# US 2016/0257613 A2 · Extruded Lightweight Thermal Insulating Cement-Based Materials > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2016/0257613 A2 - Document ID: US20160257613A2 - Status: Published application - Kind: A2 - Application number: 14/785,968 - Filed: 2014-04-24 - Published: 2016-09-08 - Earliest claimed: 2013-04-24 - Assignees: The Intellectual Gorilla GmbH - Applicants: The Intellectual Gorilla GmbH - Inventors: Evan R. Daniels; Per Just Andersen - Web page: https://patentgrep.com/patent/US20160257613A2 ## CPC - C04B 18/027: {Lightweight materials} - C04B 14/16: porous, e.g. pumice - C04B 28/02: containing hydraulic cements other than calcium sulfates - C04B 41/4543: {by spraying, e.g. by atomising} - C04B 2111/00129: {Extrudable mixtures} - C04B 2111/28: Fire resistance, i.e. materials resistant to accidental fires or high temperatures - C04B 2111/40: Porous or lightweight materials - C04B 2201/32: for the thermal conductivity, e.g. K-factors - Y02W 30/91: Use of waste materials as fillers for mortars or concrete - 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 - Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT ## Abstract An extrudable cement-based material is formed from a mixture that includes cement in the range of about 40 to 90% by wet weight percent, a lightweight expanded aggregate in the range of about 10 to 60% by wet weight percent, a secondary material in the range of about 0.1 to 50% by wet weight percent, a reinforcement fiber in the range of about 1 to 20% by wet weight percent, a rheology modifying agent in the range of about 0.5 to 10% by wet weight percent, a retarder in the range of about 0.1 to 8% by wet weight percent, and water in the range of 10 to 60% of a total wet material weight. ## Claims ### Claim 1 An extrudable lightweight thermal insulating cement-based material formed from a mixture comprising: a cement in the range of about 40 to 90% by wet weight percent; a lightweight expanded aggregate in the range of about 5 to 40% by wet weight percent; a secondary material in the range of about 0.1 to 50% by wet weight percent; a reinforcement fiber in the range of about 1 to 20% by wet weight percent; a rheology modifying agent in the range of about 0.5 to 10% by wet weight percent; a retarder in the range of about 0.1 to 8% by wet weight percent; a water in the range of 10 to 60% of a total wet material weight; and the mixture is extrudable. ### Claim 2 (depends on 1) The extrudable lightweight thermal insulating cement-based material as recited in claim 1, the lightweight expanded aggregate comprising clay, Perlite, expanded glass, expanded pumice, or a combination thereof. ### Claim 3 (depends on 2) The extrudable lightweight thermal insulating cement-based material as recited in claim 2, the expanded glass or the expanded pumice formed from a mixture comprising: a ground glass or pumice in the range of about 40 to 60% by weight percent for a slurry; a water in the range of about 40 to 60% by weight percent for the slurry; a sodium silicate in the range of about 3 to 15% by weight percent for the slurry; a NaNO3 in the range of about 0.1 to 5% for the slurry; the ground glass or pumice in the range of about 50 to 80% by weight percent for a granulator; and the slurry in the range of about 15 to 50% by weight percent for the granulator. ### Claim 4 (depends on 3) The extrudable lightweight thermal insulating cement-based material as recited in claim 3, the granulator having a ratio of about 1 part slurry to about 2.5 parts ground glass or pumice. ### Claim 5 (depends on 2) The extrudable lightweight thermal insulating cement-based material as recited in claim 2, the expanded glass or the expanded pumice formed from a mixture consisting essentially of: a ground glass or pumice in the range of about 40 to 60% by weight percent for a slurry; a water in the range of about 40 to 60% by weight percent for the slurry; a sodium silicate in the range of about 3 to 15% by weight percent for the slurry; a NaNO3 in the range of about 0.1 to 5% for the slurry; the ground glass or pumice in the range of about 50 to 80% by weight percent for a granulator; and the slurry in the range of about 15 to 50% by weight percent for the granulator. ### Claim 6 (depends on 2) The extrudable