WO2016076811A1 - Manufacturing of porous structural building materials - Google Patents
Manufacturing of porous structural building materials Download PDFInfo
- Publication number
- WO2016076811A1 WO2016076811A1 PCT/TR2015/050165 TR2015050165W WO2016076811A1 WO 2016076811 A1 WO2016076811 A1 WO 2016076811A1 TR 2015050165 W TR2015050165 W TR 2015050165W WO 2016076811 A1 WO2016076811 A1 WO 2016076811A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- glass
- porous
- pore
- building materials
- porous structural
- Prior art date
Links
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
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/62605—Treating the starting powders individually or as mixtures
- C04B35/62625—Wet mixtures
-
- 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
- C03C11/00—Multi-cellular glass ; Porous or hollow glass or glass particles
- C03C11/007—Foam glass, e.g. obtained by incorporating a blowing agent and heating
-
- 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 invention relates to glass and/or ceramic based structural building materials porous building blocks having a porous internal structure.
- the invention in particular, relates to building materials having porous structure made of glass materials in which the porous structure can be produced under room temperature conditions.
- Porous building materials also known in today's world as light weight concrete group, has a wide array of applications especially due to its insulation property. Quartz, cement, hydrated lime, and limestone are known to be used as raw materials in these types of light weight concrete structures. These materials are ground in an aqueous media in powder form with the addition of pore forming materials and the mix made thereof is cast into molds for shaping. Aluminum metal powder is a good example for use as a pore forming material. This manufacturing method has been used for many years using room temperature conditions to develop the porous structure with the finished product strengthened by subjecting the shaped porous body to curing conditions to a high temperature and, if needed to high pressure.
- Foamed glass is another building material that possesses properties similar to light weight concrete. Foamed glass is made by mixing glass powder with a foaming agent and subjecting the shaped mix to high temperature to produce the porous structure and sinter the particles. Original or recycled flat and container glass are examples of the type of glass used to produce foam glass. Foam glass possesses most of the properties needed for an insulation material. Resistance to steam penetration and flam inability, light weight, ease of shaping, and ability to be used at high temperatures can be listed as some of the important properties. The porous glass structure provides insulating properties with light weight.
- the glass grains are mixed with pore forming particles that are preferably smaller in size than the glass grains.
- Calcium carbonate is a widely used material in this technology for the pore forming (foaming) material.
- the mixed material is thereafter shaped to give it a rigid structure. This structure is then sintered.
- the sintering temperature ranges within 800-1000°C for a typical flat or container glass chemistry. This temperature depends on the glass chemistry, which relates to the softening and working temperature range of the particular formulation.
- calcium carbonate dissociates to form CaO and C0 2 gas.
- the glass particles start binding together by forming a viscous melt.
- the evolution of the carbon dioxide gas through the dissociation of the calcium carbonate particles that are present in between the glass particles during their sintering process forms the most important basis for the formation of the pore structure.
- the main difference between light weight cement and foam glass technology is in the foam formation temperature.
- foam glass foaming occurs at high temperatures whereas light weight cement foams at around room temperature.
- the main problem in the foam glass processing described above can be described as the control over the pore formation during the high temperature heat treatment process.
- the pore forming material in the mix is expected to uniformly disperse in the matrix and to uniformly decompose at the high temperature regime. Hence, control over pore uniformity critically depends on the control over the pore forming material both at room temperature in the mix and at high temperature.
- any non-uniformity in these parameters will result in uncontrolled pore structure in the final material.
- An example of poor distribution at room temperature mixing can be the agglomeration of pore forming particles with fine particle size matrix material, resulting in poor pore size and pore distribution in the matrix.
- a good dispersion of the pore forming material in the mix can be attained by proper process controls during the powder mixing stage of the process.
- a uniform decomposition at high temperature regime would require a tight control over the heating profile and heat distribution uniformity of the part that is to be expanded. The latter control is of essence in reaching pore distribution uniformity and can be considered to demand a sophisticated furnace and heat transfer control mechanism in the heat treatment process design. In the current foam glass technology it is difficult to control the pore size and pore distribution during the sintering temperatures.
- Ketov et al. describes the "method for producing foam glass" in their patent number WO 2003/055815.
- This patent is considered to be the closest relevant description where glass powder, liquid sodium silicate (water glass), and pore forming material is mixed with water to form slurry that is then cast into molds to form the desired shapes.
- the liquid-solid suspension is hardened using acid or glass powder, without producing any pores in the mixed material. Foaming of this material is achieved at 780-900°C for a treatment period of 2-6 hours.
