US3869295A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Uniform lightweight concrete and plaster
Assignee: Individual
•
Filing: 1973-03-23
•
Granted: 1975-03-04
•
Expires: 1993-03-23
Abstract
Abstract Lightweight concrete and plaster are prepared by a novel method which assures that the aggregate is uniformly admixed with the cementitious material and other relatively heavy ingredients of the concrete and plaster mixes. This is accomplished by wetting the surfaces of the lightweight aggregate particles with an aqueous medium, admixing the wet aggregate particles with dry finely divided cementitious material to form a coating thereon, and thereafter adding additional aqueous medium in an amount to produce a coherent formable uncured concrete or plaster matrix. The uncured concrete or plaster matrix may be formed into a desired configuration, and then is allowed to set in the usual manner. The addition of hydrated lime improves the cohesive properties of an uncured concrete matrix. Increased strength in cured lightweight concrete may be obtained by admixing pozzolan, hydrated lime and/or finely divided inert inorganic fillers such as sand with the uncured concrete matrix. A lightweight aggregate including expanded polystyrene beads is preferred, and further increased strength may be obtained by using polystyrene beads expanded in hot water.
Inventors
- 👤 Andrew D Bowles
- 👤 Samuel J Parsons
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 18:59
CPC Classifications
C; C04; C04B; C04B20/00; C04B20/10; C04B20/1055; C04B28/00; C04B28/02; Y; Y10; Y10S; Y10S264/00; Y10S264/07
Claims Analysis
Total Claims: 29
Claim 1
Independent Claim
187 words
IN A METHOD OF PREPARING LIGHTWEIGHT BUILDING MATERIAL WHEREIN A LIGHTWEIGHT AGGREGATE COMPRISING EXPANDED POLYSTYRENE BEADS IS ADMIXED WITH AN AQUEOUS MEDIUM AND INORGANIC CEMENTITIOUS MATERIAL IN AMOUNTS TO PRODUCE A COHERENT FORMABLE UNCURED LIGHTWEIGHT MATRIX WHICH SETS UPON STANDING, SAID MATRIX IS FORMED INTO A BODY OF UNCURED LIGHTWEIGHT SELF-SETTING BUILDING MATERIAL HAVING A DESIRED CONFIGURATION AND SAID BODY IS MAINTAINED IN THE DESIRED CONFIGURATION UNTIL IT SETS AND THE RESULTING SET BODY IS CURED TO FORM CURED LIGHTWEIGHT BUILDING MATERIAL, THE IMPROVEMENT WHICH COMPRISES PREPARING THE COHERENT FORMABLE UNCURED LIGHTWEIGHT MATRIX FROM AN AGGREGATE CONSISTING ESSENTIALLY OF POLYSTYRENE BEADS EXPANDED IN HOT WATER, THE SAID POLYSTYRENE BEADS CONTAINING WATER FROM THE EXPANSION THEREOF IN THE HOT WATER AND THE SAID WATER CONTENT CAUSING THE POLYSTYRENE BEADS TO HAVE A WEIGHT OF AT LEAST 3 POUNDS PER CUBIC FOOT, THE POLYSTYRENE BEADS BEING ADMIXED WITH THE AQUEOUS MEDIUM AND INORGANIC CEMENTITIOUS MATERIAL IN THE ABSENCE OF AN ADDED HOMOGENIZING AGENT WHICH AIDS IN COATING THE POLYSTYRENE BEADS WITH THE CEMENTITIOUS MATERIAL, AND THE SAID BODY UPON SETTING AND CURING BEING COHERENT AND SUBSTANTIALLY FREE OF CRACKS.
Claim 2
Dependent Claim
187 words
IN A METHOD OF PREPARING LIGHTWEIGHT BUILDING MATERIAL WHEREIN A LIGHTWEIGHT AGGREGATE COMPRISING EXPANDED POLYSTYRENE BEADS IS ADMIXED WITH AN AQUEOUS MEDIUM AND INORGANIC CEMENTITIOUS MATERIAL IN AMOUNTS TO PRODUCE A COHERENT FORMABLE UNCURED LIGHTWEIGHT MATRIX WHICH SETS UPON STANDING, SAID MATRIX IS FORMED INTO A BODY OF UNCURED LIGHTWEIGHT SELF-SETTING BUILDING MATERIAL HAVING A DESIRED CONFIGURATION AND SAID BODY IS MAINTAINED IN THE DESIRED CONFIGURATION UNTIL IT SETS AND THE RESULTING SET BODY IS CURED TO FORM CURED LIGHTWEIGHT BUILDING MATERIAL, THE IMPROVEMENT WHICH COMPRISES PREPARING THE COHERENT FORMABLE UNCURED LIGHTWEIGHT MATRIX FROM AN AGGREGATE CONSISTING ESSENTIALLY OF POLYSTYRENE BEADS EXPANDED IN HOT WATER, THE SAID POLYSTYRENE BEADS CONTAINING WATER FROM THE EXPANSION THEREOF IN THE HOT WATER AND THE SAID WATER CONTENT CAUSING THE POLYSTYRENE BEADS TO HAVE A WEIGHT OF AT LEAST 3 POUNDS PER CUBIC FOOT, THE POLYSTYRENE BEADS BEING ADMIXED WITH THE AQUEOUS MEDIUM AND INORGANIC CEMENTITIOUS MATERIAL IN THE ABSENCE OF AN ADDED HOMOGENIZING AGENT WHICH AIDS IN COATING THE POLYSTYRENE BEADS WITH THE CEMENTITIOUS MATERIAL, AND THE SAID BODY UPON SETTING AND CURING BEING COHERENT AND SUBSTANTIALLY FREE OF CRACKS.
