CA2637475A1 - Building product material - Google Patents
Building product material Download PDFInfo
- Publication number
- CA2637475A1 CA2637475A1 CA002637475A CA2637475A CA2637475A1 CA 2637475 A1 CA2637475 A1 CA 2637475A1 CA 002637475 A CA002637475 A CA 002637475A CA 2637475 A CA2637475 A CA 2637475A CA 2637475 A1 CA2637475 A1 CA 2637475A1
- Authority
- CA
- Canada
- Prior art keywords
- glass
- product material
- particle size
- compact
- particles
- 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.)
- Abandoned
Links
- 239000000463 material Substances 0.000 title claims abstract description 72
- 239000011521 glass Substances 0.000 claims abstract description 93
- 239000011230 binding agent Substances 0.000 claims abstract description 27
- 238000010304 firing Methods 0.000 claims abstract description 12
- 238000004519 manufacturing process Methods 0.000 claims abstract description 9
- 238000002156 mixing Methods 0.000 claims abstract description 8
- 239000002245 particle Substances 0.000 claims description 60
- 238000000034 method Methods 0.000 claims description 32
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 claims description 22
- 229910002092 carbon dioxide Inorganic materials 0.000 claims description 11
- 239000001569 carbon dioxide Substances 0.000 claims description 11
- 239000004115 Sodium Silicate Substances 0.000 claims description 9
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 9
- 229910052911 sodium silicate Inorganic materials 0.000 claims description 9
- 230000015572 biosynthetic process Effects 0.000 claims description 5
- 239000011449 brick Substances 0.000 claims description 4
- 238000005253 cladding Methods 0.000 claims description 4
- 239000005357 flat glass Substances 0.000 claims description 4
- 239000005356 container glass Substances 0.000 claims description 3
- 239000000047 product Substances 0.000 description 46
- 238000003825 pressing Methods 0.000 description 20
- 239000007789 gas Substances 0.000 description 10
- 238000003801 milling Methods 0.000 description 6
- 238000004064 recycling Methods 0.000 description 4
- 238000004040 coloring Methods 0.000 description 3
- 239000000356 contaminant Substances 0.000 description 3
- 238000000227 grinding Methods 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 238000012546 transfer Methods 0.000 description 3
- 230000001680 brushing effect Effects 0.000 description 2
- 238000005056 compaction Methods 0.000 description 2
- 230000008030 elimination Effects 0.000 description 2
- 238000003379 elimination reaction Methods 0.000 description 2
- 238000011049 filling Methods 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 238000012856 packing Methods 0.000 description 2
- 230000035699 permeability Effects 0.000 description 2
- 230000000717 retained effect Effects 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 238000000889 atomisation Methods 0.000 description 1
- 238000005422 blasting Methods 0.000 description 1
- 239000002419 bulk glass Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- 239000003517 fume Substances 0.000 description 1
- 229910052736 halogen Inorganic materials 0.000 description 1
- 150000002367 halogens Chemical class 0.000 description 1
- 230000002045 lasting effect Effects 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000007639 printing Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000007650 screen-printing Methods 0.000 description 1
- 238000012216 screening Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
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
- 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
- C04B28/26—Silicates of the alkali metals
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B1/00—Preparing the batches
- C03B1/02—Compacting the glass batches, e.g. pelletising
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B5/00—Melting in furnaces; Furnaces so far as specially adapted for glass manufacture
- C03B5/005—Melting in furnaces; Furnaces so far as specially adapted for glass manufacture of glass-forming waste materials
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C1/00—Ingredients generally applicable to manufacture of glasses, glazes, or vitreous enamels
- C03C1/002—Use of waste materials, e.g. slags
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C14/00—Glass compositions containing a non-glass component, e.g. compositions containing fibres, filaments, whiskers, platelets, or the like, dispersed in a glass matrix
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Ceramic Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Life Sciences & Earth Sciences (AREA)
- Dispersion Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Structural Engineering (AREA)
- Glass Compositions (AREA)
Abstract
A building product material is provided which comprises domestic lamp glass. A
method of making the building product material is also provided comprising blending domestic lamp glass and other glass types with an inorganic binder, forming a compact thereof and firing the compact.
method of making the building product material is also provided comprising blending domestic lamp glass and other glass types with an inorganic binder, forming a compact thereof and firing the compact.
Description
BUILDING PRODUCT MATERIAL
The invention relates to a building product material which comprises domestic lamp glass and to a method of manufacturing said building product material from said glass.
An average home will discard a significant number of domestic lamp units (including light bulbs and fluorescent tubes) during the course of a year. Throughout the world, this constitutes a significant amount of waste glass generated from wastage of such domestic lamp units. There is an increasing worldwide drive to become more energy efficient and therefore many households are now switching from regular light bulbs to longer lasting energy saving light bulbs. However, this also creates wastage as the replaced light bulbs are often discarded. Significant amounts of other types of waste glass are available and are currently being recycled. However, recycling of such lamp units is often not possible because the units are accompanied by several other components such as the attachment mechanism and the filament within the lamp unit.
