U.S. patent application number 14/816522 was filed with the patent office on 2015-11-26 for foamed glass composite material and a method for using the same.
The applicant listed for this patent is W. Gene Ramsey, Andrew Ungerleider. Invention is credited to W. Gene Ramsey, Andrew Ungerleider.
Application Number | 20150336846 14/816522 |
Document ID | / |
Family ID | 38427377 |
Filed Date | 2015-11-26 |
United States Patent
Application |
20150336846 |
Kind Code |
A1 |
Ungerleider; Andrew ; et
al. |
November 26, 2015 |
FOAMED GLASS COMPOSITE MATERIAL AND A METHOD FOR USING THE SAME
Abstract
An aircraft runway safety area for slowing an aircraft that has
overrun a runway, including a brittle, nondeformable material for
arresting the travel of an aircraft without catastrophically
damaging the aircraft, the nondeformable material being configured
to crush upon being contacted by the aircraft to effect arrest, and
comprising incompressible material in the form of one or more
foamed glass bodies, each respective body having a top surface, a
bottom surface and oppositely disposed side surfaces, and a
frangible matrix encasing the one or more foamed glass bodies, the
frangible matrix fabricated to protect the incompressible material
and having a breaking strength sufficient to readily break without
subverting the arrestment characteristics of the incompressible
material. The frangible matrix is different from the incompressible
material.
Inventors: |
Ungerleider; Andrew; (Santa
Fe, NM) ; Ramsey; W. Gene; (Richland, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ramsey; W. Gene
Ungerleider; Andrew |
Richland
Santa Fe |
WA
NM |
US
US |
|
|
Family ID: |
38427377 |
Appl. No.: |
14/816522 |
Filed: |
August 3, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11276193 |
Feb 17, 2006 |
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14816522 |
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Current U.S.
Class: |
106/676 |
Current CPC
Class: |
C04B 18/141 20130101;
C04B 28/04 20130101; Y02W 30/94 20150501; C04B 38/08 20130101; C04B
14/24 20130101; Y02W 30/91 20150501; C04B 28/04 20130101; C04B
38/08 20130101; C04B 28/04 20130101; C04B 14/24 20130101; C04B
38/08 20130101; C04B 18/141 20130101; C04B 20/04 20130101 |
International
Class: |
C04B 14/24 20060101
C04B014/24 |
Claims
1. An aircraft runway safety area for slowing an aircraft that has
overrun a runway, comprising: a brittle, nondeformable material for
arresting the travel of an aircraft without catastrophically
damaging the aircraft, the nondeformable material being configured
to crush upon being contacted by the aircraft to effect arrest, and
comprising incompressible material in the form of one or more
foamed glass bodies, each respective body having a top surface, a
bottom surface and oppositely disposed side surfaces; and a
frangible matrix encasing the one or more foamed glass bodies, the
frangible matrix fabricated to protect the incompressible material
and having a breaking strength sufficient to readily break without
subverting the arrestment characteristics of the incompressible
material; wherein the frangible matrix is different from the
incompressible material.
2. The runway safety area of claim 1 wherein the incompressible
material is at least about 90 volume percent foamed glass
bodies.
3. The runway safety area of claim 2 wherein the foamed glass
bodies have a closed cell structure.
4. The runway safety area of claim 2 wherein the foamed glass
bodies have a crush strength of between about 50 PSI and about 150
PSI.
5. The runway safety area of claim 2 wherein the foamed glass
bodies have a crush strength of at least about 100 PSI, and wherein
the foamed glass bodies have densities of between about 100
kg/m.sup.3 and 180 kg/m.sup.3.
6. The runway safety area of claim 1 wherein the foamed glass
bodies have compositions in the range of about 72 percent silica,
13 percent Na.sub.2O and about 10 percent CaO.
7. An aircraft runway end safety area for slowing an oncoming
aircraft, comprising: a plurality of brittle incompressible foamed
glass bodies; and a frangible matrix enveloping the respective
foamed glass bodies to define a runway safety area; wherein the
frangible matrix is strong enough to readily break without
subverting the arrestment characteristics of the incompressible
material.
8. The aircraft runway end safety area of claim 7 wherein the
frangible matrix is a concrete, and wherein the plurality of
brittle incompressible foamed glass bodies make up at least 50
volume percent of the runway safety area.
9. The aircraft runway end safety area of claim 7 wherein the
frangible matrix is a concrete, and wherein the plurality of
brittle incompressible foamed glass bodies make up at least 75
volume percent of the runway safety area.
10. The aircraft runway end safety area of claim 7 wherein the
frangible matrix is a concrete, and wherein the plurality of
brittle incompressible foamed glass bodies make up at least 85
volume percent of the runway safety area.
11. The aircraft runway end safety area of claim 7 wherein the
frangible matrix is a concrete, and wherein the plurality of
brittle incompressible foamed glass bodies make up at least 90
volume percent of the runway safety area.
