Inorganic Hydraulic Settable Material Shaping Patents (Class 264/333)
  • Patent number: 5520729
    Abstract: The invention relates to a process for producing heat-insulating material from silicate-containing material, hydrated lime, water, foam and a reactive aluminates-containing quick-setting cement, from which a pourable raw mixture is produced which is poured into molds, the green moldings formed in the molds being demolded and autoclaved after sufficient setting. To achieve very low bulk densities, it is provided that, as silicate-containing material, a quartz powder with a specific surface area according to BET of at least approx. 3 m.sup.2 /g, in particular approx. 4 to 5 m.sup.2 /g, is used, the raw mixture is produced with a weight ratio of water/solids (excluding foam) of at least approx. 1.25 and an essentially stoichiometric amount, with respect to the virtually complete reaction of the quartz powder and the reactive aluminates, of hydrated lime with a surface area according to BET of at least approx. 15 m.sup.
    Type: Grant
    Filed: June 8, 1994
    Date of Patent: May 28, 1996
    Assignee: SICOWA Verfahrenstechnik fur Baustoffe GmbH & Co. KG
    Inventors: Hanns-Jorg Engert, Thomas Koslowski
  • Patent number: 5520531
    Abstract: A portable concrete molding apparatus for forming concrete structures of a predetermined configuration, either on-site or at a central manufacturing facility. The apparatus includes a trailer having furnace plenum bounded by a pair of fixed walls. Each fixed wall cooperates with a movable wall for forming a mold therebetween. Each movable wall includes a concrete inlet for introducing concrete into the bottom portion of the mold. The fixed and movable walls include push-off valves for ensuring separation of a concrete structure from the mold walls, as the mold walls are separated.
    Type: Grant
    Filed: June 6, 1994
    Date of Patent: May 28, 1996
    Inventor: Ernest J. Del Monte
  • Patent number: 5518540
    Abstract: Cured cement matrices are exposed to dense-phase or supercritical CO.sub.2 which enters the matrix through passages therein to neutralize the natural alkalinity of the cement so that alkali-intolerant materials can be incorporated in the cement. The CO.sub.2 converts calcium hydroxide in the cement to calcium carbonate and water, and the high pressure of the dense-phase or supercritical CO.sub.2 forms rounded, closely packed and aligned crystals with few or no visible pores or capillaries to enhance the homogeneity and strength of the cured cement and its bonding with, for example, uncoated reinforcing glass fibers. The supercritical CO.sub.2 can be used to transport other organic or inorganic materials, including pulverized metal, in solution or suspension into the interior of the cement matrix to alter its chemical and/or physical characteristics. The supercritical CO.sub.
    Type: Grant
    Filed: June 7, 1995
    Date of Patent: May 21, 1996
    Assignee: Materials Technology, Limited
    Inventor: Roger H. Jones, Jr.
  • Patent number: 5514316
    Abstract: A ceramic article such as a sanitary pottery ware is produced by slip casting using a porous composite mold. A green ceramic body of a part such as a trap of sanitary ware is separately formed in advance by, for example, slip casting. The green ceramic body is placed in the mold cavity of the porous composite mold. Then, a slip as the material of the main part of the sanitary ware is supplied into the mold cavity to form deposit integral with the green ceramic body, whereby an integral sanitary ware is obtained by slip casting.
    Type: Grant
    Filed: May 28, 1993
    Date of Patent: May 7, 1996
    Assignee: Toto Ltd.
    Inventors: Tatsuhiro Kosugi, Mitsuru Saka, Akio Matsumoto, Minoru Inoue, Toshiaki Nogami, Takazi Naotsuka, Masao Yamasaki, Hiroyuki Suzuki
  • Patent number: 5507996
    Abstract: A method and apparatus for manufacturing a building block by molding under pressure a mixture of a hydraulic binder such as plaster, an inert filler such as sand, and water, by passing a mold (50) through various stations, including a station (A) for filling the mold with a measured quantity of the mixture (56), a station (B) for installing a mold top plate (38), a station (C) for compressing the mixture in the mold, a station (D) for keeping the top and bottom plates (38, 40) in place in the mold, a station (E) for withdrawing the top plate (38), and an unmolding station (F).
    Type: Grant
    Filed: November 12, 1993
    Date of Patent: April 16, 1996
    Assignee: TECFIM
    Inventor: Jean Brouard
  • Patent number: 5505893
    Abstract: A method of manufacturing an open top, walled member for containing a molten metal, especially a flowing molten metal or reconstructing a worn or damaged member. The method includes the step of forming the inner walls of a mold which define the inner surfaces of the walled member of an open metal mesh screen which is meltable by the molten metal which is to be contained. The next step is to transfer, usually by pumping, an alumina-silicon carbide casting compound into the space between the open mesh metal screen and the outer walls defining the mold, which outer walls may be in situ structures. If an existing walled member is being repaired, any damaged or worn portions of the existing walled member are removed and the casting compound is poured in to replace these portions. The next step is to apply heat to dry the casting compound while the open mesh screen of the mold remains in place in contact with the casting compound.
