produced is retained.
Whilst endeavoring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.
Claims
1. A method of forming an articles, the method comprising wetting an expanded calcined clay with up to three times its own weight of water then combining the wetted clay with a binder in a mixed dispersion such that the mixed dispersion can be formed in a mould and set.
2. A method as claimed in claim 1 , wherein the expanded calcined clay is Ultralite supplied by Ceramic Gas Products Limited.
3. A method as claimed in claim 1 or claim 2, wherein the expanded calcined clay is wetted in a granular or powdered form (prill).
4. A method as claimed in any of claims 1 , 2 or 3, wherein the wetted clay (prill) and binder are combined in a mechanical mixer.
5. A method as claimed in any preceding claim, wherein the expanded calcined clay has a bulk packing density of about 75 kilograms per cubic metre.
6. A method as claimed in any preceding claim, wherein the mixed dispersion is combined in proportions of 40% - 75% by volume expanded calcined clay and 25% - 60% by volume binder.
7. A method is claimed in any preceding claim, wherein further additives are combined with the wetted clay and binder at the combination stage in the mixed dispersion and the further additives may include colorants, fire inhibitors and other functional additives to alter and adjust the performance of the formed article.
8. A method as claimed in any preceding claim, wherein the mixed dispersion is either poured into the mould or pressed into shapes defined by the mould.
9. A method as claimed in any preceding claim, wherein the mixed dispersion is set or cured to release the article from the mould
10. A method as claimed in claim 9 wherein the mixed dispersion is set or cured by an exothermic reaction.
11. A method as claimed in any preceding claim wherein the article is dried by forced air drying and/or fired by varying curingl temperature.
12. A method as claimed in any preceding claim, wherein the binder is a Gypsum slurry.
13. A method as claimed in any preceding claim, wherein the binder is up to 15% of a glass bond material.
14. A method as claimed in any preceding claim, wherein the binder is up to 80% of a high alumina castable cement.
15. A method as claimed in any preceding claim, wherein the binder is up to 30% of a refractory ball clay.
16. A method as claimed in any preceding claim, wherein the binder is up to 30% colloidal silica.
17. A method as claimed in any preceding claim, wherein the binder is up to 30% phosphate bonded cement.
18. A method as claimed in any preceding claim, wherein the binder includes ethyl silicate bonding.
19. A method as claimed in any preceding claim, wherein the article includes a chemically inert filler..
20. A method as claimed in any preceding claim, wherein the binder included Portland cement or concrete products.
21. A method as claimed in any preceding claim, wherein the binder includes polyvinyl acetate (PVA) and/or cellulose.
22. A method as claimed in any preceding claim, wherein the binder includes up to 80% of a ceramic fibre.
23. A method of forming an article substantially as hereinbefore described with reference to the accompanying drawings.
24. An article formed in accordance with a method as claimed in any preceding claim.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0921488.3A GB2463186B (en) | 2007-05-11 | 2008-05-12 | Method of forming an article |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0709046.7 | 2007-05-11 | ||
| GBGB0709046.7A GB0709046D0 (en) | 2007-05-11 | 2007-05-11 | Method of forming an article |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2008139180A1 true WO2008139180A1 (en) | 2008-11-20 |
Family
ID=38219211
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/GB2008/001644 Ceased WO2008139180A1 (en) | 2007-05-11 | 2008-05-12 | Method of forming an article |
Country Status (2)
| Country | Link |
|---|---|
| GB (2) | GB0709046D0 (en) |
| WO (1) | WO2008139180A1 (en) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AT513933A1 (en) * | 2013-02-12 | 2014-08-15 | Horst Wustinger | Method of joining grains of puffed volcanic glass |
| BE1022709B1 (en) * | 2015-02-11 | 2016-08-22 | JAAMANN Albert Christiaan R. | Building block for constructions |
| CN108503305A (en) * | 2018-04-04 | 2018-09-07 | 袁亮久 | A kind of the light-weight water-proof foam cement packing material and foaming method of fire resistant heat preserving |
| AT520113A1 (en) * | 2017-07-11 | 2019-01-15 | Dullinger Heinz | Method for making a tile |
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|---|---|---|---|---|
| FR1446498A (en) * | 1965-06-12 | 1966-07-22 | Further training in the manufacture of industrial panels for the building industry | |
| DE1930478A1 (en) * | 1968-06-19 | 1970-01-02 | Artmann Dipl Ing Paul | Lightweight building material, in particular lightweight concrete, and process for its production |
