earthstone international v. frederick hart

7/28/2019 Earthstone International v. Frederick Hart

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UNITED STATES DISTRICT COURT

FOR THE DISTRICT OF NEW MEXICO

EARTHSTONE INTERNATIONAL LLC,

Plaintiff,

vs. Case No. ________________________

FREDERICK HART CO., INC.,d/b/a COMPAC INDUSTRIES, INC.,

Defendant.

______________________________________________________________________________

COMPLAINT AND DEMAND FOR TRIAL BY JURY______________________________________________________________________________

Plaintiff Earthstone International LLC (Earthstone), by its undersigned counsel and for

its complaint against Defendant Frederick Hart Co., Inc., d/b/a Compac Industries, Inc.

(Compac), alleges as follows:

THE PARTIES

1. Earthstone is a Delaware limited liability company organized and existing under

the laws of the state of Delaware, and has a principal place of business at 1197 Parkway Drive,

Santa Fe, New Mexico 87507.

2. Compac is a Georgia corporation organized and existing under the laws of the

state of Georgia, and has a principal place of business at 2617 Talley Street, Decatur, GA 30030.

Compac is a manufacturing and distribution company that manufactures, imports, markets, and

distributes home cleaning solutions and household gadgets for sale in the state of New Mexico

and throughout the United States.


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NATURE OF THE ACTION

3. This is an action for infringement of U.S. Patent No. 5,972,817 (the 817

Patent), for unfair competition under 15 U.S.C. 1125(a), and for related and ancillary state law

claims of unfair competition, interference with contractual relations and advantageous business

relationships, and defamation.

JURISDICTION AND VENUE

4. This action arises under the patent and trademark laws of the United States,

including 35 U.S.C. 271 and 15 U.S.C. 1125(a). Subject matter jurisdiction is conferred upon

this Court by 28 U.S.C. 1331 and 1338(a). This Court has supplemental jurisdiction over

Earthstones state law claims pursuant to 28 U.S.C. 1367.

5. This Court has personal jurisdiction over Compac, which regularly and

continuously transacts business in this judicial district. Compac manufactures, imports, markets,

distributes, and sells cleaning solutions and household gadgets throughout the United States,

including the state of New Mexico.

6. Venue is proper in this judicial district under 28 U.S.C. 1391 and 1400(b).

7. Compac has offered to sell, and has sold, the accused product through its

nationwide distribution networks with the reasonable expectation that the accused product would

be purchased or used by consumers in this judicial district. According to the website for

Compac, a majority of [Compacs] products are made in the U.S.A., and shipped from Atlanta,

GA throughout the U.S. and internationally. In addition, through its website Compac asserts

that its product lines are carried in a variety of drug stores, grocery stores, specialty stores, and

on-line due to [Compacs] emphasis on quality and [its] many lifelong customers wanting a

variety of avenues to purchase [its] products.


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8. Compac, either directly or through intermediaries, sells products to national and

regional retail drug, supermarket, specialty, and mass merchandise stores in New Mexico, and

Compac derives substantial revenue from these sales. Compac, either directly or through

intermediaries, sells products on-line directly to consumers in New Mexico, and Compac derives

substantial revenue from these sales.

COUNT I

PATENT INFRINGEMENT

9. On October 26, 1999, U.S. Patent No. 5,972,817 titled Foamed Glass Article for

Preparing Surfaces, Use Therefor, and Method of Making Same (the 817 Patent), was duly

and lawfully issued naming Haines et al. as inventors, and Andrew Ungerleider as Assignee. A

true copy of the 817 Patent is attached hereto as Exhibit A.

10. The 817 Patent, issued on October 26, 1999 to Andrew Ungerleider by

assignment, was reassigned on January 6, 2000 to Earthstone.

11. Earthstone is the owner, by assignment, of all right, title, and interest in the 817

Patent, including the right to bring this action to recover damages and obtain other relief for

infringement of the 817 Patent.

12. Earthstone manufactures and sells its GrillStone Cleaning Block, which

employs the method covered by claims in the 817 Patent.

13. Earthstone has complied with the statutory requirements under

35 U.S.C. 287(a) of placing a notice of the 817 Patent on the GrillStone Cleaning Block

products in the United States that it manufactures and sells under the 817 Patent.

14. Earthstone has on-going sale arrangements with multiple retailers for its

GrillStone Cleaning Block, and also has licensing agreements in place which grant third


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parties a license to resell and/or become an Earthstone product distributor of the GrillStone

Cleaning Block in exchange for a royalty payment to Plaintiff Earthstone.

15. To date, neither Earthstone nor any of its licensees have entered into a sale and/or

licensing agreement with Compac for the 817 Patent.

16. Upon information and belief, Compac has infringed the 817 Patent by making,

using, offering for sale, and/or selling in the United States and in this district, without

Earthstones permission or consent, a product titled Magic Stone Grill Cleaner, that is covered

by one or more claims of the 817 Patent, and Compac will continue to do so unless enjoined by

the Court.

17. Compacs Magic Stone Grill Cleaner has been made available for sale at local

retailers, convenience stores, including but not limited to those listed for sale on Compacs

website, http://www.compacind.com/, and on online at Amazon, http://www.amazon.com/.

18. Upon information and belief, Compacs infringement of the 817 Patent has been

willful and in complete disregard of, or with indifference to, Earthstones rights and interests.

19. Earthstone has suffered damage as a result of Compacs infringement to date.

COUNT II

UNFAIR COMPETITION IN VIOLATION OF 15 U.S.C. 1125(a)

20. Earthstone re-alleges and incorporates by reference paragraphs 1-19 of this

Complaint as if fully set forth herein.

21. Upon information and belief, Compac knowingly, willfully, and intentionally

engaged in unfair competitive practices in violation of 43(a) of the Lanham Act (15 U.S.C.

1125(a)) while engaging in sales promotions and other marketing activities, by making

inaccurate statements to customers, and potential customers, of Earthstone regarding

Earthstones enforceable patent rights in its GrillStone Cleaning Block.


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22. Upon information and belief, Compac also misrepresented the characteristics of

Earthstones product during these same sales promotions and other marketing activities, by

making false comparisons between the two products that are the subjects of Earthstones

Complaint.

23. Earthstone has no adequate remedy at law, and Earthstone will continue to be

irreparably harmed unless Compac is enjoined from conducting its unfair competitive practices.

COUNT III

UNFAIR COMPETITION



25. Upon information and belief, Compac has been, and continues to be, engaged in

unfair or deceptive trade practices and unconscionable trade practices by interfering with

contractual and prospective business relationships of Earthstone in violation of the common law

of New Mexico and New Mexicos Uniform Trade Secrets Act, NM Stat. Ann. 57-3A-5.

26. Upon information and belief, Compac is interfering with the well-established

reputation of Earthstone, built up over long years of dealings with the public, and based upon a

large expenditure of money and effort both in the production of Earthstones GrillStone

Cleaning Block product, and in advertising that product.

27. Upon information and belief, the conduct of Compac as set forth herein

constitutes unfair and deceptive acts or practices, including, but not limited to, making false

claims to potential customers regarding Earthstones enforceable patent rights, and making

claims that Compacs product is the same as Earthstones but cheaper.

28. Compacs conduct described herein has been willful and malicious.


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29. Unless restrained and enjoined by this Court, Compac will continue its acts of

unfair competition, in violation of the common law of New Mexico and New Mexicos Uniform

Trade Secrets Act, and Earthstone will continue to be damaged by Compacs conduct unless it is

halted.

COUNT IV

TORTIOUS INTERFERENCE WITH

ADVANTAGEOUS BUSINESS RELATIONSHIPS

AND CONTRACTUAL RELATIONS



31. Eathstone has on-going sale arrangements with multiple retailers for its product

titled GrillStone Cleaning Block, retailers including but not limited to Bed, Bath and Beyond,

and also has licensing agreements in place by which it grants third parties a license to resell

and/or become an Earthstone product distributor of the GrillStone Cleaning Block in exchange

for a royalty payment to Plaintiff Earthstone.

32. Upon information and belief, Compac intentionally and improperly interfered

with Earthstones advantageous business relationships and expectancies relating to the sale of

GrillStone Cleaning Block by making false and defamatory statements to third parties,

including existing and/or potential customers, distributors, and/or wholesalers, with the express

purpose of interfering with and/or preventing the formation of business relationships with

Earthstone.

33. As a direct and proximate result of Compacs intentional interference with

Earthstones advantageous business relationships, business expectancies, and contractual

relations, Earthstone has suffered and will continue to suffer damages, including but not limited


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to, damage to its business reputation and goodwill, loss of business and reasonable and valid

business expectancy, loss of customers, and loss of economic gain.

COUNT V

DEFAMATION



35. Upon information and belief, Compac has made, and continues to make, false

statements of material fact to third parties, including existing and/or potential customers,

distributors, and/or wholesalers, including, but not limited to, making false claims to potential

customers regarding Earthstones enforceable patent rights, and making claims that Compacs

product is the same as Earthstones but cheaper.

36. Upon information and belief, Compac acted with bad faith and intentionally or

negligently made oral and/or written statements to Earthstones customers that were false and

defamatory.

37. Such false and defamatory statements are the proximate cause of economic injury

to Earthstone. Earthstone has suffered and will continue to suffer damages, including but not

limited to, damage to its business reputation and goodwill, loss of business and reasonable and

valid business expectancy, loss of customers, and loss of economic gain.

PRAYER FOR RELIEF

WHEREFORE, Earthstone respectfully demands judgment against Compac as follows:

1. That judgment be entered in favor of Earthstone, and against Compac, finding that

Compac has infringed the 817 Patent, and that such infringement has been and is willful;

2. That Compac, its officers, agents, employees, directors, servants, successors, and

assigns, and all those acting in concert or participation with it or them, or any of them, be


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permanently restrained and enjoined from infringing the 817 Patent and that Compac further be

ordered to recall all infringing products;

3. An accounting of Compacs sales and profits in connection with sales of products

produced through infringement of the 817 Patent;

4. That Earthstone be awarded, under 35 U.S.C. 284, damages adequate to

compensate it for Compac's infringement of the '817 Patent, and that such damages be trebled

because of the willful and deliberate character of the infringement;

5. A preliminary and permanent injunction enjoining Compac, its officers, agents,

servants, employees, attorneys, and those in active concert or participation with them who

receive action notice of the order by personal service or otherwise, from:

a. Characterizing, describing, referencing, using, reproducing,advertising, or promoting any slogan, comment, statement, or

description that may be calculated to represent or that has the effect of

improperly injuring Earthstones business reputation; and

b. Unfairly competing with Earthstones business.6. An award of damages to Earthstone under the Lanham Act and, in particular,

pursuant to 15 U.S.C. 1117(b), of up to three times the damages suffered by Earthstone and

three times the profits earned by Compac;

7. An award of injunctive relief to require Compac to stop the unfair and deceptive

conduct alleged herein, and to assess costs and attorneys' fees against it;

8. An award to Earthstone of compensatory, consequential, and/or incidental

damages, in an amount to determined at trial;

9. An award to Earthstone of treble, exemplary, and/or punitive damages;


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10. That the Court award Earthstone reasonable attorneys' fees pursuant to 35 U.S.C.

285 and/or NM Stat. Ann. 57-3A-5, and the costs of this action;

11. The grant of prejudgment and post judgment interest on the above monetary

awards; and

12. All such other and further relief as this Court deems equitable and just.

JURY DEMAND

Plaintiff Earthstone respectfully requests a trial by jury of all issues raised by its

complaint.

Dated: July 10, 2013 Respectfully submitted,

/s/ Steven G. Cracraft_______

Steven G. Cracraft, Indiana Attorney No. 3417-49

Beth A. Behrens, Indiana Attorney No. 30804-49BRANNON SOWERS &CRACRAFT,P.C.

1. North Pennsylvania Street, Suite 800

Indianapolis, IN 46204

Office: (317) 630-2810Fax: (317) 630-2813

Email: [email protected];

[email protected]

/s/Jeffrey L. Squires_______________

Jeffrey L. Squires, NM Bar No. 143015PEACOCK MYERS, P.C.