- the problems regarding pore size and distribution non-uniformity achieved at high temperature regime described above for conventional foam glass process is therefore applicable for this patent.
- the ultimate goal in the finished product is to achieve the highest level in thermal insulation, light weighting, and mechanical strength. Control over the pore size and pore distribution within the matrix structure is, therefore, of critical importance in achieving these goals.
- Another aim of the invention is to achieve pore formation, i.e., foaming, at room temperature conditions compared to the high sintering temperatures of the current technique.
- Another aim of the invention is to achieve improvement in the mechanical properties of the finished product through controlled pore formation (foaming) under room temperature conditions compared to what is currently known in the foam glass technology.
- Another aim of the invention is to achieve control over a uniform pore size and pore distribution in the finished product.
- Another aim of the invention is to achieve the foaming at room temperature conditions rather than the more difficult high temperature foaming of the current foam glass technology.
- Another aim of the invention is to achieve control over thermal insulation and to improve the thermal insulation properties of the finished product through the control over its pore size and pore distribution.
- Another aim of the invention is to attain a positive change in the strength and density of the finished product through controlled pore formation.
- Foam glass which can be found in form of granules or blocks, has a wide usage in today's applications. In its block form, foam glass has wide usage area in the construction industry in forms such as light weight concrete panels, building exterior applications, floors, applications for concrete insulation, pipe insulation, concrete blocks.
- Porous structures based on glass and/or ceramic raw materials are conventionally achieved through pore formation during a high temperature heat treatment process as explained in the previous sections of the invention. It has been necessary to develop a new processing method due to the lack of proper control over pore structure during the formation stage of the process, the energy intensive process design, and the poor mechanical properties of the finished product.
- the innovation in the foam glass production is in forming the pore structure at room temperature conditions using a liquid suspension. While the conventional technique uses a mixture - pressing - sintering - cooling production route the new technique uses raw materials in liquid/solid suspension mixture - casting of slurry into molds - drying - and sintering route.
- the most radical change in the proposed technique is in the removal of the foaming process in the conventional technique replaced by the foaming during the liquid/solid suspension mixture stage in the new process.
- the liquid/solid suspension can also be referred to as the casting slurry.
- the foaming process in the liquid/solid suspension mixture stage is achieved by using additives that promote or cause gas formation. This process takes place at room temperature conditions.
- this method allows a control over the uniformity in pore distribution and the pore size distribution in the slurry mix. Homogeneity of pore size and pore distribution of the structural material plays an important role in achieving improvements on its mechanical properties.
- the quality of the finished product is especially defined through its thermal insulation (thermal conductivity), strength, and density properties.
- the new process reduces the high energy demand required in the conventional foam glass technology through the use of lower sintering temperatures and reduced sintering duration. Based on this, savings in energy consumptions will also be achieved with the new process technique.
Abstract
The invention relates to glass and/or ceramic based structural building materials porous building blocks having a porous internal structure. The invention, in particular, relates to building materials having porous structure made of glass materials in which the porous structure can be produced under room temperature conditions.
Description
MANUFACTURING OF POROUS STRUCTURAL BUILDING MATERIALS
DESCRIPTION
FIELD OF INVENTION The invention relates to glass and/or ceramic based structural building materials porous building blocks having a porous internal structure.
The invention, in particular, relates to building materials having porous structure made of glass materials in which the porous structure can be produced under room temperature conditions.
BACKGROUND OF INVENTION
Porous building materials, also known in today's world as light weight concrete group, has a wide array of applications especially due to its insulation property. Quartz, cement, hydrated lime, and limestone are known to be used as raw materials in these types of light weight concrete structures. These materials are ground in an aqueous media in powder form with the addition of pore forming materials and the mix made thereof is cast into molds for shaping. Aluminum metal powder is a good example for use as a pore forming material. This manufacturing method has been used for many years using room temperature conditions to develop the porous structure with the finished product strengthened by subjecting the shaped porous body to curing conditions to a high temperature and, if needed to high pressure.
Foamed glass is another building material that possesses properties similar to light weight concrete. Foamed glass is made by mixing glass powder with a foaming agent and subjecting the shaped mix to high temperature to produce the porous structure and sinter the particles. Original or recycled flat and container glass are examples of the type of glass used to produce foam glass. Foam glass possesses most of the properties needed for an insulation material. Resistance to steam penetration and flam inability, light weight, ease of shaping, and ability to be used at high temperatures
can be listed as some of the important properties. The porous glass structure provides insulating properties with light weight.
