U.S. patent application number 15/210694 was filed with the patent office on 2017-01-05 for premixing and dry fibration process.
The applicant listed for this patent is Carlos Javier FERNANDEZ-GARCIA. Invention is credited to Carlos Javier FERNANDEZ-GARCIA.
Application Number | 20170001907 15/210694 |
Document ID | / |
Family ID | 39429921 |
Filed Date | 2017-01-05 |
United States Patent
Application |
20170001907 |
Kind Code |
A1 |
FERNANDEZ-GARCIA; Carlos
Javier |
January 5, 2017 |
PREMIXING AND DRY FIBRATION PROCESS
Abstract
The process is described for the dry mixing of fibers of
different types and sizes with materials formulated with cementants
or agglutinant components, granular aggregates and able to include
or otherwise other additional ingredients. The principal
characteristics of the process are to ensure a correct
incorporation of the fibers with the rest of the materials,
increase the mechanical fastening of same with the rest of the
components and facilitate the use of formulas with high fiber
content (over-fibration).
Inventors: |
FERNANDEZ-GARCIA; Carlos
Javier; (Morelos, MX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FERNANDEZ-GARCIA; Carlos Javier |
Morelos |
|
MX |
|
|
Family ID: |
39429921 |
Appl. No.: |
15/210694 |
Filed: |
July 14, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12516792 |
Jan 11, 2010 |
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PCT/MX06/00130 |
Nov 21, 2006 |
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15210694 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C04B 16/0683 20130101;
C04B 16/0616 20130101; C04B 2111/00293 20130101; C04B 26/06
20130101; C04B 14/06 20130101; C04B 2111/802 20130101; C04B 16/0633
20130101; C04B 16/0691 20130101; C04B 16/0625 20130101; Y02W 30/97
20150501; Y02W 30/91 20150501; C04B 28/02 20130101; C04B 16/065
20130101; C04B 26/06 20130101; C04B 14/10 20130101; C04B 14/18
20130101; C04B 24/38 20130101; C04B 28/02 20130101; C04B 14/06
20130101; C04B 14/22 20130101; C04B 20/0048 20130101; C04B 20/0076
20130101; C04B 40/0028 20130101; C04B 28/02 20130101; C04B 14/06
20130101; C04B 14/22 20130101; C04B 14/48 20130101; C04B 20/0076
20130101; C04B 40/0028 20130101; C04B 28/02 20130101; C04B 14/06
20130101; C04B 14/22 20130101; C04B 16/08 20130101; C04B 20/0076
20130101; C04B 40/0028 20130101; C04B 28/02 20130101; C04B 14/06
20130101; C04B 14/22 20130101; C04B 18/24 20130101; C04B 20/0076
20130101; C04B 40/0028 20130101 |
International
Class: |
C04B 16/06 20060101
C04B016/06; C04B 14/06 20060101 C04B014/06; C04B 28/02 20060101
C04B028/02 |
Claims
1-34. (canceled)
35. A cementitious product comprising a mixture of micro-structured
components, comprising: fibers having thicknesses of from about
0.02 .mu.m to about 5008 .mu.m and lengths of from about 0.2 mm to
about 100 mm; cementants or agglutinant compounds selected from
Portland cement or Puzolana cement, polymers, glass, clay, gum,
elastomer, volcanic ash and combinations thereof; and sandy
granular materials having particle sizes from about 400 mesh (0.037
mm) to about 25 mm.
36. The cementitious product in accordance with claim 35, wherein
the fibers are organic, inorganic, mineral, non mineral, natural,
synthetic or metallic, or mixtures thereof.
37. The cementitious product in accordance with claim 35, wherein
the fibers are of the same or different thicknesses and of the same
or different lengths.
38. The cementitious product in accordance with claim 35, wherein
the fibers are monofilament or multifilament fibers having circular
cross-sections or of other naturally occurring or synthetic
forms.