201 Third St. NW, Suite 1340

Albuquerque, NM 87102Office: (505) 998-6116

Fax: (505) 243-2542

Email:[email protected]

ATTORNEYS FOR PLAINTIFF


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US005972817AUlllted States Patent [ 1 9 ] [ 1 1 ] P a t e n t N u m b e r : 5 , 9 7 2 , 8 1 7Haines e t a l . [ 4 5 ] Date o f P a t e n t : * O c t . 2 6 , 1 9 9 9[ 5 4 ] FOAMED GLASS ARTICLE FOR [ 5 6 ] R e f e r e n c e s C i t e dPREPARING SURFACES, USE THEREFOR,

AND METHOD OF MAKING SAME Us ATENT DOCUMENTS[ 7 5 ] I n v e n t o r s : Steven C. Haines; Tai B - BiXby, both 3 , 9 6 3 , 5 0 3 6 / 1 9 7 6 M a c k e n z i e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0 1 / 3 9

o f Santa F e , N-M9X-; H e nr y Oat, 4 , 9 3 3 , 3 0 6 6 / 1 9 9 0 P i e t s c h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0 1 / 3 9A t l a n t a , Ga ; Carl E- Frahme, La s 4 , 9 8 1 , 8 2 0 1 / 1 9 9 1 Renlund e t a l . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0 1 / 3 9Vegas, N-MeX- 5,326,382 7/1994 Oa t . . . . . . . . . . . . . . . . . 501/39

5,821,184 10/1998 Hai nes e t a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501/39[ 7 3 ] A s s i g n e e : Andrew U n g e r l e i d e r , S a n t a F e , N . M e x .[ * ] N o t i c e : T h i s p a t e n t i s s u b j e c t t o a t e r m i n a l d i s - P r i m a r y Examiner_MiChae1 M a r c h e s c h i

C l a l m e r ' A t t o r n e y , A g e n t , o r FirmRobert W. B e c k e r & s s o c i a t e s[ 2 1 ] A p p l . N o . : 0 9 / 1 2 8 , 5 5 7 [ 5 7 ] ABSTRACT[ 2 2 ] F i l e d i Aug- 3 , 1 9 9 8 A o a m e d g l a s s a r t i c l e f o r p r e p a r i n g s u r f a c e s , t h e u s e

R d U A l _ _ D t h e r e f o r , and a method o f making same a r e p r o v i d e d . Th ee a t e ' ' pp l c a t l o n ata foamed g l a s s a r t i c l e i s i n t h e form of a b l o c k , disk o r s i m i l a r

[ 6 3 ] C o n t i n u a t i o n - i n - p a r t o f a p p l i c a t i o n N o . 0 8 / 7 6 6 , 5 5 2 , D e c . p r o d l l c t a n d _ 1 S u s e d f o r P r e p a n n g S u r f a c e s S u c h a s b y1 0 1 9 9 6 P a t N o _ 5 , 8 2 1 , 1 8 4 s a n d m g , r u b b i n g a n d s c r a p i n g t h e same t o c l e a n , a b r a d e ,[ 6 0 ] P r o v i s i o n a l a p p l i c a t i o n N o . 6 0 / 0 1 4 , 2 7 0 , M a r . 2 9 , 1 9 9 6 . p o l i s h , s m o o t h , o r t h e l i k e s u c h a s u r f a c e . Th e foamed g l a s s51 I t . C ] . 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . C03C 1 0 0 ' C 0 4 B 38 0 2 ' a r t i c l e i s formed from a S t a r t i n g mixture t h a t Comprised[ 1 n C 0 4 1 3 3 5 4 / 1 6 C 0 3 B 1 4 / 0 5 ; g l a s s , 0 . 1 0 2 0 % b y W e i g h t o f a t l e a s t o n e n o n - c a r b o n / s u l f a t e

[ 5 2 ] US. C l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0 1 / 3 9 , 5 0 1 / 3 2 , 5 0 1 / 8 4 ; b a s e d _ f o a m i n g _ a g e m > a n d O p t i o n a l l y a n a d d i t i o n a l a b r a s i v eS o l / 1 5 5 ; 6 5 / 2 2 ; 5 1 / 2 9 6 ; 5 1 / 3 0 7 ; 5 1 / 3 0 9 ; m a t e r i a l . A i x t u r e o f p o W d e r e d g l a s s a n d n o n - c a r b o n /5 1 0 / 1 0 9 ; 5 1 0 / 1 8 0 ; 5 1 0 / 2 3 8 ; 5 1 0 / 2 9 3 ; 5 1 0 / 2 4 0 ; s u l f a t e b a s e d f o a m i n g a g e n t c a n b e p l a c e d i n a m o l d a n d

5 1 0 / 2 4 1 ; 5 1 0 / 2 4 3 ; 5 1 0 / 2 4 4 ; 5 1 0 / 2 4 5 h e a t e d s o t h a t t h e m i x t u r e s m t e r ' s a n d s u b s e q u e n t l y f o a m s .[ 5 8 ] F i e l d Of Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0 1 / 3 9 , 3 2 , 8 4 , T h e r e / a f t t h e foamed ?xture 1 S annealed5 0 1 / 1 5 5 , 1 1 , 8 0 , 8 5 ; 6 5 / 2 2 ; 5 1 / 2 9 6 , 3 0 7 ,

3 0 9 1 9 C l a i m s , 1 Drawing S h e e t

EXHIBIT A


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5 , 9 7 2 , 8 1 7c t . 2 6 , 1 9 9 9. S . P a t e n t


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5 , 9 7 2 , 8 1 71

FOAMED GLASS ARTICLE FORPREPARING SURFACES, USE THEREFOR,ANDMETHOD OFMAKING SAME

T h i s a p p l i c a t i o n i s a c o n t i n u a t i o n - i n - p a r t o f US. p a t e n ta p p l i c a t i o n S e r . N o . 0 8 / 7 6 6 , 5 5 2 , ? l e d D e c . 1 0 , 1 9 9 6 , US.P a t . No . 5 , 8 2 1 , 1 8 4 Which Was based on P r o v i s i o n a l a p p l ic a t i o n N o . 6 0 / 0 1 4 , 2 7 0 , ? l e d M a r . 2 9 , 1 9 9 6 .

BACKGROUND OF THE INVENTIONTh e p r e s e n t i n v e n t i o n r e l a t e s t o a foamed g l a s s a r t i c l e ,

such a s a b l o c k , d i s k o r s i m i l a r p r o d u c t , f o r p r e p a r i n g o rt r e a t i n g h a r d s u r f a c e s , an d a l s o r e l a t e s t o t h e u s e o f an d amethod o f making s u c h a p r o d u c t .

S u r f a c e s o f ma ny d i f f e r e n t a r t i c l e s an d m a t e r i a l s have t ob e p r e p a r e d e i t h e r t o make them i m m e d i a t e l y r e a d y f o r u s eo r t o p r e p a r e them f o r s u b s e q u e n t t r e a t m e n t . Such s u r f a c ep r e p a r a t i o n i n c l u d e s s a n d i ng , r u b b i n g a n d s c r a p i n g a s u r f a c et o c l e a n , a b r a d e , p o l i s h , e t c . s u c h a s u r f a c e . F o r e x a m p l e ,p a i n t e d s u r f a c e s , s u c h a s m e t a l , W o o d , p l a s t i c , ? b e r g l a s s ,a n d t h e l i k e f r e q u e n t l y h a v e t o b e r e p a i n t e d . P r i o r t o b e i n gr e p a i n t e d , t h e s e s u r f a c e s have t o be sanded o r o t h e r W i s ecleaned an d s m o o t h e d s o t h a t a neW o a t of p a i n t o r o t h e rt r e a t m e n t c a n b e a p p l i e d t o s u c h a s u r f a c e . S i m i l a r l y , roughs u r f a c e s o f v a r i o u s m a t e r i a l s f r e q u e n t l y need o b e sanded o ro t h e r W i s e smoothed s o t h a t t h e y c a n b e p a i n t e d a n d t r e a t e d .G r i l l s , g r i d d l e s , b a r b e c u e s , a n d t h e l i k e f r e q u e n t l y n e e d t o b ed e g r e a s e d , c l e a n e d a n d / o r p o l i s h e d . R u s t , s t a i n s a n d g r e a s ef r e q u e n t l y h a v e t o b e removed f r o m p o t s a n d p a n s , g l a Z e dp o r c e l a i n , c e r a m i c o r g l a s s t i l e s , b a k e d - o n e n a m e l e d m e t a l? x t u r e s, c o n c r e t e , g l a s s s h o W e r d o o r s a n d t h e l i k e .

V a r i o u s p r o d u c t s a r e k n o W n f o r p r e p a r i n g t h e a f o r e m e nt i o n e d W i d e v a r i e t y o f s u r f a c e s . Such p r o d u c t s , Which a r eg e n e r a l l y l i m i t e d t o s p e c i ? c a p p l i c a t i o n s , i n c l u d e s a n d p a p e r ,p u m i c e , c h e m i c a l s , s t e e l , W o v e n a n d non-Woven p l a s t i cp a d s , W i r e b r u s h e s , k n u r l e d m e t a l ? l e s , a n d t h e l i k e . None ft h e k noW n r o d u c t s p r o v i d e a u n i v e r s a l p r o d u c t f o r a l l o f t h ea f o r e m e n t i o n e d s u r f a c e s , a n d a l l h a v e t h e i r i n h e r e n t draWb a c k s . F o r e x a m p l e , s a n d p a p e r t e a r s e a s i l y a n d W e a r s o u tf a s t . I n a d d i t i o n , s a n d p a p e r p r o d u c e s ? n e a i r - b o r n e d u s t a n dt h e a b r a s i v e s u r f a c e o f t h e s a n d p a p e r q u i c k l y becomesc l o g g e d , e s p e c i a l l y When s a n d i n g p a i n t f r o m a s u r f a c e . I na d d i t i o n , s a n d p a p e r d o e s n o t W o r k W e l l on m e t a l , a n d c a ng ou g e o r s c r a t c h a n u n d e r l y i n g s u r f a c e . F u r t h e r m o r e , g r i t o rg r a n u l a r m a t e r ia l e m b e d d e d i n t h e s a n d p a p e r d u l l s , t h u sq u i c k l y r e d u c i n g t h e e f f e c t i v e n e s s o f t h e s a n d p a p e r . I na d d i t i o n , i n o r d e r t o o b t a i n a smooth s u r f a c e , s a n d p a p e r o fi n c r e a s i n g l y ? n e r g r i t m u s t b e u s e d t h r o u g h o u t t h e p r o c e s s .F i n a l l y , s a n d p a p e r W i l l n o t conform t o i r r e g u l a r , i . e . nonp l a n a r , s u r f a c e s , e s p e c i a l l y When h e s a n d p a p e r i s m o u n t e do n a ? a t block o r a sanding machine. Th e use o f pumice i se n v i r o n m e n t a l l y u n f r i e n d l y i n t h a t p u m i c e m u s t b e s t r i pm i n e d an d i s a non-reneWable r e s o u r c e . F u r t h e r m o r e , t h eq u a l i t y o f p u m i c e i s i n c o n s i s t e n t a n d c a n n o t b e r e g u l a t e d , s ot h a t a u n i f o r m p r o d u c t c a n n o t b e g u a r a n t e e d . I n a d d i t i o n ,p u m i c e b l o c k s a r e n o t s u i t a b l e f o r s a n d i n g a p p l i c a t i o n s .Chemicals a r e inconvenient t o u s e , a r e o f t e n t o x i c , an d a r ei n e f f e c t i v e on some d e e p l y s t a i n e d s u r f a c e s . I n a d d i t i o n , t h eu s e o f c h e m i c a l s f r e q u e n t l y r e q u i r e s f u r t h e r p r o d u c t s a n ds u b s e q u e n t f u r t h e r t r e a t m e n t o f a s u r f a c e i n o r d e r t o p r e p a r ei t . A l s o , some c h e m i c a l s W i l l n o t W o r k u n d e r W a t e r . R i g i dm e t a l ? l e s a n d t h e l i k e , i n a d d i t i o n t o b e c o m i n g c l o g g e d ,W i l l n o t conform t o a n i r r e g u l a r a n g l e d o r r o u n d e d s u r f a c e .

I t i s t h e r e f o r e a n o b j e c t o f t h e p r e s e n t i n v e n t i o n t o p r o v i d ea n economical y e t e f f e c t i v e u n i v e r s a l mechanical s u r f a c ep r e p a r a t i o n p r o d u c t t h a t i s e a s y t o p r o d u c e a n d W i l l o v e rc o m e t h e aforementione d draWbacks.

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2I n p a r t i c u l a r , i t i s a f u r t h e r o b j e c t o f t h e p r e s e n t i n v e n t i o n

t o p r o v i d e a s u p e r i o r s u r f a c e p r e p a r a t i o n p r o d u c t , s u c h a s f o rs a n d i n g , s m o o t h i n g , c l e a n i n g a n d p o l i s h i n g a s u r f a c e , t h a tc o m p r i s e s f o a m e d g l a s s . T h i s g l a s s c a n b e o f v i r g i n g l a s s , o rca n b e ma d e from a m i x t u r e , t h e main c o n s t i t u e n t o f Whichi s r e c y c l e d W a s t e g l a s s , t h u s p r o v i d i n g a v e r y e c o n o m i c a lp r o d u c t t h a t a t t h e same t i m e i s a v e r y e n v i r o n m e n t a l l yf r i e n d l y u s e f o r W a s t e g l a s s .

