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1. (WO1983001441) PROCEDE ET COMPOSITION PERMETTANT DE FABRIQUER DE LA MOUSSE DE VERRE A PARTIR DE DIATOMITE ET DE CENDRES VOLANTES
Note: Texte fondé sur des processus automatiques de reconnaissance optique de caractères. Seule la version PDF a une valeur juridique

Claims

1. A process for making a foam glass body from diatomaceous earth, fly ash, volcanic ash and mixtures thereof comprising:
(a) impregnating diatomaceous earth, fly ash, volcanic ash or a mixture thereof with an impregnating solution comprising at least one water soluble glass former, at least one water soluble flux, at least one water soluble carbohydrate gas generator, and water to form an impregnated material;
(b) heating the impregnated material above the glass transition temperature of the impregnated material;
(c) cooling the impregnated material;
(d) pulverizing the cooled impregnated
material; and
(e) heating the pulverized impregnated
material in an oxidizing atmosphere to a sufficient temperature to cause foaming of the impregnated material thereof thereby forming a foam glass body.
2. A process for making a foam glass body comprising:
(a) heating diatomaceous earth, fly ash, wash ash or a mixture thereof to at least 500°C to form a calcined material;
(b) impregnating the calcined material with an impregnating solution comprising at least one water soluble glass former, at least one water soluble flux, at least one water soluble gas generator, and water;
(c) heating the impregnated material to a sufficient temperature to cause foaming of the impregnated material thereby forming a foam glass body; and
(d) cooling the foam glass body.

3. A process for making a foam glass body from diatomaceous earth or a mixture of diatomaceous earth and fly ash comprising:
(a) forming a bed of diatomaceous earth or a mixture of diatomaceous earth and fly ash;
(b) passing an impregnating solution through the bed to impregnate the diatomaceous earth or mixture of diatomaceous earth and fly ash and form an impregnated material, said impregnating solution comprising at least one water soluble glass former, at least one water soluble flux, at least one water soluble gas generator, and water;
(c) heating the impregnated material to a sufficient temperature to cause foaming of the impreg nated material thereby forming a foam glass body; and
(d) cooling the foam glass body.
4. The process of claims 1, 2 or 3, wherein the diatomaceous earth is calcined diatomaceous earth.
5. The process of claims 1, 2 or 3, wherein the diatomaceous earth is flux-calcined diatomaceous earth.
6. The process of claims 1, 2 or 3, wherein the fly ash is calcined fly ash.
7. The process of claims 1, 2, or 3, wherein the impregnated material is dried to a water content less than about 5 weight percent, pulverized to a
particle size less than 1 mm, and placed in a mold prior to heating.
8. The process of claims 1, 2 or 3, wherein the temperature which causes foaming is about 720 to

1000°C.
9. The process of claim 1 wherein the
impregnated material is heated to about 800 to 1100°C and the pulverized impregnated material is heated to about 800 to 1000°C.