Thus, according to a first aspect of the invention, there is provided a building product material which comprises domestic lamp glass.
In addition to the benefits of recycling previously un-recycled domestic lamp glass, the product of the invention provides additional advantages. For example, the physical properties of the domestic lamp glass (such as their high surface area to low mass ratio) advantageously result in softening at lower temperatures, these particles therefore adhere to the coarser particles which fixes them into position prior to sinter melting of the coarser particles. Such an arrangement ultimately results in a stronger and more durable building product.
References herein to "domestic lamp glass" include glass recycled from domestic lamps or lights. Domestic lamps should be interpreted to mean lamp units within a domestic premises and include incandescent light bulbs, halogen lamps, fluorescent lamps, LED
lamps, carbon arc lamps and discharge lamps.
The invention relates to a building product material which comprises domestic lamp glass and to a method of manufacturing said building product material from said glass.
An average home will discard a significant number of domestic lamp units (including light bulbs and fluorescent tubes) during the course of a year. Throughout the world, this constitutes a significant amount of waste glass generated from wastage of such domestic lamp units. There is an increasing worldwide drive to become more energy efficient and therefore many households are now switching from regular light bulbs to longer lasting energy saving light bulbs. However, this also creates wastage as the replaced light bulbs are often discarded. Significant amounts of other types of waste glass are available and are currently being recycled. However, recycling of such lamp units is often not possible because the units are accompanied by several other components such as the attachment mechanism and the filament within the lamp unit.
Thus, according to a first aspect of the invention, there is provided a building product material which comprises domestic lamp glass.
In addition to the benefits of recycling previously un-recycled domestic lamp glass, the product of the invention provides additional advantages. For example, the physical properties of the domestic lamp glass (such as their high surface area to low mass ratio) advantageously result in softening at lower temperatures, these particles therefore adhere to the coarser particles which fixes them into position prior to sinter melting of the coarser particles. Such an arrangement ultimately results in a stronger and more durable building product.
References herein to "domestic lamp glass" include glass recycled from domestic lamps or lights. Domestic lamps should be interpreted to mean lamp units within a domestic premises and include incandescent light bulbs, halogen lamps, fluorescent lamps, LED
lamps, carbon arc lamps and discharge lamps.
In one embodiment, the domestic lamp glass is obtained from incandescent light bulbs and/or fluorescent lamps. In a further embodiment, the domestic lamp glass is obtained from fluorescent lamps. Glass from fluorescent lamps (e.g. fluorescent tubes) is approximately 0.5 to 0.7mm thick, whereas container glass is approximately 3 to 5 mm thick. The use of fluorescent lamp glass as a starting material advantageously provides a greater number and a higher quality of fine particles per unit of grinding during the milling stage. The resultant building product material therefore demonstrates superior properties with respect to quality, strength and durability.
In one embodiment, the product material additionally comprises one or more additional glass types. In a further embodiment, the one or more additional glass types include:
container glass (e.g. from bottles or jars), glass from automotive vehicles (e.g.
windscreens, side windows, aero glass and headlamps), glass used in cathode ray tubes, window glass, flat plate glass and mirrored glass.
It will be appreciated that the one or more additional glass types may envisage the use of glass which has not previously been used (e.g. virgin glass).
In one embodiment, the recycled glass is colour sorted prior to use. In an alternative embodiment, the recycled glass is coloured by the addition of a colouring material which may be in the form of metallic oxides, pigments, or stains.
In one embodiment, the product material comprises greater than 95% recycled glass, such as 97%. In a further embodiment, the product material comprises between approximately 15% and 30% domestic lamp glass and between approximately 70% and 85% of the one or more additional glass types. It will be appreciated that all percentages presented herein are by weight.
According to a second aspect of the invention, there is provided a method of making a building product material, the method comprising the steps of: blending specific proportions and size ranges of domestic lamp glass and other glass types with an inorganic binder to produce a product material, forming a compact of a product material;
and firing the compact.
The method of the invention therefore provides a novel method for converting recycled domestic lamp glass into commercial building products.
In one embodiment, the recycled glass is crushed prior to formation of the compact. In one embodiment, the recycled glass is primary milled following crushing. In one embodiment, the recycled glass is secondary milled following primary milling.
The glass raw material is intentionally milled to a relatively coarse size to:
i) reduce the exposed reaction surface area; ii) increase the size differential between the domestic glass particle size and the size of the one or more additional glass particles it is subsequently mixed with; iii) reduce milling energy consumption; iv) reduce wear on components of the milling equipment; v) reduce the binder component requirement, by minimizing the surface area of the milled glass; vi) produce the required texture and pore size, promoting durability in the final product.