SUMMARY OF THE INVENTIONT h e s e a n d o t h e r o b j e c t s a n d a d v a n t a g e s o f t h e p r e s e n t

i n v e n t i o n a r e r e a l i Z e d by p r o v i d i n g a s u r f a c e p r e p a r i n gmeans i n t h e form o f a foamed g l a s s a r t i c l e h a v i n g a n yd e s i r e d s p e c i ? c s h a p e , W i t h t h e f o a m e d g l a s s a r t i c l e b e i n gd e r i v e d f r o m a s t a r t i n g m i x t u r e t h a t c o m p r i s e s g l a s s a n d0 . 1 0 2 0 . 0 % by W e i g h t o f a t l e a s t o n e n o n - c a r b o n / s u l f a t eb a s e d f o a m i n g a g e n t . T h u s , t h e p r e s e n t i n v e n t i o n p r o v i d e sf o r t h e u s e o f a f o a m e d g l a s s a r t i c l e a s a s u r f a c e p r e p a r i n gmeans. Th e p r e s e n t i n v e n t i o n a l s o p r o v i d e s a method o fmaking foamed g l a s s a s a s u r f a c e p r e p a r i n g m e a n s , W i t hs u c h a method i n c l u d i n g t h e s t e p s o f p r o v i d i n g poWdered o rg r o u n d g l a s s , m i x i n g a t l e a s t o n e n o n - c a r b o n / s u l f a t e b a s e df o a m i n g a g e n t W i t h t h e p o W d e r e d g l a s s t o f o r m a m i x t u r e ,p l a c i n g t h e m i x t u r e o n a s u r f a c e , such a s a b e l t , p l a t e , o r i na mold, h e a t i n g t h e mixture o n h e b e l t o r i n t h e m o l d s o t h a tt h e m i x t u r e s i n t e r s a n d s u b s e q u e n t l y f o a m s , a n d a n n e a l i n gt h e foamed m i x t u r e by c o o l i n g t h e same t o r o o m t e m p e r at u r e t o form a foamed g l a s s p r o d u c t .

The g l a s s c a n b e v i r g i n g l a s s o r W a s t e g l a s s . The t e r m W a s t e g l a s s a s u s e d i n t h i s a p p l i c a t i o n i s i n t e n d e d t o r e f e rt o any Waste g l a s s t h a t i s Waste o r s c r a p , e i t h e r f r o m ap r e - c o n s u m e r m a n u f a c t u r i n g o p e r a t i o n , s u c h a s Win d o Wp l a t e m a n u f a c t u r i n g , g l a s s b o t t l e m a n u f a c t u r i n g , l i g h t b u l bm a n u f a c t u r i n g , g l a s s b e a d m a n u f a c t u r i n g , a n d t h e l i k e , o rp o s t - c o n s u m e r W a s t e g l a s s , s u c h a s b o t t l e s c o l l e c t e d by ap u b l i c o r p r i v a t e r e c y c l i n g o p e r a t i o n . S u c h r e c y c l e d o ro t h e r W is e r e c o v e r e d g l a s s i n c l u d e s s o d a l i m e g l a s s , b o r os i l i c a t e g l a s s , a l u m i n o s i l i c a t e g l a s s , a n d r e c y c l e d f o a m e dg l a s s a s made p u r s u a n t t o t h e i n s t a n t a p p l i c a t i o n . The g l a s si s u s e d i n poWdered o r o t h e r W i s e p u l v e r u l e n t f o r m a n d h a sa n a v e r a g e p a r t i c l e s i Z e d i s t r i b u t i o n t h a t r a n g e s fr om1 5 0 0 p . A l t h o u g h , a s i n d i c a t e d , a n y g l a s s c a n b e u s e d , t oe n s u r e c o n s i s t e n c y o f t h e g l a s s c l e a n g l a s s o r e v e n v i r g i ng l a s s i s p r e f e r r e d .

C a r b o n / s u l f a t e foamed g l a s s o r s o - c a l l e d b l a c k f o a m e dg l a s s h a s b e e n k n o W n o r some i m e . F o r e x a m p l e , US. a t .N o . 2 , 5 1 4 , 3 2 4 , F o r d , d i s c l o s e s t h e u s e o f s u c h c e l l u l a t e dg l a s s a s t h e r m a l i n s u l a t i o n a n d a s b u o y a n t e l e m e n t s . M e r e l ya s a b y - p r o d u c t , b l a c k foamed g l a s s m a n u f a c t u r e d f o r i n s ul a t i o n p u r p o s e s h a s a l s o b e e n u s e d f o r g r i l l - c l e a n i n g a p p l ic a t i o n s . H o W e v e r , s u c h b l a c k foamed g l a s s i s v e r y u n s a t i sf a c t o r y f o r s u r f a c e p r e p a r a t i o n p u r p o s e s d u e t o t h e f a c t t h a tt h e c h e m i s t r y a n d c e l l s t r u c t u r e o f s u c h b l a c k foamed g l a s si s q u i t e d i f f e r e n t f r o m t h e c h e m i s t r y a n d c e l l s t r u c t u r e o fn o n - s u l f u r b a s e d foamed W a s t e o r v i r g i n g l a s s , s o - c a l l e dW h i t e f o a m e d g l a s s . I n p a r t i c u l a r , a g a i n r e f e r r i n g t o US. a t .N o . 2 , 5 1 4 , 3 2 4 f o r c r i t i c a l b a c k g r o u n d i n f o r m a t i o n c o n c e r ni n g b l a c k f o a m e d g l a s s , d u r i n g t h e f a r m o r e e x p e n s i v ep r o d u c t i o n o f t h i s c u s t o m made s p e c i a l t y g l a s s , a s u l f u rc o n t a i n i n g compound, g e n e r a l l y a s u l f a t e , i s a d d e d t o ab a t c h o f v i r g i n a n d n o t r e c y c l e d g l a s s , a n d a r e a g e n t i n t h ef o r m o f ? n e l y d i v i d e d c a r b o n m u s t a l s o b e p r o v i d e d t op r o d u c e t h e s u l f u r b a s e d f o a m i n g g a s s e s . S u c h b l a c k f o a m e dg l a s s c o m p r i s e s a c l o s e d c e l l u l a r s t r u c t u r e i n Which i se n c l o s e d s u l f u r d i o x i d e a n d h y d r o g e n s u l ? d e g a s . T h u s , n o to n l y W h e n t h e g l a s s s h e e t s a r e c u t t o s i Z e f o r u s e , b u t m o r ep a r t i c u l a r l y d u r i n g u s e o f t h e b l o c k s t h e m s e l v e s t o c l e a n


13/17

5 , 9 7 2 , 8 1 73

g r i l l s , n o x i o u s s u l f u r d i o x i d e a n d h y d r o g e n s u l ? d e g a s i sg i v e n o f f . T h i s o c c u r s b e c a u s e a s t h e b l o c k s o f b l a c k foamedg l a s s a r e u s e d , t h e s u r f a c e o f t h e b l o c k Wears a W a y , t h u sc o n t i n u o u s l y b r e a k i n g doWn e l l s a n d a l l o W i n g t h e e n c l o s e dn o x i o u s g a s t o e s c a p e . F u r t h e r m o r e , s u c h b l a c k foamedg l a s s b l o c k s a r e r a t h e r b r i t t l e , Wear aWay r a t h e r q u i c k l y , a n dd i s p e r s e r e s i d u e over a Wide a r e a , an d a r e t h e r e f o r e u n s u i ta b l e f o r m o s t a p p l i c a t i o n s c o n t e m p l a t e d b y t h e i n s t a n ta p p l i c a t i o n .

The u s e o f n o n - c a r b o n / s u l f a t e b a s e d foamed g l a s s f o rv a r i o u s a p p l i c a t i o n s h a s a l s o b e e n p r o p o s e d . F o r e x a m p l e ,US. P a t . N o . 2 , 9 5 5 , 0 4 9 , B o o t h , p r o v i d e s f o r a c e l l u l a t e dg l a s s i n t h e p r o d u c t i o n o f t h e r m a l a n d s o u n d a b s o r b i n gi n s u l a t i o n m a t e r i a l s . US . P a t . N o . 3 , 4 4 3 , 9 2 0 , O v e r c a s h i e r ,a l s o p r o v i d e s f o r a foamed g l a s s m a t e r i a l a s t h e r m a l i n s ul a t i o n . Foamed g l a s s u t i l i Z i n g u s e d - c o n t a i n e r g l a s s i s p r op o s e d b y U . S . P a t . N o . 3 , 9 6 3 , 5 0 3 , M c K e n z i e , f o r t h e p u rp o s e o f p r o v i d i n g s t r u c t u r a l a n d d e c o r a t i v e m a t e r i a l s .F i n a l l y , US. P a t . N o . 4 , 9 3 3 , 3 0 6 , P i e t s c h , d i s c l o s e s t h e u s eo f c e l l u l a r g l a s s b o d i e s i n t h e c l o t h d i s t r e s s i n g s t o n e W a s h i n gi n d u s t r y t o t e a r t h e ? b e r s o f c l o t h .

Applicants a r e u na Wa re of any knoWn d i s c l o s u r e o rs u g g e s t i o n f o r t h e u s e o f foamed W a s t e o r v i r g i n g l a s s ,s o - c a l l e d W h i t e foamed g l a s s , a s a s u r f a c e p r e p a r a t i o n meanst h a t Works a s d o e s t h e p r o d u c t o f t h e i n s t a n t a p p l i c a t i o n ,namely t o r e m o v e a c o a t i n g , d i r t o r s t a i n from a s u r f a c e , o rt o m a k e a s u r f a c e smooth o r o t h e r W i s e p r e p a r e i t f o r f u r t h e rtreatment.

Although t h e s t a r t i n g m i x t u r e i s i n t e n d e d t o c o v e r a r a n g eo f p o W d e r e d o r g r o u n d g l a s s a n d 0 . 1 0 2 0 % b y W e i g h t o ff o a m i n g a g e n t , i t i s p r e s e n t l y c o n t e m p l a t e d t h a t a p r e f e r r e dr a n g e W i l l b e 0 . 5 5 . 0 % b y W e i g h t o f f o a m i n g a g e n t . I na d d i t i o n , p u r s u a n t t o a p r e f e r r e d h e a t i n g s t e p , t h e m i x t u r e o fpoWdered g l a s s a n d f o a m i n g a g e n t i s ? r s t h e a t e d t o as i n t e r i n g t e m p e r a t u r e a n d s u b s e q u e n t l y t h e t e m p e r a t u r e i si n c r e a s e d t o e f f e c t f o a m i n g . F o r e x a m p l e , t h e m i x t u r e c a n? r s t b e h e a t e d t o a t e m p e r a t u r e o f a b o u t 1 2 5 0 F . , W i t h t h i st e m p e r a t u r e b e i n g m a i n t a i n e d f o r a g i v e n p e r i o d o f t i m e ,such a s f o r on e h o u r ; t h e t e m p e r a t u r e i s t h e n i n c r e a s e d t o ar a n g e o f 1 2 7 4 1 7 0 0 F . t o e f f e c t f o a m i n g . A n n e a l i n g o f t h efoamed m i x t u r e c a n e i t h e r c o m p r i s e a g r a d u a l c o o l i n g t oroom t e m p e r a t u r e , o r , p u r s u a n t t o a p r e f e r r e d embodiment,c a n c o m p r i s e t h e s t e p s o f ? r s t r a p i d l y c o o l i n g t h e f o a m e dm i x t u r e t o a t e m p e r a t u r e beloW a foaming t e m p e r a t u r e , an dt h e n s l o W l y c o o l i n g t h e foamed m i x t u r e t o room t e m p e r at u r e . A n y g l a s s y s k i n o r c r u s t t h a t i s formed on t h e r e s u l t i n gp r o d u c t c a n b e r e m o v e d , a t l e a s t f r o m a b r a s i v e s u r f a c e s ,s u c h a s by c u t t i n g o r p l a n i n g u s i n g a n y s u i t a b l e m e a n s .

T h e s t a r t i n g m i x t u r e o f p o W d e r e d g l a s s a n d f o a m i n g a g e n tc a n c o m p r i s e 6 9 . 9 9 9 . 9 % b y W e i g h t g l a s s a n d 0 . 1 0 2 0 % b yW e i g h t f o a m i n g a g e n t i n c l u d i n g m i x t u r e s o f tWo o r moref o a m i n g a g e n t s ; i n a d d i t i o n , 0 3 0 . 0 % b y W e i g h t o f a d d it i o n a l a b r a s i v e m at e r i a l can be added t o t h e m i x t u r e p r i o r t op l a c i n g s u c h a m i x t u r e i n a m o l d . I t s h o u l d be n o t e d t h a ta l t h o u g h t h e m i x t u r e c a n be p l a c e d on a b e l t o r p l a t e , i t i sp r e s e n t l y p r e f e r r e d t o u s e m o l d s . A i n g l e l a r g e r mold o r ap l u r a l i t y o f s m al l e r d i s c r e t e molds c a n b e p r o v i d e d . Thes m a l l e r molds c a n a c t u a l l y have a geometry t h a t i s s u b s t a nt i a l l y t h e same a s t h e d e s i r e d ? n a l geometry o f t h e foamedg l a s s a r t i c l e s . I f a l a r g e r m o l d i s u s e d , t h e p r o d u c t p r o d u c e dc a n b e c u t t o t h e d e s i r e d s i Z e a n d s h a p e . I n a d d i t i o n , t h em i x t u r e c a n b e p l a c e d i n t h e mold o r molds by p l a c i n g on eo r more mounds t h e r e o f i n t h e mold o r molds, p o s s i b l yforming one o r m o r e r o W s of such moun ds.