Production methods for making foam glass has been known and been in use for a long time. In the classic method, the glass grains are mixed with pore forming particles that are preferably smaller in size than the glass grains. Calcium carbonate is a widely used material in this technology for the pore forming (foaming) material. The mixed material is thereafter shaped to give it a rigid structure. This structure is then sintered. The sintering temperature ranges within 800-1000°C for a typical flat or container glass chemistry. This temperature depends on the glass chemistry, which relates to the softening and working temperature range of the particular formulation. During this temperature treatment period, calcium carbonate dissociates to form CaO and C02 gas. At the same time, the glass particles start binding together by forming a viscous melt. The evolution of the carbon dioxide gas through the dissociation of the calcium carbonate particles that are present in between the glass particles during their sintering process forms the most important basis for the formation of the pore structure. The main difference between light weight cement and foam glass technology is in the foam formation temperature. In other words, foam glass foaming occurs at high temperatures whereas light weight cement foams at around room temperature. The main problem in the foam glass processing described above can be described as the control over the pore formation during the high temperature heat treatment process. The pore forming material in the mix is expected to uniformly disperse in the matrix and to uniformly decompose at the high temperature regime. Hence, control over pore uniformity critically depends on the control over the pore forming material both at room temperature in the mix and at high temperature. Any non-uniformity in these parameters will result in uncontrolled pore structure in the final material. An example of poor distribution at room temperature mixing can be the agglomeration of pore forming particles with fine particle size matrix material, resulting in poor pore size and pore distribution in the matrix. A good dispersion of the pore forming material in the mix can be attained by proper process controls during the powder mixing stage of
the process. A uniform decomposition at high temperature regime would require a tight control over the heating profile and heat distribution uniformity of the part that is to be expanded. The latter control is of essence in reaching pore distribution uniformity and can be considered to demand a sophisticated furnace and heat transfer control mechanism in the heat treatment process design. In the current foam glass technology it is difficult to control the pore size and pore distribution during the sintering temperatures.
Ketov et al. describes the "method for producing foam glass" in their patent number WO 2003/055815. This patent is considered to be the closest relevant description where glass powder, liquid sodium silicate (water glass), and pore forming material is mixed with water to form slurry that is then cast into molds to form the desired shapes. The liquid-solid suspension is hardened using acid or glass powder, without producing any pores in the mixed material. Foaming of this material is achieved at 780-900°C for a treatment period of 2-6 hours. The problems regarding pore size and distribution non-uniformity achieved at high temperature regime described above for conventional foam glass process is therefore applicable for this patent.
The ultimate goal in the finished product is to achieve the highest level in thermal insulation, light weighting, and mechanical strength. Control over the pore size and pore distribution within the matrix structure is, therefore, of critical importance in achieving these goals.
AIM OF THE INVENTION
Current invention aims to overcome the disadvantages described above and to provide additional processing advantages in the production of foam glass.
Another aim of the invention is to achieve pore formation, i.e., foaming, at room temperature conditions compared to the high sintering temperatures of the current technique.
Another aim of the invention is to achieve improvement in the mechanical properties of the finished product through controlled pore formation (foaming) under room
temperature conditions compared to what is currently known in the foam glass technology.
Another aim of the invention is to achieve control over a uniform pore size and pore distribution in the finished product. Another aim of the invention is to achieve the foaming at room temperature conditions rather than the more difficult high temperature foaming of the current foam glass technology.
Another aim of the invention is to achieve control over thermal insulation and to improve the thermal insulation properties of the finished product through the control over its pore size and pore distribution.
Another aim of the invention is to attain a positive change in the strength and density of the finished product through controlled pore formation.
DETAILED EXPLANATION OF THE INVENTION
In this detailed explanation, the modifications in the pore forming method towards achieving the improvements in thermal insulation and mechanical properties of the finished foam glass products will be detailed.
Foam glass, which can be found in form of granules or blocks, has a wide usage in today's applications. In its block form, foam glass has wide usage area in the construction industry in forms such as light weight concrete panels, building exterior applications, floors, applications for concrete insulation, pipe insulation, concrete blocks.
Porous structures based on glass and/or ceramic raw materials are conventionally achieved through pore formation during a high temperature heat treatment process as explained in the previous sections of the invention. It has been necessary to develop a new processing method due to the lack of proper control over pore structure during the formation stage of the process, the energy intensive process design, and the poor mechanical properties of the finished product.
