U.S. patent number 3,640,787 [Application Number 04/623,882] was granted by the patent office on 1972-02-08 for method of producing shaped bodies of low specific gravity.
Invention is credited to Rudolf Heller.
United States Patent |
3,640,787 |
Heller |
February 8, 1972 |
METHOD OF PRODUCING SHAPED BODIES OF LOW SPECIFIC GRAVITY
Abstract
Bodies of low specific gravity produced by coating a mass of
roundish hollow granules, such as expanded or swelled polystyrene
granules, with a hardenable liquid binder material, mixing the mass
of thus coated granules with a pulverulent solid material so as to
adhere particles of the solid material to the coating, and
hardening the hardenable binder coating, and shaped cellular
structures formed by compressing the mass of hardenable binder
coated hollow granules having pulverulent material adhering to the
coating during or prior to the hardening of the hardenable liquid
binder material.
Inventors: |
Heller; Rudolf (Zurich,
CH) |
Family
ID: |
25694902 |
Appl.
No.: |
04/623,882 |
Filed: |
March 17, 1967 |
Foreign Application Priority Data
|
|
|
|
|
Mar 23, 1966 [CH] |
|
|
4201/66 |
Jul 1, 1966 [CH] |
|
|
9601/66 |
|
Current U.S.
Class: |
156/77; 52/325;
156/296; 264/DIG.7; 428/407; 156/279; 252/62; 264/122; 264/123 |
Current CPC
Class: |
B29C
67/207 (20130101); C04B 26/10 (20130101); C08J
9/22 (20130101); F16L 59/14 (20130101); B29C
44/12 (20130101); C04B 20/12 (20130101); B29C
70/00 (20130101); C08J 9/236 (20130101); C04B
26/02 (20130101); E04C 2/205 (20130101); B29K
2309/08 (20130101); Y10S 264/07 (20130101); Y10T
428/2998 (20150115); B29K 2105/06 (20130101) |
Current International
Class: |
B29C
44/02 (20060101); B29C 44/12 (20060101); C04B
20/12 (20060101); C04B 26/02 (20060101); C04B
20/00 (20060101); C04B 26/00 (20060101); C04B
26/10 (20060101); B29C 67/20 (20060101); B29C
70/00 (20060101); F16L 59/00 (20060101); E04C
2/10 (20060101); C08J 9/236 (20060101); C08J
9/00 (20060101); C08J 9/22 (20060101); E04C
2/20 (20060101); F16L 59/14 (20060101); F16l
059/00 (); C04b 043/00 (); B32b 019/00 () |
Field of
Search: |
;181/33
;161/160,161,68,43,168 ;52/323,325,404-407,421,503,504,698,747
;252/62 ;156/279,296,77 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Ansher; Harold
Claims
What is claimed as new and desired to be protected by Letters
Patent is set forth in the appended claims.
1. A method of producing shaped bodies of low specific gravity,
comprising the steps of introducing into a mixing container a mass
of discrete roundish hollow granules; thereupon introducing into
said mixing container a hardenable liquid binder material and
stirring the resulting mixture so as to cause substantially
complete wetting of the outer surfaces of said granules with said
liquid binder material and formation of a coating of said liquid
binder material on said outer surfaces; stirring into the thus
formed mass of wetted granules a pulverulent solid material so as
to adhere particles of said solid pulverulent material to said
binder material coating on said hollow granules to thereby form a
flowable dry nonadhering mass composed of said hollow granules
which are provided, respectively, with a shell consisting of said
coating of hardenable binder material and particles of said
pulverulent material adhering thereto and at least partially
embedded therein; and subjecting said flowable mass to elevated
pressure while causing hardening of said binder material, to
thereby obtain a coherent, shaped cellular body.
2. A method as defined in claim 1, wherein the mass of
shell-covered hollow granules is subjected to an elevated pressure
sufficient to reduce the volume of said mass by at least 25 percent
during deformation thereof into said shaped body.
3. A method as defined in claim 1, wherein said roundish hollow
granules are foamed particles of plastic material and said
hardenable binder material is heat hardenable.
4. A method as defined in claim 3, wherein said roundish hollow
granules are expanded polystyrene granules.
5. A method as defined in claim 3, wherein said solid pulverulent
material is a mineral material.
6. A method as defined in claim 3, wherein said solid pulverulent
material is a metal powder.
7. A method as defined in claim 3, wherein said hollow foamed
granules of plastic material, respectively, have diameters of
between about 2 and 8 mm.
8. A method as defined in claim 3, wherein said particles of
pulverulent solid material, respectively, have a size of between
about 0.01 and 0.4 mm.
9. A method as defined in claim 1, wherein said hardening of said
hardenable binder material is carried out by blowing hot gas
through the mass of shell-covered hollow particles.
10. A method as defined in claim 9, wherein said hot gas is hot
air.
11. A method as defined in claim 1, and including the step of
adhesively adhering a substantially planar cover material to at
least a portion of said shaped, coherent cellular body.
