WO2001070647A1 - Method of producing a hydraulic binder foam - Google Patents
Method of producing a hydraulic binder foam Download PDFInfo
- Publication number
- WO2001070647A1 WO2001070647A1 PCT/IB2001/000357 IB0100357W WO0170647A1 WO 2001070647 A1 WO2001070647 A1 WO 2001070647A1 IB 0100357 W IB0100357 W IB 0100357W WO 0170647 A1 WO0170647 A1 WO 0170647A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- hydraulic binder
- foam
- aqueous foam
- water
- polyvinyl alcohol
- 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
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
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/10—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam
- C04B38/106—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam by adding preformed foams
-
- 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
- C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
- C04B24/24—Macromolecular compounds
- C04B24/26—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- C04B24/2623—Polyvinylalcohols; Polyvinylacetates
-
- 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
Definitions
- This invention relates to a method of producing a hydraulic binder foam, and to a method of making a finished product from the hydraulic binder foam
- a hydraulic binder foam by introducing an aqueous foam into a paste or a slurry of the hydraulic binder in water
- the foam may be produced in a foam generator by passing a stream of water containing a foaming agent such as a surfactant, a protein or a hydrophihc polymer, through a ventu ⁇ , in which air is injected into the passing stream to generate a stable foam
- PCT/GB 98/03556 to Windsor Technologies Limited teaches a method of making a composite product by mixing (i) a hydraulic binder (n) finely divided lignocellulosic fibres and (in) water optionally containing a polyvinyl alcohol, the water being present in an amount sufficient to form a paste, introducing a foam generated from a polyvinyl alcohol into the paste and mixing to form a foamed product, forming the foamed product into a desired shape, and allowing the hydraulic binder to set to form the composite product
- the composite product may be for example a building board or the like
- a method of producing a hydraulic binder foam for the subsequent manufacture of a finished product including the steps of
- step (b) mixing the aqueous foam of step (a) with a hydraulic binder in finely divided dry particle form to produce the hydraulic binder foam
- the foaming agent preferably comprises polyvinyl alcohol or a combination of polyvinyl alcohol and a protein such as gelatin
- the aqueous foam may be added to the hydraulic binder either batchwise or continuously preferably in- a paddle-type mixer or the hydraulic binder may be added to the aqueous foam either batchwise or continuously
- the aqueous foam may also be mixed with a filler in finely divided dry particle or fibre form, the filler being selected from the group consisting of
- the filler may be mixed with the hydraulic binder before being mixed with the aqueous foam, or the filler and the hydraulic binder may simultaneously be mixed with the aqueous foam or the filler may be mixed with the foam before or after the hydraulic binder has been mixed with the foam
- a method of making a finished product from a hydraulic binder foam produced as described above including the steps of
- a hydrauhc binder foam is prepared by mixing a pre-generated aqueous foam comprising water and a foaming agent, with dry components, viz, the hydraulic binder and optionally a filler
- the first step is thus to prepare the aqueous foam
- the aqueous foam is prepared from water and a foaming agent comprising a hydrophihc polymer which is soluble miscible or dispersible in water
- the hydrophihc polymer is used in an amount of from 1 % to 10% inclusive by mass of the water
- hydrophihc polymers examples include modified starches natural carbohydrates such as gums or seaweed coloids semi-synthetic polymers such as the cellulose ethers hydrogels such as homo- and co- polymer derivatives of acrylic and methacryhc acid or the polyacrylamide polyacrylate co-polymers, and dispersions such as polyvinyl acetate and styrenated acrylics
- the preferred hydrophihc polymer is polyvinyl alcohol which may be used in an amount of from 1 % to 10% inclusive by mass of the water or preferably in an amount of from 3% to 8% inclusive by mass of the water
- the volume of the aqueous foam produced from a given quantity of water is strongly influenced by the viscosity of the polyvinyl alcohol used
- the preferred polyvinyl alcohols are those having a viscosity of from 10 to 75 mPa s inclusive, determined at a 5% concentration in water at 20°C These include the partially hydrohsed grades with a degree of hydrolysis mol % in the range of 82% to 90%, preferably about 87%, with an ester value mg/KOH/g of 140, and residual acetyl content weight percent of 10,7
- suitable polyvinyl alcohols are the Mowiol grades by Cla ⁇ ant, particularly grade 8/88 which has a viscosity of 12 mPa s grade 1 8/88 which is the most preferred polyvinyl alcohol and which has a viscosity of 55 mPa s, and grade 23/88 which has a viscosity of 75 mPa s
- the choice of foaming agent to be used will depend on the nature of the hydraulic binder and its pH as well as the relative hardness of the water to be used
- foaming agent such as for example polyvinyl alcohol
