Claims
- 1. A method of producing a low density material comprising providing a precursor by forming an aqueous mixture of inorganic primary component and a blowing agent, drying the mixture and firing the precursor to activate the blowing agent to expand the precursor and form a low density material wherein activation of the blowing agent is controlled such that the blowing agent is activated within a predetermined optimal temperature range.
- 2. The method of claim 1 wherein the low density material is a microparticle with a diameter of up to about 1,000 microns.
- 3. The method of claim 1 wherein the blowing agent is activated within a temperature range in which the inorganic primary component has melted and is within an optimal viscosity range.
- 4. The method of claim 1 wherein the blowing agent is controlled by addition of a control agent.
- 5. The method of claim 4 wherein the blowing agent is provided as a primary blowing agent, and the control agent is provided as a secondary blowing agent.
- 6. The method of claim 5 wherein the primary blowing agent has a first activation temperature and the secondary blowing agent has a second activation temperature which is less than the first activation temperature.
- 7. The method of claim 5, wherein the primary blowing agent is selected from the group consisting of powdered coal, carbon black, activated carbon, graphite, carbonaceous polymeric organics, oils, carbohydrates such as sugar, corn syrup or starch, PVA, carbonates, carbides, sulfates, sulfides, nitrides, nitrates, amines, polyols, glycols, glycerine, and combinations thereof.
- 8. The method of claim 5, wherein the secondary blowing agent is selected from the group consisting of powdered coal, carbon black, activated carbon, graphite, carbonaceous polymeric organics, oils, carbohydrates such as sugar, corn syrup or starch, PVA, carbonates, carbides, sulfates, sulfides, nitrides, nitrates, amines, polyols, glycols, glycerine, and combinations thereof.
- 9. The method of claim 6, wherein the precursor further comprises a tertiary blowing agent having a third activation temperature, wherein the third activation temperature is less than the first activation temperature.
- 10. The method of claim 9, wherein the tertiary blowing agent is selected from the group consisting of powdered coal, carbon black, activated carbon, graphite, carbonaceous polymeric organics, oils, carbohydrates, PVA, carbonates, sulfates, sulfides, nitrates, amines, polyols, glycols, glycerine, and combinations thereof.
- 11. The method of claim 1, wherein firing of the precursor is conducted under such conditions as to control activation of the blowing agent.
- 12. The method of claim 1 wherein firing of the precursor is conducted in an oxygen deficient environment.
- 13. The method of claim 12 wherein firing of the precursor is conducted in a fuel rich and less oxidising environment.
- 14. The method of claim 1, wherein activation of the blowing agent is controlled by appropriate dosing with O2 depleting or O2 enriching gases during firing of the precursor.
- 15. The method of claim 1 wherein the precursor is formed with a predetermined distribution of blowing agent there through, said distribution providing a controlled activation of the blowing agent during firing of the precursor.
- 16. The method of claim 1, wherein the drying step is performed using a spray dryer having an aqueous slurry feed.
- 17. The method of claim 16, wherein the spray dryer has an inlet temperature in the range of about 300 to 600° C.
- 18. The method of claim 16, wherein the spray dryer has an outlet temperature in the range of about 90 to 220° C.
- 19. The method of claim 1, wherein the amount of inorganic primary component is at least about 50 wt. %, based on the total dry weight of the precursor.
- 20. The method of claim 1, wherein the amount of blowing agent is in the range of about 0.05 to 10 wt. %, based on the total dry weight of the precursor.
- 21. The method of claim 1 wherein the ratio of inorganic primary component to blowing agent is in the range of about 1000:1 to 10:1.
- 22. The method of claim 1, wherein the mixture is dried such that the water content of the precursor is less than about 14 wt. %.
- 23. The method of claim 1, wherein the resultant precursors have an average agglomerate particle size in the range of about 10 to 1000 microns.
- 24. The method of claim 1, wherein the resultant precursors have a total alkali metal oxide content of about 10 wt. % or less, based on the total dry weight of the precursor.
- 25. The method of claim 1, wherein the inorganic primary component comprises at least one material selected from the group consisting of inorganic oxides, non-oxides, salts, and combinations thereof.