39. The cementitious product in accordance with claim 36, wherein
the fibers are polymer fibers selected from the group consisting of
polyethylene, polypropylene, polyester, polyamide, acrylic,
polyvinyl and aramid fibers, and are in an amorphous-cylindrical
state.
40. The cementitious product in accordance with claim 35, wherein
the fibers have thicknesses of from about 0.02 .mu.m to about 600
.mu.m.
41. The cementitious product in accordance with claim 40, wherein
the fibers have thicknesses of from about 100 .mu.m to about 200
.mu.m.
42. The cementitious product in accordance with claim 35, wherein
the fibers have lengths from about 3 mm to about 80 mm.
43. The cementitious product in accordance with claim 35, wherein
the cementant is Portland cement or Puzolana cement.
44. The cementitious product in accordance with claim 35, wherein
the sand granular materials have particle sizes from about 400 mesh
to about 9.5 mm.
45. The cementitious product in accordance with claim 35, wherein
the sand granular materials have particle sizes from about 0.149 mm
to about 9.5 mm.
46. The cementitious product in accordance with claim 35, further
comprising water, such that while setting the cementitious product
can be formed to a desired shape without forms or molds.
47. A cementitious product comprising a mixture of micro-structured
components, prepared by: adding multiple stages of loads of sandy
granular materials consisting of particle sizes from 0.149 mm to
9.5 mm and fibers to a mixer; mixing each bad of said sandy
granular materials and fibers for 5 to 10 seconds; adding and
mixing cementant materials to said mixer to form a dry premix
product having an isotropic and homogeneous distribution of said
fibers; adding and mixing water; and unloading said cementitious
product from said mixer, wherein while setting the cementitious
product can be formed to a desired shape without forms or
molds.
48. The cementitious product in accordance with claim 47, wherein
the fibers are organic, inorganic, mineral, non mineral, natural,
synthetic or metallic, or mixtures thereof.
49. The cementitious product in accordance with claim 47, wherein
the fibers are of the same or different thicknesses and of the same
or different lengths.
50. The cementitious product in accordance with claim 47, wherein
the fibers are monofilament or multifilament fibers having circular
cross-sections or of other naturally occurring or synthetic
forms.
51. The cementitious product in accordance with claim 50, wherein
the fibers are polymer fibers selected from the group consisting of
polyethylene, polypropylene, polyester, polyamide, acrylic,
polyvinyl and aramid fibers, and are in an amorphous-cylindrical
state.
52. The cementitious product in accordance with claim 47, wherein
the fibers have thicknesses of from about 0.02 .mu.m to about 600
.mu.m.
53. The cementitious product in accordance with claim 52, wherein
the fibers have thicknesses of from about 100 .mu.m to about 200
.mu.m.
54. The cementitious product in accordance with claim 47, wherein
the fibers have lengths from about 3 mm to about 80 mm.
55. The cementitious product in accordance with claim 47, wherein
the cementant is Portland cement or Puzolana cement.
Description
[0001] This application is a divisional of U.S. patent application
Ser. No. 12/516,792, filed Jan. 11, 2010, which is incorporated
herein by reference in its entirety.
FIELD OF INVENTION
[0002] This process innovates the production of premixing products
for application in the arts, construction, engineering and industry
in general for diverse products that contain cementants and/or
adhesives or agglutinants, as well as loads or fine and/or heavy
aggregates in a dry and inactive state, typically in powder or
granular products prior to activation in order for their hardening
process to start. In particular, these materials will be fibrated,
micro-fibrated and/or multi-fibrated using this process, as well as
micro-structured and/or pre-structured, whichever is
applicable.
[0003] This invention also increases the content of fiber in
material, referred to hereinafter as "over-fibration", since due to
its technical status, amounts of fiber considerably lower than
those proposed are used. The purpose of "over-fibration",
independently of inhibiting the formation of fissures and
micro-fissures during initial and subsequent setting, is to provide
greater mechanical resistance in an isotropic arrangement and thus
modify the rheology of the material by interconnecting the
filaments.