12. A method as defined in claim 1, and including the step of
incorporating in said mass of shell-covered hollow granules, prior
to subjecting said mass to said elevated pressure, at least one
solid body having a specific gravity higher than that of said
shaped, coherent cellular body.
13. A method as defined in claim 1, and including the step of
adhering to at least a portion of the surface of said shaped, body,
during compression of same and hardening of the hardening binding
material thereof, a substantially planar surface layer.
14. A method as defined in claim 13, wherein said planar layer
consists of a sheet material.
15. A method as defined in claim 14, wherein said sheet material is
a metal sheet.
16. A method as defined in claim 14, wherein said sheet material is
a foil of nonmetallic material.
17. A method as defined in claim 1, and including the step of
anchoring and at least partially embedding at least one auxiliary
member in the mass of shell-covered hollow granules during
compressing of the latter.
18. A method as defined in claim 17, wherein said auxiliary member
is a connecting member.
19. A method as defined in claim 17, wherein said auxiliary member
is a reinforcing member.
Description
BACKGROUND OF THE INVENTION
The present invention relates to shaped bodies of low specific
gravity which consist essentially of a hollow shell formed of
hardened binder material having solid particulate material
incorporated therein and including in the interior of the hollow
shell, only partly filling such interior, a plastic material which
may be in the form of a hollow granule adhering to the inner face
of the respective shell. The present invention is also concerned
with a cellular structure comprising cell walls consisting of
hardened binder material having incorporated therein solid
pulverulent particles and including in substantially each cell of
the cellular structure, either as a thin layer adhering to the
inner face of the cell walls, or otherwise partly filling the
interior of the cell, a plastic material which at least during the
first stages of producing such structure was present in the form of
discrete roundish hollow granules.
The present invention thus relates to bodies of low specific
gravity and a method of producing the same. The product of the
present invention may be a loose mass of roundish bodies, for
instance of spheric or spheroid shape, which may be introduced as
aggregate into a concrete-forming mass, a gypsum mass or other
casting masses, in order to reduce the specific gravity or
heat-conductivity thereof and/or to increase the mechanical
strength thereof. The mass of roundish granules formed according to
the present invention may also serve as additive as described above
in place of the conventional roundish and porous granules of
swelling clay. Granules of swelling clay are available at
relatively low cost and also possess considerable strength and
shape-retention, however, they have a specific gravity of between
about 0.9 and 1.5 and thus are relatively heavy. Furthermore, they
possess considerable heat conductivity. In addition, swelling clay
granules are capable of absorbing water more or less like a sponge.
Thus, for instance, building walls of concrete including swelling
clay granules as an additive dry only very slowly and, under
unfavorable climatic conditions, will become moist again. In moist
condition, the heat-conductivity and heat capacity of granules of
swelling clay is of the same magnitude as that of concrete formed
without such additive.
If granules of swelling clay are introduced as additive into foamed
masses, for instance of polystyrene or hardenable urethane foam, in
order to reduce costs or to increase strength or to improve
acoustic insulation, the addition of swelling clay granules will
increase the specific weight and heat-conductivity of the foamed
structure to such a large extent that the introduction of swelling
clay granules into such lightweight building elements is generally
completely impractical.
Furthermore, a loose flowable mass of roundish granules of very low
specific gravity, as obtained in accordance with the present
invention, may be used as filler material for the filling of
cavities, for instance in structural elements, for the purpose of
obtaining heat-insulating properties. The loose mass which may be
produced in accordance with the present invention thus will replace
comminuted cork or bricks.
The term "roundish" is used throughout the present specification
and claims to define a curved, more or less spherical or spheroid
configuration. The shape of the granules of the loose mass which
may be obtained in accordance with the present invention will more
or less depend on the foamed material which is utilized in the
process, for instance swelled polystyrene granules. When replacing
comminuted cork or bricks as filler material, it is an advantage of
the granular mass produced according to the present invention that
the same will not absorb water and is of very low specific gravity.
Furthermore, filler materials of vegetable origin, such as
comminuted cork, tent to rot when exposed to moisture for long
periods of time, and this danger obviously does not exist when
utilizing the granular mass of the present invention.
The granular mass of the present invention is also eminently
qualified for replacing spun rock wool or spun glass fibers as a
filler material and will not be subject to the disadvantage
connected with the use of the last-mentioned conventional filler
materials, namely the tendency to felt and bake together and
thereby to lose heat-insulating capacity. Furthermore, the flowable
granular mass of the present invention can be much more easily
introduced into the cavities which are to be filled therewith than
fibrous material and the like.
For the above-described and other purposes there exists a great
need for a loose granular uniform material of very low specific
gravity and correspondingly little heat-conductivity, which
material should absorb very little water, should not be subject to
decomposition under unfavorable climatic conditions, but should at
the same time possess a relatively considerable mechanical strength
and shape-retention. Thus, the desired granular material should not
be squashed when exposed to a low degree of elevated pressure as
would be the case with, for instance, exfoliated mica or swelled
polystyrene granules which have not been processed according to the
present invention. Furthermore, the granular material should not be
subject to destruction when exposed to contact with certain
solvents such as acetone.
