Back to results
US 2016/0355439 A1Published application
Hollow-core articles and composite materials, methods of production and uses thereof
AssigneeSolidia Technologies, Inc.
InventorsLarry E. McCandlish, Orlando Narine, Daniel Castro, David Patten, John P. Kuppler
Life of this patent
Estimating the term…
Abstract
The invention provides novel articles of composite materials having hollow interior channels or passageways, or otherwise being hollowed out, and formulations and methods for their manufacture and uses. These hollow core objects are suitable for a variety of applications in construction, pavements and landscaping, and infrastructure.
Claims21
An article of manufacture having a body prepared from a composite material, wherein
- the body comprises one or more interior ducts or channels exhibiting one or more surfaces capable of fluid communication with an exterior of the body, and
- the composite material comprises:
- 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;
- and
- filler particles comprising coarse filler particles and/or fine filler particles, 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.
3 more elements
A process for producing an article of manufacture, comprising:
- mixing a particulate composition and a liquid composition to form a mixture;
- embedding a reinforcement element in the mixture;
- casting or extruding or otherwise forming the mixture in a mold to generate a casted or extruded or otherwise formed body having the reinforcement element embedded therein and one or more interior ducts or channels in the formed body exhibiting one or more surfaces and capable of fluid communication with interior of the body wall;
- maintaining an atmosphere of CO2 and/or water vapor in the one or more interior ducts or channels;
- and
- curing the casted or extruded body at a temperature in the range from about 20° C. to about 150° C. for about 1 hour to about 80 hours under an atmosphere of water and/or CO2 having a pressure in the range from ambient atmospheric pressure to about 60 psi above ambient and having a CO2 concentration ranging from about 10% to about 90%, wherein
- the particulate composition comprises a ground calcium silicate, comprising one or more of natural or synthetic wollastonite, pseudo-wollastonite, rankinite, gehlenite, belite, alite and amorphous phase having a median particle size in the range from about 1 μm to about 100 μm, and
- the liquid composition comprises water.
5 more elements
An article prepared by a process according to any of claims 15-27.
Dependencies are inferred from the claim text.