10. The method of claim 3, wherein the
impregnating solution is passed through the bed by continuously introducing impregnating solution at a point below the bed at sufficient velocity to fluidize the bed.
11. The process of claim 3, wherein a gas is passed upwardly through the bed and impregnating solution to fluidize the bed.
12. The process of claims 1, 2, or 3, wherein the impregnating solution contains water soluble glass former in an amount expressed as its oxide of about 3 to 14 weight percent, water soluble flux in an amount expressed as its oxide of about 10 to 20 weight percent, and water in an amount of about 50 to 80 weight percent.
13. The process of claim 12, wherein the water soluble glass former is a member of the group consisting of a boron oxide containing compound, a silicon oxide containing compound, a phosphorus oxide containing compound and mixtures thereof.
14. The process of claim 12, wherein the water soluble flux is an alkali metal flux.
15. The process of claim 12, wherein the gas generator is a carbon oxide gas generator.
16. The process of claims 2 or 3, wherein the carbon oxide gas generator is selected from the group consisting of carbonates, bicarbonates, carbohydrates, and mixtures thereof.
17. The process of claims 1 or 16, wherein the carbohydrate is selected from the group consisting of sugar and glycerin.
18. The process of claims 1, 2, or 3, wherein the impregnated material contains modifiers selected from the group consisting of volcanic ash, petalite, perlite, sand, silica dust, clays, refractory slags, gypsum, talc, glass powder, refractory fibrous material, naturally occurring minerals and oxides, and mixtures thereof.
19. The process of claim 18, wherein the modifier is volcanic ash.
20. The process of claims 1, 2 or 3, wherein the water soluble glass former is selected from the group consisting of boric acid, alkali metal borates and mixtures thereof, in an amount expressed as boron oxide of about 4 to 9 weight percent of the solution, the flux is selected from the group consisting of
alkali metal carbonates, alkali metal bicarbonates, alkali metal borates, alkali metal silicates, alkali metal phosphates and mixtures thereof in an amount
expressed as alkali metal oxide of about 12 to 16
weight percent of the impregnating solution, the gas generator is a carbon oxide gas generator, and water is present in an amount of about 55 to 70 weight percent of the solution.
21. The process of claims 1, 2 or 3, wherein the water soluble glass former is an alkali metal
silicate in an amount expressed as silicon oxide of about 5 to 11 weight percent of the solution, the flux is an alkali metal carbonate, alkali metal bicarbonate, alkali metal borate, alkali metal silicate, alkali
metal phosphate, or mixture thereof in an amount expressed as alkali metal oxide of about 12 to 19 weight percent of the impregnating solution, the gas generator is a carbon oxide gas generator, and water is prejsent in an amount of about 55 to 70 weight percent of the solution.
22. The process of claims 1, 2 or 3, wherein the water soluble glass former is a mixture of an
alkali metal silicate and a boron oxide containing
compound selected from the group consisting of boric acid, alkali metal borates, and mixtures thereof, in an amount expressed as their oxide of about 5 to 14 weight percent of the solution, the boron oxide containing
compound being present in solution in an amount expressed as boron oxide greater than about 0.5 weight percent, the flux is alkali metal carbonate, alkali metal bicarbonate, alkali metal borate, alkali metal silicate, alkali metal phosphate, or mixture thereof in an amount expressed as alkali metal oxide of about 12 to 19 weight percent of the impregnating solution, the gas generator is a carbon oxide gas generator, and water is present in an amount of about 55 to 70 weight percent of the solution.
23. The process of claims 1, 2 or 3, wherein the water soluble glass former is a mixture of an
alkali metal silicate and a phosphorus oxide containing compound selected from the group consisting of alkali metal phosphates in an amount expressed as their oxide of about 5 to 14 weight percent of the solution, the
phosphorus oxide containing compound being present in solution in an amount expressed as phosphorus oxide
greater than about 0.5 weight percent, the flux is
alkali metal carbonate, alkali metal bicarbonate,
alkali metal borate, alkali metal silicate, alkali
metal phosphate, or mixture thereof in an amount expressed as alkali metal oxide of about 12 to 19 weight percent of the impregnating solution, the gas generator is a
carbon oxide gas generator, and water is present in an amount of about 55 to 70 weight percent of the solution.
24. The process of claim 3, wherein excess impregnating solution is removed from the bed of impregnated diatomaceous earth or mixture of diatomaceous
earth and fly ash by applying a pressure differential across the bed.
25. A process for making a foam glass body from diatomaceous earth, fly ash or a mixture thereof comprising: (a) impregnating diatomaceous earth, fly ash or a mixture thereof using an impregnating solution comprising at least one water soluble glass former selected from the group consisting of boron oxide containing compound, and a mixture of a boron oxide containing compound and a silicon oxide containing compound, in an amount expressed as their oxide of about 3 to 20 weight percent, at least one water soluble alkali metal flux, in an amount expressed as alkali oxide of about 10 to 20 weight percent, at least one water soluble gas generator, and water in an amount of about 50 to 80 weight percent;
(b) heating the impregnated diatomaceous earth, fly ash or mixture thereof to a sufficient temperature to cause foaming of the impregnated diatomaceous earth, fly ash or mixture thereof, thereby forming a foam glass body; and
(c) cooling the foam glass body having a surface glaze.
26. The process of claim 25, wherein the boron oxide containing compound is present in an amount of about 4 to 9 weight percent, the alkali metal flux is present in an amount of between about 12 to 16 weight percent, the gas generator is carbon oxide gas generator and is present in an amount expressed as carbon of about 1.5 to 3.5 weight percent, and water is present in an amount of about 55 to 70 weight percent.
27. The process of claim 25, wherein the mixture of silicon oxide containing compound and boron oxide containing compound are present in solution in an amount of about 5 to 14 weight percent, the alkali metal flux is present in solution in an amount of about 12 to 19 weight percent, the gas generator is a carbon dioxide gas generator and is present in solution in an amount expressed as carbon of about 1.5 to 3.5 weight percent, and water is present in an amount of about 55 to 70 weight percent, said boron oxide containing
compound being present in solution in an amount greater than about 0.5 weight percent.
28. The process of claim 26, wherein the alkali metal flux is selected from the group consisting of alkali metal carbonates and alkali metal bicarbonates.
29. The process of claim 25, wherein the gas generator is a carbon oxide gas generator.
30. The process of claim 29, wherein the carbon oxide gas generator is selected from the group consisting of carbonates, bicarbonates, carbohydrates, and mixtures thereof.
31. The process of claim 30, wherein the carbohydrate is selected from the group consisting of sugar and glycerin.
32. The process of claim 25, wherein the diatomaceous earth is selected from the group consisting of natural diatomaceous earth, calcined diatomaceous earth, and flux-calcined diatomaceous earth.
33. A composition for making a foam glass comprising on a dry basis:
(a) about 55 to 85 weight percent diatomaceous earth, fly ash or mixture thereof or combinations
thereof with at least one water insoluble modifier, said diatomaceous earth being selected from the group consisting of calcined and flux-calcined diatomaceous earth and said fly ash being calcined fly ash;
(b) about 2.5 to 20 weight percent of at least one water soluble glass former expressed as its oxide;
(c) about 8 to 20 weight percent of at least one water soluble flux expressed as its oxide; and
(d) a water soluble gas generator.

