Foamed concrete composition and process
DCFirst Claim
1. A concrete mix comprising from about 1 to about 50 percent by volume of cement, from about 0 to about 75 percent by volume of washed sand, from about 0 to about 60 percent by volume of coarse aggregate, from about 4 to about 50 percent by volume water, from about 0 to about 50 percent by volume of a member selected from the group consisting of cementitious and pozzolanic materials, from about 0 to about 20 oz of water reducer per 100 pounds of cementitious and pozzolanic material, from about 0 to about 20 oz of accelerator per 100 pounds of cementitious and pozzolanic material, and from about 1 to about 90 percent by volume of air as bubbles comprising from about 0.01 to about 1.0 percent by weight of a foam stabilizing fluorinated surfactant of the formula
wherein Rf is a perfluorinated alkyl selected from the group consisting of straight chain, branched chain, and cyclic perfluoroalkylenes of 1 to about 20 carbon atoms, perfluoroalkyls substituted with perfluoroalkoxy of 2 to about 20 carbon atoms, perfluoroalkyl oligomers and polymers of greater than 10 carbon atoms, and mixtures thereof, E is selected from the group consisting of direct bonds, alkylenes containing from 2 to about 20 carbon atoms and selected from the group consisting of branched chain, straight chain, and cyclic alkylenes, alkylenes interrupted by one or more members selected from the group consisting of, --NR--, --O--, --S--, --SO2 --, --COO--, --OOC--, --CONR--, --NRCO--, --SO2 NR--, --NRSO2 --, --SiR2 --, alkylenes terminated with a member selected from the group consisting of --CONR-- and --SO2 NR-- in which case Rf is attached to the carbon or sulfur atom, and wherein R is selected from the group consisting of hydrogen, alkyl of from 1 to about 10 carbon atoms and hydroxyalkyl having 2 to about 10 carbon atoms, a and b are independently 0 or 1, M1 is a nonionic hydrophilic monomer or mixture of nonionic hydrophilic monomers, and M2 is an anionic hydrophilic monomer or mixture of anionic hydrophilic monomers, wherein x and y are both greater than zero, the sum of x+y is between about 5 and 200, and y/x+y is between about 0.01 and 0.98.
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Abstract
The present invention describes fluorochemical foam stabilizers used in combination with surfactants to yield foams that are exceptionally stable in cementitious media. The stabilized foams that incorporate these fluorochemical agents are useful as novel ultra-lightweight foam aggregates in concrete compositions of tailorable density, strength, and other properties. Methods of making concrete compositions that include such foam aggregates are also described.
42 Citations
24 Claims
- 1. A concrete mix comprising from about 1 to about 50 percent by volume of cement, from about 0 to about 75 percent by volume of washed sand, from about 0 to about 60 percent by volume of coarse aggregate, from about 4 to about 50 percent by volume water, from about 0 to about 50 percent by volume of a member selected from the group consisting of cementitious and pozzolanic materials, from about 0 to about 20 oz of water reducer per 100 pounds of cementitious and pozzolanic material, from about 0 to about 20 oz of accelerator per 100 pounds of cementitious and pozzolanic material, and from about 1 to about 90 percent by volume of air as bubbles comprising from about 0.01 to about 1.0 percent by weight of a foam stabilizing fluorinated surfactant of the formula
- space="preserve" listing-type="equation">R.sub.f --E.sub.a --(S).sub.b --[M.sub.1 ].sub.x --[M.sub.2 ].sub.y --H
wherein Rf is a perfluorinated alkyl selected from the group consisting of straight chain, branched chain, and cyclic perfluoroalkylenes of 1 to about 20 carbon atoms, perfluoroalkyls substituted with perfluoroalkoxy of 2 to about 20 carbon atoms, perfluoroalkyl oligomers and polymers of greater than 10 carbon atoms, and mixtures thereof, E is selected from the group consisting of direct bonds, alkylenes containing from 2 to about 20 carbon atoms and selected from the group consisting of branched chain, straight chain, and cyclic alkylenes, alkylenes interrupted by one or more members selected from the group consisting of, --NR--, --O--, --S--, --SO2 --, --COO--, --OOC--, --CONR--, --NRCO--, --SO2 NR--, --NRSO2 --, --SiR2 --, alkylenes terminated with a member selected from the group consisting of --CONR-- and --SO2 NR-- in which case Rf is attached to the carbon or sulfur atom, and wherein R is selected from the group consisting of hydrogen, alkyl of from 1 to about 10 carbon atoms and hydroxyalkyl having 2 to about 10 carbon atoms, a and b are independently 0 or 1, M1 is a nonionic hydrophilic monomer or mixture of nonionic hydrophilic monomers, and M2 is an anionic hydrophilic monomer or mixture of anionic hydrophilic monomers, wherein x and y are both greater than zero, the sum of x+y is between about 5 and 200, and y/x+y is between about 0.01 and 0.98. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method for producing a stabilized foam concrete mix comprising:
