Inorganic binders employing waste glass

• US 6,296,699 B1
• Filed: 01/27/2000
• Issued: 10/02/2001
• Est. Priority Date: 01/27/1999
• Status: Active Grant

• Current Assignee: Jin, Weihua
• Original Assignee: Jin, Weihua
• Inventors: Jin, Weihua
• Primary Examiner(s): GREEN, ANTHONY J
• Application Number:
  US09/493,025
• Time in Patent Office: 614 Days
• Field of Search: 106/600, 106/606, 106/638, 106/692, 106/814, 106/691, 106/716, 106/286.1, 106/286.2, 106/286.7, 264/333
• US Class Current: 106/814
• CPC Class Codes: B28B 7/384 Treating agents for plastic moulding materials in general B29C33/60; lubricants in general C10M
• CPC Class Codes: C03C 14/004 the non-glass component being in the form of particles or flakes
• CPC Class Codes: C03C 2214/14 Waste material, e.g. to be disposed of
• CPC Class Codes: C04B 14/22 Glass ; Devitrified glass
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 2103/0006 Alkali metal or inorganic ammonium compounds
• CPC Class Codes: C04B 2103/0008 Li
• CPC Class Codes: C04B 2103/14 Hardening accelerators
• CPC Class Codes: C04B 2103/32 Superplasticisers
• CPC Class Codes: C04B 2103/50 Defoamers, air detrainers
• CPC Class Codes: C04B 2103/54 Pigments; Dyes
• CPC Class Codes: C04B 2111/2023 Resistance against alkali-aggregate reaction
• CPC Class Codes: C04B 2111/54 Substitutes for natural stone, artistic materials or the like
• CPC Class Codes: C04B 2111/542 Artificial natural stone
• CPC Class Codes: C04B 22/0093 Aluminates
• CPC Class Codes: C04B 22/062 of the alkali or alkaline-earth metals
• CPC Class Codes: C04B 22/064 of the alkaline-earth metals
• CPC Class Codes: C04B 22/10 containing carbon in the anion
• CPC Class Codes: C04B 22/126 Fluorine compounds, e.g. silico-fluorine compounds
• CPC Class Codes: C04B 22/147 Alkali-metal sulfates; Ammonium sulfate
• CPC Class Codes: C04B 22/16 : containing phosphorus in the anion, e.g. phosphates
• CPC Class Codes: C04B 24/26 : obtained by reactions only involving carbon-to-carbon unsaturated bonds C04B24/243 takes precedence
• CPC Class Codes: C04B 28/00 : 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
• CPC Class Codes: C04B 28/02 : containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/26 : Silicates of the alkali metals
• CPC Class Codes: C04B 40/0028 : Aspects relating to the mixing step of the mortar preparation
• CPC Class Codes: C04B 40/0263 : Hardening promoted by a rise in temperature C04B40/024 takes precedence
• CPC Class Codes: C04B 41/53 : involving the removal of at least part of the materials of the treated article, e.g. etching, drying of hardened concrete C04B41/0036 - C04B41/0054 take precedence
• CPC Class Codes: C04B 7/00 : Hydraulic cements calcium sulfate cements C04B11/00
• CPC Class Codes: C04B 7/02 : Portland cement
• CPC Class Codes: E04F 13/147 : with an outer layer imitating natural stone, brick work or the like

Abstract

The present invention relates to a binder composition comprising a glass powder with a particle size of at least less than 0.15 mm and an alkali activator containing at least one alkali metal and at least one silicate. Preferably, a sodium silicate with a SiO₂:Na₂O weight ratio between about 1.6:1 to about 2.0:1. Mixed with water, the binder composition can be cured at ambient temperature, but rapidly yields a very high strength at an elevated temperature between about 40° C. to about 120° C. Preferably, between about 70° C. to about 90° C. The invention further provides a method of making artificial stone using glass as a sole binder and aggregate.

Claims

1. A water-curable and high-strength binder composition, comprising a glass powder and an alkali activator selected from the group consisting of alkali metal hydroxide, alkali metal silicate, alkali metal aluminate, alkali metal carbonate, alkali metal sulfate, alkali metal phosphate and alkali metal fluoride, wherein the amount of alkali activator is about at most 20% by weight of the glass powder.

2. The binder composition as claimed in claim 1, wherein the glass powder has a particle size of less than 0.15 mm.

3. The binder composition as claimed in claim 1, wherein the alkali activator is selected from the group consisting of alkali metal hydroxide, alkali metal silicate, and alkali metal aluminate.

4. The binder composition as claimed in claim 1, wherein the alkali metal in the alkali activator is selected from the group consisting of sodium, potassium, and lithium.

5. The binder composition as claimed in claim 1, wherein the glass powder is a soda-lime glass and has a particle size of about less than 0.075 mm.

6. The binder composition as claimed in claim 1, wherein the alkali activator is alkali metal silicate.

7. The binder composition as claimed in claim 5, wherein the alkali activator is sodium silicate and has a weight ratio of about 0.5:

1 to about 3.22;

1 between SiO₂;

Na₂O and present in an amount of about 3% to about 15% by weight of the glass powder.

8. The binder composition as claimed in claim 5, wherein the alkali activator is sodium silicate and has a weight ratio of about 1.6:

1 to about 2.0;

1 between SiO₂;

Na₂O and is present in an amount of about 4% to about 10% by weight of the glass powder.

9. The binder composition as claimed in claim 1, further comprising a hardener selected from the group consisting of sodium silicofluoride, aluminum phosphate, and aluminum metaphosphate in an amount of about 0% to about 50% by weight of the alkali activator.