- protein compound such as gelatin
- the aqueous foam may be prepared in any suitable manner, such as for example, using a foam generator which involves passing a stream of water containing the foaming agent through a ventu ⁇ , in which air is injected into the passing stream, to generate a stable foam
- the aqueous foam may be produced by mechanical entrainment of air into the water containing the foaming agent
- step (b) is to mix the aqueous foam of step (a) with a hydraulic binder in finely divided dry particle form
- hydraulic binder an inorganic binder which in the presence of water hydrates and sets
- the hydraulic binder may be selected from the group consisting of a hydraulic cement, a calcium sulphoaluminate cement a high alumina cement, a gypsum cement, calcium sulphate hemihydrate in either the alpha or beta form, an alkali silicate, magnesium oxychlonde, magnesium oxysulphate, a pozzolanic binder such as finely ground furnace slag or fly ash silica fume, or a mixture of two or more thereof
- the hydraulic binder must be used in finely divided dry particle form This means that 98% or more of the hydraulic binder particles must pass through a 200 mesh or finer (i e a 74 micron screen or finer)
- Portland cement typically has a Blame of 475, i e 475m 2 per kg
- the aqueous foam and the hydraulic binder are mixed in a proportion of from 20 parts oy weight of the aqueous foam to 100 parts by weight of hydraulic binder up to and including 120 parts by weight of the aqueous foam to 100 parts bv weight of the hydraulic binder
- the filler may comprise dry inorganic particles or fibres such as for example silica, diatomaceous earth expanded per te, exfoliated vermicultte refractories such as alumina or grog, ceramic fibres, mineral fibres and glass fibres
- dry inorganic particles or fibres such as for example silica, diatomaceous earth expanded per te, exfoliated vermicultte refractories such as alumina or grog, ceramic fibres, mineral fibres and glass fibres
- the filler may also comprise dry natural organic particles or fibres such as paper fibres, e g common mixed paper waste paper mill sludge pulp cellulose and the like, or agricultural fibres such as fibres from extracted wattle bark, palm fibre, kenaf and natural organic particles such as ground cork, bark, sawdust and ground seed
- the filler may also comprise dry synthetic organic particles or fibres such as organic particles formed from milled thermoplastic foams e g PVC polystyrene or expanded polystyrene foams milled thermosetting foams e g phenol formaldehyde resole or polyurethane rigid or flexible foams and organic fibres such as carbon aramid polyacrylonit ⁇ le polyvinyl alcohol polyethylene, polypropylene, polyester and acrylics
- the fibres When the filler comprises synthetic fibres, the fibres preferably have a diameter of about 20 to 40 microns inclusive and a length of from 4 to 6 mm inclusive
- the fibres When the filler comprises natural fibres the fibres preferably have a diameter of about 20 to 40 microns inclusive and a length of from 6 to 8 mm inclusive
- the filler comprises particles, the particles preferably have a maximum dimension of less than 0,5 mm, more preferably a size similar to the size of the hydraulic binder, viz, 98% passing through a 200 mesh
- suitable fillers are silica flour in Portland cement where the product is subsequently to be autoclaved bubble alumina in a calcium aluminate cement to improve the refractory nature of the product and expanded vermiculite in a high alumina cement to improve the refractory nature of the product (in) when the filler is a fibre then the fibres reinforce the product and may also propagate ⁇ mproved sound attenuation or noise reduction coefficients of the final product (iv) to enhance foam stability by air bubble entrapment in which case a suitable filler is cellulose fibre particularly paper mill sludge or common mixed paper waste
- aqueous foam and the hydraulic binder/filler may be mixed in various ways.
- the various possibilities are set out below
- the aqueous foam is added to the hydraulic binder optionally mixed with the filler, either batchwise or continuously
- the aqueous foam is added to the hydraulic binder in a paddle-type mixer
- a dry particulate material i e the hydraulic binder optionally with the filler to a pre ⁇ enerated aqueous foam
- additives that promote resistance to high relative humidity minimising softening back or sagging, such as the anhydrous si cones based on hydrogen polysiloxane added in an amount of from 0 1 % to 0 5% inclusive by mass of the hydraulic binder
- an aqueous fluorochemical dispersion such as Zonyl 8740 or a fluorochemical solution in water such as Zonyl 9027, both by du Pont, may be mixed with the foamed binder, or more preferably post-applied as a surface or subsurface water repellant at concentrations by mass of mixing water in the range 1 % to 12%, more usually 2% to 6% inclusive
- Reinforcing resins such as a dispersion of a natural or synthetic latex, polyvinyl acetate, a styrenated acrylic or the like
- hydraulic binder is a calcium aluminate cement
- a gelation agent for example lithium carbonate or a proportion of Portland cement
- the hydraulic binder foam may be formed into a desired shape, for example by conventional techniques such as casting or pouring or otherwise dispensing into a suitable mould or on to a moving belt or the like.