Although c a l c i u m c a r b o n a t e a p p e a r s t o b e a p a r t i c u l a r l ye x p e d i e n t f o a m i n g a g e n t , a l a r g e v a r i e t y o f n o n - c a r b o n /

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4s u l f a t e b a s e d f o a m i n g a g e n t s c a n b e u s e d . Examples o f s u c hf o a m i n g a g e n t s i n c l u d e m a g n e s i u m c a r b o n a t e , s o d i u mc a r b o n a t e , s t r o n t i u m c a r b o n a t e , l i t h i u m c a r b o n a t e , b a r i u mc a r b o n a t e , s u g a r , u r e a , W a t e r , a n d m i x t u r e s t h e r e o f . Thea d d i t i o n a l a b r a s i v e m a t e r i a l t h a t c a n o p t i o n a l l y be added t ot h e m i x t u r e t o v a r y t h e a b r a s i v e q u a l i t y o f t h e ? n a l foamedg l a s s a r t i c l e can be s e l e c t e d from a Wide v a r i e t y o f commona b r a s i v e g r i t m a t e r i a l s , s u c h a s , b u t n o t l i m i t e d t o , s a n d ,a l u m i n u m o x i d e , s i l i c o n c a r b i d e , g a r n e t , a n d m i x t u r e st h e r e o f .

BRIEF DESCRIPTION OF THE DRAWINGThe p r e s e n t i n v e n t i o n i s d e s c r i b e d i n g r e a t e r d e t a i l

s u b s e q u e n t l y , a s W e l l a s W i t h t h e a i d o f Examples a n d t h ea c c o m p a n y i n g s c h e m a t i c d r a W i n g , i . e . , F I G . 1 , W h i c h i l l u st r a t e s on e exemplary embodiment o f a l a r g e mold i n WhichroWs o f mounds o f s t a r t i n g m i x t u r e a r e p l a c e d .

DESCRIPTION OF THE PREFERREDEMBODIMENTS

A p p l i c a n t s h a v e d i s c o v e r e d t h a t f o a m e d g l a s s made W i t ha t l e a s t o n e n o n - c a r b o n / s u l f a t e b a s e d foaming a g e n t p r ov i d e s a u n i v e r s a l p r o d u c t f o r t h e m e c h a n i c a l p r e p a r a t i o n o fs u r f a c e s o f a g r e a t v a r i e t y o f m a t e r i a l s , i n c l u d i n g W o o d ,m e t a l , p o r c e l a i n , t i l e s , c o n c r e t e , p l a s t i c , g l a s s , ? b e r g l a s s ,a n d t h e l i k e .

The foamed g l a s s a r t i c l e o f t h e p r e s e n t i n v e n t i on i sp r i m a r i l y u s e d i n b l o c k o r d i s k f o r m . A l t h o u g h s u c h b l o c k sc a n h a v e a n y d e s i r e d an d c o n v e n i e n t s h a p e , t h e b l o c k st h e m s e l v e s W i l l h a v e a s p e c i ? c g e o m e t r y . The i n v e n t i v efoamed g l a s s a r t i c l e c a n b e u s e d f o r c l e a n i n g g r i l l s a n dg r i d d l e s , c a n b e u s e d f o r c l e a n i n g t i l e s , p o r c e l a i n a n denameled s u r f a c e s , can be used a s a s a n d i n g d i s k o r b l o c k ,such a s f o r removing p a i n t o r o t h e r s u r f a c e t r e a t m e n t s , c a nbe u s e d t o c l e a n c e m e n t , c a n b e used t o c l e a n m e t a l ,i n c l u d i n g r e m o v i n g r u s t t h e r e f r o m , a n d f o r a n y o t h e r s i m i l a rc l e a n i n g o r p o l i s h i n g a p p l i c a t i o n . F u r t h e r m o r e , t h e i n v e nt i v e f o a m e d g l a s s s u r f a c e p r e p a r i n g p r o d u c t c a n b e u s e de i t h e r manually, With o r Without a h a n d l e , o r a s an a t t a c hment t o , f o r e x a m p l e , a v i b r a t i n g o r r o t a t i n g m a c h i n e .

Foamed g l a s s a r t i c l e s made from g l a s s a n d a t l e a s t o n en o n - c a r b o n / s u l f a t e b a s e d f o a m i n g a g e n t , a s t a u g h t b y t h ei n s t a n t a p p l i c a t i o n , an d used a s a s u r f a c e p r e p a r i n g means,h a v e d i s t i n c t a d v a n t a g e s o v e r t h e h e r e t o f o r e k n o W n s u r f a c ep r e p a r a t i o n p r o d u c t s . The i n v e n t i v e foamed o r c e l l u l a t e dg l a s s s u r f a c e p r e p a r i n g means i s u n i q u e i n t h a t i t s s u r f a c ei n h e r e n t l y Wears d o W n i n such a W ay a s t o f u l l y conform t oc u r v e d , n o n - p l a n a r , o r o t h e r W i s e i r r e g u l a r l y s h a p e d o b j e c t sd u r i n g a c l e a n i n g o r s a n d i n g p r o c e s s . F u r t h e r m o r e , t h ei n v e n t i v e foamed g l a s s p r o d u c t Wears aWay i n s u c h a W ayt h a t i t s s u r f a c e d o e s n o t become c l o g g e d W i t h d e b r i s fromt h e m a t e r i a l t h a t i s b e i n g c l e a n e d o r s a n d e d , a n d r a t h e r t h a nb e c o m i n g d u l l , t h e i n v e n t i v e f o a m e d g l a s s p r o d u c t r e m a i n sc o n t i n u a l l y s h a r p a n d a b r a s i v e . F u r t h e r m o r e , t h e i n v e n t i v efoamed g l a s s p r o d u c t h a s a u n i f o r m a n d r e g u l a t a b l ec o n s i s t e n c y , and one and t h e same foamed g l a s s block canbe used t o b r i n g a rough s u r f a c e t o a smooth c o n d i t i o n . Thei n v e n t i v e p r o d u c t W i l l c l e a n a n d p o l i s h e n a m e l e d m e t a l a n dg l a Z e d p o r c e l a i n s u r f a c e s W i t h o u t s c r a t c h i n g o r s t a i n i n g t h esame, and can furthermore be used on Wet s u r f a c e s Withoutd i s i n t e g r a t i o n o r a l o s s o f e f ? c i e n c y . The i n v e n t i v e foamedg l a s s p r o d u c t h a s a c o n t r o l l a b l y v a r i a b l e c o n t e n t t o t h e r e b ybe a b l e t o p r o v i d e f o r a Wide r a n g e o f h a r d n e s s ,a b r a s i v e n e s s , s t r e n g t h , d e n s i t y , a n d c e l l o r p o r e s i Z e i n o r d e rt o meet market demands.

I n a d d i t i o n , t h e i n v e n t i v e foamed g l a s s p r o d u c t i s n o nt o x i c , l o n g e r l a s t i n g , a n d d o e s n o t g e n e r a t e ? n e a i r - b o r n e


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5 , 9 7 2 , 8 1 75

d u s t a s do o t h e r a b r a s i v e s such a s s a n d p a p e r . Th e i n v e n t i v efoamed g l a s s p r o d u c t W i l l Work We t o r u n d e r W a t e r W i t h o u ta n y l o s s o f p e r f o r m a n c e . T h e i n v e n t i v e f o a m e d g l a s s p r o du c t has a f a r d i f f e r e n t c e l l u l a r s t r u c t u r e t h a n does s o c a l l e db l a c k foamed g l a s s , Which i s mad e W i t h a c a r b o n / s u l f a t eb a s e d f o a m i n g a g e n t . I n p a r t i c u l a r , i n c o n t r a s t t o t h e c l o s e da n d r e g u l a r c e l l u l a r s t r u c t u r e o f b l a c k foamed g l a s s , W h i c he n c l o s e s n o x i o u s g a s , t h e i n v e n t i v e foamed g l a s s i s ? r s t o fa l l f o r m e d , f o r e x a m p l e , b y e x p a n d i n g a n d e s c a p i n g c a r b o nd i o x i d e g a s , r a t h e r t h a n s u l f u r d i o x i d e a n d / o r h y d r o g e ns u l ? d e g a s . F u r t h e r m o r e , t h e c e l l s t r u c t u r e o f t h e i n v e n t i v ef o a m e d g l a s s i s o p e n , i n t e r c o n n e c t e d , a n d i r r e g u l a r , a l l o W i n ga m b i e n t a t m o s p h e r i c g a s s e s t o p e n e t r a t e t h e c e l l s .A i s t i n c t a n d s u r p r i s i n g a d v a n t a g e o f t h e i n v e n t i v e

foamed g l a s s i s t h e f a c t t h a t i t i s a n e x t r e m e l y e c o n o m i c a lp r o d u c t . T h i s i s p a r t i c u l a r l y s u r p r i s i n g a n d u n e x p e c t e d d u et o t h e e x p e r i e n c e i n t h e p a s t W i t h b l a c k foamed g l a s s , W h i c hi s v e r y e x p e n s i v e t o p r o d u c e . T h e p r e s e n t i n v e n t i o n p r o v i d e sf o r t h e u s e o f a f a r l e s s e x p e n s i v e g l a s s , e s p e c i a l l y WhenW a s t e g l a s s i s u s e d , Which a t t h e same t i m e h a s a s i g n i ? c a n tp o s i t i v e e n v i r o n m e n t a l i m p a c t , e s p e c i a l l y s i n c e t h e m a r k e tf o r W a s t e g l a s s i s v e r y l i m i t e d , b e i n g a l m o s t n o n e x i s t e n t f o rm i x e d c o l o r W a s t e g l a s s ; t h u s , p r e s e n t l y a l a r g e p e r c e n t a g eo f W a s t e g l a s s e n d s u p i n l a n d ? l l s .

P r i o r t o p r o v i d i n g s p e c i ? c e x a m p l e s , t h e f o l l o W i n g i s am o r e g e n e r a l d i s c u ss i o n c o n c e r n i n g p r o d u c t i o n o f t h e i n v e nt i v e f o a m e d g l a s s p r o d u c t . As i n d i c a t e d p r e v i o u s l y , poWd e r e d v i r g i n g l a s s o r r e c y c l e d W a s t e g l a s s i s m i x e d W i t h? n e l y g r o u n d n o n - c a r b o n / s u l f a t e b a s e d f o a m i n g a g e n t t y p ic a l l y i n t h e a v e r a g e r a n g e o f a b o u t 80 t o minus ( i . e . a n yp a r t i c l e s s m a l l e r t h a n t h i s W i l l p a s s t h r o u g h ) 3 2 5 m e s h .A d d i t i o n a l a b r a s i v e o r r e f r a c t o r y m a t e r i a l can a l s o be addedt o t h e s t a r t i n g m i x t u r e t o v a r y o r enhance t h e a b r a s i v ec h a r a c t e r i s t i c o f t h e ? n a l p r o d u c t . T h e r e s u l t i n g d r y m i x t u r ec a n be p l a c e d i n t o a mold, s u c h a s t h e m o l d 1 o f F I G . 1 . Th em i x t u r e i s e x p e d ie n t l y p l a c e d i n t o t h e mold 1 i n t h e f o r m o fs e v e r a l roWs 2 o f t h e m i x t u r e . These m o und s o r p i l e s o fm i x t u r e t y p i c a l l y h a v e a n a t u r a l a n g l e o f r e p o s e o f a b o u t 1 5t o 50 d e g r e e s . Even g r e a t e r a n g l e s t o t h e h o r i Z o n t a l c a n b ea c h i e v e d b y c o m p r e s s i n g t h e d r y m i x t u r e . D e p o s i t i n g t h em i x t u r e i n t o s h a p e d m o u n d s , W i t h o r W i t h o u t c o m p a c t i n g ,a n d i n t h e form o f d i s c r e t e p i l e s o r r o W s , h e l p s t o e l i m i n a t et h e f o l d s a n d v o i d s t h a t t y p i c a l l y a p p e a r When m i x t u r e s o ft h i s t y p e a r e foamed a s ? a t t e n e d beds o f p o W d e r .

