Abstract: An insulation board suitable for use as a roof insulating board has a density between about 8 and about 15 pounds per cubic foot; a MOR/density ratio of at least 10.5 to 1 and includes, by dry weight, between about 45% and about 76% expanded perlite; between about 15% and about 45% cellulosic fibers; between about 0.1% and about 10% latex binder; between about 2% and about 9% bituminous material; and about 0% to about 3% alum.

Abstract: A method and a mixture for preparing an ablative material for fire and heat protection is provided. The mixture includes calcium sulfate hemihydrate and a hydrated salt and the ablative material is prepared by adding water to the mixture.

Abstract: A composition suitable for making acoustical tiles in a water-felting process comprises expanded perlite, cellulosic fiber, and, optionally, a secondary binder and mineral wool. The perlite has been treated to reduce its water retention.

Abstract: A composition suitable for making acoustical tiles in a water-felting process comprises expanded perlite, clay, a binder component selected from the group consisting of starch, latex, cellulosic fiber and mixtures thereof and optionally mineral wool. The use of an expanded perlite having a relatively high density, preferably between about 9 pounds per cubic foot to about 20 pounds per cubic foot, enables the formation of a suitable slurry with a relatively low amount of water and enables a more complete dewatering of the mat prior to drying.

Abstract: The invention relates to an improved sound absorbing cementitious composition and method of making involving a preformed foam solution made from a surfactant, such as an ammonium salt of a sulfated linear alcohol ethoxylate surfactant, preblended with water at a dilution ratio in a range of water to surfactant of from about 40:1 to 10:1. Thereafter, the preformed foam solution is combined with components including cement(s), aggregate(s), water and optional additives. The composition provides for an open cellular surface capable of absorbing sound.

Abstract: The object of the present invention is to prevent delamination of an inorganic board. To attain this object, a method of manufacturing an inorganic board comprising forming a single mat by the paper making method by using slurry of raw material mixture substantially consisting of cement material, fiber material and inorganic filler inside of which is empty wherein said empty inorganic filler is effected on an alkali treatment; laminating the plural number of said single mats to form a laminated mat; and molding, incubating and curing said laminated mat.

Abstract: A roof tile which is lightweight and yet strong has a dry component that includes cement, gypsum, perlite aggregate, lava stone and a powder that may be perlite powder or volcanic ash. Water and a styrene acrylic catalyst are mixed with the dry constituents. The composition can be formed into the shape of roof tiles by conventional equipment.

Abstract: A perlite-based insulation board includes, by dry weight, between about 50% and about 76% expanded perlite; between about 15% and about 45% fibers; between about 1% and about 5% starch; between about 2% and about 9% bituminous material; and about 0% to about 3% alum. The fibers are between about 50% and about 95% by dry weight recycled newsprint fibers and between about 5% and about 50% by dry weight virgin cellulose fibers, such as flax and/or peanut hull fibers. In one embodiment, the virgin cellulose fibers are, by dry weight, between about 10% and 40% flax fibers and about 60% and 90% peanut hull fibers.

Abstract: A premixed ultra-light sandless mortar for use with clay and concrete tiles. The mortar uses ASTM standard C-332 aggregate, vermiculite or perlite aggregate in place of heavy aggregates such as sand. The mortar cement is made from portland cement, lime, air entraining agents, and water repelling agents. The resulting compound retains large amounts of moisture which increases hydration time resulting in improved bonding strength, and increased tile uplift strength. The light weight of the mortar also allows a full bed of mortar to be laid on the roof with the resulting benefit of an addition insulating layer for the building. The mortar is suitable for roofing or floor tile applications.

Abstract: The invention relates to a freely flowable, soil conditioner consisting of a granular perlite with a coating on the externally accessible surface of the perlite grains of unfired clay. The invention also relates to a process for the preparation of the soil conditioner in which a clay slurry is sprayed onto the perlite grains.

Abstract: Compositions and methods for manufacturing sheets having a hydraulically settable matrix. Suitable compositions are prepared by mixing together a hydraulic binder, water, and appropriate additives (such as aggregates, fibers, and rheology-modifying agents) which impart predetermined properties so that a sheet formed therefrom has the desired performance criteria. The compositions are formed into sheets by first extruding them into a sheet and then calendering the sheet using a set of rollers. The calendered sheets are dried in an accelerated manner to form a substantially hardened sheet. The drying is performed by heated rollers and/or a drying chamber. The hydraulically settable sheets so formed may have properties substantially similar to sheets made from presently used materials like paper, cardboard, polystyrene, or plastic. Such sheets can be rolled, pressed, scored, perforated, folded, and glued. They have especial utility in the mass production of containers, particularly food and beverage containers.

