Lightweight composite materials produced from carbonatable calcium silicate and methods thereof

• US 10,695,949 B2
• Filed: 05/18/2015
• Issued: 06/30/2020
• Est. Priority Date: 05/18/2015
• Status: Active Grant

• Current Assignee: Asahi Kasei Homes Corp. (Asahi Kasei Corporation), Solidia Technologies, Inc.
• Original Assignee: Solidia Technologies, Ltd.
• Inventors: Atakan, Vahit, Sahu, Sadananda, Takase, Hirotaka, Kamata, Takayuki, Kanno, Katsuhiko, Fukasawa, Yoshihito, Deo, Omkar, Vuong, David
• Primary Examiner(s): Ruthkosky, Mark
• Assistant Examiner(s): Rummel, Julia L
• Application Number:
  US14/715,497
• Publication Number:
  US 20160340261A1
• Time in Patent Office: 1,870 Days
• CPC Class Codes: B28B 1/50 specially adapted for producing articles of expanded material, e.g. cellular concrete chemical aspects or making expanded aggregate C04B
• CPC Class Codes: C04B 14/043 Alkaline-earth metal silicates, e.g. wollastonite
• CPC Class Codes: C04B 22/04 Metals, e.g. aluminium used as blowing agent
• CPC Class Codes: C04B 28/188 the Ca-silicates being present in the starting mixture
• CPC Class Codes: C04B 38/0051 characterised by the pore size, pore shape or kind of porosity
• CPC Class Codes: C04B 38/0054 the pores being microsized or nanosized
• CPC Class Codes: C04B 38/02 by adding chemical blowing agents
• CPC Class Codes: C04B 40/0231 Carbon dioxide hardening
• CPC Class Codes: C04B 40/024 Steam hardening, e.g. in an autoclave
• CPC Class Codes: Y02P 40/18 Carbon capture and storage [CCS]
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

An aerated composite material produced from carbonatable calcium silicate compositions (carbonation cured AAC) that has a compressive strength equivalent to autoclaved aerated concrete (ordinary AAC) at substantially the same density and a process of production of the same are provided. The composite material of the present invention comprises: a plurality of bonding elements, each including a core comprising calcium silicate, a first layer which partially or fully surrounds the core and is rich in SiO₂, and a second layer which partially or fully surrounds the first layer and is rich in CaCO₃; a plurality of filler particles having their particle sizes ranging from 0.1 μm to 1000 μm; and a plurality of voids; wherein the plurality of bonding elements and plurality of filler particles together form a bonding matrix and are substantially evenly dispersed in the matrix and bonded together, the plurality of voids are bubble-shaped and/or interconnected channels, a pore volume with a radius of 0.004 μm to 10.0 μm in the plurality of voids is 0.30 ml/composite material 1 g or less, and a estimated compressive strength expressed by the following formula (1): estimated compressive strength (absolute dry density=0.50)=compressive strength×(0.50+absolute dry density)² is 2.0 N/mm² or greater.

Claims

1. A composite material comprising:

a plurality of bonding elements, each including a core comprising calcium silicate, a first layer which partially or fully surrounds the core and is rich in SiO₂, and a second layer which partially or fully surrounds the first layer and is rich in CaCO₃;

a plurality of filler particles having particle sizes of 0.1 μ

m to 1000 μ

m;

wherein the plurality of bonding elements and plurality of filler particles together form a bonding matrix and are substantially evenly dispersed in the matrix and bonded together, the bonding matrix having a pore volume;

the pore volume comprises pores with a radius greater than 10.0 μ

m,

the pore volume further comprising 0.142-0.247 ml/1.0 g of composite material of pores with a radius of 0.004 μ

m to 10.0 μ

m,

the composite material having an absolute dry density, as measured after drying a sample of the composite material in a convection dryer at 110°

C. for at least 4 days, of 0.50 g/cm³ or more,

the composite material having an estimated compressive strength, when the compressive strength is measured at an absolute dry density of 0.50 g/cm³, expressed by the following formula (1);

Estimated compressive strength=compressive strength×

(0.50÷

absolute dry density)² of 2.0 N/mm² or more.