A field of application of the bodies of low specific gravity such
as may be produced in accordance with the present invention, which
is even more important from a technical and economic point of view,
may be found in building elements, i.e., shaped bodies, for
instance plates or other shapes, which, according to the present
invention, may have a specific gravity as low as between about 0.1
and 0.3, a correspondingly excellent heat-insulating capacity but
nevertheless relatively high strength and shape-retention even at
temperatures above ambient temperature. The strength
characteristics of the shaped bodies of low specific gravity are
desired to correspond about to those of bodies formed by
compressing mixtures of fibrous material and synthetic resins, or
should be corresponding to those of concrete or brick walls.
It is known that such requirements basically are best met by hollow
cellular structures, for instance sandwich structures, which
comprise outer solid and tight shells which shells are filled with
one or more hollow cellular structures, possibly including
reinforcing elements.
Known compound structures including such hollow cellular elements,
comprise, for instance, interior honeycomb structures formed of
prefolded and stripwise connected cardboard, synthetic resin or
metal foils, which are so arranged as to form six-edged hollow
tubes, whereby the initially open frontal ends of the tubes are
glued to outer shells or intermediate layers. Apart from the fact
that honeycomb structures of this kind are resistant against
tensile and pressure forces only in the direction of the honeycomb
axes and show considerably less resistance against deforming forces
acting in directions transverse thereto, the heat-insulating effect
of such structures is not very good because unimpeded air
convection is possible within the cells of the honeycomb structure
from one end thereof to the other. In cases where a better
heat-insulating effect is required, it has been attempted to
overcome this disadvantage of the above-described conventional
honeycomb structures by arranging plates of foamed material or of
fibrous material at the opposite front ends of the honeycomb
structure, or by filling the honeycomb structure with foamed
material prior to closing the same. The production of such
composite building elements with an inner honeycomb structure is
generally economically possible only in the case of plates having
parallel opposite surfaces which plates preferably are of
relatively small thickness. This is particularly so because the
frontal terminal planes of the honeycomb arrangements have to be
cut in advance into the desired shapes and dimensions of the
compound structure which is to be produced. In most cases, it is
attempted to obtain the desired heat-insulating properties and the
low specific gravity of a lightweight building element by filling
the mold cavity for a cast or compressed body of desired shape with
a foamable mass or blowable material and to cause foaming or
blowing thereof in the closed mold, thereby also achieving a
certain limited degree of strengthening of the thus formed cellular
body. This method is carried out, for instance, with respect to
initially liquid masses of synthetic material, for instance
polyurethane which may be foamed in a mold, or with foamable or
blowable granules of synthetic material, for instance polystyrene
granules, which may be swelled upon application of heat, such as
are available under the trade name "Styropor."
By using polyurethane, it is possible to obtain a hollow cellular
structure with small cells which is relatively shape-retaining and
load-supporting, however, only as long as the temperature does not
rise substantially above 50.degree. C. If the temperature rises
beyond this range, softening of the material takes place and a
potentially dangerous gas expansion.
On the other hand, polystyrene is sufficiently stable at
temperatures of up to about 110.degree. C., however even at lower
temperatures the mechanical strength and shape-retention of
cellular polystyrene bodies is much too small to permit the use of
this material for load-carrying structural elements or for
producing plates which during use will be exposed to mechanical
stress. Only in cases where such material is covered on all sides
with strong solid plates has a partial usefulness been found. These
disadvantages cannot be remedied by embedding in the foamed
material occlusion bodies of greater strength, for instance swollen
clay granules.
Furthermore, it has been proposed to produce hollow cellular
structures by introducing into a mold cavity a mixture of rigid
hollow spheres and liquid hardenable binding agents, particularly
if the mold cavity is at least partially lined with a foil which is
destined to form the outer shell of the thus produced building
element of cellular structure. The entire mass of hollow spheres
and binding agents inside the foil lining of the mold is then
subjected to pressure, which is maintained until hardening of the
binding agent has been completed. However, it has been found that
it is not easy to produce such stable hollow spheres on a large
scale in a sufficiently economical manner, and, furthermore,
particularly when using smooth-walled and substantially
shape-retaining hollow spheres, the liquid hardenable binding
material will tend upon pressing of the hollow spheres against each
other to escape from the contacting portions of adjacent hollow
spheres into the interstices therebetween and this results in an
insufficient adherence of the hollow spheres to each other.
SUMMARY OF THE INVENTION
The present invention proposes a method of producing shaped bodies
of low specific gravity, which comprises the steps of wetting a
mass of discrete roundish hollow granules with a hardenable,
preferably heat-hardenable, liquid binder material so as to cause
substantially complete wetting of the outer surfaces of the
granules and the formation of a coating of the liquid binder
material thereon. This is followed by mixing the thus formed mass
of wetted granules with a pulverulent solid material so as to
adhere particles of the solid pulverulent material to the liquid
binder coating on the hollow granules, in such a manner as to form
on each of the hollow granules an outer shell which will consist of
the coating of hardenable binder material and particles of the
solid pulverulent material adhering thereto and at least partially
embedded therein, and which outer shell encloses a nucleus
constituted by the respective hollow granule.