    Type: Grant
    Filed: October 25, 1994
    Date of Patent: April 9, 1996
    Assignee: Magneco/Metrel, Inc.
    Inventor: Charles W. Connors, Jr.
  • Patent number: 5503789
    Abstract: Herein disclosed is a "METHOD FOR FORMING AND MAKING A CARVABLE/MOLDABLE MATERIAL" used for making artistic works of art. The method includes a mixture of pozzolan, plaster of paris, a liquid binder and water which when mixed, then poured into a mold and allowed to cure, forms a workpeice of carvable material. However a most important feature of the present invention is the fact that at any later time if the artist so desires, application of a small amount of water upon the surface of the workpeice will restore the workpeice into a moldable condition so as to allow the artist to recarve, mold, shape and/or restore, unlike any artistic carvable/moldable material heretofore disclosed.
    Type: Grant
    Filed: April 4, 1994
    Date of Patent: April 2, 1996
    Inventors: Harold L. Hull, John D. Barton
  • Patent number: 5501055
    Abstract: A reticulated net for use in reinforced concrete construction includes a first plurality of evenly spaced coplanar rods forming an upper rim and a second plurality of evenly spaced coplanar rods forming a lower rim. The rods of the upper and lower rims are laterally offset and connected by triangular waveform connecting rods. Each connected adjacent pair of upper and lower rods, in conjunction with the associated connecting rod, forms an individual truss member. Pursuant to the disclosed method for reinforced concrete construction, to pour a concrete slab, inexpensive permanent concrete forms are disposed within the upper and lower rims of the net. After completion, lower portions of the net remain exposed to facilitate securement of conventional construction elements such as electrical boxes, suspending ceilings, insulation, lighting fixtures, sprinkling systems, partition wall systems, etc.
    Type: Grant
    Filed: December 6, 1993
    Date of Patent: March 26, 1996
    Inventors: Herman Storch, Ernesto E. Storch
  • Patent number: 5500044
    Abstract: A process for forming an ash aggregate is provided. The process involves mixing a cellulose sludge material with an ash component. The ash component may comprise fly ash or sanitary waste ash in combination with fly ash. The sludge component preferably comprises paper mill sludge or pulp mill sludge. The hard lightweight aggregate may be utilized in a variety of manners, for example, to provide lightweight concrete and lightweight concrete mixes.
    Type: Grant
    Filed: October 15, 1993
    Date of Patent: March 19, 1996
    Assignee: Greengrove Corporation
    Inventors: William D. Meade, John W. Pearson
  • Patent number: 5492659
    Abstract: Process for the production of concrete tiles by cutting a block of concrete mixture, characterized in that the block of mixture is subjected to a preliminary curing at room temperature for a duration of at least 24 hours or to a low-pressure steam treatment at a temperature <100.degree. C. until the compression strength reaches a value of at least 20 MPa, and to a second treatment with steam in an autoclave. The cement tiles thus obtained may be bonded to the floor using a normal setting layer of cement mortar, without giving rise to any problems of detachment.
    Type: Grant
    Filed: May 7, 1993
    Date of Patent: February 20, 1996
    Assignee: Quarella S.R.L.
    Inventor: Mario Collepardi
  • Patent number: 5478521
    Abstract: A method for making, clean, bughole-free hardened cement structural units, including the steps of a) applying a release agent to the surface of a form; b) preparing a cement composition; c) adding to the cement composition a water-soluble polymer dispersant and a solution viscosity-reducing agent; d) placing the cement composition of step c) into the form, e) curing the cement composition of step c) to form a hardened structural unit, and f) removing the structural unit from the form.
    Type: Grant
    Filed: October 12, 1994
    Date of Patent: December 26, 1995
    Assignee: W. R. Grace & Co.-Conn.
    Inventor: Paul Scheiner
  • Patent number: 5474726
    Abstract: An interlocking checker brick used to form a checkerwork for use in recovering heat in thermal regenerators and recuperators. The checker brick is made of a refractory material and is of a generally trapezoidal shape with each side wall having at least a section forming an acute angle with respect to the base. The preferred brick has spaced side walls each of which includes top and bottom sections adjacent to and perpendicular to top and bottom surfaces respectively. Each side wall also includes a central section flaring outwardly and downwardly from its top to its bottom section. Checkerworks utilizing these bricks increase turbulence while reducing laminar flow during alternating cycles of flowing gases and air.
    Type: Grant
    Filed: April 4, 1994
    Date of Patent: December 12, 1995
    Assignee: North American Refractories Company
    Inventor: Jack Hyde
  • Patent number: 5468435
    Abstract: A process and apparatus for transforming contaminated material such as liquid wastewaters, into a solid and chemically stable composition which can be utilized as construction material, or which is safe for land disposal. The contaminated material is blended with solidification agents such as cement or lime until substantial amalgamation of the agent and material is completed. The contaminated material is contained within microencapsulation matrices which physically isolate the contaminated material from the environment. The apparatus is transportable and can be brought to the contamination site to transform the contaminated material into the solid and chemically stable composition.
