Abstract:
A moldable matrix comprises a mixture of magnesium chloride, magnesium oxide, sodium hexametaphosphate, and/or sodium pyrophosphate. The matrix can be used as an environmentally-friendly substitute to conventional construction material such as plastics and woods.

Description:
FIELD OF INVENTION 
       [0001]    This invention relates to a moldable matrix, and in particular, a moldable inorganic matrix. 
       BACKGROUND OF INVENTION 
       [0002]    In recent years, with the increasing consumption of petroleum, the resources thereof have been diminishing quickly, leading to the enormous rises in the petroleum prices. Consequently, the prices of petroleum by-products, such as plastics, have also been increasing drastically with that of petroleum. Apart from prices, there is also a growing concern in using plastics as construction materials due to its potential release of poisonous materials such as volatile organic compounds (VOCs), and the nature of its non-biodegradability. 
         [0003]    Beside plastics, woods are also widely popular as construction materials, especially in the building industry. However, the excessive exploitation of woods not only destroys the natural habitant for thousands types of animals and plants, but also adversely affect the ecological system for human beings. 
       SUMMARY OF INVENTION 
       [0004]    In the light of the foregoing background, it is an object of the present invention to provide an alternate construction material. 
         [0005]    Accordingly, the present invention, in one aspect, is a moldable matrix comprising a mixture of magnesium chloride, magnesium oxide together with sodium hexametaphosphate and/or sodium pyrophosphate. The moldable matrix may be obtained by admixing sodium hexametaphosphate and/or sodium pyrophosphate with magnesium chloride and magnesium oxide. 
         [0006]    In another embodiment, the moldable matrix further comprises fiber, stabilizing agent, and iron (II) sulphate. In yet another embodiment, any two of the three aforesaid ingredients can be added to the moldable matrix. 
         [0007]    The moldable matrix of the instant invention is not susceptible to mildew and not affected by humidity. The matrix according to the present invention is easily molded, manufactured and has good tensile strength. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0008]    As used herein and in the claims, “comprising” means including the following elements but not excluding others. 
         [0009]    In one aspect of the present invention, the moldable matrix comprises magnesium chloride, magnesium oxide, sodium hexametaphosphate, and/or sodium pyrophosphate. In one embodiment, the moldable matrix further comprises fiber, stabilizing agent, and iron (II) sulphate. 
         [0010]    In one embodiment, the fiber is glass fiber, rock fiber, and vegetal fiber (e.g. sisal fiber). The stabilizing agent is a polymer; in yet another embodiment, the polymer is a resin selected from methylcellulose, urea formaldehyde, and melamine formaldehyde. Further, iron (II) sulphate can be replaced by sulfuric acid (H 2 SO 4 ) and iron (III) chloride (FeCl 3 ). 
         [0011]    In another embodiment, the moldable matrix comprises magnesium chloride, magnesium oxide, glass fiber, methylcellulose, iron (II) sulphate, sodium hexametaphosphate, and sodium pyrophosphate. The composition of this embodiment of the invention is listed in Table 1 below. Example 1 provides a workable range while Example 2 discloses a more specific working range for each component of the moldable matrix according to the present invention. 
         [0000]    
       
         
               
               
               
               
             
               
               
               
               
             
           
               
                   
                 TABLE 1 
               
               
                   
                   
               
               
                   
                   
                 EXAMPLE 1 
                 EXAMPLE 2 
               
               
                   
                 Ingredients 
                 By weight % 
                 By weight % 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                 1 
                 Magnesium chloride 
                 32-35 
                 33-34 
               
               
                 2 
                 Magnesium oxide 
                 60-63 
                 61-62 
               
               
                 3 
                 Glass fiber 
                 1-3 
                 1.5-2.5 
               
               
                 4 
                 Methylcellulose 
                 0.2-3.5 
                 1-2 
               
               
                 5 
                 Iron (II) sulphate 
                 0.2-3.5 
                 1-2 
               
               
                 6 
                 Sodium hexametaphosphate 
                 0.2-3.5 
                 1-2 
               
               
                 7 
                 Sodium pyrophosphate 
                 0.2-3.5 
                 1-2 
               
               
                   
               
             
          
         
       
     
         [0012]    Since a mixture of magnesium chloride and magnesium oxide is relatively brittle, the stabilizing agent added is used to stabilize the matrix and most importantly and increase the tensile strength thereof. As a result, the endurance of the overall matrix will be greatly enhanced. Also, the fiber added is used to further reinforce the resultant matrix. 
         [0013]    In yet another embodiment, different materials can be added to the moldable matrix as fillers to diversify the applications of the resulting matrix. In one embodiment, the amount of fillers added can be up to 30% by weight of the resulting matrix, with a proportionate reduction in magnesium chloride and magnesium oxide. The corresponding composition of this embodiment is listed in Table 2 below. Similar to the format of Table 1, there are two examples in Table 2 to respectively describe a workable range (i.e. Example 3), and a more specific workable range (i.e. Example 4) for each ingredient thereof. 
         [0000]    
       
         
               
               
               
               
             
               
               
               
               
             
           
               
                   
                 TABLE 2 
               
               
                   
                   
               
               
                   
                   
                 EXAMPLE 3 
                 EXAMPLE 4 
               
               
                   
                 Ingredients 
                 By weight % 
                 By weight % 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                 1 
                 Magnesium chloride 
                 22-35 
                 26-31 
               
               
                 2 
                 Magnesium oxide 
                 40-63 
                 48-58 
               
               
                 3 
                 Glass fiber 
                 1-3 
                 1.5-2.5 
               
               
                 4 
                 Methylcellulose 
                 0.2-3.5 
                 1-2 
               
               
                 5 
                 Fillers 
                  1-30 
                  5-20 
               
               
                 6 
                 Iron (II) sulphate 
                 0.2-3.5 
                 0.5-2     
               
               
                 7 
                 Sodium hexametaphosphate 
                 0.2-3.5 
                 0.5-2     
               
               
                 8 
                 Sodium pyrophosphate 
                 0.2-3.5 
                 0.5-2     
               
               
                   
               
             
          
         
       
     
         [0014]    In another aspect of the present invention, a method for preparing a moldable matrix is provided. In one implementation, the method for producing the moldable matrix having ingredients and corresponding compositions as shown in Table 1 includes the first step of admixing magnesium chloride, magnesium oxide, glass fiber, methylcellulose, iron (II) sulphate, sodium hexametaphosphate, and sodium pyrophosphate under ambient conditions. Then, the mixture is applied into a mold by hand and/or spray lay-up for gelatification and curing to obtain the cast. 
         [0015]    The moldable matrix according to the instant invention can be used as raw materials for the manufacture of indoor and/or outdoor furniture or decorative items, and can also be applied in architectural moldings. Its application can further be extended to non-load bearing engineering products such as coverage panels, fitting out panels, ceiling tiles, and wood-substitute panels. 
         [0016]    The exemplary embodiments of the present invention are thus fully described. Although the description referred to particular embodiments, it will be clear to one skilled in the art that the present invention may be practiced with variation of these specific details. Hence this invention should not be construed as limited to the embodiments set forth herein. 
         [0017]    For example, in one embodiment, the moldable matrix according to the present invention comprises magnesium chloride, magnesium oxide, and sodium hexametaphosphate, whereas in another embodiment, sodium hexametaphospate is replaced by sodium pyrophosphate for admixing with magnesium chloride and magnesium oxide to obtain the moldable matrix. The amounts of sodium hexametaphosphate or sodium pyrophosphate added vary under different experimental conditions such as humidity and temperature, and the added amounts are generally determined by one skilled in the art.