Aluminosilicate hydrogel bonded aggregate articles

Abstract

Aggregate-containing products bonded by an aluminosilicate hydrogel are disclosed. A system of two-part mixing and blending of binder components with various granular-like aggregates, modifiers and/or fillers is described in which the resulting compositions are temporarily fluid and formable for short, controllable periods of time but which thereafter become strong, rigid, adherent, erosion resistant composites, requiring little or no external heat supply to achieve full set. The compositions can be formulated for molding on suitable forms or patterns, and may also be prepared in slurry form suitable for spray coating or sealing applications. A wide variety of products can be manufactured of the compositions, including investment molds and cores for foundry use, as well as non-foundry products such as heat and electrical insulators, construction blocks, panels, coating slurries, etc. which may be of essentially solid or foamed (cellular) construction. The novel compositions may be totally inorganic if desired and have advantage in their preparation and use of being non-toxic and environmentally safe, possessing properties of good soundproofing, fire and fluid erosion resistance. The compositions are formulated of readily available, non-critical materials and are correspondingly very cost effective.