Pervious Composite Materials via Gas-Assisted Hydrothermal Sintering
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Solution Overview
Problem
Pervious concrete materials face limitations in high volume traffic areas due to durability and weather resistance issues, require specialized construction practices, and are sensitive to water content and control, making them costly and energy-intensive to produce.
Innovation Solution
A process for producing pervious composite materials using widely available, low-cost raw materials like particulate calcium silicate and aggregates, with a fluid component of water and CO2, allowing for efficient gas-assisted hydrothermal liquid phase sintering, reducing equipment needs and energy consumption while enhancing carbon footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pervious concrete is used, then water permeability is achieved, but durability and weather resistance are insufficient
Solution Approach 1:
The invention uses composite materials combining calcium silicate particles, calcium carbonate particles, and silica gel to create a bonding matrix that provides both water permeability and enhanced durability. This composite approach allows the material to maintain pore structure for water flow while the chemical bonds between components provide weather resistance.
Solution Approach 2:
The invention changes the chemical composition parameters by using calcium silicate as the primary binder instead of traditional Portland cement, and controls the particle size distribution of calcium carbonate (3-60 μm) and silica gel (1-50 μm) to optimize both durability and permeability properties.
2Productivity
If conventional pervious concrete production is used, then material is produced, but energy consumption is high
Solution Approach 1:
The invention changes the curing temperature parameter from conventional high-temperature cement curing to low-temperature curing at 20-100°C, dramatically reducing energy consumption while maintaining production efficiency through the chemical reaction between calcium silicate, calcium carbonate, and water.
Solution Approach 2:
The invention replaces the mechanical/thermal system of high-temperature cement hydration with a chemical system based on the reaction between calcium silicate, calcium carbonate, and water that proceeds at ambient to moderate temperatures, reducing energy input requirements.
3Strength
If conventional pervious concrete is used, then structural integrity is achieved, but curing time is extended
Solution Approach 1:
The invention changes the chemical composition to use calcium silicate and calcium carbonate particles with specific size ranges, and controls the water-to-binder ratio to accelerate the chemical reaction rate, achieving full structural integrity within 6-60 hours at 20-100°C compared to extended curing times for conventional concrete.
4Reliability
If specialized construction practices are used, then pervious concrete performance is achieved, but manufacturing complexity increases
Solution Approach 1:
The invention uses homogeneous mixing of calcium silicate particles, calcium carbonate particles, and water to form a uniform slurry that self-bonds without requiring specialized construction techniques. The consistent particle size distribution and chemical composition ensure uniform performance throughout the structure.
Solution Approach 2:
The calcium silicate and calcium carbonate particles self-bond through chemical reaction with water to form a cohesive matrix, eliminating the need for specialized bonding agents or complex construction procedures. The material self-hardens and self-bonds under controlled curing conditions.
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 process results in pervious composite materials with improved durability, water permeability, and reduced curing time, offering a cost-effective, environmentally friendly solution for large-scale production with enhanced mechanical properties and carbon neutrality.
Implementation Method 1
efficient gas-assisted hydrothermal liquid phase sintering (HLPS) process
Implementation Method 2
a reagent, comprising carbon dioxide (CO2), which is consumed in the production as a reactive species and ends up sequestered in the final product
Implementation Method 3
curing the casted wet mixture at a temperature in the range from 20°C to 100°C for 6 hour to 60 hours under an atmosphere of water vapor and CO2
Data Source
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AI summary
The invention provides novel pervious composite materials that possess excellent physical and performance characteristics of conventional pervious 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.