Abstract: The invention relates to a freely flowable, soil conditioner consisting of a granular perlite with a coating on the externally accessible surface of the perlite grains of unfired clay. The invention also relates to a process for the preparation of the soil conditioner in which a clay slurry is sprayed onto the perlite grains.

Abstract: An acoustical tile composition based on a gypsum/cellulosic fiber composition which can replace all or a portion of the mineral wool normally present in acoustical ceiling tiles. The gypsum/cellulosic fiber composition is combined with a lightweight aggregate material and a binder to form a composition which is used in a water-felting process to manufacture acoustical ceiling tiles and panels. The preferred source of the cellulosic fiber is a composite gypsum/cellulose fiber material which is prepared by mixing the gypsum and cellulosic fiber material with sufficient water to form a dilute slurry which is then heated under pressure to calcine the gypsum, converting it to an alpha calcium sulfate hemihydrate. The resulting composite material comprises cellulosic fibers physically interlocked with calcium sulfate crystals. Another source of both gypsum and cellulosic fibers is waste (scrap) gypsum wallboard. Expanded perlite is the preferred lightweight aggregate material.

Abstract: A premixed ultra-light sandless mortar for use with clay and concrete tiles. The mortar uses vermiculite or perlite aggregate in place of heavy aggregates such as sand. The mortar cement is made from portland cement, lime, air entraining agents, and water repelling agents. The resulting compound retains large amounts of moisture which increases hydration time resulting in improved bonding strength, and increased tile uplift strength. The light weight of the mortar also allows a full bed of mortar to be laid on the roof with the resulting benefit of an addition insulating layer for the building. The mortar is suitable for roofing or floor tile applications.

Abstract: Cementitious containers which have a cementitious structural matrix for use in the packaging, storing, partitioning, and/or shipping of goods. The containers are manufactured from cementitious materials in order to be strong, durable, tough, lightweight, cushioning, insulative, inexpensive, and more environmentally compatible than those currently used in packaging, storing, and/or shipping goods. The cementitious structural matrix of the containers includes a hydraulic cement paste (formed from the reaction of water with, e.g., a portland cement) in combination with a rheology-modifying plasticizer, such as methylhydroxyethylcellulose. Preferred embodiments may also include various aggregate materials, fibrous materials, and air voids, which add the necessary strength while making the product lightweight, and which can provide insulative properties (if desired) at a cost which is economically justified in comparison to conventional paper and polystyrene products.

Abstract: This invention provides an improved water-based coating composition. The said coating composition comprises a light mineral such as expanded perlite, dilute sodium metasilicate solution, and a metal oxide. The coating composition of the invention has one or more of the following qualities when cured: non-poisonous; odorless; water resistant; non-conductive; heat resistant; acid resistant; alkaline resistant; rust resistant; ability to withstand burning; and ability to integrate with cement.

Abstract: A structural article of manufacture having a specific gravity less than about 1.5, composed of a compressed, dry cementitious composition comprising a particulate aggregate substantially free from particles smaller than about minus 80 mesh.

Abstract: Containers incorporating a hydraulically settable structural matrix including a hydraulically settable binder such as cement for use in the storing, dispensing, and/or packaging of food and beverage products are disclosed. The disposable and nondisposable food and beverage articles of manufacture have high tensile, compressive, and flexural strengths, and are lightweight, insulative (if desired), inexpensive, and more environmentally compatible than those currently used. These disposable containers and cups are particularly useful for dispensing hot and cold food and beverages in the fast food restaurant environment. The structural matrix of the food and beverage containers includes a hydraulic cement paste (formed from the reaction of water with, e.g., a portland-type cement) preferably in combination with a theology-modifying plasticizer, such as methylhydroxyethylcellulose, various aggregate materials and fibrous materials which provide desired properties at a cost which is economical.

Abstract: A low cost cement composition that can be admixed with water and hydrothermally closed cured to give acid-resistant products of high compressive strength consisting essentially of, in parts by weight, 1 to 1.5 parts of a calcium oxide material containing at least about 60% CaO, 10 to 15 parts of pozzolanic material containing at least about 30% by weight amorphous silica, and 0.025 to 0.075 parts by weight of an alkali metal catalyst and building materials made therefrom as well as the method of making such building materials by closed curing.

