Fiber Reinforced Cement Composition Using Segmented Lightweight Aggregates
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Solution Overview
Problem
Fiber reinforced cement products face challenges in achieving high bending strength, dimensional stability, and installation properties such as handling and nail performance while maintaining uniform specific gravity, particularly due to issues with lightweight aggregates rising during the forming process and causing unevenness.
Innovation Solution
A fiber reinforced cement composition incorporating a hydraulic inorganic material, siliceous materials like inorganic hollow and spherical materials, and woody reinforcement, which includes finely dividing inorganic hollow and spherical materials to improve fluidity and prevent aggregate rise, combined with a water-soluble resin for enhanced adhesion and resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If lightweight aggregates are added to improve specific gravity and bending strength, then bending strength and dimensional stability improve, but lightweight aggregates rise during forming process causing unevenness and delamination
Solution Approach 1:
The patent changes the particle size parameter of lightweight aggregates by dividing them into two ranges: 0.1-2mm for structural strength and 0.01-0.1mm for preventing rise during forming. This parameter differentiation resolves the contradiction by allowing each size range to fulfill its specific function without causing the other's problems.
Solution Approach 2:
The patent segments the lightweight aggregate into two distinct particle size categories with different functions. The coarser fraction (0.1-2mm) provides bending strength, while the finer fraction (0.01-0.1mm) prevents rising during the forming process, thereby resolving the contradiction between strength enhancement and manufacturing precision.
2Reliability
If powder is added to increase specific gravity for better freezing and fusion resistance, then freezing and fusion resistance improve, but product becomes hard reducing nail performance
Solution Approach 1:
The patent changes the particle size parameter of powder materials to optimize both freezing/fusion resistance and nail performance. By using finer powder particles, the composition achieves adequate density for thermal resistance while maintaining sufficient workability for nail installation.
3Productivity
If spherical lightweight aggregate is used to reduce extrusion pressure and improve fluency, then extrusion fluency improve, but aggregate rises in slurry during wet forming causing delamination
Solution Approach 1:
The patent segments spherical lightweight aggregate into two particle size groups: larger spheres (0.1-2mm) that provide fluency and reduce extrusion pressure, and finer particles (0.01-0.1mm) that remain suspended in slurry during wet forming and prevent rising and delamination.
Solution Approach 2:
The patent applies parameter changes by differentiating particle size within spherical lightweight aggregates. The dual-size approach allows the material to exhibit both high fluency during extrusion and stability during wet forming, resolving the contradiction between productivity and manufacturing precision.
Data Source
AI summary
The problems to be solved by the invention are to provide a fiber reinforced cement composition for obtaining a fiber reinforced cement product which is excellent in bending strength, dimensional stability and installing property such as handling property, flexibility performance and nail performance, as well as a process for manufacturing the product.Namely, the fiber reinforced cement composition comprises the following raw materials: a hydraulic inorganic material, a siliceous material and a woody reinforcement, wherein the siliceous material is an inorganic hollow material and/or an inorganic spherical material and a finely dividing inorganic hollow material and/or a finely dividing inorganic spherical material.The effects of the present invention, it is possible to obtain a fiber reinforced cement product having good bending strength, dimensional stability and installing property such as handling property, flexibility performance and nail performance.