Extruded cement based materials
First Claim
Patent Images
1. An extrudable cement-based material formed from a mixture comprising:
- a cement in the range of about 0.1 to 88% by wet weight percent;
a gypsum in the range of about 0.1 to 88% by wet weight percent;
a secondary material in the range of about 0.1 to 50% by wet weight percent, wherein the secondary material comprising sand, silica fume, fumed silica, fly ash, slag, rock, or a combination thereof;
a reinforcement fiber in the range of about 0.5 to 20% by wet weight percent, wherein the reinforcement fiber comprising cellulose fiber, glass fiber, polypropylene fiber, polyvinyl alcohol (PVA) fiber, Dolanit fiber, or a combination thereof;
a rheology modifying agent in the range of about 0.5 to 10% by wet weight percent wherein the rheology modifying agent comprising a polysaccharide, a polysaccharide derivative, a protein, a protein derivative, a synthetic organic material, a synthetic organic material derivative, or a combination thereof;
a water in the range of 10 to 60% of a total wet material weight; and
the mixture is extrudable.
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Abstract
An extrudable cement-based material formed from a mixture that includes cement, water, gypsum, secondary materials, reinforcement fibers and rheology modifying agent. The extrudable cement-based material is a lightweight material that has a density in the range of about 1.4 to 2.4 g/cm3, a compressive strength in the range of about 5 to 100 MPa, and a flexural strength in the range of about 5 to 35 MPa. Note that the cement may contain gypsum such that the gypsum is not added to the mixture.
303 Citations
21 Claims
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1. An extrudable cement-based material formed from a mixture comprising:
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a cement in the range of about 0.1 to 88% by wet weight percent; a gypsum in the range of about 0.1 to 88% by wet weight percent; a secondary material in the range of about 0.1 to 50% by wet weight percent, wherein the secondary material comprising sand, silica fume, fumed silica, fly ash, slag, rock, or a combination thereof; a reinforcement fiber in the range of about 0.5 to 20% by wet weight percent, wherein the reinforcement fiber comprising cellulose fiber, glass fiber, polypropylene fiber, polyvinyl alcohol (PVA) fiber, Dolanit fiber, or a combination thereof; a rheology modifying agent in the range of about 0.5 to 10% by wet weight percent wherein the rheology modifying agent comprising a polysaccharide, a polysaccharide derivative, a protein, a protein derivative, a synthetic organic material, a synthetic organic material derivative, or a combination thereof; a water in the range of 10 to 60% of a total wet material weight; and the mixture is extrudable. - View Dependent Claims (2, 3, 4, 5)
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6. An extrudable cement-based material formed from a mixture consisting essentially of:
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a cement in the range of about 0.1 to 88% by wet weight percent; a gypsum in the range of about 0.1 to 88% by wet weight percent; a secondary material in the range of about 0.1 to 50% by wet weight percent, wherein the secondary material comprising sand, silica fume, fumed silica, fly ash, slag, rock, or a combination thereof; a reinforcement fiber in the range of about 0.5 to 20% by wet weight percent, wherein the reinforcement fiber comprising cellulose fiber, glass fiber, polypropylene fiber, polyvinyl alcohol (PVA) fiber, Dolanit fiber, or a combination thereof; a rheology modifying agent in the range of about 0.5 to 10% by wet weight percent, wherein the rheology modifying agent comprising a polysaccharide, a polysaccharide derivative, a protein, a protein derivative, a synthetic organic material, a synthetic organic material derivative, or a combination thereof; a water in the range of 10 to 60% of a total wet material weight; and the mixture is extrudable.
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7. A method for manufacturing an extrudable cement-based material comprising:
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mixing a cement in the range of about 0.1 to 88% by wet weight percent, a secondary material in the range of about 0.1 to 50% by wet weight percent, a reinforcement fiber in the range of about 0.5 to 20% by wet weight percent, and a rheology modifying agent in the range of about 0.5 to 10% by wet weight percent with water in the range of 10 to 60% of a total wet material weight at a same time, wherein the cement contains a gypsum in the range of about 0.1 to 90% by wet weight percent or the gypsum is added separately or a combination of both, the secondary material comprises sand, silica fume, fumed silica, fly ash, slag, rock, or a combination thereof, the reinforcement fiber comprises cellulose fiber, glass fiber, polypropylene fiber, polyvinyl alcohol (PVA) fiber, Dolanit fiber, or a combination thereof, and the rheology modifying agent comprises a polysaccharide, a polysaccharide derivative, a protein, a protein derivative, a synthetic organic material, a synthetic organic material derivative, or a combination thereof; extruding the mixture through a die using an extruder; and allowing the extruded mixture to set. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21)
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8. A method for manufacturing an extrudable cement-based material comprising:
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mixing a cement in the range of about 0.1 to 88% by wet weight percent with a water in the range of 10 to 60% of a total wet material weight, wherein the cement contains a gypsum in the range of about 0.1 to 90% by wet weight percent; blending the cement-gypsum-water mixture with a secondary material in the range of about 0.1 to 50% by wet weight percent and a reinforcement fiber in the range of about 0.5 to 20% by wet weight percent, wherein the secondary material comprises sand, silica fume, fumed silica, fly ash, slag, rock, or a combination thereof, and the reinforcement fiber comprises cellulose fiber, glass fiber, polypropylene fiber, polyvinyl alcohol (PVA) fiber, Dolanit fiber, or a combination thereof; adding a rheology modifying agent to the mixture in the range of about 0.5 to 10% by wet weight percent to the mixture, wherein the rheology modifying agent comprises a polysaccharide, a polysaccharide derivative, a protein, a protein derivative, a synthetic organic material, a synthetic organic material derivative, or a combination thereof; extruding the mixture through a die using an extruder; and allowing the extruded mixture to set.
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9. A method for manufacturing an extrudable cement-based material comprising:
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mixing a cement in the range of about 0.1 to 88% by wet weight percent and a gypsum in the range of about 0.1 to 90% by wet weight percent with a water in the range of 10 to 60% of a total wet material weight; blending the cement-gypsum-water mixture with a secondary material in the range of about 0.1 to 50% by wet weight percent and a reinforcement fiber in the range of about 0.5 to 20% by wet weight percent, wherein the secondary material comprises sand, silica fume, fumed silica, fly ash, slag, rock, or a combination thereof, and the reinforcement fiber comprises cellulose fiber, glass fiber, polypropylene fiber, polyvinyl alcohol (PVA) fiber, Dolanit fiber, or a combination thereof; adding a rheology modifying agent to the mixture in the range of about 0.5 to 10% by wet weight percent to the mixture, wherein the rheology modifying agent comprises a polysaccharide, a polysaccharide derivative, a protein, a protein derivative, a synthetic organic material, a synthetic organic material derivative, or a combination thereof; extruding the mixture through a die using an extruder; and allowing the extruded mixture to set.
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Specification