Extruded fiber reinforced cementitious products having stone-like properties and methods of making the same
AssigneeE. Khashoggi Industries
InventorsPer Just Andersen, Simon K. Hodson
Life of this patent
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Abstract
A cementitious composite product that can function as a substitute for stone and solid surface materials, such as granite, marble, and engineered stone is provided. Furthermore methods for manufacturing the cementitious composite product using an extrudable cementitious composition that can be extruded or otherwise shaped into stone-like building products that can be used as a substitute for many known stone products is disclosed. In one embodiment, the cementitious composite products can be manufactured more cheaply to be as tough or tougher and more durable than stone and solid surface materials.
Claims27
A cementitious composite product having stone-like properties, the product comprising an extrudable cementitious composition comprised of a hydraulic cement, aggregate, a rheology-modifying agent, and from about 1.5% (by volume of the extrudable cementitious composition) to about 5.0% (by volume of the extrudable cementitious composition) cellulose fibers and from about 1.5% (by volume of the extrudable cementitious composition) to about 3.5% (by volume of the extrudable cementitious composition) polyvinyl alcohol fibers, wherein the composition comprises from 3.5% (by volume of the extrudable cementitious composition) to 8% (by volume of the extrudable cementitious composition) total fibers, the fibers substantially homogeneously distributed through the extrudable cementitious composition, wherein the cementitious composite product has a hardness value of at least 4 MOH and a bulk density of from about 1.3 g/cm3 to about 2.3 g/cm3.
A method for manufacturing a cementitious composite product having stone-like properties, the method comprising:
- mixing together water, fibers and a rheology-modifying agent to form a fibrous mixture in which the fibers are substantially homogeneously dispersed;
- adding a mix of hydraulic cement and aggregate to the fibrous mixture to yield an extrudable cementitious composition having a plastic consistency and which includes from about 1.5% (by volume of the extrudable cementitious composition) to about 5.0% (by volume of the extrudable cementitious composition) cellulose fibers and from about 1.5% (by volume of the extrudable cementitious composition) to about 3.5% (by volume of the extrudable cementitious composition) polyvinyl alcohol fibers, and wherein the composition comprises from 3.5% (by volume of the extrudable cementitious composition) to 8% (by volume of the extrudable cementitious composition) total fibers;
- extruding the extrudable cementitious composition into a green intermediate extrudate having a predefined cross-sectional area, the extrudate being form-stable upon extrusion and capable of retaining substantially the cross-sectional area so as to permit handling without breakage;
- and
- causing or allowing the hydraulic cement to cure to form the cementitious composite product, wherein the cementitious composite product has a hardness value of at least 4 MOH and a bulk density of from about 1.3 g/cm3 to about 2.3 g/cm3.
Dependencies are inferred from the claim text.