Carbon fiber-reinforced cementitious composite and method for producing the composite

• US 5,030,282 A
• Filed: 07/10/1989
• Issued: 07/09/1991
• Est. Priority Date: 06/14/1986
• Status: Expired due to Term

• Current Assignee: Taisei Corporation, TOHO Rayon Company Limited
• Original Assignee: Taisei Corporation, TOHO Rayon Company Limited
• Inventors: Sugimoto, Kenji, Saito, Kazuhisa, Aga, Masahide, Suzuki, Kuniomi, Matsuhashi, Toshikazu, Yamamiya, Teruo, Tsuruta, Yutaka, Ogawa, Hiroyasu
• Primary Examiner(s): Kendell, Lorraine T.
• Application Number:
  US07/377,737
• Time in Patent Office: 729 Days
• Field of Search: 428/367, 428/372, 428/408, 428/288, 428/294, 428/297, 428/283, 106/99, 106/85, 106/104, 106/98
• US Class Current: 106/692
• CPC Class Codes: C04B 14/386 Carbon carbon nanotubes C04B14/026
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 20/0076 characterised by the grain distribution
• CPC Class Codes: C04B 2111/00439 Physico-chemical properties of the materials not provided for elsewhere in C04B2111/00
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/28 Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• CPC Class Codes: C04B 2111/30 Nailable or sawable materials
• CPC Class Codes: C04B 2111/94 Electrically conducting materials
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 40/00 Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability active ingredients C04B22/00 - C04B24/00; hardening of a well-defined composition C04B26/00 - C04B28/00; making porous, cellular or lightening C04B38/00; mechanical aspects B28, e.g. conditioning the materials prior to shaping B28B17/02
• CPC Class Codes: C04B 40/06 Inhibiting the setting, e.g. mortars of the deferred action type containing water in breakable containers ; Inhibiting the action of active ingredients
• CPC Class Codes: C04B 7/527 obtaining cements characterised by fineness, e.g. by multi-modal particle size distribution
• CPC Class Codes: E04C 5/07 Reinforcing elements of material other than metal, e.g. of glass, of plastics, or not exclusively made of metal metal elements with non-structural coatings E04C5/01
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10T 428/24993 Fiber is precoated
• CPC Class Codes: Y10T 428/2918 including free carbon or carbide or therewith [not as steel]
• CPC Class Codes: Y10T 428/2927 including structurally defined particulate matter
• CPC Class Codes: Y10T 428/30 Self-sustaining carbon mass or layer with impregnant or other layer

Abstract

A carbon fiber-reinforced cementitious composite having high strength, which comprises continuous carbon fibers and a cured cement composition, comprising cement particles having an average particle size up to about the average diameter of the carbon fibers, the cured cement composition being substantially interposed between the individual carbon fibers; and a method for producing it.

Claims

1. A carbon fiber-reinforced cementitious composite comprising (1) unidirectionally oriented continuous carbon fibers and (2) a cured cement composition which comprises (a) larger cement particles having an average particle size not less than 1/10 of and not more than the average diameter of the carbon fibers, and (b) smaller cement particles having an average particle size of from 1/10 to 1/100 of the average size of the larger cement particles, said smaller cement particles being incorporated in an amount of from 5 to 30% by weight of the amount of the larger cement particles, said cured cement composition being substantially interposed between the individual carbon fibers by impregnation, and said carbon fibers being present in an amount of at least 5% of the total volume of the raw composition for the composite, wherein said carbon fibers are present in an amount of up to 30% of the total volume of the raw composition for the composite and wherein said cement contains no more than 30% by volume based on the total volume of the cement of cement particles having a particle size larger than the average diameter of the carbon fibers.

2. A carbon fiber-reinforced cementitious composite as in claim 1, wherein said carbon fibers have a tensile strength of at least 100 Kgf/mm².

3. A carbon fiber-reinforced cementitious composite as in claim 1, wherein said carbon fibers have a modulus of elasticity of at least 10,000 Kgf/mm².

4. A carbon fiber-reinforced cementitious composite as in claim 1, wherein said carbon fibers have an average diameter of from 1 to 20 μ

m.

5. A carbon fiber-reinforced cementitious composite as in claim 1, wherein the carbon fibers are present in an amount up to 10% of the total volume of the raw composition for the composite.

6. A carbon fiber-reinforced cementitious composite as in claim 1, wherein the carbon fibers are present in an amount of from 10 to 20% of the total volume of the raw composition for the composite for the composite and the cement contains up to 20% by volume based on the total volume of the cement of cement particles having a particle size larger than the average diameter of the carbon fibers.

7. A carbon fiber-reinforced cementitious composite as in claim 1, wherein the carbon fibers are present in an amount greater than 20% of the total volume of the raw composition for the composite and the cement contains up to 10% by volume based on the total volume of the cement of cement particles having a particle size larger than the average diameter of the carbon fibers.

8. A carbon fiber-reinforced cementitious composite as in claim 1, wherein the carbon fibers are present in an amount of from 10 to 20% of the total volume of the raw composition for the composite and the total of the cement particles present in the cement have a particle size no more than 70% of the average diameter of the carbon fibers.

9. A carbon fiber-reinforced cementitious composite as in claim 1, wherein the carbon fibers are present in an amount than 20% of the total volume of the raw composition for the composite and the total of the cement particles present in the cement have an average particle size no more than 60% of the average diameter of the carbon fibers.

10. A carbon fiber-reinforced cementitious composite as in claim 1, wherein said smaller cement particles have a particle size within the range of from 0.01 to 2 μ

m and have a surface area within the range of from 15 to 45 m² /g.

11. A carbon fiber-reinforced cementitious composite as in claim 1, wherein said cement comprises hydraulic inorganic fine powders.

12. A carbon fiber-reinforced cementitious composite as in claim 11, wherein said cement further comprises a cement having latent hydraulic properties.

13. A carbon fiber-reinforced cementitious composite in claim 11, wherein said hydraulic inorganic fine powders are selected from the group consisting of portland cement, blast furnace cement, alumina cement, sulfate resisting cement, and a mixture thereof.

14. A carbon fiber-reinforced cementitious composite as in claim 12, wherein said cement having latent hydraulic properties comprises ultrafine silica particles.

15. A carbon fiber-reinforced cementitious composite as in claim 1, wherein the amount of water is from 20 to 60% by weight based on the total amount of the raw cement used for the composite.

16. A carbon fiber-reinforced cementitious composite as in claim 1, wherein the raw cement composition used for the composite contains at least one of a high-performance water reducing agent, a contraction reducing agent, an expanding agent, a cationic or anionic acrylic polymer, dispersion capable of increasing the tensile strain of the composite, a curing accelerator, and a curing retardant.

17. A carbon fiber-reinforced cementitious composite as in claim 1, wherein said carbon fibers are distributed in the composite such in a cross section that at least 80% of the carbon fibers are from neighboring fibers by a distance at least equal to the a radius of the carbon fibers.

18. A carbon fiber-reinforced cementitious composite as in claim 1, wherein said composite has a void in an amount 0 to 20% by volume based on the volume of the composite.

19. A carbon fiber-reinforced cementitious composite as in claim 1, wherein said carbon fibers have an average diameter of from 4 to 15 μ

m.

20. A carbon fiber-reinforced cementitious composite as in claim 1, wherein said composite contains at least 100 filaments.

21. A carbon fiber-reinforced cementitious composite as in claim 1, wherein said composite contains carbon fibers in an amount of at least 10% of the total volume of the raw composition for the composite.