Mineral binder

Patent metadata

Field	Value
Publication number	US-2023111461-A1
Application number	US-202117906117-A
Country	US
Kind code	A1
Filing date	Mar 15, 2021
Priority date	Mar 13, 2020
Publication date	Apr 13, 2023
Grant date	—

Abstract

The invention relates to a mineral binder suitable for use in binding aggregate in a mineral mortar or concrete mixture, said binder comprising the following components:a) at least 40 wt % of calcined kaolinitic clay and ultrafine crushed CDW,wherein the ratio between calcined clay and ultrafine crushed CDW is between 3:7 and 1:1 (w/w),b) optionally 2-50 wt. % of a chemical activator; andwherein the calcined kaolinitic clay, the ultrafine crushed CDW and the optionally present chemical activator are present in a combined amount of at least 90 wt. %, based on the total weight of the binder. The invention further relates to mineral mortar or concrete mixtures based on this mineral binder, as well as building units made from these mixtures.

First claim

1 . A mineral binder suitable for use in binding aggregate in a mineral mortar or concrete mixture, said binder comprising the following components:
a) at least 40 wt. % of a calcined kaolinitic clay and ultrafine crushed construction and demolition waste (CDW), b) 2-50 wt. % of a chemical activator; and wherein the calcined kaolinitic clay, the ultrafine crushed CDW and the chemical activator are present in a combined amount of at least 90 wt. %, based on the total weight of the binder.

2 . The mineral binder according to claim 1 , wherein the calcined kaolinitic clay, the ultrafine crushed CDW and the chemical activator are present in a combined amount of at least 95 wt. %, based on the total weight of the mineral binder.

3 . The mineral binder according to claim 1 , wherein the ultrafine crushed CDW is selected from the group consisting of ultrafine crushed ceramics, ultrafine crushed concrete and combinations thereof.

4 . The mineral binder according to claim 1 , wherein the ultrafine crushed CDW is ultrafine crushed brick and wherein the calcined kaolinitic clay and ultrafine crushed brick contains between 70-80 wt. % of SiO 2 , between 10 and 20 wt. % of Al 2 O 3 and between 2 and 6 wt. % of Fe 2 O 3 , based on the total weight of the mineral binder.

5 . A mineral mortar precursor mixture suitable for use in a mineral mortar mixture based on the mineral binder according to claim 1 in an amount of 15-50 wt. %, said mineral mortar precursor mixture further comprising:
c) 50-85 wt. % of a fine aggregate comprising particles having a diameter of up to 4 mm; and
wherein the combined amount of components a)-c) is at least 90 wt. %, based on the total weight of the mineral mortar precursor mixture.

6 . A mineral mortar mixture based on the mineral mortar precursor mixture of claim 5 in an amount of 65-96 wt. %, wherein said mineral mortar mixture comprises said chemical activator and wherein said mineral mortar mixture further comprises:
d) water in an amount of 25 wt. % or less, wherein the combined amount of components a)-d) is at least 90 wt. %, based on the total weight of the mineral mortar mixture.

7 . A concrete precursor mixture suitable for use in a concrete mixture based on the mineral binder according to claim 1 in an amount of 15-45 wt. %, said precursor concrete mixture further comprising:
c) 50-85 wt. % of a coarse and optionally fine aggregate, wherein the coarse aggregate comprises particles having a diameter of between 4 mm and 50 mm; and
wherein the combined amount of components a)-c) is at least 90 wt. %, based on the total weight of the concrete precursor mixture.

8 . A concrete mixture based on the concrete precursor mixture of claim 7 in an amount of 65-96 wt. %, wherein said concrete mixture comprises said chemical activator and wherein said concrete mixture further comprises:
d) 4-25 wt. % of water; wherein the combined amount of components a)-d) is at least 90 wt. %, based on the total weight of the concrete mixture.

9 . A building unit based on the cured mineral mortar mixture of claim 6 , comprising a soluble calcium content of less than 12.5 wt. %.

10 . A building unit comprising a rigid layer, the rigid layer is at least partly covered with an outer layer of the cured mineral mortar mixture according to claim 6 , wherein the outer layer has a layer thickness in the range of 0.5 to 30 mm.

11 . The building unit according to claim 10 , wherein at least 10% of the surface of the rigid layer is covered by the outer layer.

12 . The building unit according to claim 10 wherein the outer layer has a maximum layer thickness of less than 20% based on the total thickness of the building unit.

13 . The building unit according to claim 10 , wherein said rigid layer comprises an insulating material having a thermal conduction value (A) less than 0.065 W/mK.

14 . The building unit according to claim 10 , wherein said rigid layer comprises an insulating material selected from the group consisting of expanded polystyrene (EPS), extruded polystyrene (XPS), polyisocyanurate (PIR), polyurethane (PUR), polyisocyanurate (PIR), biobased insulation materials, stonewool, glasswool, foamglass, hemp wool, phenolic foam, aerogel and combinations thereof.

15 . A method for the preparation of the building unit according to claim 10 , comprising the steps of:
providing the rigid layer in a suitable form; covering at least 10% of the surface of the rigid layer with the mineral mortar mixture; and allowing said mineral mortar mixture to cure.

16 . (canceled)

17 . A building, comprising the building units according to claim 10 .

18 . A sewage system, comprising the building units according to claim 9 .

19 . (canceled)

20 . (canceled)

21 . The mineral binder of claim 1 , wherein the calcined kaolinitic clay is metakaolin.

22 . The building unit of claim 10 , wherein said rigid layer is a rigid insulating layer with insulating properties.

23 . A building unit based on the cured concrete mixture of claim 8 , comprising a soluble calcium content of less than 12.5 wt. %.

Assignees

• TNO

Inventors

• Valcke Siska Lisa Albertine
• Visser Johanna Hendrica Maria
• Garzón Amórtegui Juan Felipe

Classifications

• Y02W30/91

  Use of waste materials as fillers for mortars or concrete · CPC title

• Y02P40/10

  Production of cement, e.g. improving or optimising the production methods; Cement grinding · CPC title

• C04B2111/29

  Frost-thaw resistance · CPC title

• C04B14/045

  Alkali-metal containing silicates, e.g. petalite (waterglass C04B12/04) · CPC title

• C04B2111/60

  Flooring materials · CPC title