Pervious composite materials, methods of production and uses thereof

• US 9,938,189 B2
• Filed: 06/04/2014
• Issued: 04/10/2018
• Est. Priority Date: 06/07/2013
• Status: Active Grant

• Current Assignee: Solidia Technologies, Inc.
• Original Assignee: Solidia Technologies, Inc.
• Inventors: Kuppler, John, Patten, Devin, Ravikumar, Deepak, Deo, Omkar, Atakan, Vahit
• Primary Examiner(s): Ruthkosky, Mark
• Assistant Examiner(s): Rummel, Julia L
• Application Number:
  US14/295,601
• Publication Number:
  US 20140363665A1
• Time in Patent Office: 1,406 Days
• CPC Class Codes: B28B 11/24 for curing, setting or hardening processes for influencing or modifying the setting or hardening ability of mortars, concrete or artificial stone compositions, in general C04B40/00
• CPC Class Codes: C04B 14/02 Granular materials , e.g. microballoons
• CPC Class Codes: C04B 14/043 Alkaline-earth metal silicates, e.g. wollastonite
• CPC Class Codes: C04B 2/12 in shaft or vertical furnaces shaft or vertical furnaces in general F27B1/00
• CPC Class Codes: C04B 20/1066 Oxides, Hydroxides
• CPC Class Codes: C04B 20/107 Acids or salts thereof
• CPC Class Codes: C04B 20/12 Multiple coating or impregnating
• CPC Class Codes: C04B 2103/0067 the ingredients being formed in situ by chemical reactions or conversion of one or more of the compounds of the composition
• CPC Class Codes: C04B 2103/32 Superplasticisers
• CPC Class Codes: C04B 2111/00284 Materials permeable to liquids
• CPC Class Codes: C04B 28/10 Lime cements or magnesium oxide cements
• CPC Class Codes: C04B 28/18 containing mixtures of the silica-lime type
• CPC Class Codes: C04B 28/188 the Ca-silicates being present in the starting mixture
• CPC Class Codes: C04B 38/0038 by superficial sintering or bonding of particulate matter
• CPC Class Codes: C04B 38/0058 open porosity
• CPC Class Codes: C04B 38/0067 characterised by the density of the end product
• CPC Class Codes: C04B 40/0231 Carbon dioxide hardening
• CPC Class Codes: C04B 40/024 Steam hardening, e.g. in an autoclave
• CPC Class Codes: Y02P 40/18 Carbon capture and storage [CCS]
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249975 : Void shape specified [e.g., crushed, flat, round, etc.]
• CPC Class Codes: Y10T 428/249986 : Void-containing component contains also a solid fiber or solid particle
• CPC Class Codes: Y10T 428/268 : Monolayer with structurally defined element

Abstract

The invention provides novel pervious composite materials that possess excellent physical and performance characteristics of conventional pervious concretes, and methods of production and uses thereof. These composite materials can be readily produced from widely available, low cost raw materials by a process suitable for large-scale production with improved energy consumption, desirable carbon footprint and minimal environmental impact.

Claims

1. A pervious composite material comprising:

a plurality of bonding elements, wherein each bonding element comprises;

a core comprising primarily calcium silicate,

a silica-rich first or inner layer, and

a calcium carbonate-rich second or outer layer;

a plurality of aggregates having sizes of about 0.25 mm to about 25 mm, wherein the aggregates comprise a first group of particle aggregates of a size about ⅛

″

to about ¼

″ and

a second group of particle aggregates of a size about ⅜

″

to about ½

″

; and

a plurality of pores having sizes from about 0.1 mm to about 10 mm, wherein

the plurality of bonding elements and the plurality of aggregates together form one or more bonding matrices and the bonding elements and aggregates are substantially evenly dispersed therein and bonded together; and

the plurality of pores account for from about 5 vol. % to about 40 vol. % of the pervious composite material and form interconnected channels allowing the composite material to be water permeable; and

,

 

whereby

the pervious composite material exhibits a density from about 1,500 kg/m³ to 2,200 kg/m³, a compressive strength from about 3.0 MPa to about 30 MPa, a flexural strength from about 1.0 MPa to about 4.0 MPa, and a hydraulic conductivity from about 100 cm/hr to about 8,000 cm/hr,

wherein the aggregates account for about 50 wt. % to about 85 wt. % of the pervious composite material.

2. The pervious composite material of claim 1, wherein the plurality of bonding elements have a median particle size in the range from about 5 μ

m to about 100 μ

m.

3. The pervious composite material of claim 1, wherein the aggregates comprise a material selected from crushed trap rock, sand, perlite or vermiculite and pea-gravel.

4. The pervious composite material of claim 1, wherein the plurality of bonding elements is chemically transformed from ground calcium silicate and the coarse aggregates are crushed trap rock.

5. The pervious composite material of claim 1, wherein the aggregates account for about 70 wt. % to about 80 wt. % of the pervious composite material.

6. The pervious composite material of claim 1, wherein the plurality of bonding elements are chemically transformed from a precursor calcium silicate other than ground calcium silicate.

7. The pervious composite material of claim 1, wherein the plurality of bonding elements are chemically transformed from a precursor calcium silicate comprising one or more of aluminum, magnesium and iron.

8. The pervious composite material of claim 1, wherein the plurality of pores account for from about 10 vol. % to about 40 vol. % of the pervious composite material.

9. The pervious composite material of claim 8, wherein the plurality of voids account for from about 15 vol. % to about 30 vol. % of the pervious composite material.

10. The pervious composite material of claim 1, wherein the plurality of bonding elements are prepared by chemical transformation from ground calcium silicate by reacting it with CO₂ via a controlled hydrothermal liquid phase sintering process.

11. The pervious composite material of claim 1, wherein the plurality of bonding elements are prepared by chemical transformation from the precursor calcium silicate other than ground calcium silicate by reacting it with CO₂ via a controlled hydrothermal liquid phase sintering process.

12. The pervious composite material of claim 1, exhibiting a density from about 1,600 kg/m³ to 2,200 kg/m³, a compressive strength from about 4.0 MPa to about 30 MPa, a flexural strength from about 1.0 MPa to about 4.0 MPa, and a hydraulic conductivity from about 100 cm/hr to about 6,000 cm/hr.

13. The pervious composite material of claim 12, exhibiting a density from about 1700 kg/m³ to 2100 kg/m³, a compressive strength from about 6.0 MPa to about 24 MPa, a flexural strength from about 2.0 MPa to about 4.0 MPa, and a hydraulic conductivity from about 100 cm/hr to about 5000 cm/hr.

14. The pervious composite material of claim 1, further comprising one or more additives to modify the appearance, physical or mechanical properties of the product.

15. The pervious composite material of claim 14, wherein the one or more additives are selected from plasticizers, retarders, accelerators, and dispersants.

16. The pervious composite material of claim 15, wherein the one or more additives account for less than about 0.5 wt. % of the pervious composite material.

17. The pervious composite material of claim 1, further comprising one or more pigments.

18. The pervious composite material of claim 1, wherein the pigment comprises one or more of black iron oxide, cobalt oxide and chromium oxide.

19. The pervious composite material of claim 1, further comprising one or more of silica fume, fly ash and blast furnace slag, cement-kiln dust, and crusher dust.

20. An article of manufacture made from the pervious composite material of claim 1.

21. The article of manufacture of claim 20, selected from the group consisting of pavements, driveways, parking lots, sidewalks, pathways, tennis courts, well linings, patios, swimming pool decks, noise barriers, and walls.