Calcium sulfoaluminate cement-containing inorganic polymer compositions and methods of making same

• US 8,864,901 B2
• Filed: 11/30/2011
• Issued: 10/21/2014
• Est. Priority Date: 11/30/2011
• Status: Expired due to Fees

• Current Assignee: Westlake Royal Building Products Incorporated
• Original Assignee: Boral Ip Holdings (Australia) Pty Limited (Seven Group Holdings Limited)
• Inventors: Lloyd, Redmond Richard, Keyte, Louise Margaret, Hill, Russell L., Zhang, Zhaozhou, Hollett, Mark, Ai, Li
• Primary Examiner(s): MARCANTONI, PAUL D
• Application Number:
  US13/307,188
• Publication Number:
  US 20130133554A1
• Time in Patent Office: 1,056 Days
• Field of Search: 106/692, 106/705, 106/724, 106/728, 106/819, 106/823
• US Class Current: 106/692
• CPC Class Codes: C04B 18/027 Lightweight materials
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 2103/20 Retarders
• CPC Class Codes: C04B 2111/10 Compositions or ingredients thereof characterised by the absence or the very low content of a specific material
• CPC Class Codes: C04B 2111/1006 Absence of well-defined organic compounds
• CPC Class Codes: C04B 22/0013 Boron compounds
• CPC Class Codes: C04B 22/062 of the alkali or alkaline-earth metals
• CPC Class Codes: C04B 22/143 Calcium-sulfate
• CPC Class Codes: C04B 22/16 containing phosphorus in the anion, e.g. phosphates
• CPC Class Codes: C04B 24/06 containing hydroxy groups
• CPC Class Codes: C04B 28/065 Calcium aluminosulfate cements, e.g. cements hydrating into ettringite
• CPC Class Codes: C04B 7/02 Portland cement
• CPC Class Codes: C04B 7/32 Aluminous cements
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

Inorganic polymer compositions and methods for their preparation are described herein. The compositions include the reaction product of a reactive powder, an activator, and optionally a retardant. The reactive powder includes fly ash, calcium sulfoaluminate cement, and less than 10% by weight portland cement. In some examples, the composition is substantially free from alkanolamines. In some examples, the ratio of water to reactive powder is from 0.06:1 to less than 0.2:1. Also described herein are building materials including the compositions.

Claims

1. An inorganic polymer composition, comprising a reaction product of:

reactive powder comprising fly ash, calcium sulfoaluminate cement, and less than 10% by weight portland cement; and

an activator;

wherein the composition is free from alkanolamines.

2. The composition of claim 1, wherein the calcium sulfoaluminate cement is present in an amount of from 1% to 5% by weight of the reactive powder.

3. The composition of claim 1, wherein the fly ash is present in an amount of greater than 95% by weight of the reactive powder.

4. The composition of claim 1, wherein greater than 75% of the fly ash comprises Class C fly ash.

5. The composition of claim 1, wherein greater than 95% of the fly ash comprises Class C fly ash.

6. The composition of claim 1, wherein the activator includes citric acid.

7. The composition of claim 1, wherein the activator includes sodium hydroxide.

8. The composition of claim 1, wherein the retardant includes borax, boric acid, gypsum, phosphates, gluconates, or a mixture thereof.

9. The composition of claim 1, wherein the reactive powder further comprises calcium aluminate cement.

10. The composition of claim 1, further comprising aggregate.

11. The composition of claim 10, wherein the aggregate includes lightweight aggregate selected from the group consisting of bottom ash, expanded clay, expanded shale, expanded perlite, vermiculite, volcanic tuff, pumice, hollow ceramic spheres, hollow plastic spheres, expanded plastic beads, ground tire rubber, and mixtures thereof.

12. The composition of claim 1, wherein the composition is free from retardants.

20. The composition of claim 1, wherein the activator is selected from the group consisting of citrates, hydroxides, metasilicates, carbonates, aluminates, sulfates, tartrates, and mixtures thereof.

21. The composition of claim 1, wherein the composition has a pH of from 12 to 13.5.

22. The composition of claim 1, wherein the reactive powder includes no portland cement.

26. The composition of claim 1, further comprising water.

27. The composition of claim 1, wherein the reactive powder comprises 85% or greater fly ash, by weight of the reactive powder.

29. The composition of claim 26, wherein the ratio of water to reactive powder is 0.06:

1 to less than 0.2;

1.

30. The composition of claim 29, wherein the ratio of water to reactive powder is from 0.06:

1 to less than 0.17;

1.

31. The composition of claim 30, wherein the ratio of water to reactive powder is from 0.06:

1 to less than 0.15;

1.

32. The composition of claim 31, wherein the ratio of water to reactive powder is from 0.06:

1 to less than 0.14;

1.

13. A method of producing an inorganic polymer composition, comprising:

mixing reactants comprising a reactive powder, and an activator in the presence of water, wherein the reactive powder comprises fly ash, calcium sulfoaluminate cement, and less than 10% by weight portland cement, and wherein the composition is free from alkanolamines; and

allowing the reactants to react to form the inorganic polymer composition.

14. The method of claim 13, wherein the reactants are mixed for a period of 15 seconds or less.

15. The method of claim 13, wherein the mixing is performed at ambient temperature.

16. The method of claim 13, wherein the activator includes citric acid and sodium hydroxide.

17. The method of claim 16, wherein the citric acid and sodium hydroxide are combined prior to mixing with the reactants.

18. The method of claim 16, wherein the weight ratio of citric acid to sodium hydroxide is from 0.4:

1 to 2.0;

1.

19. The method of claim 16, wherein the weight ratio of citric acid to sodium hydroxide is from 1.0:

1 to 1.6;

1.

23. The method of claim 13, wherein the activator is selected from the group consisting of citrates, hydroxides, metasilicates, carbonates, aluminates, sulfates, tartrates, and mixtures thereof.

24. The method of claim 13, wherein the composition has a pH of from 12 to 13.5.

25. The method of claim 13, wherein the reactive powder includes no portland cement.

28. The method of claim 13, wherein the reactive powder comprises 85% or greater fly ash, by weight of the reactive powder.