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International Hydrolytics Ltd.
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AHC
Technology
AHC materials are self-hardening combinations of
siliceous (silicate-based) Hydrolytic cements, which can be mixed with a wide
variety of aggregates, fibers, fillers, and/or waste products. The basic
hydrolytic cement is formed from a proprietary two-part admixture, which forms
a type of artificial stone when cured. The `dispersed phase additive' gives the
final AHC material unique properties for each application. AHC materials are
typically lightweight, fire resistant, non-toxic, chemically inert, and
non-corrosive. They have excellent thermal, electrical, and acoustic insulation
properties and are weather-, water-, and vermin-proof. These properties,
combined with the low cost of Hydrolytic ingredients, provide the basis for commercialization
of a wide spectrum of AHC materials whose physical properties can be tailored
to meet pre-specified performance requirements and engineering objectives.
AHC
Technology
The
basis for AHC products resides in a 16 year accumulation of technical
information from the following interrelated activities: assessing the
compatibility of hydrolytic cements with candidate materials; establishing
appropriate fabrication techniques for processing compatible aggregates;
determining thermo
physical properties; classifying end-user applications, and identifying
cost benefits for a growing list of engineered AHC materials; and extending AHC
technology into restricted environmental regimes or high technology
applications; In general, this archived database supports AHC product
development and marketing activities that focus on applied research and
engineering, rather than the fundamental aspects of Sol-Gel
chemistry.
Sol-Gel
Chemistry
AHC
materials typically exhibit the following two-phase characteristics:
three-dimensional interpenetrating networks (matrices) of silicate-based,
ceramic-like, hydrolytic materials; and dispersions of organic/inorganic
additives of various geometric shapes and dimensions. These two phases, in
turn, provide parallel paths to composite synergisms, i.e., subtle
micro-modification of basic Sol-Gel chemistry or macro-modification of
dispersed phase particulate structure, and nothing limits the size
distribution, density, or chemical formulation of composite additives. These
observations, combined with extremely low costs of Hydrolytic ingredients,
provide the basis for worldwide commercialization of a near-limitless spectrum
of AHC materials whose effective physical properties can be tailored to meet
pre-specified performance requirements.
Hydrolytic
Cements
The
heart of AHC technology is a patented, proprietary; two-part siliceous
hydrolytic cement formulated from standard industrial-grade inorganic chemicals
in a water-based system. Specifically, mixing the liquid and dry components
initiates a low exothermic, sol-gel, polymerization and bonding process that
proceeds through several phases at ambient temperature and produces a rigid,
non-toxic, insoluble, and near-chemically-inert cement whose physical
properties are similar to ceramics. In addition, although hydrolytic cements
bond directly to most materials, including wood, glass, and metal, certain plastics
require surfactants to achieve an effective bond, and accelerated curing can be
accomplished by applying heat, e.g., draft or microwave ovens, for periods as
short as 15 minutes. Finally, normal cleanup is with water, unless the
hydrolytic cement has proceeded past the early gel phase (later phase gels cure
underwater to form insoluble products).
Dispersed-Phase
Additives
AHC
additives include essentially every entry from the basic and acidic oxides to a
host of synergistic and more structured organic and inorganic fibers, fillers,
aggregates, and extenders. As a result, the range of tailored physical
properties exhibited by AHC materials is limited only by the imagination and
innovative ability of design engineers. A partial listing, by major categories,
of compatible dispersed phase additives for a fascinating array of AHC
materials includes: waste materials i.e., flyash, recycled paper sludge,
confetti, rice husks, rice and wheat straw, bagasse, and sander dust; inexpensive
volcanic aggregates i.e., expanded perlite, pumice, scoria, and obsidian; mineral
forms i.e., expanded mica or vermiculite, borosilicates, clays, metal
oxides, plant and animal exoskeletons, remains, excreta, diatomaceous earth,
sea shells, and steer manure; manufactured materials i.e., silica glass
spheres and fillers, refractory fibers and mats, fiberglass, rock wools, metal
turnings or shavings; and petrochemicals i.e., expanded polystyrene,
polyethyleneterephthalate (PET) fibers and mats, polypropylene, and volatile
liquids. AHC products fabricated from these raw materials generally exhibit the
following desirable properties: fireproof, non-toxic, insoluble, chemically
inert, acid and base resistant, low thermal and electrical conductivities, low
acoustic transmissivities, high radiation resistance, high refractory melting
points, mildew proof, rot proof, and vermin resistant.
Fabrication
Processes
AHC
manufacturing processes include: compression forming or rolling of wetted
powders and fibers; sculpting, injecting, molding, or compressing pastes; and
pour-casting or spraying of liquid slurries. These fabrication processes
provide for a variety of manufacturing scenarios spanning the range from
single-unit hand mixing and pour-casting into inexpensive molds by unskilled
labor to large-scale automated production lines using continuous belts,
feeders, etc. In addition, manufacturing processes for existing products are
easily converted into an AHC production line, e.g., substituting hydrolytic
cements for ureaformaldehyde to produce a fireproof, waterproof, non-toxic, and
insoluble wood chip particle board. Finally, ambient cure of AHC materials, in
most cases, offers potentially significant energy savings over competing or
existing production processes.
Cost
Trade-offs
Depending
on the density of individual dispersed phase components, AHC materials with
bulk densities from 11 pounds per cubic foot (pcf) to over 100 pcf reflect
relative Hydrolytic dry weight percentages in the 30-90 percent range. These
physical characteristics translate to raw material costs ranging from $0.60 pcf
to nearly $10.00 pcf.
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