阅读说明：本技术 基于土工聚合物的无机泡沫 (Geopolymer-based inorganic foams ) 是由 S·图尔钦斯卡斯 B·费克滕施拉格 G·阿尔布雷奇特 P·珀蒂 U·贡岑巴赫 P·斯图尔岑 于 2018-03-05 设计创作，主要内容包括：本发明涉及一种制备基于土工聚合物的颗粒稳定化无机泡沫的方法,一种基于土工聚合物的颗粒稳定化无机泡沫,一种可以通过硬化并任选干燥该基于土工聚合物的颗粒稳定化无机泡沫得到的泡孔材料以及一种制备用于提供基于土工聚合物的颗粒稳定化无机泡沫的无机泡沫配制剂的组合物。(The present invention relates to a process for the preparation of a geopolymer-based particulate stabilised inorganic foam, a cellular material obtainable by hardening and optionally drying the geopolymer-based particulate stabilised inorganic foam and a composition for the preparation of an inorganic foam formulation for providing a geopolymer-based particulate stabilised inorganic foam.)

1. A method of making an inorganic foam comprising the steps of:

(1) The following components were mixed:

(i) At least one type of inorganic particles;

(ii) At least one amphiphilic compound;

(iii) at least one inorganic binder mixture comprising:

(iiia) at least one inorganic binder selected from the group consisting of blast furnace slag, micro silica, metakaolin, aluminosilicates and mixtures thereof,

(iiib) at least one basic activator selected from the group consisting of alkali metal hydroxides, alkali metal carbonates, alkali metal aluminates, alkali metal silicates, and mixtures thereof;

(iv) Water; and optionally

(v) At least one additive; and

(2) Foaming the resulting foam formulation by chemical, physical or mechanical foaming,

Wherein the at least one amphiphilic compound comprises an amphiphilic compound having at least one polar head group and at least one non-polar tail group, wherein the at least one head group is selected from the group consisting of phosphates, phosphonates, sulfates, sulfonates, alcohols, amines, amides, pyrrolidines, gallates, and carboxylic acids; and wherein said at least one tail group is selected from aliphatic or aromatic or cyclic groups having 2 to 8 carbon atoms, wherein the carbon atoms are optionally substituted by one or more groups selected from C₁-C₈alkyl, secondary-OH and secondary-NH₂Are substituted by the same or different substituents.

2. The method according to claim 1, wherein the at least one type of inorganic particles is selected from the group consisting of oxides, hydroxides, carbides, nitrides, phosphates, carbonates, silicates, sulfates, and mixtures thereof.

3. The method according to claim 1 or 2, wherein the at least one type of inorganic particles is selected from the group consisting of silica particles, alumina particles, zirconia particles and CaCO₃Granules and mixtures thereof.

4. a method according to any one of claims 1 to 3, wherein the at least one type of inorganic particles has an average particle size D₅₀In the range of 30nm-300 μm.

5. The method of any of claims 1-4, wherein said at least one amphiphilic compound comprises an amphiphilic compound having at least one head group selected from carboxylic acids, gallates, and amines and at least one tail group selected from aliphatic groups having 2-8 carbon atoms.

6. The method according to any one of claims 1 to 5, wherein the at least one inorganic binder is metakaolin.

7. The method according to any one of claims 1 to 6, wherein the at least one alkaline activator is water glass.

8. The method of any of claims 1-7, wherein the at least one additive is selected from the group consisting of fillers, accelerators, retarders, rheology modifiers, high-efficiency water reducers, fibers, surfactants, catalysts, other hydrophobizing agents, and mixtures thereof.

9. A method according to any one of claims 1 to 8 wherein the amount of amphiphilic compound on the surface of the inorganic particles is in the range of from 0.5 to 160 μmol/m²(ii) a And/or wherein the inorganic particles are provided in an amount of 1-25 wt% relative to the amount of the at least one inorganic binder mixture; and/or wherein the weight ratio of water to the at least one inorganic binder mixture is from 0.1 to 2.0.

10. the method according to any one of claims 1 to 9, wherein step (1) comprises the steps of:

(1a) dispersing said at least one type of inorganic particles, said at least one amphiphilic compound and optionally said at least one additive in water to obtain an aqueous dispersion; and

(1b) Mixing the aqueous dispersion with the at least one inorganic binder mixture.

