Pumpably verifiable fluid fiber compositions

• US 6,790,275 B2
• Filed: 03/29/2002
• Issued: 09/14/2004
• Est. Priority Date: 09/25/2001
• Status: Expired due to Fees

• Current Assignee: W R Grace & Company - CONN (WR Grace & Company)
• Original Assignee: W R Grace & Company - CONN (WR Grace & Company)
• Inventors: Buchanan, Michael, Westgate, Paul, Shen, Ding Feng, Fierke, Randall, Indge, Donald, Agresti, David, Verrill, Jessica, Ranganathan, Anandakumar, Rieder, Klaus-Alexander, Macklin, Michael B.
• Primary Examiner(s): Marcantoni, Paul
• Application Number:
  US10/113,441
• Publication Number:
  US 20030056695A1
• Time in Patent Office: 900 Days
• Field of Search: 106/644, 106/724, 106/802
• US Class Current: 106/644
• CPC Class Codes: B28C 5/404 Pre-treatment of fibres
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/062 Microsilica, e.g. colloïdal silica preparing microsilica slurries or suspensions C04B18/148
• CPC Class Codes: C04B 14/08 Diatomaceous earth
• CPC Class Codes: C04B 14/18 Perlite
• CPC Class Codes: C04B 14/202 Vermiculite
• CPC Class Codes: C04B 14/386 Carbon carbon nanotubes C04B14/026
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 16/06 fibrous
• CPC Class Codes: C04B 16/0616 from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: C04B 16/0625 Polyalkenes, e.g. polyethylene
• CPC Class Codes: C04B 16/0633 Polypropylene
• CPC Class Codes: C04B 18/02 Agglomerated materials , e.g. artificial aggregates
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 20/008 Micro- or nanosized fillers, e.g. micronised fillers with particle size smaller than that of the hydraulic binder colloidal silica C04B14/062 ; silica fume C04B18/146
• CPC Class Codes: C04B 20/1018 with organic materials pigments or dyes C04B20/1096
• CPC Class Codes: C04B 2103/00 Function or property of ingredients for mortars, concrete or artificial stone
• CPC Class Codes: C04B 2103/0057 added as redispersable powders
• CPC Class Codes: C04B 2103/44 : Thickening, gelling or viscosity increasing agents
• CPC Class Codes: C04B 2111/21 : Efflorescence resistance
• CPC Class Codes: C04B 22/002 : Water
• CPC Class Codes: C04B 24/02 : Alcohols; Phenols; Ethers
• CPC Class Codes: C04B 24/22 : Condensation or polymerisation products thereof
• CPC Class Codes: C04B 24/2641 : Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 24/2676 : Polystyrenes
• CPC Class Codes: C04B 24/32 : Polyethers, e.g. alkylphenol polyglycolether
• CPC Class Codes: C04B 24/38 : Polysaccharides or derivatives thereof C04B24/243 takes precedence
• CPC Class Codes: C04B 24/383 : Cellulose or derivatives thereof
• CPC Class Codes: C04B 28/02 : containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/06 : Aluminous cements monolithic refractories or refractory mortars C04B35/66
• CPC Class Codes: C04B 40/0039 : Premixtures of ingredients
• CPC Class Codes: C04B 40/0263 : Hardening promoted by a rise in temperature C04B40/024 takes precedence
• CPC Class Codes: C04B 41/4884 : Polyurethanes; Polyisocyanates
• CPC Class Codes: E04C 5/073 : Discrete reinforcing elements, e.g. fibres
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

The invention relates to fiber compositions that can be pumped and metered in the fashion of fluid chemical admixtures into a concrete mix, thereby enabling the fibers to be dispensed by concrete ready-mix plant operators who can provide verification of fiber administration and dosage. The fibers, particularly plastic shrinkage control fibers having large cumulative surface area, are suspended in an aqueous or non-aqueous medium such that their surface area is already wetted out, thereby virtually assuring that substantial uniform fiber dispersion can be achieved without clumping and the delay that is usually required by fiber intermixing.