12. The aircraft runway end safety area of claim 7 wherein the
foamed glass bodies have a crush strength of between about 50 PSI
and about 150 PSI.
13. The aircraft runway end safety area of claim 7 wherein the
foamed glass bodies have a crush strength of at least about 100
PSI, and wherein the foamed glass bodies have densities of between
about 100 kg/m.sup.3 and 180 kg/m.sup.3.
14. The aircraft runway end safety area of claim 7 wherein the
runway safety area includes a plurality of raised ridges for
slowing the forward speed of an oncoming aircraft.
15. A runway safety area positioned adjacent a runway, comprising:
a plurality of incompressible foamed glass bodies; and a
cementitious matrix covering and at least partially surrounding the
respective foamed glass bodies and defining a runway safety
composite; wherein the runway safety composite has a principal
compressive failure mode of crushing; wherein the runway safety
composite will preferentially crushingly fail under the compressive
and torsional loads produced by an aircraft rolling over the runway
safety area.
16. The runway safety area of claim 15 wherein the respective
foamed glass bodies have a closed cell structure.
17. The runway safety area of claim 15 wherein the respective
foamed glass bodies have a crush strength of between about 50 PSI
and about 150 PSI.
18. The runway safety area of claim 15 wherein the respective
foamed glass bodies have a crush strength of at least about 100
PSI, and wherein the respective foamed glass bodies have densities
of between about 100 kg/m.sup.3 and 180 kg/m.sup.3.
19. The aircraft runway safety area of claim 15 wherein the runway
safety composite includes a plurality of raised ridges for slowing
the forward speed of an oncoming aircraft.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This continuation-in-part patent application claims priority
to co-pending U.S. patent application Ser. No. 11/276,193 filed on
Feb. 17, 2006.
TECHNICAL FIELD
[0002] The invention relates generally to the field of ceramic
composite materials and, specifically, to an incompressible ceramic
material and/or composite ceramic material having a tailored
failure mode for use as a runway safety area construction material,
and method of making and using such a runway safety area.
BACKGROUND
[0003] Foamed glass is an established lightweight ceramic material.
Typically, foamed glass is made in one of two ways. The first way
involves preparing a stable foam from water and foaming agent,
preparing a wet mixture or slurry of solid components (where cement
is the main substance), quick mixing the foam and the slurry,
filling molds with prepared the mixed foam/slurry, and firing the
same. The second way to make foamed glass involves making use of
the property of some materials to evolve a gas when heated. A
foamed glass material may be prepared by mixing crushed vitreous
particles and a foaming agent (such as CaCO.sub.3 or CaSO.sub.4),
placing the mixture in a mold, heating the mold (such as by passing
the mold through a furnace) to a foaming temperature, and cooling
the mold to produce foamed glass bodies.
[0004] Slag is a nonmetallic byproduct of metallurgical operations.
Slags typically consist of calcium, magnesium, and aluminum
silicates in various combinations. Iron and steel slags are
byproducts of iron and steel production. For example, an iron blast
furnace is typically charged with iron ore, fluxing agents (such as
limestone or dolomite) and coke (as fuel and reducing agent). Iron
ore is typically a mixture of iron oxides, silica, and alumina.
When sufficiently heated, molten slag and iron are produced. Upon
separation of the iron, the slag is left over. The slag occurs as a
molten liquid melt and is a complex solution of silicates and
oxides that solidifies upon cooling.
[0005] The physical properties of the slag, such as its density,
porosity, mean particle size, particle size distribution, and the
like are affected by both its chemical composition and the rate at
which it was cooled. The types of slag produced may thus
conveniently be classified according to the cooling method used to
produce them--air cooled, expanded, and granulated. Each type of
slag has different properties and, thus, different
applications.
[0006] While useful as insulation and as abrasive materials, foamed
glass bodies (made with or without foamed slag), are typically
unsuitable for use as lightweight filler and/or in composite
materials due to factors including cost and the propensity for
foamed glass to hydrate and expand.
[0007] Thus, there remains a need for an easily produced foamed
glass material that is more resistant to expansion from hydration
and/or more easily aged, and for composite materials incorporating
the same. The present invention addresses this need.
SUMMARY
[0008] The technology discussed below relates to manufactured
composite materials, such as roadbed and airport runway safety
areas (RSA's) incorporating lightweight foamed glass and
cementitious or other ceramic materials to define structural
composite materials having controlled failure mode properties, and
the method for making the same. One object of the present invention
is to provide an improved foamed glass-containing structural
composite RSA material. Related objects and advantages of the
present invention will be apparent from the following
description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic view of a first embodiment of a
process for making foamed glass composites.
[0010] FIG. 2A is a schematic view of a second embodiment of a
process for making foamed glass bodies and composites and its
uses.
[0011] FIG. 2B is a schematic view of a third embodiment of a
process for making foamed glass bodies and composites and its
uses.
[0012] FIG. 3A is a schematic view of a process for mixing a batch
of precursors for a foamed glass article according to a fourth
embodiment of the present novel technology.
