Cementitious composite material including a plurality of filled fibers

Patent metadata

Field	Value
Publication number	US-10513460-B2
Application number	US-201414899376-A
Country	US
Kind code	B2
Filing date	May 20, 2014
Priority date	Jun 21, 2013
Publication date	Dec 24, 2019
Grant date	Dec 24, 2019

Abstract

A composite material includes a cementitious composition and a plurality of fibers disposed in the cementitious composition. Each of the plurality of fibers includes a plastic component. Each of the plurality of fibers further includes a surfactant and a metal oxide, each independently heterogeneously dispersed throughout each of the plurality of fibers. A method of forming the composite material includes the step of combining the plastic component, the surfactant, and the metal oxide, to form the plurality of fibers. The method further includes the step of disposing the plurality of fibers in the cementitious composition to form the composite material.

First claim

What is claimed is:

1. A composite material comprising: a cementitious composition; and a plurality of fibers disposed in said cementitious composition, each of said plurality of fibers comprising;
a plastic component,
a surfactant, and
a metal oxide;
wherein each of said surfactant and said metal oxide is independently heterogeneously dispersed throughout each of said plurality of fibers, wherein said metal oxide comprises silicon dioxide, and
wherein said surfactant is chosen from the group of an alcohol alkoxylate, an alcohol block/heteric alkoxylate, a polyoxyethylene/polyoxypropylene block/heteric copolymer, a fatty alcohol, a fatty alkoxy alcohol, a polyalkylene glycol, a alkylphenol alkoxylate, and combinations thereof.

2. The composite material of claim 1 wherein said metal oxide is present in an amount of from 0.1 to 5 weight percent based on a total weight of said plurality of fibers.

3. The composite material of claim 1 wherein said surfactant is an alcohol alkoxylate.

4. The composite material of claim 1 wherein said surfactant is an alcohol block/heteric alkoxylate.

5. The composite material of claim 1 wherein said surfactant is a polyoxyethylene/polyoxypropylene block/heteric copolymer.

6. The composite material of claim 1 wherein said surfactant is a fatty alcohol.

7. The composite material of claim 1 wherein said surfactant is a fatty alkoxy alcohol.

8. The composite material of claim 1 wherein said surfactant is a polyalkylene glycol.

9. The composite material of claim 1 wherein said surfactant is an alkylphenol alkoxylate.

10. The composite material of claim 1 wherein said surfactant has an average molecular weight of less than or equal to 100,000 g/mol.

11. The composite material of claim 1 wherein each of said plurality of fibers comprises greater than 0 to less than or equal to 10 parts by weight of said surfactant based on 100 parts by weight of each of said plurality of fibers.

12. The composite material of claim 1 wherein said plastic component is chosen from the group of polyolefins, polyolefin elastomers, polystyrene, polyvinyl chloride, and combinations thereof.

13. The composite material of claim 12 wherein said polyolefin is polyethylene, polypropylene, polymethylpentene, polybutene-1, or combinations thereof.

14. The composite material of claim 1 wherein each of said plurality of fibers comprises at least 90 parts by weight of said plastic component based on 100 parts by weight of each of said plurality of fibers.

15. The composite material of claim 1 wherein said cementitious composition is further defined as concrete.

16. The composite material of claim 1 wherein said plurality of fibers is present in an amount of from 0.1 to 5 parts by weight based on 100 parts by weight of said composite material.

17. A method of forming a composite material comprising a cementitious composition, and a plurality of fibers disposed in the cementitious composition and comprising a plastic component, a surfactant, and a metal oxide, said method comprising the steps of:
combining the plastic component, the surfactant, and the metal oxide to form the plurality of fibers; and
disposing the plurality of fibers in the cementitious composition to form the composite material;
wherein each of the surfactant and the metal oxide is independently heterogeneously dispersed throughout each of said plurality of fibers,
wherein the surfactant is chosen from the group of an alcohol alkoxylate, an alcohol block/heteric alkoxylate, a polyoxyethylene/polyoxypropyl ene block/heteric copolymer, a fatty alcohol, a fatty alkoxy alcohol, a polyalkylene glycol, a alkylphenol alkoxylate, and combinations thereof, and wherein said metal oxide comprises silicon dioxide.

18. The method of claim 17 wherein the step of combining the plastic component and the surfactant to form the plurality of fibers includes:
extruding the plastic component, the surfactant, and the metal oxide through a first extruder at a temperature of from 185° C. to 215° C. to form at least one strand;
quenching the at least one strand with water and subsequently cutting the at least one strand quenched with water to form pellets; and
extruding the pellets through a second extruder to form the plurality of fibers.

19. The method of claim 18 wherein the first extruder is further defined as a single screw extruder.

20. The method of claim 19 wherein the first extruder is further defined as a twin screw extruder.

21. The method of claim 18 wherein the first extruder has a length to diameter ratio (L/D) of from 35 to 1 to 45 to 1.

22. The method of claim 18 wherein the first extruder comprises a screw rotating at a speed of 140 to 160 revolutions per minute (RPM).

23. A composite material comprising: a cementitious composition;
and a plurality of fibers disposed in said cementitious composition, each of said plurality of fibers comprising;
polypropylene,
a surfactant chosen from the group of an alcohol alkoxylate, an alcohol block/heteric alkoxylate, a polyoxyethylene/polyoxypropylene block/heteric copolymer, a fatty alcohol, a fatty alkoxy alcohol, a polyalkylene glycol, a alkylphenol alkoxylate, and combinations thereof and present in an amount of greater than 0 to 10 weight percent based on a total weight of said plurality of fibers, and
silicon dioxide present in an amount of from 0.1 to 5 weight percent based on a total weight of said plurality of fibers;
wherein each of said surfactant and said silicon dioxide is independently heterogeneously dispersed throughout each of said plurality of fibers.

Assignees

• Construction Research & Technology Gmbh

Inventors

• Kerobo Charles
• Attiogbe Emmanuel
• Chirayil Thomas
• Reinicker Roger
• Vojtko Dan
• Schaef Steve
• Randolph John

Classifications

• B29C48/05

  Filamentary, e.g. strands · CPC title

• C04B20/0068

  Composite fibres, e.g. fibres with a core and sheath of different material · CPC title

• C04B20/0048

  Fibrous materials · CPC title

• C04B28/02

  containing hydraulic cements other than calcium sulfates · CPC title

• C04B16/0633 Primary

  Polypropylene · CPC title