Claims

1. A fiber composition, comprising:

a plurality of fibers suspended in the form of bundles in an aqueous or non-aqueous environment which, if comprising water, is essentially devoid of a water-settable inorganic binder material;

said fibers having a mean transverse dimension no less than 5 μ

m and wherein said fibers have a mean transverse dimension no greater than 100 μ

m;

said fibers having two opposed ends connected by an elongate intermediate body, the average length of said fiber bodies being no less than 5 mm (millimeter), the average length of said fiber bodies being no greater than 50 mm, the mean transverse dimension of said fiber bodies being no less than 5 μ

m, and the mean transverse dimension of said fiber bodies being no greater than 100 μ

m;

said fibers being in an amount no less than 5 percent based on total weight of composition;

said fibers being in an amount no greater than 40 percent based on total weight of composition;

said aqueous or non-aqueous environment having a viscosity no less than 5,000 milliPascal seconds as measured by Brookfield viscometer at 25 degrees C.;

said aqueous or non-aqueous environment having a viscosity no greater than 200,000 milliPascal seconds as measured by Brookfield viscometer at 25 degrees C.;

said aqueous or non-aqueous environment having at least one viscosity modifier for increasing viscosity within said aqueous or non-aqueous environment.

2. The composition of claim 1 wherein said fibers comprise at least one material selected from the group consisting of polyethylene, high density polyethylene, low density polyethylene, ultra high molecular weight polyethylene, polypropylene, polyoxymethylene, polyacrylate, polyvinyl acetate, polyester, polyamide, thermotropic liquid crystal polymers, regenerated cellulose, natural fibers, carbon fibers and glass fibers.

3. The composition of claim 1 wherein said fibers comprise a polyolefin.

4. The composition of claim 1 wherein said fibers comprise polypropylene.

5. The composition of claim 1 wherein said fibers have a mean transverse dimension no less than 15 μ

m and said fibers have a mean transverse dimension no greater than 35 μ

m.

6. The composition of claim 1 wherein said plurality of fibers are comprised of fibers having two opposed ends connected by an elongate intermediate body, the average length of said fiber bodies being no less than 10 mm, the average length of said fiber bodies being no greater than 20 mm, the mean transverse dimension of said fiber bodies being no less than 15 μ

m, and the mean transverse dimension of said fiber bodies being no greater than 35 μ

m.

7. The composition of claim 1 wherein

said fibers are present in an amount no less than 15 percent based on total weight of the composition; and said fibers are present in an amount no greater than 25 percent based on total weight of the composition.

8. The composition of claim 1 wherein

said aqueous or non-aqueous environment has a viscosity no less than 7,500 milliPascal seconds as measured by Brookfield viscometer at 25 degrees C. and 1 rpm;

and

said aqueous or non-aqueous environment has a viscosity no greater than 50,000 milliPascal seconds as measured by Brookfield viscometer at 25 degrees C. and 60 rpm.

9. The composition of claim 1 wherein

said aqueous or non-aqueous environment has a viscosity no less than 10,000 milliPascal seconds as measured by Brookfield viscometer at 25 degrees C. and 1 rpm;

and

said aqueous or non-aqueous environment has a viscosity no greater than 20,000 milliPascal seconds as measured by Brookfield viscometer at 25 degrees C. and 60 rpm.

10. The composition of claim 1 wherein said at least one viscosity modifier comprises:

an acrylic acid or salt thereof;

a polysulfonic acid or salt thereof;

a polyvinyl alcohol;

a polyethylene glycol;

a polyethylene oxide;

a polysaccharide or derivative thereof;

a non-water-settable inorganic material;

or a mixture of the foregoing.

11. The composition of claim 1 wherein said at least one viscosity modifier is selected form the group consisting of hydroxy propyl methylcellulose, welan gum, and xanthan gum.

12. The composition of claim 1 wherein said at least one viscosity modifier is present in an amount no less than 0.5 percent based on weight of composition and said at least one viscosity modifier is present in an amount no greater than 5.0 percent based on weight of composition.

13. The composition of claim 1 further comprising an admixture selected from the group consisting of a superplastizicer, water reducer, strength enhancer, concrete-fiber bond enhancement agent, air entrainer, air detrainer, corrosion inhibitor, set accelerator, set retarder, shrinkage reducing admixture, fly ash, silica fume, pigment, finish enhancing chemicals, internal curing compounds, or a mixture thereof.