[0013] FIG. 3B is a schematic view of a process for firing a foamed
glass article mixed according to FIG. 3A.
[0014] FIG. 3C is a perspective view of as milled glass powder
according to the process of FIG. 3B.
[0015] FIG. 3D is a perspective view of rows of milled glass powder
mixture ready for firing.
[0016] FIG. 3E is a perspective view of FIG. 3D after firing into a
substantially continuous foamed glass sheet.
[0017] FIG. 4 is a process diagram of the process illustrated in
FIGS. 3A and 3B.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] For the purposes of promoting an understanding of the
principles of the claimed technology and presenting its currently
understood best mode of operation, reference will now be made to
the embodiments illustrated in the drawings and specific language
will be used to describe the same. It will nevertheless be
understood that no limitation of the scope of the invention is
thereby intended, with such alterations and further modifications
in the illustrated device and such further applications of the
principles of the claimed technology as illustrated therein being
contemplated as would normally occur to one skilled in the art to
which the claimed technology relates.
[0019] Vitreous materials, such as soda-lime-silica glasses and
metallurgical byproduct slags, are typically foamed through a
gasification processes to yield a typically predominately vitreous,
typically silaceous incompressible cellular glass product.
Typically, a foaming precursor is predominately vitreous or
non-crystalline prior to the foaming process, since a glassy
precursor slag material typically has a viscosity at temperature
that is convenient to the foaming process. More typically, the
vitreous starting material will have a traditional soda-lime-silica
glass composition, but other compositions, such as aluminosilicate
glasses, borosilicate glasses, vitreous peralkaline slag or other
vitreous slag compositions may be foamed as well. For example, a
peraluminous slag with significant alkali and alkaline earth oxides
may also be utilized. After the vitreous precursor is foamed, the
foamed glass is physically combined with cement to form a composite
material suitable for building or structural applications or the
like.
[0020] In the case of slagaceous precursor materials, the slag is
typically predominately vitreous in character, and more typically
has a maximum 40% by volume crystalline material. The slag is
typically initially crushed and sized to approximately 10 microns
median particle size, more typically at least 90 percent of all
particles are less than 75 microns.
[0021] If the crushed and/or powdered slag is dry, water is added
to the powdered slag to about 0.1 to about 0.5% (by mass).
Alternately, if no water is added, limestone or other solid foaming
agent may be added (typically about 4 percent or less by mass, more
typically about 2 percent or less by mass). The mixture is then
formed into pellets (between 0.05 and 1 cubic centimeter),
preheated (to no more than within 25.degree. C. of the dilatometric
softening point) and then passed through a high temperature zone,
such as one generated by a rotary kiln or a flame (contained in a
ceramic or refractory metal tube). The residence time in the zone
is short, typically about 0.5 to about 10 seconds, and the
temperature is high (adiabatic flame temperature in excess of
1300.degree. C.). In the case of a flame, the thermal energy
provided to the material by the direct flame enables a change of
state reaction in the foaming agent and the resulting gas will
force the now viscous matter to foam. The foamed pellets or foamed
media are air quenched below the dilatometric softening point of
the material, and then allowed to dry by slow cooling.
[0022] The foamed glass or ceramic media are incompressible and
typically have a relative volume expansion in excess of three fold,
and more typically the volume expansion is as high as 10 fold or
greater. This process results in individual, low-density (specific
gravity less than 0.3) foamed media with a median pore size in the
range of 0.1 to 2 mm.
[0023] Composite materials may be prepared by mixing the foamed
slag with Portland cement; at least two types of composite
materials may be made according to this technique. A first
composite material may be prepared by mixing a thin mixture of
cement with foamed media, wherein the foamed media comprises at
least 85 volume percent of the total cement/other aggregate. The
foamed media are typically incorporated into the cement (and
aggregates, if needed) after the water has been added. The
resulting mixture acts as a very viscous material and is pressure
or gravity formed into a slab (or other coherent shape) or direct
cast into a prefabricated form. The shape or form is then allowed
to set. The resulting composite material sets up to be a rigid,
relatively lightweight (specific gravity <0.75) incompressible
material with surface properties typical of Portland cements.
Chemicals and finishing systems compatible with Portland cement can
be used in conjunction with this material. The resultant composite
material has a brittle fracture or failure mode, with successive
cells fracturing under applied compression. The energy imparted by
a compressive load is thus dissipated through the fracture of
successive glass cells. The composite material is for all practical
purposed substantially or completely rigid and substantially or
completely incompressible and non-deformable, as a compressive load
is supported by a body formed from the composite material without
deformation or compression of the body, until the load exceeds the
compressive strength of the body, whereupon cells begin to
catastrophically fail through a crushing mechanism. At no point
does the body compress or deform such that removal of the applied
force results in a decompression or recoil of the body into its
original uncompressed, undeformed shape.
