Hollow Core Slabs Using Carbonated Calcium Silicate Composite
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Solution Overview
Problem
Conventional hollow-core slabs made of concrete have high energy consumption and carbon footprints, necessitating the development of novel composite materials that match or exceed their physical and performance characteristics while being more cost-effective and environmentally friendly.
Innovation Solution
The production of hollow-core slabs using a composite material comprising calcium silicate phases, particulate filler materials, and a fluid component with CO2, which reacts to form a carbonated product, reducing energy consumption and environmental impact, and incorporating reinforcement elements for enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional concrete is used to manufacture hollow-core slabs, then the slabs achieve adequate structural strength and durability, but the energy consumption and carbon footprint increase significantly
Solution Approach 1:
The patent uses a composite material system consisting of calcium silicate phases (wollastonite, pseudowollastonite, rankinite, belite, larnite), calcium carbonate, and silica. This composite replaces conventional Portland cement concrete, achieving comparable structural strength and durability while significantly reducing energy consumption and carbon footprint by utilizing materials with lower embodied energy and enabling CO2 sequestration during curing
Solution Approach 2:
The patent changes the chemical composition parameters of the binding material from conventional cement-based concrete to a calcium silicate-carbonate-silica composite system. This parameter change allows the material to achieve similar mechanical properties while reducing environmental impact through lower production energy requirements and CO2 sequestration during the carbonation curing process
2Reliability
If conventional concrete materials are used, then the slabs meet performance requirements, but the production cost and environmental impact are unfavorable
Solution Approach 1:
The patent converts CO2, traditionally a harmful greenhouse gas, into a beneficial component by using it as a curing agent for the calcium silicate composite. The CO2 carbonates the calcium silicate phases, forming calcium carbonate and strengthening the material structure. This transforms CO2 from an environmental liability into a value-added ingredient that improves material performance while sequestering carbon
Solution Approach 2:
The patent employs a composite material formulation using calcium silicate phases, calcium carbonate, and silica in specific proportions. This composite replaces conventional concrete materials, achieving comparable performance characteristics while reducing production costs through the use of abundant raw materials and eliminating the need for expensive cement production processes
3Weight of moving object
If hollow cores are incorporated into the slab design, then the weight and material cost are reduced, but the structural integrity and bending resistance must be maintained
Solution Approach 1:
The calcium silicate-carbonate-silica composite material provides high strength-to-weight ratio, enabling the hollow-core design to achieve both weight reduction and maintained structural integrity. The composite's inherent mechanical properties allow for thinner walls and hollow sections while preserving bending resistance
Solution Approach 2:
The slab is segmented into hollow cores and solid sections, creating a voided structure that reduces overall weight and material usage. The hollow cores are strategically positioned to optimize both weight reduction and structural performance, with the composite material ensuring adequate bending resistance in the reduced-section areas
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables the creation of hollow-core slabs with superior physical and performance characteristics, achieving reduced production costs, lower energy consumption, and a more desirable carbon footprint, while maintaining or exceeding the properties of conventional concrete slabs.
Implementation Method 1
a fluid component with CO2, which reacts to form a carbonated product
Implementation Method 2
maintaining an atmosphere of CO2 and water vapor in the one or more interior ducts or channels; and curing the casted or extruded body at a temperature in the range from about 20°C to about 150°C for about 1 hour to about 80 hours under an atmosphere of water and CO2
Data Source
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AI summary
The invention provides novel articles of composite materials having hollow interior channels or passageways, or otherwise being hollowed out, and formulations and methods for their manufacture and uses. These hollow core objects are suitable for a variety of applications in construction, pavements and landscaping, and infrastructure.