lightweight thermal insulating cement-based material as recited in claim 2, the expanded glass or the expanded pumice formed from a mixture comprising: a ground glass or pumice in the range of about 40 to 60% by weight percent for a slurry; a water in the range of about 45 to 50% by weight percent for the slurry; a sodium silicate in the range of about 6 to 7% by weight percent for the slurry; a NaNO3 in the range of about 0.9 to 1.1% for the slurry; and a granulator having a ratio of 1 part slurry to about 2.5 parts ground glass or pumice. ### Claim 7 (depends on 2) The extrudable lightweight thermal insulating cement-based material as recited in claim 2, the expanded glass or the expanded pumice having a diameter of about 0-8 mm, a bulk density in the range of about 0.10 to 0.5 g/cm3, a effective density in the range of about 0.10 to 0.8 g/cm3, a compressive strength in the range of about 0.5 MPa to 5 MPa, and a heat conductance in the range of about 0.04 to 0.15 W/mK. ### Claim 8 (depends on 1) The extrudable lightweight thermal insulating cement-based material as recited in claim 1, the lightweight expanded aggregate having a particle size comprising about 0-1 mm, 1-2 mm, 2-4 mm, 4-8 mm or a combination thereof. ### Claim 9 (depends on 1) The extrudable lightweight thermal insulating cement-based material as recited in claim 1, the secondary material comprising sand, gypsum, silica fume, fumed silica, fly ash, slag, rock, cellulose fiber, glass fiber, plastic fiber, polyvinyl alcohol (PVA) fiber, or a combination thereof. ### Claim 10 (depends on 1) The extrudable lightweight thermal insulating cement-based material as recited in claim 1, the reinforcement fiber comprising cellulose fiber, glass fiber, polypropylene fiber, polyvinyl alcohol (PVA) fiber, Dolanit fiber, or a combination thereof. ### Claim 11 (depends on 1) The extrudable lightweight thermal insulating cement-based material as recited in claim 1, the rheology modifying agent comprising a polysaccharide, a polysaccharide derivative, a protein, a protein derivative, a synthetic organic material, a synthetic organic material derivative, or a combination thereof. ### Claim 12 (depends on 11) The extrudable lightweight thermal insulating cement-based material as recited in claim 11, the polysaccharide comprising a cellulose-based material, a cellulose-based material derivative, a starch-based material, a starch-based material derivative, or a combination thereof. ### Claim 13 (depends on 12) The extrudable lightweight thermal insulating cement-based material as recited in claim 12, the cellulose-based material is selected from the group consisting essentially of methylhydroxyethylcellulose (MHEC), hydroxymethylethylcellulose (HMEC), carboxymethylcellulose (CMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethylcellulose (HEC), hydroxyethylpropylcellulose (HEPC) and hydroxypropoylmethylcelluose (HPMC). ### Claim 14 (depends on 12) The extrudable lightweight thermal insulating cement-based material as recited in claim 12, the starch-based material is selected from the group consisting essentially of wheat starch, pre-gelled wheat starch, potato starch, pre-gelled potato starch, amylopectin, amylose, seagel, starch acetates, starch hydroxyethyl ethers, ionic starches, long-chain alkylstarches, dextrins, amine starches, phosphate starches, or dialdehyde starches. ### Claim 15 (depends on 1) The extrudable lightweight thermal insulating cement-based material as recited in claim 1, the retarder comprising sodium citrate, or a mixture of Plaster of Paris, sodium citrate and crystalline silica. ### Claim 16 (depends on 1) The extrudable lightweight thermal insulating cement-based material as recited in claim 1, the extrudable lightweight thermal insulating cement-based material having a density in the range of about 0.2 to 1.0 g/cm3, a compressive strength in the range of about 0.5 MPa to 10 MPa, and a heat conductance in the range of about 0.05 to 0.3 W/mK. ### Claim 17 An extrudable lightweight thermal insulating cement-based material formed from a mixture consisting essentially of: a cement in the range of about 40 to 90% by wet weight percent; a lightweight expanded aggregate in the range of about 5 to 40% by wet weight percent; a secondary material in the