2. The composite material according to claim 1, wherein the pore volume comprised of pores with a radius of 0.004 μ

m to 10.0 μ

m in the composite material is 0.24 ml/1 g of composite material or less and the estimated compressive strength is 2.5 N/mm² or more.

3. The composite material according to claim 2, wherein the pore volume comprised of pores with a radius of 0.004 μ

m to 10.0 μ

m in the composite material is 0.19 ml/1 g of composite material or less and the estimated compressive strength is 3.7 N/mm² or more.

4. The composite material according to claim 3, wherein the pore volume comprised of pores with a radius of 0.004 μ

m to 10.0 μ

m in the composite material is 0.17 ml/1 g of composite material or less and the estimated compressive strength is 4.5 N/mm² or more.

5. The composite material according to claim 4, wherein the pore volume comprised of pores with a radius of 0.004 μ

m to 10.0 μ

m in the composite material is 0.15 ml/1 g of composite material or less and the estimated compressive strength is 5.0 N/mm² or more.

6. The composite material according to claim 1, wherein the plurality of bonding elements is chemically transformed from ground calcium silicate selected from natural or synthetic sources.

7. The composite material according to claim 6, wherein the ground calcium silicate comprises one or more of a group of calcium silicate phases selected from CS (wollastonite or pseudowollastonite), C3S2 (rankinite), C2S (belite, lamite, bredigite), an amorphous calcium silicate phase, each of which material optionally comprises one or more metal ions or oxides, or blends thereof.

8. The composite material according to claim 7, wherein the plurality of bonding elements are chemically transformed from ground calcium silicate by reacting the ground calcium silicate with CO₂ via a controlled hydrothermal liquid phase sintering (HLPS) process.

9. The composite material according to claim 1, wherein the filler particles are a CaO-rich material.

10. The composite material according to claim 1, wherein the filler particles are selected from the group consisting of lime and quartz.

11. The composite material according to claim 1, wherein the filler particles are selected from the group consisting of industrial waste, lime, slag, and silica fume.

12. The composite material according to claim 1, wherein the plurality of voids are formed by hydrogen gas, which is generated by reacting an aerating agent in an alkaline environment.

13. The composite material according to claim 11, wherein the aerating agent is a powder which includes at least one of aluminum, iron, calcium carbonate, and blends of the same.

14. The composite material according to claim 1, wherein

the pore volume comprising 0.142-0.181 ml/1.0 g of composite material of pores with a radius of 0.004 μ

m to 10.0 μ

m,

the composite material having an absolute dry density, as measured after drying a sample of the composite material in a convection dryer for at least 4 days, of 0.58 g/cm³ to 0.67 g/cm³, and

the composite material having an estimated compressive strength, when the compressive strength is measured at an absolute dry density of 0.50 g/cm³, expressed by the formula (1) of 3.85-5.48 N/mm² or more.

15. The composite material according to claim 1, wherein the composite material has an absolute dry density of 0.51 g/cm³ to 0.67 g/cm³.

16. A carbonation-cured composite material comprising:

a plurality of bonding elements, each including a core comprising calcium silicate, a first layer which partially or fully surrounds the core and is rich in SiO₂, and a second layer which partially or fully surrounds the first layer and is rich in CaCO₃, wherein the plurality of bonding elements are chemically transformed from ground calcium silicate by reacting the ground calcium silicate with CO₂ by a carbonation reaction;

a plurality of filler particles having particle sizes of 0.1 μ

m to 1000 μ

m;

wherein the plurality of bonding elements and plurality of filler particles together form a bonding matrix and are substantially evenly dispersed in the matrix and bonded together;

a pore volume comprising pores with a radius greater than 10.0 μ

m, the pore volume further comprising 0.142-0.247 ml/1.0 g of composite material of pores with a radius of 0.004 μ

m to 10.0 μ

m,

the composite material having an absolute dry density, as measured after drying a sample of the composite material in a convection dryer at 110°

C. for at least 4 days, of 0.50 g/cm³ or more,

the composite material having an estimated compressive strength, when the compressive strength is measured at an absolute dry density of 0.50 g/cm³, of 2.0 N/mm² or more.