    Type: Grant
    Filed: May 9, 1994
    Date of Patent: November 21, 1995
    Assignee: Texas Incinerator Co., TX
    Inventor: Albert G. Hancock, Jr.
  • Patent number: 5466407
    Abstract: Residue produced by incineration of commercial, industrial or municipal waste is treated to remove oversize material and ferrous materials. The moisture content of the untreated residue is adjusted, and the residue is mixed with Portland cement to partially aggregate the residue into a free-flowing, granular material containing no more than about five percent by weight fines and having a hydraulic conductivity of at least about 0.001 cm/sec after curing for 24 hours. The treated residue can be used to form a gas-venting layer for a landfill, and retains its good hydraulic conductivity as it cures into a cohesive mass, such that leaching of hazardous materials is reduced.
    Type: Grant
    Filed: February 10, 1994
    Date of Patent: November 14, 1995
    Assignee: Rolite, Inc.
    Inventors: James J. Downs, William A. Roberts
  • Patent number: 5447798
    Abstract: A concrete article having a mixture layer comprising concrete and a polysulfide-modified epoxy resin as an intermediate layer between a concrete body and a cured layer of a polysulfide-modified epoxy resin, which concrete article is excellent in corrosion resistance, durability and workability, and shows good adhesion to the concrete body and to the cured layer of the polysulfide-modified epoxy resin. This concrete article can be produced by applying a coating composition containing the polysulfide-modified epoxy resin to the concrete body in an uncured state.
    Type: Grant
    Filed: June 22, 1993
    Date of Patent: September 5, 1995
    Assignees: Toray Industries, Inc., Toray Thiokol Co., Ltd.
    Inventors: Tadami Kamaishi, Hideaki Tanisugi, Keiichi Minami, Akio Takahashi, Takashi Taniguchi, Hiroyoshi Kuramoto
  • Patent number: 5445772
    Abstract: A method of producing a patterned shaped article includes the steps of disposing at a prescribed position within a main form for molding the shaped article a projection-bristling form having a support member and a plurality of projections standing upright from the support member, charging a prescribed amount of dry pattern-course material for forming the pattern course of the shaped article into spaces defined by a prescribed number of projections of the bristling form, charging a base-course material for forming the base course of the shaped article into the main form including the remaining space of the bristling form not filled with the pattern-course material, removing the bristling form, causing the charged pattern-course material and base-course material to set into a shaped article, removing the shaped article from the main form and, optionally, sintering the shaped article.
    Type: Grant
    Filed: May 22, 1992
    Date of Patent: August 29, 1995
    Assignee: CCA Inc.
    Inventors: Hiroshi Uchida, Mituhiro Onuki, Hideo Watanabe
  • Patent number: 5437829
    Abstract: A kit and method for forming a decorative, three-dimensional object in which a die or template initially forms a two-dimensional sheet of material, following which the sheet, which is larger in size than the size of a three-dimensional mold, is placed in the three-dimensional mold. The material thereafter hardens to form a three-dimensional member such as a pastry shell.
    Type: Grant
    Filed: February 10, 1994
    Date of Patent: August 1, 1995
    Inventor: Pamela J. Rist
  • Patent number: 5435951
    Abstract: A process for producing a slab of stony material by filling of a mold (42) with a mixture of stony material for the realization of a slab of the material, supplying the mixture with a volumetric distributor with rotating blades (92) and moving the volumetric distributor from a first end to the other end of the mold (42) and then returning the distributor to the first end with the blades (92) in a swinging motion or angle widening motion, and stopping the distributor for a prefixed period of time at each end, during which time the blades (92) are given a limited rotation in the direction of the stopped end.
    Type: Grant
    Filed: March 11, 1994
    Date of Patent: July 25, 1995
    Inventor: Luca Toncelli
  • Patent number: 5425807
    Abstract: The present invention relates to a novel composition which is useful for forming construction blocks and encapsulating hazardous materials, a process for producing blocks and encapsulating the material, and blocks made of the material. This composition is a mixture of klin dust or volcanic fly ash and aggregate. The process comprises the steps of (a) blending a dry mixture comprising the kiln dust or volcanic fly ash mixture with water; (b) transferring the blended mixture into a compression zone and (c) compressing the blended mixture in the compression zone to form a brick of the desired size.