| DD83531A5 (en) * | 1969-06-03 | 1971-07-20 | Paul Dipl Ing Artmann | Lightweight construction material, in particular lightweight concrete, and method for its production |
| WO1992007714A1 (en) * | 1990-10-25 | 1992-05-14 | Erik Arne Kristoffer Westin | Multi-component composition for system of joists and floor, and method of manufacturing such composition |
| GB2265144A (en) * | 1992-03-11 | 1993-09-22 | Yen Hui Shan | Preformed cellular composite wall |
| DE19643367A1 (en) * | 1996-10-09 | 1998-04-16 | Witega Angewandte Werkstoff Forschung Gemeinnuetzige Gmbh Adlershof | Highly insulating light constructional concrete |
| DE10116141A1 (en) * | 2001-09-07 | 2003-03-27 | Liapor Gmbh & Co Kg | Making highly-porous object from e.g. bulk wastes, first saturates porous granules of inorganic material with binder, then solidifies molding using microwaves |
| WO2004069766A1 (en) * | 2003-02-08 | 2004-08-19 | Technical Lightweight Composites Ltd | Composite materials |
| FR2882551A1 (en) * | 2005-02-25 | 2006-09-01 | Lero Soc Civ Ile | Composition for making a building material that can be shaped comprises expanded clay granules, a binder and water |
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| GB1456641A (en) * | 1973-10-29 | 1976-11-24 | Ici Ltd | Composite foamed polyurethane material |
| SU1761728A1 (en) * | 1990-07-31 | 1992-09-15 | Центральный межведомственный институт повышения квалификации руководящих работников и специалистов строительства | Expanded-clay lightweight concrete mix |
| DE19831295A1 (en) * | 1998-07-13 | 2000-01-20 | Hubert Koertge | Porous lightweight concrete for prefabricated housing parts contains cement-coated expanded polystyrene beads, prewetted expanded slate, melamine-based flow improver, foam and water |
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2007
- 2007-05-11 GB GBGB0709046.7A patent/GB0709046D0/en not_active Ceased
-
2008
- 2008-05-12 GB GB0921488.3A patent/GB2463186B/en active Active
- 2008-05-12 WO PCT/GB2008/001644 patent/WO2008139180A1/en not_active Ceased
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| FR1446498A (en) * | 1965-06-12 | 1966-07-22 | Further training in the manufacture of industrial panels for the building industry | |
| DE1930478A1 (en) * | 1968-06-19 | 1970-01-02 | Artmann Dipl Ing Paul | Lightweight building material, in particular lightweight concrete, and process for its production |
| DD83531A5 (en) * | 1969-06-03 | 1971-07-20 | Paul Dipl Ing Artmann | Lightweight construction material, in particular lightweight concrete, and method for its production |
| WO1992007714A1 (en) * | 1990-10-25 | 1992-05-14 | Erik Arne Kristoffer Westin | Multi-component composition for system of joists and floor, and method of manufacturing such composition |
| GB2265144A (en) * | 1992-03-11 | 1993-09-22 | Yen Hui Shan | Preformed cellular composite wall |
| DE19643367A1 (en) * | 1996-10-09 | 1998-04-16 | Witega Angewandte Werkstoff Forschung Gemeinnuetzige Gmbh Adlershof | Highly insulating light constructional concrete |
| DE10116141A1 (en) * | 2001-09-07 | 2003-03-27 | Liapor Gmbh & Co Kg | Making highly-porous object from e.g. bulk wastes, first saturates porous granules of inorganic material with binder, then solidifies molding using microwaves |
| WO2004069766A1 (en) * | 2003-02-08 | 2004-08-19 | Technical Lightweight Composites Ltd | Composite materials |
| FR2882551A1 (en) * | 2005-02-25 | 2006-09-01 | Lero Soc Civ Ile | Composition for making a building material that can be shaped comprises expanded clay granules, a binder and water |
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| CHEMICAL ABSTRACTS, vol. 111, no. 2, 10 July 1989, Columbus, Ohio, US; abstract no. 11711, GUSEV, B. V.; MUSTAFIN, Y. I.; DIDENKO, E.A.: "Control of the preparation of concrete mixes" page 282; XP002496847 * |
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Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AT513933A1 (en) * | 2013-02-12 | 2014-08-15 | Horst Wustinger | Method of joining grains of puffed volcanic glass |
| BE1022709B1 (en) * | 2015-02-11 | 2016-08-22 | JAAMANN Albert Christiaan R. | Building block for constructions |
| BE1022783B1 (en) * | 2015-02-11 | 2016-09-02 | Albert Christiaan R JAAMANN | Building element for constructions |
| AT520113A1 (en) * | 2017-07-11 | 2019-01-15 | Dullinger Heinz | Method for making a tile |
| AT520113B1 (en) * | 2017-07-11 | 2019-06-15 | Dullinger Heinz | Method for making a tile |
| CN108503305A (en) * | 2018-04-04 | 2018-09-07 | 袁亮久 | A kind of the light-weight water-proof foam cement packing material and foaming method of fire resistant heat preserving |
Also Published As
| Publication number | Publication date |
|---|---|
| GB2463186A (en) | 2010-03-10 |
| GB2463186B (en) | 2013-02-20 |
| GB0921488D0 (en) | 2010-01-20 |
| GB0709046D0 (en) | 2007-06-20 |
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