In one embodiment, the recycled glass used in the method is milled to a particle size of less than 2000 m. In a further embodiment, the recycled glass used in the method has a particle size of less than 1000 m. For example, between 99% (e.g. 99.5%) and 100% of the glass particles used in the method will have a particle size of less than 1000 m.
In a yet further embodiment, between 25% and 35% (e.g. approximately 29% to 35%) of the glass particles used in the method has a particle size of between 500 m and 100011m.
In a yet further embodiment, between 25% and 35% (e.g. approximately 28% to 32%) of the glass particles used in the method has a particle size of between 250gm and 500 m.
In one embodiment, the product material additionally comprises one or more additional glass types. In a further embodiment, the one or more additional glass types include:
container glass (e.g. from bottles or jars), glass from automotive vehicles (e.g.
windscreens, side windows, aero glass and headlamps), glass used in cathode ray tubes, window glass, flat plate glass and mirrored glass.
It will be appreciated that the one or more additional glass types may envisage the use of glass which has not previously been used (e.g. virgin glass).
In one embodiment, the recycled glass is colour sorted prior to use. In an alternative embodiment, the recycled glass is coloured by the addition of a colouring material which may be in the form of metallic oxides, pigments, or stains.
In one embodiment, the product material comprises greater than 95% recycled glass, such as 97%. In a further embodiment, the product material comprises between approximately 15% and 30% domestic lamp glass and between approximately 70% and 85% of the one or more additional glass types. It will be appreciated that all percentages presented herein are by weight.
According to a second aspect of the invention, there is provided a method of making a building product material, the method comprising the steps of: blending specific proportions and size ranges of domestic lamp glass and other glass types with an inorganic binder to produce a product material, forming a compact of a product material;
and firing the compact.
The method of the invention therefore provides a novel method for converting recycled domestic lamp glass into commercial building products.
In one embodiment, the recycled glass is crushed prior to formation of the compact. In one embodiment, the recycled glass is primary milled following crushing. In one embodiment, the recycled glass is secondary milled following primary milling.
The glass raw material is intentionally milled to a relatively coarse size to:
i) reduce the exposed reaction surface area; ii) increase the size differential between the domestic glass particle size and the size of the one or more additional glass particles it is subsequently mixed with; iii) reduce milling energy consumption; iv) reduce wear on components of the milling equipment; v) reduce the binder component requirement, by minimizing the surface area of the milled glass; vi) produce the required texture and pore size, promoting durability in the final product.
In one embodiment, the recycled glass used in the method is milled to a particle size of less than 2000 m. In a further embodiment, the recycled glass used in the method has a particle size of less than 1000 m. For example, between 99% (e.g. 99.5%) and 100% of the glass particles used in the method will have a particle size of less than 1000 m.
In a yet further embodiment, between 25% and 35% (e.g. approximately 29% to 35%) of the glass particles used in the method has a particle size of between 500 m and 100011m.
In a yet further embodiment, between 25% and 35% (e.g. approximately 28% to 32%) of the glass particles used in the method has a particle size of between 250gm and 500 m.
In a yet further embodiment, between 15% and 25% (e.g. approximately 17% to 21%) of the glass particles used in the method has a particle size of between 125 m and 250gm.
In a yet further embodiment, between 15% and 25% (e.g. approximately 16% to 20%) of the glass particles used in the method has a particle size of less than 125 m.
According to a third aspect of the invention, there is provided a method of making a building product material, the method comprising the step of: blending the following specific proportions and size ranges of glass particles:
25-35% of glass particles having a particle size of between 500 m and 1000 m;
25-35% of glass particles having a particle size of between 250 m and 500 m;
15-25% of glass particles having a particle size of between 125 m and 250 .m;
15-25% of glass particles having a particle size of less than 125 m;
with an inorganic binder to produce a product material and forming a compact of a product material.
The identification of the above particle size ranges and compositions result in an optimal product which has both strength and durability. For example, the presence of particular amounts of the smaller particles advantageously result in softening at lower temperatures, these particles therefore adhere to the coarser particles which fixes them into position prior to sinter melting of the coarser particles.
The products are intentionally compacted and then gassed under pressure whilst still in the press, to: i) reduce the magnitude of shrinkage during firing, through elimination of porosity during pressing; ii) reduce the maturing temperature and increase final strength, through elimination of porosity during pressing; iii) reduce the binder requirement, by increasing intimacy of particle contact; iv) simplify the hardening process, by facilitating gassing through existing standard press components; v) allow the rapid hardening of the product before removal from the mould box, to increase press production output.
The products may be intentionally vibrated during the initial stages of compaction to: i) improve the efficiency of grain and particle packing within the product material; ii) reduce the applied load required to achieve the desired bulk density in the pressed product, facilitating the production of larger surface area products without a requirement for 5 increased press loading capacity.