[0024] A second composite material is formed as a mixture of cement
with typically less than 50 volume percent foamed slag media. The
media is typically dry mixed with cement prior to water additions.
The mixture is then prepared as common cement. Additional
aggregates may be incorporated as per common practice. This second
composite material is likewise incompressible and has a very high
strength; the composite compressive strength is typically at least
25% higher per unit mass than is that of the identical cement
prepared without the foamed slag addition. It can be used in any
application compatible with Portland cement.
[0025] A third incompressible composite material is formed as
aqueous slurry mixture comprised of gypsum with typically less than
50 percent by volume foamed glass or slag. The media are typically
added to the gypsum after the material is slurried. Additional
binders, fillers and setting agents may be added per common
practice. The resulting material has a very low density and high
acoustic absorption. There are no chemical compatibility
limitations on the extent of foamed glass additions. Any
limitations typically arise from strength considerations and other
physical properties.
[0026] In another example, the vitreous precursors 210 to the
foaming process are waste glasses. Waste glasses typically have a
soda-lime-silica composition, and are generally first crushed or
ground 220, and then typically sized 230, to produce a particulate
frit 235 suitable for pelletizing 250 or otherwise forming into
regular shapes for foaming.
[0027] As with slagaceous precursors as described above, if the
particulate waste glass 210 is dry, water may be added to the in
small amounts to promote handling and to better adhere the foaming
agent uniformly to the particles for more even distribution.
Alternately, if no water is added, limestone or other solid foaming
agent 240 may still be added, typically in small amounts (such as
less than 2 percent by mass) and mixed to form a substantially
heterogeneous foamable vitreous mixture. The mixture 245 is then
typically formed 250 into pellets (between 0.05 and 1 cubic
centimeter), loaves, or other regular green bodies 260 convenient
for foaming and is next preheated 265, typically to no more than
within 25.degree. C. of the dilatometric softening point.
Preheating 265 readies the green bodies 260 for rapid heating 270
into the foaming temperature region.
[0028] The preheated green bodies 260 are then passed through a
high temperature zone 275, such as one generated by a rotary kiln
or a flame (contained in a ceramic or refractory metal tube). The
residence time in the zone is short, typically about 0.5 to about
10 seconds, but may be longer for larger green bodies 260. The
temperature is substantially high (adiabatic flame temperature at
least about 1200.degree. C. and typically around 1300.degree. C. or
higher). The rapid influx of thermal energy provided to the
material enables a change of state reaction in the foaming agent
240 and the resulting gas will force the now viscous matter to
foam.
[0029] The foamed bodies 275 are then rapidly quenched 280 to below
the dilatometric softening point of the material, and then allowed
to cool to room temperature at a second, typically slower, cooling
rate. The cooling rate is typically rapid enough such that the
foamed glass 275 does not anneal or only partially anneals,
resulting in a harder foamed glass body 285 with built-in stresses
that enhance its crushing strength and toughness, and also give
rise to a crushing failure mode in compression and torsion. The
cooling rate typically varies due to belt speed. The high end is
typically about 15-25.degree. C. per minute, while the low end is
typically about 10-20.degree. C. per minute for the temperature
range from the foaming temperature to just below the dilatometric
softening point; more typically, cooling from the foaming
temperature to below the dilatometric softening pint temperature
occurs at a rate of about 20 degrees Celsius per minute. The
cooling rate typically diminishes as the body 285 approaches the
softening point.
[0030] After foaming, the bodies 275 leave the kiln and are
quenched 280, typically via exposure to air or forced water jacket
cooling, and the cooling rate is increased to about 25-40.degree.
C. per minute during the rapid quench, more typically at least
about 30 degrees Celsius per minute. After the rapid quench, the
cooling rate is decreased to about 3-10.degree. C. per minute. All
cooling rate values are for the center of the foamed glass bodies
285.
[0031] For foamed media produced on a belt process, the pellets or
green bodies 260 are typically configured such that the resultant
foamed glass bodies 275, 285 have irregular oblong or ovoid shapes.
More typically, the green bodies 260 are preformed or pressed
pellets sized such that the resultant foamed bodies 275, 285 have
major axis dimensions of between about 10 mm and 80 mm.
Accordingly, these bodies 285 are typically sized and shaped to be
engineered drop-in replacements for mined gravel aggregate and have
superior water management, compressive strength, failure mode,
erosion, stackability, chemical stability and toughness properties.
Alternately, the foamed bodies 285 may be made to other convenient
size and shape specifications, such as in larger orthorhombic
parallelepiped or `brick` shapes, still larger `cinder block`
dimensions, relatively thin plates, and the like.
[0032] One advantage of this process is that the furnace residence
time of vitreous bodies 275 during the foaming process is reduced a
factor of 4-9 over most conventional glass foaming techniques.
