Utility materials incorporating a microparticle matrix formed with a setting agent

Abstract

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.

What is claimed and desired to be secured by Letters Patent is: 
     
         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.