Abstract: The present invention belongs to the field of composite materials, and particularly to a non-flowable quick-setting phosphate cement repair material with strong cohesive forces and the preparation method thereof. The material comprises the following raw materials in percentage by weight: 20% to 40% of sand, 5% to 12% of ammonium dihydrogen phosphate, 10% to 25% of magnesium oxide, 2% to 8% of fly ash, 30% to 60% of rubber powder, 6% to 10% of silica fume, 0.35% to 0.6% of a polycarboxylate high efficiency water-reducing agent, 1% to 5% of sodium silicate, 1.5% to 2% of a polypropylene fiber, 0.5% to 2% of a retarder, and 8% to 10% of water. The material is used as the repair material for the special positions of bottom boards of bridges or facades of buildings which are damaged, and the repair effect thereof is remarkable.

Abstract: The invention relates to a fire-resistant ceramic product, a batch for manufacturing a product of said type, and a process for manufacturing a product of said type.

Abstract: A material for use in building construction (partition, wall, ceiling, floor or door) that exhibits improved acoustical sound proofing and fracture characteristics optimized for efficient installation. The material comprises a laminated structure having as an integral part thereof one or more layers of viscoelastic material which also functions both as a glue and as an energy dissipating layer; and one or more constraining layers, such as gypsum or cement-based panel products modified for easy fracture. In one embodiment, standard paper-faced wallboard, typically gypsum, comprises the external surfaces of the laminated structure with the inner surface of said wallboard being bare with no paper or other material being placed thereon.

Abstract: A method for reducing leakage of bodily fluids or air through lung tissue within a patient is provided. In one embodiment, the method comprises applying, to an appropriate area of lung tissue, an adhesive composition that is derived from a mixture of KH2PO4, metal oxide, a calcium compound, and water, wherein the weight percent ratio of KH2PO4 and the oxide is at least approximately 1:0.5. The method also comprises polymerizing the adhesive composition to form a sealant that substantially seals the body area with a coating.

Abstract: A new investment material for the pressing loss wax technique for dental glass ceramics. It has been found that the addition of fillers to a magnesium phosphate investment, specifically metal oxides with elevated melting points ranging from 1800 to 2800° C., provides a protection barrier against the reaction between the high alkaline content of the glass ceramic and the investment during the pressing process in the range of 800 to 950° C. Specifically, it has been found that the addition of aluminum oxide of about 2 to 5 percent of the total dry mix in combination with any of the zirconium oxide, yttrium stabilized zirconium, titanium dioxide and boron nitride in proportions of about 3.5%, enhances the barrier against a surface reaction and improves the thermal properties of the investment.

Abstract: A magnesium aluminate-based sintered body and a member for a semiconductor manufacturing apparatus. The magnesium aluminate-based sintered body contains magnesium aluminate as a main crystal phase. The magnesium aluminate-based sintered body also contains Zn and K such that a sum of zinc content in terms of ZnO and potassium content in terms of K2O is in a range of 30 ppm to 500 ppm relative to the total mass of oxides calculated from the contents of all constituents. The member for a semiconductor manufacturing apparatus includes the magnesium aluminate-based sintered body.

Abstract: A new investment material for the pressing loss wax technique for dental glass ceramics. It has been found that the addition of fillers to a magnesium phosphate investment, specifically metal oxides with elevated melting points ranging from 1800 to 2800° C., provides a protection barrier against the reaction between the high alkaline content of the glass ceramic and the investment during the pressing process in the range of 800 to 950° C. Specifically, it has been found that the addition of aluminum oxide of about 2 to 5 percent of the total dry mix in combination with any of the zirconium oxide, yttrium stabilized zirconium, titanium dioxide and boron nitride in proportions of about 3.5%, enhances the barrier against a surface reaction and improves the thermal properties of the investment.

Abstract: A composition of matter and method of forming a radiation shielding member at ambient temperatures in which the composition of matter includes a ‘cold-fired’ chemically bonded oxide-phosphate ceramic cement matrix; with one or more suitably prepared and distributed radiation shielding materials dispersed in the ‘cold-fired’ chemically bonded oxide-phosphate ceramic cement matrix.

