# US 8,062,741 B2 · Cement based laminated armor panels > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,062,741 B2 - Document ID: US8062741B2 - Status: Granted - Kind: B2 - Application number: 12/394,396 - Filed: 2009-02-27 - Published: 2010-09-16 - Granted: 2011-11-22 - Earliest claimed: 2008-03-03 - Assignees: U.S. Gypsum Company - Inventors: Timothy D. Tonyan; William A. Frank; Ashish Dubey; Cesar Chan; Bartley P. Durst; Pamela G. Kinnebrew; Toney K. Cummins; Nicholas Boone; William F. Heard; Michael J. Roth; James L. Davis - Web page: https://patentgrep.com/patent/US8062741B2 ## CPC - F41H 5/0471: {Layered armour containing fibre- or fabric-reinforced layers (in combination with ceramic layers F41H5/0428, with metal layers F41H5/0457)} - B28B 1/522: {for producing multi-layered articles (B28B1/526, B28B1/527 take precedence)} - B28B 5/027: {the moulding surfaces being of the indefinite length type, e.g. belts, and being continuously fed (feeding B28B13/02)} - B28B 23/02: wherein the elements are reinforcing members {(B28B23/0006 takes precedence)} - B32B 5/024: {Woven fabric} - B32B 7/12: using interposed adhesives or interposed materials with bonding properties - B32B 13/02: with fibres or particles {being present as additives in the layer} - B32B 13/12: of synthetic resin - B32B 27/18: characterised by the use of special additives - B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)} - B32B 27/36: comprising polyesters - C04B 28/02: containing hydraulic cements other than calcium sulfates - E04C 2/06: reinforced - B32B 2250/42: Alternating layers, e.g. ABAB(C), AABBAABB(C) - B32B 2255/00: Coating on the layer surface - B32B 2255/26: Polymeric coating - B32B 2262/0223: Vinyl resin fibres - B32B 2262/0246: Acrylic resin fibres - B32B 2262/0253: Polyolefin fibres - B32B 2262/0261: Polyamide fibres - B32B 2262/0269: Aromatic polyamide fibres - B32B 2262/062: Cellulose fibres, e.g. cotton - B32B 2262/101: Glass fibres - B32B 2262/103: Metal fibres - B32B 2262/106: Carbon fibres, e.g. graphite fibres - B32B 2262/14: Mixture of at least two fibres made of different materials - B32B 2264/102: Oxide or hydroxide - B32B 2307/50: having particular mechanical properties - B32B 2419/00: Buildings or parts thereof - B32B 2571/00: Protective equipment - B32B 2607/00: Walls, panels - C04B 2111/00612: {as one or more layers of a layered structure} - C04B 2111/00974: {for pyrotechnic applications, e.g. blasting} - C04B 2111/62: Self-levelling compositions - Y02W 30/91: Use of waste materials as fillers for mortars or concrete - Y10T 428/249932: Fiber embedded in a layer derived from a water-settable material [e.g., cement, gypsum, etc.] - F41H: ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL - B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - 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 - E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S) - Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A cementitious panel with ballistic and blast resistant properties having a core layer of ultra-high compressive strength composite and at least one skin layer. The panels can also be used in walls, ceiling and flooring panels which require high compressive strength for resistance to earthquakes and surfaces resistant to surface abuse such as in prison and other institutions. The panel core layer has a continuous cementitious phase resulting from the curing of an aqueous mixture, in the absence of silica flour, of inorganic cement binder, inorganic mineral filler having a particle size of about 150-450 microns, a pozzolanic mineral filler, polycarboxylate based superplasticizer, alkanolamine and acid or alkali metal acid salt; and water. The mixture may be uniformly reinforced with fiber added before curing. The cementitious core layer is then reinforced with the skin, such as fiber reinforced polymer, attached to at least one panel surface. ## Claims ### Claim 1 A fiber reinforced, cementitious armor panel comprising: a cementitious core comprising reinforcing fiber uniformly distributed within a continuous phase, the continuous phase resulting from the curing of an aqueous mixture of 25-45 weight % inorganic cement binder, an absence of silica flour, 35-65 weight % silica sand filler having a median particle size of about 150-450 microns, 5-15 weight % pozzolanic filler having a median particle size of less than or equal to 50 microns, 0.25-5.0 weight % polycarboxylate based self-leveling agent, and 6-12 weight % water, and a skin layer attached to at least one surface of the cured continuous phase. ### Claim 2 (depends on 1) The panel of claim 1, wherein the cementitious core comprises the reinforcing fiber in an amount of about 0.5-6.0% by volume of the cementitious core before the continuous phase is cured. ### Claim 3 (depends on 1) The panel of claim 1, wherein the cementitious panel has a compressive strength of at least about 10,000 psi when cured. ### Claim 4 (depends on 1) The panel of claim 1, wherein the cementitious panel has a compressive strength of at least about 15,000 psi when cured. ### Claim 5 (depends on 1) The panel of claim 1, wherein the aqueous mixture comprises an alkanolamine in an amount of about 0.005 wt. % to about 0.500 wt. % by weight of the cement binder, and an acid or acid salt in an amount of about 0.10 wt. % to about 1.80 wt. % by weight of the combined weight of the cement binder and pozzolanic filler. ### Claim 6 (depends on 5) The panel of claim 5, wherein the aqueous mixture comprises triethanolamine and tartaric acid. ### Claim 7 (depends on 1) The panel of claim 1, wherein the