Upon subsequent hardening of the hardenable binder material of the
outer shell, granules are obtained which form a mass of shaped
bodies of low specific gravity consisting of a plurality of
roundish hollow bodies or granules, each comprising a hard outer
shell consisting of the hardened binder material and the
pulverulent material adhering thereto, and also including the
plastic material of the initial hollow granule, for instance a
foamed or blown polystyrene granule. The material of the
polystyrene granule or the like may adhere as a thin inner layer to
the inner surface of the outer shell, or may be disposed in the
interior of the outer shell in some other manner, however, in any
event, only partially filling such interior space.
It is also within the scope of the present invention to apply
pressure during the hardening of the hardenable binder material so
as to deform the mass of coated granules into a shaped coherent
polyhedric cellular structure.
The cell walls of such cellular structure preferably are relatively
thin down to about 0.05 mm., and the pulverulent material
incorporated in the cell walls preferably has a maximum dimension
somewhat smaller than the thickness of the cell wall and may be as
small as about 0.01 mm.
The individual hollow granules, such as swelled polystyrene
granules, which are initially subjected to being coated with the
liquid hardenable binder material and the pulverulent material, may
be of any desired size; but very good results are achieved with
hollow granules having diameters of between about 2 and 8 mm.
The novel features which are considered as characteristic for the
invention are set forth in particular in the appended claims, The
invention itself, however, both as to its construction and its
method of operation, together with additional objects and
advantages thereof, will be best understood from the following
description of specific embodiments when read in connection with
the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic illustration of the first essential step of
the process of the present invention, namely the wetting of the
blown polystyrene granules with a hardenable liquid epoxy
resin;
FIG. 2 is a schematic illustration of the second essential step of
the process, namely the adhering of pulverulent solid material to
the liquid binder-coated polystyrene granules;
FIG. 3 is a schematic illustration of the compressing and hardening
of the mass obtained according to FIG. 2; and
FIG. 4 is an enlarged schematic illustration of a section of the
walls of the cellular structure obtained as illustrated in FIG.
3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to the present invention, hollow bodies of low specific
gravity and the above-described desirable properties, particularly
with respect to strength, shape-retention and resistance against
chemical and atmospheric attacks, may be produced by wetting a
loose mass of roundish foamed or swelled granules of synthetic
material with a liquid hardenable binder material, for instance a
mixture of an epoxy resin and a conventional hardener therefor,
until at least nearly complete wetting of the entire surfaces of
all foamed granules is achieved. Thereafter, solid pulverulent
material is admixed to the mass of liquid-coated hollow granules
until the liquid binder coating is at least substantially coated
with pulverulent material. Thereby a dry loose mass is obtained
consisting of roundish swelled granules of synthetic plastic
material, for instance of polystyrene, each granule being covered
by an outer shell consisting of the hardenable binder and solid
pulverulent material adhering thereto and at least partially
embedded therein.
Preferably, the swelled granules will consist of thermoplastic
material which, at least at elevated temperatures below the
softening point of the thermoplastic material, are resilient and
which have a smooth rather than a rough surface. This assumes, on
the one hand, that the pulverulent particles can become partially
embedded in the material of the granules, and on the other hand,
that the granules are coated evenly over their outer surface.
In order to produce a loose mass of roundish hard-shelled granules
of very low specific gravity such as may be used as aggregate for
casing masses or as filler material for the filling of cavities in
structural elements or the like, as described further above, or
also suitable for use as filler material for air filters or air
humidifiers in air conditioning installations, the above-described
dry and loose mass of coated swelled granules is exposed to heat,
preferably in loose and moving condition, for instance by passing a
stream of warm air therethrough. The heat serves for hardening of
the hardenable binder material forming part of the outer shell of
each granule. In this manner, roundish granules are obtained, each
including a continuous closed outer shell consisting of hardened
binder material with solid pulverulent material embedded therein.
It is generally advantageous if in the interior of the shell the
initial foamed granules are maintained and serve, in contact with
the inner face of the shell, as a reinforcing element which will
help to protect the outer shells against destruction under the
influence of localized pressure or impact. However, if, for
instance due to excessively high temperatures during the drying of
the hardenable binder material or due to the presence of certain
chemical substances in the binder material, wall portions of the
swelled granules of plastic material are destroyed, the hollow
shells which now surround the material of the foamed plastic
granules will nevertheless be capable of fulfilling their
above-described functions.