Th e mold 1 c a n be made o f s t e e l , c e r a m i c , o r c e r a m i c? b e r , a n d i s e x p e d i e n t l y i n t h e s h a p e o f a f r u s t u m i n o r d e rt o f a c i l i t a t e e a s y r e l e a s e o f t h e ? n a l foamed g l a s s p r o d u c t . I na d d i t i o n , t h e i n s i d e s u r f a c e s o f t h e mold c a n b e c o a t e d W i t ha s o f t r e f r a c t o r y r e l e a s e a g e n t t o f u r t h e r f a c i l i t a t e s e p a r a t i o no f t h e foam g l a s s p r o d u c t f r o m t h e m o l d .

One o r more molds W i t h t h e m i x t u r e t h e r e i n i s p l a c e d i n t oa f u r n a c e f o r e i t h e r a batch o r continuous foaming p r o c e s s .The m i x t u r e i s t h e n h e a t e d i n o r d e r t o s i n t e r and foam t h em i x t u r e a n d t h e r e b y p r o d u c e t h e f o a m e d g l a s s p r o d u c th a v i n g a d e s i r e d d e n s i t y , p o r e s i Z e a n d h a r d n e s s . A s t h ep o W d e r e d m i x t u r e i s h e a t e d t o a b o v e t h e s o f t e n i n g p o i n t o fg l a s s , a p p r o x i m a t e l y 1 0 5 0 F , t h e m i x t u r e b e g i n s t o s i n t e r .Th e d i v i s i o n o f t h e poWdered m i x t u r e i n t o roWs o r m o und sa l l o W s t h e g l a s s t o a b s o r b h e a t more r a p i d l y a n d t o t h e r e f o r ef o a m f a s t e r b y r e d u c i n g t h e a b i l i t y o f t h e f o a m i n g g l a s s t oi n s u l a t e i t s e l f . At a p p r o x i m a t e l y 1 0 5 8 F . t h e c a l c i u mc a r b o n a t e , i f c a l c i u m c a r b o n a t e h a s been u s e d a s t h e foami n g a g e n t , b e g i n s t o r e a c t W i t h some o f t h e s i l i c o n d i o x i d e i nt h e g l a s s t o p r o d u c e c a r b o n d i o x i d e g a s . C a r b o n d i o x i d e i sa l s o f o r m e d by a n y r e m a i n i n g c a l c i u m c a r b o n a t e o n c e t h em i x t u r e r e a c h e s 1 2 7 4 F , a b o v e Which c a l c i u m c a r b o n a t eb r e a k s d o Wn i n t o c a l c i u m o x i d e a n d c a r b o n d i o x i d e g a s . The

10

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25

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6c a r b o n d i o x i d e i s p r i m a r i l y r e s p o n s i b l e f o r t h e f o r m a t i o n o fc e l l s an d p o r e s i n t h e s o f t e n e d g l a s s mass a s t h e carbond i o x i d e e x p a n d s . Th e m i x t u r e i n t h e mold s h e l d f o r a p e r i o do f t i m e a t a p e a k f o a m i n g t e m p e r a t u r e o f , f o r e x a m p l e ,betWeen 12741700 E, o r even h i g h e r , depending on t h ep r o p e r t i e s t h a t a r e d e s i r e d . By a d j u s t i n g t h e p r o c e s s temp e r a t u r e s a n d t i m e s , t h e d e n s i t y an d h a r d n e s s a s W e l l a so t h e r p r o p e r t i e s c a n b e c l o s e l y c o n t r o l l e d .

A s t h e f u r n a c e r e a c h e s foaming t e m p e r a t u r e s , e a c h masso f f o a m i n g g l a s s , o r i g i n a t i n g from o n e o f t h e d i s c r e t e roWso r m oun ds , f oa m s u n t i l i t comes i n t o c o n t a c t and f u s e s W i t hi t s n e i g h b o r s . T h e f u s e d m a s s o f f o a m i n g g l a s s t h e n e x p a n d st o c o n f o r m t o t h e s h a p e o f t h e W a l l s o f t h e m o l d , ? l l i n g a l lo f t h e c o r n e r s . The s h a p e s a n d s i Z e s o f t h e i n i t i a l mounds o fm i x t u r e a r e v e r y i m p o r t a n t and a r e determined W i t h t h ea n t i c i p a t i o n t h a t t h e f o a m i n g m i x t u r e e x a c t l y ? l l t h e m o l d .A f t e r t h e g l a s s i s foamed t o t h e d e s i r e d d e n s i t y a n d p o r es t r u c t u r e , t h e t e m p e r a t u r e o f t h e f u r n a c e i s r a p i d l y r e d u c e dt o h a l t f o a m i n g o f t h e g l a s s . W hen t h e e x t e r i o r o f t h e foamedg l a s s i n t h e mold h a s r i g i d i ? e d s u f ? c i e n t l y , t h e mass o ffoamed g l a s s c o o l e d i n t h e m o l d o r c a n be removed from t h emold a n d p l a c e d i n t o a l e h r f o r a n n e a l i n g . The t e m p e r a t u r eo f t h e l e h r i s s l o W l y l o W e r e d f r o m t h e s o f t e n i n g t e m p e r a t u r eo f t h e g l a s s t o a m b i e n t t e m p e r a t u r e t o a n n e a l t h e b l o c k o ffoamed g l a s s . Once c o o l e d , any s k i n o r c r u s t can be c u t o f fo f t h e foamed g l a s s p r o d u c t , a n d t h e p r o d u c t c a n b e c u t i n t oa v a r i e t y o f d e s i r e d s h a p e s .

T h e f o l l o W i n g e x a m p l e s i l l u s t r a t e t h e W i d e v a r i e t y o fc o m p o s i t i o n s a n d a p p l i c a t i o n s f o r t h e i n v e n t i v e f o a m e dg l a s s a r t i c l e s .

EXAMPLET o p r o d u c e a g r i l l c l e a n i n g b l o c k h a v i n g e m b e d d e d

a b r a s i v e m a t e r i a l t h e r e i n , 1 3 . 6 8 g ( 2 . 4 % ) c a l c i u m c a r b o n a t e ,m i n u s 2 0 0 m e s h , 4 4 2 . 3 2 g ( 7 7 . 6 %) r e c y c l e d ? o a t g l a s sg r o u n d t o m i n u s 1 4 0 m e s h , a n d 1 1 4 g ( 2 0 % ) s a n d , 6 0 t o 1 0 0m e s h , W e r e m i x e d t h o r o u g h l y t o g e t h e r . T h e r e s u l t i n g m i xt u r e Wa s p l a c e d i n t o a s t a i n l e s s s t e e l m o l d h a v i n g i n s i d ed i m e n s i o n s o f 4 1 A 1 i n c h e s > < 4 i n c h e s > < 8 1 A 1 i n c h e s . The moldWas c o v e r e d W i t h a 1 / 2 i n c h s t a i n l e s s s t e e l p l a t e . The moldWith t h e m i x t u r e t h e r e i n Was ?red t o 1250 F . t o s i n t e r f o r 60m i n u t e s . Th e t e m p e r a t u r e Wa s t h e n r a i s e d t o 1450 F . t ofoam f o r 30 m i n u t e s . The foamed g l a s s i n t h e mold Wasa n n e a l e d by c o o l i n g s l o W l y t o room t e m p e r a t u r e o v e r 1 2 0m i n u t e s . Th e c o o l e d b l o c k o f foamed g l a s s Was removedfrom t h e m o l d , and t h e o u t e r l a y e r o f c r u s t Was removed W i t ha band s aW t o expose t h e a b r a s i v e c e l l s . Th e r e s u l t i n g blockhad a d e n s i t y o f 1 3 . 9 pounds p e r c u b i c f o o t and a p o r e s i Z ed i s t r i b u t i o n r a n g i n g from a b o u t 0 . 5 t o 2 m m . Th e r e s u l t i n gb l o c k had ? n a l d i m e n s i o n s o f 4 i n c h e s > < 3 . 7 5 i n c h e s > < 8 i n c h e s( i t i s c o n t e m p l a t e d t h a t g r i l l c l e a n i n g b l o c k s W o u l d r a n g e i ns i Z e from 1 1 / 2 i n c h e s > < 3 % n c h e s > < 4 i n c h e s t o 2 1 / 2 i n c h e s > < 31 / 2 i n c h e s > < 6 i n c h e s t o 4 i n c h e s > < 4 i n c h e s > < 8 i n c h e s ) . Th er e s u l t i n g b l o c k h a d n o o d o r , Was W h i t e t o l i g h t g r a y i n c o l o r ,a n d h ad o p e n , i n t e r c o n n ec t e d c e l l s .

EXAMPLEA f u r t h e r g r i l l c l e a n i n g b l o c k h a v i n g n o s a n d o r embedded

a b r a s i v e s Was formed by a p r o c e d u r e s i m i l a r t o t h a t o fE x a m p l e 1 u s i n g 1 7 . 1 g ( 3 % ) c a l c i u m c a r b o n a t e , m i n u s 2 0 0m e s h , a n d 5 5 2 . 9 g ( 9 7 % ) r e c y c l e d c o n t a i n e r g l a s s , m i n u s325 m e s h . Th e foaming t e m p e r a t u r e Was 1 4 0 0 F . f o r 4 5m i n u t e s . Th e r e s u l t i n g d e n s i t y Wa s 7 . 2 p o u n d s p e r c u b i cf o o t , W i t h t h e r e s u l t i n g m a t e r i a l h a v i n g a p o r e s i Z e d i s t r ib u t i o n r a n g i n g from a b o u t 1 t o 3 mm.

EXAMPLETo p r e p a r e a b l o c k f o r c l e a n i n g t i l e , p o r c e l a i n o r enameled

s u r f a c e s , g l a s s , a n d g l a s s o r c e r a m i c t i l e a p r o c e d u r e s i m i l a r


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5 , 9 7 2 , 8 1 77

t o t h a t o f Example 1 Was u s e d by m i x i n g t o g e t h e r 5 6 4 . 3 g( 9 8 . 5 % ) r e c y c l e d c o n t a i n e r g l a s s , m i n u s 3 2 5 m e s h , a n d 5 . 7g ( 1 . 5 % ) c a l c i u m c a r b o n a t e , m i n u s 2 0 0 m e s h . T h e f o a m i n gt e m p e r a t u r e Wa s 1 3 6 0 F . f o r 60 m i n u t e s . The r e s u l t i n gd e n s i t y Wa s 1 7 . 6 pounds p e r c u b i c f o o t , W i t h a p o r e s i Z ed i s t r i b u t i o n r a n g i n g from a b o u t 0 . 0 5 t o 0 . 2 m m . T he r e s u l ti n g block W a s p u r e W h i t e i n c o l o r due t o t h e u s e o f c l e a rc o n t a i n e r g l a s s . The r e s u l t i n g b l o c k Was c u t i n t o s m a l l e rb l o c k s o f a s i Z e s u i t a b l e f o r c l e a n i n g t i l e , p o r c e l a i n , e t c . , a n dh a d ? n a l d i m e n s i o n s o f 2 i n c h e s > < 2 i n c h e s > < 4 i n c h e s ( i n t h i sc a s e , i t i s c o n t e m p l a t e d t h a t s u c h b l o c k s c a n r a n g e i n s i Z efrom 1 i n c h > < 1 1 / 2 i n c h e s > < 6 i n c h e s t o 2 i n c h e s > < 2 1 / 2 i n c h e s > < 4i n c h e s t o 3 i n c h e s > < 4 i n c h e s > < 1 1 / 2 i n c h e s ) . The c u t b l o c k s canbe mounted o n t o a h a n d l e by ?xing t h e h a n d l e i n t o a h o l ed r i l l e d i n t o e a c h b l o c k .

EXAMPLEAnother c l e a n e r block f o r u s e on t i l e , p o r c e l a i n , o r

ena m e l ed s u r f a c e s Wa s p r e p a r e d i n a p r o c e d u r e s i m i l a r t ot h a t o f E x a m p l e 1 b y m i x i n g t o g e t h e r 5 6 9 . 4 g ( 9 9 . 9 % )r e c y c l e d c o n t a i n e r g l a s s , m i n u s 3 2 5 m e s h , a n d 0 . 6 g ( 0 . 1 % )c a l c i u m c a r b o n a t e , m i n u s 3 2 5 m e s h . T h e f o a m i n g t e m p e r at u r e Was 1 4 2 5 F . f o r 2 5 m i n u t e s . The d e n s i t y o f t h e r e s u l t i n gm a t e r i a l W a s 1 5 . 3 pounds p e r c u b i c f o o t , W i t h a p o r e s i Z ed i s t r i b u t i o n r a n g i n g from a b o u t 0 . 0 1 t o 0 . 1 m m . A g a i n , t h er e s u l t i n g b l o c k c a n be c u t i n t o s m a l l e r b l o c k s .