skin layer is a fiberglass reinforced plastic. ### Claim 8 (depends on 1) The panel of claim 1, wherein the skin layer is a fiberglass reinforced polyester. ### Claim 9 (depends on 1) The panel of claim 1, wherein the inorganic cement binder is Portland cement. ### Claim 10 (depends on 1) The panel of claim 1, wherein the compressive strength after 1 day curing is less than about 2000 to 4000 psi and the compressive strength develops to more than about 20,000 psi after curing for 28 days. ### Claim 11 (depends on 2) The panel of claim 2, wherein the reinforcing fibers are selected from the group consisting of glass fibers, metal fibers, polymer fibers and mixtures thereof. ### Claim 12 (depends on 2) The panel of claim 2, wherein the reinforcing fiber is glass fibers. ### Claim 13 (depends on 1) The panel of claim 1, wherein the weight ratio of pozzolanic filler to inorganic cement binder is about 0.05 to 0.30:1.0. ### Claim 14 (depends on 1) The panel of claim 1, wherein the weight ratio of silica sand filler to the combined weight of inorganic cement binder and pozzolanic filler is about 0.75:1.0 to about 1.50:1.0. ### Claim 15 (depends on 1) The panel of claim 1, wherein the weight ratio of water to the combined weight of the inorganic cement binder and pozzolanic filler dry reactive powders is less than or equal to about 0.35:1.0. ### Claim 16 (depends on 1) The panel of claim 1, wherein the weight ratio of pozzolanic filler to inorganic cement binder is about 0.15 to about 0.20:1.0; the weight ratio of silica sand filler to the combined weight of inorganic cement binder and pozzolanic filler is about 0.90 to 1.10:1.0; and the weight ratio of water to the combined weight of the inorganic cement binder and pozzolanic filler dry reactive powders in the continuous phase is less than or equal to about 0.20:1.0. ### Claim 17 (depends on 1) The panel of claim 1, wherein the median particle size of the silica sand filler is about 250 to about 350 microns. ### Claim 18 (depends on 1) The panel of claim 1, wherein the median particle size of the pozzolanic filler is less than about 0.1 to 1.0 microns. ### Claim 19 (depends on 1) The panel of claim 1, wherein the polycarboxylate based self-leveling agent is polycarboxylate polyether. ### Claim 20 (depends on 1) The panel of claim 1, wherein the pozzolanic filler is silica fume. ### Claim 21 (depends on 1) The panel of claim 1, wherein the continuous phase comprises 0.75-2.5 weight % polycarboxylate polyether self-leveling agent. ### Claim 22 (depends on 1) The panel of claim 1, wherein the polycarboxylate polyether is present in an amount of about 0.75-1.0 weight %. ### Claim 23 (depends on 2) The panel of claim 2, wherein the fiber in the continuous phase of the cementitious core is present in about 3.0 to 3.5% by volume of the continuous phase. ### Claim 24 (depends on 1) The panel of claim 1, wherein the alkanolamine is triethanolamine present in an amount of about 0.025 to about 0.075% by weight and the acid is tartaric acid and is present in an amount of about 0.40% to about 0.60% by weight based upon the weight of the cement components. ### Claim 25 (depends on 1) The panel of claim 1, wherein the polycarboxylate agent is an ether and is present in an amount of about 0.75%-1.50% by wt. of the cementitious mixture on a dry basis. ### Claim 26 (depends on 1) The panel of claim 1, wherein the polycarboxylate agent is present in an amount of about 1.00% - 1.25% by weight of the cementitious mixture on a dry basis. ### Claim 27 (depends on 1) The panel of claim 1, wherein the panel has been sanded and cut to size before said skin layer is attached to the surface of the panel. ### Claim 28 (depends on 1) The panel of claim 1, wherein the skin layer is a fiber reinforced polymer and adhesively laminated to the surface of the cementitious core. ### Claim 29 (depends on 1) The panel of claim 1, wherein the skin layer is a glass fiber reinforced polymer. ### Claim 30 (depends on 29) The panel of claim 29, wherein the glass fiber reinforced polymer is a woven fiber glass reinforced polyester. ### Claim 31 (depends on 1) The panel of claim 1, wherein the reinforcing skin layer is mechanically fastened to the cementitious core. ### Claim 32 (depends on 1) The panel of claim 1, wherein the skin layer is laminated to the surface of the cementitious core with an epoxy adhesive. ### Claim 33 (depends on 1) The panel of claim 1, wherein at least one said skin layer is between opposed surfaces of two adjacent core layers. ### Claim 34 A fiber reinforced, cementitious armor panel comprising: a cementitious core comprising a continuous phase resulting from the curing of an aqueous mixture of 25-45 weight % inorganic cement binder, an absence of silica flour, 35-65 weight % silica sand filler having a median particle size of about 150-450 microns, 5-15 weight % pozzolanic filler having a median particle size of less than or equal to 50 microns, 0.25-5.0 weight % polycarboxylate based self-leveling agent, and 6-12 weight % water, and a skin layer of fiberglass reinforced polyester attached to at least one surface of the cured continuous phase, wherein the compressive strength after 1 day curing is less than about 2000 to 4000 psi and the compressive strength develops to more than about 20,000 psi after curing for 28 days. ### Claim 35 (depends on 34) The panel of claim 34, wherein the panel has a modulus of 5140 Ksi and a panel flexural strength of 3105 psi. ### Claim 36 (depends on 34) The panel of claim 34, wherein the panel has a modulus exceeding 5000 Ksi and a panel flexural strength exceeding 3000 psi.