Moreover, the foamed glass bodies 285 can be produced with mean
cell sizes of less than about 0.2 mm in diameter, and with
typically individual cells sizes ranging down to about 0.1 mm in
diameter or less. Bodies 285 having such small cell sizes are
typically of the closed cell type, which gives rise to crushing
strengths of at least about 50 psi, typically between about 50 and
150 psi, and more typically well over the typical 100 psi (for
comparably dense open cell material) to well over 200 psi. Further,
bodies 285 having substantially open cells sized in the less than
0.1-0.2 mm range exhibit enhanced capillary action and accordingly
rapidly absorb and efficiently retain water.
[0033] The natural break-up of the material under rapid cool down,
due to thermally induced stresses, results in a more angular,
jagged foamed glass body 285 as opposed to a foamed glass piece
shaped by crushing a large body. The physical measure is that the
so-produced foamed glass bodies 285 have a range of aspect ratios
(largest to smallest diameter) about 50% higher than the 1 to 1.25
ratio average for smaller bodies formed via a crushing process.
This gives rise to the 35 degree stacking angle and ensures the
material breaks up before slip failure.
[0034] In one example, oblong, irregularly shaped foamed bodies 285
produced as described above and having major axial dimensions of
about 80 mm are used as fill material 290 behind rock retaining
walls. As these fill material bodies are relatively light weight,
relatively strong in compression, have a characteristic stacking
angle of about 35 degrees and are characterized by an open pore
structure, a substantially smaller volume of foamed glass aggregate
fill is required as compared to traditional mined gravel. For a 6
foot retaining rock wall, the required foundation thickness is
reduced from 54 inches to 24 inches, the required rock is reduced
by 7.5 cubic feet per linear foot of wall, and the required
concrete is reduced by 2.5 cubic feet per linear foot of wall. The
amount of graded fill is reduced from 40 cubic feet per linear foot
of wall to 24 cubic feet per linear foot of wall. This reduction is
made possible by the high stacking angler (about 35 degrees) of the
foamed glass aggregate material 290, the physical manifestation of
which is its tendency to fail by a crushing mechanism (shattering
of the individual cells) instead of the individual aggregate pieces
sliding over themselves. Additionally, the open pore structure of
the foamed glass aggregate 285 gives rise to superior drainage and
water management properties, reducing or eliminating the need for a
separate inlaid drain pipe. In other words, by replacing mined
gravel with engineered foamed glass aggregate 290 characterized by
a high stacking angle, the amount of fill may be nearly halved and,
consequently, the foundation depth and wall thickness may likewise
be substantially reduced.
[0035] Likewise, the foamed glass aggregate fill may replace
traditional mined fill gravel 295 in road beds. Less volume of the
foamed glass aggregate fill is required, as it has superior
strength, porosity and failure mode characteristics, giving rise to
shallower road beds, reduced construction time and expenses, less
excavated dirt to be trucked away, reduced energy usage in road
construction, simplified road drainage, and the like. Moreover, the
roads themselves may be constructed of concrete including foamed
glass aggregate made as described above, which likewise has
enhanced strength and decreased weight characteristics.
[0036] In another embodiment, the foamed glass bodies produced as
described above may be incorporated into acoustic ceiling tiles
300. The foamed glass material is chemically stable and inert,
non-toxic, lightweight, and its porosity gives rise to
sound-dampening. The tiles may be made entirely of shaped foamed
glass (in the form of relatively thin panels), or may incorporate
foamed glass particles or bodies in a structural matrix, such as a
polymer based, fibrous, cementitious, or like matrix material. Of
course, the foamed glass bodies 285 may also be used as aggregate
305 in traditional concrete.
[0037] In another embodiment, incompressible foamed glass bodies
285 are produced, in some typical embodiments as described above,
for incorporation into RSA's 350. Typically, the incompressible
foamed glass bodies 285 are produced having a closed cell or closed
porosity structure to retard or prevent water infiltration and
hydration. The foamed glass material is physically incompressible
and chemically stable and inert. The RSA's 350 are typically formed
from an incompressible foamed glass composite material 360
including foamed glass bodies 285 in a ceramic matrix 370.
Typically, the composite material includes at least about 50 volume
percent foamed glass, more typically at least about 60 volume
percent foamed glass, still more typically at least about 70 volume
percent foamed glass, yet more typically at least about 80 volume
percent foamed glass, and in some embodiments at least about 90
volume percent foamed glass. The foamed glass bodies 285 may be in
the form of aggregate 305, shaped foamed glass blocks, or a
combination of sizes and shapes incorporated into a structural
matrix 370, such as a polymer based, fibrous, cementitious, or like
matrix material. In some embodiments, the foamed glass bodies 285
may also be used as aggregate 305 in traditional concrete. For
RSA's, a higher relative volume of the foamed glass aggregate 305
and/or bodies 285 fill is required, as the composite RSA 360
typically has lower crush strength to provide the desired
predetermined failure mode characteristics, i.e., the RSA 360 will
crush under the weight of an oncoming aircraft to bleed off its
kinetic energy and slow its progress across the RSA 360 until it
stops without incurring significant or catastrophic damage.