range of about 0.1 to 50% by wet weight percent; a reinforcement fiber in the range of about 1 to 20% by wet weight percent; a rheology modifying agent in the range of about 0.5 to 10% by wet weight percent; a retarder in the range of about 0.1 to 8% by wet weight percent; a water in the range of 10 to 60% of a total wet material weight; and the mixture is extrudable. ### Claim 18 A method for manufacturing an extrudable lightweight thermal insulating cement-based material comprising the steps of: mixing a cement, a lightweight expanded aggregate, a secondary material, a reinforcement fiber, a rheology modifying agent and a retarder with water; extruding the mixture through a die using an extruder; and allowing the extruded mixture to set. ### Claim 19 (depends on 18) The method as recited in claim 18, the mixture comprising: the cement in the range of about 40 to 90% by wet weight percent; the lightweight expanded aggregate in the range of about 5 to 40% by wet weight percent; the secondary material in the range of about 0.1 to 50% by wet weight percent; the reinforcement fiber in the range of about 1 to 20% by wet weight percent; the rheology modifying agent in the range of about 0.5 to 10% by wet weight percent; the retarder in the range of about 0.1 to 8% by wet weight percent; and the water in the range of 10 to 60% of a total wet material weight. ### Claim 20 (depends on 18) The method as recited in claim 18, the mixture consisting essentially of: the cement in the range of about 40 to 90% by wet weight percent; the lightweight expanded aggregate in the range of about 5 to 40% by wet weight percent; the secondary material in the range of about 0.1 to 50% by wet weight percent; the reinforcement fiber in the range of about 1 to 20% by wet weight percent; the rheology modifying agent in the range of about 0.5 to 10% by wet weight percent; the retarder in the range of about 0.1 to 8% by wet weight percent; and the water in the range of 10 to 60% of a total wet material weight. ### Claim 21 (depends on 18) The method as recited in claim 18, the lightweight expanded aggregate comprising clay, Perlite, expanded glass, expanded pumice, or a combination thereof. ### Claim 22 (depends on 21) The method as recited in claim 21, the expanded glass or the expanded pumice formed from a mixture comprising: a ground glass or pumice in the range of about 40 to 60% by weight percent for a slurry; a water in the range of about 40 to 60% by weight percent for the slurry; a sodium silicate in the range of about 3 to 15% by weight percent for the slurry; a NaNO3 in the range of about 0.1 to 5% for the slurry; the ground glass or pumice in the range of about 50 to 80% by weight percent for a granulator; and the slurry in the range of about 15 to 50% by weight percent for the granulator. ### Claim 23 (depends on 22) The method as recited in claim 22, the granulator having a ratio of about 1 part slurry to about 2.5 parts ground glass or pumice. ### Claim 24 (depends on 21) The method as recited in claim 21, the expanded glass or the expanded pumice formed from a mixture consisting essentially of: a ground glass or pumice in the range of about 40 to 60% by weight percent for a slurry; a water in the range of about 40 to 60% by weight percent for the slurry; a sodium silicate in the range of about 3 to 15% by weight percent for the slurry; a NaNO3 in the range of about 0.1 to 5% for the slurry; the ground glass or pumice in the range of about 50 to 80% by weight percent for a granulator; and the slurry in the range of about 15 to 50% by weight percent for the granulator. ### Claim 25 (depends on 21) The method as recited in claim 21, the expanded glass or the expanded pumice formed from a mixture comprising: a ground glass or pumice in the range of about 40 to 60% by weight percent for a slurry; a water in the range of about 45 to 50% by weight percent for the slurry; a sodium silicate in the range of about 6 to 7% by weight percent for the slurry; a NaNO3 in the range of about 0.9 to 1.1% for the slurry; and a granulator having a ratio of 1 part slurry to about 2.5 parts ground glass or pumice. ### Claim 26 (depends on 21) The method as recited in claim 21, the expanded glass or the expanded pumice having a diameter of about 0-8 mm, a bulk density