Thus, the present invention provides a loose, flowable granular
mass on the basis of foamed or swelled granules preferably of
synthetic resin which satisfies all of the above-discussed
requirements and which consists essentially of roundish foamed
granules of synthetic material, preferably roundish polystyrene
granules which have been swelled to the maximum possible extent,
whereby each of the swelled granules is encapsulated in a
thin-walled closed roundish shell of hardened synthetic resin
binder material with solid particles embedded therein or adhering
to the outer face thereof. The flowable granular mass of the
present invention as described above has the following
characteristics:
a. low weight per unit of volume which generally ranges from a
maximum of 300 kg./m..sup.3 to a preferred weight of 100
Kg./m..sup.3
b. considerable pressure-resistance and shape-retention of the
individual granules which will prevent destruction of the same upon
compression, transportation and mixing of the granular mass, for
instance when incorporating the same into a concrete-forming
mass.
c. resistance against unfavorable climatic conditions such as high
humidity, extensive temperature changes and contaminations of the
air.
d. high resistance against microbes, insects and other biological
pests.
It is also within the scope of the present invention to produce
unitary bodies of cellular structure, low specific gravity and
relatively high pressure resistance and shape retention, which
cellular structures possess high resistance against climatic and
chemical attacks. Such bodies can be produced by compressing the
above-described dry and loose mass of foamed granules of synthetic
material which are coated with a mixture of hardenable binder
material and pulverulent solid material, under simultaneous
hardening of the hardenable binder, so as to obtain a hollow
cellular structure with interconnected hardened polyhedric cell
walls and the material of the initial blown granules of synthetic
material such as polystyrene located within the individual cells,
preferably covering the inner faces of the walls of the individual
cells.
Preferably, such body of cellular structure consists of a unitary
arrangement of cell walls forming a plurality of at least
substantially closed cells and consisting of the hardened binder
material, preferably a synthetic material such as a hardened epoxy
resin, and of particles of pulverulent material embedded therein.
Such pulverulent material, according to one preferred embodiment of
the present invention, is mineral material such as quartz or chalk
powder having particle sizes which generally are only slightly
below the thickness of the cell walls, the latter preferably having
a thickness of at least 0.05 mm. The individual polyhedric cells
defined by the cell walls preferably are of substantially equal
width, length and thickness, and each of these three main
dimensions of the cells preferably is between about 2 mm. and 8
mm.
It will be understood that the above-described cellular structure
possesses excellent strength and shape-retaining characteristics
and is resistant against stresses exerted in all directions to an
extent which may be comparable with the stress resistance of
concrete and bricks. In addition, the cellular structure of the
present invention is of very low specific gravity and
correspondingly low heat-conductivity and, particularly if a
high-quality binding agent which is stable at elevated temperatures
of up to 200.degree.- 300.degree. C., has been used for producing
the cell walls, the structure will maintain its strength and shape
even at higher than normal surrounding temperatures and when
exposed to extensive sun radiation. Furthermore, such cellular
structure is not sensitive to moisture, does not form a nutrient
medium for micro-organisms and will not be eaten up by animals,
particularly insects, for instance termites.
Preferably, the swelled plastic granules will have an average
diameter within the range of between 1 and 10 mm., however in
extreme cases the average diameter may be smaller or also greater,
for instance up to 100 mm.
Advantageously, loose, more or less strongly preswelled polystyrene
granules, for instance granules having diameters of between 2 mm.
and 8 mm., are used as the roundish foamed granules, Foamable
polystyrene in granular form is commercially available for
instance, under the trade name "Styropor" and may be foamed by
being immersed in hot water or exposed to superheated steam, to a
foamed granular mass having a weight per liter of less than 0.01
kg. By blowing the granular polystyrene mass in an unconfined
space, individual blown granules of approximately spheric or
egg-shaped configuration and rather smooth surfaces are formed.
Such blown polystyrene granules form an excellent heat-insulating
material and are hydrophobic, i.e., they absorb practically no
water and are highly resistant against water or biologic-organic
decomposition as long as the temperature does not rise above
100.degree. C. However, these granules are not resistant against
specific solvents, such as acetone. At higher temperatures or under
the effect of specific solvents, the granules collapse and only a
small amount of the residual material remains. Furthermore, the
polystyrene granules are of low inflammability and generally are
self-extinguishing when ignited.
The lack of shape-retention or the lack in mechanical strength of
the blown polystyrene granules is important for the purposes of the
present invention. If the blown polystyrene granules after having
been wetted with a liquid binder and coated with the dry sand or
pulverulent material are adhered to the liquid binder so that dry
solid shells have been formed about each blown granule, are
subjected to pressure, the initially roundish shaped polystyrene
granules with the shells thereon will be deformed into polyhedrons
which contact each other along relatively large surface areas.
Thereby, the closely adjacent particles of solid material are
partially compressed into the resiliently yielding surface of the
polystyrene granule so that the liquid binder material cannot
escape laterally or be pushed aside on pressure contact between
adjacent polyhedrons, but will be squeezed outwardly between the
adjacent solid particles. Thereby a mixture of liquid hardenable
binding agent and solid particles is formed, and this mixture is
then hardened by application of heat into a unitary polyhedric
hollow cellular structure of considerable mechanical strength.
