# US 11,111,180 B2 · Building elements made from binders hardening by combined hydration and carbonation > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,111,180 B2 - Document ID: US11111180B2 - Status: Granted - Kind: B2 - Application number: 16/754,439 - Filed: 2018-09-18 - Published: 2020-10-29 - Granted: 2021-09-07 - Earliest claimed: 2017-10-09 - Assignees: HConnect 2 GmbH - Applicants: HConnect 2 GmbH - Inventors: Jan Skocek; Maciej Zajac; Mohsen Ben Haha; Frank Bullerjahn - Web page: https://patentgrep.com/patent/US11111180B2 ## CPC - C04B 7/3453: {Belite cements, e.g. self-disintegrating cements based on dicalciumsilicate} - C04B 28/188: {the Ca-silicates being present in the starting mixture} - C04B 7/323: {Calcium aluminosulfate cements, e.g. cements hydrating into ettringite} - C04B 28/065: {Calcium aluminosulfate cements, e.g. cements hydrating into ettringite} - C04B 40/0231: {Carbon dioxide hardening} - B28B 1/14: by simple casting, the material being neither forcibly fed nor positively compacted (for molten material B28B1/54) - C04B 2103/302: {Water reducers} - C04B 2103/304: {Air-entrainers} - C04B 2103/32: Superplasticisers - Y02P 40/10: Production of cement, e.g. improving or optimising the production methods; Cement grinding - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE - B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B) - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract A method of manufacturing building elements has the steps: providing a binder comprising at least 8% by weight ternesite, at least 15% by weight dicalcium silicate and at least 5% by weight ye'elimite, each with respect to the total binder, as hydraulically reactive phases; mixing the binder with water to form a paste; casting the paste into a desired shape for the building element; reacting the paste hydraulically to form calcium-silicate-hydrates, calcium-aluminium-silicate-hydrates, portlandite, brucite, strätlingite, hydrotalcite-like phases and ettringite/AFm and capillary pores, and carbonation hardening to provide the building element and to building elements obtainable by the method. ## Claims ### Claim 1 A method of manufacturing building elements comprising the steps: providing a binder comprising at least 8% by weight ternesite, at least 15% by weight dicalcium silicate and at least 5% by weight ye'elimite, each with respect to the total binder, as hydraulically reactive phases mixing the binder with water to form a paste casting the paste into a shape for the building element reacting the paste hydraulically to form hydrated phases and to create additional capillary pores, and carbonation hardening to provide the building element. ### Claim 2 (depends on 1) The method according to claim 1, wherein the binder contains at least 28% by weight hydraulically reactive phases relative to the total binder weight. ### Claim 3 (depends on 1) The method according to claim 1, wherein in addition to ternesite, dicalcium silicate, and ye'elimite at least one additional hydraulically reactive phase selected from the group consisting of ellestadite, ferritic phases, and amorphous hydraulic phases is contained. ### Claim 4 (depends on 1) The method according to claim 1, wherein the water-to-binder ratio with respect to the sum of hydraulically reactive phases in binder is set from 0.2 to 1.2. ### Claim 5 (depends on 1) The method according to claim 1, wherein the hydrated phases of the hydraulically reactive phases form a major part of the phases hardening by carbonation. ### Claim 6 (depends on 1) The method according to claim 1, wherein periclase or free lime hardening by carbonation are present in the provided binder in an amount of up to 15% by weight each and up to 30% combined. ### Claim 7 (depends on 1) The method according to claim 1, wherein at least one of water reducing agents, plasticizers and/or super plasticizers are added to adjust consistency while keeping the water-to-binder ratio in the range suitable for self-desiccation. ### Claim 8 (depends on 1) The method according to claim 1, wherein air entraining agents are added to the binder. ### Claim 9 (depends on 1) The method according to claim 1, wherein additives are added, selected from the group consisting of fillers, pigments, reinforcing elements, and self-healing agents. ### Claim 10 (depends on 1) The method according to claim 1, wherein the binder contains 8 to 75% by weight ternesite, 15 to 80% by weight dicalcium silicate, 5 to 70% by weight ye'elimite, 0 to 50% by weight C6AxFy with x+y=3 and both x and y≥0 and x≤y, 0 to 20% by weight reactive aluminates 0 to 30% by weight hydraulic X-ray amorphous phase, 0 to 30% by weight minor phases, all with respect to the total amount of binder. ### Claim 11 (depends on 1) The method according to claim 1, wherein the paste is subjected to hydraulic hardening within an atmosphere of 40 to 99% relative humidity and having a temperature from 10 to 80° C. ### Claim 12 (depends on 1) The method according to claim 1, wherein carbonation takes place in an atmosphere rich in CO2 that has a pressure of CO2 ranging from of 0.005 to 2 MPa, and a temperature in the range from 15° C. up to 100° C. ### Claim 13 (depends on 12) The method according to claim 12, wherein CO2 rich exhaust gas is used to provide the atmosphere rich in CO2. ### Claim 14 (depends on 1) A building element obtained from a binder comprising at least 8% by weight ternesite, at least 15% by weight dicalcium silicate and at least 5% by weight ye'elimite as hydraulically reactive phases, by a method according to claim 1. ### Claim 15 (depends on 14) The building element according to claim 14 in the form of a pre-cast concrete element. ### Claim 16 (depends on 1) The method according to claim 1, wherein the binder contains at least 50% by weight hydraulically reactive phases relative to the total binder weight. ### Claim 17 (depends on 1) The method according to claim 1, wherein the water-to-binder ratio with respect to the sum of hydraulically reactive phases in the binder is set from 0.25 to 0.8. ### Claim 18 (depends on 1) The method according to claim 1, wherein the water-to-binder ratio with respect to the sum of hydraulically reactive phases in the binder is set from 0.35 to 0.6. ### Claim 19 (depends on 10) The method according to claim 10, wherein the water-to-binder ratio with respect to the sum of hydraulically reactive phases in the binder is set from 0.25 to 0.8. ### Claim 20 (depends on 10) The method according to claim 10, wherein the paste is subjected to hydraulic hardening within an atmosphere of 40 to 99% relative humidity and having a temperature from 10 to 80° C. ### Claim 21 (depends on 12) The method according to claim 12, wherein the atmosphere rich in CO2 has pressure of CO2 ranging from 0.05 to 0.5 MPa and a temperature ranging from 15° C. up to 50° C. ### Claim 22 (depends on 21) The method according to claim 21, wherein the binder contains 8 to 75% by weight ternesite, 15 to 80% by weight dicalcium silicate, 5 to 70% by weight ye'elimite, 0 to 50% by weight C6AxFy with x+y=3 and both x and y≥0 and x≤y, 0 to 20% by weight reactive aluminates 0 to 30% by weight hydraulic X-ray amorphous phase, 0 to 30% by weight minor phases, all with respect to the total amount of binder, and the water-binder ratio with respect to the sum of hydraulically reactive phases in the binder is set from 0.35 to 0.6.