    Type: Grant
    Filed: July 14, 1994
    Date of Patent: June 20, 1995
    Assignee: TIDE Company
    Inventor: Mitchell S. Riddle
  • Patent number: 5397752
    Abstract: Disclosed is a porous sepiolite having an improved water-resistance and thermal shock resistance obtained by grinding, moisture-conditioning and molding sepiolite, and then calcining said molded sepiolite at a temperature in the range of about 650.degree. C. to about 800.degree. C. Also disclosed is a porous sepiolite having a large specific surface area, wherein the pores having a pore diameter of 50 angstroms or less have a specific surface area in the range of from 40 to 200 m.sup.2 /g and in which no less than 20% of the total surface of the sepiolite is occupied with the pores having a pore diameter of 50 angstroms or less and wherein the pore distribution curve of the sepiolite has a main peak at a pore diameter of no more than 50 angstroms. This sepiolite is obtained by grinding, moisture-conditioning and molding sepiolite, calcining the same at a temperature in the range of about 650.degree. to about 800.degree. C., and then subjecting said calcined sepiolite to an acid treatment.
    Type: Grant
    Filed: November 19, 1993
    Date of Patent: March 14, 1995
    Assignee: Nikki-Universal Co., Ltd.
    Inventors: Norio Inoue, Eiki Iida, Makoto Sakura, Hideyuki Yunoki, Koji Hara, Yoshiki Nakano, Takashi Aihara
  • Patent number: 5397516
    Abstract: A process of molding a building panel which includes the steps of combining about 25 pounds of Portland Cement Type I, about 15 pounds of water at around 21.degree. Centigrade, added about 1 ounce of aluminum, calcium, magnesium, and silica, respectively, and about 12 ounces of synthetic fibers with about 0.1 ounce of ferro chloride in 40% solution by volume, and pouring the mixture into the lower portion of a mold to about 1/2 its depth and waiting for approximately 4 hours for the mixture to increase by about 100% of its original volume to fill the mold and thereafter stripping the mold from the form and placing it in a heated environment for curing for a period of approximately 24 hours and thereafter removing the panel from the heated environment.
    Type: Grant
    Filed: March 25, 1993
    Date of Patent: March 14, 1995
    Assignee: Thermo Cement Engineering Corp.
    Inventor: Faiz Sikaffy
  • Patent number: 5395561
    Abstract: A method of producing solid molding products from a slurry which has undergone absorption in wet-limestone gypsum desulfurization of flue gas includes the steps of concentrating the gypsum-containing absorption slurry, mixing and kneading the solid concentrated slurry with flyash and quicklime or slaked lime, molding the mixture into a given shape using a mold and then curing a resulting molding product in a reaction chamber wherein a part of desulfurized gas is passed. The method also includes solidifying a molded product by drying with water-saturated hot air produced with heat recovered from the flue gas and with water added into a heat recovery process.
    Type: Grant
    Filed: November 20, 1992
    Date of Patent: March 7, 1995
    Assignee: Mitsubishi Jukogyo Kabushiki Kaisha
    Inventors: Naohiko Ukawa, Hiroshi Fujita, Toru Takashina, Masakazu Onizuka, Atsushi Tatani, Kenji Inoue, Tsuyoshi Ohishi
  • Patent number: 5389172
    Abstract: A method of carrying out aggregate exposed finish for concrete capable of extremely reducing the usage amount of decorative aggregates, and of facilitating the work without requiring the long working time and the technique of a high level is as follows. The method includes the steps of: loading aggregates on an adhesive sheet; burying part of the aggregates in an adhesive layer of the adhesive sheet; casting mortar or concrete onto an aggregate loading surface of the aggregate loading adhesive sheet; hardening the mortar or concrete; and removing the adhesive sheet.
    Type: Grant
    Filed: September 27, 1993
    Date of Patent: February 14, 1995
    Assignees: Sliontec Corporation, Seltec Corporation
    Inventors: Teruaki Kobayashi, Masahito Oyama, Hiroyuki Enomoto, Hiroyuki Ogawa, Yutaka Tamura
  • Patent number: 5376321
    Abstract: A method of producing a patterned shaped article includes the steps of constituting a patterning form by disposing at a prescribed position within a main form for molding the shaped article an auxiliary form of a configuration appropriate for a pattern to be formed, charging a dry material for pattern formation into the patterning form at a prescribed form cavity portion thereof, charging a base-course material for forming the base course of the shaped article into the remaining space of the patterning form not filled with the pattern material, removing the auxiliary form, causing the pattern material and base-course material charged into the patterning form to set into a shaped article, removing the shaped article from the main form and, optionally, sintering the shaped article.
    Type: Grant
    Filed: August 27, 1991
    Date of Patent: December 27, 1994
    Assignee: CCA Inc.
    Inventors: Hiroshi Uchida, Mituhiro Onuki, Hideo Watanabe
  • Patent number: 5374303
    Abstract: A biodegradable oil and water emulsion release composition for facilitating the unmoulding of hydraulic bonding material comprises as the oil component an ester of a hindered polyhydric alcohol having no hydrogen atoms attached to any carbon atom in a beta-position to any hydroxyl group and a straight or branched chain, saturated or unsaturated C.sub.4 -C.sub.24 monocarboxylic acid. The ester may be partial and the partial ester may be alkoxylated. In a preferred embodiment also a straight or branched chain, saturated or unsaturated C.sub.8 -C.sub.24 monohydric alcohol is present. Also a method of unmoulding has been described.