- 26. The method of claim 1, wherein the inorganic primary component comprises at least one material selected from the group consisting of industrial by-products, residential by-products, minerals, rocks, clays, technical grade chemicals, and combinations thereof.
- 27. The method of claim 1, wherein the inorganic primary component comprises at least one silicate material.
- 28. The method of claim 27, wherein the at least one silicate material is selected from the group consisting of fly ash, bottom ash, blast-furnace slag, paper ash, basaltic rock, andesitic rock, feldspars, aluminosilicate clays, bauxite, volcanic ash, volcanic rocks, volcanic glasses, geopolymers, and combinations thereof.
- 29. The method of claim 1, wherein the inorganic primary component is capable of forming a viscoelastic liquid.
- 30. The method of claim 1, wherein the inorganic primary component has an average primary particle size in the range of about 0.01 to 100 microns.
- 31. The method of claim 5, wherein the primary blowing agent is relatively less water-soluble than the secondary blowing agent.
- 32. The method of claim 1, wherein the blowing agent has an average particle size in the range of 0.01 to 10 microns.
- 33. The method of claim 1, further comprising mixing a binding agent with the inorganic primary component and the blowing agent.
- 34. The method of claim 33, wherein the binding agent is selected from the group consisting of alkali metal silicates, alkali metal aluminosilicates, alkali metal borates, alkali or alkaline earth metal carbonates, alkali or alkaline earth metal nitrates, alkali or alkaline earth metal nitrites, boric acid, alkali or alkaline earth metal sulfates, alkali or alkaline earth metal phosphates, alkali or alkaline earth metal hydroxides, carbohydrates, colloidal silica, ultrafine fly ash, Type C fly ash, Type F fly ash, inorganic silicate cements, Portland cement, alumina cement, lime-based cement, phosphate-based cement, organic polymers, and combinations thereof.
- 35. The method of claim 33, wherein the binding agent has a melting point which is lower than the melting point of the resultant precursor as a whole.
- 36. The method of claim 32, wherein the binding agent has a melting point in the range of about 700 to 1000° C.
- 37. The method of claim 35, wherein the binding agent is a silicate
- 38. The method of claim 35, wherein the binding agent is an alkali metal silicate generated by in situ reaction of an alkali metal hydroxide and an silicate primary component.
- 39. The method of claim 35, wherein the amount of binding agent is in the range of about 0.1 to 50 wt. %, based on the total dry weight of the precursor.
- 40. The method of claim 35, wherein the binding agent is relatively more water-soluble than the primary blowing agent.
- 41. The method of claim 1, wherein the primary component and the blowing agent are co-ground together.
- 42. A method of forming a precursor for a low density material comprising the steps of:
providing an inorganic primary component; forming an aqueous mixture comprising the inorganic primary component, a blowing agent and a control agent, and; drying the mixture to provide an expandable precursor for forming a low density material, wherein said blowing agent and control agent are selected to control activation of the blowing agent such that the blowing agent is activated within a predetermined optimal temperature range.
- 43. The method of claim 42, wherein the blowing agent is provided as a primary blowing agent, and the control agent is provided as a secondary blowing agent.
- 44. The method of claim 43, wherein the primary blowing agent has a first activation temperature and the secondary blowing agent has a second activation temperature which is less than the first activation temperature.
- 45. The method claim 43, wherein the primary blowing agent is selected from the group consisting of powdered coal, carbon black, activated carbon, graphite, carbonaceous polymeric organics, oils, carbohydrates such as sugar, corn syrup or starch, PVA, carbonates, carbides, sulfates, sulfides, nitrides, nitrates, amines, polyols, glycols, glycerine, and combinations thereof.
- 46. The method of claim 45, wherein the secondary blowing agent is selected from the group consisting of powdered coal, carbon black, activated carbon, graphite, carbonaceous polymeric organics, oils, carbohydrates such as sugar, corn syrup or starch, PVA, carbonates, carbides, sulfates, sulfides, nitrides, nitrates, amines, polyols, glycols, glycerine, and combinations thereof.
- 47. The method of claim 44, wherein the precursor further comprises a tertiary blowing agent having a third activation temperature, wherein the third activation temperature is less than the first activation temperature.