Abstract: A stable, phase-pure magnesium-substituted crystalline hydroxyapatite containing from about 2.0 to about 29 wt % magnesium, wherein at least 75 wt % of the magnesium content is substituted for calcium ions in the hydroxyapatite lattice structure.

Abstract: The invention relates to an unshaped refractory material comprising a refractory base component and a binder component, the binder component comprising, related to the refractory material, an acidic component of the group comprising an acid, salt of an acid, ester of an acid, salt and ester of an acid as phosphate, sulfate or carbonate, in an amount of ?1.5 wt.-% and ?6 wt.-%, and a basic component of the group comprising: base, urotropin, calcium oxide, calcium hydroxide, magnesium oxide, caustic MgO, sodium hydroxide, potassium hydroxide, magnesium hydroxide, in an amount of ?1 wt.-% and ?4 wt.-%, wherein said material receives an earth-moist, crumbly consistency by addition of 1 to 5 wt.-% of water and which solidifies after an exothermic reaction of the binder component.

Abstract: A stable, phase-pure magnesium-substituted crystalline hydroxyapatite containing from about 2.0 to about 29 wt % magnesium, wherein at least 75 wt % of the magnesium content is substituted for calcium ions in the hydroxyapatite lattice structure.

Abstract: Disclosed are a fire-resistant ordinary ceramic batch and a fire-resistant product predominantly comprising a) at least one granular, fire-resistant, mineral, alkaline main component made of an MgO-based or MgO and CaO-based fire-resistant material that is based on at least one alkaline fire-resistant raw material, and b) at least one granular, fire-resistant, mineral, MgO-based, additional elasticator in the form of a forsterite material or a mixture forming forsterite material preferably as small molded articles such as pellets or granulate that is comminuted from compacts. The small molded articles have a grain size ranging from 0.3 to 8 mm while being advantageously provided with a binder at an amount that elasticates the main component.

Abstract: The composition applied to the refractory structure has a magnesia-based refractory material, calcium carbonate and a binder. After application of the refractory material to a refractory structure and upon application of heat to the applied refractory material a matrix is formed which protects against penetration of the slag into the refractory material. The resulting refractory material has improved hot strength, slag resistance and durability.

Abstract: Composite materials made from reactive compounds such as oxides are disclosed. The materials comprise a reaction producing of metal oxide, phosphate and reactive residual materials. The metal oxide may comprise MgO, CaO, ZnO, TiO2 or the like. The phosphate may comprise mono-potassium phosphate, mono-ammonium phosphate, mono-sodium phosphate or the like. The reactive residual material may be ash, phosphate clay, phosphate residual slurry, mining waste or the like. The composite materials may be used for many applications including rapid repair materials, pre-cast structures, in-situ structures, mixes and coatings.

Abstract: A structural material of a polystyrene base and the reaction product of the polystyrene base and a solid phosphate ceramic is applied as a slurry which includes one or more of a metal oxide or a metal hydroxide with a source of phosphate to produce a phosphate ceramic and a poly (acrylic acid or acrylate) or combinations or salts thereof and polystyrene or MgO applied to the polystyrene base and allowed to cure so that the dried aqueous slurry chemically bonds to the polystyrene base. A method is also disclosed of applying the slurry to the polystyrene base.

Abstract: A structural material of a polystyrene base and the reaction product of the polystyrene base and a solid phosphate ceramic. The ceramic is applied as a slurry which includes one or more of a metal oxide or a metal hydroxide with a source of phosphate to produce a phosphate ceramic and a poly (acrylic acid or acrylate) or combinations or salts thereof and polystyrene or MgO applied to the polystyrene base and allowed to cure so that the dried aqueous slurry chemically bonds to the polystyrene base. A method is also disclosed of applying the slurry to the polystyrene base.

