Compressed low density hydraulically bonded composite articles
First Claim
Patent Images
1. A hydraulically bonded article prepared by the process comprising the steps of:
- a. applying pressure to a substantially unhydrated hydraulic cement composition including a solid removable aggregate dispersed therein within a mold such that the hydraulic cement composition is formed into a mechanically self-supporting structure corresponding substantially to a desired configuration of the hydraulically bonded article and such that air within the hydraulic cement composition is substantially removed;
b. removing the mechanically self-supporting structure from the mold, the mechanically self-supporting structure having sufficient mechanical strength such that it may be hydrated by immersion in water without significant mechanical disruption of the structure;
c. hydrating the hydraulic cement composition of the mechanically self-supporting structure without substantial mechanical mixing of the hydraulic cement composition and water; and
d. removing a substantial portion of the solid removable aggregate from the hydraulic cement composition by causing the solid removable aggregate to undergo a phase change, thereby forming the hydraulically bonded article having void spaces therein.
1 Assignment
0 Petitions
Accused Products
Abstract
Incorporation of solid removable aggregates into powdered cement which later completely dissolve, evaporate, volatilize, or melt leaving voids in the cement composition is discussed. Cementitious articles are prepared by manipulating powdered hydraulic cement or cement paste compositions into mechanically self-supporting structures of a predetermined configuration and thereafter hydrating the hydraulic cement compositions without mechanical mixing of the cement and water.
106 Citations
43 Claims
-
1. A hydraulically bonded article prepared by the process comprising the steps of:
-
a. applying pressure to a substantially unhydrated hydraulic cement composition including a solid removable aggregate dispersed therein within a mold such that the hydraulic cement composition is formed into a mechanically self-supporting structure corresponding substantially to a desired configuration of the hydraulically bonded article and such that air within the hydraulic cement composition is substantially removed; b. removing the mechanically self-supporting structure from the mold, the mechanically self-supporting structure having sufficient mechanical strength such that it may be hydrated by immersion in water without significant mechanical disruption of the structure; c. hydrating the hydraulic cement composition of the mechanically self-supporting structure without substantial mechanical mixing of the hydraulic cement composition and water; and d. removing a substantial portion of the solid removable aggregate from the hydraulic cement composition by causing the solid removable aggregate to undergo a phase change, thereby forming the hydraulically bonded article having void spaces therein. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
-
-
18. A hydraulically bonded article having a low density prepared by the process comprising the steps of:
-
a) placing a substantially unhydrated hydraulic cement composition into a mold, the hydraulic cement composition including a hydraulic cement binder and a removable aggregate; b) compressing the hydraulic cement composition within the mold in order to form the substantially unhydrated hydraulic cement composition into a mechanically self-supporting structure corresponding substantially to a desired configuration of the hydraulically bonded article and to remove a substantial portion of air from within the hydraulic cement composition; c) removing the mechanically self-supporting structure from the mold, the mechanically self-supporting structure having sufficient mechanical strength such that it may be hydrated by immersion in water without significant mechanical disruption of the structure; d) hydrating the hydraulic cement composition of the mechanical self-supporting structure with water without substantial mechanical mixing of the hydraulic cement composition and water; and e) removing the removable aggregate from the hydraulic cement composition of the mechanically self-supporting structure by causing the removable aggregate to undergo a phase change, the removal of the removable aggregate leaving a predetermined level of porosity within the hydraulically bonded article, thereby forming the hydraulically bonded article having low density. - View Dependent Claims (19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35)
-
-
36. An article prepared by the process comprising the steps of:
-
a) placing a substantially unhydrated cement composition into a mold, the hydraulic cement composition including hydraulic cement particles, nonremovable aggregate particles, and removable aggregate particles, the hydraulic cement particles and nonremovable aggregate particles having a particle size distribution that maximizes the packing density of the hydraulic cement composition; b) forming the hydraulic cement composition under pressure into a substantially unhydrated, mechanically self-supporting structure corresponding substantially to a desired configuration of the article and such that air within said unhydrated hydraulic cement composition is substantially removed; and c) removing the mechanically self-supporting structure from the mold, the substantially unhydrated structure having sufficient mechanical strength such that it may be hydrated by immersion in water without significant mechanical disruption of the structure. - View Dependent Claims (37, 38, 39, 40, 41, 42, 43)
-
Specification