Cement based armor panel system

• US 8,061,257 B2
• Filed: 02/27/2009
• Issued: 11/22/2011
• Est. Priority Date: 03/03/2008
• Status: Active Grant

• Current Assignee: United States Of America As Represented By The Secretary Of The Army (Government of the United States of America)
• Original Assignee: United States Gypsum Company (GEBR Knauf Verwaltungsgesellschaft KG)
• Inventors: Stinson, Ryan, Frank, William A., Boone, Nicholas, Tonyan, Timothy D., Kinnebrew, Pamela G., Roth, Michael J., Heard, William F., Durst, Bartley P., Cummins, Toney K., Johnson, Carol F., Davis, James L., Natesaiyer, Kumar, Dubey, Ashish, Slawson, Thomas
• Primary Examiner(s): Johnson; Stephen M
• Assistant Examiner(s): Abdosh; Samir
• Application Number:
  US12/394,564
• Publication Number:
  US 20100229715A1
• Time in Patent Office: 998 Days
• Field of Search: 89/360.2, 89901-939, 428/911, 109/49.5
• US Class Current: 89/36.02
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 18/146 Silica fume
• 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 20/0096 Fillers with bimodal grain size distribution
• CPC Class Codes: C04B 2103/20 Retarders
• CPC Class Codes: C04B 2111/2038 Resistance against physical degradation
• CPC Class Codes: C04B 24/06 containing hydroxy groups
• CPC Class Codes: C04B 24/122 Hydroxy amines
• CPC Class Codes: C04B 24/2647 containing polyether side chains
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: F41H 5/0428 Ceramic layers in combination with additional layers made of fibres, fabrics or plastics
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10S 428/911 Penetration resistant layer

Abstract

A cementitious armor panel assembly including cementitious armor panel with ballistic and blast resistant properties attached to a frame structure to produce a protective structure. The cementitious armor panels have a continuous phase resulting from the curing of an aqueous mixture of an inorganic cement binder, an inorganic mineral filler having a particle size of about 150-450 microns, a pozzolanic mineral filler, a polycarboxylate based superplasticizer self-leveling agent, and water. The mixture may also contain alkanolamine, and acid or acid salt. Prior to curing, the continuous phase is reinforced with fiber uniformly distributed in the continuous phase before it is cured to form the panel. The panel may be reinforced with a skin attached to at least one surface of the panel.

Claims

1. A cementitious armor panel system comprising:

a frame;

a blast resistant cementitious panel supported on the frame,

the blast resistant cementitious armor panel comprising;

a reinforcing fiber uniformly distributed within a cementitious core comprising a continuous phase resulting from the curing of a self-leveling aqueous mixture of 25-45 weight % inorganic cement binder,

an absence of silica flour,

35-65 weight % sand filler having a median particle size of 150-450 microns,

5-15 weight % pozzolanic filler having a median particle size of less than or equal to 50 microns,

0.25-5.0 weight % polycarboxylate based self-leveling agent, and

6-12 weight % water, wherein the weight ratio of water to the combined weight of the inorganic cement binder and pozzolanic filler dry reactive powders is less than or equal to 0.35;

1.0, and

a skin-layer attached to at least one surface of the cured continuous phase.

2. The panel of claim 1, wherein the cementitious core comprises the reinforcing fiber in an amount of 0.5-6.0% by volume of the cementitious core, the sand filler having a median particle size of 200-350 microns, and having a compressive strength of at least 10,000 psi.

3. The system of claim 1, wherein the cementitious panel has a compressive strength of more than 25,000 psi when cured.

4. The system of claim 1, wherein the skin-layer is a fiberglass reinforced plastic.

5. The system of claim 1, wherein the compressive strength after 1 day curing is less than 2000 psi and the compressive strength develops to more than 20,000 psi after curing for 28 days.

6. The system of claim 1, wherein the weight ratio of pozzolanic filler to inorganic cement binder is 0.05 to 0.30:

1.0.

7. The system of claim 1, wherein the weight ratio of sand filler to the combined weight of inorganic cement binder and pozzolanic filler is 0.75 to about 1.50:

1.0.

8. The system of claim 1, wherein the weight ratio of water to the combined weight of the inorganic cement binder and pozzolanic filler dry reactive powders is less than or equal to 0.20:

1.0.

9. The system of claim 1, wherein the pozzolanic filler is silica fume.

10. The system of claim 1, wherein the continuous phase comprises 0.75-2.5 weight % polycarboxylate polyether self-leveling agent.

11. The system of claim 1, wherein the skin-layer is mechanically fastened to the cementitious core.

12. The system of claim 1, wherein the frame is a metal frame and has a channel for receiving the cementitious panels in a laid in structure on at least one surface of the metal frame and clips are attached to the frame having the channel for receiving the cementitious panels in the laid in structure on at least one surface of the metal frame.

13. The system of claim 1, wherein the cementitious panels have pre-drilled holes for use with mechanical fasteners for attaching the panels to the frame structure.

14. The system of claim 4, wherein the cementitious panels are adhesively attached to the frame structure.

15. The system of claim 1, comprising said frame, a first said panel on one side of the frame, a second said panel on an opposed side of the frame, and an infill material in a cavity in the frame formed between the first and second panels.

16. The system of claim 15, wherein the infill material is selected from the group consisting of concrete, sand, cellular concrete, and light weight aggregate.

17. The system of claim 1, wherein there is more than one frame structure and the cementitious panels are attached to opposed sides of the frame structures.

18. The system of claim 1, wherein the frame structure is in the form of metal studs arranged in the form of a wall structure and the cementitious armor panels are attached to at least one side of the frame structure to form a wall.

19. The system of claim 1, wherein the assembly is comprised of frames formed in the shape of an easel with cross supports joining the frame structures and the panel is laid into channels formed by clips which are attached to the frame.

20. A cementitious armor panel system comprising:

a frame;

a blast resistant cementitious panel supported on the frame,

the panel comprising;

a cementitious core comprising

a continuous phase resulting from the curing of a self-leveling aqueous mixture of 25-45 weight % inorganic cement binder,

an absence of silica flour, 35-65 weight % sand filler having a median particle size of 250-350 microns,

5-15 weight % pozzolanic filler having a median particle size of less than or equal to 0.1 microns,

1.0-1.25 weight % polycarboxylate based self-leveling agent,

triethanolamine in an amount of 0.025 wt. % to 0.075 wt. % by weight of the cement binder,

tartaric acid in an amount of 0.40 wt. % to 0.60 wt. % by weight of the combined weight of the cement binder and pozzolanic filler, and

6-12 weight % water, wherein the weight ratio of water to the combined weight of the inorganic cement binder and pozzolanic filler dry reactive powders is less than or equal to 0.25;

1.0,

reinforcing glass fiber in an amount of 3.0-3.5% by volume of the cementitious core uniformly distributed within the continuous phase before the continuous phase is cured, and

a fiber glass reinforced plastic skin layer attached to at least one surface of the cured continuous phase.