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US 2014/0272216 A1Published application
Aerated composite materials, methods of production and uses thereof
OwnerOmkar Deo, Vahit Atakan +5inventors
InventorsOmkar Deo, Vahit Atakan, Deepak Ravikumar, Xudong Hu, Sadananda Sahu, Surojit Gupta, Richard Riman
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Abstract
The invention provides novel aerated composite materials that possess excellent physical and performance characteristics of aerated 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.
Claims37
An aerated 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 filler particles having sizes of about 0.1 μm to about 1 mm;
- and
- a plurality of voids,
- wherein
- the plurality of bonding elements and the plurality of filler particles together form one or more bonding matrices and the bonding elements and the filler particles are substantially evenly dispersed therein and bonded together;
- and
- the plurality of voids are bubble-shaped and/or interconnected channels account for from about 50 vol. % to about 80 vol. % of the composite material, whereby
- the aerated composite material exhibits a density from about 300 kg/m3 to 1500 kg/m3, a compressive strength from about 2.0 MPa to about 8.5 MPa, and a flexural strength from about 0.4 MPa to about 1.7 MPa.
9 more elements
A process for producing an aerated composite material, comprising:
- forming a wet mixture, wherein the wet mixture comprises:
- water,
- a particulate comprising calcium oxide or silica having a median particle size in the range from about 10 μm to about 1 mm;
- a ground calcium silicate having a median particle size in the range from about 1 μm to about 100 μm, and
- an aerating agent,
- casting the wet mixture in a mold;
- allowing the aerating agent to generate a gaseous product thereby causing volume expansion of the wet mixture;
- and
- curing the expanded mixture at a temperature in the range from about 20° C. to about 100° C. for about 6 hour to about 60 hours under an atmosphere of water and CO2.
6 more elements
Dependencies are inferred from the claim text.