In one embodiment, the oversize particles (e.g. those greater than 1000 m) are removed from the crushed and milled bulk glasses using vibratory screening. Particle sizes in excess of the desired percentages for the smaller size particle ranges (e.g. less than 125 m) may be removed from their respective crushed and milled bulks by air classification techniques.
In one embodiment, contaminants are removed during and/or after crushing and/or milling.
In the embodiment wherein the recycled glass is coloured by addition of a colouring material, the colouring material is mixed with the glass components after mixing with the binder.
In one embodiment, the one or more additional glass types are firstly mixed with the inorganic binder, after which, the domestic lamp glass is added and mixed. In a further embodiment, the 1000 m to 125 m particle sized glass is firstly mixed with the inorganic binder, after which, the less than 125 m particle sized glass is added and mixed.
In an alternative embodiment, the one or more additional glass types are blended with the domestic lamp glass, followed by mixing with inorganic binder. In a further embodiment, the 1000 m to 125 m particle sized glass is blended with the less than 125 m particle sized glass, followed by mixing with inorganic binder.
In one embodiment, the inorganic binder is cured during or following formation of the compact but prior to firing.
In a yet further embodiment, between 15% and 25% (e.g. approximately 16% to 20%) of the glass particles used in the method has a particle size of less than 125 m.
According to a third aspect of the invention, there is provided a method of making a building product material, the method comprising the step of: blending the following specific proportions and size ranges of glass particles:
25-35% of glass particles having a particle size of between 500 m and 1000 m;
25-35% of glass particles having a particle size of between 250 m and 500 m;
15-25% of glass particles having a particle size of between 125 m and 250 .m;
15-25% of glass particles having a particle size of less than 125 m;
with an inorganic binder to produce a product material and forming a compact of a product material.
The identification of the above particle size ranges and compositions result in an optimal product which has both strength and durability. For example, the presence of particular amounts of the smaller particles advantageously result in softening at lower temperatures, these particles therefore adhere to the coarser particles which fixes them into position prior to sinter melting of the coarser particles.
The products are intentionally compacted and then gassed under pressure whilst still in the press, to: i) reduce the magnitude of shrinkage during firing, through elimination of porosity during pressing; ii) reduce the maturing temperature and increase final strength, through elimination of porosity during pressing; iii) reduce the binder requirement, by increasing intimacy of particle contact; iv) simplify the hardening process, by facilitating gassing through existing standard press components; v) allow the rapid hardening of the product before removal from the mould box, to increase press production output.
The products may be intentionally vibrated during the initial stages of compaction to: i) improve the efficiency of grain and particle packing within the product material; ii) reduce the applied load required to achieve the desired bulk density in the pressed product, facilitating the production of larger surface area products without a requirement for 5 increased press loading capacity.
In one embodiment, the oversize particles (e.g. those greater than 1000 m) are removed from the crushed and milled bulk glasses using vibratory screening. Particle sizes in excess of the desired percentages for the smaller size particle ranges (e.g. less than 125 m) may be removed from their respective crushed and milled bulks by air classification techniques.
In one embodiment, contaminants are removed during and/or after crushing and/or milling.
In the embodiment wherein the recycled glass is coloured by addition of a colouring material, the colouring material is mixed with the glass components after mixing with the binder.
In one embodiment, the one or more additional glass types are firstly mixed with the inorganic binder, after which, the domestic lamp glass is added and mixed. In a further embodiment, the 1000 m to 125 m particle sized glass is firstly mixed with the inorganic binder, after which, the less than 125 m particle sized glass is added and mixed.
In an alternative embodiment, the one or more additional glass types are blended with the domestic lamp glass, followed by mixing with inorganic binder. In a further embodiment, the 1000 m to 125 m particle sized glass is blended with the less than 125 m particle sized glass, followed by mixing with inorganic binder.
In one embodiment, the inorganic binder is cured during or following formation of the compact but prior to firing.
In one embodiment, the inorganic binder may comprise sodium silicate, desirably in liquid form. The use of the inorganic sodium silicate binder provides a number of advantages.
Firstly, relatively small proportions of this material are required, and this is a non volatile material which can thus be handled without the requirement for fume extraction and the like. During firing the sodium silicate is incorporated into the material.
Therefore this binder and also the materials which have also already been fired at a higher temperature, produce very few emissions during firing. The sodium silicate once cured by carbon dioxide provides sufficient rigidity to the materials to be handled up to and during firing. The low proportions of sodium silicate mean that the materials can be fired immediately following pressing without any requirement for drying or other processing.
In one embodiment, less than 3.5% inorganic binder is included, and desirably less than 2%. In one embodiment, the sodium silicate is cured by carbon dioxide gas. In one embodiment, the carbon dioxide gas is introduced at a pressure of between 1 and 4 Bar, and for a time period of between one and ten seconds. In one embodiment, the pressing pressure is in the range 15 to 62 Mpa.
