Back to results
US 2011/0254190 A1Published application
Phosphate bonded composites and methods
AssigneeLatitude 18, Inc.
InventorsArun S. Wagh, Sameerkumar Vasantlal Patel, Anand Paul Mangalam
Life of this patent
Estimating the term…
Abstract
Inorganic-organic composite articles and methods for producing them using inorganic acidic/alkaline precursor components as inorganic adhesives is provided. Articles prepared therefrom provide improved flexibility, zero flame spread, no release of volatile organic compounds, and low carbon foot print.
Claims50
A method of producing a composite product, the method comprising
- providing an organic material, and
- contacting the organic material with an inorganic adhesive, the inorganic adhesive comprising a mixture of an inorganic acidic precursor and an alkaline precursor.
A method of producing a fiber reinforced ceramic composite, the method comprising
- providing an inorganic phosphate adhesive comprising a mixture of:
- (i) an inorganic acidic precursor of at least one of a saturated solution of phosphoric acid, sodium dihydrogen phosphate (NaH2PO4), potassium dihydrogen phosphate (KH2PO4), cesium dihydrogen phosphate (CsH2PO4), magnesium dihydrogen phosphate (Mg(H2PO4)2.2H2O), calcium dihydrogen phosphate (Ca(H2PO4)2.2H2O), zinc dihydrogen phosphate (Zn(H2PO4)2), mono aluminum hydro phosphate (AlH3(PO4)2.H2O), MgCl2, MgSO4, and mixtures thereof;
- and
- (ii) an alkaline precursor of at least one of a monovalent-divalent-, or trivalent metal oxide or hydroxide of magnesium, calcium, iron, manganese, zinc, barium, strontium, aluminum, lanthanide, and mixtures thereof, wherein the alkaline precursor is in solution;
- providing less than about 40 wt. % cellulosic material;
- and
- contacting the cellulosic with the material inorganic phosphate adhesive.
4 more elements
The method of a claim 38, further comprising applying vacuum and/or sonication.
A method of producing non-flammable blowable insulation, the method comprising
- providing a blowable material comprising at least one of shredded paper, saw dust, wood shavings, shredded plastics, glass particles or glass fibers;
- gypsum, expandable clays, or mixtures thereof;
- providing an inorganic adhesive, the inorganic adhesive comprising:
- (i) an inorganic acidic component comprising at least one of a saturated solution of phosphoric acid, sodium dihydrogen phosphate (NaH2PO4), potassium dihydrogen phosphate (KH2PO4), cesium dihydrogen phosphate (CsH2PO4), magnesium dihydrogen phosphate (Mg(H2PO4)2.2H2O), calcium dihydrogen phosphate (Ca(H2PO4)2.2H2O), zinc dihydrogen phosphate (Zn(H2PO4)2), MgCl2, MgSO4, mono aluminum hydrophosphate (AlH3(PO4)2.H2O), and mixtures thereof;
- and
- (ii) an alkaline precursor comprising a saturated solution or a paste of at least one of a monovalent-, divalent-, or trivalent-metal oxide or hydroxide of magnesium, calcium, iron, manganese, zinc, barium, strontium, aluminum or lanthanide, and mixtures thereof;
- contacting the material with the inorganic adhesive for a sufficient time to bond the inorganic adhesive with the blowable material;
- and
- providing a non-flammable, blowable insulation.
6 more elements
A method of producing zero flame spread articles, the method comprising
- providing a combustible article;
- and
- introducing a coating of inorganic adhesive to at least a portion of the combustible article;
- the inorganic adhesive comprising a mixture of:
- (i) at least one of a saturated solution of phosphoric acid, or an acid phosphate salt comprising sodium dihydrogen phosphate (NaH2PO4), potassium dihydrogen phosphate (KH2PO4), cesium dihydrogen phosphate (CsH2PO4), magnesium dihydrogen phosphate (Mg(H2PO4)2.2H2O), calcium dihydrogen phosphate (Ca(H2PO4)2.2H2O), zinc dihydrogen phosphate (Zn(H2PO4)2), MgCl2, MgSO4, mono aluminum hydrophosphate (AlH3(PO4)2.H2O), and mixtures thereof;
- (ii) at least one of calcium silicate, olivine, mullite, talc, oxide minerals, fly ash, bottom ash, Bayer process waste, acidic waste streams generated during extraction of copper from copper ore, or waste streams containing silicate and aluminate minerals, and mixtures thereof;
- and
- (iii) at least one alkaline precursor component comprising a saturated solution or a paste of at least one of a monovalent-divalent-, or trivalent metal oxide or hydroxide of magnesium, calcium, iron, manganese, zinc, barium, strontium, aluminum, lanthanide, and mixtures thereof.
5 more elements
A method of producing fire resistant paper and paper products, the method comprising
- providing a cellulosic material;
- providing an inorganic adhesive comprising as components:
- (i) an inorganic phosphate solution comprising at least one of a saturated solution of phosphoric acid, or an acid phosphate salt comprising sodium dihydrogen phosphate (NaH2PO4), potassium dihydrogen phosphate (KH2PO4), cesium dihydrogen phosphate (CsH2PO4), magnesium dihydrogen phosphate (Mg(H2PO4)2.2H2O), calcium dihydrogen phosphate (Ca(H2PO4)2.2H2O), zinc dihydrogen phosphate (Zn(H2PO4)2), MgCl2, MgSO4, mono aluminum hydrophosphate (AlH3(PO4)2.H2O), and mixtures thereof;
- and
- (ii) an alkaline precursor solution comprising at least one of a saturated solution or a paste of at least one of a monovalent-divalent-, or trivalent metal oxide or hydroxide of magnesium, calcium, iron, manganese, zinc, barium, strontium, aluminum or lanthanide, and mixtures thereof;
- combining the cellulosic material and the inorganic adhesive;
- and
- forming a paste comprising the cellulosic material and the inorganic adhesive suitable for paper forming.
5 more elements
A method of treating wood to produce zero flame spread wooden articles, the method comprising:
- contacting a wood article with a composition comprising:
- (i) a saturated solution of phosphoric acid, or an acid phosphate salt comprising sodium dihydrogen phosphate (NaH2PO4), potassium dihydrogen phosphate (KH2PO4), cesium dihydrogen phosphate (CsH2PO4), magnesium dihydrogen phosphate (Mg(H2PO4)2.2H2O), calcium dihydrogen phosphate (Ca(H2PO4)2.2H2O), zinc dihydrogen phosphate (Zn(H2PO4)2), MgCl2, MgSO4, mono aluminum hydro phosphate (AlH3(PO4)2.H2O);
- or mixtures thereof;
- (ii) an alkaline precursor solution of one or more of a saturated solution or a paste of at least one of a monovalent-divalent-, or trivalent metal oxide or hydroxide of magnesium, calcium, iron, manganese, zinc, barium, strontium, aluminum, lanthanide, and mixtures thereof;
- and
- (iii) optionally, at least one of calcium silicate, olivine, mullite, talc, oxide minerals, fly ash, bottom ash, Bayer process waste, acidic waste streams generated during extraction of copper from copper ore, or waste streams containing silicate and aluminate minerals, or mixtures thereof;
- and
- drying the wood article contacted with the composition.
5 more elements
Dependencies are inferred from the claim text.