- 48. The method of claim 47, wherein the tertiary blowing agent is selected from the group consisting of powdered coal, carbon black, activated carbon, graphite, carbonaceous polymeric organics, oils, carbohydrates, PVA, carbonates, sulfates, sulfides, nitrates, amines, polyols, glycols, glycerine and combinations thereof.
- 49. The method of claim 42, wherein activation of the blowing agent is controlled by appropriate dosing with O2 depleting or O2 enriching gases during firing of the precursor.
- 50. The method of claim 42, wherein the precursor is formed with a predetermined distribution of blowing agent there through, said distribution providing a controlled activation of the blowing agent during firing of the precursor.
- 51. The method of claim 42, wherein the drying step is performed using a spray dryer having an aqueous slurry feed.
- 52. The method of claim 51, wherein the spray dryer has an inlet temperature in the range of about 300 to 600° C.
- 53. The method of claim 51, wherein the spray dryer has an outlet temperature in the range of about 90 to 220° C.
- 54. The method of claim 42, wherein the amount of inorganic primary component is at least about 50 wt. %, based on the total dry weight of the agglomerate precursor.
- 55. The method of claim 42, wherein the amount of blowing component is in the range of about 0.05 to 10 wt. %, based on the total dry weight of the agglomerate precursor.
- 56. The method of claim 42, wherein the ratio of inorganic primary component to blowing component is in the range of about 1000:1 to 10:1.
- 57. The method of claim 42, wherein the mixture is dried such that the water content of the precursor is less than about 14 wt. %.
- 58. The method of claim 42, wherein the resultant agglomerate precursors have an average agglomerate particle size in the range of about 10 to 1000 microns.
- 59. The method of claim 42, wherein the resultant agglomerate precursors have a total alkali metal oxide content of about 10 wt. % or less, based on the total dry weight of the agglomerate precursor.
- 60. The method of claim 42, wherein the inorganic primary component comprises at least one material selected from the group consisting of inorganic oxides, non-oxides, salts and combinations thereof.
- 61. The method of claim 42, wherein the inorganic primary component comprises at least one material selected from the group consisting of industrial by-products, residential by-products, minerals, rocks, clays, technical grade chemicals and combinations thereof.
- 62. The method of claim 42, wherein the inorganic primary component comprises at least one silicate material.
- 63. The method of claim 62, wherein the at least one silicate material is selected from the group consisting of fly ash, bottom ash, blast-furnace slag, paper ash, basaltic rock, andesitic rock, feldspars, aluminosilicate clays, bauxite, volcanic ash, volcanic rocks, volcanic glasses, geopolymers, and combinations thereof
- 64. The method of claim 42, wherein the inorganic primary component is capable of forming a viscoelastic liquid.
- 65. The method of claim 42, wherein the inorganic primary component has an average primary particle size in the range of about 0.01 to 100 microns.
- 66. The method of claim 43, wherein the primary blowing agent is relatively less water-soluble than the secondary blowing agent.
- 67. The method of claim 42, wherein the blowing agent has an average particle size in the range of about 0.01 to 10 microns.
- 68. The method of claim 42, further comprising mixing a binding agent with the inorganic primary component and the blowing agent.
- 69. The method of claim 68, wherein the binding agent is selected from the group consisting of alkali metal silicates, alkali metal aluminosilicates, alkali metal borates, alkali or alkaline earth metal carbonates, alkali or alkaline earth metal nitrates, alkali or alkaline earth metal nitrites, boric acid, alkali or alkaline earth metal sulfates, alkali or alkaline earth metal phosphates, alkali or alkaline earth metal hydroxides, carbohydrates, colloidal silica, ultrafine fly ash, Type C fly ash, Type F fly ash, inorganic silicate cements, Portland cement, alumina cement, lime-based cement, phosphate-based cement, organic polymers and combinations thereof.
- 70. The method of claim 68, wherein the binding agent has a melting point which is lower than the melting point of the resultant agglomerate precursor as a whole.
- 71. The method of claim 68, wherein the binding agent has a melting point in the range of about 700 to 1000° C.
- 72. The method of claim 70, wherein the binding agent is a silicate.
