Abstract: Intercalates formed by contacting a layered material, e.g., a phyllosilicate, with an intercalant monomer including an alkyl radical having at least 10 carbon atoms and having a dipole moment greater than the dipole moment of water, to sorb or intercalate the intercalant monomer between adjacent platelets of the layered material. Sufficient intercalant monomer is sorbed between adjacent platelets to expand the adjacent platelets to a spacing of at least about 5 .ANG. (as measured after water removal to a maximum of 5% by weight water), up to about 100 .ANG. and preferably in the range of about 10-45 .ANG., so that the intercalate easily can be exfoliated into individual platelets. The intercalated complex can be combined with an organic liquid into a viscous carrier material, for delivery of the carrier material, or for delivery of an active compound; or the intercalated complex can be combined with a matrix polymer to form a strong, filled polymer matrix.

Abstract: The present invention relates to a heat-resistant expansive member suitably used as a holding member for holding a ceramic monolithic catalyst in a motor vehicle or the like. The heat-resistant expansive member of the present invention is made at the blending ratio of 1 to 5 wt % of sepiolite, 30 to 60 wt % of treated vermiculite, 20 to 40 wt % of ceramic fibers and 5 to 20 wt % of an organic binder, or at the blending ratio of 21 to 30 wt % of sepiolite, 30 to 40 wt % of treated vermiculite, 20 to 40 wt % of ceramic fibers and 5 to 20 wt % of an organic binder. Regardless of the low- or high-temperature zone, the heat-resistant expansive member of the present invention presents a great holding force to the monolithic catalyst or the like. The heat-resistant expansive member is improved in cushioning properties and gas-attack resisting properties particularly in the high-temperature zone.

Abstract: A fire-retardant polymer composition is provided which comprises 100 parts by weight of a polymer such as polystyrene, 1 to 30 parts by weight of heat-expandable graphite, and 1 to 30 parts by weight of a phosphorus compound. The polymer composition is fire-retardant, and emits less smoke and less corrosive gas on burning.

Abstract: A method of preparing particles of an exfoliated vermiculite for the manufacture of a finished product, such as a particle board, includes the steps of, if necessary, chemically modifying the vermiculite by impregnating the vermiculite with a suitable anhydride in a non-aqueous solvent; if necessary, applying to the particles of vermiculite an adhesion promoter to promote the adherence of a resin to the surfaces of the particles of vermiculite; and resinating the particles of vermiculite either with a thermoplastic resin which has been surface modified by irradiation or by fluorination, or by an isocyanate thermosetting resin, or by a dry powder novolac thermosetting resin; and if necessary removing any solvent present.

Abstract: A composite for mounting a catalytic converter or diesel particulate filter. The composite comprises a flexible mat and a layer of an intumescent paste comprising an intumescent material. A catalytic converter element and diesel particulate filter comprising such a composite are also described.

Abstract: Gel formers comprising acid aluminum phosphate and a reaction product of boric acid and an alkanolamine, and further comprising alkali metal compounds in the aluminum: alkali metal ratio of 1:1.3-2.5 require short gelling times, and form gels having improved melting resistance.

Abstract: A porous material composed of many SiO.sub.4 tetrahedra sheets having interlayer bridges of SiO.sub.2. It has pores having a diameter of 10 .ANG. or above, and possesses the properties of a solid acid formed by the isomorphous substitution of metal atoms for Si of SiO.sub.4 frameworks. It is made by a process including introducing an organic substance into interlayer space of crystals of layered silicates to expand the spacing between crystal layers, as well as forming bridges of SiO.sub.2 therebetween, bringing the intercalated compounds into contact with a metal salt to link metal atoms to the SiO.sub.4 frameworks, and firing the products. The material can withstand a temperature of 800.degree. C., has a pore diameter larger than that of zeolites, etc., and is useful in making an adsorbent or catalyst for molecules having a high molecular weight, such as a catalyst for the catalytic cracking of petroleum.

Abstract: Fire fighting compositions are disclosed which are distinguished from the prior art by the presence of alum as a component of the composition, by the use of a combination of salts in concentrations which will form a eutectic mixture when heated, and by the inclusion of a salt of an organic acid which will generate carbon dioxide by the heat of a fire. Additional inorganic salts may be added to increase the effectiveness of the composition. These fire fighting compositions may be permeated into a cellulosic material to provide fire retardant articles of manufacture.