- step (d) of the method of the invention the hydraulic binder is allowed to set to form the final product Thereafter, the final product may be used directly or be cured and dried and thereafter machined into suitable s ⁇ zes " and the like
- An aqueous foam is generated from a 5% solution of partially hydro sed polyvinyl alcohol, e g Mowiol 4/88 by Clanant
- a dry mix is formed of a hydraulic binder e g calcium sulphate (1-hem ⁇ -hydrate with acrylonitrile fibres e g Dolanit by Acordis Kelheim of Germany These fibres are approximately 4mm in length and 6 7dtex
- the hydraulic binder foam is formed into a desired shape for example, a board shape and the hydraulic binder is then allowed to set to form the finished product
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Inorganic Chemistry (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
Abstract
A method of producing a hydraulic binder foam for the subsequent manufacture of a finished product, such as a foamed building board, is disclosed. An aqueous foam is prepared from water and a foaming agent comprising a hydrophilic polymer which is soluble, miscible or dispersible in water, preferably polyvinyl alcohol. The aqueous foam is mixed with a hydraulic binder in finely divided dry particle form, to produce the hydraulic binder foam. The hydraulic binder foam may then be formed into a desired shape and the hydraulic binder allowed to set to form the finished product.
Description
METHOD OF PRODUCING A -HYDRAULIC BINDER FOAM
BACKGROUND OF THE INVENTION
This invention relates to a method of producing a hydraulic binder foam, and to a method of making a finished product from the hydraulic binder foam
It is well known to produce a hydraulic binder foam by introducing an aqueous foam into a paste or a slurry of the hydraulic binder in water The foam may be produced in a foam generator by passing a stream of water containing a foaming agent such as a surfactant, a protein or a hydrophihc polymer, through a ventuπ, in which air is injected into the passing stream to generate a stable foam
For example PCT/GB 98/03556 to Windsor Technologies Limited teaches a method of making a composite product by mixing (i) a hydraulic binder (n) finely divided lignocellulosic fibres and (in) water optionally containing a polyvinyl alcohol, the water being present in an amount sufficient to form a paste, introducing a foam generated from a polyvinyl alcohol into the paste and mixing to form a foamed product, forming the foamed product into a desired shape, and allowing the hydraulic binder to set to form the composite product
The composite product may be for example a building board or the like
Another example of the manufacture of a product from a hydraulic binder foam is disclosed in United States Patent No 4 518 652 to United States Gypsum Company
A further example is disclosed in United States Patent No 6 046 255 to Gray et al A foam of very small microscopic bubbles of surfactant each bubble containing a small quantity of water is mixed with a water/cement mixture having a water to cement ratio of less than 0 33 The small bubbles have a ball-bearing effect on tne smaller cement and sand particles increasing plasticity or flowability thus reducing the water requirements of the mixture The foamed cement mixture is laid to form a desired concrete structure and the bubbles disintegrate or transform to leave voids of similar size uniformly dispersed throughout the concrete structure
There is, however always a need for another method of producing a hydraulic binder foam
SUMMARY OF THE INVENTION
According to a first aspect of the invention, there is provided a method of producing a hydraulic binder foam for the subsequent manufacture of a finished product, including the steps of
(a) preparing an aqueous foam from water and a foaming agent comprising a hydrophihc polymer which is soluble miscible or dispersible in water and
(b) mixing the aqueous foam of step (a) with a hydraulic binder in finely divided dry particle form to produce the hydraulic binder foam
The foaming agent preferably comprises polyvinyl alcohol or a combination of polyvinyl alcohol and a protein such as gelatin
In step (b) the aqueous foam may be added to the hydraulic binder either batchwise or continuously preferably in- a paddle-type mixer or the hydraulic binder may be added to the aqueous foam either batchwise or continuously
In step (b) the aqueous foam may also be mixed with a filler in finely divided dry particle or fibre form, the filler being selected from the group consisting of
(i) dry inorganic particles or fibres
(II) dry natural organic particles or fibres and
(in) dry synthetic organic particles or fibres
In this case, the filler may be mixed with the hydraulic binder before being mixed with the aqueous foam, or the filler and the hydraulic binder may simultaneously be mixed with the aqueous foam or the filler may be mixed with the foam before or after the hydraulic binder has been mixed with the foam
According to a second aspect of the invention there is provided a method of making a finished product from a hydraulic binder foam produced as described above, including the steps of
(c) forming the hydraulic binder foam into a desired shape, and
(d) allowing the hydraulic binder to set to form the finished product
DESCRIPTION OF EMBODIMENTS
The crux of the invention is that a hydrauhc binder foam is prepared by mixing a pre-generated aqueous foam comprising water and a foaming agent, with dry components, viz, the hydraulic binder and optionally a filler