10. The binder composition as claimed in claim 1, wherein the alkali activator further comprises calcium hydroxide in an amount of about 0% to about 10% by weight of the glass powder.

11. The binder composition as claimed in claim 1, further comprising Portland cement in an amount of about 0% to about 15% by weight of the glass powder.

12. The binder composition as claimed in claim 1, wherein the alkali activator is an alkali metal hydroxide present in an amount of about 3% to about 15% by weight of glass powder.

13. The binder composition as claimed in claim 1, wherein the alkali activator is an alkali metal aluminate present in an amount of about 3% to about 15% by weight of glass powder.

14. The binder composition as claimed in claim 1, further comprising a glass aggregate in an amount of about 0.5 to about 4 times by the total weight of the glass powder and the alkali activator.

15. A method of making a high strength hardened composition comprising:

(a) forming a binder composition by mixing a glass powder and an alkali activator selected from the group consisting of alkali metal hydroxide, alkali metal silicate, alkali metal aluminate, alkali metal carbonate, alkali metal sulfate, alkali metal phosphate and alkali metal fluoride, wherein the alkali activator is present in an amount of about 1% to about 20% by weight of the glass powder;

(b) admixing the binder composition with water in an amount of about 25% to about 50% by weight of the binder composition to obtain a plastic mixture; and

(c) curing the mixture at a temperature of about 0°

C. to about 120°

C. for a time sufficient for the mixture to yield a compressive strength of at least about 2,000 psi (about 13.79 MPa).

16. The method as claimed in claim 15, wherein the curing temperature is about 40°

C. to about 100°

C.

17. The method as claimed in claim 15, wherein the curing time is about one hour to about sixty hours.

18. The method as claimed in claim 16, wherein the curing time is about one hour to about twenty-four hours.

19. The method as claimed in claim 15, wherein the curing temperature is about 70°

C. to about 90°

C.

20. A composition for making an artificial stone comprising:

(a) a binder composition having a glass powder with a particle size of less than about 0.15 mm and an alkali activator selected from the group consisting of alkali metal hydroxide, alkali metal silicate, alkali metal aluminate, alkali metal carbonate, alkali metal sulfate, alkali metal phosphate and alkali metal fluoride and present in an amount of about 1% to about 20% by weight of the glass powder;

(b) a glass aggregate having a graded particle size of between about 9.52 mm to about 0.15 mm and present in an amount of about 0.5 times to about 3.5 times by weight of the binder composition;

(c) water in an amount of about 25% to about 50% by weight of the binder composition; and

(d) at least one color pigment in an amount of about 0% to about 10% by weight of the binder composition.

21. A method of making an artificial stone composition comprising:

(a) forming a mixture comprising

(1) a binder composition which comprises a glass powder having a particle size of less than about 0.15 mm and an alkali activator selected from the group consisting of alkali metal hydroxide, alkali metal silicate, alkali metal aluminate, alkali metal carbonate, alkali metal sulfate, alkali metal phosphate and alkali metal fluoride and present in an amount of about at most 20% by weight of the glass powder,

(2) a glass aggregate having a graded particle size of between about 4.76 mm to about 0.15 mm and present in an amount of about 0.5 times to about 4 times by weight of the binder composition,

(3) water in an amount of about 25% to about 50% by weight of the binder composition, and

(4) at least one color pigment in an amount of about 0% to about 10% by weight of the binder composition;

(b) preparing a mold having an inner surface;

(c) applying a thin layer of a liquid selected from the group consisting of a form releasing agent and a defoaming agent to the inner surface of the mold;

(d) casting the mixture into the mold and consolidating the mixture;

(e) curing the mixture at an elevated temperature for a time sufficient to form a hardened mixture with a compressive strength of at least 2,000 psi (13.79 MPa);

(f) releasing the hardened mixture from the mold; and

(g) polishing the hardened mixture.

22. The method as claimed in claim 21, wherein the liquid is a silicone based emulsion.

23. A concrete composition comprising:

a binder composition having a glass powder and an alkali activator selected from the group consisting of alkali metal hydroxide, alkali metal silicate, alkali metal aluminate, alkali metal carbonate, alkali metal sulfate, alkali metal phosphate, and alkali metal fluoride and present in an amount of about 1% to about 20% by weight of the glass powder, and

a glass aggregate in an amount of about 0.5 times to about 4 times by weight of the binder composition.

24. The concrete composition as claimed in claim 23, further comprising at least one supplementary material selected from the group consisting of fibers, color pigments, polymer latexes, plasticizers defoaming agents and mineral admixtures in an amount of up to about 10% by weight of the binder composition.

25. An artificial stone or concrete composition formed from a mixture comprising:

(1) a binder composition which comprises a glass powder having a particle size of less than about 0.15 mm and an alkali activator selected from the group consisting of alkali metal hydroxide, alkali metal silicate, alkali metal aluminate, alkali metal carbonate, alkali metal sulfate, alkali metal phosphate and alkali metal fluoride and present in an amount of about at most 20% by weight of the glass powder;

(2) a glass aggregate having a graded particle size of between about 4.76 mm to about 0.15 mm and present in an amount of about 0.5 times to about 4 times by weight of the binder composition;

(3) water in an amount of about 25% to about 50% by weight of the binder composition; and

(4) at least one color pigment in an amount of about 0% to about 10% by weight of the binder composition;

wherein the composition has a compressive strength of at least 2,000 psi (13.79 Mpa).