    Type: Grant
    Filed: March 22, 1993
    Date of Patent: December 20, 1994
    Assignee: Unilever Patent Holdings B.V.
    Inventor: Bart van Hoorn
  • Patent number: 5368791
    Abstract: A method of producing a patterned shaped article includes the steps of disposing at a prescribed position within a main form for molding the shaped article a cell form having a plurality of cells arranged in a contiguous manner, charging a prescribed amount of dry pattern-course material for forming the pattern course of the shaped article into prescribed cells of the cell form, charging a base-course material for forming the base course of the shaped article into the remaining space of the main form not filled with the pattern-course material, removing the cell form, causing the charged pattern-course material and base-course material to set into a shaped article, removing the shaped article from the main form and, optionally, sintering the shaped article.
    Type: Grant
    Filed: September 30, 1991
    Date of Patent: November 29, 1994
    Assignee: CCA Inc.
    Inventors: Hiroshi Uchida, Mituhiro Onuki, Hideo Watanabe
  • Patent number: 5366676
    Abstract: A method for manufacturing concrete panels by continuously pressing and an apparatus for carrying out the method. The concrete panels are successively manufactured by continuously feeding pallets onto a conveyor, feeding a concrete material onto the pallets, continuously pressure frames against the concrete material from the upper side and both lateral sides of the concrete material while imparting vibrations to the pressure frames, forming hollows in the concrete material by thrusting a rotary screw-type core rod therethrough to provide a panel shape hollow molding, and cutting the molded concrete material into a length corresponding to the length of each pallet. In the manufacture process, an organic or inorganic fiber material may be incorporated into the concrete material for the purpose of reinforcement of the finished products.
    Type: Grant
    Filed: June 22, 1993
    Date of Patent: November 22, 1994
    Inventor: Shigeru Kobayashi
  • Patent number: 5367116
    Abstract: Solid residues obtained in flue gas purification, in particular flue dusts, are disposed in an environmentally compatible and economical manner by acid extracting heavy metals from the residues, precipitating the heavy metals from the extract, separating the precipitate from the mother liquor, subjecting the precipitate containing heavy metals to mechanical stress during which procedure the water contained in the precipitate is released and the precipitate itself is resuspended, and then adding a hydraulic binder to the resuspended precipitate containing heavy metals and/or to the extracted residues separately from one another. The binder-containing mixture can be used to form moldings which, after hardening, are employed for the erection of boundary walls in a landfill, Additionally or alternatively, the plastic binder-containing mixture can be introduced in the form of layers into preformed landfill spaces, where it then hardens.
    Type: Grant
    Filed: June 2, 1993
    Date of Patent: November 22, 1994
    Assignee: Von Roll AG
    Inventor: Rudolf Frey
  • Patent number: 5366549
    Abstract: A method is provided for making a fiber-reinforced slag gypsum cement lightweight hardened product. The method consists essentially of mixing (1) from 5 to 140 parts by weight of aggregates having a maximum size of not larger than 2000 .mu.m to (2) 100 parts by weight of a mixture which comprises 100 parts by weight of Portland cement, (3) from 20 to 350 parts by weight of slag fine powder which has a fineness ranging from 6,000 to 12,000 cm.sup.2 /g as Blaine's specific surface area, (4) from 0 to 20 parts by weight of lime, (5) from 20 to 100 parts by weight of calcium aluminate and gypsum fine powder, (6) 0.01 to 1.5 parts of a setting retardant; mixing water, prefoamed foams and reinforcing fibers with the mixture to obtain a slurry; subjecting the slurry to molding to obtain a molded product; removing the molded product to obtain a hardened product; and curing the hardened product with steam.
    Type: Grant
    Filed: March 24, 1994
    Date of Patent: November 22, 1994
    Assignees: Kyowa Giken Co., Ltd., Takeda Chemical Industries, Ltd., Dai-Ichi Cement Co., Ltd., Naigai Technos Corporation, Obayashi Corporation
    Inventors: Shokichi Imaizumi, Tsuyoshi Aoyama, Nagao Hori, Katsumi Takenami, Kiyoshi Koibuchi, Youich Ishikawa, Seiji Kazama, Koji Nasu
  • Patent number: 5362319
    Abstract: The invention provides a novel, environmentally stabilized formed product and to a method of producing a hard, dry, e.g., agglomerated or formed, environmentally stabilized product useful as a construction material, e.g., as pellets, panels, bricks, etc. comprising: a) ash such as RDF or coal ash (typically stack scrubber solids or bottom ash obtained from the burning of coal), b) an oxidizer and c) water. The amount of water present is selected to render the product plastic so that it can be molded to the desired shape. The oxidizer is provided in a sufficient amount to oxidize unstable compounds and to convert potassium, calcium or magnesium bisulfite to the sulfate form. Following the addition of the oxidizer, the admixture is exposed to electromagnetic energy, preferably ultraviolet light, to help drive the oxidation reaction to completion.
