Process for producing bound aggregate building material

Claim 2

A PROCESS FPR MATERIAL COMPOSITION CONSISTING ESSENTIALLY OF THE STEPS OF: A. FORMING A FIRST MIXTURE COMPRISING A MONOMERIC BINDER MIXTURE OF FROM 99.5 PERCENT TO 99.9875 PERCENT BY WEIGHT MONOMERIC FURFURYL ACHOLOL, AND FROM 0.5 PERCENT TO 0.125 PERCENT BY WEIGHT OF A SILANE COUPLING AGENT OR THE GENERAL FORMULA:

Claim 3

A process as in claim 1 wherein said first mixture includes from 2 percent to 10 percent by weight of aqueous urea-formaldehyde mixture and said aqueous urea-formaldehyde mixture contains from 5 percent to about 25 percent by weight water.

Claim 4

The process as in claim 1 in which said acidic catalyst is toluene sulfonic acid.

Claim 5

The process of claim 1 wherein said silane coupling agent is gamma-aminopropyltriethoxysilane.

Claim 6

The process of claim 1 wherein said silane coupling agent is gamma-mercaptopropyltrimethoxysilane.

Claim 7

The process of claim 1 wherein said silane coupling agent is N-beta-(aminoethyl)-gamma-aminopropyltrimethoxysilane.

Claim 8

The process of claim 1 wherein said silane coupling agent is beta-(3,4-epoxycyclohexyl)ethyltrimethoxysilane.

Claim 9

The process of claim 1 wherein said silane coupling agent is gamma-glycidoxypropyltrimethoxysilane.

Claim 10

The process of claim 1 wherein said silane coupling agent is gamma-aminopropyltriphenoxysilane.

Claim 11

The process of claim 1 wherein said silane coupling agent is gamma-aminopropyltribenzyloxysilane.

Claim 12

The process of claim 1 wherein said silane coupling agent is gamma-aminopropyltrifurfuroxysilane.

Claim 13

The process of claim 1 wherein said silane coupling agent is gamma-aminopropyltri(o-chlorophenoxy)silane.

Claim 14

The process of claim 1 wherein said silane coupling agent is gamma-aminopropyltri(p-chlorophenoxy)silane.

Claim 15

The process of claim 1 wherein said silane coupling agent is gamma-aminopropyltri(tetrahydrofurfuroxy)silane.

Claim 16

A process for producing a bound aggregate building material composition comprising the steps of: a. forming a first package comprising a monomeric binder mixture of from 99 1/2 percent to 99 7/8 percent by weight monomeric furfuryl alcohol and from 1/2 percent to 1/8 percent by weight of a silane coupling agent of the general formula: X-R''-Si-(OR'''')3 wherein R'' is a short chain alkylene containing between about 3 and 6 carbon atoms; R'''' is a radical selected from the group consisting of aryl, alkyl, substituted aryl, and heteroalkyl; and X is a reactive member selected from thE group consisting of amino, mercapto, epoxy, and glycidoxy; b. forming a second package comprising a mixture of aggregate and acidic catalyst, said aggregate and said acidic catalyst being mixed in a proportion such that when from 2 percent to 20 percent by weight monomeric binder is mixed with from 98 percent to 80 percent by weight of the aggregate-acidic catalyst mixture, the acidic catalyst is present in an amount of from 5 percent to 50 percent by weight of the monomeric binder; and c. admixing said first package and said second package in an amount such that the first package contributes from 2 percent to 20 percent by weight and said second package contributes from 98 percent to 80 percent by weight.

Claim 17

A process for producing a bound aggregate building material composition comprising the steps of: a. forming a first package comprising a monomeric binder mixture of from 99 1/2 percent to 99 7/8 percent by weight monomeric furfuryl alcohol and from 1/2 percent to 1/8 percent by weight of a silane coupling agent of the general formula: X-R''-Si-(OR'''')3 wherein R'' is a short chain alkylene containing between about 3 and 6 carbon atoms; R'''' is a radical selected from the group consisting of aryl, alkyl, substituted aryl, and heteroalkyl; and X is a reactive member selected from thE group consisting of amino, mercapto, epoxy, and glycidoxy; b. forming a second package comprising a mixture of aggregate and acidic catalyst, said aggregate and said acidic catalyst being mixed in a proportion such that when from 2 percent to 20 percent by weight monomeric binder is mixed with from 98 percent to 80 percent by weight of the aggregate-acidic catalyst mixture, the acidic catalyst is present in an amount of from 5 percent to 50 percent by weight of the monomeric binder; and c. admixing said first package and said second package in an amount such that the first package contributes from 2 percent to 20 percent by weight and said second package contributes from 98 percent to 80 percent by weight.

Claim 18

A process of producing a bound aggregate building material composition comprising the steps of: a. forming a first package consisting essentially of a monomeric binder mixture of from 99 1/2 percent to 99 7/8 percent by weight monomeric furfuryl alcohol and from 1/2 percent to 1/8 percent by weight of a silane coupling agent of the general formula: X-R''-Si-(OR'''')3 wherein R'' is a short chain alkylene containing between about 3 and 6 carbon atoms; R'''' is a radical selected from the group consisting of aryl, alkyl, substituted aryl, and heteroalkyl; and X is a reactive member selected from the group consisting of amino, mercapto, epoxy, and glycidoxy; b. forming a second package consisting essentially of a mixture of aggregate and acidic catalyst, said aggregate and said acidic catalyst being mixed in a proportion such that when from 2 percent to 20 percent by weight monomeric binder is mixed with from 98 percent to 80 percent by weight of the aggregate-acidic catalyst mixture, the acidic catalyst is present in an amount of from 5 percent to 50 percent by weight of the monomeric binder; and c. admixing said first package and said second package in an amount such that the first package contributes from 2 percent to 20 percent by weight and said second package contributes from 98 percent to 80 percent by weight.

Claim 19

A process of producing a bound aggregate building material composition comprising the steps of: a. forming a first package consisting essentially of a monomeric binder mixture of from 99 1/2 percent to 99 7/8 percent by weight monomeric furfuryl alcohol and from 1/2 percent to 1/8 percent by weight of a silane coupling agent of the general formula: X-R''-Si-(OR'''')3 wherein R'' is a short chain alkylene containing between about 3 and 6 carbon atoms; R'''' is a radical selected from the group consisting of aryl, alkyl, substituted aryl, and heteroalkyl; and X is a reactive member selected from the group consisting of amino, mercapto, epoxy, and glycidoxy; b. forming a second package consisting essentially of a mixture of aggregate and acidic catalyst, said aggregate and said acidic catalyst being mixed in a proportion such that when from 2 percent to 20 percent by weight monomeric binder is mixed with from 98 percent to 80 percent by weight of the aggregate-acidic catalyst mixture, the acidic catalyst is present in an amount of from 5 percent to 50 percent by weight of the monomeric binder; and c. admixing said first package and said second package in an amount such that the first package contributes from 2 percent to 20 percent by weight and said second package contributes from 98 percent to 80 percent by weight.