In one embodiment, the compact is formed by pressing, vibropressing or ramming the product material in a mould space. In one embodiment, the inorganic binder is cured following pressing, vibropressing or ramming of the compact, but whilst the compact is still in the mould space. In one embodiment, a perforated punch, other permeable item, or inlet into the mould space, is provided through which carbon dioxide is passed to enter the compact.
In one embodiment, one or more surfaces of the compact are profiled. This may be achieved by using any of a profiled punch, a profiled mould, or a profiled former provided in the mould space. Alternatively or in addition, a surface of the compact can be treated prior to firing, and desirably by any of brushing, compressed air or glass blasting.
Firstly, relatively small proportions of this material are required, and this is a non volatile material which can thus be handled without the requirement for fume extraction and the like. During firing the sodium silicate is incorporated into the material.
Therefore this binder and also the materials which have also already been fired at a higher temperature, produce very few emissions during firing. The sodium silicate once cured by carbon dioxide provides sufficient rigidity to the materials to be handled up to and during firing. The low proportions of sodium silicate mean that the materials can be fired immediately following pressing without any requirement for drying or other processing.
In one embodiment, less than 3.5% inorganic binder is included, and desirably less than 2%. In one embodiment, the sodium silicate is cured by carbon dioxide gas. In one embodiment, the carbon dioxide gas is introduced at a pressure of between 1 and 4 Bar, and for a time period of between one and ten seconds. In one embodiment, the pressing pressure is in the range 15 to 62 Mpa.
In one embodiment, the compact is formed by pressing, vibropressing or ramming the product material in a mould space. In one embodiment, the inorganic binder is cured following pressing, vibropressing or ramming of the compact, but whilst the compact is still in the mould space. In one embodiment, a perforated punch, other permeable item, or inlet into the mould space, is provided through which carbon dioxide is passed to enter the compact.
In one embodiment, one or more surfaces of the compact are profiled. This may be achieved by using any of a profiled punch, a profiled mould, or a profiled former provided in the mould space. Alternatively or in addition, a surface of the compact can be treated prior to firing, and desirably by any of brushing, compressed air or glass blasting.
A different product material may be provided just near a surface of the compact, and this can be achieved by initially filling the mould space with the different material, or finally filling the mould space with the different material.
In one embodiment, a surface of the compact is decorated and this can be achieved by spraying, atomisation, brushing, and/or printing and in particular screen printing.
In one embodiment, the compact can be finished following firing, and by any of edge grinding, surface grinding, surface polishing and/or cutting.
Material rejected during formation is preferably recycled in the method.
In one embodiment, firing takes place at a peak temperature of between 600 and 725 C, with a peak temperature dwell of between five and sixty minutes.
It will be appreciated that the materials formed can be readily pressed into required shapes to make products such as interior or exterior bricks, pavers, blocks, cladding products, or garden ware.
According to a further aspect of the invention, there is provided a building product material obtainable by a method according to any of the preceding paragraphs.
In one embodiment, the building product material is selected from interior or exterior bricks, pavers, blocks, cladding products, or garden ware.
The invention further provides a method of making an article, the method comprising using a method according to any of said preceding paragraphs, with a mould space of a required shape to form the article.
In one embodiment, a surface of the compact is decorated and this can be achieved by spraying, atomisation, brushing, and/or printing and in particular screen printing.
In one embodiment, the compact can be finished following firing, and by any of edge grinding, surface grinding, surface polishing and/or cutting.
Material rejected during formation is preferably recycled in the method.
In one embodiment, firing takes place at a peak temperature of between 600 and 725 C, with a peak temperature dwell of between five and sixty minutes.
It will be appreciated that the materials formed can be readily pressed into required shapes to make products such as interior or exterior bricks, pavers, blocks, cladding products, or garden ware.
According to a further aspect of the invention, there is provided a building product material obtainable by a method according to any of the preceding paragraphs.
In one embodiment, the building product material is selected from interior or exterior bricks, pavers, blocks, cladding products, or garden ware.
The invention further provides a method of making an article, the method comprising using a method according to any of said preceding paragraphs, with a mould space of a required shape to form the article.
The invention further provides an article made by such a method. The article may comprise a building product, including any of interior/exterior bricks, pavers, blocks, cladding or garden ware.
Embodiments of the present invention will now be described by way of example only. and with reference to the figures of the accompanying drawings in which:
Figure 1 is a cross-sectional view of a press; and Figure 2 is a cross-sectional view of a vibropress.
Two general examples relating to the formation of a compact by pressing and vibropressing will now be briefly described.