- 73. The method of claim 70, wherein the binding agent comprises an alkali metal silicate generated by in situ reaction of an alkali metal hydroxide and an silicate primary component.
- 74. The method of claim 70, wherein the amount of binding agent is in the range of about 0.1 to 50 wt. %, based on the total dry weight of the agglomerate precursor.
- 75. The method of claim 70, wherein the binding agent is relatively more water-soluble than the primary blowing agent.
- 76. The method of claim 42, wherein the primary component and the blowing agent are co-ground together.
- 77. A method of forming a precursor for a low density material comprising the steps of:
providing an inorganic primary component; forming an aqueous mixture of the inorganic primary component and a blowing agent; and drying the mixture to provide an expandable precursor for forming a low density material wherein the blowing agent is selected and/or distributed in the precursor to control activation of the blowing agent upon firing of the precursor such that the blowing agent is activated within a predetermined optimal temperature range.
- 78. A precursor suitable for producing expanded micro particles, said precursor comprising an expandable inorganic primary component, a blowing agent adapted to be activated and thereby expand said primary component, and a control agent selected to control activation of the blowing agent such that the blowing agent is activated within a predetermined optimal temperature range.
- 79. The precursor of claim 78 wherein the blowing agent is provided as a primary blowing agent, and the control agent is provided as a secondary blowing agent.
- 80. The precursor of claim 79 wherein the primary blowing agent has a first activation temperature and the secondary blowing agent has a second activation temperature which is less than the first activation temperature.
- 81. The precursor of claim 78, wherein the primary blowing agent is selected from the group consisting of powdered coal, carbon black, activated carbon, graphite, carbonaceous polymeric organics, oils, carbohydrates such as sugar, corn syrup or starch, PVA, carbonates, carbides, sulfates, sulfides, nitrides, nitrates, amines, polyols, glycols, glycerine and combinations thereof.
- 82. The precursor of claim 79, wherein the secondary blowing agent is selected from the group consisting of powdered coal, carbon black, activated carbon, graphite, carbonaceous polymeric organics, oils, carbohydrates such as sugar, corn syrup or starch, PVA, carbonates, carbides, sulfates, sulfides, nitrides, nitrates, amines, polyols, glycols or glycerine and combinations thereof.
- 83. The precursor of claims 80, wherein the precursor further comprises a tertiary blowing agent having a third activation temperature, wherein the third activation temperature is less than the first activation temperature.
- 84. The precursor of claim 83, wherein the tertiary blowing agent is selected from the group consisting of powdered coal, carbon black, activated carbon, graphite, carbonaceous polymeric organics, oils, carbohydrates, PVA, carbonates, sulfates, sulfides, nitrates, amines, polyols, glycols, glycerine and combinations thereof.
- 85. The precursor of claim 78 wherein activation of the blowing agent is controlled by appropriate dosing with O2 depleting or O2 enriching gases during firing of the precursor.
- 86. The precursor of claim 78, wherein the precursor is formed with a predetermined distribution of blowing agent there through, said distribution providing a controlled activation of the blowing agent during firing of the precursor.
- 87. The precursor of claim 78, wherein the amount of inorganic primary component is at least about 50 wt. %, based on the total dry weight of the agglomerate precursor.
- 88. The precursor of claim 78, wherein the amount of blowing component is in the range of about 0.05 to 10 wt. %, based on the total dry weight of the agglomerate precursor.
- 89. The precursor of claim 78, wherein the ratio of inorganic primary component to blowing component is in the range of about 1000:1 to 10:1.
- 90. The precursor of claim 78, wherein the mixture is dried such that the water content of the precursor is less than about 14 wt. %.
- 91. The precursor of claim 78, wherein the resultant agglomerate precursors have an average agglomerate particle size in the range of about 10 to 1000 microns.
- 92. The precursor of claims 78, wherein the resultant agglomerate precursors have a total alkali metal oxide content of about 10 wt. % or less, based on the total dry weight of the agglomerate precursor.
- 93. The precursor of claim 78, wherein the inorganic primary component comprises at least one material selected from the group consisting of inorganic oxides, non-oxides, salts and combinations thereof.