Suitable pulverulent materials include mineral sands of low
porosity and low water absorption and metal powders which can be
bound to the binder material, such as steel or aluminum.
A quartz sand with particle size of between 0.01 and 0.2 mm. has
been found particularly suitable as the pulverulent solid material
which adheres to the liquid binder coating. However, in order to
avoid absorption of binder liquid other mineral and stone powders
of more or less corresponding particle sizes, for instance
impregnated chalk powder or ground ceramic fragments may be
utilized. Highly suitable binder materials are epoxy resins which
are used in liquid form with a suitable hardener admixed thereto,
so that they will harden at the desired speed under the influence
of elevated temperatures.
The hardenable binder materials must not give up gases during
hardening. This condition is met, for instance by epoxy resin and
polyester resin hardeners. The hardenable binder material may be
applied in the form of a liquid or as a paste having a viscosity of
up to SAE 10.
It is essential that the hardenable binder and the solid
pulverulent material as well as the material of the initial swelled
granules are compatible with each other so that the liquid binder
will form a coherent coating on the swelled granules and the
pulverulent solid material will be easily adhered to the liquid
binder, thereby facilitating the formation of thin but mechanically
highly stable hard shells. In certain cases it is advantageous to
use as the pulverulent material a metal powder, for instance
aluminum powder. This is particularly desirable if a somewhat
higher degree of heat-transmission throughout the completed
cellular structure is desired, or a higher degree of acoustic
insulation, or a somewhat higher specific gravity.
With solid pulverulent materials of somewhat larger particle size,
for instance 0.1 mm., and by using a relatively small proportion of
the liquid hardenable binder it will still be possible to obtain an
average thickness of the walls of the hardened hollow cellular
structure of the same magnitude and thus of a good average
strength, as described above. By using more finely subdivided solid
pulverulent material and an even smaller proportion of liquid
hardenable binder, a correspondingly less resistant hollow cellular
structure of smaller cell wall thickness and even lesser specific
gravity will be obtained. On the other hand, utilization of solid
pulverulent material of relatively coarse granules, for instance
pulverulent material of a particle size of between about 0.2 and
0.4 mm. and of somewhat more viscous hardenable binder material in
a larger proportion, will result in a hollow cellular structure
having thicker cell walls and possessing higher mechanical
strength. The heating of the coated mass of foamed granules in a
mold under pressure may be carried out by placing the mold into a
suitable furnace, or, for instance, by exposure to a high-frequency
alternating electric field.
The hardening temperature in the case of swelled polystyrene
granules preferably will be between 80.degree. and 90.degree. C.,
but will also depend on the characteristics of the hardenable
binder material the speed of hardening of which will increase with
increasing temperatures.
Since the hardening of the epoxy resin is an exothermic process and
the heat produced thereby is only slightly absorbed by the foamed
granules and cause, due to the low heat capacity of the granules of
a relatively quick rise in temperature, it frequently suffices to
heat the compressed mass of coated foamed granules from the outside
in order to progressively effect the heat-hardening of the
hardenable resin throughout the interior of the mass. Generally it
is preferred to carry out the compression of the loose mass of
coated foamed granules, i.e., granules coated with the hardenable
binder and the pulverulent material adhering thereto at pressures
of at least 1 atmosphere above atmospheric pressure, so as to
reduce the volume of the compressed mass to at most 75 percent,
preferably between 50 percent and 60 percent of the initial volume
of the loose mass of coated granules.
The amount of binder material preferably should be sufficient to
fill the portion of the interstices between the swelled granules
which is not taken up by the pulverulent material.
It is also possible without difficulty to incorporate into the
loose mass of coated foamed granules prior to compression of the
same solid bodies having dimensions larger than the dimension of
the coated granules and consisting of material of higher specific
gravity, such as swelled clay bodies, so that these occlusions will
become integral with the hollow cellular structure during
compression and formation of the same.
Primarily, it has been found advantageous to form during
compression of the coated granular mass in the mold a compound
structure consisting of the polyhedric cellular structure formed as
described above and substantially planar, resistant and for
instance smooth and suitably colored cover materials, such as
plates, sheets, foils, mats, for instance mats of synthetic resin
impregnated glass or asbestos fibers, whereby it is frequently
advantageous to wet these plates or the like prior to introduction
into the mold with the liquid hardenable resin. It is also within
the scope of the present invention to incorporate in the walls
during the compression of the same connecting elements such as door
fittings, screws, jointing members and the like, which may
themselves act as or may be replaced by or be in addition to
supporting or reinforcing elements which may be completely or
partially embedded in the cellular structure so as to be integral
therewith. Particular types of reinforcing elements are not part of
the invention. On the other hand, it is also within the scope of
the present invention to adhesively adhere a covering sheet
material to the hollow cellular structure after completion of
compression of the same and of hardening of the binder material
thereof. Such covering material may be in the form of plates,
sheets, foils, mats and the like.
