Formed building materials

• US 8,869,477 B2
• Filed: 10/31/2011
• Issued: 10/28/2014
• Est. Priority Date: 09/30/2008
• Status: Active Grant

• Current Assignee: Arelac, Inc.
• Original Assignee: Calera Corporation
• Inventors: Calas, Guillaume, Lu, Peng, Camire, Chris, Bourcier, William, Kendall, Treavor, Chen, Irvin, Devenney, Martin, Ha, Eric
• Primary Examiner(s): DRODGE, JOSEPH W
• Application Number:
  US13/285,534
• Publication Number:
  US 20120082839A1
• Time in Patent Office: 1,093 Days
• Field of Search: 522/231, 522/236, 522/238, 522/231.4, 522/234, 522/92, 522/94, 523/091.7, 525/96, 527/821, 527/911, 527/991, 951/49, 952/05, 106/15.05, 106/463, 106/464, 106/638, 106/644, 106/719, 106/720, 106/724, 106/728, 106/729, 106/705, 106/772, 106/78, 106/9, 106/817, 210/652, 210/702, 210/710, 210/806, 423/220, 423/223, 423/232, 423/419.1, 423/420.2, 423/430, 423/431, 423/437.1, 423/438, 423/439, 423/441, 428/537.7
• US Class Current: 52/223.6
• CPC Class Codes: B01D 2257/504 Carbon dioxide
• CPC Class Codes: B28B 17/02 Conditioning the material prior to shaping for mixtures containing clay or cement B28C
• CPC Class Codes: B28B 5/00 Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 14/28 of calcium
• CPC Class Codes: C04B 16/04 Macromolecular compounds C04B16/02 takes precedence
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 18/162 Cement kiln dust; Lime kiln dust
• CPC Class Codes: C04B 18/241 Paper, e.g. waste paper; Paper pulp
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 2103/0086 Chelating or complexing agents
• CPC Class Codes: C04B 2103/10 Accelerators; Activators
• CPC Class Codes: C04B 2103/22 Set retarders
• CPC Class Codes: C04B 2103/30 Water reducers, plasticisers, air-entrainers, flow improvers
• CPC Class Codes: C04B 2103/67 Biocides
• CPC Class Codes: C04B 2111/00017 Aspects relating to the protection of the environment
• CPC Class Codes: C04B 2111/0062 Gypsum-paper board like materials
• CPC Class Codes: C04B 2111/00629 the covering sheets being made of material other than paper
• CPC Class Codes: C04B 22/10 containing carbon in the anion
• CPC Class Codes: C04B 22/106 : Bicarbonates
• CPC Class Codes: C04B 24/2623 : Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 28/02 : containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/04 : Portland cements
• CPC Class Codes: C04B 28/14 : containing calcium sulfate cements gypsum-paper plates E04C
• CPC Class Codes: C04B 38/0074 : expressed as porosity percentage
• CPC Class Codes: C04B 38/10 : by using foaming agents C04B38/02 takes precedenceor by using mechanical means, e.g. adding preformed foam
• CPC Class Codes: E01C 5/04 : made of bricks of asphalt bricks E01C5/12
• CPC Class Codes: E01C 5/06 : made of units with cement or like binders
• CPC Class Codes: E01C 5/065 : characterised by their structure or component materials, e.g. concrete layers of different structure, special additives
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10T 428/31996 : Next to layer of metal salt [e.g., plasterboard, etc.]

Abstract

Formed building materials comprising a sequestered CO₂ are provided. The building materials of the invention include a composition comprising a carbonate/bicarbonate component. Additional aspects of the invention include methods of making and using the formed building materials.

Claims

1. A lightweight construction panel, comprising:

at least 50% w/w sequestered-CO₂ component, wherein the sequestered-CO₂ component comprises metastable carbonate selected from the group consisting of vaterite, aragonite, and combination thereof, wherein the sequestered-CO₂ component has a δ

¹³ C less than -15%, and wherein the lightweight construction panel has a porosity of at least 30%.

