Method for producing materials from recycled glass and cement compositions

• US 7,700,017 B2
• Filed: 08/24/2004
• Issued: 04/20/2010
• Est. Priority Date: 08/25/2003
• Status: Expired due to Fees

• Current Assignee: IceStone LLC
• Original Assignee: IceStone LLC
• Inventors: McCarthy, Timothy, McCarthy, legal representative, Rangarajan, Sriram
• Primary Examiner(s): Daniels; Matthew J.
• Application Number:
  US10/925,199
• Publication Number:
  US 20050045069A1
• Time in Patent Office: 2,065 Days
• Field of Search: 264/71, 264/333, 264/338, 264/915, 264/72, 428/325
• US Class Current: 264/71
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 14/22 Glass ; Devitrified glass
• CPC Class Codes: C04B 14/28 of calcium
• CPC Class Codes: C04B 14/34 Metals , e.g. ferro-silicon
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 20/0076 characterised by the grain distribution
• CPC Class Codes: C04B 2103/302 Water reducers
• CPC Class Codes: C04B 2103/408 Dispersants
• CPC Class Codes: C04B 2103/44 Thickening, gelling or viscosity increasing agents
• CPC Class Codes: C04B 2103/50 Defoamers, air detrainers
• CPC Class Codes: C04B 2103/54 Pigments; Dyes
• CPC Class Codes: C04B 2103/603 Agents for controlling alkali-aggregate reactions
• CPC Class Codes: C04B 24/18 Lignin sulfonic acid or derivatives thereof, e.g. sulfite lye
• CPC Class Codes: C04B 24/22 Condensation or polymerisation products thereof
• CPC Class Codes: C04B 24/2641 Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 40/0067 making use of vibrations
• CPC Class Codes: C04B 40/024 : Steam hardening, e.g. in an autoclave
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10S 264/915 : From inorganic material containing articles or products, e.g. hydro-set, cement, plaster, wire, cable

Abstract

A method of producing material from recycled glass comprising: preparing a mixture of glass in a cementitious matrix, and an alkali-silica reaction suppressant; providing a mold of the material and coating said mold with a release agent; casting said mixture into said mold; curing said mold; and removing the material from said mold. The recycled glass and concrete compositions are: 25-79% by weight glass; 8-35% by weight cement and up to 22% by weight of an alkali-silica reaction suppressant.

Claims

1. A process to produce recycled glass/cement panels comprising:

(a) delivering materials including (i) 25-79% by weight of glass having a particle size in the range of 1 μ

m to 25 mm;

(ii) 19-30% by weight Portland cement; and

(iii) an alkali-silica reaction suppressant selected from the group consisting of metakaolin, fly ash, silica fume and blast furnace slag present in an amount up to 22% by weight

(b) adding up to 3% by weight of a dispersant and water to said materials to create a slurry that is inert, non-toxic and greater than 90% inorganic material, wherein the water content in said slurry ranges from 4% to 20% by weight;

(c) mixing said slurry under conditions to avoid curing of the product during operation and to breakdown agglomerate and to mix said slurry;

(d) casting said slurry into a mold having a dimension ranging from 48″

×

96″

to 60″

×

120″

;

(e) vibrating said mold to further spread said slurry in the mold evenly and to release all entrapped air at a vibration frequency in the range of 10-200 Hz and a vibration amplitude in the range of 0-5 mm;

(g) curing said mold at temperatures ranging from 50 to 185°

F. with a humidity range from 70% RH to 100% RH; and

(h) removing the recycled glass/cement panel from said mold wherein said panel has a compressive strength between 2000-16,750 psi, a flexural strength between 648-1170 psi and a porosity between 0.1% to 6.5%.

2. The method according to claim 1, wherein said glass is in a crushed or ground form.

3. The method according to claim 1, wherein said curing is in a controlled environmental chamber.

4. The method according to claim 1, wherein said mold is in the form of a flat panel.

5. The method according to claim 1, wherein said mold is in the form of a 3-D objects.

6. The method according to claim 1, wherein said dispersant is selected from the group consisting of polycarboxylate based dispersants, naphthalene based dispersants, melamine based dispersants and lignosulphate based dispersants.

7. The method according to 1, wherein said mixture further comprises a pigment component present in an amount up to 15% by weight.

8. The method according to claim 1, wherein said mixture further comprises a fiber component present in an amount up to 5% by weight.

9. The method according to claim 1, wherein said mixture further comprising at least one material from the group consisting of stone chips, shell chips, mother of pearl chips, metal chips, air-entraining agents, anti-foaming agents, and viscosity modifying agents.

10. The method according to claim 1, comprising the further step of polishing the material removed from the mold.

11. The method according to claim 1, wherein said glass is amorphous silica and is selected from the group consisting of borosilicate glass, E-glass, soda-lime glass and colored glass.

12. The method according to claim 1, wherein particle size distribution of said glass is varied to control viscosity of said mixture.