Abstract: Bloated minerals previously used as aggregates for light-weight concrete are here fragmented, wetted, and intermixed with particulate chemical reactants or catalysts, to serve as inert carriers therefor in industrial processes. One use is in the deep-bed flow-through process of reacting and removing hydrogen sulfide as contained in natural gas.

Abstract: A fire resistant composition for forming a fire resisting lining is characteristically and substantially composed of ettringite contained as a main ingredient. A panel that is attachable to a building body so as to form an external wall thereof is composed of a base plate and the fire resisting lining that contains ettringite as its main ingredient and covers the base plate. A structure of an external wall of buildings, the structure has the panels attached to the building body to form a plane and having their sides adjoined one to another, and the base plate in each panel has a periphery not covered with the lining. A groove-shaped cavity appearing between the adjacent lining edges facing one another is filled with a caulking material, so that the fire resistance afforded by the composition and the panels is further enhanced.

Abstract: Process for producing an active composite consisting of a support and an active agent is disclosed. The process comprises mixing expanded graphite and an exfoliated lamellar compound, compressing the mixture to form a support which has a graphite density between 0.02 and 0.5 kg/dm.sup.3, and impregnating the support with the active agent. Such active composites are employed as reactants in thermochemical systems.

Abstract: Gel formers and gels containa) acidic aluminium phosphates, optionally in the form of reaction products with 0.01 to 4 mol of alkanolamines per mol of aluminium phosphate, andb) reaction products of boric acid with alkanolamines, a) and b) being present in a weight ratio of 100:55 to 100:0.5, calculated as solids.

Abstract: A blend for producing refractory imitation fireplace objects comprises between 30% and 50% amorphous aluminum siliceous mineral silicate, between 1% and 5% fibre and between 40% and 60% high temperature cement. A method of producing a slurry for casting the refractory objects consists of blending the amorphous aluminum siliceous mineral silicate, the fibre, an aggregate and colorant, adding and blending a high temperature cement and a dispersant and adding between 35% and 45% by weight of water.

Abstract: The invention provides an intumescent sheet material comprising 25 to 60 dry weight percent of at least one unexpanded intumescent material, 25 to 60 dry weight percent of ceramic fibers, 0.5 to 5 dry weight percent of glass fibers having a diameter of less than about 2 microns, and 0.1 to 15 dry weight percent of organic binder, wherein said intumescent sheet material has a cold erosion rate of less than 0.05 grams/hour. The invention also provides catalytic converters and diesel particulate filters containing the sheet material.

Abstract: Halogen-free, flame-resistant polymeric compositions contain an intumescence flameproofing system which comprises ammonium polyphosphate and an organophosphorus nitrogen component. The organophosphorus nitrogen component here is a phosphoric acid polyester according to the formula ##STR1## In these formulae, R is CH.sub.2, C.sub.2 H.sub.4 or C.sub.3 H.sub.6, while m is 1 to 10 and n is 1 to 6.

Abstract: Fire-retardant compositions are disclosed. The compositions include at least one nitrogen-liberating compound which will release nitrogen gas during burning, a primary fire-retardant agent; casein resin, and an activator of the casein resin. In the preferred embodiment, there are two nitrogen-liberating compounds, dicyandiamide and nitro-urea, the primary fire-retardant agent is diammonium phosphate, and a filler, titanium dioxide, is also included. The compositions are prepared in a mixing tank and can be applied in a known manner, optionally under high pressure, to cellulosic products such as cloth, yarn, paper, wood and wood substrates in order to impart a fire-retardant quality thereto. Fire-retardant glue and wood laminate structures produced using the glue are also disclosed.

Abstract: Mouldings containing expanded expandable graphite are characterised in that they additionally contain acid phosphates of metals of group 2 and/or 3 of the periodic table of the elements and/or pyrolysis products thereof. Such mouldings are distinguished by the fact that they have low odour and are mechanically stable, and, when in contact with water, do not have pH values which are too low.

Abstract: This invention relates to a method for manufacturing an inorganic porous layered member which can maintain a sufficient distance between layers to show a high degree of heat insulating properties. In the manufacturing method for the inorganic porous layered member according to the present invention, an inorganic layered compound 12 having swelling charecteristics is swelled, and an inorganic pillar and an organic pillar are intercalated to form inorganic compound 16 between layers 14 of the inorganic layered compound 12. Fine gaps are thus formed in a wide range by the intercalation of the inorganic compound 16 between the layers 14 to maintain a sufficient distance between the layers 14, and the inorganic porous layered member 10 having high heat insulating properties is thus produced.