Abstract: A fire resistant and high temperature insulating composition is provided. The composition generally comprises a carbonate material in an amount from about 20% to about 80% by weight, an aluminosilicate in amount from about 0.5% to about 15% by weight, talc in amount from about 0.5% to about 10% by weight, cellulose in amount from about 1% to about 30% by weight, a binder in an amount from about 1% to about 45% by weight, and a gelling agent in an amount from about 1% to about 45% by weight. The binder is preferably a mixture of an organic adhesive such as a polymeric resin, and a non-organic adhesive such as cement, but other adhesives can be used alone or in combination therewith. The gelling agent is preferably a polymeric substance that swells in the presence of a liquid such as superabsorbent polymers. The components are combined and water may be added in an amount from about 1 to about 50% by weight to obtain a composition of the desired consistency.

Abstract: A clay-free, asbestos-free and glass microbubble-free, drying type Joint compound containing an in-situ or associative thickener as a substitute for asbestos and any clay substitute therefor. In particular, these drying type joint compounds contain no attapulgus clay thereby improving viscosity stability, crack resistance and shrinkage. The lightweight joint compounds contain treated expanded perlite, treated to render it water-insensitive. The preferred in-situ thickeners are acidic acrylate copolymers. It has been found that the in-situ thickeners should be used in combination with the normal cellulosic thickeners used in joint compounds Instead of as replacements therefor. The joint compounds contain the usual fillers and latex emulsion binders, with at least about 50% by weight of the drying type joint compound being a filler selected from the group consisting of calcium carbonate and calcium sulfate dihydrate.

Abstract: A pumpable backfill grout which hardens into a controlled low strength material and an additive for making up such a backfill grout. The grout consists essentially of portland cement, a smooth surfaced vesicular expanded perlite, fly ash, fine aggregate, water, an air entraining agent, a quick dispersing thixiotropic suspending agent and a bentonite thickening agent.

Abstract: A formula of lightweight aggregates, fiber, and Portland Cement, which, when graded, prepared and mixed as described produces a lightweight, fire and thermal resistive concrete which can be successfully and easily extruded into shapes for use in construction, principally, roofing tiles, shingles and shakes. This mix can also be pressed into the same shapes and brick and block shapes. The resultant compressed product is homogeneous and uniform thus creating superior strength characteristics. This "concrete" is approximately half the weight of traditional concrete (specific weight is 0.85 to 1.0, or expressed in metric, 0.85 gr. per cc.) and is greater than half as strong and absorbs the same amount of water.

Abstract: A dry mix-type, drywall panel joint compound is produced which comprises (a) a fine plaster which is applied to a joint formed between adjacent drywall panels in the plastic state to form a hardened material, (b) a material which imparts internal strength and workability to the joint compound, (c) a material for retaining water and inhibits shrinkage of the joint compound within the joint formed between adjacent drywall panels, and (d) a set time control agent. The more preferred joint compound formulation of this invention includes (a) stucco, (b) methyl cellulose, and (c) perlite. A longer set time version of the subject dry mix-type, drywall panel joint compound can also be provided which comprises, in addition to (a)-(d), (e) at least one water absorption agent, (f) at least one shrinkage and cracking inhibitor, (g) at least one adhesive strengthening agent, and (h) an alkaline material for raising the pH of material.

Abstract: An insulating board is provided in which the capacity to absorb the moisture exemplified by wood fiber based board, cellulose fiber based board and perlite based board is coupled with the high permeability of fiberglass insulation to provide a board having a balance between the capacity to hold moisture and sufficient permeance to allow the board to give up the moisture as the board is passed through a cycle of absorption and desorption, whether it be on a daily or seasonable cycle.

Abstract: An improved composite material is prepared by first uniformly mixing cement and perlite fines. The perlite fines comprise particles that are less than 200 mesh. The mixture of perlite fines and cement is then mixed with water, formed into a desired shaped, and allowed to dry. The dried material is useful in many applications where cement is used and has fireproofing and strength characteristics superior to ordinary concrete.

Abstract: The toothpaste for preventative oral hygiene contains a mixture of synthetically prepared precipitated silicic acid and perlite in addition to a solvent as cleaning body.A mixture consisting of glycerol (86%) and water is used as solvent.

Abstract: A high strength concrete particularly useful for precast, prestressed products comprising by weight of the wet concrete mix, 8 to 60 percent cement, 0.5 to 20 percent smooth-surfaced, vesicular, expanded perlite, 5 to 30 percent water, 0 to 12 percent pozzolan, and fine aggregate and coarse aggregate as appropriate and available in the circumstances. The concrete provides superior bond to reinforcing strands. The smooth-surfaced, vesicular, expanded perlite is unique and novel.

Abstract: An improved composite material is prepared by first uniformly mixing cement and perlite fines. The perlite fines comprise particles that are less than 200 mesh. The mixture of perlite fines and cement is then mixed with water, formed into a desired shaped, and allowed to dry. The dried material is useful in many applications where cement is used and has fireproofing and strength characteristics superior to ordinary concrete.

