Lightweight substance molded body, method for the production and use thereof

• US 6,805,737 B2
• Filed: 10/22/2001
• Issued: 10/19/2004
• Est. Priority Date: 03/26/1997
• Status: Expired due to Term

• Current Assignee: Fraunhofer Gesellschaft Zur Foerderung Der Angewandten Forsching E.V., Gips-Schule-Stiftung
• Original Assignee: Fraunhofer Gesellschaft Zur Foerderung Der Angewandten Forsching E.V., Gips-Schule-Stiftung
• Inventors: Gödeke, Holger, Werner, Jürgen, Babuke, Gerhard
• Primary Examiner(s): MARCANTONI, PAUL D
• Application Number:
  US10/008,680
• Publication Number:
  US 20020128142A1
• Time in Patent Office: 1,093 Days
• Field of Search: 106/38.2, 106/38.3, 106/600, 252/62
• US Class Current: 106/38.2
• CPC Class Codes: C04B 14/08 Diatomaceous earth
• CPC Class Codes: C04B 14/12 Expanded clay
• CPC Class Codes: C04B 14/18 Perlite
• CPC Class Codes: C04B 14/202 Vermiculite
• CPC Class Codes: C04B 14/24 porous, e.g. foamed glass
• CPC Class Codes: C04B 18/082 Cenospheres
• CPC Class Codes: C04B 2111/28 Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• CPC Class Codes: C04B 28/26 Silicates of the alkali metals
• CPC Class Codes: C04B 38/08 by adding porous substances
• CPC Class Codes: C04B 40/0268 Heating up to sintering temperatures C04B41/0072 takes precedence
• CPC Class Codes: F01N 2310/06 Porous ceramics
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

The invention relates to a lightweight substance molded body made of a lightweight aggregate and a sintering auxiliary agent, wherein said molded body consist of a sintering product containing 60-95 wt. % lightweight aggregate with 40-5 wt. % water-soluble alkali silicate.

Claims

1. A molded body from a lightweight substance formed from a lightweight aggregate and a sintering auxiliary, comprising:

a sintered product obtained by mixing a lightweight substance of 80 to 93 wt % of a lightweight aggregate, selected from the group consisting of expanded glass, scrap glass, and their mixtures with 20 to 7 wt % of an aqueous alkali silicate solution, where the lightweight aggregate is bonded in a network structure exclusively at the contact sites to obtain its essential properties, wherein the molded body has a dry bulk density and that dry bulk density lies in the range from 150 to 750 kg/m³.

2. Molded body according to claim 1 further comprising that the molded body has a compressive strength and that the compressive strength lies in the range from 0.1 to 15 N/mm².

3. Molded body according to claim 1 wherein the aqueous alkali silicate solution is alkali silicates.

4. The molded body according to claim 1, wherein the molded body is used as insulation.

5. The molded body according to claim 1, wherein the molded body is used as construction material.

6. The molded body according to claim 1, wherein the molded body is used as furnace lining.

7. The molded body according to claim 1, wherein the molded body is used as a brick for formation of exhaust installation.

8. The molded body according to claim 1, wherein the molded body is used for technical sound protection in interior rooms.

9. The molded body according to claim 1, wherein the molded body is used for a sound-absorbing segment for fixed passageways of rail vehicles.

10. The molded body according to claim 1, wherein the molded body is used as a fireproofing element.

11. The molded body according to claim 1, wherein the molded body is used as a sound absorber in exhaust lines.

12. A process for the production of a molded body from a lightweight substance formed from a lightweight aggregate and a sintering auxiliary, the process comprising the steps of:

obtaining a sintered product by mixing a lightweight substance of 80 to 93 wt % of a lightweight aggregate selected form the group consisting of expanded glass, scrap glass, and their mixtures with 20 to 7 wt % of an aqueous alkali silicate solution, where the lightweight aggregate is bonded in a network structure exclusively at the contact sites to obtain its essential properties, wherein the molded body has a dry bulk density and that dry bulk density lies in the range from 150 to 750 kg/m³.

13. Process for the production of a molded body according to claim 12 further comprising the steps of:

subjecting the lightweight aggregate and the aqueous alkali silicate solution to a shaping process after mixing and sintering at 400°

C. to 1000°

C. over a period from 0.1 h to 5 h.

14. Process according to claim 13, wherein the molded body has a compressive strength in the range from 0.1 to 15 N/mm³ and at least one of the dry bulk density and the compressive strength is adjusted as a function of the lightweight aggregate and the process parameters during sintering.

15. Process according to claim 13 further comprising the step of drying at 50°

C. to 95°

C. after shaping and before sintering.

16. Process according to claim 13 wherein the sintering process is conducted at 550 to 850°

C.

17. Process according to claim 13 wherein sintering occurs during a period from 0.1 h to 0.5 h.