The first step is thus to prepare the aqueous foam
The aqueous foam is prepared from water and a foaming agent comprising a hydrophihc polymer which is soluble miscible or dispersible in water
The hydrophihc polymer is used in an amount of from 1 % to 10% inclusive by mass of the water
Examples of suitable hydrophihc polymers are modified starches natural carbohydrates such as gums or seaweed coloids semi-synthetic polymers such as the cellulose ethers hydrogels such as homo- and co- polymer derivatives of acrylic and methacryhc acid or the polyacrylamide polyacrylate co-polymers, and dispersions such as polyvinyl acetate and styrenated acrylics
The preferred hydrophihc polymer is polyvinyl alcohol which may be used in an amount of from 1 % to 10% inclusive by mass of the water or preferably in an amount of from 3% to 8% inclusive by mass of the water The volume of the aqueous foam produced from a given quantity of water is strongly influenced by the viscosity of the polyvinyl alcohol used
The preferred polyvinyl alcohols are those having a viscosity of from 10 to 75 mPa s inclusive, determined at a 5% concentration in water at 20°C These include the partially hydrohsed grades with a degree of hydrolysis mol % in the range of 82% to 90%, preferably about 87%, with an ester value mg/KOH/g of 140, and residual acetyl content weight percent of 10,7 Examples of suitable polyvinyl alcohols are the Mowiol grades by Claπant, particularly grade 8/88 which has a viscosity of 12 mPa s grade 1 8/88 which is the most preferred polyvinyl alcohol and which has a viscosity of 55 mPa s, and grade 23/88 which has a viscosity of 75 mPa s
The choice of foaming agent to be used will depend on the nature of the hydraulic binder and its pH as well as the relative hardness of the water to be used
In certain circumstances it may be advisable to use a combination of the foaming agent, such as for example polyvinyl alcohol, with a protein compound such as gelatin
The aqueous foam may be prepared in any suitable manner, such as for example, using a foam generator which involves passing a stream of water containing the foaming agent through a ventuπ, in which air is injected into the passing stream, to generate a stable foam Alternatively, the aqueous foam may be produced by mechanical entrainment of air into the water containing the foaming agent
The second step of the method of the invention viz step (b) is to mix the aqueous foam of step (a) with a hydraulic binder in finely divided dry particle form
By "hydraulic binder" is meant an inorganic binder which in the presence of water hydrates and sets The hydraulic binder may be selected from the group consisting of a hydraulic cement, a calcium sulphoaluminate cement a high alumina cement, a gypsum cement, calcium sulphate hemihydrate in either the alpha or beta form, an alkali silicate, magnesium oxychlonde, magnesium oxysulphate, a pozzolanic binder such as finely ground furnace slag or fly ash silica fume, or a mixture of two or more thereof
The hydraulic binder must be used in finely divided dry particle form This means that 98% or more of the hydraulic binder particles must pass through a 200 mesh or finer (i e a 74 micron screen or finer) For example Portland cement typically has a Blame of 475, i e 475m2 per kg
Preferably, the aqueous foam and the hydraulic binder are mixed in a proportion of from 20 parts oy weight of the aqueous foam to 100 parts by weight of hydraulic binder up to and including 120 parts by weight of the aqueous foam to 100 parts bv weight of the hydraulic binder
For example, when 25 parts by weight of an aqueous foam are mixed with 100 parts by weight of Portland cement, there results a finished product with a density of about 900 kg/m3 When 45 parts by weight of an aqueous foam are mixed with 100 parts by weight of Portland cement there results a finished product with a density of aoout 600 kg/m3 When 75 parts by weight of an aqueous foam are mixed with 1 00 parts by weight of gypsum (calcium sulphate hemi-hydrate) there results a finished product with a density of about 300 kg/m3 When 100 parts weight of an aqueous foam are mixed with 100 parts by weight of gypsum there results a finished product with a density of about 170 kg/m3
In addition to the hydraulic binder which must be in finely divided dry particle form, there may also be added to the aqueous foam a filler in finely divided dry particle or fibre form
The filler may comprise dry inorganic particles or fibres such as for example silica, diatomaceous earth expanded per te, exfoliated vermicultte refractories such as alumina or grog, ceramic fibres, mineral fibres and glass fibres
The filler may also comprise dry natural organic particles or fibres such as paper fibres, e g common mixed paper waste paper mill sludge pulp cellulose and the like, or agricultural fibres such as fibres from extracted wattle bark, palm fibre, kenaf and natural organic particles such as ground cork, bark, sawdust and ground seed
The filler may also comprise dry synthetic organic particles or fibres such as organic particles formed from milled thermoplastic foams e g PVC polystyrene or expanded polystyrene foams milled thermosetting foams e g phenol formaldehyde resole or polyurethane rigid or flexible foams and organic fibres such as carbon aramid polyacrylonitπle polyvinyl alcohol polyethylene, polypropylene, polyester and acrylics