Abstract: The present invention relates to a method of providing thermal insulation and fire-resistance to buildings, by filling voids or spaces in and around structural members with a low density thermally insulating and fire-resistant cementitious composition containing a high proportion of a relatively smooth-surfaced, vesicular, expanded perlite. The method includes placing a flexible, woven, fire-resistant bag in the space to be filled, so as to act as a containment vessel, pumping a cementitious composition into the bag to fill a space by conforming to the shape of the space, while the bag simultaneously contains the cementitious composition in the desired position, and allowing the composition to cure into a lightweight, fire-resistant, and thermally insulating concrete. The method is particularly useful in and directed to remedial, post-construction applications in occupied buildings.

Abstract: A vermiculite composition capable of exhibiting a high degree of volume increase upon subjection to thermal exfoliation composed of vermiculite mineralogical species having specific gravity of from 2.5 g/cm.sup.3 to 2.9 g/cm.sup.3. Further, intumescent sheets formed with said vermiculite composition exhibit low initial expansion temperature and very high maximum expansion properties.

Abstract: A method of rendering water resistant a vermiculite article such as a film or coating comprised of delaminated vermiculite lamellae is provided comprising the step of contacting the article with a solution of an inorganic monovalent cation selected from the group consisting of: H.sup.+, Na.sup.+, K.sup.+, Cs.sup.+, Rb.sup.+ and Fr.sup.+ and mixtures thereof.The invention further relates to a water resistant article such as a film or coating comprised of delaminated vermiculite lamellae, which article is produced by contacting the article with a solution of an inorganic monovalent cation selected from the group consisting of: H.sup.+, Na.sup.+, K.sup.+, Cs.sup.+, Rb.sup.+ and Fr.sup.+.

Abstract: This invention relates to a method for preparing fine graphite particles which can be used as a highly functional graphite material in wide applications. According to this method, foliated fine graphite particles having a high aspect ratio and hence well-developed anisotropy can be prepared, without formation of secondary particles, by dispersing expanded graphite particles into a liquid and then exposing them to ultrasonic waves. Articles molded of the resulting foliated fine graphite particles exhibit high electrical conductivity and thermal conductivity.

Abstract: A vermiculite composition composed of particulate vermiculite mineral species having a density of 2.3 g/cm.sup.3 to 2.7 g/cm.sup.3 which has intercalated cations of lithium or organo ammonium and to dispersions obtained therefrom.

Abstract: In an advantageous process for the production of mouldings from expandable graphite, a liquid is first added to the expandable graphite and the resulting moist preparation form of the expandable graphite is heated in moulds to temperatures above 180.degree. C.

Abstract: An active composite consists of a compressed support and an agent which reacts with a gas. According to the invention, the compressed support comprises recompressed expanded graphite having a density between 0.02 and 1.5. A process for implementing gas-solid type reactions in which said active composite is used as the reaction medium is also described.

Abstract: Intumescent vermiculite flakes useful in mountings of catalytic converters are prepared by partially dehydrating vermiculite ore to afford a uniform content of chemically bound water from about 1.0 to 3.2% by weight and a uniform bulk density from about 0.2 to 0.9 g/cm.sup.3. Such a mounting affords good support to the monolith at warm-up temperatures, exerts adequate holding forces at operating temperatures without danger of cracking the monolith, and does not incur gradual reduction in holding forces at operating temperatures. The mounting layer can be applied as either a mat or a paste.

Abstract: A water resistant or repellant article comprised of delaminated vermiculite lamellae is provided, which article is produced by immersing the article in a solution of a cationic exchange agent.The invention further relates to a method of producing such a water resistant or repellant article comprising the step of contacting the film with a solution of a cationic exchange agent.

Abstract: The heat resistant expansion member used as the holding member of the ceramic honeycomb monolithic catalyst in an automobile comprises 20 to 40 wt. % of sepiolite, 30 to 54 wt. % of particulate vermiculite, 20 to 40 wt. % of ceramic fibers, and 5 to 20 wt. % of organic bonding material, or 20 to 40 wt. % of sepiolite, 30 to 54 wt. % of treated vermiculite, 20 to 40 wt. % of ceramic fibers, 5 to 20 wt. % of organic bonding material, and 1 to 10 wt. % of E-glass with fiber diameter of 1 .mu.m or less, so that a large holding force is maintained whether in a low temperature region or in a high temperature region.

