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Aerated composite materials, methods of production and uses thereof

a technology of aerated composite materials and aerated concrete, which is applied in the direction of solid waste management, pipes, animal housing, etc., can solve the problems of unfavorable carbon footprint and relatively high cost, and achieve the effects of low cost, easy production and excellent physical and performance characteristics

Inactive Publication Date: 2014-09-18
DEO OMKAR +6
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The invention is about the creation of new materials that can be made from cheap and readily available materials. These materials have the physical and performance characteristics of aerated concretes, but are produced using a process that is more efficient and environmentally friendly. The raw materials used for the formulation of these materials include calcium silicate, calcium oxide-containing material, lightweight aggregates, and industrial waste materials. An aerating agent is used to create a highly porous material, and a fluid component is used as a reaction medium. The final product contains sequestered carbon dioxide. Other additives such as rheology modifying admixtures and coloring pigments can be added for improved consistency and flow. The process of production is also more energy efficient and environmentally friendly.

Problems solved by technology

The manufacture process of conventional aerated concretes involves special equipment, large energy consumption, and excessive carbon dioxide emission, leaving unfavorable carbon footprint.
In addition, they are relatively expensive due to high finishing costs, difficulty to recycling, etc.

Method used

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  • Aerated composite materials, methods of production and uses thereof
  • Aerated composite materials, methods of production and uses thereof
  • Aerated composite materials, methods of production and uses thereof

Examples

Experimental program
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Effect test

example 1

Aerated Composite Material Made Using Synthetic Wollastonite

Raw Materials

[0142]Synthetic Wollastonite (SC-C2), Donghai Golden Resources Industries, Donghai, China; Calcium Oxide, Austin, Tex. (Capitol Brand); Aluminum Powder, Eckrat America Corporation, New Jersey.

TABLE 5Mixture Proportions (5 kg batch size)Solid Components:64.94%Synthetic Wollastonite (SC-C2) 58.1%2.906 kgLime (Calcium Oxide) 6.5%0.325 kgAluminum powder (30 microns) 0.32%0.016 kgLiquid Components:35.06%Tap Water35.06%1.753 kg

Mixing Procedure

[0143]1. Measure and load the liquid component (1.753 kg of tap water as in this example) into a laboratory scale mixer.

[0144]2. Measure and load 2.906 kg of the first solid component, which is Synthetic Wollastonite (SC-C2) into the slurry and continue mixing at the same rate for approximately five more minutes.

[0145]3. Measure and load 0.325 kg of the second solid component, which is lime (Calcium Oxide) into the mixer and mix the two components at approximately 40 RPM for a d...

example 2

Aerated Composite Material Made Using Synthetic Wollastonite and Non-Silica Based Aggregate

[0167]This example specifies the formulation of aerated concrete using non-silica based aggregate materials such as fine limestone filler (with a particle size, d50 of 3 microns) as a partial replacement of Synthetic Wollastonite (SC-C2). The amount of replacement can vary from 5% to 65% of synthetic wollastonite depending on the density requirement. The amount of water content or the water-to-solids ratio can also vary based on the replacement level. The mixing, casting, and curing procedures were similar to those mentioned previously. A 60% replacement of synthetic wollastonite by fine limestone filler has shown very dry low densities that vary from 350 kg / m3 to 450 kg / m3 (21.8 lbs / ft3 to 28.1 lbs / ft3).

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Abstract

The invention provides novel aerated composite materials that possess excellent physical and performance characteristics of aerated concretes, and methods of production and uses thereof. These composite materials can be readily produced from widely available, low cost raw materials by a process suitable for large-scale production with improved energy consumption, desirable carbon footprint and minimal environmental impact.

Description

PRIORITY CLAIMS AND RELATED PATENT APPLICATIONS[0001]This application claims the benefit of priority from U.S. Provisional Application Ser. No. 61 / 780,719, filed on Mar. 13, 2013, the entire content of which is incorporated herein by reference in its entirety.FIELD OF THE INVENTION[0002]The invention generally relates to aerated composite materials and aerated concretes. More particularly, the invention relates to novel aerated composite materials, and formulations and methods for their manufacture and uses. These aerated composite materials are suitable for a variety of applications in construction, fire resistance and insulation, landscaping, and infrastructure.BACKGROUND OF THE INVENTION[0003]Autoclaved aerated concrete is a type of lightweight, precast concrete that is formed under high temperatures and pressures using raw materials such as cement, fine aggregates such as sand or other filler materials, lime, water, and an aerating agent. The aerating agent causes air voids to f...

Claims

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Application Information

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IPC IPC(8): C04B38/00
CPCC04B38/0058C04B38/0061Y02P40/18Y10T428/24496Y10T428/1314Y10T428/249921C04B38/02Y02P40/60Y02W30/91C04B14/06C04B18/08C04B18/141C04B18/146C04B20/0076C04B28/188C04B38/0074C04B40/0231C04B40/024C04B40/0268C04B2103/0079C04B2103/10C04B2103/20C04B2103/54C04B14/30C04B14/308
Inventor DEO, OMKARATAKAN, VAHITRAVIKUMAR, DEEPAKHU, XUDONGSAHU, SADANANDAGUPTA, SUROJITRIMAN, RICHARD
Owner DEO OMKAR
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