When the filler comprises synthetic fibres, the fibres preferably have a diameter of about 20 to 40 microns inclusive and a length of from 4 to 6 mm inclusive When the filler comprises natural fibres the fibres preferably have a diameter of about 20 to 40 microns inclusive and a length of from 6 to 8 mm inclusive When the filler comprises particles, the particles preferably have a maximum dimension of less than 0,5 mm, more preferably a size similar to the size of the hydraulic binder, viz, 98% passing through a 200 mesh
The purpose of adding one or more of the fillers is as follows
(i) to contribute syntactic voids in the hydraulic binder foam as a function of the low bulk density of the filler Examples of suitable fillers in this regard are exfoliated vermiculite ground phenol formaldehyde resole resin foam polystyrene re-gπnd, cork and flexible polyurethane re-gπnd
(II) to propagate improved properties of the hydraulic binder foam Examples of suitable fillers here are silica flour in Portland cement where the product is subsequently to be autoclaved bubble alumina in a calcium aluminate cement to improve the refractory nature of the product and expanded vermiculite in a high alumina cement to improve the refractory nature of the product
(in) when the filler is a fibre then the fibres reinforce the product and may also propagate~ιmproved sound attenuation or noise reduction coefficients of the final product (iv) to enhance foam stability by air bubble entrapment in which case a suitable filler is cellulose fibre particularly paper mill sludge or common mixed paper waste
As indicated above, the aqueous foam and the hydraulic binder/filler may be mixed in various ways The various possibilities are set out below
(1 ) The aqueous foam is added to the hydraulic binder optionally mixed with the filler, either batchwise or continuously
(2) The hydraulic binder is added to the aqueous foam either batchwise or continuously
(3) The hydraulic binder is mixed with the filler and the mixture is then added to the aqueous foam either batchwise or continuously
(4) The hydraulic binder and the filler are simultaneously added to the aqueous foam either batchwise or continuously
(5) The hydraulic binder is added to the aqueous foam whereafter the filler is added to the aqueous foam (or vice versa) either batchwise or continuously
Preferably, the aqueous foam is added to the hydraulic binder in a paddle-type mixer
It is surprising that the adding of a dry particulate material, i e the hydraulic binder optionally with the filler to a pre^enerated aqueous foam, produces a hydraulic binder foam with superior properties to that which can be produced by adding an aqueous foam to a slurry or a paste i e a wetted product containing the hydraulic binder
In other words, it has been found that pre-generating an aqueous foam and then adding to this directly the dry product, or alternatively, adding the dry product to the pre-generated aqueous foam with mixing produces an excellent hydraulic binder foam with a dry density in the range of from 170kg/m3 upwards, with very small ceil sizes The process is rapid with minimal equipment costs and is thus economically efficient, and dry to wet constituent ratios are consistently and easily controllable It is a significant advantage that the water to hydraulic binder ratio may be reduced significantly as compared to wet-to-wet processes, more particularly at the lower finished product densities The reason for this is that a paste does not have to be pre-formed and at pourable consistencies in order to minimise surface tension
It is particularly surprising that this method of mixing is effective in that one would expect the addition of a dry particle to an aqueous foam more particularly a particle not soluble in water would result in immediate foam collapse or at least the coalescence of air cells resulting in a coarse variable and unreliable hydraulic binder foam As indicated above this is not the case with the method of the invention
Various other components may be added into the hydraulic binder foam to provide the hydraulic binder foam with specific desired properties These additives include
(i) Additives that promote resistance to high relative humidity minimising softening back or sagging, such as the anhydrous si cones based on hydrogen polysiloxane added in an amount of from 0 1 % to 0 5% inclusive by mass of the hydraulic binder Alternatively an aqueous fluorochemical dispersion such as Zonyl 8740 or a fluorochemical solution in water such as Zonyl 9027, both by du Pont, may be mixed with the foamed binder, or more preferably post-applied as a surface or subsurface water repellant at concentrations by mass of mixing water in the range 1 % to 12%, more usually 2% to 6% inclusive
(II) Reinforcing resins such as a dispersion of a natural or synthetic latex, polyvinyl acetate, a styrenated acrylic or the like
(in) When the hydraulic binder is Portland cement, a solution of sodium silicate in order to propagate gelling The solution may be added in an amount of from 1 % to 7% by mass of the hydraulic binder
(iv) Where the hydraulic binder is a calcium aluminate cement, a gelation agent, for example lithium carbonate or a proportion of Portland cement
After steps (a) and (b) of the method of the invention, in step (c), the hydraulic binder foam may be formed into a desired shape, for example by conventional techniques such as casting or pouring or otherwise dispensing into a suitable mould or on to a moving belt or the like.
