UTILITY MATERIALS INCORPORATING A MICROPARTICLE MATRIX FORMED WITH A SETTING AGENT
A composition, utility material, and method of making a utility material is disclosed. A composition having an improved setting time may include a plurality of microparticles mixed with a sodium silicate binder and an isocyanate setting agent, where the microparticle composition has a setting time of less than or equal to one hour. A utility material may be a wallboard that includes the composition.
1 . (canceled)
2 . A utility material comprising:
a wallboard having a first facing membrane and a second facing membrane; and
a core matrix disposed between the first facing membrane and the second facing membrane, wherein the core matrix includes:
a plurality of microparticles blended with expanded siliceous inorganic particles,
an inorganic binder, and
a setting agent.
3 . The utility material of claim 2 , wherein the inorganic binder is a sodium silicate binder and the setting agent is an isocyanate setting agent.
4 . The utility material of claim 3 , wherein the sodium silicate binder and the isocyanate setting agent are at a ratio of from about 1:1 to about 15:1.
5 . The utility material of claim 3 , wherein the sodium silicate binder and the isocyanate setting agent are at a ratio of from about 8:1 to about 12:1.
6 . The utility material of claim 2 , wherein the expanded siliceous inorganic particles are perlite particles.
7 . The utility material of claim 2 , wherein the microparticles are cenospheres ranging in size from about 10 microns to about 1500 microns.
8 . The utility material of claim 2 , wherein the expanded siliceous inorganic particles are present in an amount between 0.01% and 50% by weight of the total weight of the core matrix in wet mixture.
9 . The utility material of claim 7 , wherein the cenospheres have an outer shell and a hollow interior filled with a gas
10 . The utility material of claim 7 , wherein the cenospheres have a crush strength between 3000 psi and 5000 psi.
11 . The utility material of claim 7 , wherein the core matrix, as a wet formulation, includes from about 25 wt % to about 75 wt % of cenospheres.
12 . The utility material of claim 7 , wherein the core matrix, as a wet formulation, includes from about 50 wt % to about 60 wt % of cenospheres.
13 . The utility material of claim 3 , wherein the core matrix, as a wet formulation, includes from about 20 wt % to about 60 wt % of sodium silicate binder.
14 . The utility material of claim 3 , wherein the core matrix, as a wet formulation, includes from about 35 wt % to about 45 wt % of sodium silicate binder.
15 . The utility material of claim 2 , wherein a reinforcing member is disposed within the core matrix.
16 . The utility material of claim 2 , wherein the core matrix comprises a protruding configuration formed within and along an edge of the core matrix.
17 . The utility material of claim 2 , wherein the core matrix comprises a recess formed within and along an edge of the core matrix.
18 . The utility material of claim 2 , wherein the core matrix comprises a notch and a nub formed within and along an edge of the core matrix.
19 . The utility material of claim 3 , wherein the core matrix, as a wet formulation, includes from about 2 wt % to about 10 wt % of the isocyanate setting agent.
20 . The utility material of claim 3 , wherein the core matrix, as a wet formulation, includes from about 3 wt % to about 6 wt % of the isocyanate setting agent.