EXAMPLE 4ATo produce a f u r t h e r c l e a n e r block f o r u s e on t i l e ,

p o r c e l a i n , g l a s s , o r e n a m e l e d s u r f a c e s , 4 4 g ( 2 % ) c a l c i u mc a r b o n a t e m i n u s 2 0 0 m e s h , 5 . 5 g ( 0 . 0 2 5 % ) s o d i u m c a r b o na t e m i n u s 2 0 0 m e s h , 5 5 g ( 0 . 0 2 5 % ) magnesium c a r b o n a t em i n u s 2 0 0 m e s h , 2 . 1 5 k g ( 9 7 . 9 5 % ) r e c y c l e d ? o a t g l a s sminus 200 mesh W e r e mixed t h o r o u g h l y t o g e t h e r . Ther e s u l t i n g m i x t u r e Was p l a c e d o n t o a c e r a m i c mold h a v i n gi n s i d e d i m e n s i o n s o f 1 8 i n c h e s > < 1 0 1 / z i n c h e s > < 6 i n c h e s . Them o l d W a s covered W i t h a ceramic l i d 5 / s i n c h e s t h i c k . T h et e m p e r a t u r e W a s t h e n r a i s e d t o 1250 F . t o s i n t e r f o r 75m i n u t e s , t h e t e m p e r a t u r e W a s t h e n r a i s e d t o 1320 F . t o f o a mf o r 40 m i n u t e s . The foamed g l a s s i n t h e m o l d Wa s a n n e a l e db y c o o l i n g s l o W l y t o room t e m p e r a t u r e o v e r 1 2 0 m i n u t e s .The r e s u l t i n g b l o c k had a t h i c k n e s s o f 3 i n c h e s . The c o o l e db l o c k o f foamed g l a s s Was removed from t h e m o l d , a n d t h eo u t e r l a y e r of c r u s t W a s r e m o v e d With a b a n d s a W t o expo s et h e a b r a s i v e c e l l s . The r e s u l t i n g b l o c k h a d a d e n s i t y o f 1 4 . 9pounds p e r c u b i c f o o t a n d a p o r e s i Z e r a n g i n g from a b o u t 0 . 5t o 1 . 5 m m . The r e s u l t i n g c u t b l o c k had ? n a l dimensions o f2 i n c h e s> < 2 i n c h e s> < 4 i n c h e s ( i t i s c o n t e m p l a t e d t h a t s u c hb l o c k s c an r a n g e i n s i Z e from 1 i n c h > < 1 1 / z i n c h e s > < 6 i n c h e s t o2 i n c h e s > < 2 1 / z i n c h e s > < 4 i n c h e s t o 2 i n c h e s > < 3 i n c h e s > < 4i n c h e s ) . Th e c u t b l o c k s c a n be mounted o n t o a h a n d l e b y? x i n g t h e h a n d l e i n t o a h o l e d r i l l e d i n t o e a c h b l o c k .

EXAMPLEA and h e l d ? ne p o r e s u r f a c e p r e p a r a t i o n b l o c k Wa s

p r o d u c e d i n a p r o c e d u r e s i m i l a r t o t h a t o f Example 1 bym i x i n g t o g e t h e r 5 6 4 . 3 g ( 9 9 % ) r e c y c l e d c o n t a i n e r g l a s s ,m i n u s 6 0 mesh a n d 5 . 7 g ( 1 % ) c a l c i u m c a r b o n a t e , m i n u s 200m e s h . The foaming t e m p e r a t u r e Was 1 5 0 0 F . f o r 20 mi nu t e s . The r e s u l t i n g m a t e r i a l h a d a d e n s i t y o f 2 4 . 3 p o u n d s p e rc u b i c f o o t a n d a p o r e s i Z e d i s t r i b u t i o n r a n g i n g from a b o u t0 . 1 t o 0 . 5 mm. T h e r e s u l t i n g block can be c u t i n t oc o n v e n i e n t - t o - h o l d b l o c k s h a v i n g ? n a l d i m e n s i o n s o f 4i n c h e s > < 3 . 7 5 i n c h e s > < 2 i n c h e s ( i t i s c o n t e m p l a t e d t h a t s u c hb l o c k s c o u l d h a v e a s i Z e r a n g i n g from 4 i n c h e s > < 4 1 / z i n c h e s > < 3 1 / z i n c h e s > < 6 i n c h e s t o 3 i n c h e s > < 2

10

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8i n c h e s > < 8 i n c h e s ) . T h e c o l o r o f t h e r e s u l t i n g b l o c k Was p a l ey e l l o W t o t a n d u e t o t h e u s e o f amb er c o n t a i n e r g l a s s ( i ts h o u l d b e n o t e d t h a t a n y c o n t a i n e r g l a s s o r p l a t e g l a s s Wouldb e s u i t a b l e f o r t h i s p u r p o s e ) .

EXAMPLEA n o t h e r h a n d h e l d ?ne p o r e s u r f a c e p r e p a r a t i o n b l o c k

Was p r o d u c e d i n a p r o c e d u r e s i m i l a r t o t h a t o f Example 1 bym i x i n g t o g e t h e r 5 5 2 . 9 g ( 9 7 % ) r e c y c l e d ? o a t g l a s s , m i n u s1 4 0 m e s h , a n d 1 7 . 1 g ( 3 % ) c a l c i u m c a r b o n a t e , m i n u s 2 0 0m e s h . The foaming t e m p e r a t u r e Wa s 1 3 6 0 F . f o r 60 m inu t e s . The r e s u l t i n g m a t e r i a l h a d a d e n s i t y o f 1 9 . 8 p o u n d s p e rc u b i c f o o t , a n d a p o r e s i Z e d i s t r i b u t i o n r a n g i n g from a b o u t0 . 0 5 t o 0 . 2 mm. g a i n , t h e r e s u l t i n g b l o c k c a n be c u t i n t oc o n v e n i e n t - t o - h o l d b l o c k s .

EXAMPLEA u r t h e r hand h e l d b u t t h i s t i m e m e d i u m p o r e s u r f a c e

p r e p a r a t i o n b l o c k Was p r o d u c e d i n a p r o c e d u r e s i m i l a r t ot h a t o f E x a m p l e 1 b y m i x i n g t o g e t h e r 5 5 2 . 9 g ( 9 7 % )r e c y c l e d ? o a t g l a s s , m i n u s 2 0 0 m e s h , a n d 1 7 . 1 g ( 3 % )c a l c i u m c a r b o n a t e , m i n u s 2 0 0 m e s h . T h e f o a m i n g t e m p e r at u r e W a s 1500 f o r 2 0 m i n u t e s . T he r e s u l t i n g m a t e r i a l ha d ad e n s i t y o f 1 1 . 2 pounds p e r c u b i c f o o t , a n d a p o r e s i Z ed i s t r i b u t i o n r a n g i n g from a b o u t 0 . 5 t o 1 . 5 m m . The r e s u l t i n gb l o c k Wa s c u t i n t o c o n v e n i e n t - t o - h o l d b l o c k s h a v i n g ? n a ld i m e n s i o n s o f 4 i n c h e s > < 3 . 7 5 i n c h e s > < 2 i n c h e s .

EXAMPLEA n o t h e r h a n d h e l d med i u m p o r e s u r f a c e p r e p a r a t i o n

b l o c k W a s p r o d u c e d b y m i x i n g t o g e t h e r 5 3 5 . 8 g ( 9 4 % )r e c y c l e d ? o a t g l a s s , m i n u s 1 4 0 m e s h , a n d 3 4 . 2 g ( 6 % )c a l c i u m c a r b o n a t e , m i n u s 2 0 0 m e s h . T h e f o a m i n g t e m p e r at u r e W a s 1500 F . f o r 20 m i n u t e s . The r e s u l t i n g m a t e r i a l ha da d e n s i t y o f 1 5 . 6 pounds p e r c u b i c f o o t , a n d a p o r e s i Z ed i s t r i b u t i o n r a n g i n g from a b o u t 0 . 5 t o 1 . 0 m m . A g a i n , t h er e s u l t i n g b l o c k Wa s c u t i n t o c o n v e n i e n t - t o - h o l d b l o c k s .

EXAMPLEAnother hand h e l d b u t t h i s t i m e c o a r s e p o r e s u r f a c e

p r e p a r a t i o n b l o c k Wa s p r e p a r e d i n a p r o c e d u r e s i m i l a r t o t h a to f E x a m p l e 1 b y m i x i n g t o g e t h e r 1 3 . 6 8 g ( 2 . 4 % ) c a l c i u mc a r b o n a t e , m i n u s 2 0 0 m e s h , 4 4 2 . 3 2 ( 7 7 . 6 % ) r e c y c l e d c o nt a i n e r g l a s s g r o u n d t o m i n u s 6 0 m e s h , a n d 1 1 4 g ( 2 0 % ) s a n d ,60 t o 100 m e s h . The foaming t e m p e r a t u r e Wa s 1 5 0 0 F . f o r20 m i n u t e s . The r e s u l t i n g m a t e r i a l h a d a d e n s i t y o f 2 7 . 8p o u n d s p e r c u b i c f o o t , a n d a p o r e s i Z e d i s t r i b u t i o n r a n g i n gfrom a b o u t 1 t o 3 m m . Th e r e s u l t i n g b l o c k Wa s a g a i n c u t i n t ob l o c k s o f a s i Z e c o n v e n i e n t t o h o l d b y h a n d . The r e s u l t i n gb l o c k Wa s p a l e yelloW t o t a n i n c o l o r due t o t h e u s e o f a m b erc o n t a i n e r g l a s s .

EXAMPLE 0Another hand h e l d c o a r s e p o r e s u r f a c e p r e p a r a t i o n b l o c k

Was p r o d u c e d i n a p r o c e d u r e s i m i l a r t o t h a t o f Example 1 bym i x i n g t o g e t h e r 5 7 . 0 g ( 1 0 % ) c a l c i u m c a r b o n a t e , m i n u s 2 0 0m e s h , a n d 5 1 3 ( 9 0 % ) r e c y c l e d c o n t a i n e r g l a s s g r o u n d t ominus 325 m e s h . The foaming t e m p e r a t u r e Was 1 6 0 0 F . f o r1 5 m i n u t e s . The r e s u l t i n g m a t e r i a l h a d a d e n s i t y o f 1 7 . 2p o u n d s p e r c u b i c f o o t , a n d a p o r e s i Z e d i s t r i b u t i o n r a n g i n gfrom a b o u t 2 t o 4 m m . Th e r e s u l t i n g b l o c k Wa s a g a i n c u t i n t ob l o c k s o f a s i Z e c o n v e n i e n t t o h o l d by h a n d .

EXAMPLE 1I n o r d e r t o p r o d u c e a random r b i t a l s a n d e r d i s k , 1 5 . 8 1 kg

( 9 3 % ) o f m i n u s 1 4 0 mesh r e c y c l e d ? o a t g l a s s Was m i x e d


16/17

5 , 9 7 2 , 8 1 79

t o g e t h e r W i t h 1 . 1 9 k g ( 7 % ) o f m i n u s 2 0 0 mesh c a l c i u mc a r b o n a t e . The m i x t u r e Was p l a c e d i n a mold h a v i n g dimens i o n s o f 22 i n c h e s > < 4 6 i n c h e s > < 5 i n c h e s an d t h e mold Wascovered With a s t a i n l e s s s t e e l l i d . Th e mold an d mixture Wer es i n t e r e d a t 1 2 5 0 F . f o r 6 0 m i n u t e s , Whereupon t h e t e m p e r at u r e Was r a i s e d t o foam a t 1500 F . f o r 40 m i n u t e s . T h et e m p e r a t u r e Was loWered sloWly t o r o o m t e m p e r a t u r e over360 m i n u t e s . The r e s u l t i n g mass o f foamed g l a s s h a dd i m e n s i o n s o f 22 i n c h e s > < 4 6 i n c h e s > < 6 i n c h e s ( t h e e x t r a i n c hWa s d u e t o t h e l i f t i n g o f t h e l i d by t h e e x p a n d i n g f o a m ) . Ther e s u l t i n g m a t e r i a l h a d a d e n s i t y o f 1 9 . 5 p o u n d s p e r c u b i cf o o t , an d a p o r e s i Z e d i s t r i b u t i o n r a n g i n g from a b o u t 1 t o 2 . 4m m . The r e s u l t i n g mass o f foamed g l a s s c o u l d b e c u t i n t om u l t i p l e b l o c k s , W h i c h a r e t h e n c u t i n t o m u l t i p l e c y l i n d r i c a ls h a p e s h a v i n g 5 i n c h d i a m e t e r s , W h i c h a r e t h e n s l i c e d i n t od i s k s 2 i n c h e s t h i c k ; t h e c u t s W e r e m a d e With a ban d s a W . I ti s c o n t e m p l a t e d t h a t random o r b i t a l s a n d e r d i s k s c o u l d r a n g ei n s i Z e from 46 i n c h e s i n d i a m e t e r t o 1 t o 2 i n c h e s t h i c k .S u c h d i s k s can be coated on one s i d e With an adhesivecompound a n d t h e l o o p p a r t o f a h o o k - a n d - l o o p f a b r i cs y s t e m c o u l d t h e n b e a p p l i e d t h e r e t o . The r e s u l t i n g d i s k c a nb e e a s i l y mounted o n t o c o m m o n o r b i t a l s a n d i n g poWer t o o l s? t t e d W i t h h e a d s h a v i n g t h e h o o k p a r t o f t h e h o o k - a n d - l o o pf a b r i c s y s t e m .