- adding to a concrete mix comprising from about 1 to about 50 percent by volume of cement, from about 0 to about 75 percent by volume of washed sand, from about 0 to about 60 percent by volume of coarse aggregate, from about 4 to about 50 percent by volume water, from about 0 to about 50 percent by volume of a member selected from the group consisting of cementitious and pozzolanic materials, from about 0 to about 20 oz of water reducer per 100 pounds of cementitious and pozzolanic material, and from about 0 to about 20 oz of accelerator per 100 pounds of cementitious and pozzolanic material, a foam aggregate comprising from about 1 to about 90 percent by volume of air as bubbles and comprising from about 0.01 to about 1.0 percent by weight of a foam stabilizing fluorinated surfactant of the formula
space="preserve" listing-type="equation">R.sub.f --E.sub.a --(S).sub.b --[M.sub.1 ].sub.x --[M.sub.2 ].sub.y --Hwherein R is a perfluorinated alkyl selected from the group consisting of straight chain, branched chain, and cyclic perfluoroalkylenes of 1 to about 20 carbon atoms, perfluoroalkyls substituted with perfluoroalkoxy of 2 to about 20 carbon atoms, perfluoroalkyl oligomers and polymers of greater than 10 carbon atoms, and mixtures thereof, E is selected from the group consisting of direct bonds, alkylenes containing from 2 to about 20 carbon atoms and selected from the group consisting of branched chain, straight chain, and cyclic alkylenes, alkylenes interrupted by one or more members selected from the group consisting of, --NR--, --O--, --S--, --SO2 --, --COO--, --OOC--, --CONR--, --NRCO--, --SO2 NR--, --NRSO2 --, --SiR2 --, alkylenes terminated with a member selected from the group consisting of --CONR-- and --SO2 NR-- in which case Rf is attached to the carbon or sulfur atom, and wherein R is selected from the group consisting of hydrogen, alkyl of from 1 to about 10 carbon atoms and hydroxyalkyl having 2 to about 10 carbon atoms, a and b are independently 0 or 1, M1 is a nonionic hydrophilic monomer or mixture of nonionic hydrophilic monomers, and M2 is an anionic hydrophilic monomer or mixture of anionic hydrophilic monomers, wherein x and y are both greater than zero, the sum of x+y is between about 5 and 200, and y/x+y is between about 0.01 and 0.98. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16)
- adding to a concrete mix comprising from about 1 to about 50 percent by volume of cement, from about 0 to about 75 percent by volume of washed sand, from about 0 to about 60 percent by volume of coarse aggregate, from about 4 to about 50 percent by volume water, from about 0 to about 50 percent by volume of a member selected from the group consisting of cementitious and pozzolanic materials, from about 0 to about 20 oz of water reducer per 100 pounds of cementitious and pozzolanic material, and from about 0 to about 20 oz of accelerator per 100 pounds of cementitious and pozzolanic material, a foam aggregate comprising from about 1 to about 90 percent by volume of air as bubbles and comprising from about 0.01 to about 1.0 percent by weight of a foam stabilizing fluorinated surfactant of the formula
- 17. A concrete mix for the formation of a foamed concrete product comprising cement, water in an amount adequate to hydrate said cement, coarse aggregate, and a stabilized foam aggregate comprising from about 1 to about 90 percent by volume of air as bubbles comprising from about 0.01 to about 1.0 percent by weight of a foam stabilizing fluorinated surfactant of the formula
- space="preserve" listing-type="equation">R.sub.f --E.sub.a --(S).sub.b --[M.sub.1 ].sub.x --[M.sub.2 ].sub.y --H
wherein Rf is a perfluorinated alkyl selected from the group consisting of straight chain, branched chain, and cyclic perfluoroalkylenes of 1 to about 20 carbon atoms, perfluoroalkyls substituted with perfluoroalkoxy of 2 to about 20 carbon atoms, perfluoroalkyl oligomers and polymers of greater than 10 carbon atoms, and mixtures thereof, E is selected from the group consisting of direct bonds, alkylenes containing from 2 to about 20 carbon atoms and selected from the group consisting of branched chain, straight chain, and cyclic alkylenes, alkylenes interrupted by one or more members selected from the group consisting of, --NR--, --O--, --S--, --SO2 --, --COO--, --OOC--, --CONR--, --NRCO--, --SO2 NR--, --NRSO2 --, --SiR2 --, alkylenes terminated with a member selected from the group consisting of --CONR-- and --SO2 NR-- in which case Rf is attached to the carbon or sulfur atom, and wherein R is selected from the group consisting of hydrogen, alkyl of from 1 to about 10 carbon atoms and hydroxyalkyl having 2 to about 10 carbon atoms, a and b are independently 0 or 1, M1 is a nonionic hydrophilic monomer or mixture of nonionic hydrophilic monomers, and M2 is an anionic hydrophilic monomer or mixture of anionic hydrophilic monomers, wherein x and y are both greater than zero, the sum of x+y is between about 5 and 200, and y/x+y is between about 0.01 and 0.98. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24)
Specification