INTEGRAL TILE/FOAM BUILDING BLOCK AND METHOD FOR MAKING SAME

摘要

An integral dual module geopolymer building block includes an inner foam module for insulation and an outer dense tile surface on an outer side of the inner foam module for weather protection. The outer porous module comprises a geopolymer paste including sodium silicate and sodium hydroxide flakes dissolved in the sodium silicate to form an activated solution and adding calcined kaolin clay to the activated solution to form a geopolymer paste. A first relatively dense tile layer has a thickness of about 0.5 cm to 1.5 cm. A second geopolymer layer made from a second mass of paste mixed with hydrogen peroxide forms a geopolymer foam having a thickness of between 5 cm and 15 cm.

主权项

1. An integral dual module geopolymer building block comprising:
an inner foam module for insulation and an outer dense tile surface on an outer side of the inner foam module for weather protection; and wherein said dense module comprises a geopolymer paste including sodium silicate and sodium hydroxide flakes dissolved in the sodium silicate to form an activating solution, and calcined kaolin clay mixed with the activating solution to form a mass of geopolymer paste; a first relatively dense tile layer with a thickness of about 0.5 to 1.5 cm from a first mass of geopolymer paste; and a second foam layer of a geopolymer layer made from a second mass of geopolymer paste with hydrogen peroxide (H2O2) mixed with the geopolymer paste wherein the H2O2 varies from about 0.5% to about 2.0% by wgt. of a 35% concentration of H2O2 to form a geopolymer foam having a thickness of between 5 cm and 15 cm; and wherein said module is cured at about 40° C. for one hour and at about 80° C. for about 23 hours.