Abstract: Disclosed is a non-inflammable insulating, composite material capable of being shooted onto a surface to be coated, such as the wall of a building to be insulated. This material comprises a fibrous-like, synthetic forsterite obtained by calcination of chrysolite asbestos fibers at a temperature from 650.degree. to 1450.degree. C.; an inorganic, lightweight filler selected amongst vermiculite, perlite and their mixtures; and a non-inflammable, hydraulic or silicate binder contained in such an amount as to make the material sufficiently adhesive to be shooted as a coating, either as such or after wetting, onto the surface to be insulated. The weight ratio of the synthetic forsterite to the inorganic filler is ranging from 20:80 to 80:20 to adjust the volumic weight of the final product from about 0.20 to about 0.50 gram per cm3. Also disclosed are methods of manufacturing such a non inflammable, insulating, composite material in a wet, ready-to-be-shooted form.

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: There are disclosed high temperature refractory mixes especially adapted for relining and resizing chimney flues, comprising from 65 to 70 weight percent of portland cement, from 21 to 25 weight percent of volcanic glass, from 6 to 10 weight percent of microsilica, from 0.05 to 0.12 weight percent of at least one air entraining agent and from 0.5 to 1.0 weight percent of at least one plasticizer.

Abstract: The present invention provides a refractory coating composition comprising:(i) 100 parts by weight of a hydraulic cement,(ii) 3 to 50 parts by weight of a re-emulsion type powdery resin,(iii) 50 to 600 parts by weight of a mixture of 15 to 85% by weight of aluminum hydroxide powder and 85 to 15% by weight of carbonate decomposable at a temperature of 300.degree. to 1000.degree. C., and(iv) 20 to 300 parts by weight of a lightweight aggregate having open cells at a ratio of at least 50% based on the total cells.

Abstract: A product and method for conditioning fabrics, especially denim, is disclosed. The product is an artificial stone made up of an inorganic filler, inorganic abrasive particles and an inorganic bond for the filler and abrasive. The method is the use of the stone to condition fabrics.

Abstract: A fireproof panel for closing structural openings within building structures such as those between rooms, floors, ceilings, and the like through which essential-service hardware such as ducts, pipes, electrical conduit, and the like penetrates, or for providing support for such hardware. The panel comprises a solid matrix of refractory material having reinforcement material embedded therein. Preferably, the reinforcement material is embedded immediately beneath essentially all of at least one of the panel's front and back exterior surfaces. A preferred reinforcement material is a fiberglass material, preferably embedded immediately beneath both the front and back exterior surfaces of the panel. The reinforcement material inhibits fracture of the panel to thereby provide a greater workability in panel installation. The panel can be flat or shaped in accord with its intended function, and openings therethrough to accommodate penetrating hardware can be readily made.

Abstract: Expanded perlite compositions containing thereon, therein or thereon and therein buffered aqueous silane emulsion compositions as well as hydrophobic expanded perlite compositions as described above but from which residual water has been removed are provided. A process for the preparation of the same is also provided.

Abstract: A closed gas-cell cellular material is formed by heat treating a hydrosilicate, especially perlite, at a low temperature and then in the form of grains of a grain size of 5 to 8000 micrometers, feeding these grains through a space at a temperature of 800.degree. C. to 2000.degree. C. for a short residence time at a uniform space load of 0.1 to 500 kg/h. Then the grains are subjected to thermal shock in a thermal shock space connector directly to the feed spacing and heated to 1,000.degree. C. to 3,500.degree. C. The density of the granular material thus produced is 0.12 to 27 g/cm.sup.3 and the weight per volume thereof at 0.01 to 1 kg/liter.

Abstract: Novel single layer materials of the form MX.sub.2, where MX.sub.2 is a layer-type dichalcogenide such as MoS.sub.2, TaS.sub.2, WS.sub.2, or the like, exfoliated by intercalation of an alkali metal, and immersion in water, are disclosed. MoS.sub.2 has been exfoliated into monolayers by intercalation with lithium followed by reaction with water. X-ray diffraction analysis demonstrates that the exfoliated MoS.sub.2 in suspension is in the form of one-molecule-thick sheets. X-ray patterns from dried and re-stacked films of exfoliated MoS.sub.2 indicate that the layers are randomly stacked. By adsorbing monolayers or precipitating clusters of various species such as compounds of Co, Ni, Pb, Cd, Al, Ce, In and Zn, on MoS.sub.2 while the sulfide is suspended as single layers and then recrystallizing, a new group of inclusion compounds can be formed. In the re-crystallized or re-stacked materials, the inter-layer spacing can be expanded or contracted compared to MoS.sub.2.