Moreover, the RSAs 360 are typically constructed of incompressible
foamed glass bodies 295 and/or aggregate 305 (more typically closed
cell foamed glass aggregate 305 and/or bodies 295) in a thin
ceramic or structural frangible matrix 370, wherein the surface 375
of the RSA 360 is matrix material 370. The matrix 370 may be
concrete, asphalt, or the like. The RSA 360 typically has a solid
surface 375, and more typically has a ridged, textured or contoured
surface 375 to further bleed kinetic energy from an oncoming
aircraft. The frangible matrix 375 typically has a different
composition than the enveloped bodies 295 and/or aggregate 305, and
is more typically sufficiently strong to provide protection and
structural support to the bodies 285, but no so strong as to not
yield to the oncoming aircraft, so as to break readily without
subverting the aircraft arrestment characteristics of the
incompressible material 360.
[0038] For RSA's 360 featuring ridges 363, the ridges 363 are
typically sized to be about the height of a landing gear tire or
less, such that when an oncoming tire encounters a ridge 363, the
tire both crushes the ridge 363 with both oncoming (forward
directed) force and the supported weight (downward directed force)
of the aircraft, to more directly bleed off forward momentum and
thus more efficiently slow the aircraft.
[0039] The foamed glass bodies 285 for the RSA composite 360 may
generally be prepared as described above, albeit the bodies 285 are
typically foamed at a higher temperature, typically between about
1600 degrees Celsius and about 1900 degrees Celsius, to yield a
closed pore structure. In other embodiments, the foamed glass may
be prepared by the techniques described in U.S. Pat. Nos. 5,821,184
and 5,983,671, or the like. In still other embodiments, the foamed
glass is prepared so as to have a very low to substantially zero
crystalline silica content.
[0040] Typically, the foamed glass bodies make up at least 50
volume percent of the RSA composite 360, more typically at least 75
volume percent, still more typically at least 85 volume percent,
yet more typically at least 90 volume percent, and may make up as
much as 95 volume percent or more. By varying the ratio of foamed
glass bodies 295 to cementitious matrix material 375 in the
composite 360, and by varying the thickness of the top layer of
matrix material 375 in the composite 360, the crushing strength of
the composite 360 bed may be `fine-tuned` so as to allow
maintenance and emergency vehicles to traverse the composite 360
beds without crushing them, but not so as to allow an oncoming
aircraft free traverse without crushing the composite 360 beds. In
all cases, the RSA composites 360 including foamed glass bodies 285
are inherently non-flammable.
[0041] FIGS. 3A-4 illustrate another method of producing
lightweight foamed glass matrix 110 defining a plurality of
voluminous, closed off and/or interconnecting pores 115. The pores
115 typically have diameters ranging from about 0.2 mm to about 2.0
mm. The pore walls 117 can be formed to exhibit a crazed or
microcracked microstructure 119. As illustrated schematically in
FIGS. 3A-4, a ground, milled and/or powdered glass precursor 120,
such as recycled waste bottle and/or window glass, is mixed with a
foaming agent 122 (typically a finely ground non-sulfur based gas
evolving material, such as calcium carbonate) to define an
admixture 127. The foaming agent 122 is typically present in
amounts between about 1 weight percent and about 3 weight percent
and sized in the average range of about 80 to minus 325 mesh (i.e.
any particles smaller than this will pass through--typically, the
apertures in 80 mesh are between about 150 and about 200
micrometers across and the apertures in--352 mesh are between about
40 and about 60 micrometers across). More typically, the foaming
agent has a particle size between about 5 and about 150 microns.
Typically, a pH modifier such as dicalcium phosphate 124 is added
to the admixture 27, wherein the pH modifier 124 becomes effective
when the foamed glass product 110 is used in an aqueous
environment. The pH modifier 124 is typically present in amounts
between about 0.5 and 5 weight percent, more typically between
about 1 and about 2 weight percent. Additional plant growth
nutrient material may be added to the starting mixture to vary or
enhance the plant growth characteristic of the final product
110.
[0042] Foamed glass, like most ceramics, is naturally hydrophobic.
As hydrophobic surfaces are not conducive to wetting and impede
capillary action, treatment is typically done to make the pore
walls 117 hydrophyllic. In one embodiment, the pore walls 117 are
coated to form a plurality of microcracks 119 therein. The
microcracks 119 supply increased surface area to support wicking.
Alternately, or in addition, an agent may be added to further amend
the surface properties to make the foamed glass more hydrophilic.
Such an agent may be a large divalent cation contributor, such as
ZnO, BaO, SrO or the like. The hydrophilic agent is typically added
in small amounts, typically less than 1.5 weight percent and more
typically in amounts of about 0.1 weight percent.
[0043] The combination is mixed 126, and the resulting dry mixture
127 may then be placed into a mold 128, pressed into a green body
and fired without the use of a mold, or, more typically, arrayed
into rows 131 of powder mixture 127 for firing and foaming.