34. The composition of claim 33, wherein the composition contains about 55 to 70 weight percent of the diatomaceous earth, fly ash or mixture or combination thereof and about 5 to 15 weight percent of at least one water soluble glass former.
35. The composition of claim 33, wherein the glass former is selected from the group consisting of a boron oxide containing compound, a silicon oxide containing compound, a phosphorus oxide containing compound and mixtures thereof; the flux is an alkali metal flux; and the gas generator is a carbon oxide gas generator.
36. The composition of claim 35, wherein the silicon oxide containing compound is an alkali metal silicate.
37. The composition of claim 35, wherein the carbon oxide gas generator is selected from the group consisting of carbonates, bicarbonates, carbohydrates, and mixtures thereof.
38. The composition of claim 37, wherein the carbohydrate is sugar or glycerin.
39. The composition of claim 33, wherein the at least one water insoluble modifier is selected from the group consisting of volcanic ash, petalite, perlite, sand, silica dust, clays, refractory slag, gypsum, talc, glass powders, refractory fibers, naturally
occurring minerals and oxides and mixtures thereof, said modifier being present in an amount less than 50 weight percent based on diatomaceous earth, fly ash or mixture thereof.
40. A composition for making a foam glass comprising on a dry basis:
(a) about 55 to 85 weight percent diatomaceous earth, fly ash or mixture thereof or combination thereof with at least one water insoluble modifier;

(b) about 2.5 to 12 weight percent of at least one water soluble boron oxide containing compound glass former expressed as its oxide;
(c) about 8 to 20 weight percent of at least one water soluble flux expressed as its oxide; and
(d) a water soluble gas generator.
41. The composition of claim 40, wherein the composition contains about 55 to 70 weight percent of the diatomaceous earth, fly ash or mixture or combination thereof and about 3.5 to 8 weight percent of the boron oxide.
42. The composition of claim 40, wherein the flux is an alkali metal flux and the gas generator is a carbon oxide gas generator.
43. The process of claim 42, wherein the carbon oxide gas generator is selected from the group consisting of carbonates, bicarbonates, carbohydrates, and mixtures thereof.
44. The composition of claim 43, wherein the carbohydrate is sugar or glycerin.
45. The composition of claim 40, wherein the diatomaceous earth is calcined diatomaceous earth and the fly ash is calcined fly ash.
46. The composition of claim 45, wherein the at least one water insoluble modifier is selected from the group consisting of volcanic ash, petalite, perlite, sand, silica dust, clays, refractory slag, gypsum, talc, glass powders, refractory fibers, naturally
occurring minerals and oxides and mixtures thereof, said modifier being present in an amount less than
about 50 weight percent based on diatomaceous earth, fly ash or mixture thereof.

47. A shaped foam glass body having a substantially water impermeable non-porous glazed outer surface and a porous interior comprising about 18 to 22 weight percent alkali oxide, about 6 to 10 weight percent boron oxide or phosphorus oxide and about 58 to 76 weight percent substantially silica, alumina and iron oxide.
48. A shaped foam glass body according to claim 47 having a substantially water impermeable
non-porous outer surface and a porous interior.
49. The foam glass body of claims 47 or 48 which is shaped in the form of a member selected from the group consisting of a roof shingle, exterior siding, or rigid sheet insulation.
50. A composite concrete-foam glass body wherein the glass body portion is formed from the
composition of claims 33 or 40.
51. The composite concrete-foam glass body according to claim 50 wherein the foam glass body is fused to the concrete by contacting the foam glass body with wet concrete.