In step (d) of the method of the invention, the hydraulic binder is allowed to set to form the final product
Thereafter, the final product may be used directly or be cured and dried and thereafter machined into suitable sιzes"and the like
An example of the invention will now be given
EXAMPLE
An aqueous foam is generated from a 5% solution of partially hydro sed polyvinyl alcohol, e g Mowiol 4/88 by Clanant
A dry mix is formed of a hydraulic binder e g calcium sulphate (1-hemι-hydrate with acrylonitrile fibres e g Dolanit by Acordis Kelheim of Germany These fibres are approximately 4mm in length and 6 7dtex
900gm of the calcium sulphate (i-hemi-hydrate mixed with 12gm of the acrylonitrile fibres are added to 800gm of the pre-generated aqueous foam and the whole is mixed with high shear and with a driven propeller mixter to produce a very fine creamed foam, which is pumpable stable for lengthy periods, and which provides a consistent end product with an open cellular structure and very fine cell size and a dry density of 300kg/m3 This mix yields the minimum obtainable water to calcium sulphate (i-hemi-hydrate ratio in the pourable stable wet foam mix for the final density required
Thereafter, the hydraulic binder foam is formed into a desired shape for example, a board shape and the hydraulic binder is then allowed to set to form the finished product
Claims
1 A method of producing a hydraulic binder foam for the subsequent manufacture of a finished product including the steps of
(a) preparing an aqueous foam from water and a foaming agent comprising a hydrophihc polymer which is soluble miscible or dispersible in water, and
(b) mixing the aqueous foam of step (a) with a hydraulic binder in finely divided dry particle form to produce the hydraulic binder foam
A method according to claim 1 wherein the foaming agent comprises polyvinyl alcohol
A method according to claim 2 wherein the polyvinyl alcohol has a viscosity of from 10 to 75 mPa s inclusive at a 5% concentration in water at 20°C
A method according to claim 2 or claim 3 wherein the foaming agent comprises polyvinyl alcohol and a protein
A method according to any one of claims 2 to 4 wherein in step (a) the polyvinyl alcohol is used in an amount of from 1 % to 10% inclusive by mass of the water
A method according to any one of claims 1 to 5 wherein the hydraulic binder is selected from the group consisting of a hydraulic cement, a calcium sulphoaluminate cement, a high alumina cement a gypsum cement, calcium sulphate hemihydrate in either the alpha or beta form,
A
an alkali silicate magnesium oxychlonde magnesium oxysulphate a pozzolanic binder silica fume and a mixture of two or more thereof
A method according to any one of claims 1 to 6 wherein in step (b) the aqueous foam is also mixed with a filler in finely divided dry particle or fibre form, the filler being selected from the group consisting of (i) dry inorganic particles or fibres (n) dry natural or organic particles or fibres (in) dry synthetic organic particles or fibres, or a mixture of two or more thereof
A method according to any one of claims 1 to 7 wherein in step (b) the aqueous foam is added to the hydraulic binder either batchwise or continuously
A method according to claim 8 wherein in step (b) the aqueous foam is added to the hydraulic binder in a paddle-type mixer
A method according to any one of claims 1 to 7 wherein in step (b) the hydraulic binder is added to the aqueous foam either batchwise or continuously
A method of making a finished product from a hydraulic binder foam including the steps of
(a) preparing an aqueous foam from water and a foaming agent comprising a hydrophihc polymer which is soluble miscible or dispersible in water,
(b) mixing the aqueous foam of step (a) with a hydraulic binder in finely divided dry particle form, to produce the hydraulic binder foam,
(c) forming the hydraulic binder foam into a desired shape and
(d) allowing the hydraulic binder to set to form the finished product
A method according to claim 1 1 wherein the foaming agent comprises polyvinyl alcohol
A method according to claim 12 wherein the polyvinyl alcohol has a viscosity of from 10 to 75 mPa s inclusive at a 5% concentration in water at 20°C
A method according to claim 12 or claim 1 3 wherein the foaming agent comprises polyvinyl alcohol and a protein
A method according to any one of claims 12 to 14 wherein the polyvinyl alcohol is used in an amount of from 1 % to 10% inclusive by mass of the water
A method according to any one of claims 1 1 to 15 wherein the hydraulic binder is selected from the group consisting of a hydraulic cement, a calcium sulphoaluminate cement, a high alumina cement a gypsum cement, calcium sulphate hemihydrate in either the alpha or beta form, an alkali silicate magnesium oxychlonde, magnesium oxysulphate, a pozzolanic binder silica fume, and a mixture of two or more thereof
A method according to any one of claims 1 1 to 16 wherein in step (b) the aqueous foam is also mixed with a filler in finely divided dry particle or fibre form, the filler being selected from the group consisting of (i) dry inorganic particles or fibres, (n) dry natural organic particles or fibres, (in) dry synthetic organic particles or fibres, or a mixture of two or more thereof