General example of pressing A compact is formed by pressing a product material formed largely of particulate recycled glass. The compact is formed in the apparatus 10 shown in Fig. 1 of the accompanying drawing. The apparatus 10 includes a press table 12 which mounts a mould box 14 which defines a pressing space 16. A lower punch 18 is provided in the bottom of the space 16.
In use, product materia120 to be pressed is located in the space 16 above the lower punch 18. An upper punch 22 is located in the space 16 on the top of the materia120, and pressing takes place.
Following pressing, the upper punch 22 is raised to the position shown in the drawing and an inflating sea124 which extends around the perimeter of the upper punch 22 and in this position remains in the space 16, is inflated. An accelerant which in this instance is carbon dioxide to cure the inorganic binder in the product material 20, is introduced from a supply 26 through a channe128 into the mould space 16. A sealing valve 30 is provided over the opening of the channel 28 leading into the space 16, to prevent product material entering the channel 28. After a required exposure time to the accelerant gas, injection of the gas is stopped and the seal 24 is deflated. The upper punch 22 is then fully withdrawn from the mould box and the hardened product is ejected from the mould box by the lower punch 18.
The inflating sea124 around the upper punch 22 ensures that the accelerant gas is retained in the mould space 16.
The product material is pressed to a specific pressure depending on the material recipe and type. The material includes a binder which in all of the following examples is sodium silicate in liquid form. The binder is cured by exposing the pressed material to carbon dioxide at specified pressures and time duration, prior to removal from the mould space.
The pressure and duration of exposure to carbon dioxide gas depends on the thickness of the material and the material permeability.
The green compact following removal from the mould space 16 is subsequently fired at required parameters for the material. Any reject compacts at any point are returned for recycling in the process.
General example of Vibropressing A compact is formed by vibropressing a product material formed largely of particulate recycled glass, in a similar manner to that described for pressing. However, in addition to the example of pressing, extra components are included in the apparatus to facilitate vibration of upper punch, lower punch and so the product material. The inclusion of vibration during pressing facilitates compaction to the required bulk density at lower applied pressure. The compact is formed in the apparatus, generally designated 32, shown in Fig. 2 of the accompanying drawings. The apparatus 32 includes a press table 12 to which is mounted a mould box 14 which defines a pressing space 16. A lower punch 18 is provided in the bottom of the space 16. The lower punch 18 is supported above the press table 12 lower isolating tubes 34.
Lower load transfer pillars 36 are located internally within the isolating tubes 34. Vibrating motors 38 are positioned on the underside of the lower punch 18. An upper punch 22 is supported below an adaptor plate 40, by isolating tubes 34, within which are located upper load transfer pillars 36. Vibrating motors 38 are positioned on the topside of the upper punch 22.
5 In use, product material 20 to be pressed is located in the space 16 above the lower punch 18. The upper punch 22 is located in the space 16 on the top of the materia120, and the vibrating motors 38 are energised. The isolating tubes 34 ensure the vibration is restricted to the required area i. e. within the pressing space 16 and between the upper and lower punches 18,22. A ram 42 provided above the adapter plate 40 is slowly extended and 10 begins to compact the product material, while the vibration encourages more efficient grain and particle packing. When the load transfer pillars 36 make solid contact and accept load, the vibrating motors 38 are de-energised. Full load pressing then takes place.
Following pressing, the upper punch 22 is raised to the position shown in the drawing and an inflatable seal 24 which extends around the perimeter of the upper punch 22 and which in the position shown, remains in the space 16, is inflated. A binder curing accelerant, for example carbon dioxide, is introduced from a supply 26 through a channel 28 into the mould space 16. A sealing valve 30 is provided over the opening of the channel 281eading into the space 16, to prevent product material entering the channel 28.
After a required exposure time to the accelerant gas, injection of the gas is stopped and the sea124 is deflated. The upper punch 22 is then fully withdrawn from the mould box and the hardened product is ejected from the mould box by the lower punch 18. The inflating seal 24 around the upper punch 22 ensures that the accelerant gas is retained in the mould space 16.
The product material is pressed to a specific pressure depending on the material recipe and type. The material includes a binder which in all of the following examples is sodium silicate in liquid form. The binder is cured by exposing the pressed material to carbon dioxide at specified pressures and time duration, prior to removal from the mould space.
Embodiments of the present invention will now be described by way of example only. and with reference to the figures of the accompanying drawings in which:
Figure 1 is a cross-sectional view of a press; and Figure 2 is a cross-sectional view of a vibropress.
Two general examples relating to the formation of a compact by pressing and vibropressing will now be briefly described.
General example of pressing A compact is formed by pressing a product material formed largely of particulate recycled glass. The compact is formed in the apparatus 10 shown in Fig. 1 of the accompanying drawing. The apparatus 10 includes a press table 12 which mounts a mould box 14 which defines a pressing space 16. A lower punch 18 is provided in the bottom of the space 16.