EXAMPLE 12Another random o r b i t a l s a n d e r d i s k Was produced i n a

p r o c e d u r e s i m i l a r t o t h a t o f E x a m p l e 1 1 b y m i x i n g t o g e t h e r1 6 . 3 2 k g ( 9 6 % ) o f m i n u s 3 2 5 m e s h r e c y c l e d c o n t a i n e r g l a s sa n d 0 . 6 8 kg ( 4 % ) o f m i n u s 200 m e s h c a l c i u m c a r b o n a t e . Thefoaming t e m p e r a t u r e Was 1 4 5 0 F . f o r 60 m i n u t e s . Ther e s u l t i n g m a t e r i a l h a d a d e n s i t y o f 1 4 . 8 p o u n d s p e r c u b i cf o o t a n d a p o r e s i Z e d i s t r i b u t i o n r a n g i n g from a b o u t 0 . 5 t o1 . 5 m m . Th e r e s u l t i n g mass o f foamed g l a s s Was a g a i n c u ti n t o tWo i n c h t h i c k d i s k s h a v i n g a 5 i n c h d i a m e t e r .

EXAMPLE 3A v i b r a t o r y p a l m s a n d e r a b r a s i v e b l o c k Wa s f o r m e d b ya p r o c e d u r e s i m i l a r t o t h a t o f E x a m p l e 1 1 b y m i x i n g t o g e t h e r

1 6 . 4 9 k g ( 9 7 % ) o f m i n u s 1 4 0 mesh ? o a t g l a s s a n d 0 . 5 1 k g( 3 % ) o f m i n u s 2 0 0 mesh c a l c i u m c a r b o n a t e . T h e f o a m i n gt e m p e r a t u r e Was 1 5 0 0 F . f o r 40 m i n u t e s . Th e r e s u l t i n gfoamed g l a s s m a t e r i a l h a d a d e n s i t y o f 1 1 . 9 p o u n d s p e r c u b i cf o o t an d a pore s i Z e d i s t r i b u t i o n o f about 1 . 2 t o 2 . 8 mm. h er e s u l t i n g mass o f foamed g l a s s Was c u t i n t o m u l t i p l e b l o c k s ,Which a r e t h e n c u t i n t o b l o c k s h a v i n g d i m e n s i o n s o f 4i n c h e s 4 i n c h e s 2 . 5 i n c h e s ( i t i s c o n t e m p l a t e d t h a t v i b r a t o r ys a n d e r b l o c k s c o u l d r a n g e i n s i Z e from 1 % i n c h e s > < 4 %i n c h e s > < 4 1 / z i n c h e s t o 2 i n c h e s > < 3 % i n c h e s > < 7 % i n c h e s ) . T h e s eblock s a r e a l s o coated on on e s i d e Wit h an adhesive comp o u n d t o W h i c h i s a p p l i e d t h e l o o p p a r t o f a h o o k - a n d l o o pf a b r i c s y s t e m . The r e s u l t i n g b l o c k s c a n b e e a s i l y mountedo n t o c o m m o n v i b r a t o r y s a n d i n g poWer t o o l s ? t t e d W i t h 4i n c h > < 4 i n c h h e a d s on Which i s d i s p o s e d t h e hook p a r t o f t h eh o o k - a n d - l o o p f a b r i c s y s t e m .

EXAMPLE 14A n o t h e r v i b r a t o r y palm s a n d e r a b r a s i v e b l o c k Was

p r o d u c e d i n a p r o c e d u r e s i m i l a r t o t h a t o f Example 1 1 bym i x i n g t o g e t h e r 1 6 . 4 9 k g ( 9 7 % ) o f m i n u s 6 0 m e s h r e c y c l e dc o n t a i n e r g l a s s a n d 0 . 5 1 k g ( 3 % ) o f m i n u s 2 0 0 mesh c a l c i u mc a r b o n a t e . Th e foaming t e m p e r a t u r e Was 1 5 0 0 F . f o r 40m i n u t e s . Th e r e s u l t i n g m a t e r i a l Was s i m i l a r t o t h a t o fExample 1 3 e x c e p t t h a t i t h a d a d e n s i t y o f 1 8 . 3 p o u n d s p e rc u b i c f o o t an d a p o r e s i Z e d i s t r i b u t i o n r a n g i n g from a b o u t 2t o 4 mm. Blocks We r e pr epar ed i n a m a n n e r s i m i l a r t o t h a t

10

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1 0d e s c r i b e d i n E x a m p l e 1 3 , W i t h t h e b l o c k s h a v i n g a p a l ey e l l o W t o t a n c o l o r du e t o t h e u s e o f amber c o n t a i n e r g l a s s .

EXAMPLE 5To produce a cement c l e a n e r b l o c k , a p r o c e d u r e s i m i l a r t ot h a t o f E x a m p l e 1 Wa s u t i l i Z e d b y t h o r o u g h l y m i x i n gt o g e t h e r 5 4 1 . 5 g ( 9 5 % ) r e c y c l e d ? o a t g l a s s , m i n u s 2 0 0

m e s h , a n d 2 8 . 5 g ( 5 % ) o f c a l c i u m c a r b o n a t e , m i n u s 2 0 0m e s h . The foaming t e m p e r a t u r e Was 1 4 0 0 F . f o r 4 5 m inu t e s . Th e r e s u l t i n g m a t e r i a l h a d a d e n s i t y o f 1 6 . 6 p o u n d s p e rc u b i c f o o t , a n d a p o r e s i Z e d i s t r i b u t i o n r a n g i n g from a b o u t0 . 0 5 t o 0 . 2 mm. Th e r e s u l t i n g block Was c u t i n t o s m a l l e rb l o c k s o f a s i Z e s u i t a b l e f o r c l e a n i n g o r d e g r e a s i n g c e m e n t ,e t c . , a n d h a d ? n a l d i m e n s i o n s o f 4 i n c h e s > < 4 i n c h e s > < 3 i n c h e s( i t i s c o n t e m p l a t e d t h a t cement c l e a n e r b l o c k s c a n r a n g e i ns i Z e from 3 1 / 2 i n c h e s > < 4 i n c h e s > < 3 i n c h e s t o 4 i n c h e s 4 i n c h e s > < 4 i n c h e s > < 8 i n c h e s) .

EXAMPLE 6An other c emen t c l e a n e r block Was produced i n a p r o c e

d u r e s i m i l a r t o t h a t o f E x a m p l e 1 b y m i x i n g t o g e t h e r 5 5 2 . 9g ( 9 7 % ) r e c y c l e d c o n t a i n e r g l a s s , m i n u s 3 2 5 m e s h , a n d 1 7 . 1g ( 3 % ) o f m a g n e i s u m c a r b o n a t e , m i n u s 2 0 0 m e s h . T h efoaming t e m p e r a t u r e Was 1 4 0 0 F . f o r 4 5 m i n u t e s . Th er e s u l t i n g m a t e r i a l h a d a d e n s i t y o f 2 8 . 6 p o u n d s p e r c u b i cf o o t , a n d a p o r e s i Z e d i s t r i b u t i o n r a n g i n g from 0 . 0 1 t o 0 . 2m m . Th e r e s u l t i n g b l o c k Was a g a i n c u t i n t o s m a l l e r b l o c k so f 4 i n c h e s > < 4 i n c h e s > < 3 i n c h e s .

EXAMPLE 17A u s t remover block Was produced b y a p r o c e d u r e

s i m i l a r t o t h a t o f E x a m p l e 1 b y m i x i n g t o g e t h e r 4 5 6 g ( 8 0 % )r e c y c l e d c o n t a i n e r g l a s s , m i n u s 3 2 5 m e s h , a n d 1 1 4 g ( 2 0 % )o f c a l c i u m c a r b o n a t e , m i n u s 3 2 5 m e s h . Th e f o a m i n g t e mp e r a t u r e Was 1 7 0 0 F . f o r 1 5 m i n u t e s . Th e r e s u l t i n g m a t e r i a lhad a d e n s i t y o f 4 2 . 6 pounds p e r c u b i c f o o t an d a p o r e s i Z ed i s t r i b u t i o n r a n g i n g from a b o u t 0 . 0 1 t o 0 . 1 m m .

EXAMPLE 8T h i s E x a m p l e p r o v i d e s some a d d i t i o n a l d e t a i l c o n c e r n i n gt h e e x p e d i e n t m o u n d i n g o f t h e f o a m a b l e m i x t u r e .To p r o d u c e a b l o c k o f foamed g l a s s m a t e r i a l s u i t a b l e f o r

u s e a s a s a n d i n g b l o c k , 12 k g o f a foamable g l a s s m i x t u r eW a s p r e p a r e d b y t h o r o u g h l y m i x i n g t o g e t h e r f o r 2 0 m i n u t e si n a m e c h a n i c a l m i x e r 2.4% by W e i g h t c a l c i u m c a r b o n a t ep o W d e r (100% o f W h i c h p a s s e s t h r o u g h a 2 0 0 mesh c r e e n ) ,7 7 . 6 % b y W e i g h t r e c y c l e d o r v i r g i n g l a s s ( 1 0 0 % o f W h i c hp a s s e s t h r o u g h a 3 2 5 mesh s c r e e n ) , a n d 20% b y W e i g h tc o m m o n s a n d (100% o f Which p a s s e s t h r o u g h a 40 m e s hs c r e e n b u t Which d o e s n o t p a s s t h r o u g h a n 80 m e s h s c r e e n ) .A A 1 i n c h s t a i n l e s s s t e e l p l a t e h a v i n g a d i m e n s i o n o f 2 0i n c h e s > < 2 6 i n c h e s Was c o a t e d W i t h a t h i n s l u r r y o f t a l c an da l u m i n a a s a g e n t s t o p r e v e n t s t i c k i n g . A t a i n l e s s s t e e l moldWas c o a t e d W i t h t h e same s l u r r y . The mold had t h e s h a p e o fa frustum and Was o p e n a t t h e b a s e . Th e base dimensionsWere 20 i n c h e s > < 2 6 i n c h e s , an d t h e peak d i m e n s i o n s Were 1 9i n c h e s > < 2 6 i n c h e s ; t h e mold Was 6 i n c h e s d e e p . Th e foama b l e m i x t u r e Was d i v i d e d i n t o f o u r e q u a l p o r t i o n s o f 3 k ge a c h , a n d e a c h p o r t i o n Was p l a c e d on t h e 2 0 i n c h > < 2 6 i n c hp l a t e i n a r oW s u c h t h a t i t had b a s e dimensions o f 4 . 5i n c h e s > < 1 6 i n c h e s . The f o u r roWs Were e v e n l y s p a c e d 2i n c h e s a p a r t . The r o W s , Which r a n p a r a l l e l t o t h e 26 i n c h e sd i m e n s i o n o f t h e p l a t e , Were s p a c e d 1 i n c h aWay from t h ee d g e o f t h e p l a t e . Th e e n d s o f t h e roWs Were p l a c e d 2 i n c h e saWay f r o m t h e e d g e s o f t h e p l a t e h a v i n g t h e 2 0 i n c hd i m e n s i o n s . Each r oW had a t r a p e Z o i d a l c r o s s -s e c t i o n t h e


17/17

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b a s e o f Which Was 4 . 5 i n c h e s an d t h e t o p o f Which Was 3 . 5i n c h e s , W i t h a h e i g h t o f 3 i n c h e s . Each p o r t i o n Was comp a c t e d i n t o t h e a b o v e s h a p e , a n d t h e b u l k d e n s i t y o f t h ep o w d e r a f t e r b e i n g c o m p a c t e d Was 2 p o u n d s p e r c u b i c f o o t .The f r u s t u m s h a p e d l i d Was l o w e r e d o n t o t h e p l a t e t h a ts u p p o r t e d t h e mounds o f f o a m a b l e m i x t u r e , W h e r e u p o n t h ee n t i r e assembly Was p l a c e d i n t o a f u r n a c e . The f u r n a c e Wasr a p i d l y h e a t e d t o 1250 F . an d Was h e l d t h e r e f o r one hourt o a l l o W t h e foamable m i x t u r e t o s i n t e r an d a b s o r b h e a te v e n l y . The t e m p e r a t u r e Was t h e n i n c r e a s e d t o 1 5 0 0 F . an dh e l d t h e r e f o r 6 0 m i n u t e s . The mounds o f poWder f o a m e d ,f u s e d , a n d ? l l e d t h e mold d u r i n g t h i s p r o c e s s . The t e m p e r at u r e Was t h e n r a p i d l y loWered t o 1050 F . an d Was h e l d t h e r ef o r 1 5 m i n u t e s t o h a l t t h e f o a m i n g p r o c e s s a n d t o s o l i d i f y t h eo u t s i d e s k i n o f t h e mass o f foamed g l a s s . The f r u s t u ms h a p e d p o r t i o n o f t h e mold Was t h e n removed from t h e masso f s o l i d i ? e d foamed g l a s s . The b l o c k o f foamed g l a s s Wast h e n p l a c e d i n a n a n n e a l i n g l e h r , W h i c h s l o W l y c o o l e d t h efoamed g l a s s f r o m 1 0 5 0 F . t o a m b i e n t t e m p e r a t u r e . The? n i s h e d a n d c o o l e d b l o c k o f foamed g l a s s Was t h e n p l a n e dan d trimmed t o remove t h e g l a s s y s k i n an d t r a c e s o f r e l e a s ea g e n t . Th e ? n i s h e d c u t b l o c k o f foamed g l a s s h a d dimens i o n s o f 1 8 i n c h e s > < 2 4 i n c h e s > < 4 i n c h e s , a d e n s i t y o f 1 9 . 3p o u n d s p e r c u b i c f o o t , a n d a p o r e s i Z e d i s t r i b u t i o n r a n g i n gfrom a b o u t 2 . 0 t o 5 . 0 mm. The ?nished block o f foamedg l a s s c o u l d t h e n b e c u t i n t o a v a r i e t y o f r e g u l a r s h a p e s f o ru s e i n s u r f a c e p r e p a r a t i o n .

