Method for the continuous production of a low-density mineral foam

Patent metadata

Field	Value
Publication number	US-10538462-B2
Application number	US-201515538877-A
Country	US
Kind code	B2
Filing date	Dec 18, 2015
Priority date	Dec 23, 2014
Publication date	Jan 21, 2020
Grant date	Jan 21, 2020

Abstract

A method for the continuous production of a mineral foam of which the density in the dry state (d) is from 40 to 600 kg/m3, includes (i) mixing cement; a water reducing agent; 0.5 to 10%, % by weight with respect to the total weight of cement, of ultrafine particles having a liquid-solid contact angle comprised from 30° to 140°, and of which the D50 is from 10 to 600 nm; water, with a water/cement weight ratio from 0.3 to 2.5; (ii) adding to the mixture from 0.5 to 10% of a pore-forming agent, % by weight with respect to the weight of cement; (iii) applying the mixture obtained at step (ii) on a support; (iv) leaving the mixture to expand on the support.

First claim

The invention claimed is:

1. A method for the continuous production of a mineral foam of which the density in the dry state (d) is comprised from 40 to 600 kg/m 3 , comprising the following steps:
(i) mixing
cement;
a water reducing agent;
0.5 to 10%, % by weight with respect to the total weight of cement, of ultrafine particles having a liquid-solid contact angle comprised from 30° to 140°, and of which the D50 is comprised from 10 to 600 nm;
water, with a water/cement weight ratio comprised from 0.3 to 2.5;

(ii) adding to the mixture from 0.5 to 10% of a pore-forming agent, % by weight with respect to the weight of cement;
(iii) applying the mixture obtained at step (ii) on a support;
(iv) leaving the mixture to expand on the support.

2. The method according to claim 1 , wherein the cement of the mixture of step (i) is a cement of which the Blaine specific surface area is comprised from 5000 to 9000 cm 2 /g.

3. The method according to claim 1 , wherein there is no foaming agent in the mixture of step (i) or (ii).

4. The method according to claim 1 , wherein the mixture of step (i) or step (ii) further comprises a transition metal salt.

5. The method according to claim 4 , wherein the transition metal salt is a manganese salt or an iron salt.

6. The method according to claim 1 , wherein the mixture of step (i) further comprises a mineral addition of which the particles have a D50 comprised from 0.1 to 4 mm.

7. The method according to claim 6 , wherein the mineral addition is selected from the group consisting of a pozzolan, a slag, calcium carbonate, a fly ash, a sand and mixtures thereof.

8. The method according to claim 1 , wherein the pore-forming agent added at step (ii) is a solution of hydrogen peroxide, a solution of peroxomonosulphuric acid, a solution of peroxodisulfphuric acid, a solution of alkaline peroxides, a solution of alkaline earth peroxides, a solution of organic peroxide, a suspension of particles of aluminium or mixtures thereof.

9. The method according to claim 8 , wherein the organic peroxide is peroxoacetic acid or peroxobenzoic acid.

10. The method according to claim 1 , wherein the mixture of step (i) further comprises a hydration accelerator of the cement.

11. The method according to claim 10 , wherein the hydration accelerator is calcium chloride.

12. The method according to claim 1 , wherein the mixture obtained at step (ii) is not fractionated.

13. The method according to claim 1 , wherein at step (iii), the mixture is applied without using a spray nozzle.

14. The method according to claim 1 wherein step (iii) is carried out without a spray.

15. The method according to claim 1 , wherein the support used at step (iii) is treated prior to the application of the mixture obtained at step (ii).

16. A mineral foam capable of being obtained according to the method of claim 1 .

17. A method comprising utilizing the mineral foam according to claim 16 as insulation material.

18. The method according to claim 17 , wherein the insulation material is a thermal or phonic insulation material.

Assignees

• Lafarge Sa
• Holcim Technology Ltd

Inventors

• Bernard Freddy
• Jezequel Pierre-Henri
• Reboussin Sandrine

Classifications

• C04B28/02 Primary

  containing hydraulic cements other than calcium sulfates · CPC title

• C04B2201/30

  for heat transfer properties such as thermal insulation values, e.g. R-values · CPC title

• C04B2111/40

  Porous or lightweight materials · CPC title

• C04B22/124

  Chlorides of ammonium or of the alkali or alkaline earth metals, e.g. calcium chloride · CPC title

• C04B2111/52

  Sound-insulating materials · CPC title