2. The lightweight construction panel of claim 1, wherein the construction panel has a porosity of between 30-90%.

3. The lightweight construction panel of claim 1, wherein the construction panel further comprises one or more additives selected from anti-desiccant, plasticizer, fibrous material, accelerator, set retarder, foaming agent, mildew resistance agent, fire resistance agent, and polyvinyl alcohol.

4. The lightweight construction panel of claim 1, wherein the construction panel further comprises recycled material selected from fly ash, slag, cement kiln dust, and combinations thereof.

5. The lightweight construction panel of claim 1, wherein the construction panel comprises between 50-99% w/w carbonate or combination of carbonate and bicarbonate.

6. The lightweight construction panel of claim 1, wherein the construction panel further comprises at least one additional component selected from clay, shale, soft slate, calcium silicate, quarried stone, Portland cement, metakaolin, cement, aggregate, silica fume, and pozzolan.

7. The lightweight construction panel of claim 1, wherein the construction panel is a cement board.

8. The lightweight construction panel of claim 7, wherein the cement board has a flexural strength of between 1-7.5 MPa, compressive strength of between 5-50 MPa, or both.

9. The lightweight construction panel of claim 1, wherein the construction panel is a drywall product.

10. The lightweight construction panel of claim 1, wherein the construction panel is a fiber-cement siding.

11. The lightweight construction panel of claim 10, wherein the fiber-cement siding has a flexural strength of between 0.5-5 MPa, compressive strength of between 2-25 MPa, or both.

21. The lightweight construction panel of claim 9, wherein the drywall has a flexural strength of between 0.1-3 MPa, compressive strength of between 1-40 MPa, or both.

22. The lightweight construction panel of claim 9, wherein the drywall product further comprises paper pulp.

23. The lightweight construction panel of claim 9, wherein the drywall product has a flexural strength between 0.1 to 3 MPa.

24. The lightweight construction panel of claim 9, wherein the drywall product does not comprise paper.

25. The lightweight construction panel of claim 9, wherein the drywall product further comprises two sheets of paper or fiberglass on an exterior of the drywall product.

12. A method for producing a construction panel, comprising:

a) processing a waste gas stream comprising carbon dioxide with a process water to produce a composition wherein the composition comprises a metastable carbonate comprising vaterite, wherein the vaterite has a δ

¹³ C less than -15%;

b) producing a slurry mixture from the composition; and

c) processing the slurry mixture to form a lightweight construction panel wherein the construction panel comprises at least 50% w/w aragonite and has a porosity of between 30-90%.

13. The method of claim 12, comprising transforming the vaterite to aragonite when the lightweight construction panel is formed.

14. The method of claim 12, further comprising concentrating the composition to dryness to produce a dry composition.

15. The method of claim 12, wherein the method further comprises adding one or more additives to the slurry mixture, wherein the one or more additives are selected from the group consisting of anti-desiccant, fibrous material, accelerator, set retarder, plasticizer, foaming agent, polyvinyl alcohol, fire resistance agent, and mildew resistance agent.

16. The method of claim 12, wherein the method further comprises adding recycled material to the slurry mixture wherein the recycled material is selected from the group consisting of fly ash, slag, cement kiln dust, and combinations thereof.

17. The method of claim 12, further comprising depositing the slurry mixture in a mold without backing material, or between two sheets of backing material, wherein the backing material comprises sheets of paper or fiberglass.

18. A lightweight construction panel produced in accordance with method claim 12.

19. The method of claim 12, wherein the method further comprises adding at least one additional component to the slurry mixture selected from clay, shale, soft slate, calcium silicate, quarried stone, Portland cement, metakaolin, cement, aggregate, silica fume, and pozzolan.

20. The method of claim 12 wherein the lightweight construction panel is cement board, fiber-cement siding, or drywall.