Typically, whether placed 129 into the mold 128 or not, the mixture
127 is typically arrayed in the form of several rows 131, such as
in mounds or piles of mixture typically having a natural angle of
repose of about 15 to 50 degrees, although even greater angles to
the horizontal can be achieved by compressing the dry mixture 127.
This arraying of the rows 131 allows increased control,
equilibration and optimization of the heating of the powder 127
during firing, reducing hot and cold spots in the furnace as the
powder 127 is heated. This combing of the powder 127 into typically
rows 131 of triangular cross-sections allows heat to be reflected
and redirected to keep heating of the rows generally constant.
[0044] The mold 128, if used, is typically a refractory material,
such as a steel or ceramic, and is more typically made in the shape
of a frustum so as to facilitate easy release of the final foamed
glass substrate 110. Typically, the inside surfaces of the mold 128
are coated with a soft refractory release agent to further
facilitate separation of the foam glass substrate 110 from the mold
128. In a continuous process, the powder 127 is typically supported
by a fiberglass mesh fleece or the like to prevent fines from
spilling as the powder 127 is moved via conveyor through a tunnel
kiln; the fleece is burned away as the powder 127 sinters.
[0045] The so-loaded mold 128 is heated 130 in a furnace by either
a batch or continuous foaming process. More typically, the mixture
127 is then heated 130 in order to first dry 132, the sinter 134,
fuse 136, soften 138, and foam 140 the mixture 127 and thereby
produce a foamed glass substrate 110 having a desired density, pore
size and hardness. As the powdered mixture 127 is heated to above
the softening point of glass (approximately 1050 degrees
Fahrenheit) the mixture 127 begins to soften 138, sinter 134, and
shrink. The division of the powdered mixture 127 into rows or
mounds allows the glass to absorb heat more rapidly and to
therefore foam faster by reducing the ability of the foaming glass
to insulate itself. At approximately 1025 degrees Fahrenheit, the
calcium carbonate, if calcium carbonate has been used as the
foaming agent 122, begins to react with some of the silicon dioxide
in the glass 120 to produce calcium silicate and evolved carbon
dioxide. Carbon dioxide is also evolved by decomposition of any
remaining calcium carbonate once the mixture reaches about 1540
degrees Fahrenheit, above which calcium carbonate breaks down into
calcium oxide and carbon dioxide gas. Once the temperature of the
mixture 127 reaches about 1450 degrees Fahrenheit, the glass
mixture 127 will have softened sufficiently for the released carbon
dioxide to expand and escape through the softened, viscous glass;
this escape of carbon dioxide through the softened glass mass is
primarily responsible for the formation of cells and pores therein.
The mixture 127 in the mold 128 is held for a period of time at a
peak foaming temperature of, for example, between about 1275 and
about 1900 degrees Fahrenheit, more typically between about 1550
and about 1800 degrees Fahrenheit, still more typically between
about 1650 and about 1850 degrees Fahrenheit, or even higher,
depending on the properties that are desired. By adjusting the
firing temperatures and times, the density and hardness as well as
other properties of the resultant substrate 110 may be closely
controlled.
[0046] As the mixture 127 reaches foaming temperatures, each mass
of foaming 140 glass, originating from one of the discrete rows or
mounds, expands until it comes into contact and fuses with its
neighbors. The fused mass of foaming glass then expands to conform
to the shape of the walls of the mold 128, filling all of the
corners. The shapes and sizes of the initial mounds of mixture are
determined with the anticipation that the foaming 140 mixture 127
exactly fills the mold 128. After the glass is foamed 140 to the
desired density and pore structure, the temperature of the furnace
is rapidly reduced to halt foaming 140 of the glass. When the
exterior of the foamed glass in the mold has rigidified
sufficiently, the resultant body 110 of foamed glass is removed
from the mold 128 and is typically then air quenched to thermally
shock the glass to produce a crazed microstructure 119. Once
cooled, any skin or crust is typically cut off of the foamed glass
substrate 110, which may then be cut or otherwise formed into a
variety of desired shapes. Pore size can be carefully controlled
within the range of about 5 mm to about 0.5 mm, more typically
within the range of between about 2.0 mm and 0.2 mm. Substrate
density can be controlled from about 0.4 g/cc to about 0.26 g/cc.
Typically, the bulk density of the crushed foam may be as low as
50% of the polyhedral density.
[0047] The substrate 110 may be either provided as a machined
polyhedral shape 110 or, more typically, as a continuous sheet that
may be impacted and/or crushed to yield aggregate or pebbles 150
(typically sized to be less than 1 inch in diameter). The crushed
substrate material 150 may be used to retain water and increase air
volume in given soil combinations. The polyhedrally shaped
substrate bodies 110 are typically sized and shaped as aggregate
for use in an RSA composite material. The foamed glass material 110
itself is typically resistant to aqueous corrosion and has minimal
impact on solution pH. In order to provide better pH control, the
foamed glass material 110 is typically doped (in batch stage, prior
to foaming) with specific dicalcium phosphate or a like pH
stabilizing material 124 which dissolves in water to help stabilize
the pH. The foamed glass substrate 110 can typically hold between
about 1.5 and about 5 times its own weight in water in the
plurality of interconnected pores 117.
