Method of producing formed articles of a fiber reinforced, hydraulically setting material

• US 5,795,515 A
• Filed: 07/08/1996
• Issued: 08/18/1998
• Est. Priority Date: 08/16/1995
• Status: Expired due to Term

• Current Assignee: The Plycem Company Inc. (Mexalit Industrial SA de CV)
• Original Assignee: Nueva AG
• Inventors: Fischer, Hans
• Primary Examiner(s): DERRINGTON, JAMES H
• Application Number:
  US08/676,482
• Time in Patent Office: 771 Days
• Field of Search: 264/82, 264/333, 162/145, 162/181.3, 162/181.6, 162/156, 162/157.2, 162/157.6, 162/123
• US Class Current: 264/82
• CPC Class Codes: C04B 14/062 Microsilica, e.g. colloïdal silica preparing microsilica slurries or suspensions C04B18/148
• CPC Class Codes: C04B 14/28 of calcium
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 14/46 Rock wool ; Ceramic or silicate fibres C04B14/40, C04B14/42 take precedence
• CPC Class Codes: C04B 16/06 fibrous
• CPC Class Codes: C04B 18/06 Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
• CPC Class Codes: C04B 18/141 Slags
• 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 18/28 Mineralising; Compositions therefor
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 22/148 Aluminium-sulfate
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 40/0064 Processes of the Magnini or Hatscheck type
• CPC Class Codes: C04B 40/0231 Carbon dioxide hardening
• CPC Class Codes: C04B 40/0263 Hardening promoted by a rise in temperature C04B40/024 takes precedence
• CPC Class Codes: C04B 40/0281 Hardening in an atmosphere of increased relative humidity
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

At the method of producing formed articles of a fiber reinforced, hydraulically setting material the organic fibers are mineralized by aluminum sulfate and silica, the mixture processed with excess water to multilayered products, the laminates arrived therewith are then set in two steps and finally the formed articles produced treated by CO₂ for a pre-carbonization.

Claims

1. A method of producing formed articles of a fiber reinforced hydraulically setting material in a Hatschek process whereby hydraulic binding agents and organic reinforcing fibers as constituents are mixed with water in an amount of 250-500% based on the dry weight of the constituents, comprising the steps of admixing aluminum sulfate and silica for mineralizing the organic reinforcing fibers,

thereafter processing said constituents with admixed aluminum sulfate and silica in the Hatschek process to obtain multilayered parts with damp laminates,

presetting the damp laminates in molds in an environment of a high relative humidity and temperature,

removing the laminates from the mold and letting them set for a plurality of days, and

thereafter subjecting the laminates to temperatures between 45°

and 125°

C. in a humid environment to a treatment by CO₂ thereby precarbonizing the laminates.

2. The method of claim 1, comprising further the step of adding aluminum sulfate in an amount of 3-25% and silica in an amount of 4-30%, each based on the dry weight of the fibers.

3. The method of claim 1, wherein the presetting proceeds during 6 to maximal 20 hours at at least 40 to maximal 110°

C. and a relative humidity in the range between 60-97%.

4. The method of claim 1, wherein the admixing step further comprises stabilizing the laminates at temperatures between 45°

and 125°

C.

5. The method of claim 1, wherein CO₂ is added in an amount of 4-15% of volume which leads to a precarbonization of 25-85%.

6. The method of claim 1, wherein the organic reinforcement fibers consist of cellulose and have a length of 0.2-6 millimeters, preferably 0.3-4 millimeters.

7. The method of claim 1, further comprising addition of filler materials selected from the group consisting of limestone powder, ashes or blast furnace slag.

8. The method of claim 7, wherein the following constituents by weight are used:

space="preserve" listing-type="tabular">______________________________________ Binding agents (cement) 60-85% Filler Filler! materials 5-30% and Organic and mineralized process fibers 1-5%! Organic and mineralized reinforcing fibers reinforcement! 4-10% ______________________________________

9. The method of claim 1, wherein formed articles having 5 to 50 layers are produced.

10. The method of claim 9 including the step of producing said layers of various thicknesses.

11. The method of claim 1 wherein filler materials are mixed with the constituents.

12. The method of claim 1 further comprising the step of adding fibers selected from the group consisting of glass fibers, synthetic fibers and mineral wool fibers.

13. The method of claim 12 further comprising adding the fibers in a percentage of 1 to 5% by weight.