Claim 3
Dependent Claim
49 words
The method of claim 1 wherein polystyrene beads including a heat activated expanding agent are introduced into hot water and expanded therein, the wet expanded polystyrene beads thus prepared are recovered from the hot water, and the expanded polystyrene beads are admixed with the inorganic cementitious material while wet.
Claim 4
Dependent Claim
28 words
The method of claim 1 wherein the said coherent formable uncured lightweight matrix is prepared from an aggregate consisting of the said polystyrene beads expanded in hot water.
Claim 5
Dependent Claim
181 words
In a method of preparing lightweight concrete wherein a lightweight aggregate comprising expanded polystyrene beads is admixed with an aqueous medium and hydraulic cement in amounts to produce a coherent formable uncured lightweight concrete matrix which sets upon standing, said concrete matrix is formed into a body of uncured lightweight concrete having a desired configuration, and said body is maintained in the desired configuration until it sets and the resulting set body is cured to form cured lightweight concrete, the improvement which comprises preparing the lightweight concrete from an aggregate consisting essentially of polystyrene beads expanded in hot water, the said polystyrene beads containing water from the expansion thereof in the hot water and the said water content causing the polystyrene beads to have a weight of at least 3 pounds per cubic foot, the polystyrene beads being admixed with the aqueous medium and the hydraulic cement in the absence of an added homogenizing agent which aids in coating the polystyrene beads with the hydraulic cement, and the said body upon setting and curing being coherent and substantially free of cracks.
Claim 6
Dependent Claim
181 words
In a method of preparing lightweight concrete wherein a lightweight aggregate comprising expanded polystyrene beads is admixed with an aqueous medium and hydraulic cement in amounts to produce a coherent formable uncured lightweight concrete matrix which sets upon standing, said concrete matrix is formed into a body of uncured lightweight concrete having a desired configuration, and said body is maintained in the desired configuration until it sets and the resulting set body is cured to form cured lightweight concrete, the improvement which comprises preparing the lightweight concrete from an aggregate consisting essentially of polystyrene beads expanded in hot water, the said polystyrene beads containing water from the expansion thereof in the hot water and the said water content causing the polystyrene beads to have a weight of at least 3 pounds per cubic foot, the polystyrene beads being admixed with the aqueous medium and the hydraulic cement in the absence of an added homogenizing agent which aids in coating the polystyrene beads with the hydraulic cement, and the said body upon setting and curing being coherent and substantially free of cracks.
Claim 7
Dependent Claim
48 words
The method of claim 4 wherein polystyrene beads including a heat activated expanding agent are introduced into hot water and Expanded therein, the wet expanded polystyrene beads thus prepared are recovered from the hot water, and the expanded polystyrene beads are admixed with the hydraulic cement while wet.
Claim 8
Dependent Claim
25 words
The method of claim 4 wherein the said lightweight concrete is prepared from an aggregate consisting of the said polystyrene beads expanded in hot water.
Claim 9
Dependent Claim
32 words
The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith up to about 30% by weight of finely divided pozzolan based upon the weight of the hydraulic cement.
Claim 10
Dependent Claim
33 words
The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith up to about 15% by weight of finely divided hydrated lime based upon the weight of the hydraulic cement.
Claim 11
Dependent Claim
34 words
The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith a finely divided inert inorganic filler in an amount up to about three times the weight of the hydraulic cement.
Claim 12
Dependent Claim
22 words
The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith an effective amount of an air entraining agent.
Claim 13
Dependent Claim
22 words
The method of claim 4 wherein the aqueous medium comprises an aqueous suspension of an organic polymeric binder for the lightweight aggregate.
Claim 14
Dependent Claim
20 words
The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith at least one additional lightweight aggregate.