Abstract: The present invention is directed to magnesium phosphate ceramics and their methods of manufacture. The composition of the invention is produced by combining a mixture of a substantially dry powder component with a liquid component. The substantially dry powder component comprises a sparsely soluble oxide powder, an alkali metal phosphate powder, a sparsely soluble silicate powder, with the balance of the substantially dry powder component comprising at least one powder selected from the group consisting of bioactive powders, biocompatible powders, fluorescent powders, fluoride releasing powders, and radiopaque powders. The liquid component comprises a pH modifying agent, a monovalent alkali metal phosphate in aqueous solution, the balance of the liquid component being water. The use of calcined magnesium oxide as the oxide powder and hydroxylapatite as the bioactive powder produces a self-setting ceramic that is particularly suited for use in dental and orthopedic applications.

Abstract: The present invention relates to a composition for converting fabric into construction material. The present invention also relates to construction material made from fabric and the process of its manufacture.

Abstract: An aerated refractory is provided comprising a mixture containing a phosphate compound, a metal oxide, a calcium containing compound; and an agent for increasing the volume of the mixture. Also provided is a method for protecting a substrate with aerated refractory, the method comprising dry mixing mono-potassium phosphate with a metal oxide and a calcium containing compound (i.e. hydroxyapatite) to produce a homogenous dry mixture; adding water to the mixture to produce a slurry; adding a foaming agent to the slurry; applying the slurry to the substrate; and allowing the slurry to dry.

Abstract: A structural material of a polystyrene base and the reaction product of the polystyrene base and a solid phosphate ceramic. The ceramic is applied as a slurry which includes one or more of a metal oxide or a metal hydroxide with a source of phosphate to produce a phosphate ceramic and a poly (acrylic acid or acrylate) or combinations or salts thereof and polystyrene or MgO applied to the polystyrene base and allowed to cure so that the dried aqueous slurry chemically bonds to the polystyrene base. A method is also disclosed of applying the slurry to the polystyrene base.

Abstract: The invention discloses a refractory material derived from a mixture comprising: potassium phosphate, magnesium oxide, tricalcium phosphate. The invention relates to a phosphate based refractory material for use in a variety of applications including: casting oven parts, panels, blocks and tiles, bonding parts together, filing in voids in finished castables.

Abstract: A new method for combining magnesium oxide, MgO, and magnesium dihydrogen phosphate to form an inexpensive compactible ceramic to stabilize very low solubility metal oxides, ashes, swarfs, and other iron or metal-based additives, to create products and waste forms which can be poured or dye cast, and to reinforce and strengthen the ceramics formed by the addition of fibers to the initial ceramic mixture.

Abstract: The present invention relates to a multi-purpose refractory material. The present material is moldable and castable and thus ideal for a variety of refractory applications including but not limited to: casting oven parts, panels, blocks, and tiles, bonding parts together, and filing in voids in finished castables. The composition generally comprising potassium phosphate, magnesium oxide and tricalcium phosphate. The present composition is able to withstand very high temperatures while maintaining stability.

Abstract: Monazite or xenotime-based blanket coatings that stiffen ceramic fabrics without causing embrittlement at temperatures of at least as high as 2400° F. are provided. Methods for making the coatings are also provided. The methods comprise the synthesis of high purity, monazite and xenotime powders with the stoichiometric ratio of metal to phosphorous of about 1:1.

Abstract: Refractory investment material for forming a positive replication of a tooth structure on which a high-alumina based porcelain tooth restoration is to be formed, the material being formed from a refractory powder which includes alumina mixed with a liquid carrier comprising an aqueous dispersion of silicon dioxide.

Abstract: The invention discloses a refractory material derived from a mixture comprising: potassium phosphate, magnesium oxide, tricalcium phosphate.

Abstract: A powder of dicalcium silicate is made by spray drying calcia and silica with incorporation of sodium and phosphorus or stabilized zirconia. The spray dried powder is sintered to form a thermal spray powder. Sprayed coatings have a web of interconnected, randomly oriented microcracks substantially perpendicular to the coating surface. The coatings are stable in thermal cycling and a hot corrosive environment.

