WOOD-LIKE COMPOSITE MATERIALS AND METHODS OF PREPARATION THEREOF
First Claim
1. A composite material comprising:
- a plurality of bonding elements, wherein each bonding element comprises;
a core comprising primarily calcium silicate,a silica-rich first or inner layer, anda calcium carbonate-rich second or outer layer; and
a plurality of filler particles comprising fine filler particles,wherein the plurality of bonding elements and the plurality of filler particles together form one or more bonding matrices and the bonding elements and the filler particles are substantially evenly dispersed therein and bonded together, whereby the composite material exhibits one or more substantially wood-like textures and patterns.
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Abstract
The invention provides novel wood-like composite materials and methods for preparation thereof. The wood-like composite materials can be readily produced from widely available, low cost precursor materials by a production process that involves casting in a mold that is suitable for large-scale production. The precursor materials include calcium silicate, for example, wollastonite, and particulate filler materials which comprise silicon dioxide-rich materials such as quartz, mica, feldspar, sand and glass. Additives can include calcium carbonate-rich and magnesium carbonate-rich materials. Various additives can be used to fine-tune the physical appearance and mechanical properties of the composite material, such as colorants such as particles of colored materials, such as, and pigments (e.g., black iron oxide, cobalt oxide and chromium oxide). These wood-like composite materials exhibit visual patterns unique to wood as well as display compressive strength, flexural strength and water absorption superior to that of wood.
28 Citations
20 Claims
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1. A composite material comprising:
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a plurality of bonding elements, wherein each bonding element comprises; a core comprising primarily calcium silicate, a silica-rich first or inner layer, and a calcium carbonate-rich second or outer layer; and a plurality of filler particles comprising fine filler particles, wherein the plurality of bonding elements and the plurality of filler particles together form one or more bonding matrices and the bonding elements and the filler particles are substantially evenly dispersed therein and bonded together, whereby the composite material exhibits one or more substantially wood-like textures and patterns. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A process for preparing a composite material, comprising the steps of:
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mixing a particulate composition and a liquid composition to form a slurry mixture, wherein the particulate composition comprises; a ground calcium silicate having a median particle size in the range from about 1 μ
m to about 100 μ
m, anda plurality of filler particles comprising fine particles, and wherein the liquid composition comprises; water, and a water-soluble dispersant; casting the slurry mixture in a mold; and curing the casted mixture at a temperature in the range from about 20°
C. to about 150°
C. for about 1 hour to about 80 hours under an atmosphere of water and CO2 having a pressure in the range from ambient atmospheric pressure to about 60 psi above ambient and having a CO2 concentration ranging from about 10% to about 90% to produce a composite material exhibiting a wood-like texture and pattern. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19)
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20. A composite material comprising:
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a plurality of bonding elements, wherein each bonding element comprises; a core comprising primarily magnesium silicate, a silica-rich first or inner layer, and a magnesium carbonate-rich second or outer layer; and a plurality of filler particles, wherein the plurality of bonding elements and the plurality of filler particles together form one or more bonding matrices and the bonding elements and the filler particles are substantially evenly dispersed therein and bonded together, whereby the composite material exhibits one or more substantially wood-like textures and patterns.
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Specification