A method according to any one of claims 1 1 to 17 wherein in step (b) the aqueous foam is added to the hydraulic binder either batchwise or continuously
A method according to claim 18 wherein in step (b) the aqueous foam is added to the hydraulic binder in a paddle-type mixer
A method according to any one of claims 1 1 to 17 wherein in step (b) the hydraulic binder is added to the aqueous foam either batchwise or continuously
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU40966/01A AU4096601A (en) | 2000-03-22 | 2001-03-14 | Method of producing a hydraulic binder foam |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| ZA2000/1435 | 2000-03-22 | ||
| ZA200001435 | 2000-03-22 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2001070647A1 true WO2001070647A1 (en) | 2001-09-27 |
Family
ID=25588678
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/IB2001/000357 Ceased WO2001070647A1 (en) | 2000-03-22 | 2001-03-14 | Method of producing a hydraulic binder foam |
Country Status (2)
| Country | Link |
|---|---|
| AU (1) | AU4096601A (en) |
| WO (1) | WO2001070647A1 (en) |
Cited By (14)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6780230B2 (en) | 2000-09-04 | 2004-08-24 | W.R. Grace & Co. -Conn. | Foamed fireproofing composition and method |
| WO2006012651A3 (en) * | 2004-07-27 | 2006-03-09 | Tower Technology Holdings Pty | A hydraulic binder product |
| US7427321B2 (en) | 2001-09-03 | 2008-09-23 | W.R. Grace & Co. -Conn. | Foamed fireproofing composition and method |
| FR2955790A1 (en) * | 2010-02-03 | 2011-08-05 | Saint Gobain Weber | METHOD FOR PROJECTING A FOAM MATERIAL AND COATING OBTAINED FROM SUCH A METHOD |
| WO2012092170A1 (en) * | 2010-12-29 | 2012-07-05 | United States Gypsum Company | Method of improving gypsum board strength |
| CN103232209A (en) * | 2013-04-25 | 2013-08-07 | 董源 | Inorganic fiber hard foam-plastic heat-insulating material and preparation method thereof |
| DE202012104490U1 (en) | 2012-11-20 | 2014-02-27 | Tremco Illbruck Productie B.V. | Foam composition for building |
| WO2015181479A1 (en) | 2014-05-27 | 2015-12-03 | Saint-Gobain Weber | Method for manufacturing a composition of lightweight concrete or mortar |
| WO2017098483A1 (en) * | 2015-12-11 | 2017-06-15 | Zetland Technologies Limited | Aggregation of small particles |
| WO2017098484A1 (en) * | 2015-12-11 | 2017-06-15 | Zetland Technologies Limited | Fibrous composite materials |
| WO2019038105A1 (en) | 2017-08-23 | 2019-02-28 | Basf Se | Hybrid foam |
| WO2019121671A1 (en) | 2017-12-20 | 2019-06-27 | Basf Se | Stabilized foamable aqueous suspension for producing inorganic-organic hybrid foams |
| EP4624924A1 (en) | 2024-03-25 | 2025-10-01 | Sika Technology AG | Method and system for the formulation or production of a mineral foam |
| EP4628671A1 (en) | 2024-04-02 | 2025-10-08 | Sika Technology AG | Sandwich panels filled with mineral foam, their manufacture and use |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH04260674A (en) * | 1991-02-08 | 1992-09-16 | Kanegafuchi Chem Ind Co Ltd | Production of lightweight cured product |
| JPH05254959A (en) * | 1992-03-13 | 1993-10-05 | Sekisui Chem Co Ltd | Method for producing hydraulic inorganic composition and method for producing molded body |
-
2001
- 2001-03-14 WO PCT/IB2001/000357 patent/WO2001070647A1/en not_active Ceased
- 2001-03-14 AU AU40966/01A patent/AU4096601A/en not_active Abandoned
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH04260674A (en) * | 1991-02-08 | 1992-09-16 | Kanegafuchi Chem Ind Co Ltd | Production of lightweight cured product |
| JPH05254959A (en) * | 1992-03-13 | 1993-10-05 | Sekisui Chem Co Ltd | Method for producing hydraulic inorganic composition and method for producing molded body |
Non-Patent Citations (2)
| Title |
|---|
| DATABASE CHEMICAL ABSTRACTS [online] XP002173111, retrieved from STN Database accession no. 118:10827 * |
| DATABASE WPI Week 199344, Derwent World Patents Index; AN 1993-348253, XP002173112 * |
Cited By (23)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6780230B2 (en) | 2000-09-04 | 2004-08-24 | W.R. Grace & Co. -Conn. | Foamed fireproofing composition and method |
| US7427321B2 (en) | 2001-09-03 | 2008-09-23 | W.R. Grace & Co. -Conn. | Foamed fireproofing composition and method |
| US8535583B2 (en) | 2004-07-27 | 2013-09-17 | Tower Technology Holdings (Pty) Ltd. | Hydraulic binder product |
| WO2006012651A3 (en) * | 2004-07-27 | 2006-03-09 | Tower Technology Holdings Pty | A hydraulic binder product |
| EP2311783A1 (en) * | 2004-07-27 | 2011-04-20 | Tower Technology Holdings (Pty) Limited | A hydraulic binder product |
| FR2955790A1 (en) * | 2010-02-03 | 2011-08-05 | Saint Gobain Weber | METHOD FOR PROJECTING A FOAM MATERIAL AND COATING OBTAINED FROM SUCH A METHOD |
| WO2011095718A1 (en) * | 2010-02-03 | 2011-08-11 | Saint-Gobain Weber | Method for spraying foam material, and coating obtained from such a method |
| JP2014508665A (en) * | 2010-12-29 | 2014-04-10 | ユナイテッド・ステイツ・ジプサム・カンパニー | How to improve gypsum board strength |
| WO2012092170A1 (en) * | 2010-12-29 | 2012-07-05 | United States Gypsum Company | Method of improving gypsum board strength |
| DE202012104490U1 (en) | 2012-11-20 | 2014-02-27 | Tremco Illbruck Productie B.V. | Foam composition for building |