OBJECT OF THE INVENTION
[0004] This new process guarantees an appropriate and correct
dosing and homogeneity in dry fibration of materials prior to the
application process. This process is used to fibrate cement-based
concrete and mortar (Portland or Puzolana) and compound material
based on other cements that include loads or granular aggregates.
It is therefore very important for the micro-structure the compound
materials and the so-called super materials and micro-concrete.
[0005] Materials obtained in this manner have increased mechanical
resistance, which is manifested isotropically, reduced permeability
due to the reduction of pores, the reduction or elimination of the
formation of cracks that form due to shrinking during setting, the
elasticity module is modified favorably and the rupture pattern
become more favorable because the rupture ceases to be fragile and
therefore maintains residual resistance that acts to reduce the
collapse of structures that have been exposed to excessive stresses
or earthquakes.
[0006] Although the practice of incorporate fibers in fresh
concrete already exists, the object of this patent is also to allow
the use of greater proportions of fiber with regard to the
cementants and aggregates, in amounts substantially greater (up to
10 times greater and in even greater proportions) that were not
possible prior to this invention. This invention also allows the
anchoring of fibers by favorably modifying their surface
properties.
BACKGROUND
[0007] The occasional use of fibers to reinforce the stopping of
the formation of cracks in the technical status is already known,
in my U.S. Pat. No. 6,099,638 describes the use of fibers in
rheological applications, concrete, micro-concrete and mortar.
Although the technical status mentions the use of fibers (for
example Garcia Rivero, J. L., "Technical Construction Manual",
published by Cementos Apasco), the mixture of fibers with the
components of concrete is prepared in a fresh, i.e., in a damp
state. The need to formulate the application in a dry state
described in my aforementioned U.S. Pat. No. 6,099,638 led to the
development of this invention.
[0008] In the particular case of the preparation of concrete and
mortars, cement, sand, gravel, additives were used and water was
added to start the setting process, and in some cases,
reinforcement fibers were added to prior to laying or application.
Due to the fluidity of these mixtures during setting, certain means
to contain and give them form must be used, for example, the
ground, frames, molds or forming.
[0009] When the designer decides to use fibers to reinforce the
stopping of cracks, which fibers are incorporate in the mix having
added water or a precursor agent and dry fibration processes are
not used. The incorporation of fibers in the wet mix leads to
problems of a lack of uniformity, compactness and stratification of
the fibers and the jamming of the mixing equipment. By the other
hand, the manner in which the fibers prevent to achieve the
mechanical fastening with the rest of the mix. Up to now, these
problems have limited the concentration of fibers in the mix and
their full use, regardless that by increasing the percentage of the
fibers recommended affects and even prevents the correct laying of
the concrete in its forming or molds.
[0010] Problems arise during the mixing of fibers with wet
materials that have prevented the correct incorporation of the
fibers because compactness is generated, mixing is difficult or the
mix stratifies or settles and a sufficiently uniform mix cannot be
obtained. This has limited the range of fiber formulations,
reducing it to small proportions in relation to the other
ingredients, to the order of 0.02% of fiber by weight in relation
to the wet mix or typically 600 g of fiber for each cubic meter of
wet mix for formulations based on Portland-type cement with gravel
and sand, according to the technical recommendations of the
providers of this type of fiber. This proportion is equivalent to
0.024% of the weight of the dry mix (without adding water).
[0011] Prior to the aforementioned patent, these fibers were many
used to reduce fissures that appeared during contracting while
drying in mortars and concrete and with the intention of providing
a certain amount of reinforcement for this purpose, although with
limited success. Before this invention, there was no process that
permitted a successful dry formulation and to date, the
manufacturers and the fibration standards themselves recommend or
stipulate the application in a fresh state (at the time of mixing)
and in a low proportion in relation to the rest of the
ingredients.