[0048] Crushed foam bodies 150 may be rapidly made by an alternate
method. Using soda-lime glass frit or powder as the glass component
122, the processing is similar to that described above but without
the annealing step. The alternate method employs the same foaming
temperature ranges as related above. The batch material 127
consists of up to 8 percent by mass limestone, magnesite, or other
applicable foaming agent 122, usually less than 2 percent by mass
dicalcium phosphate 124, with the balance being a borosilicate,
silicate, borate or phosphate glass frit 122. The batch 127 is then
placed in a typically shallow mold 128, more typically having a
configuration of less than 2'' batch for every square yard of mold
surface. The mold 128 is typically then heated to approximately
250.degree. C. above the dilatometric softening point for soda-lime
glass (or the equivalent viscosity for other glass compositions)
and allowed to foam. The mold 128 is held at the foaming
temperature for less than 30 minutes and then pan quenched, i.e.
substantially no annealing is allowed to occur
[0049] This method typically yields a material 110 of density less
than 0.25 g/cc, and more typically as low as about 0.03 g/cc. This
material 110 is then crushed into pebbles 150, with a corresponding
lower bulk density as per the above-described method. Material made
by this alternate method has similar chemical properties as
described above but has substantially lower strength.
[0050] Still another alternate method of preparing foamed glass
substrate material 110 is as follows. A batch 127 is prepared as
discussed above and pressed into small (typically less than 5 mm
diameter) pellets. The pellets are rapidly heated, such as by
passage through a flame source, passage through a rotary furnace,
or the like. Typically, the pellets are heated to about 1500
degrees Fahrenheit, such as to cause the pellet to expand as a foam
particulate without the need for a mold. This material yields the
weakest, but least dense foam particles. The typical density may be
as low as 0.02 g/cc or as high as 0.2 g/cc, or higher.
[0051] The foamed glass substrate 110 typically has a porosity in
the range of between about sixty-five and about eighty-five
percent. Air holding capacity is typically between about forty and
about fifty-five percent.
[0052] The pore size is typically between about 0.2 mm and about
2.0 mm in diameter, with a relatively tight pore size distribution.
The finished substrate 110 is typically processed through a series
of conveyors and crushing equipment to yield a desired size spread
of pellets 150.
[0053] The precursor glass material is typically recycled or
post-consumer waste glass, such as plate, window and/or bottle
glass. The glass is ground or milled to a fine mesh profile of
minus 107 microns. A typical sieve analysis of the precursor glass
is given as Table 1, and a compositional analysis of the glass is
given as Table 2.
TABLE-US-00001 TABLE 1 Sieve Analysis Class up to (.mu.m) Pass (%)
Remaindser (%) Incidence (%) 0.7 1.3 98.7 1.3 0.9 1.6 98.4 0.3 1
1.8 98.2 0.2 1.4 2.8 97.2 1.0 1.7 3.7 96.3 0.9 2 4.6 95.4 0.9 2.6
6.4 93.6 1.8 3.2 7.9 92.1 1.5 4 9.9 90.1 2.0 5 12.0 88 2.1 6 14.0
86 2.0 8 17.5 82.5 3.5 10 20.5 79.5 3.0 12 23.3 76.7 2.8 15 27.3
72.7 4.0 18 31.1 68.9 3.8 23 37.2 62.8 6.1 30 45.1 54.9 7.9 36 51.2
48.8 6.1 45 59.2 40.8 8.0 56 67.6 32.4 8.4 63 72.3 27.7 4.7 70 76.6
23.4 4.3 90 86.5 13.5 9.9 110 92.7 7.3 6.2 135 97.1 2.9 4.4 165
99.3 0.7 2.2 210 100.0 0 0.7
TABLE-US-00002 TABLE 2 Glass oxide Wt. % SiO.sub.2 71.5 Na.sub.2O
12.6 K.sub.2O 0.81 Al.sub.2O.sub.3 2.13 CaO 10.1 MgO 2.3 TiO.sub.2
0.07 Fe.sub.2O.sub.3 0.34 BaO 0.01 SO.sub.3 0.05 ZnO 0.01
[0054] While the invention has been illustrated and described in
detail in the drawings and foregoing description, the same is to be
considered as illustrative and not restrictive in character. It is
understood that the embodiments have been shown and described in
the foregoing specification in satisfaction of the best mode and
enablement requirements. It is understood that one of ordinary
skill in the art could readily make a nigh-infinite number of
insubstantial changes and modifications to the above-described
embodiments and that it would be impractical to attempt to describe
all such embodiment variations in the present specification.
Accordingly, it is understood that all changes and modifications
that come within the spirit of the invention are desired to be
protected.
* * * * *