14. The composition of claim 1 wherein fibers are coated with a wetting agent prior to being suspended in said aqueous or non-aqueous suspension.

15. A method for modifying a matrix material, comprising:

dispensing the fiber composition of claim 1 into a matrix composition.

16. The method of claim 15 wherein said matrix composition is cementitious.

17. The method of claim 16 wherein said fiber composition is pumped and metered into said matrix composition.

20. The fiber composition of claim 1 wherein said environment comprises an aqueous suspension.

21. The fiber composition of claim 1 wherein said environment comprises a non-aqueous suspension.

22. The fiber composition of claim 1 wherein said environment has a viscosity of 5,000-200,000 milliPascal seconds measured using Brookfield viscometer, 1 rpm, 25 degrees C.

23. The fiber composition of claim 22 wherein said environment has a shear thinning characteristic in terms of viscosity ratio Brookfield viscometer, Spindle #3, 25 degrees C. wherein viscosity measured at 3 rpm, divided by viscosity measured at 30 rpm, is no less than 2 and no greater than 40.

24. The fiber composition of claim 23 wherein said viscosity ratio is no less than 4 and no greater than 20.

25. The fiber composition of claim 21 wherein said non-aqueous suspension comprises a material selected from an alcohol.

26. The fiber composition of claim 21 further comprising a viscosity modifier comprising a non-water-settable inorganic or organic material.

27. The fiber composition of claim 26 wherein said viscosity modifier comprises a metal oxide, a silica, a fly ash, glass flakes, nanoclay, talc, mica, or mixture thereof.

28. The fiber composition of claim 21 wherein said non-aqueous suspension comprises an alkylene or oxyalkylene glycol or glycerol, or an ether, ester, or other derivative thereof.

29. The fiber composition of claim 21 wherein said non-aqueous suspension comprises a polyoxyalkylene glycol or glycerol or derivative thereof.

30. The fiber composition of claim 1, wherein said fiber bundles are operative to retain a significant fraction of the bundle structure through at least two successive pumping events.

31. The fiber composition of claim 30 wherein said fiber bundles are operative to maintain a significant fraction of the bundle structure when pumped into a storage tank and thereafter pumped into a hydratable cementitious composition, said fiber bundles being subsequently operative to disperse into individual fibers upon mixing of the hydratable cementitious composition.

32. The fiber composition of claim 1 wherein said non-aqueous suspension comprises a composition having alkyl ether oxyalkylene adducts and oxyalkylene glycol.

33. The fiber composition of claim 1 wherein said non-aqueous suspension comprises a polyoxyalkylene glycol represented by the formula HO(AO)_mH wherein A represents an alkylene group, O represents an oxygen atom, and m represents an integer in the range of 1-3.

18. A method for admixing fibers comprising:

pumping into a hydratable cementitious composition a plurality of fibers suspended in an aqueous or non-aqueous environment essentially devoid of a water-settable inorganic binder material;

said fibers being in an amount no less than 5 percent based on total weight of composition;

said fibers being in an amount no greater than 40 percent based on total weight of composition;

said aqueous environment having a viscosity no less than 5,000 milliPascal seconds as measured by Brookfield viscometer at 25 degrees C. and 1 rpm;

said aqueous or non-aqueous environment having a viscosity no greater than 200,000 milliPascal seconds as measured by Brookfield viscometer at 25 degrees C. and 1 rpm; and

said aqueous or non-aqueous environment having at least one viscosity modifier for increasing the water within said aqueous environment.

19. The method of claim 18 wherein said fibers are made from a polypropylene, a polyethylene, or a mixture thereof;

and said plurality of fibers comprise fibers having two opposed ends connected by an elongate intermediate body, the average length of said fiber bodies being no less than 5 mm, the average length of said fiber bodies being no greater than 50 mm, the mean transverse dimension of said fiber bodies being no less than 5 μ

m, and the mean transverse dimension of said fiber bodies being no greater than 100 μ

m.