[0012] Said dosing, mixing and wet materials management process
used by the technical status is appropriate for applications used
in the previous arts on the construction site.
[0013] Besides the problems mentioned, there are other additional
problems that arise in the application of fiber when using rocky
materials, such as (i) the mechanical fastening of the fibers with
the rest of the material components (cementants and load) is so low
that the mechanical resistance of the fibers is not used to the
fall, which prevents it reaching its full capacity in the
formulation of the material and (ii) the lack of uniformity in the
concentration of fibers in the resulting material.
[0014] The process forming the subject matter of this invention
solves all of these problems by applying controlled dispersal and
abrasion forces that distributes the fibers uniformly, positively
modify therefore, maximize the surface area of the solid
(fiber)-solid (cementants) interfaces and ensure intimate contact
with the cementing components of the mix with the fibers in order
to use its resistance to the maximum. The dry mix is homogenous in
terms of the concentration of fibers and this homogeneity is
maintained when the mix is hydrated or activated for setting and
subsequent application. This ensures that the final properties are
as intended by the formulation of the mix and increase the
possibilities of dosing, multi-fibration and over-fibration of
mortar, concrete, micro-concrete and other compound materials. This
process increases the capacity of uniform dosing of fibers or
micro-fibers and their mechanical fastening, which leads to the
commencement of a physical pre-structure process and achieves the
positive modification of the properties of the product.
[0015] The phenomenon on which this invention is based arises
primarily in the dry mix, without spoiling the complementary use of
the wet mix method.
[0016] This knowledge (which is basic for innovation) has
demonstrated that the shortcomings of construction materials is
generally due to that constructors do not have access to
well-manufactured materials or super-materials (so-called due to
their resistance and high-performance).
[0017] This novel dry-fibration process is applicable both for
concrete and mortar based on Portland or Puzolana cement and for
compound materials based on other different types of
cementants.
DESCRIPTION OF THE INVENTION
[0018] The object of this invention is to achieve the correct
fibration and over-fibration of compound materials that include
fiber in their formulation for the purposes of reducing an
isotropic material, the elements of which are perfectly aligned in
such a manner that they comply fully with the design
specifications, such as resistance to compression stress, tension
and flexion, permeability, resistance to rupture, elasticity
module, workability in a fresh state, shrinkage, surface finishing,
setting, etc.
[0019] The type of fiber (material, thickness, shape, length,
resistance, etc.) shall be appropriate for the specific application
and may be organic, inorganic, mineral, non-mineral, natural,
synthetic, smooth or textured (with terminals or nodes) or other
predetermined shapes to increase mechanical fastening. The type of
fiber may be single or two or more multiple fibers used
simultaneously, including thicknesses (of 0.02 .mu.m to 5008 .mu.m
or their equivalents of 0.78 to 200 thousands of an inch), lengths
(typically 0.2 to 100 mm and if required by the designer,
continuous fibers of lengths similar to the length of the mold or
the finished piece) and materials such as those mentioned in the
following paragraphs in order to provide different characteristics
to the resulting materials.
[0020] At the same time the cementants, which can be based on
Portland or Puzolana cement or polymers (natural or synthetic),
glass, clays (natural or synthetic) and the additives and loads
should be dosed based on the specific needs of the designer for the
desired applications.
[0021] For example, in the specific case of materials for rocky
products applicable to construction in general, the use of
polyolefins, polypropylene and polyethylene fibers is recommended,
alone or combined, and whether of a conventional or micro-fiber
type, together with monofilaments and multi filaments. The use of
fibers in other materials is also included, such as different
polymers, (polyester, polyamides, acrylic, polyvinyl, aramid
(Kevlar.RTM.) and others), inorganic fibers, (glass, coal,
metallic, mineral, ceramics, etc.) organic (cellulose, vegetal and
animal), etc.