In use, product materia120 to be pressed is located in the space 16 above the lower punch 18. An upper punch 22 is located in the space 16 on the top of the materia120, and pressing takes place.
Following pressing, the upper punch 22 is raised to the position shown in the drawing and an inflating sea124 which extends around the perimeter of the upper punch 22 and in this position remains in the space 16, is inflated. An accelerant which in this instance is carbon dioxide to cure the inorganic binder in the product material 20, is introduced from a supply 26 through a channe128 into the mould space 16. A sealing valve 30 is provided over the opening of the channel 28 leading into the space 16, to prevent product material entering the channel 28. After a required exposure time to the accelerant gas, injection of the gas is stopped and the seal 24 is deflated. The upper punch 22 is then fully withdrawn from the mould box and the hardened product is ejected from the mould box by the lower punch 18.
The inflating sea124 around the upper punch 22 ensures that the accelerant gas is retained in the mould space 16.
The product material is pressed to a specific pressure depending on the material recipe and type. The material includes a binder which in all of the following examples is sodium silicate in liquid form. The binder is cured by exposing the pressed material to carbon dioxide at specified pressures and time duration, prior to removal from the mould space.
The pressure and duration of exposure to carbon dioxide gas depends on the thickness of the material and the material permeability.
The green compact following removal from the mould space 16 is subsequently fired at required parameters for the material. Any reject compacts at any point are returned for recycling in the process.
General example of Vibropressing A compact is formed by vibropressing a product material formed largely of particulate recycled glass, in a similar manner to that described for pressing. However, in addition to the example of pressing, extra components are included in the apparatus to facilitate vibration of upper punch, lower punch and so the product material. The inclusion of vibration during pressing facilitates compaction to the required bulk density at lower applied pressure. The compact is formed in the apparatus, generally designated 32, shown in Fig. 2 of the accompanying drawings. The apparatus 32 includes a press table 12 to which is mounted a mould box 14 which defines a pressing space 16. A lower punch 18 is provided in the bottom of the space 16. The lower punch 18 is supported above the press table 12 lower isolating tubes 34.
Lower load transfer pillars 36 are located internally within the isolating tubes 34. Vibrating motors 38 are positioned on the underside of the lower punch 18. An upper punch 22 is supported below an adaptor plate 40, by isolating tubes 34, within which are located upper load transfer pillars 36. Vibrating motors 38 are positioned on the topside of the upper punch 22.
5 In use, product material 20 to be pressed is located in the space 16 above the lower punch 18. The upper punch 22 is located in the space 16 on the top of the materia120, and the vibrating motors 38 are energised. The isolating tubes 34 ensure the vibration is restricted to the required area i. e. within the pressing space 16 and between the upper and lower punches 18,22. A ram 42 provided above the adapter plate 40 is slowly extended and 10 begins to compact the product material, while the vibration encourages more efficient grain and particle packing. When the load transfer pillars 36 make solid contact and accept load, the vibrating motors 38 are de-energised. Full load pressing then takes place.
Following pressing, the upper punch 22 is raised to the position shown in the drawing and an inflatable seal 24 which extends around the perimeter of the upper punch 22 and which in the position shown, remains in the space 16, is inflated. A binder curing accelerant, for example carbon dioxide, is introduced from a supply 26 through a channel 28 into the mould space 16. A sealing valve 30 is provided over the opening of the channel 281eading into the space 16, to prevent product material entering the channel 28.
After a required exposure time to the accelerant gas, injection of the gas is stopped and the sea124 is deflated. The upper punch 22 is then fully withdrawn from the mould box and the hardened product is ejected from the mould box by the lower punch 18. The inflating seal 24 around the upper punch 22 ensures that the accelerant gas is retained in the mould space 16.
The product material is pressed to a specific pressure depending on the material recipe and type. The material includes a binder which in all of the following examples is sodium silicate in liquid form. The binder is cured by exposing the pressed material to carbon dioxide at specified pressures and time duration, prior to removal from the mould space.
The pressure and duration of exposure to carbon dioxide gas depends on the thickness of the material and the material permeability.
Following removal from the mould space 16, the green compact is subsequently fired at required parameters for the material. Any reject compacts at any point are returned for recycling in the process.
The product material for pressing in either of the manners described above is initially prepared as follows. The glass is coarsely crushed. Contaminants may be removed after the coarse crushing operation. The glass is then primary milled and contaminants again may be removed. The glass is then secondary milled and then passed through a series of vibrating screens to provide fractions of required sizes. Oversize glass is returned to secondary milling. When required, the milled and screened glass is passed through an air classifier to separate the less than 120 m fraction from the bulk.
Following removal from the mould space 16, the green compact is subsequently fired at required parameters for the material. Any reject compacts at any point are returned for recycling in the process.
