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

Patent metadata

Field	Value
Publication number	US-2024010564-A1
Application number	US-202318210636-A
Country	US
Kind code	A1
Filing date	Jun 15, 2023
Priority date	Mar 20, 2015
Publication date	Jan 11, 2024
Grant date	—

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

1 .- 49 . (canceled)

50 . A bonding matrix comprising a plurality of bonding elements, wherein the bonding elements are selected from:
(a) a bonding element comprising a core of silica fully or partially surrounded by a silica rich rim of varying thickness that is fully or partially encased by CaCO 3 particles; (b) a bonding element comprising a multi-phase core comprised of an uncarbonatable phase and partially reacted 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; and (c) a bonding element comprising particles of partially reacted calcium silicate without a distinct core, and a silica rim encased by CaCO 3 particles.

51 . The bonding matrix of claim 50 , wherein the uncarbonatable phase is selected from silica and melilite.

52 . The bonding matrix of claim 50 , wherein the calcium silicate is selected from wollastonite, pseudowollastonite, rankinite, belite, and carbonatable amorphous calcium silicates, or a combination of two or more thereof.

53 . The bonding matrix of claim 50 , wherein one or more bonding elements comprise one or more voids.

54 . The bonding matrix of claim 50 , further comprising one or more voids spatially disposed between bonding elements.

55 . The composite material of claim 50 , wherein the silica rich rim has a thickness ranging from about 0.01 μm to about 50 μm.

56 . The composite material of claim 50 , wherein the silica rich rim 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.

57 . The composite material of claim 50 , wherein the silica rich rim of varying thickness surrounds the core with a coverage of greater than about 90%.

58 . The bonding matrix of claim 50 , wherein the bonding elements comprise:
(a) a bonding element comprising a core of silica fully or partially surrounded by a silica rich rim of varying thickness that is fully or partially encased by CaCO 3 particles.

59 . The bonding matrix of claim 58 , wherein the core is formed entirely from silica.

60 . The bonding matrix of claim 50 , wherein the bonding elements comprise:
(b) a bonding element comprising a multi-phase core comprised of an uncarbonatable phase and partially reacted 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.

61 . The bonding matrix of claim 60 , wherein the uncarbonatable phase forms the majority of the core.

62 . The bonding matrix of claim 50 , wherein the bonding elements comprise:
(c) a bonding element comprising particles of partially reacted calcium silicate without a distinct core, and a silica rim encased by CaCO 3 particles.

63 . A composite material comprising the bonding matrix of claim 50 , and one or more filler materials.

64 . The composite material of claim 63 , wherein the one or more filler materials are uniformly distributed in the bonding matrix.

65 . The composite material of claim 64 , further comprising one or more supplementary materials selected from fly ash, slag and silica fume.

Assignees

• Solidia Technologies Inc

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

• C04B28/188 Primary

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

• C04B35/22

  rich in calcium oxide {, e.g. wollastonite (C04B35/195 takes precedence)} · CPC title