Method of Moulding a Part in a Hydraulically-Setting Matrix and Part Thus Produced

• US 20080113193A1
• Filed: 10/01/2004
• Published: 05/15/2008
• Est. Priority Date: 10/03/2003
• Status: Abandoned Application

• Current Assignee: Ocv Intellectual Capital, Llc (Owens Corning)
• Original Assignee: Saint Gobain Vetrotex France
• Inventors: Comino Almenara, Pablo Ignacio
• Application Number:
  US10/574,504
• Publication Number:
  US 20080113193A1
• Time in Patent Office: Days
• US Class Current: 428/361
• CPC Class Codes: B28B 1/26 by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor B28B1/52 takes precedence; specially for manufacturing articles starting from a ceramic slip; Moulds therefor of tubular articles B28B21/08
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 14/38 Fibrous materials; Whiskers
• CPC Class Codes: C04B 16/06 fibrous
• CPC Class Codes: C04B 18/24 Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper , cork
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 2103/32 Superplasticisers
• CPC Class Codes: C04B 24/2641 Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 24/38 Polysaccharides or derivatives thereof C04B24/243 takes precedence
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 32/02 with reinforcements contains no documents; reinforcing elements E04C5/00
• CPC Class Codes: C04B 40/024 Steam hardening, e.g. in an autoclave
• CPC Class Codes: C04B 40/0272 Hardening under vacuum or reduced pressure
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10T 428/2907 with coating or impregnation

Abstract

A process for manufacturing an article by molding and the article obtained by the process. The process includes an injection molding in a mold, a vacuum water extraction, and a demolding the fresh article.

Claims

1-19. -19. (canceled)

20. A process for manufacturing an article, made of a hydraulically-setting matrix, by molding, comprising:

a) injection of a slurry containing a hydraulic binder and mixing water into a mold;

b) vacuum extraction of the mixing water; and

c) demolding of the fresh article.

21. The process for manufacturing an article by molding as claimed in claim 20, wherein the injection of the slurry into the mold takes place by pressurizing an injection tank.

22. The process for manufacturing an article by molding as claimed in claim 20, wherein the injection of the slurry into the mold takes place by a peristaltic pump.

23. The process for manufacturing an article by molding as claimed in claim 20, wherein the injection of the slurry into the mold takes place by compressed air.

24. The process for manufacturing an article by molding as claimed in claim 20, wherein the injection takes place at a pressure between 1.5 and 4 bar.

25. The process for manufacturing an article by molding as claimed in claim 20, wherein the injection takes place at a pressure between 4 and 30 bar.

26. The process for manufacturing an article by molding as claimed in claim 20, wherein a water/cement ratio after the vacuum extraction step is between 0.25 and 0.5.

27. The process for manufacturing an article by molding as claimed in claim 20, allowing articles to be produced with a thicknesses between 0.2 and 5 cm.

28. The process for manufacturing an article by molding as claimed in claim 20, wherein a duration of the vacuum extraction step is less than 1 hour.

29. The process for manufacturing an article by molding as claimed in claim 20, further comprising hardening the article that takes place under relative humidity conditions between 90% and 100%.

30. The process for manufacturing an article by molding as claimed in claim 29, wherein a total duration of the hardening is between 1 and 7 days.

31. The process for manufacturing an article by molding as claimed in claim 29, wherein the hardening takes place in a presence of steam.

32. The process for manufacturing an article by molding as claimed in claim 29, wherein the hardening takes place in an autoclave.

33. An article made of a hydraulically-setting matrix, obtained using the process of claim 20, wherein the article comprises a weight percent of hydraulic binder between 2% and 98% of the total mass, a weight percent of sand between 0.1% and 95% of the total mass, a weight percent of water between 5% and 75% of the total mass, a weight percent of reinforcement fibers between 0% and 50% of the total mass, a weight percent of other fibers between 0% and 50% of the total mass, a weight percent of polymers between 0% and 75% of the total mass, a weight percent of superplasticizer between 0% and 20% of the total mass, and a weight percent of metakaolin between 0% and 50% of the total mass.

34. The article made of a hydraulically-setting matrix as claimed in claim 33, wherein the hydraulic binder comprises a cement, the cement may be a quick-setting cement with a high initial strength, a conventional Portland cement of any strength, aluminous cement, a low-alkali cement and in general any type of cement whatsoever, the choice of which must be taken into account when designing the article, so as always to maintain its hydraulic binder characteristic.

35. The article made of a hydraulically-setting matrix as claimed in claim 33, wherein the polymers may be of acrylic or synthetic type, resins of various typologies or any other polymer that can be used to modify the matrix and give the manufactured article a greater capacity in terms of various design and performance aspects that are expected of the article.

36. The article made of a hydraulically-setting matrix as claimed in claim 33, further comprising other additives which may be accelerators, retarders, emulsifiers, air entrainers, occluded air agents, stabilizers, antioxidants, plasticizers, or thickeners, such as cellulose, cellulose fibers, cellulose hydroxides of any type, and other chemical thickeners, also starches or natural products that can be used to improve the cohesion and stability of the injected slurry, and in general any additive for the purpose of modifying the matrix according to the design and performance requirements expected of the article, and also possible production requirements.

37. The article made of a hydraulically-setting matrix as claimed in claim 33, wherein the reinforcement fibers may be chopped fibers, whole fibers, a mat of whatever class of chopped reinforcement fibers, a mat of continuous fibers, or woven meshes.

38. The article made of a hydraulically-setting matrix as claimed in claim 33, wherein the reinforcement fibers may be synthetic fibers, such as polyamide, rayon, nylon, PVA and polypropylene fibers, and, in general, any organic or synthetic fiber of whatever class;

mineral fibers, such as carbon fiber, basalt fiber and, in general, any mineral fiber of whatever class;

glass fiber, such as E-, Z-, C- and AR-glass fiber and, in general, any glass fiber of any composition;

metal fibers, such as copper, steel, stainless steel, iron, cast iron and ductile cast iron fibers and, in general, any fiber of metal type.