The product material for pressing in either of the manners described above is initially prepared as follows. The glass is coarsely crushed. Contaminants may be removed after the coarse crushing operation. The glass is then primary milled and contaminants again may be removed. The glass is then secondary milled and then passed through a series of vibrating screens to provide fractions of required sizes. Oversize glass is returned to secondary milling. When required, the milled and screened glass is passed through an air classifier to separate the less than 120 m fraction from the bulk.
Claims (19)
1. A building product material which comprises domestic lamp glass.
2. A material as defined in claim 1 wherein the domestic lamp glass is obtained from incandescent light bulbs and/or fluorescent lamps.
3. A material as defined in claim 1 or claim 2 which additionally comprises one or more additional glass types.
4. A material as defined in claim 3 wherein the one or more additional glass types include container glass, glass from automotive vehicles, glass used in cathode ray tubes, window glass, flat plate glass, mirrored glass and virgin glass.
5. A material as defined in any preceding claims which comprises greater than 95%
recycled glass, such as 97%.
recycled glass, such as 97%.
6. A material as defined in any of claims 3 to 5 which comprises between approximately 15% and 30% domestic lamp glass and between approximately 70%
and 85% of the one or more additional glass types.
and 85% of the one or more additional glass types.
7. A method of making a building product material, the method comprising the steps of: blending specific proportions and size ranges of domestic lamp glass and other glass types with an inorganic binder to produce a product material, forming a compact of a product material; and firing the compact.
8. A method as defined in claim 7 wherein said size ranges are less than 2000µm.
9. A method as defined in claim 7 or claim 8 wherein between 99% and 100% of the glass particles have a particle size of less than 1000µm.
10. A method as defined in any of claims 7 to 9 wherein between 25% and 35% of the glass particles have a particle size of between 500µm and 1000µm.
11. A method as defined in any of claims 7 to 10 wherein between 25% and 35%
of the glass particles have a particle size of between 250µm and 500µm.
of the glass particles have a particle size of between 250µm and 500µm.
12. A method as defined in any of claims 7 to 11 wherein between 15% and 25%
of the glass particles have a particle size of between 125µm and 250µm.
of the glass particles have a particle size of between 125µm and 250µm.
13. A method as defined in any of claims 7 to 12 wherein between 15% and 25%
of the glass particles used have a particle size of less than 125µm.
of the glass particles used have a particle size of less than 125µm.
14. A method of making a building product material, the method comprising the step of: blending the following specific proportions and size ranges of glass particles:
25-35% of glass particles having a particle size of between 500µm and 1000µm;
25-35% of glass particles having a particle size of between 250µm and 500µm;
25-35% of glass particles having a particle size of between 500µm and 1000µm;
25-35% of glass particles having a particle size of between 250µm and 500µm;
15-25% of glass particles having a particle size of between 125µm and 250µm;
15-25% of glass particles having a particle size of less than 125µm;
with an inorganic binder to produce a product material and forming a compact of a product material.
15. A method as defined in any of claims 7 to 14 wherein the inorganic binder is cured during or following formation of the compact but prior to firing.
15-25% of glass particles having a particle size of less than 125µm;
with an inorganic binder to produce a product material and forming a compact of a product material.
15. A method as defined in any of claims 7 to 14 wherein the inorganic binder is cured during or following formation of the compact but prior to firing.
16. A method as defined in claim 15 wherein said curing comprises treatment of the binder with carbon dioxide.
17. A method as defined in any of claims 7 to 16 wherein the inorganic binder comprises sodium silicate.
18. A building product material obtainable by a method according to any of claims 7 to 17.
19. A building product material as defined in claim 18 which is selected from interior or exterior bricks, pavers, blocks, cladding products, or garden ware.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002637475A CA2637475A1 (en) | 2008-07-10 | 2008-07-10 | Building product material |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002637475A CA2637475A1 (en) | 2008-07-10 | 2008-07-10 | Building product material |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2637475A1 true CA2637475A1 (en) | 2010-01-10 |
Family
ID=41565853
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002637475A Abandoned CA2637475A1 (en) | 2008-07-10 | 2008-07-10 | Building product material |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2637475A1 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2018127696A1 (en) * | 2017-01-05 | 2018-07-12 | Gent Tim | A glass briquette and forming system |
| GB2565261A (en) * | 2017-01-05 | 2019-02-13 | Gent Tim | A glass Briquette forming system |
-
2008
- 2008-07-10 CA CA002637475A patent/CA2637475A1/en not_active Abandoned
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2018127696A1 (en) * | 2017-01-05 | 2018-07-12 | Gent Tim | A glass briquette and forming system |
| GB2565261A (en) * | 2017-01-05 | 2019-02-13 | Gent Tim | A glass Briquette forming system |
| GB2565261B (en) * | 2017-01-05 | 2021-05-19 | Gent Tim | A glass Briquette forming system |
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