in the range of about 0.10 to 0.5 g/cm3, a effective density in the range of about 0.10 to 0.8 g/cm3, a compressive strength in the range of about 0.5 MPa to 5 MPa, and a heat conductance in the range of about 0.04 to 0.15 W/mK. ### Claim 27 (depends on 18) The method as recited in claim 18, further comprising the step of making the lightweight expanded aggregate comprising the steps of: mixing a ground glass or pumice in the range of about 40 to 60% by weight percent with water in the range of about 40 to 60% by weight percent to produce a slurry; adding a sodium silicate in the range of about 3 to 15% by weight percent to the slurry; adding a NaNO3 in the range of about 0.1 to 5% to the slurry; forming aggregates in a granulator by feeding the ground glass or pumice in the range of about 50 to 80% by weight percent with the slurry in the range of about 15 to 50% by weight percent; drying the formed aggregates; heating the dried aggregates together with about 30% finely ground kaolin to a temperature of about 800 to 1400 degrees Celsius; and cooling the heated aggregates. ### Claim 28 (depends on 18) The method as recited in claim 18, the lightweight expanded aggregate having a particle size comprising about 0-1 mm, 1-2 mm, 2-4 mm, 4-8 mm or a combination thereof. ### Claim 29 (depends on 18) The method as recited in claim 18, the secondary material comprising sand, gypsum, silica fume, fumed silica, fly ash, slag, rock, cellulose fiber, glass fiber, plastic fiber, polyvinyl alcohol (PVA) fiber, or a combination thereof. ### Claim 30 (depends on 18) The method as recited in claim 18, the reinforcement fiber comprising cellulose fiber, glass fiber, polypropylene fiber, polyvinyl alcohol (PVA) fiber, Dolanit fiber, or a combination thereof. ### Claim 31 (depends on 18) The method as recited in claim 18, the rheology modifying agent comprising a polysaccharide, a polysaccharide derivative, a protein, a protein derivative, a synthetic organic material, a synthetic organic material derivative, or a combination thereof. ### Claim 32 (depends on 31) The method as recited in claim 31, the polysaccharide comprising a cellulose-based material, a cellulose-based material derivative, a starch-based material, a starch-based material derivative, or a combination thereof. ### Claim 33 (depends on 32) The method as recited in claim 32, the cellulose-based material is selected from the group consisting essentially of methylhydroxyethylcellulose (MHEC), hydroxymethylethylcellulose (HMEC), carboxymethylcellulose (CMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethylcellulose (HEC), hydroxyethylpropylcellulose (HEPC) and hydroxypropoylmethylcelluose (HPMC). ### Claim 34 (depends on 32) The method as recited in claim 32, the starch-based material is selected from the group consisting essentially of wheat starch, pre-gelled wheat starch, potato starch, pre-gelled potato starch, amylopectin, amylose, seagel, starch acetates, starch hydroxyethyl ethers, ionic starches, long-chain alkylstarches, dextrins, amine starches, phosphate starches, or dialdehyde starches. ### Claim 35 (depends on 18) The method as recited in claim 18, the retarder comprising sodium citrate, or a mixture of Plaster of Paris, sodium citrate and crystalline silica. ### Claim 36 (depends on 18) The method as recited in claim 18, the extruded mixture having a density in the range of about 0.2 to 1.0 g/cm3, a compressive strength in the range of about 0.5 MPa to 10 MPa, and a heat conductance in the range of about 0.05 to 0.3 W/mK after being set, cured or dried. ### Claim 37 (depends on 18) The method as recited in claim 18, wherein the extruded mixture is allowed to set for up to 2 to 3 hours. ### Claim 38 (depends on 18) The method as recited in claim 18, further comprising the step of curing the extruded mixture. ### Claim 39 (depends on 18) The method as recited in claim 18, further comprising the step of drying the extruded mixture. ### Claim 40 (depends on 18) The method as recited in claim 18, further comprising the step of molding, cutting, trimming, sanding or routing the extruded mixture into a specified shape. ### Claim 41 (depends on 18) The method as recited in claim 18, further comprising the step of spraying the extruded mixture with a water repellent.