| WO2014079780A2 (en) | 2012-11-20 | 2014-05-30 | Tremco Illbruck Productie B.V. | Foam composition for construction use |
| CN103232209A (en) * | 2013-04-25 | 2013-08-07 | 董源 | Inorganic fiber hard foam-plastic heat-insulating material and preparation method thereof |
| WO2015181479A1 (en) | 2014-05-27 | 2015-12-03 | Saint-Gobain Weber | Method for manufacturing a composition of lightweight concrete or mortar |
| FR3021652A1 (en) * | 2014-05-27 | 2015-12-04 | Saint Gobain Weber | PROCESS FOR PRODUCING A CONCRETE COMPOSITION OR ALLOY MORTAR |
| WO2017098483A1 (en) * | 2015-12-11 | 2017-06-15 | Zetland Technologies Limited | Aggregation of small particles |
| WO2017098484A1 (en) * | 2015-12-11 | 2017-06-15 | Zetland Technologies Limited | Fibrous composite materials |
| WO2019038105A1 (en) | 2017-08-23 | 2019-02-28 | Basf Se | Hybrid foam |
| CN111032594A (en) * | 2017-08-23 | 2020-04-17 | 巴斯夫欧洲公司 | Hybrid foam |
| WO2019121671A1 (en) | 2017-12-20 | 2019-06-27 | Basf Se | Stabilized foamable aqueous suspension for producing inorganic-organic hybrid foams |
| EP4624924A1 (en) | 2024-03-25 | 2025-10-01 | Sika Technology AG | Method and system for the formulation or production of a mineral foam |
| WO2025202014A1 (en) | 2024-03-25 | 2025-10-02 | Sika Technology Ag | Method and system for the formulation or production of a mineral foam |
| EP4628671A1 (en) | 2024-04-02 | 2025-10-08 | Sika Technology AG | Sandwich panels filled with mineral foam, their manufacture and use |
| WO2025210024A1 (en) | 2024-04-02 | 2025-10-09 | Sika Technology Ag | Sandwich panels filled with mineral foam, their manufacture and use |
Also Published As
| Publication number | Publication date |
|---|---|
| AU4096601A (en) | 2001-10-03 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| EP3818027B1 (en) | Particle-stabilized foams using sustainable materials | |
| WO2001070647A1 (en) | Method of producing a hydraulic binder foam | |
| CN113816696A (en) | A kind of ultra-high performance concrete based on internal curing of recycled fine aggregate and preparation method thereof | |
| CN113173769B (en) | Chemical foaming sludge light soil and production method thereof | |
| WO2004050582A1 (en) | Composition of materials for use in cellular lightweight concrete and methods thereof | |
| CN114163256B (en) | A kind of porous capsule noise-reducing and sound-insulating material and its preparation method and application | |
| WO2002020423A2 (en) | Method for the production of a hydraulic binder foam | |
| CN113651573B (en) | Building floor heat-preservation sound-insulation board and processing method thereof | |
| KR102228810B1 (en) | Lightweight Aerated Concret Block | |
| CN118324465A (en) | Shield residue soil lightening treatment solidified soil and preparation method and application thereof | |
| CN113929399B (en) | Interface mortar and application thereof | |
| CN115959853B (en) | High-strength high-performance concrete pavement brick admixture and preparation method thereof | |
| CN117164308A (en) | A kind of regenerated micro-powder foam concrete and its preparation method | |
| CN111943602A (en) | A kind of ultra-lightweight cement-based composite material and preparation method thereof | |
| CN114230299B (en) | A kind of all solid waste high-performance lightweight material and its preparation method and application | |
| EP1051367B1 (en) | A hydraulic hardened foamed product and a method of producing the same | |
| CN110451874B (en) | Cast-in-place light wall board and preparation method thereof | |
| CN117585972B (en) | Novel environment-friendly material taking phosphogypsum and other solid wastes as raw materials and preparation method thereof | |
| JP5513789B2 (en) | Insulation | |
| JP2843520B2 (en) | Method for producing coal ash solidified material | |
| JPH11199346A (en) | Floating block | |
| JP2863110B2 (en) | Continuously vented lightweight solidified material containing latent hydraulic particles | |
| JP3912433B2 (en) | Papermaking cement molding and its manufacturing method | |
| CN120004586B (en) | Sound absorption material and preparation method thereof | |
| CN114409335B (en) | Low-density interior calcium silicate board and preparation method and application thereof |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| AK | Designated states |
Kind code of ref document: A1 Designated state(s): AE AG AL AM AT AU AZ BA BB BG BR BY BZ CA CH CN CO CR CU CZ DE DK DM DZ EE ES FI GB GD GE GH GM HR HU ID IL IN IS JP KE KG KP KR KZ LC LK LR LS LT LU LV MA MD MG MK MN MW MX MZ NO NZ PL PT RO RU SD SE SG SI SK SL TJ TM TR TT TZ UA UG US UZ VN YU ZA ZW |
|
| AL | Designated countries for regional patents |
Kind code of ref document: A1 Designated state(s): GH GM KE LS MW MZ SD SL SZ TZ UG ZW AM AZ BY KG KZ MD RU TJ TM AT BE CH CY DE DK ES FI FR GB GR IE IT LU MC NL PT SE TR BF BJ CF CG CI CM GA GN GW ML MR NE SN TD TG |
|
| 121 | Ep: the epo has been informed by wipo that ep was designated in this application | ||
| DFPE | Request for preliminary examination filed prior to expiration of 19th month from priority date (pct application filed before 20040101) | ||
| 122 | Ep: pct application non-entry in european phase | ||
| NENP | Non-entry into the national phase |
Ref country code: JP |