Mold portions and inserted elements such as tubular cores which
during compressing of the coated granules should not become part of
the thereby formed cellular structure should be coated with
conventional separating agents, for instance silicone or
fluorocarbon-based products such as those commercially available
under the trade name TEFLON.
It is, for instance, possible, and frequently desirable, to insert
tubular cores into the mold cavity and to pass heated fluids such
as air or liquids through the tubular core in order to harden the
hardenable binder constituent of the coating of the blown granules
which are compressed to form a unitary cellular structure. Broadly,
practically all conventional pressure casting techniques can be
applied or adjusted for use in connection with the present
invention.
The present invention also encompasses the compressed cellular body
produced as described above, which body comprises polyhedric cell
walls which are integral with each other and form practically
closed cells. The cell walls consist essentially of hardened binder
material with solid pulverulent particles embedded therein. Each of
the cells defined by the cell walls will contain either a blown
granule of, for instance, polystyrene, which will form a thin layer
on the interior face of the cell, or at least the material of such
granule even though the same may no longer adhere to the inner
surface of the cell. For the purpose of the present invention, it
is of little consequence whether the initially present blown
granule forms an inner layer on the cell-defining walls or whether
the material of the granule, due to overheating or the effect of
solvents or for other reasons, while still contained within the
cell, no longer adheres to the inner face thereof. The strength of
the unitary cellular body is primarily determined by the cell walls
formed of the hardened binder and the pulverulent material embedded
therein. Nevertheless, it is somewhat preferred to have the
material of the initial swelled granule of synthetic material
within the cell forming a layer on the inner face of the
cell-defining walls.
The compressed unitary cellular body thus formed according to the
present invention may be, during compression and hardening of the
binder material, or subsequently, covered or adhesively adhered
with planar cover layers, for instance aluminum or steel sheets or
also plates of asbestos cement or any desired fibrous
material-synthetic resin combination, or with foils of such or
other material. Such cover layers may be applied during the
compression and hardening of the binder material so that the
adherence is effected by the hardening binder material, or the
cover layers may be subsequently adhered to the unitary cellular
body, or the unitary cellular body may be inserted into shells of
cover material and preferably adhesively adhered thereto. In such
cases, cover layers, for instance aluminum or steel sheet, or of
asbestos cement plates, as well as glass fiber reinforced foils of
synthetic resin act also as reinforcing elements by giving to the
entire composite body comprising the unitary cellular structure and
such cover layer not only a surface which is resistant against
mechanical attack, but in addition the cover layer will also
considerably improve the tension and the bending resistance of the
hollow cellular structure.
It is also possible within the scope of the present invention to
incorporate in the hollow cellular structure, during formation of
the same by compression and hardening or subsequently thereto,
connecting or supporting elements, for instance door fittings,
screws, and the like.
It is sometimes of advantage to use profiled plates in combination
with the hollow cellular structure, which profiled plates may be of
undulating or sharp-edged ribbed shape. The mechanical strength,
the heat-insulating and acoustic-insulating properties, the
resistance against moisture and other corrosive influences can be
adjusted, as desired, in so many different ways that the unitary
hollow cellular structure of the present invention in the shape of
a building element may, with or without cover layers and/or at
least partially embedded reinforcing and other elements, used for
self-supporting wall portions, windowsills, doors and door frames,
thresholds, floor coverings, ceilings, table tops, as a substitute
for furniture-board and as roofing materials. Furthermore, the
shaped unitary hollow cellular structures of the present invention,
due to their high strength and low specific gravity, may also be
used in the manufacture of machines and apparatus and for the
construction of automobiles and other vehicles, particularly the
body portions thereof.
Referring now to the drawing, and particularly to the schematic
illustration shown in FIG. 1, swelled polystyrene granules 10 are
introduced from a storage vessel 2 into a mixing container 1
provided with stirring equipment (not shown). Swelled polystyrene
granules 10 are of roundish shape and have a weight of between
about 5 and 10 grams per liter and an average diameter of between 3
and 6 mm. For each about 10- 15 liters of blown polystyrene
granules introduced into the mixing container 1, between about 250
and 300 grams of a liquid hardenable epoxy resin are introduced
into the mixing container 1 from storage vessel 3. The hardenable
liquid epoxy resin may be, for instance, of the type commercially
available under the trade name ARALDIT and will include the
required hardening agent. The swelled granules and the hardenable
liquid are intimately mixed until all of the granules 10 are evenly
wetted and coated with a layer 30 of the liquid hardenable binder
materials.
Depending on the proportion of hardenable liquid binder and the
viscosity, thereof, the coating of hardenable liquid binder
material on the blown polystyrene granules will be of varying
thickness. However, it is preferred that the average thickness of
the liquid hardenable material coating will be between about 0.08
and 0.25 mm.
