US 11,440,844 B2 · Concrete product and methods of preparing the same

Abstract

A concrete product set by pouring a concrete slurry includes a) a concrete mixture; b) a graphene oxide admixture; c) a colloidal silica admixture; and d) at least one reinforcing fiber selected from the group of fibers. As the poured concrete slurry cures, the poured slurry hardens into a composite material product, and the composite material defines capillary structures that at least in part fill with silica and lime, and the surrounding composite material is embedded with graphene oxide flakes. In another exemplary embodiment, the present invention is directed to a process for preparing a concrete product. The process comprises the steps of a) preparing a concrete slurry; b) pouring the concrete slurry; and c) allowing the concrete slurry to cure. In another exemplary embodiment, the present invention is directed to the product itself; namely, a concrete product with or without fibers, or to the admixture(s).

Claims41

Dependent claims

A concrete product set by pouring a concrete slurry, the poured concrete slurry comprising:

a) a concrete mixture;
b) a colloidal silica admixture;
c) a graphene oxide flake admixture;
and
d) at least one fiber selected from the group of fibers consisting of steel fibers, helix fibers, basalt fibers, polyvinyl alcohol (PVA) fibers, carbon fibers, and synthetic fibers;
wherein, as the poured concrete slurry cures, the poured slurry hardens into a composite material, the composite material defining capillary structures that at least in part fill with silica and lime, and graphene oxide flakes;
wherein the silica and lime react to produce a gel structure of calcium silicate hydrate that at least partially fill the capillary structures;
and
wherein the graphene oxide flakes embed along and partially fill the capillary structures;
whereby the calcium silicate hydrate reduces internal tensile forces acting on the concrete product, and whereby the embedded graphene oxide flakes at least in part distribute the load of the composite material acting on the concrete product, the partially-filled capillary structures reduces shrinking and cracking of the concrete product;
and
wherein the concrete product is set by pouring the concrete slurry and then applying a curing technique to the poured concrete slurry, and wherein the curing technique comprises spray-applying a secondary graphene oxide onto the poured concrete slurry.

9 more elements

A process for preparing a concrete product, the process comprising:

a) preparing a concrete slurry, the concrete slurry comprising:
i) a concrete mixture;
ii) a colloidal silica admixture;
iii) a graphene oxide flake admixture;
and
iv) at least one fiber selected from the group of fibers consisting of steel fibers, helix fibers, basalt fibers, PVA fibers, carbon fibers, and synthetic fibers;
b) pouring the concrete slurry;
and
c) allowing the concrete slurry to cure such that capillary structures develop as the concrete product sets from the poured concrete slurry, and such that the capillary structures of the product at least in part fill with silica and lime, and graphene oxide flakes, and such that the silica and lime react to produce a gel structure of calcium silicate hydrate that at least partially fill the capillary structures, and such that the graphene oxide flakes embed along and partially fill the capillary structures, the partially-filled capillary structures reduces shrinking and cracking of the concrete product;
and
d) setting the concrete product by applying a curing technique to the poured concrete slurry, the curing technique comprises spray-applying a secondary colloidal silica and graphene oxide onto the poured concrete slurry to facilitate curing thereof.

8 more elements

A fiberless concrete product set by pouring a concrete slurry onto a substrate, the poured concrete slurry comprising:

a) a concrete mixture;
b) a colloidal silica admixture;
and
c) a graphene oxide flake admixture;
wherein, as the poured concrete slurry cures, the poured slurry hardens into a composite material, the composite material defining capillary structures that at least in part fill with silica and lime, and graphene oxide flakes;
wherein the silica and lime react to produce a gel structure of calcium silicate hydrate that at least partially fill the capillary structures;
and
wherein the graphene oxide flakes embed along and partially fill the capillary structures;
whereby the calcium silicate hydrate reduces internal tensile forces acting on the concrete product, and whereby the embedded graphene oxide flakes at least in part distribute the load of the composite material acting on the concrete product, the partially-filled capillary structures reduces shrinking and cracking of the concrete product;
and
wherein the concrete product is set by pouring the concrete slurry and then applying a curing technique to the poured concrete slurry, and wherein the curing technique comprises spray-applying a secondary graphene oxide onto the poured concrete slurry.

8 more elements

A process for preparing a fiberless concrete product, the process comprising:

a) preparing a concrete slurry, the concrete slurry comprising:
i) a concrete mixture;
ii) a colloidal silica admixture;
and
iii) a graphene oxide flake admixture;
b) pouring the concrete slurry;
and
c) allowing the concrete slurry to cure such that capillary structures develop as the concrete product sets from the poured concrete slurry, and such that the capillary structures of the product at least in part fill with silica and lime, and graphene oxide flakes, and such that the silica and lime react to produce a gel structure of calcium silicate hydrate that at least partially fill the capillary structures, and such that the graphene oxide flakes embed along and partially fill the capillary structures, the partially-filled capillary structures reduces shrinking and cracking of the concrete product;
and
d) setting the concrete product by applying a curing technique to the poured concrete slurry, the curing technique comprises spray-applying a secondary colloidal silica and graphene oxide onto the poured concrete slurry to facilitate curing thereof.

7 more elements

A fiberless concrete product set from a concrete slurry, the poured concrete slurry comprising a concrete mixture, a colloidal silica admixture, the colloidal silica admixture being a suspension of silica in a colloidal liquid phase, and a graphene oxide admixture, the graphene oxide admixture being graphene oxide flakes distributed in the liquid phase, the fiberless concrete product comprising capillary structures that are at least in part filled with a reaction product of silica and lime, and at least in part embedded with and filled with graphene oxide flakes, the reaction product of silica and lime being a gel structure of calcium silicate hydrate, the embedded graphene oxide flakes being graphene oxide monolayers or overlapping graphene oxide layers, wherein the concrete product is cured by application of a spray-applied secondary colloidal silica and graphene oxide, whereby the calcium silicate hydrate reduces internal tensile forces acting on the fiberless concrete product and whereby the embedded graphene oxide monolayers or overlapping graphene oxide layers at least in part distribute the load acting on the fiberless concrete product and the partially-filled capillary structures reduces shrinking and cracking of the concrete product.

Dependencies are inferred from the claim text.

Concrete product and methods of preparing the same

Life of this patent

Concrete product and methods of preparing the same

Life of this patent

Abstract

Claims41