Geopolymer foam formulation for a non-flammable, sound-absorbing, thermally insulating geopolymer foam element

Patent metadata

Field	Value
Publication number	US-10214452-B2
Application number	US-201415030490-A
Country	US
Kind code	B2
Filing date	Oct 14, 2014
Priority date	Oct 31, 2013
Publication date	Feb 26, 2019
Grant date	Feb 26, 2019

Abstract

A geopolymer foam formulation, comprising at least one inorganic binder selected from the group consisting of latently hydraulic binders, pozzolanic binders and mixtures thereof; at least one alkaline activator selected from the group consisting of alkali metal hydroxides, alkali metal carbonates, alkali metal aluminates, alkali metal silicates and mixtures thereof; at least one surfactant selected from the group consisting of anionic surfactants, cationic surfactants, non-ionic surfactants and mixtures thereof; a gas phase and water. This formulation can also comprise a cement, and also additives for foam stabilization, shrinkage reduction, flexibilization, hydrophobization, or dispersion, fibers and fillers or a mixture thereof, and can be a single-component or two-component formulation. Also, a process for the production of this formulation via foaming by mechanical introduction of air, the use of the formulation for the production of an incombustible, sound-absorbing, thermally insulating geopolymer foam element and the geopolymer foam element.

First claim

The invention claimed is:

1. A geopolymer foam formulation comprising:
at least one inorganic binder which includes blast furnace slag, and also microsilica and/or metakaolin;
at least one alkaline activator selected from the group consisting of alkali metal hydroxides, alkali metal carbonates, alkali metal aluminates, alkali metal silicates and mixtures thereof;
at least one alkyl polyglucoside surfactant;
a gas phase and
water.

2. The formulation according to claim 1 , wherein the inorganic binder comprises blast furnace slag and metakaolin.

3. The formulation according to claim 1 , wherein the alkaline activator is selected from alkali metal hydroxides of the formula MOH and alkali metal silicates of the formula m SiO 2 .n M 2 O, where M is the alkali metal, Li, Na, or K or a mixture thereof, and the molar ratio m:n is ≤4.0.

4. The formulation according to claim 3 , wherein the alkaline activator comprises a mixture of alkali metal hydroxides and of alkali metal silicates.

5. The formulation according to claim 1 , wherein the formulation comprises
from 3 to 60% by weight of blast furnace slag,
from 3 to 70% by weight of microsilica and/or metakaolin,
from 0 to 50% by weight of flyash,
from 1 to 55% by weight of alkaline activator (calculated as solids content),
from 10 to 60% by weight of water (total quantity),
and also surfactant and gas phase.

6. The formulation according to claim 1 , wherein the alkyl polyglucoside has the formula H—(C 6 H 10 O 5 ) m —O—R 1 , where (C 6 H 10 O 5 ) is a glucose unit and R 1 is a C 8-12 -alkyl group, and m=from 1 to 5.

7. The formulation according to claim 1 , wherein the gas phase is selected from the group consisting of air, nitrogen, noble gas, hydrocarbons and mixtures thereof.

8. The formulation according to claim 1 , wherein from 20 to 90 percent by volume of the formulation consists of the gas phase.

9. The formulation according to claim 1 , wherein the formulation comprises from 10 to 60% by weight of water.

10. The formulation according to claim 1 , wherein the formulation also comprises at most 20% by weight of a cement, Portland cement, calcium aluminate cement or a mixture thereof.

11. The formulation according to claim 1 , wherein the formulation also comprises at least one additive for foam stabilization, shrinkage reduction, flexibilization, hydrophobization, or dispersion; fibres, fillers, or a mixture thereof.

12. The formulation according to claim 11 , wherein the additive for foam stabilization is selected from the group consisting of fumed silica, proteins, rheology-modifying agents, starches, modified starches, poly(meth)acrylates bearing sulpho and/or quaternized ammonium groups, poly-(meth)acrylamides bearing sulpho and/or quaternized ammonium groups, and mixtures thereof.

13. The formulation according to claim 11 , wherein the additive for shrinkage reduction is selected from the group consisting of amines, alkanolamines, betaine(s), glycols, polyols, hollow aluminosilicate beads, hollow glass beads, foamed glass and mixtures thereof.

14. The formulation according to claim 11 , wherein the additive for flexibilization is selected from the group consisting of redispersible polymer powders, polyisocyanates, polyisocyanate prepolymers, epoxy resins, epoxy compounds and mixtures thereof.

15. The formulation according to claim 11 , wherein the additive for hydrophobization is selected from the group consisting of triglycerides, paraffins, polysiloxanes, hydrosilanes, alkoxysilanes, sodium methylsiliconate and mixtures thereof.

16. The formulation according to claim 11 , wherein the additive for dispersion is selected from the group consisting of comb polymers, polycarboxylate ethers, comb-shaped polyaromatic ethers, comb-shaped cationic copolymers and mixtures thereof.

17. The formulation according to claim 11 , wherein the fibres are selected from the group consisting of rock fibres, glass fibres, carbon fibres, optionally modified organic fibres, cellulose fibres, lignocellulose fibres, metal fibres and mixtures thereof.

18. The formulation according to claim 11 , wherein the fillers are selected from the group consisting of quartz sand, calcium carbonate, rock flour, low-density fillers, pigments, high-density fillers, metal salts and mixtures thereof.

19. The formulation according to claim 1 , wherein either all of the constituents are present together as a single component or solid constituents are held in a first, solid component and the water is held in a second, liquid component.

20. A process for the production of the formulation according to claim 1 , wherein foaming of the formulation is carried out via mechanical introduction of air.

21. The process according to claim 20 , wherein the foaming is carried out with the aid of a stator-rotor process, or of an oscillating process or by means of mechanical agitation.

22. An incombustible, sound-absorbing, thermally insulating geopolymer foam element comprising the geopolymer foam formulation according to claim 1 .

23. The geopolymer foam element according to claim 22 , wherein the geopolymer foam element is in sheet form.

24. The geopolymer foam element according to claim 23 with thickness from 2 cm to 20 cm, and with edge length from 20 cm to 150 cm.

Assignees

• Construction Research & Technology Gmbh

Inventors

• Turcinskas Sarunas
• Mönnig Sven
• Pulkin Maxim
• Herth Gregor
• Zhou Shengzhong

Classifications

• C04B14/106

  Kaolin · CPC title

• C04B28/006 Primary

  containing mineral polymers, e.g. geopolymers of the Davidovits type · CPC title

• C04B2103/006

  Comb polymers · CPC title

• C04B2201/50

  for the mechanical strength · CPC title

• C04B2111/52

  Sound-insulating materials · CPC title