The innovation in the foam glass production is in forming the pore structure at room temperature conditions using a liquid suspension. While the conventional technique uses a mixture - pressing - sintering - cooling production route the new technique uses raw materials in liquid/solid suspension mixture - casting of slurry into molds - drying - and sintering route. The most radical change in the proposed technique is in the removal of the foaming process in the conventional technique replaced by the foaming during the liquid/solid suspension mixture stage in the new process. The liquid/solid suspension can also be referred to as the casting slurry. The foaming process in the liquid/solid suspension mixture stage is achieved by using additives that promote or cause gas formation. This process takes place at room temperature conditions. In addition, this method allows a control over the uniformity in pore distribution and the pore size distribution in the slurry mix. Homogeneity of pore size and pore distribution of the structural material plays an important role in achieving improvements on its mechanical properties. The quality of the finished product is especially defined through its thermal insulation (thermal conductivity), strength, and density properties.
In addition, by achieving the foaming and the foam structure at room temperatures, the new process reduces the high energy demand required in the conventional foam glass technology through the use of lower sintering temperatures and reduced sintering duration. Based on this, savings in energy consumptions will also be achieved with the new process technique.
Claims
1. The invention is related to the production method of porous structural materials based on glass and/or ceramic raw materials called foam glass; said structural material characterized by a raw material mixing step, which is within the production stage of the said structural material, adding a slurry mixture step by mixing the raw material mixture into a liquid suspension, forming the mentioned pores during the slurry mixing stage.
2. Production of the porous structural material of claim 1, wherein said raw material and liquid suspension mixture is mixed under room temperature conditions.
3. Production of the porous structural material of claim 1, wherein said liquid suspension material is preferably water.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| TR2014/13183 | 2014-11-10 | ||
| TR201413183 | 2014-11-10 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2016076811A1 true WO2016076811A1 (en) | 2016-05-19 |
Family
ID=55070121
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/TR2015/050165 WO2016076811A1 (en) | 2014-11-10 | 2015-11-10 | Manufacturing of porous structural building materials |
Country Status (1)
| Country | Link |
|---|---|
| WO (1) | WO2016076811A1 (en) |
Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4158685A (en) * | 1978-03-16 | 1979-06-19 | Kaiser Aluminum & Chemical Corporation | Foamed insulation refractory |
| US4248810A (en) * | 1978-12-20 | 1981-02-03 | Aci Technical Centre Pty Ltd. | Foamed insulating materials and method of manufacture |
| WO1993001148A1 (en) * | 1991-07-05 | 1993-01-21 | Cornwell Charles E | Foamed cementitious composition and method of making |
| WO2003055815A1 (en) | 2001-12-25 | 2003-07-10 | Ketov Alexander A | Method for producing foamglass (variants) |
| EP1842839A1 (en) * | 2006-04-04 | 2007-10-10 | Covalent Materials Corporation | Porous body and producing method thereof |
| WO2008123671A2 (en) * | 2007-04-04 | 2008-10-16 | Sem Co., Ltd. | Ceramic foam and method for manufacturing it |
| RU2351574C2 (en) * | 2006-12-19 | 2009-04-10 | Виталий Викторович Герасимов | Method for production of autoclave-free organic-inorganic especially light concrete |
-
2015
- 2015-11-10 WO PCT/TR2015/050165 patent/WO2016076811A1/en active Application Filing
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4158685A (en) * | 1978-03-16 | 1979-06-19 | Kaiser Aluminum & Chemical Corporation | Foamed insulation refractory |
| US4248810A (en) * | 1978-12-20 | 1981-02-03 | Aci Technical Centre Pty Ltd. | Foamed insulating materials and method of manufacture |
| WO1993001148A1 (en) * | 1991-07-05 | 1993-01-21 | Cornwell Charles E | Foamed cementitious composition and method of making |
| WO2003055815A1 (en) | 2001-12-25 | 2003-07-10 | Ketov Alexander A | Method for producing foamglass (variants) |
| EP1842839A1 (en) * | 2006-04-04 | 2007-10-10 | Covalent Materials Corporation | Porous body and producing method thereof |
| RU2351574C2 (en) * | 2006-12-19 | 2009-04-10 | Виталий Викторович Герасимов | Method for production of autoclave-free organic-inorganic especially light concrete |
| WO2008123671A2 (en) * | 2007-04-04 | 2008-10-16 | Sem Co., Ltd. | Ceramic foam and method for manufacturing it |
Non-Patent Citations (1)
| Title |
|---|
| WANG MIN ET AL: "Microstructure control in ceramic foams via mixed cationic/anionic surfactant", MATERIALS LETTERS, vol. 88, 17 August 2012 (2012-08-17), pages 97 - 100, XP028940499, ISSN: 0167-577X, DOI: 10.1016/J.MATLET.2012.08.028 * |
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