Abstract: A chemically bonded phospho-silicate ceramic formed by chemically reacting a monovalent alkali metal phosphate (or ammonium hydrogen phosphate) and a sparsely soluble oxide, with a sparsely soluble silicate in an aqueous solution. The monovalent alkali metal phosphate (or ammonium hydrogen phosphate) and sparsely soluble oxide are both in powder form and combined in a stochiometric molar ratio range of (0.5-1.5):1 to form a binder powder. Similarly, the sparsely soluble silicate is also in powder form and mixed with the binder powder to form a mixture. Water is added to the mixture to form a slurry. The water comprises 50% by weight of the powder mixture in said slurry. The slurry is allowed to harden. The resulting chemically bonded phospho-silicate ceramic exhibits high flexural strength, high compression strength, low porosity and permeability to water, has a definable and bio-compatible chemical composition, and is readily and easily colored to almost any desired shade or hue.

Abstract: A new method for combining elemental iron and other metals to form an inexpensive ceramic to stabilize arsenic, alkaline red mud wastes, swarfs, and other iron or metal-based additives, to create products and waste forms which can be poured or dye cast.

Abstract: Monazite or xenotime-based blanket coatings that stiffen ceramic fabrics without causing embrittlement at temperatures of at least as high as 2400° F. are provided. Methods for making the coatings are also provided. The methods comprise the synthesis of high purity, monazite and xenotime powders with the stoichiometric ratio of metal to phosphorous of about 1:1.

Abstract: A dry refractory composition having superior insulating value. The dry refractory composition also may have excellent resistance to molten metals and slags. The composition includes filler lightweight material, which may be selected from perlite, vermiculite, expanded shale, expanded fireclay, expanded alumina silica hollow spheres, bubble alumina, sintered porous alumina, alumina spinel insulating aggregate, calcium alumina insulating aggregate, expanded mulllite, cordierite, and anorthite, and matrix material, which may be selected from calcined alumina, fused alumina, sintered magnesia, fused magnesia, silica fume, fused silica, silicon carbide, boron carbide, titanium diboride, zirconium boride, boron nitride, aluminum nitride, silicon nitride, Sialon, titanium oxide, barium sulfate, zircon, a sillimanite group mineral, pyrophyllite, fireclay, carbon, and calcium fluoride.

Abstract: A structure made predominately of an NZP-type phase having the general formula RxZ4P6−ySiyO24, where 0≦x≦8, 0 ≦y≦6, R is Li, Na, K, Rb, Cs, Mg, Ca, Sr, Ba, Y, and/or lanthanides, and Z is Zr, Ti, Nb, Ta, Y, and/or lanthanidess, and optionally a sintering additive. The structure has an open porosity of at least 20% by volume, median pore diameter in micrometers of at least a value defined by the quantity [10-0.10 (% open porosity)], both as measured by mercury porosimetry, and four-point modulus of rupture as measured on a solid rod of circular cross section, of at least 300 psi. Method of making the structure involves forming a mixture of NZP-forming raw material powders that are metal oxide sources capable of reacting to form an NZP-type reaction product, and/or pre-reacted powder having the above general formula.

Abstract: This invention relates to novel process of preparing chemically bonded composite hydroxide ceramics by exposing a thermally treated hydroxide ceramic to phosphate reagent and subsequent heat treating the resulting system to initiate a rapid chemical bonding reaction. Such combined hydroxide/chemical bonding process can be used to fabricate ceramics or ceramic coatings for a variety of high and low temperature applications, including corrosion protection, wear resistance, dielectric properties, metal reinforced ceramics, ceramic membranes, non-sticky surfaces, bio-active ceramics, thermal barrier ceramics, non-wetted surfaces, and others.