[0022] The dry fibration process allows the fibers, on being
subjected in a controlled manner to the abrasion forces, undergo a
modification to the cylindrical state which results in their
extrusion and elongation process passing to an
amorphous-cylindrical state which considerably benefits the
mechanical anchoring of the fiber and results in a very significant
increase in the surface area which the fiber will present to the
cementant.
[0023] In order to continue with the "optimum process" (solely as
an example), it is advisable that dosing take place at intervals
with the granular loads (basically sands), and subsequently, as
applicable, heavy aggregates, gravels for example, and conclude
finally with the cementant, without discarding that the heavy
aggregates can be mixed fresh, at the work site.
[0024] To do this as an additive (without loads) or with micronized
loads, the mixing time should be increased and inspection tests
carried out to ensure the correct incorporation and uniform
distribution of the fibers.
[0025] For this type of materials an abrasive process is
recommended. This can be achieved through various mixing methods in
the technical state, to mention only a few: the "trouser" type
mixers with paddles, the helicoidal worm, the intensive mixer and
others which are highly efficient. This patent does not pretend to
design the optimum model of machinery for the mixing. The intention
is to claim the inventive concept of the process for dry fibration
and over-fibration.
[0026] The advantages of the novel concept of dry fibration will
benefit the isotropy and uniformity, being even able to
micro-structure by increasing the resistance of the materials. It
will also facilitate application and work at the work-site, thus
making it possible to have premixed fibrated materials
available.
[0027] This process also benefits the end resistances, and when
well dosed and executed can even eliminate the pores from the end
product. This characteristic has the novel effect that with certain
formulas a material with a very high level of impermeability is
obtained. On another aspect, novel materials obtained from this
process are generated which can be utilized as high resistance
micro-structured rocky materials for reinforcement operations or as
a structural element in itself, and also for waterproofing due to
its low permeability.
[0028] Also, when the materials are dosed, fibrated and mixed with
suitable formula following the recommendations contained herein and
the claims of this patent, the stress-deformation curves of the
materials can be favorably modified on an average of 500%, thus
benefiting resistances as important as the anti-seismic. With this
we achieve a new generation of mortars and concretes and sundry
other materials, and promote a better use of cementants.
[0029] An additional point is that the invention does not imply the
use of materials harmful to health or the environment. For this
object the recommendation is not to utilize fibers such as asbestos
or those which, due to their size and properties, remain suspended
in the air and do not decant.
[0030] The process forming the subject matter of this invention
consists of the following: [0031] 1. Design of the product (for
specific application), preferably to obtain a micro structured
product. In this product, the proportions of the cementing agent,
granular material (aggregates), additives, hardener, water (as
applicable), fibers and other components of the mixture and other
characteristics known by the designer to obtain the physical,
mechanical and molding characteristics required for the application
considered will be established. [0032] 2. Initial mixture,
preferably with the most abrasive or granular products (a
helicoidal mixer is recommended, although other types of mixer can
be used by making the adjustments corresponding to process
conditions). [0033] 3. Strict supervision that the product is
homogenous. In the first applications it is recommended that an
optical microscope be used for inspection.
[0034] Once the optimum type of fiber or fibers have been selected
for the purpose desired on formulating the material, the load of
fiber will be mixed with the rest of the components in accordance
with the following process:
Stage A (First Step): One part of granular material (aggregates)
will be loaded in the mixing equipment, preferably of particle size
which is in the range from about 400 mesh to about 25 mm, more
preferably in the range from 0.149 mm to 9.5 mm, corresponding to
sands and grits. Stage B (Second Step): A proportional part of the
fibers is loaded. The process forming the subject matter of this
invention is applicable to cylindrical section fibers, and also to
non-cylindrical section fibers such as sundry natural and synthetic
fibers available on the market. It is also applicable to smooth,
textured, fuzzy and pre-determined fibers, either in mono or multi
filament.
[0035] The process forming the subject matter of this invention
possesses sufficient flexibility for application to mixtures
incorporating fibers of different origins, such as organic,
inorganic, mineral, non-mineral, natural and synthetic.