As shown in FIG. 2, to the thus coated granules in the mixing
container 1, finely subdivided pulverulent material such as quartz
sand 40 is introduced and intimately mixed with the liquid-coated
granules in container 1. Quartz sand 40 may be replaced with other
suitable solid pulverulent materials, for instance impregnated
chalk powder or metal powder, such as aluminum powder having a
particle size of between about 0.05 and 0.25 mm. The particle size
of the pulverulent material preferably will be close to or somewhat
below the thickness of coating 30. The amount of the pulverulent
material which is admixed should be sufficient to cover the liquid
binder coated blown polystyrene granules 10 with an outwardly dry,
finely particulate sand layer 40, the individual particles of which
adhere to liquid binder coating 3.
If the thus produced double coated polystyrene blown granules,
i.e., coated with the hardenable liquid binder material and the
solid particulate material are then exposed to a stream of hot air
in order to harden the liquid hardenable binder material, roundish
extremely lightweight cellular granules with thin hard shells are
formed which are excellently suitable as aggregate for
incorporation into casting masses, as filler material for filling
cavities in a variety of structural and other elements, or as
similar material for air purification and air humidifying. The thus
produced loose mass of hardened binder material coated polystyrene
granules, furthermore provided with a cover layer of solid finely
subdivided particles, is excellently suitable as filler material
for producing a composite building plate, as illustrated in FIG.
3.
FIG. 3 shows a mold cavity which is defined by mold members 51 and
52. The mold cavity has been filled successively with a lower metal
sheet 61, tubular cores 62, a mass of filler material 60 which
consisted of swelled polystyrene granules covered with a layer or
coating of set binder material and an outer layer of finely
particulate solid material the particles of which are partially
embedded in the hardened binder layer, such as the granule 10, 30,
40 illustrated in FIG. 2. Finally, on top of the mass of coated
granules, an upper metal sheet 63 was introduced into the mold.
Cover sheets 61 and 63 were previously coated at their faces
directed towards the interior of the mold cavity with hardenable
binder material. The entire contents of the mold are then
compressed to less than one-half of their original volume, which
can be accomplished with a gauge pressure of between about 1-5
atmospheres, assuming that the finished plate should have a
thickness of about 6 cm. During such compression, the resiliently
yielding polystyrene granules are deformed to polyhedric bodies
contacting each other along relatively large surface portions. The
plastic liquid hardenable binder material 30 is thereby squeezed
outwardly between the solid particles 40, so that solid particles
40 become completely embedded in binder material 30. On the other
hand, the sand or the like particles 40 will partially penetrate
into the soft polystyrene walls of granules 10 and thereby will
prevent the squeezing out of the still flowable hardenable binder
30 from between the contacting surface portions of adjacent
granules. While maintaining pressure, mold 51, 52 and, if desired
also tubular cores 62 are heated, for instance by passing heating
fluid through tubular cores 62 so that the contents of the mold
will be heated, for instance to a temperature of between
50.degree.- 90.degree. C., causing complete hardening of the
hardenable binder material.
In this manner, a unitary, polyhedric hollow cellular structure is
formed which is adhesively attached to metal sheets 61 and 63. The
inner surface portions of the mold directly adjacent the material
filling the mold and the outer face of tubular core 62 had been
previously treated with separating agents, for instance silicone or
the like, so that these mold portions can be easily separated from
the compressed body formed in the mold. It may also be provided for
heating the contents of the mold, after hardening of the binder
material, for a short period of time to a higher temperature, for
instance 130.degree. C., whereby it will be achieved that the
polystyrene granules within the interior of the individual hollow
polyhedric cells will collapse and lose their resiliency.
FIG. 4 is a fragmentary enlarged illustration of a portion of the
cellular structure produced in mold 51, 52 as shown in FIG. 3.
The cellular structure, as shown in FIG. 4, consists essentially of
cell walls which comprise the hardened binder material 30 with
solid particles 40 embedded therein. Each of the polyhedric cell
chambers 23 contains the material of one of the original blown
polystyrene granules (not shown), which material, as described
above, may either adhere to the inner face of the cell walls or may
be collapsed.
The wall thickness of the swelled polystyrene granules, for
instance, may be of the magnitude of 0.1 mm., and the weight per
cubic meter of such swelled polystyrene granules preferably will be
between 5 and 15 kg.
By way of example, for producing one cubic meter of the completed
unitary cellular structure according to the present invention,
there may be required:
12 kg. .+-. 30 percent swelled Styropor granules of 2- 8 mm.
diameter,
60 kg. .+-. 30 percent quartz powder of about 0.1 mm. particle
size,
12 kg. .+-. 30 percent epoxy resin with required hardener
addition.
Thus the total weight will be 84 kg./m.sup.3. .+-.30 percent. The
unitary cellular structure may be formed, as described further
above, by compressing the binder-powder covered granules at a gauge
pressure of about two atmospheres.
Without further analysis, the foregoing will so fully reveal the
gist of the present invention that others can by applying current
knowledge readily adapt it for various applications without
omitting features that, from the standpoint of prior art, fairly
constitute essential characteristics of the generic or specific
aspects of this invention and, therefore, such adaptations should
and are intended to be comprehended within the meaning and range of
equivalence of the following claims.
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