Abstract: The invention provides a refractory material for use in the manufacture of dental restorations, the refractory material comprising essentially of an admixture of Silica, Silicon Carbide, Magnesium Oxide, Mono Ammonium Phosphate, and Zircon or Aluminium Oxide in predetermined proportions by weight. The material is formed as an homogenous powder and mixed with a colloidal silica based solution to form a creamy mixture suitable for casting into a silicone based impression of a prepared tooth so as to form a refractory model of said tooth. The homogenous powder may be stored in moisture resistant material until required to be mixed with said colloidal silica based solution.

Abstract: Substantially dry, self-hardening, thermally activated refractory compositions, suitable for use to produce linings for furnaces or metallurgical vessels such as ladles, tundishes or launders, comprise particulate refractory material, an inorganic binder having associated therewith chemically or physically bound water such as sodium metasilicate pentahydrate or tribasic sodium phosphate dodecahydrate, and an element or compound, such as aluminium, which will react exothermically with the inorganic binder. The compositions may also contain an inhibitor such as a mineral oil or a vegetable oil to inhibit premature exothermic reaction.

Abstract: This invention relates to a novel method of decreasing porosity of ceramics produced by sol-gel processing. The process of preparing chemically bonded sol-gel ceramics comprises phosphating a sol-gel derived oxide or hydrated oxide and polymerizing the phosphated product with heat treatment. Such combined sol-gel/chemical bonding process can be used to fabricate dense, thick ceramics or ceramic coatings for a variety of applications, including high temperature corrosion protection, wear resistance, dielectric properties, non-sticky surfaces, bio-active ceramics, thermal barrier ceramics, non-wetted surfaces, and others.

Abstract: A pumpable ceramic composition is provided comprising an inorganic oxide, potassium phosphate, and an oxide coating material. Also provided is a method for preparing pumpable ceramic-based waste forms comprising selecting inorganic oxides based on solubility, surface area and morphology criteria; mixing the selected oxides with phosphate solution and waste to form a first mixture; combining an additive to the first mixture to create a second mixture; adding water to the second mixture to create a reactive mixture; homogenizing the reactive mixture; and allowing the reactive mixture to cure.

Abstract: A powder of dicalcium silicate is made by spray drying calcia and silica with incorporation of sodium and phosphorus or stabilized zirconia. The spray dried powder is sintered to form a thermal spray powder. Sprayed coatings have a web of interconnected, randomly oriented microcracks substantially perpendicular to the coating surface. The coatings are stable in thermal cycling and a hot corrosive environment.

Abstract: Known phosphate ceramic formulations are improved and the ability to produce iron-based phosphate ceramic systems is enabled by the addition of an oxidizing or reducing step during the acid-base reactions that form the phosphate ceramic products. The additives allow control of the rate of the acid-base reactions and concomitant heat generation. In an alternate embodiment, waste containing metal anions are stabilized in phosphate ceramic products by the addition of a reducing agent to the phosphate ceramic mixture. The reduced metal ions are more stable and/or reactive with the phosphate ions, resulting in the formation of insoluble metal species within the phosphate ceramic matrix, such that the resulting chemically bonded phosphate ceramic product has greater leach resistance.

Abstract: A premix composition for producing an inorganic solid foamed mass by mixing component (A) an aqueous acidic phosphate solution of mainly polyvalent cations and phosphoric acid wherein between 0.8 and 1.75 protons of the phosphoric acid molecule of said phosphate are neutralized by the cations, which also contains one or more fillers dispersed therein, with (B) an oxide, hydroxide or polyvalent salt of a weak acid as hardener and a carbonate foaming agent. A process of producing an inorganic foamed mass using the premix composition and a solid foamed mass produced by the process are also disclosed. The process produces a relatively elastic cross-linked structure due to mainly the secondary phosphates being neutralized versus the tertiary phosphate groups.

Abstract: The present invention is directed to a dry phosphate cement mixture and process for manufacture of same. The dry mixture includes at least Al(H.sub.2 PO.sub.4).sub.3, a group IIA metal bonded to oxygen, and an aggregate. The process for manufacturing cement includes associating the dry reagent with a substantially polar solvent, such as water. The total reagent concentration is formulated such that only nominally exothermic reactions are observed. The process accommodates variable setting times and provides resulting concrete which exhibits formidable structural integrity.