The p r e s e n t i n v e n t i o n i s , o f c o u r s e , i n no Way r e s t r i c t e d t ot h e s p e c i ? c d i s c l o s u r e o f t h e s p e c i ? c a t i o n , d r a W i n g s a n de x a m p l e s , b u t a l s o e n c o m p a s s e s a n y m o d i ? c a t i o n s W i t h i nt h e s c o p e o f t h e a p p e n d e d c l a i m s .

Wha t We claim i s :1 . A ethod o f t r e a t i n g a h a r d s u r f a c e t o remove m a t e r i a l

t h e r e f r o m , c o m p r i s i n g t h e s t e p s o f :p r o v i d i n g a f o a m e d g l a s s a r t i c l e f o r m e d f r o m a s t a r t i n g

m i x t u r e t h a t c o m p r i s e s g l a s s a n d 0 . 1 0 2 0 % b y W e i g h to f a t l e a s t o n e n o n - c a r b o n / s u l f a t e b a s e d foaming a g e n t ;a n d

c o n t a c t i n g s a i d s u r f a c e W i t h s a i d f o a m e d g l a s s a r t i c l e a n dp r o v i d i n g r e l a t i v e movement betWeen s a i d a r t i c l e a n ds a i d s u r f a c e .

2 . A method a c c o r d i n g t o c l a i m 1 , W h e r e i n t h e h a r ds u r f a c e i s t r e a t e d b y s a n d i n g , r u b b i n g , s c r a p i n g , d e g r e a s i n g ,p o l i s h i n g , c l e a n i n g o r s m o o t h i n g .3 . A method a c c o r d i n g t o c l a i m 2 , W h e r e i n t h e h a r ds u r f a c e c o m p r i s e s W o o d , m e t a l , p l a s t i c , ? b e r g l a s s , p o r c e l a i n ,g l a s s , e n a m e l e d s u r f ac e s, c o n c r e t e , o r t i l e s .4 . A ethod a c c o r d i n g t o c l a i m 1 , W h e r e i n s a i d s t a r t i n gm i x t u r e f u r t h e r c o m p r i s e s u p t o 3 0 . 0 % b y W e i g h t a b r a s i v em a t e r i a l s e l e c t e d f r o m t h e g r o u p c o n s i s t i n g o f s a n d , a l u m in um o x i d e , s i l i c o n c a r b i d e , g a r n e t , t r i p o l i , g r o u n d c e r a m i c ,a n d m i x t u r e s t h e r e o f .5 . A ethod a c c o r d i n g t o c l a i m 4 , W h e r e i n s a i d s t a r t i n gm i x t u r e c o m p r i s e s 6 9 . 9 9 9 . 9 % b y W e i g h t v i r g i n g l a s s o rW a s t e g l a s s , 0.1020% o f a t l e a s t o n e f o a m i n g a g e n t s e l e c t e df r o m t h e g r o u p c o n s i s t i n g o f c a l c i u m c a r b o n a t e , m a g n e s i u mc a r b o n a t e , s o d i u m c a r b o n a t e , s t r o n t i u m c a r b o n a t e , l i t h i u mc a r b o n a t e , b a r i u m c a r b o n a t e , s u g a r , u r e a , W a t e r a n d mixt u r e s t h e r e o f , a n d u p t o 30.0% by W e i g h t a b r a s i v e m a t e r i a ls e l e c t e d f r o m t h e g r o u p c o n s i s t i n g o f s a n d , a l u m i n u m o x i d e ,s i l i c o n c a r b i d e , g a r n e t , t r i p o l i , g r o u n d c e r a m i c , a n d m i x t u r e st h e r e o f .6 . A ethod a c c o r d i n g t o c l a i m 5 , W h e r e i n s a i d s t a r t i n gm i x t u r e c o m p r i s e s p o W d e r e d g l a s s a n d 0 . 5 5 . 0 % b y W e i g h to f s a i d f o a m i n g a g e n t .7 . A ethod a c c o r d i n g t o c l a i m 1 , W h e r e i n s a i d foamedg l a s s a r t i c l e h a s a s h a p e o f a block o r d i s k .

8 . A ethod o f making foamed g l a s s a s a means t o t r e a ta hard s u r f a c e t o remove m a t e r i a l t h e r e f r o m , s a i d methodc o m p r i s i n g t h e s t e p s o f :

10

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35

40

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1 2p r o v i d i n g p o W d e r e d g l a s s ;m i x i n g a t l e a s t o n e n o n - c a r b o n / s u l f a t e b a s e d f o a m i n g

a g e n t W i t h s a i d poWdered g l a s s t o f o r m a m i x t u r e ;p l a c i n g s a i d m i x t u r e o n t o a s u r f a c e ;h e a t i n g s a i d m i x t u r e s o t h a t s a i d m i x t u r e s i n t e r s a n ds u b s e q u e n t l y foams t o form a foamed m i x t u r e ; a n da n n e a l i n g s a i d foamed m i x t u r e b y c o o l i n g i t t o room

t e m p e r a t u r e t o f o r m a foamed g l a s s p r o d u c t , W h e r e i ns a i d h e a t i n g s t e p c o m p r i s e s ? r s t h e a t i n g s a i d m i x t u r e t oa t e m p e r a t u r e o f a b o u t 1 2 5 0 F . , m a i n t a i n i n g t h i st e m p e r a t u r e f o r a s u f f i c i e n t p e r i o d o f t i m e t o a l l o W s a i dm i x t u r e t o s i n t e r a n d a b s o r b h e a t e v e n l y , a n d t h e ni n c r e a s i n g s a i d t e m p e r a t u r e t o 1 2 7 4 1 7 0 0 F .

9 . A e t h o d a c c o r d i n g t o c l a i m 8 , W h e r e i n s a i d m i x i n gs t e p c o m p r i s e s m i x i n g 0 . 1 0 2 0 % b y W e i g h t o f s a i d f o a m i n ga g e n t W i t h s a i d p o W d e r e d g l a s s .

1 0 . A ethod a c c o r d i n g t o c l a i m 9 , W h e r e i n s a i d m i x i n gs t e p c o m p r i s e s m i x i n g 0 . 5 5 . 0 % b y W e i g h t o f s a i d f o a m i n ga g e n t W i t h s a i d p o W d e r e d g l a s s .1 1 . A e t h o d a c c o r d i n g t o c l a i m 8 , W h e r e i n s a i d p l a c i n gs t e p c o m p r i s e s p l a c i n g s a i d m i x t u r e o n t o a c o n t i n u o u s b e l t ,onto a p l a t e , o r i n t o at l e a s t on e mold.

1 2 . A ethod a c c o r d i n g t o c l a i m 8 , W h e r e i n s a i d a n n e a li n g s t e p c o m p r i s e s t h e s t e p s o f ? r s t r a p i d l y c o o l i n g s a i dfoamed mixture t o a temperature be loW a foamingt e m p e r a t u r e , a n d t h e n s l o W l y c o o l i n g s a i d f o a m e d m i x t u r e t oroom t e m p e r a t u r e .

1 3 . A ethod a c c o r d i n g t o c l a i m 8 , W h e r e i n s a i d p r o v i di n g s t e p c o m p r i s e s p r o v i d i n g 6 9 . 9 9 9 . 9 % b y W e i g h t v i r g i ng l a s s o r W a s t e g l a s s , s a i d m i x i n g s t e p c o m p r i s i n g m i x i n g0.1020% by W e i g h t o f a t l e a s t o n e f o a m i n g a g e n t , a n dW h i c h i n c l u d e s t h e f u r t h e r s t e p o f a d d i n g u p t o 30.0% b yW e i g h t o f a b r a s i v e m a t e r i a l t o s a i d m i x t u r e p r i o r t o s a i dp l a c i n g s t e p .

1 4 . Amethod a c c o r d i n g t o c l a i m 1 3 , W h e r e i n s a i d a t l e a s to n e f o a m i n g a g e n t i s s e l e c t e d f r o m t h e g r o u p c o n s i s t i n g o fc a l c i u m c a r b o n a t e , m a g n e s i u m c a r b o n a t e , s o d i u m c a r b o n a t es t r o n t i u m c a r b o n a t e , l i t h i u m c a r b o n a t e , b a r i u m c a r b o n a t e ,s u g a r , u r e a , W a t e r , a n d m i x t u r e s t h e r e o f , a n d s a i d a b r a s i v em a t e r i a l i s s e l e c t e d f r o m t h e g r o u p c o n s i s t i n g o f s a n d ,a l u m i n u m o x i d e , s i l i c o n c a r b i d e , g a r n e t , t r i p o l i , g r o u n dc e r a m i c , a n d m i x t u r e s t h e r e o f .

1 5 . A method a c c o r d i n g t o c l a i m 8 , Which i n c l u d e s t h ea d d i t i o n a l s t e p s , a f t e r s a i d a n n e a l i n g s t e p , o f r e m o v i n g a n yg l a s s y s k i n t h a t i s f o r m e d o n s a i d p r o d u c t , a n d c u t t i n g s a i df o a m e d g l a s s p r o d u c t i n t o a r t i c l e s .

1 6 . A u r f a c e t r e a t i n g a r t i c l e c o m p r i s i n g a foamed g l a s s ,s a i d foamed g l a s s i s f o r m e d f r o m a s t a r t i n g m i x t u r e t h a tc o m p r i s e s g l a s s a n d 0 . 1 0 2 0 % b y W e i g h t o f a t l e a s t o n en o n - c a r b o n / s u l f a t e b a s e d f o a m i n g a g e n t , W h e r e i n t h e s u rf a c e t o b e t r e a t e d c o m p r i s e s W o o d , m e t a l , p l a s t i c , ? b e r g l a s s ,p o r c e l a i n , g l a s s , e n a m e l e d s u r f a c e s , c o n c r e t e o r t i l e s .

1 7 . An r t i c l e a c c o r d i n g t o c l a i m 1 6 , W h e r e i n s a i d s t a r t i n gm i x t u r e c o m p r i s e s 6 9 . 9 9 9 . 9 % b y W e i g h t v i r g i n o r W a s t eg l a s s , 0 . 1 0 2 0 % n o n - c a r b o n / s u l f a t e b a s e d f o a m i n g a g e n t ,a n d u p t o 30.0% by W e i g h t o f a b r a s i v e m a t e r i a l .

1 8 . An r t i c l e a c c o r d i n g t o c l a i m 1 7 , W h e r e i n s a i d a t l e a s to n e f o a m i n g a g e n t i s s e l e c t e d f r o m t h e g r o u p c o n s i s t i n g o fc a l c i u m c a r b o n a t e , magnesium c a r b o n a t e , s o d i u mc a r b o n a t e , s t r o n t i u m c a r b o n a t e , l i t h i u m c a r b o n a t e , b a r i u mc a r b o n a t e , s u g a r , u r e a , W a t e r a n d m i x t u r e s t h e r e o f , a n d s a i da b r a s i v e m a t e r i a l i s s e l e c t e d f r o m t h e g r o u p c o n s i s t i n g o fs a n d , a l u m i n u m o x i d e , s i l i c o n c a r b i d e , g a r n e t , t r i p o l i ,g r o u n d c e r a m i c , a n d m i x t u r e s t h e r e o f .

1 9 . An r t i c l e a c c o r d i n g t o c l a i m 1 7 , W h e r e i n s a i d foamedg l a s s a r t i c l e h a s a s h a p e o f a block o r d i s k .

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