Abstract: A mix for producing a chemically resistant concrete which comprises, percent by mass:liquid glass: 8 to 18a finely divided volcanic acid water-containing glass: 30 to 40a modifying additive such as silicon dioxide of a crystalline modification: 1 to 6and/or kaolinite of the pelitic structure: 1 to 5and/or melaminocyanurate: 0.2 to 1.0an alkali-acid-resistant aggregate: the balance.

Abstract: Disclosed is an improved process for producing dispersions of vermiculite ore particles by intercalating organo-cation salts into the vermiculite structure under shearing conditions to delaminate the ore and reduce particle size in one step.

Abstract: A decorative tile having a front face with a design thereon varies in density so that the front face of the tile presents a solid appearance, but the overall weight of the tile is less than for a comparable conventional plaster tile. The tile of the invention can be made from a mixture including a binder, fiber strands, and a bulk enhancing agent. The decorative tile of this invention is particularly useful for ceiling decoration.

Abstract: A gypsum plaster and chopped glass fiber tile having increased insulation values, reduced weight and reduced density due to the presence of vermiculite and perlite.

Abstract: Expanded perlite coated with an amino-functional siloxane and a silicone wetting agent, and a joint compound incorporating same, which, when applied to gypsum wallboard, has improved bonding properties and greater uniformity in paint gloss appearance between the surface of the joint compound and the surface of the wallboard.

Abstract: A process is described for the formation of shaped hydrated calcium silicate products. The process comprises reacting an aqueous slurry containing a source of calcium hydroxide, perlite as a source of silica, and a soluble calcium salt in the presence of high pressure saturated steam, then adding cooling water followed by subsequent venting of the reactor vessel to ambient pressure. Reinforcing fibers may then be added after which the desired shapes are molded and dried.

Abstract: A process of using a thermally insulating board, made of a homogeneous mixture of expanded perlite particles and cellulosic and/or mineral and/or ceramic fibers, bonded together, comprising placing on the surface of a molten steel mass, in direct contact with the surface, so as to cover substantially all the surface. According to a preferred embodiment, the board consists of 51 to 80% by weight of expanded perlite particles, 15 to 39% by weight of cellulosic and/or mineral fibers and 5 to 10% by weight of binder.

Abstract: An ultra light weight insulating building block is manufactured from an aggregated particulate formed by mixing expanded perlite together with cement in the proportions of approximately 24 parts of perlite for each part of cement by volume and thereafter adding a minimum amount of potable water to agglomerate the contents until the mixture is tacky. The mixture is thereafter cured in air to form the agglomerated particulate which may thereafter be used together with cementious material to manufacture the building blocks. The cementious material may be cement or a mixture of cement, fly ash and an air entrainer.

Abstract: Shaped articles made from expanded minerals, otained by using a mineral binder system composed either of calcium aluminate and aluminum phosphate or of waterglass and a catalyst to consolidate an expanded mineral which has been rendered hydrophobic and wherein the expanded mineral is rendered hydrophobic by means of an organosiloxane.

Abstract: A coherent, rigid, heat stable, low density, low thermal conductivity, strong, impact resistant, water repellant thermal insulation material, having an average maximum linear shrinkage of 2% or less at temperatures up to 1200.degree. F., made from expanded perlite, alkali metal silicate solution, kaolin clay, and organic fiber. Additions of methylcellulose and polydimethyl silicone liquid enhance the insulation material's strength and water repellency characteristics. The material may be cured and dried at a temperature of about 170.degree. or less for a period of about 24 hours or more without humidity control.

Abstract: The invention relates to a process for insulating surfaces for the purpose of preventing or reducing occurrence of condensation on the surface, comprising applying to the surface a layer of a coating composition containing a binder and, distributed therein, granules of an expanded inorganic material having a bulk density of at least 150 kgs/m.sup.3. The invention also provides for a composition suitable for carrying out such process, comprising a binder and granules of an expanded inorganic material of the nature indicated.

Abstract: Novel perlite-silicate type insulation materials are provided having improved physical strength qualities. More particularly, such materials are provided having high flexural or transverse strength as measured by A.S.T.M. standard C-203. According to a preferred embodiment, amounts of phosphate within a limited proportioned range are added to insulation mixtures to yield shaped insulating bodies having a flexural strength in excess of about 60 lb./in..sup.2. Addition of clay is made according to another preferred embodiment, whereby substantial reduction in shrinkage is accomplished.