[0036] This process is applicable to fibers of different lengths
and diameters (calibers), which can range from a length of 3 mm to
80 mm with a diameter from 0.02 .mu.m to 600 .mu.m, preferably in a
range from 5 mm to 50 mm in length and with a diameter of 100 .mu.m
to 200 .mu.m (if mono filament fibers or for the individual
elements of the multi filaments).
Stage C (Third Stage): The mixture is applied briefly (5 to 10
seconds) Subsequent Steps: The adding continues of successive loads
of granular material and fibers in the same way with brief
intermediate mixing, until the total load has been completed. The
mixing of the total load of fiber with the sandy granular material
then takes place for a period of 45 to 900 seconds, preferably in
the range of 60 to 720 seconds. More specifically, the time will be
determined by the characteristics of the fiber itself, including
its hardness), the granular material, other components of the
mixture and the intensity of the abrasive mixing due to the type
and characteristics of the mixing equipment. It can also take place
in a single stage if the intensity and time of the mixing are
increased. Termination: The remaining components involved in
formulation of the mixture such as the larger granules, the
cementants and other components, are then added and the final
mixture takes place during a period ranging from 10 to 900
additional seconds, and preferably from 90 to 600 seconds. More
specifically, the final mixing time will depend on the properties
of the mixture components, on the size of the ingredients of lesser
and greater size, their densities and the intensity of the abrasive
mixture, based on the type and characteristics of the mixing
equipment. Discharge: In this stage a low intensity movement is
maintained, always providing the characteristics of the equipment
so permit, in order to retain the homogeneity of the fibrated
mixture.
[0037] A third version of the present invention consists of the
following:
[0038] Once stages A, B and C have been completed (steps 1 to 3),
of the first pattern, incorporation of the fibers takes place as
follows:
Stage D (First Step): Part of the granular material is loaded in
mixing equipment of a continuous type, preferably of a particle
size coming within the sands and grits range. The granular material
can be dosed through a feeder of the vibratory or revolving band or
helical worm type.
[0039] Stage E (Second Step): A proportional part of the fibers are
loaded by means of a worm-type feeder.
Following Steps: Successive loads of granular material and fibers
will be added continually until all the loads have been placed.
[0040] The mixing of the total load of fiber with the granular
material will then take place during a period ranging from 45
seconds to 20 minutes, preferably in the 60 to 900 second range,
and the time will be determined more specifically by the
characteristics of the fiber itself (including its hardness), the
granular materials, other components of the mixture and the
intensity of the abrasive mixture, depending on the type and
characteristics of the mixing equipment. A rotary drum-type mixer
with or without inner partition walls is recommended.
[0041] Discharge: This stage is carried out by maintaining the
movement with low intensity, always providing the characteristics
of the equipment so permit, in order to retain the homogeneity of
fibrated mixture.
[0042] A fourth embodiment of the present invention consists of
utilizing fibers of greater length, up to several meters.
[0043] In this fourth embodiment, the fibers are conditioned by
having a mixture of only the granular materials in any of the
methods 1 to 3.
[0044] The conditioned fibers then separate while mixture of the
formula takes place, following the descriptions of methods 1 to
3.
[0045] The mixture between formula ingredients and the long
previously-conditioned fibers, together with the granules used in
the conditioning, is then combined with the rest of the dry
formula, preferably following the form of the final piece it is
desired to produce. This operation can incorporate an adjustment of
the fibers to place the resistance in the desired direction.
[0046] Finally, the water or the activator agent of the setting is
added, it should be mixed or kneaded in order to maintain the
homogeneity of the water or activator incorporated. This step is
easy due the pre conditioning fibers according to this invention
can be incorporated more easily with the dry formula and it
produces a wet mix more uniform.
[0047] This embodiment is advantageous for manufacturing processes
of extruded or formed pieces with mechanical processes.
* * * * *