    Type: Grant
    Filed: October 21, 1993
    Date of Patent: November 8, 1994
    Inventor: William B. Johnson
  • Patent number: 5358749
    Abstract: The present invention provides a composition of matter and methods of using such composition which will substantially minimize the detrimental adherence to and buildup of living marine organisms on exposed surface areas of underwater structures. Such composition of matter includes a mixture of cement, sand and an anti-fouling agent. According to the methods disclosed the composition of matter can be used to line or coat surface areas of existing underwater structures or to manufacture an underwater structure totally with such composition of matter.
    Type: Grant
    Filed: January 31, 1994
    Date of Patent: October 25, 1994
    Inventor: Clois D. Fears
  • Patent number: 5358676
    Abstract: The present invention relates to hydraulically bonded cement compositions and methods of manufacture. Hydraulically bonded cement compositions and methods of manufacture include materials prepared by manipulating under pressure powdered hydraulic cement compositions using known or novel powder packing, casting, or expanding techniques, such that air within the powdered hydraulic cement is successfully removed while the cement is formed into a self-supporting near net final position. Thereafter, the formed hydraulic cement article is hydrated without mechanical mixing of the cement and water.
    Type: Grant
    Filed: November 25, 1992
    Date of Patent: October 25, 1994
    Assignee: E. Khashoggi Industries
    Inventors: Hamlin M. Jennings, Per J. Andersen, Simon K. Hodson
  • Patent number: 5356579
    Abstract: Incorporation of solid removable aggregates into powdered cement which later completely dissolve, evaporate, volatilize, or melt leaving voids in the cement composition is discussed. Cementitious articles are prepared by manipulating powdered hydraulic cement or cement paste compositions into mechanically self-supporting structures of a predetermined configuration and thereafter hydrating the hydraulic cement compositions without mechanical mixing of the cement and water.
    Type: Grant
    Filed: April 21, 1993
    Date of Patent: October 18, 1994
    Assignee: E. Khashoggi Industries
    Inventors: Hamlin M. Jennings, Simon K. Hodson
  • Patent number: 5354375
    Abstract: Disclosed is a method and an apparatus for the heat treatment of lime sludge (CaCO.sub.3) to form burnt lime (CaO). In the method of the present invention lime sludge is dried in a gas dryer means, to produce a dried lime sludge. The dried lime sludge is separated from the gases and thereafter is first fed to a compacting means wherein it is compacted into a plurality of substantially uniform bodies which are thereafter fed to a shaft kiln in which the compacted dried lime sludge is converted to active burnt lime.
    Type: Grant
    Filed: October 12, 1993
    Date of Patent: October 11, 1994
    Assignee: Fuller Company
    Inventor: Sidney M. Cohen
  • Patent number: 5350549
    Abstract: Cementitious compositions useful as lightweight aggregates are formed from a blend of spent bed material from fluidized bed combustion and fly ash. The proportions of the blend are chosen so that ensuing reactions eliminate undesirable constituents. The blend is then mixed with water and formed into a shaped article. The shaped article is preferably either a pellet or a "brick" shape that is later crushed. The shaped articles are cured at ambient temperature while saturated with water. It has been found that if used sufficiently, the resulting aggregate will exhibit minimal dimensional change over time. The aggregate can be certified by also forming standardized test shapes, e.g., cylinders while forming the shaped articles and measuring the properties of the test shapes using standardized techniques including X-ray diffraction.
    Type: Grant
    Filed: April 15, 1993
    Date of Patent: September 27, 1994
    Assignee: Valley Forge Laboratories, Inc.
    Inventor: Michael J. Boyle
  • Patent number: 5346549
    Abstract: The invention provides a novel formed product and method of producing a hard, dry, e.g., agglomerated or formed, product useful as a construction material comprising: a) papermill sludge made up of paper fiber, clay and calcium carbonate, b) ash such as coal ash (typically stack scrubber solids obtained from the burning of coal), and c) water. The amount of water present is selected to render the product plastic so that it can be molded to the desired shape. An oxidizer is provided in a sufficient amount to oxidize unstable compounds and to convert potassium, calcium or magnesium bisulfite to the sulfate form. Following the addition of the oxidizer, the admixture is exposed to electromagnetic energy, preferably ultraviolet light, to help drive the oxidation reaction to completion. In an optional form of the invention, a minor amount of a cation exchange resin is added to the mixture to sequester heavy metals.
    Type: Grant
    Filed: October 23, 1992
    Date of Patent: September 13, 1994
    Inventor: William B. Johnson
  • Patent number: 5342445
    Abstract: A hydraulic composition comprising blast furnace slag powder, a water-soluble polymer and an alkaline substance, and a high-strength composite material produced by kneading and molding a composition which comprises blast furnace slag powder, a water-soluble polymer, an alkaline substrate and water, and wet curing the molded composition. The high-strength composite material has high bending strength and excellent water resistance by using uncostly blast furnace slag powder.