Abstract: Composites of flexible graphite particles and an amorphous carbon phase useful for applications such as valve packing end rings.

Abstract: The present invention is a method for producing swellable or nonswellable fluorine mica at a relatively lower temperature by heating a powdery mixture comprising 10 to 35% by weight of an alkali silicofluoride as the main component optionally together with an alkali fluoride and the balance of talc. This fluorine mica is used for pigments, etc.

Abstract: New intumescence media contain ammonium and/or amine salts of acid phosphates of metals of the 2nd and/or 3rd group of the periodic system of the elements and can be employed for a very wide variety of fire prevention purposes.

Abstract: Apparatus for continuous production of intumesced, expanded, puffed, or exfoliated particles. A rotatable processing table is driven by a speed controllable motor connected to rotate the table at a desired rotational rate. Particulate feeding means overlie the table for depositing the particles to be intumesced onto a first sector in the path of the upper surface of the processing table during rotation thereof. Heating means are mounted above and below the plane of the processing table at a second sector in the rotational path of same which is spaced from the first sector, and heat expand the particles during passage through the second sector. A scraper blade is mounted above the processing table at a third sector in the rotational path of the table which is spaced and downstream from the second sector.

Abstract: A monolith can be mounted in a catalytic converter by a material containing intumescent vermiculite flakes that have a uniform content of chemically bound water from about 1.0 to 3.2% by weight and a uniform bulk density from about 0.2 to 0.9 g/cm.sup.3. Such a mounting affords good support to the monolith at warm-up temperatures, exerts adequate holding forces at operating temperatures without danger of cracking the monolith, and does not incur gradual reduction in holding forces at operating temperatures.

Abstract: To form a coating of silica on a substrate, the substrate is coated with a silica precursor having a melting point between about 50.degree. and about 450.degree. C. The coating is heated to a temperature above its melting point in an inert environment to allow the coating to melt and flow. The melted coating is then heated in an environment which facilitates conversion to silica for a time sufficient to convert it to silica.

Abstract: An aqueous dispersion of vermiculite lamellae is provided having incorporated therein from about 0.2 to about 10% by weight of at least one internal sizing agent based on the dry weight of the vermiculite in the dispersion.

Abstract: There is disclosed a wet friction material which comprises 5 to 40% by weight of a thermosetting resin as a binder component with the balance being a filler, wherein the filler includes at least a rubber and an exfoliated graphite.

Abstract: A method of decreasing the expansion temperature and improving the expansion characteristics of vermiculite ore comprising subjecting vermiculite ore containing interlamellar cations to a potassium nitrate solution for a time interval sufficient to ion-exchange interlamellar cations within said ore with potassium ions. Subsequent to this ion exchange the low temperature expandable vermiculite may be expanded by heating in an oven, or incorporated in an intumescent material and heat expanded in situ, or expanded by other heating means. An intumescent sheet is provided which may be used for mounting automotive catalytic converter monoliths comprising an unexpanded vermiculite produced by the method of the invention; an inorganic fibrous material; and a binder.

Abstract: The invention relates to fabric softening clays, detergent compositions comprising clays and processes for producing the clays. The fabric softening clays are dioctahedral 2:1 layer phyllosilicates comprising at least 100 micrograms of lithium per gram of clay mineral. Problems of poor clay color may be overcome.

Abstract: A method of decreasing the expansion temperature and improving the expansion characteristics of vermiculite ore comprising subjecting vermiculite ore containing interlamellar cations to a potassium nitrate solution for a time interval sufficient to ion-exchange interlamellar cations within said ore with potassium ions. Subsequent to this ion exchange the low temperature expandable vermiculite may be expanded by heating in an oven, or incorporated in an intumescent material and heat expanded in situ, or expanded by other heating means. An intumescent sheet is provided which may be used for mounting automotive catalytic converter monoliths comprising an unexpanded vermiculite produced by the method of the invention; an inorganic fibrous material; and a binder.

