US 4,141,744 A · Cellular inorganic resin cements, and process and compositions for forming them

Abstract

Process and composition for forming cellular inorganic plastic cements of magnesium oxychlorides and magnesium oxysulfates. A water slurry containing a magnesium salt, magnesium oxide and a water-soluble phosphate is formed and to it are added an anionic water-repellent surfactant and a blowing agent capable of providing a gaseous component in the strongly alkaline environment either through decomposition or reaction or through vaporization. Inorganic filler material may be added to impart strength, the maximum flexural strength being attained when at least about one-half of the filler comprises microfibers. The resulting cellular product is nonflammable and exhibits essentially zero flame spread, zero smoke density and zero fuel contribution. The cellular products are further characterized as being formed of substantially uniformly sized cells and having densities over a wide range.

Claims82

Dependent claims

A process for forming a cellular inorganic resin cement, comprising the steps of

(a) forming a reactant water slurry of a magnesium salt selected from magnesium chloride hexahydrate and magnesium sulfate heptahydrate, a water-soluble phosphate and reactive magnesium oxide, the amount of said magnesium salt ranging from about 50% to about 75% by weight of the total weight of said water and said magnesium salt, said slurry having a viscosity ranging between about 700 and 15,000 centipoises;
(b) blending into said slurry at least 0.5% by slurry weight of an anionic water-repellent surfactant;
(c) uniformly dispersing throughout said slurry a blowing agent, capable of providing a gaseous component either through decomposition or reaction or through vaporization at a temperature below that at which said inorganic resin cement is cured, in an amount required to form said cellular inorganic resin cement with a predetermined density, thereby to provide a foaming composition capable of attaining said predetermined density and final cell structure before said foaming composition gels to form said inorganic resin cement;
and
(d) curing said foaming composition under conditions to retain essentially all of its water content.

2 more elements

A composition for forming a cellular inorganic resin cement, comprising in combination

(a) a reactant water slurry of a magnesium salt selected from magnesium chloride hexahydrate and magnesium sulfate heptahydrate, reactive magnesium oxide and at least one water-soluble phosphate, said slurry having a viscosity ranging between about 700 and 15,000 centipoises and being one in which the solids concentration of said magnesium salt ranges between about 50% and about 70% by weight of the total weight of water of said slurry and said magnesium salt;
(b) an anionic, water-repellent surfactant present in said slurry in an amount between about 0.5% and about 3% by slurry weight;
and
(c) a blowing agent, capable of providing a gaseous component either through decomposition or reaction or through vaporization in the strongly alkaline environment of said slurry, uniformly dispersed throughout said slurry and present in an amount required to form said cellular inorganic resin cement with a predetermined density, thereby to provide a foaming composition capable of attaining said predetermined density and final cell structure before said foaming composition gels to form said cellular inorganic resin cement and from which essentially no water is removed upon curing.

1 more element

Dependencies are inferred from the claim text.

Cellular inorganic resin cements, and process and compositions for forming them

Life of this patent

Cellular inorganic resin cements, and process and compositions for forming them

Life of this patent

Abstract

Claims82