11. An inorganic foam obtainable by the process according to any one of claims 1 to 10.

12. An inorganic foam comprising:

(i) At least one type of inorganic particles;

(ii) At least one amphiphilic compound;

(iii) At least one inorganic binder mixture comprising:

(iiia) at least one inorganic binder selected from blast furnace slag, micro-silica, metakaolin, aluminosilicates and mixtures thereof, and

(iiib) at least one basic activator selected from the group consisting of alkali metal hydroxides, alkali metal carbonates, alkali metal aluminates, alkali metal silicates, and mixtures thereof;

(iv) Water; and optionally

(v) At least one additive.

13. A cellular material obtainable by hardening and optionally drying an inorganic foam according to claim 11 or 12.

14. A composition for preparing an inorganic foam formulation comprising as components:

(i) At least one type of inorganic particles;

(ii) At least one amphiphilic compound;

(iii) At least one inorganic binder mixture comprising:

(iiia) at least one inorganic binder selected from blast furnace slag, micro-silica, metakaolin, aluminosilicates and mixtures thereof, and

(iiib) at least one basic activator selected from the group consisting of alkali metal hydroxides, alkali metal carbonates, alkali metal aluminates, alkali metal silicates, and mixtures thereof;

Wherein

Components (i), (ii) and (iii) are present separately; or

Components (i) and (ii) are present as a mixture and component (iii) is present separately; or

The components (i), (ii) and (iii) are present as a mixture.

15. Use of the inorganic foam according to claim 11 or 12, the cellular material according to claim 13 and/or the composition according to claim 14 in the manufacture or as thermal insulation, sound insulation or sound absorption material, for fire protection and/or as building material with low density.

Examples

Comparative example 1

Geopolymer foams were prepared from the following raw materials consisting of (wt%):

20.5% metakaolin (Argical)^TMM 1200S，Imerys)

20.5% fly ash (M10，BauMineral)

7.8% calcium aluminate cement (Ciment)Kerneos)

1.2% surfactant (alkyl polyglucoside,225DK，BASF)

0.2% PAN fibre (6mm, 6.7dtex)

19.5% of water

27.4% water glass ("Kaliwasserglass K58", BASF)

2.9％NaOH

the liquid feed is first mixed with NaOH. The solid feedstock is added to the liquid components and stirred until a homogeneous slurry is produced. The foam was then generated with a kitchen mixer. The foam thus obtained is poured into a mould. A setting reaction occurs and the foam begins to cure. The geopolymer foam was stored under a humid atmosphere for 3 days to allow for proper coagulation. It was then demolded and dried at 70 ℃ until constant mass.

The resulting geopolymer foam part had dimensions of 300mm x 40 mm. The dry density of the powder was 144kg/m³And the thermal conductivity thereof is 42.1 mW/m.K. The compressive strength was 49kPa, and the bending strength was 28 kPa. The sample is characterized by a gas flow resistivity of 4.2kPa s/m². The foam is predominantly open-celled.

working example 1

A mixture containing 79.8 wt% calcium carbonate (sonal 31), 15.1 wt% butyl gallate and 5.1 wt% manganese (IV) oxide was pre-mixed as a "foam forming powder".

geopolymer foams were prepared from the following raw materials consisting of (wt%):

19.2% metakaolin (Argical)^TMM 1200S，Imerys)

19.2% fly ash (M10，BauMineral)

7.3% calcium aluminate cement (Ciment)Kerneos)

2.3% foam forming powder

0.2% PAN fibre (6mm, 6.7dtex)

23.4% of water

26.3% water glass ("Kaliwasserglass K58", BASF)

2.8% Hydrogen peroxide (50% by weight solution)

the foam-forming powder is first dispersed in water. The suspension is then added to water glass. A mixture of metakaolin and fly ash was added and the suspension was stirred for 10 minutes. The calcium aluminate cement is then mixed. After stirring for 15 minutes the foaming of the suspension was initiated by adding hydrogen peroxide. The slurry thus obtained is poured into a mould in which the expansion of the foam gradually takes place until the decomposition of the hydrogen peroxide is complete. The wet foam produced was stable until after about 30 minutes the setting reaction occurred and the foam began to cure. The geopolymer foam was stored in a humid atmosphere for 3 days to allow for proper coagulation. It was then demolded and dried at 70 ℃ until constant mass.

The resulting geopolymer foam part had dimensions of 200mm x 50 mm. The dry density of the powder was 127kg/m³And the thermal conductivity thereof was 39.6 mW/mK. The compressive strength was 117kPa, and the bending strength was 82 kPa. The sample is characterized by a gas flow resistivity of 233kPa s/m². The foam is predominantly closed cell.