Cementuous fiber impregnated construction composition and process for formation thereof

• US 4,799,961 A
• Filed: 08/19/1986
• Issued: 01/24/1989
• Est. Priority Date: 08/19/1986
• Status: Expired due to Fees

• Current Assignee: Walter R. Friberg
• Original Assignee: Walter R. Friberg
• Inventors: Friberg, Walter R.
• Primary Examiner(s): Dixon, Jr., William R.
• Assistant Examiner(s): Griffis, Andrew B.
• Application Number:
  US06/897,860
• Time in Patent Office: 889 Days
• Field of Search: 106/89, 106/93, 106/99
• US Class Current: 106/720
• CPC Class Codes: C04B 14/308 Iron oxide
• CPC Class Codes: C04B 18/26 Wood, e.g. sawdust, wood shavings
• CPC Class Codes: C04B 22/124 Chlorides of ammonium or of the alkali or alkaline earth metals, e.g. calcium chloride
• CPC Class Codes: C04B 22/143 Calcium-sulfate
• CPC Class Codes: C04B 28/18 containing mixtures of the silica-lime type
• CPC Class Codes: C04B 40/0028 Aspects relating to the mixing step of the mortar preparation
• CPC Class Codes: C04B 40/0082 making use of a rise in temperature, e.g. caused by an exothermic reaction
• CPC Class Codes: C04B 40/0259 Hardening promoted by a rise in pressure C04B40/024 takes precedence
• CPC Class Codes: C04B 40/0263 Hardening promoted by a rise in temperature C04B40/024 takes precedence
• CPC Class Codes: C04B 7/02 Portland cement
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

A construction composition comprising an alkalin earth oxide, such as calcium oxide, a siliceous material having a high surface area to volume ratio such as diatomite, cement, fiber and other additive constituents is disclosed. The material may be formed in place or preferably pressure molded to predetermined structural shapes. A method of making the composition is disclosed wherein a dry concentrate of the alkaline earth oxide, siliceous matter, and additives is formed by ball milling; a slurry embodying additional alkaline earth oxide, siliceous material and fiber is formed with heating; and a final composition is formed by mixing the first two mixtures with additional necessary materials, including fiber, cement and siliceous material, to a paste consistency. The paste is preferably molded under pressure and thereafter cured by heating to form structural shapes. The final composition can replace many conventional building materials, may be shaped and fastened after formation similarly to wood, is thermally and acoustically insulative and fire, rot and vermin resistant.

Claims

1. A method of preparing a moldable cementuous building composition containing wood fibers, comprising:

(a) forming a first slurry by boiling for at least two hours a first aqueous slurry comprising on a weight basis;

(1) about 0 to 20 percent fibrous material, at least part of which is processed wood fiber,

(2) about 20 to 50 percent calcium oxide,

(3) about 20 to 50 percent particulated silicious material chosen from the group consisting of diatomite, diatomaceous earth, tripolite and chert,

(4) water to 100 percent to form a fluidic slurry;

(b) allowing the first slurry to stand for at lease three days after formation;

(c) forming a second dry concentrate by ball milling for at least thirty minutes a mixture comprising on a weight basis

(1) about 10 to 25 percent calcium oxide,

(2) about 5 to 20 percent calcium chloride,

(3) about 0 to 20 percent of calcium sulfate,

(4) about 10 to 20 percent of particulated silicious material chosen from the group consisting of diatomite, diatomaceous earth, tripolite and chert,

(5) about 0 to 10 percent iron oxide, and

(6) about 0 to 10 percent Portland cement;

(d) mixing on a weight basis from about 10 to 50 percent of the first slurry and from about 3 to 10 percent of the second dry concentrate with from 40 to 80 percent of a third supplement mixture comprising on a weight basis;

(1) about from 5 to 40 percent Portland cement,

(2) about from 10 to 35 percent fiber, at least part of which is processed wood fiber, and

(3) about from 10 to 50 percent particulated silicious material chosen from the group consisting of diatomite, diatomaceous earth, tripolite and chert.

2. The process of forming a moldable, settable cementuous construction composition containing wood fibers, including at least:

(a) boiling a mixture of calcium oxide, silicious material chosen from the group consisting of diatomite, diatomaceous earth, tripolite and chert, and fiber including at least wood fiber in water for at least two hours to form a slurry,

(b) ball milling a mixture of calcium salts, including at least calcium oxide and calcium chloride, and particulated silicious material for at least thirty minutes to form a dry concentrate, and

(c) combining and mixing the first slurry and the dry concentrate with additional cement, fiber and siliceous material to form a construction composition.

3. The method of claim 2 further characterized by:

(a) molding the construction composition in a mold, and

(b) subjecting the molded construction composition to pressure to extract a portion of contained water therefrom to form a self-supporting product.

4. The method of claim 3 further comprising:

(a) unmolding the molded and pressed product and

(b) curing the unmolded product at a temperature of from 37 to 94 degrees C. for a period of at least 12 hours.