    Type: Grant
    Filed: March 9, 1993
    Date of Patent: August 30, 1994
    Assignee: Nippon Kayaku Kabushiki Kaisha
    Inventors: Masayuki Kiyomoto, Akira Kajikawa, Toru Murakado, Hiroshi Sakurai, Motokazu Mano, Kazutika Sizume
  • Patent number: 5340513
    Abstract: A method and composition for the preparation of calcium silicate bounded shaped articles comprising mixing SiO.sub.2 containing powder, unslaked or slaked lime, calcium hydroxide, with a waste paper pulper slurry containing cellulosic particle of less than 1.1 mm in length is described. Additionally, Portland cement, alumina cement, calcium sulfate anhydride, plaster of Paris, a foam, and a thermally activated accelerator may also be added to the mixture which is then shaped into blanks, and autoclaved.
    Type: Grant
    Filed: December 14, 1992
    Date of Patent: August 23, 1994
    Assignee: SICOWA Verfahrenstechnik fur Baustoffe GmbH & Co., KG
    Inventors: Thomas Koslowski, Klaus-Michael Hessler, Olaf Musebrink
  • Patent number: 5340512
    Abstract: An improved electrical insulator for high voltage transmission lines is formed from certain polymer-based concrete compositions. An apparatus provides for the molding of the polymer-based mixture to form a highly degassed product. The method and apparatus include the ability to combine the constituents of the mixture in a mixer. A vacuum is applied to the mixture to degas the mixture. A mold is filled with the degassed mixture without introducing air thereinto in the absence of a vacuum. The resulting insulator has highly reduced air entrainment.
    Type: Grant
    Filed: January 29, 1993
    Date of Patent: August 23, 1994
    Assignee: Thomas & Betts Corporation
    Inventors: John Slocum, Peter N. Kiproff, Daryl Gibson, Will Merritt
  • Patent number: 5338498
    Abstract: A method for assembly and disassembly of formwork for walls (1) of poured material raised above a reference surface (2) using boards (3) each including a shuttering face (4) and equipped with wheels (31, 32) at their base. Assembly includes from an unshuttered position, rocking toward the wall (1) to be shuttered of at least the base (29) of the shuttering face (4) of the board (3) by rotating about an axis defined substantially by the support points (10) of the wheels (31) on the reference surface until the lower edge (35) of the shuttering face (4) is made to rest on the reference surface (2). The rocking is continued toward the wall (1) to be shuttered of at least the base (29) of the shuttering face of the board (3) by rotating about an axis substantially defined by the lower edge (35) of the shuttering face of the board (3) until the wheels (31) are raised from the reference surface. For disassembly, the rocking about the two axes is performed in reverse.
    Type: Grant
    Filed: June 19, 1992
    Date of Patent: August 16, 1994
    Inventor: Louis Lefebvre
  • Patent number: 5330694
    Abstract: A method of patterning a concrete surface and a pattern transfer mat for use in the method. The pattern transfer mat has a transfer surface having three-dimensional irregularities and carrying a multiplicity of grains to be transferred to the substrate concrete. Concrete is cast against the transfer surface of the mat and cured in situ and the mat is then detached.
    Type: Grant
    Filed: December 15, 1992
    Date of Patent: July 19, 1994
    Assignee: Tokai Rubber Industries, Ltd.
    Inventor: Nobuo Iwaya
  • Patent number: 5324469
    Abstract: A single wood concrete layer, sound absorption panel is formed as a single wood concrete layer, cast panel body of kaolin mineralized organic fiber chips encased in Portland cement with steel reinforcement. The panels have a noise reduction coefficient of at least about 0.85 for a panel thickness of about 10 cm and a panel density of 86.5 kg/m.sup.2.
    Type: Grant
    Filed: August 26, 1992
    Date of Patent: June 28, 1994
    Assignee: Insul Holz-Beton Systems, Inc.
    Inventors: Hansruedi Walter, Leni M Walter-Gurzeler
  • Patent number: 5322738
    Abstract: The clay tile proposed consists of a clay-bound core layer (20) with, on each side of it, a surface layer (22,24) of netlike tear-resistant textile material which is at least partially embedded in the clay of the core layer (20).
    Type: Grant
    Filed: November 25, 1992
    Date of Patent: June 21, 1994
    Inventor: Peter Breidenbach
  • Patent number: 5320790
    Abstract: A patterned tool and method for producing a durable tactile warning surface for sidewalks and other walkways including pouring a concrete base, applying pigmented or colored hardener to the upper surface of the concrete base, stamping the upper surface of the concrete base with the patterned tool including a substantially flat member having a plurality of symmetrically disposed recesses of a predetermined diameter and depth formed on the lower surface thereof and a plurality of corresponding vent channels formed through the substantially flat member in communication with each corresponding recess and curing the concrete base to form a durable tactile warning surface including a plurality of symmetrically disposed raised elements of a predetermined diameter, height and spacing corresponding to the plurality of recesses to produce an uneven surface visually contrasting with adjacent surface areas.