- 94. The precursor of claim 78, wherein the inorganic primary component comprises at least one material selected from the group consisting of industrial by-products, residential by-products, minerals, rocks, clays, technical grade chemicals and combinations thereof.
- 95. The precursor of claim 79, wherein the inorganic primary component comprises at least one silicate material.
- 96. The precursor of claim 95, wherein the at least one silicate material is selected from the group consisting of fly ash, bottom ash, blast-furnace slag, paper ash, basaltic rock, andesitic rock, feldspars, aluminosilicate clays, bauxite, volcanic ash, volcanic rocks, volcanic glasses, geopolymers, and combinations thereof.
- 97. The precursor of claim 78, wherein the inorganic primary component is capable of forming a viscoelastic liquid.
- 98. The precursor of claim 78, wherein the inorganic primary component has an average primary particle size in the range of about 0.01 to 100 microns.
- 99. The precursor of claim 78, wherein the primary blowing agent is relatively less water-soluble than the secondary blowing agent.
- 100. The precursor of claim 78, wherein the blowing agent has an average particle size in the range of about 0.01 to 10 microns.
- 101. The precursor of claim 78, further comprising mixing a binding agent with the inorganic primary component and the blowing agent.
- 102. The precursor of claim 101, wherein the binding agent is selected from the group consisting of alkali metal silicates, alkali metal aluminosilicates, alkali metal borates, alkali or alkaline earth metal carbonates, alkali or alkaline earth metal nitrates, alkali or alkaline earth metal nitrites, boric acid, alkali or alkaline earth metal sulfates, alkali or alkaline earth metal phosphates, alkali or alkaline earth metal hydroxides, carbohydrates, colloidal silica, ultrafine fly ash, Type C fly ash, Type F fly ash, inorganic silicate cements, Portland cement, alumina cement, lime-based cement, phosphate-based cement, organic polymers and combinations thereof.
- 103. The precursor of claim 101, wherein the binding agent has a melting point which is lower than the melting point of the resultant agglomerate precursor as a whole.
- 104. The precursor of claim 101, wherein the binding agent has a melting point in the range of about 700 to 1000° C.
- 105. The precursor of claim 103, wherein the binding agent is a silicate.
- 106. The precursor of claim 103, wherein the binding agent is an alkali metal silicate generated by in situ reaction of an alkali metal hydroxide and an silicate primary component.
- 107. The precursor of claim 103, wherein the amount of binding agent is in the range of about 0.1 to 50 wt. %, based on the total dry weight of the agglomerate precursor.
- 108. The precursor of claim 103, wherein the binding agent is relatively more water-soluble than the primary blowing agent.
- 109. A precursor suitable for producing expanded micro particles, said precursor comprising an expandable inorganic primary component and a blowing agent selected and/or distributed within the precursor to control activation of the blowing agent whereby upon firing of the precursor to produce the expanded micro particles, the blowing agent is activated within a predetermined optimal temperature range.
- 110. A method of controlling activation of the blowing agent in an inorganic mixture to produce expanded micro particles, said method comprising:
providing at least one blowing agent which is activated under predetermined conditions to release a blowing gas and produce expanded micro particles and controlling such conditions whereby said activation takes place within a predetermined optimal viscosity range of the inorganic mixture.
- 111. A blowing component for producing expanded micro particles, said blowing component comprising a primary blowing agent and a predetermined quantity of compatible control agent wherein upon inclusion of such a blowing component within an expandable mixture, the control agent may be activated prior or simultaneously with the blowing agent to control and conserve the blowing agent.
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/648,184, filed Aug. 25, 2003, which claims the benefit of U.S. Provisional Patent Application No. 60/405,790, filed Aug. 23, 2002 and U.S. Provisional Patent Application No. 60/471,400, filed May 16, 2003, the entirety of each of these references are herein incorporated by reference in their entirety.
Provisional Applications (2)
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Number |
Date |
Country |
|
60471400 |
May 2003 |
US |
|
60405790 |
Aug 2002 |
US |
Continuation in Parts (1)
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Number |
Date |
Country |
Parent |
10648184 |
Aug 2003 |
US |
Child |
10787894 |
Feb 2004 |
US |