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

Patent metadata

Field	Value
Publication number	US-2016244366-A1
Application number	US-201415030490-A
Country	US
Kind code	A1
Filing date	Oct 14, 2014
Priority date	Oct 31, 2013
Publication date	Aug 25, 2016
Grant date	—

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, fibres 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

1 . 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.

2 . The formulation according to claim 1 , wherein the inorganic binder is selected from the group consisting of blast furnace slag, microsilica, metakaolin, aluminosilicates, flyash and mixtures thereof.

3 . The formulation according to claim 2 , wherein the inorganic binder comprises metakaolin.

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

5 . The formulation according to claim 1 , wherein the inorganic binder comprises blast furnace slag, and also microsilica and/or metakaolin.

6 . 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.

7 . The formulation according to claim 6 , wherein the alkaline activator comprises a mixture of alkali metal hydroxides and of alkali metal silicates.

8 . 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.

9 . The formulation according to claim 1 , wherein the surfactant is a non-ionic surfactant, preferably optionally an alkyl polyglucoside.

10 . The formulation according to claim 9 , wherein the alkyl polyglucoside is present and 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′ is a C 8-12 -alkyl group, and m=from 1 to 5.

11 . 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.

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

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

14 . 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.

15 . 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.

16 . The formulation according to claim 15 , 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, and poly-(meth)acrylamides bearing sulpho and/or quaternized ammonium groups, and mixtures thereof.

17 . The formulation according to claim 15 , 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.

18 . The formulation according to claim 15 , 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.

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

20 . The formulation according to claim 15 , 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.

21 . The formulation according to claim 15 , 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.

22 . The formulation according to claim 15 , 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.

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

24 . 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.

25 . The process according to claim 24 , 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.

26 . (canceled)

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

28 . The geopolymer foam element according to claim 27 , wherein the geopolymer foam element is in sheet form.

29 . The geopolymer foam element according to claim 28 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

• C04B2111/40

  Porous or lightweight materials · CPC title

• C04B18/141

  Slags · CPC title

• C04B2103/0088

  Compounds chosen for their latent hydraulic characteristics, e.g. pozzuolanes · CPC title

• C04B2111/52

  Sound-insulating materials · CPC title

• C04B2111/28

  Fire resistance, i.e. materials resistant to accidental fires or high temperatures · CPC title