    Type: Grant
    Filed: July 10, 1992
    Date of Patent: June 14, 1994
    Inventor: Michael Lowe
  • Patent number: 5308572
    Abstract: A method for manufacturing a reinforced cementitious structural member having a predetermined shape and size includes providing a mold having a cavity which corresponds to the shape and size of the member, placing at last one permeable fibrous mat into the cavity, introducing a slurry of cementitious material into the cavity so that the slurry of cementitious material fills the cavity and infiltrates and encapsulates the fibrous mat, curing the reinforced cementitious material, and separating the cured reinforced cementitious structural member from the mold.
    Type: Grant
    Filed: November 17, 1992
    Date of Patent: May 3, 1994
    Assignee: Ribbon Technology Corporation
    Inventor: Lloyd E. Hackman
  • Patent number: 5304333
    Abstract: Green concrete products, such as building products, are placed on pallets. Those pallets are transported to a kiln for curing and from the kiln after cure by an overhead crane. Pallets are lowered into and removed from open top kilns layer by layer being supported by movable support ledges, for example rotatable toggles, at each layer position which permit vertical entry and removal of the pallet layers. Three kiln compartments permit continuous production, one being filled, one being emptied and the third curing a load of pallet layers.
    Type: Grant
    Filed: October 23, 1992
    Date of Patent: April 19, 1994
    Inventor: Francisco Trevino-Gonzales
  • Patent number: 5301927
    Abstract: A switch cross tie is made in a mold having a base plate formed with a plurality of holes in a predetermined pattern corresponding to a particular type of concrete switch cross tie by first overlying the entire base plate of a mold with a covering sheet provided with markings in a pattern corresponding to that of the holes needed for another particular type of concrete cross ties. This covering sheet overlies and blocks all the holes formed in the base plate and it is fixed in place atop the base plate. Then the operator or a computer-guided drill press cuts through the covering sheet and into the base plate at each of the markings to form thereat a respective new hole. Each such new hole is fitted with an anchor, and the mold is filled with concrete over and around the anchors with the covering sheet blocking all the holes other than the new holes. It is important that the covering sheet be sufficiently strong to inhibit entry of concrete through it into any of the holes other than the new holes.
    Type: Grant
    Filed: February 16, 1993
    Date of Patent: April 12, 1994
    Assignee: Wayss & Freytag Aktiengesellschaft
    Inventor: Frithjof Schimpff
  • Patent number: 5302335
    Abstract: A method for the fabrication of water-repellent hardened moldings wherein the diorganopolysiloxane is not discharged into the effluent water during the molding or forming process and the molding itself is free of nonuniformities in its water repellency. The method for the preparation of water-repellent hardened moldings includes forming a slurry of a mixture including a calcareous raw material and a siliceous raw material in an arbitrary quantity of water; emulsifying a diorganopolysiloxane using nonionic surfactant and adding this emulsion to the slurry at a temperature at or above the cloud point of the nonionic surfactant; subsequentially draining off the water, then molding or forming, and finally drying or steam-curing to produce the water-repellent hardened molding.
    Type: Grant
    Filed: March 18, 1993
    Date of Patent: April 12, 1994
    Assignee: Dow Corning Toray Silicone Co., Ltd.
    Inventors: Tsutomu Naganawa, Isao Ona
  • Patent number: 5302331
    Abstract: A process for recycling household waste, garbage or trash into useful articles including in one preferred embodiment the steps of collecting the waste material, feeding the waste material into a pulverizer to convert the material to a powdery mass, adding water to the mass to form a slurry, adding a binder to the slurry to inhibit bacteriological growth, pouring or otherwise forming the slurry into a useful shape such as a block, or sheet, and allowing the formed shape to air dry under relatively low humidity. The resulting useful article may then be used as a building block, wall board, ceiling tile and so on. In an alternative example, the binder is added directly to the pulverized waste material to produce a useful article such as a flexible roof shingle.
    Type: Grant
    Filed: November 30, 1992
    Date of Patent: April 12, 1994
    Inventor: Robert E. Jenkins
  • Patent number: 5296028
    Abstract: A method and composition for making concrete includes an antifreeze admixe which is added to the concrete to prevent the freezing of water in the concrete when the concrete is cured during the winter or other cold conditions. The concrete admixture includes sodium nitrate and sodium sulfate combined with one another in a predetermined ratio. In a preferred a embodiment the ratio of sodium nitrate to sodium sulfate equals 3:1. A dosage of greater than 2% by weight of cement of the above described admixture was found to significantly increase the compressive strength of concrete cast of cold (below freezing, or 0 degrees celsius) temperatures, and dosages of 6% and 8% by weight of cement of the specified admixture were found to be particularly effective.
    Type: Grant
    Filed: May 11, 1993
    Date of Patent: March 22, 1994
    Assignee: The United States of America as represented by the Secretary of the Army
    Inventors: Charles J. Korhonen, Edel R. Cortez