Two-phase material of concrete and polymer and its method of preparation

DETAILED DESCRIPTION The invention provides an improvement over these prior techniques.
An improved structural, thermal insulating member is obtained by a method providing foamed masonry materials, impregnating them with liquid monomers or resins by vacuum means, in cooperation with or independent of a hydraulic head, to a pond of the liquid monomer or resin and a polymerization catalyst maintained in contact with a surface of a foamed masonry slab or block by a dike arranged around the perimeter of the slab or block and by subsequent in situ polymerization producing a two-phase material of foamed masonry material and polymer.
The method produces a foamed masonry article composed of an unimpregnated foam concrete core and impregnated surface regions of the two-phase material having a higher polymer through a large volume of foam voids.
The method does not require vacuum or thermal drying to remove evaporable water to obtain useful polymer loadings.
Viscous liquids with viscosities as high as 700 times the viscosity of water may be used for partly impregnated concrete, and there is little capillary adsorption to dilute impregnated regions.
Accordingly, it is an object of this invention to provide a method for producing polymer impregnated foamed masonry material having a high polymer loading in regions of high flexural stresses.
It is a further object of this invention to provide a method for producing masonry material capable of impregnation with liquid monomers or resins having viscosities as high as 700 times that of water and which is not diluted by capillary adsorption during partial impregnation processes.
It is a further object of this invention to provide a method for producing a two-phase masonry material having polymer impregnation in foam voids in surface regions and an unimpregnated foam core utilizing hydraulic head and vacuum means independently and in combination for impregnation.
It is a further object of this invention to provide a method for producing a masonry material with high polymer loading adjacent surface regions and an unimpregnated foam cement core, the material having high thermal insulating value commensurate with high structural properties