Abstract: The present invention relates to a refractory binder that comprises a mixture of aqueous phosphate and silica sol. The silica sol has been found to gel and set in a surprisingly effective and useful way. Preferably, the refractory binder further incorporates a small amount of magnesia as an accelerator. The present invention also provides a method of binding a refractory material such, for example, as alumina, zirconia mullite or aluminium silicate by using a refractory binder according to the invention.

Abstract: This moldable refractory composition is intended to be used in the production of cast refractory pieces resistant to molten metals, especially molten aluminum. It comprises 8 to 25% by weight of an aqueous phosphoric acid solution having a concentration of phosphoric acid ranging from 40 to 85% by weight, with up to 50% of the primary acidic function of the acid phosphoric acid neutralized by reaction with vermiculite. It also comprises from 75 to 92% by weight of a mixture containing wollastonite and an aqueous suspension containing from 20 to 40% by weight of colloidal silica. The weight ratio of the aqueous suspension to the wollastonite within the mixture ranges from 0.5 to 1.2. The composition according to the invention is particularly interesting in that it can be unmolded within a very short period of time that is less than 2 hours and can be as small as 10 minutes.

Abstract: A method for regulating the reaction temperature of a ceramic formulation process is provided comprising supplying a solution containing a monovalent alkali metal; mixing said solution with an oxide powder to create a binder; contacting said binder with bulk material to form a slurry; and allowing the slurry to cure. A highly crystalline waste form is also provided consisting of a binder containing potassium and waste substrate encapsulated by the binder.

Abstract: The preparation of a phosphate-bonded magnesia cement from mixtures of magnesium oxide and an aqueous solution of ammonium polyphosphate, where the mixtures further include a solid monoammonium phosphate fraction that functions to prevent undesired ammonia emission during setting up of the mixtures to produce hardened concrete.

Abstract: The present invention discloses a low density basic refractory lining material with improved resistance to corrosion by molten slag and metal that is especially adapted for use as a disposable liner in molten metal containing vessels. This material incorporates hollow ceramic microspheres of alumina, silica or mixtures thereof, having diameters of between about 5 and 500 microns as a density reducing material. This material may also include a stiffening agent, a set retarding agent, a foaming agent to further reduce the density, a plasticizer, and a low temperature binder. The addition of the ceramic microspheres has been found to provide reduced open porosity, improving resistance to corrosion. Also, the invention relates to methods for applying the disposable lining and vessels which include the lining applied thereon.

Abstract: A refractory powder includes a filler, a binder, and a metal powder. This provides improved heat transfer in the refractory material during heating, and reduces the problem of explosive cracking and spalling so the refractory material can be burned out at substantially constant temperature, thereby saving considerable amounts of time and energy.

Abstract: A binder for binding reinforcement materials is provided in which an aluminum and/or Group IIa-containing compound is combined, in a liquid, with a phosphorus-containing compound wherein said binder has a ratio of phosphorus to aluminum and/or Group IIa ions of 14 to 34, preferably 20 to 30. The binder is useful in binding reinforcement materials, particularly suited for preparing preforms for making metal matrix composite materials.

Abstract: A method of manufacturing a refractory object which comprises setting basic refractory grains and a polyphosphate into a green shape characterised by the inclusion of minerals which, when the slurry is set and fired, develop spinel linkages.

Abstract: This invention relates to inorganic no-bake foundry binder systems and their uses. The binder systems comprise as separate components: (A) mono-aluminum phosphate in an aqueous solution containing specified phosphoric acids, and (B) magnesium oxide; and certain specified zinc compounds in either the Component A, Component B or both. The components of the binder system react when they are mixed with a foundry aggregate to prepare foundry mixes which are used to prepare foundry molds and cores. The foundry molds and cores are used to cast metals.