Compressed hydraulically bonded composite articles
AssigneeE. Khashoggi Industries
InventorsHamlin M. Jennings, Per J. Andersen, Simon K. Hodson
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Abstract
The present invention relates to hydraulically bonded cement compositions and methods. More particularly, the present invention is directed to novel compositions and methods of hydrating hydraulic cement without mechanical mixing of the cement and water. The present invention includes materials prepared by manipulating under pressure powdered hydraulic cement compositions using known or novel powder packing, casting, or expanding techniques, such that air within the powdered hydraulic cement is substantially removed while the cement is formed into a self-supporting near net final position. Thereafter, the formed hydraulic cement is hydrated without mechanical mixing of the cement and water.
Claims67
A hydraulically bonded composite article prepared by the process comprising the steps of:
- (a) applying pressure to a powdered hydraulic cement composition within a mold such that the powdered hydraulic cement composition is formed into a mechanically self-supporting structure of a predetermined configuration corresponding substantially to a desired configuration of the hydraulically bonded composite article and such that air within the powdered hydraulic cement composition is substantially removed, the powdered hydraulic cement composition being capable of forming a continuous matrix having powdered hydraulic cement particles and aggregate particles dispersed therein;
- (b) removing the mechanically self-supporting structure from the mold, the mechanically self-supporting structure having sufficient mechanical strength such that it may be hydrated by immersion in water without significant mechanical disruption of the structure;
- and
- (c) hydrating the hydraulic cement composition of the mechanically self-supporting structure with an aqueous solution without substantial mechanical mixing of the hydraulic cement composition and aqueous solution, thereby forming the hydraulically bonded composite article.
A hydraulically bonded composite article prepared by the process comprising the steps of:
- (a) applying pressure to a powdered hydraulic cement composition within a mold such that air within the powdered hydraulic cement composition is substantially removed and the powdered hydraulic cement composition is positioned into a mechanically self-supporting structure of a predetermined configuration corresponding substantially to a desired configuration of the hydraulically bonded composite article;
- (b) removing the mechanically self-supporting structure from the mold, the mechanically self-supporting structure having sufficient mechanical strength such that it may be hydrated by immersion in water without significant mechanical disruption of the structure;
- and
- (c) hydrating the powdered hydraulic cement composition of the mechanically self-supporting structure with an aqueous solution without substantial mechanical mixing of the hydraulic cement composition and the aqueous solution, thereby forming the hydraulically bonded composite article, wherein the aqueous solution includes at least one component that modifies the hydration of the powdered hydraulic cement composition.
An article prepared by the process comprising the steps of:
- (a) applying pressure to a powdered hydraulic cement composition within a mold such that air within the powdered hydraulic cement composition is substantially removed and the powdered hydraulic cement composition is positioned into a mechanically self-supporting structure of a predetermined configuration corresponding substantially to a desired configuration of the substantially unhydrated cementitious article;
- and
- (b) removing the mechanically self-supporting structure from the mold, the substantially unhydrated cementitious article having sufficient mechanical strength such that it may be hydrated by immersion in water without significant mechanical disruption of the structure.
A hydraulically bonded composite article prepared by the process comprising the steps of:
- (a) applying pressure to a powdered hydraulic cement composition within a mold such that the powdered hydraulic cement composition is formed into a mechanically self-supporting structure of a predetermined configuration corresponding substantially to a desired configuration of the hydraulically bonded composite article and such that air within the powdered hydraulic cement composition is substantially removed, the applied pressure being in a range from about 10,000 psi to about 200,000 psi;
- (b) removing the mechanically self-supporting structure from the mold, the mechanically self-supporting structure having sufficient mechanical strength such that it may be hydrated by immersion in water without significant mechanical disruption of the structure;
- and
- (c) hydrating the hydraulic cement composition of the mechanically self-supporting structure with an aqueous solution without substantial mechanical mixing of the hydraulic cement composition and aqueous solution, thereby forming the hydraulically bonded composite article.
Dependencies are inferred from the claim text.