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. 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 having an outer shell and a hollow interior, and at least one binder;
wherein the at least one binder is excluded from the hollow interior;
wherein the hollow interior is filled with a gas; and
wherein the plurality of microparticles are from about 10 microns to about 1500 microns in size.
2. The utility material of claim 1 , wherein the plurality of microparticles are from about 10 microns to about 500 microns in size.
3. The utility material of claim 1 , wherein the core matrix, as a wet formulation, includes from about 25 wt % to about 75 wt % of the plurality of microparticles.
4. The utility material of claim 1 , wherein a reinforcing member is disposed within the core matrix.
5. The utility material of claim 1 , wherein the core matrix comprises a protruding configuration formed within and along an edge of the core matrix.
6. The utility material of claim 1 , wherein the core matrix comprises a recess formed within and along an edge of the core matrix.
7. The utility material of claim 1 , wherein the core matrix comprises a notch and a nub formed within and along an edge of the core matrix.
8. The utility material of claim 3 , wherein the core matrix, as a wet formulation, includes from about 50 wt % to about 60 wt % of microparticles.
9. The utility material of claim 1 , wherein at least one binder is an inorganic binder.
10. The utility material of claim 9 , wherein the inorganic binder is a sodium silicate binder.
11. The utility material of claim 10 , wherein the core matrix, as a wet formulation, includes from about 20 wt % to about 60 wt % of the sodium silicate binder.
12. The utility material of claim 10 , wherein the core matrix further includes a setting agent.
13. The utility material of claim 11 , wherein the core matrix, as a wet formulation, includes from about 35 wt % to about 45 wt % of the sodium silicate binder.
14. The utility material of claim 12 , wherein the core matrix, as a wet formulation, includes from about 2 wt % to about 10 wt % of the isocyanate setting agent.
15. The utility material of claim 12 , wherein the core matrix, as a wet formulation, includes from about 3 wt % to about 6 wt % of the setting agent.
16. The utility material of claim 12 , wherein the setting agent is an isocyanate setting agent.
17. The utility material of claim 16 , wherein the sodium silicate binder and the isocyanate setting agent are at a ratio of from about 1:1 to about 15:1.
18. The utility material of claim 16 , wherein the sodium silicate binder and the isocyanate setting agent are at a ratio of from about 8:1 to about 12:1.