Claim 15
Dependent Claim
12 words
The method of claim 12 wherein the additional lightweight aggregate is perlite.
Claim 16
Dependent Claim
44 words
The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith up to about 30% by weight of finely divided pozzolan and up to about 15% by weight of finely divided hydrated lime based upon the weight of the hydraulic cement.
Claim 17
Dependent Claim
53 words
The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith up to about 30% by weight of finely divided pozzolan based upon the weight of the hydraulic cement and a finely divided inert inorganic filler in an amount up to about three times the weight of the hydraulic cement.
Claim 18
Dependent Claim
52 words
The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith a finely divided inert inorganic filler in an amount up to about three times the weight of the hydraulic cement and finely divided hydrated lime in an amount up to about 15% by weight of the hydraulic cement.
Claim 19
Dependent Claim
65 words
The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith up to about 30% by weight of finely divided pozzolan based upon the weight of the hydraulic cement, sand in an amount up to about three times the weight of the hydraulic cement, and finely divided hydrated lime in an amount up to about 15% by weight of the hydraulic cement.
Claim 20
Dependent Claim
189 words
In a method of preparing lightweight plaster wherein a lightweight aggregate comprising expanded polystyrene beads is admixed with an aqueous medium and inorganic cementitious material for plaster in amounts to produce a coherent formable uncured lightweight plaster matrix which sets upon standing, said plaster matrix is formed into a body of uncured lightweight plaster having a desired configuration, and said body is maintained in the desired configuration until it sets and the resulting set body is cured to form cured lightweight plaster, the improvement which comprises preparing the lightweight plaster from an aggregate consisting essentially of polystyrene beads expanded in hot water, the said polystyrene beads containing water from the expansion thereof in the hot water and the said water content causing the polystyrene beads to have a weight of at least 3 pounds per cubic foot, the polystyrene beads being admixed with the aqueous medium and the inorganic cementitious material for plaster in the absence of an added homogenizing agent which aids in coating the polystyrene beads with the said inorganic cementitious material, and the said body upon setting and curing being coherent and subStantially free of cracks.
Claim 21
Dependent Claim
189 words
In a method of preparing lightweight plaster wherein a lightweight aggregate comprising expanded polystyrene beads is admixed with an aqueous medium and inorganic cementitious material for plaster in amounts to produce a coherent formable uncured lightweight plaster matrix which sets upon standing, said plaster matrix is formed into a body of uncured lightweight plaster having a desired configuration, and said body is maintained in the desired configuration until it sets and the resulting set body is cured to form cured lightweight plaster, the improvement which comprises preparing the lightweight plaster from an aggregate consisting essentially of polystyrene beads expanded in hot water, the said polystyrene beads containing water from the expansion thereof in the hot water and the said water content causing the polystyrene beads to have a weight of at least 3 pounds per cubic foot, the polystyrene beads being admixed with the aqueous medium and the inorganic cementitious material for plaster in the absence of an added homogenizing agent which aids in coating the polystyrene beads with the said inorganic cementitious material, and the said body upon setting and curing being coherent and subStantially free of cracks.
Claim 22
Dependent Claim
48 words
The method of claim 18 wherein polystyrene beads including a heat activated expanding agent are introduced into hot water and expanded therein, the wet expanded polystyrene beads thus prepared are recovered from the hot water, and the expanded polystyrene beads are admixed with the cementitious material while wet.
Claim 23
Dependent Claim
25 words
The method of claim 18 wherein the said lightweight plaster is prepared from an aggregate consisting of the said polystyrene beads expanded in hot water.
Claim 24
Dependent Claim
25 words
The method of claim 18 wherein the cementitious material is selected from the group consisting of calcined gypsum, hydrated lime, Portland cement and admixtures thereof.
Claim 25
Dependent Claim
34 words
The method of claim 18 wherein the uncured plaster matrix also contains admixed therewith a finely divided inert inorganic filler in an amount up to about three times the weight of the cementitious material.
Claim 26
Dependent Claim
22 words
The method of claim 18 wherein the aqueous medium comprises an aqueous suspension of an organic polymeric binder for the lightweight aggregate.
Claim 27
Dependent Claim
20 words
The method of claim 18 wherein the uncured plaster matrix also contains admixed therewith at least one additional lightweight aggregate.
Claim 28
Dependent Claim
12 words
The method of claim 18 wherein the cementitious material comprises calcined gypsum.
Claim 29
Dependent Claim
12 words
The method of claim 18 wherein the cementitious material comprises hydrated lime.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-03-03 | 1978-09-02 | 1979-03-04 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-03-03 | 1982-09-02 | 1983-03-04 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-03-03 | 1986-09-02 | 1987-03-04 | $7700.00 | Window Closed / Lapsed |