Composite materials and bonding elements from carbonation of calcium silicate and methods thereof

Patent metadata

Field	Value
Publication number	US-11718566-B2
Application number	US-201615074692-A
Country	US
Kind code	B2
Filing date	Mar 18, 2016
Priority date	Mar 20, 2015
Publication date	Aug 8, 2023
Grant date	Aug 8, 2023

Abstract

The invention provides composite materials comprising novel bonding elements exhibiting unique microstructures and chemical compositions, and methods for their manufacture and uses, for example, in a variety of concrete components with or without aggregates in the infrastructure, construction, pavement and landscaping industries.

First claim

What is claimed is:

1. A composite material produced by carbonation of calcium silicate with CO 2
comprising a plurality of bonding elements,
said bonding elements comprising a multi-phase core comprised of intermixed silica and calcium silicate, which multi-phase core is fully or partially surrounded by a silica rich rim of varying thickness that is fully or partially encased by CaCO 3 particles;
wherein the silica rich rim has a thickness ranging from about 0.01 μm to about 50 μm and is characterized by a silica content ranging from about 50% to about 90% by volume and a CaCO 3 content ranging from about 10% to about 50% by volume.

2. The composite material of claim 1 , wherein the calcium silicate is selected from wollastonite, pseudowollastonite, rankinite, belite, and carbonatable amorphous calcium silicates, or a combination of two or more thereof.

3. The composite material of claim 1 , further comprising one or more voids spatially disposed between bonding elements.

4. The composite material of claim 1 , further comprising one or more filler materials.

5. The composite material of claim 4 , wherein the one or more filler materials are uniformly distributed in the bonding matrix.

6. The composite material of claim 1 , further comprising one or more supplementary materials selected from fly ash, slag and silica fume.

7. A bonding matrix comprising a plurality of bonding elements, wherein the bonding elements comprise
a multi-phase core comprised of intermixed silica and calcium silicate, which multi-phase core is fully or partially surrounded by a silica rich rim of varying thickness that is fully or partially encased by CaCO 3 particles;
wherein the silica rich rim has a thickness ranging from about 0.01 μm to about 50 μm and is characterized by a silica content ranging from about 50% to about 90% by volume and a CaCO 3 content ranging from about 10% to about 50% by volume.

8. The bonding matrix of claim 7 , wherein the calcium silicate is selected from wollastonite, pseudowollastonite, rankinite, belite, and carbonatable amorphous calcium silicates, or a combination of two or more thereof.

9. The bonding matrix of claim 7 , further comprising one or more voids spatially disposed between bonding elements.

10. The composite of claim 7 , wherein the silica and the calcium silicate are intermixed at a central region.

11. The composite material of claim 1 , wherein the silica and the calcium silicate are intermixed at a central region of the core.

Assignees

• Solidia Technologies Inc
• Lafarge Sa

Inventors

• Atakan Vahit
• Sahu Sadananda
• Quinn Sean
• Decristofaro Nicholas
• Meyer Vincent
• Comparet Cédric
• Walenta Günther

Classifications

• C04B2111/00019

  Carbon dioxide sequestration · CPC title

• C04B40/0231

  Carbon dioxide hardening · CPC title

• C04B28/24 Primary

  containing alkyl, ammonium or metal silicates; containing silica sols {(reaction mixtures resulting in mineral polymers C04B28/006; polymeric reaction products of alkali metal silicates with isocyanates C08G18/3895)} · CPC title

• C04B7/345

  Hydraulic cements not provided for in one of the groups C04B7/02 - C04B7/34 · CPC title

• C04B28/188 Primary

  the Ca-silicates being present in the starting mixture · CPC title