Abstract: An activated carbon coated with an intumescent material which will expand at an elevated temperature and render the activated carbon resistant to oxidation. The activation carbon can be in granulated form, including pelletized, and impregnated. The intumescent material is preferably attached to about 10% of the exterior surface of the activated carbon and when exposed to a certain elevated temperature the intumescent material will expand and cover all or almost all of the exterior surface of the activated carbon thereby preventing its burning. The amount of intumescent material is not operable for causing a detrimental reduction in the adsorption capacity of the activated carbon when the coated activated carbon is at temperatures below the certain designed elevated temperature.

Abstract: Disclosed are flocced mineral materials which may be utilized to prepare high temperature resistant, water resistant articles. These materials are prepared by utilizing, as a starting material, a gellable layered swelled silicate that has an average charge per structural unit that ranges from about -0.4 to -1 and which contains interstitial cations which promote swelling with a source of at least one species of multiamine derived cations.

Abstract: A non-porous, substantially hollow, expanded mineral product, such as expanded perlite, is produced by uniformly and indirectly heating ore for about 1 to 30 seconds in an expansion chamber maintained at about 1400.degree. F.-2100.degree. F. to produce uncoated particles which exhibit superior short term and long term density stability characterics in liquid systems, and which may subsequently be coated to provide enhanced density stability characteristics.

Abstract: Chemically prepared mica and vermiculite materials are described along with the method for preparing them. The mica and vermiculite has dimethylacetamide-lithium chelation complexes at interlayer cationic sites. These materials can be made into suspensions and flocculated.

Abstract: There is disclosed a method of treating phyllosilicate materials by exposing the materials to a source of hydrogen ions to hydrate hydroxyl ions on and in the phyllosilicate structure. The source of hydrogen ions may be a simple organic, or mineral, acid, preferably formic or hydrochloric acid. The hydrated phyllosilicate may then be dehydrated and delaminated by thermal treatment.

Abstract: Obsidian having less than one percent of combined water is expanded to a volume many times the original by a two stage heating process carried out in at least one refractory-lined, rotary kiln. It is heated gradually by a first flame to a temperature of 1800-1900 F., then subjected to a second flame at a temperature of 2400-2500 F. for a very few minutes. The heating is carried out in the presence of dust which has a softening point considerably above those temperatures. The dust prevents the softened obsidian from sticking to itself or to the lining of the kiln. In some embodiments, the entire process is carried out in a single kiln with both flames entering the discharge end of the kiln, the first flame being directed toward the feed end and the second flame directed transversely or toward the discharge end. In another embodiment, the obsidian is gradually heated in a first kiln, then immediately fed to a second rotary kiln where the second flame enters the feed end and is directed toward the discharge end.

Abstract: A method of manufacturing a microporous thermally insulating body comprises mixing together a finely divided microporous insulating material such as silica aerogel or pyrogenic silica and a solid ammonia-generating compound in particulate form, and compressing the mixture to form a thermally insulating body. The ammonia-generating compound is dispersed evenly throughout the insulating material and may comprise, for example, ammonium carbonate, ammonium acetate or urea. Preferably, the ammonia-generating compound comprises a mixture of about one third by weight of ammonium carbonate and about two thirds by weight of ammonium bicarbonate together with a small proportion of magnesium oxide.

Abstract: Graphite fibers are exfoliated to produce a fiber of reduced density, increased diameter, and flexibility with respect to graphite fibers prior to exfoliation. The fibers may also be used in composite articles. A method of producing exfoliated graphite fibers intercalates the fibers and then exfoliates the intercalated fiber by heating.

Abstract: Certain articles required to function in air at temperatures of 250.degree. C. or higher comprise very fine particles of vermiculite from which the interstitial magnesium ions have been at least partially removed and which has been swollen in water. These articles are not ordinarily exposed to water when in use, but if they are they are likely to disintegrate quickly because of the ready dispersibility of the vermiculite particles. By the invention, water-resistance is given to such articles by treating them with a solution of an aluminate salt e.g. NaAlO.sub.2 or a zirconyl salt e.g. ZrOCl.sub.2.

Abstract: It has been found that water stable articles, such as films and sheets, can be prepared from chemically delaminated vermiculite platelets if radical or ionically polymerizable organo-substituted onium salts are ionically bonded to the platelets and the resulting system cured.

Abstract: A novel flocculated methanation, hydrogenation or hydrodesulfurization catalyst of the form MS.sub.2 :Y:Z wherein MS.sub.2 is a single layer transition metal dichalcogenide sulfide, Y is a promoter substance and Z is a support substance, is disclosed.