Pervious composite materials, methods of production and uses thereof

Patent metadata

Field	Value
Publication number	US-9938189-B2
Application number	US-201414295601-A
Country	US
Kind code	B2
Filing date	Jun 4, 2014
Priority date	Jun 7, 2013
Publication date	Apr 10, 2018
Grant date	Apr 10, 2018

Abstract

The invention provides novel pervious composite materials that possess excellent physical and performance characteristics of conventional pervious concretes, and methods of production and uses thereof. These composite materials can be readily produced from widely available, low cost raw materials by a process suitable for large-scale production with improved energy consumption, desirable carbon footprint and minimal environmental impact.

First claim

What is claimed is:

1. A pervious composite material comprising:
a plurality of bonding elements, wherein each bonding element comprises:
a core comprising primarily calcium silicate,
a silica-rich first or inner layer, and
a calcium carbonate-rich second or outer layer;

a plurality of aggregates having sizes of about 0.25 mm to about 25 mm, wherein the aggregates comprise a first group of particle aggregates of a size about ⅛″ to about ¼″ and a second group of particle aggregates of a size about ⅜″ to about ½″; and
a plurality of pores having sizes from about 0.1 mm to about 10 mm, wherein
the plurality of bonding elements and the plurality of aggregates together form one or more bonding matrices and the bonding elements and aggregates are substantially evenly dispersed therein and bonded together; and
the plurality of pores account for from about 5 vol. % to about 40 vol. % of the pervious composite material and form interconnected channels allowing the composite material to be water permeable; and,

 whereby
the pervious composite material exhibits a density from about 1,500 kg/m 3 to 2,200 kg/m 3 , a compressive strength from about 3.0 MPa to about 30 MPa, a flexural strength from about 1.0 MPa to about 4.0 MPa, and a hydraulic conductivity from about 100 cm/hr to about 8,000 cm/hr,

wherein the aggregates account for about 50 wt. % to about 85 wt. % of the pervious composite material.

2. The pervious composite material of claim 1 , wherein the plurality of bonding elements have a median particle size in the range from about 5 μm to about 100 μm.

3. The pervious composite material of claim 1 , wherein the aggregates comprise a material selected from crushed trap rock, sand, perlite or vermiculite and pea-gravel.

4. The pervious composite material of claim 1 , wherein the plurality of bonding elements is chemically transformed from ground calcium silicate and the coarse aggregates are crushed trap rock.

5. The pervious composite material of claim 1 , wherein the aggregates account for about 70 wt. % to about 80 wt. % of the pervious composite material.

6. The pervious composite material of claim 1 , wherein the plurality of bonding elements are chemically transformed from a precursor calcium silicate other than ground calcium silicate.

7. The pervious composite material of claim 1 , wherein the plurality of bonding elements are chemically transformed from a precursor calcium silicate comprising one or more of aluminum, magnesium and iron.

8. The pervious composite material of claim 1 , wherein the plurality of pores account for from about 10 vol. % to about 40 vol. % of the pervious composite material.

9. The pervious composite material of claim 8 , wherein the plurality of voids account for from about 15 vol. % to about 30 vol. % of the pervious composite material.

10. The pervious composite material of claim 1 , wherein the plurality of bonding elements are prepared by chemical transformation from ground calcium silicate by reacting it with CO 2 via a controlled hydrothermal liquid phase sintering process.

11. The pervious composite material of claim 1 , wherein the plurality of bonding elements are prepared by chemical transformation from the precursor calcium silicate other than ground calcium silicate by reacting it with CO 2 via a controlled hydrothermal liquid phase sintering process.

12. The pervious composite material of claim 1 , exhibiting a density from about 1,600 kg/m 3 to 2,200 kg/m 3 , a compressive strength from about 4.0 MPa to about 30 MPa, a flexural strength from about 1.0 MPa to about 4.0 MPa, and a hydraulic conductivity from about 100 cm/hr to about 6,000 cm/hr.

13. The pervious composite material of claim 12 , exhibiting a density from about 1700 kg/m 3 to 2100 kg/m 3 , a compressive strength from about 6.0 MPa to about 24 MPa, a flexural strength from about 2.0 MPa to about 4.0 MPa, and a hydraulic conductivity from about 100 cm/hr to about 5000 cm/hr.

14. The pervious composite material of claim 1 , further comprising one or more additives to modify the appearance, physical or mechanical properties of the product.

15. The pervious composite material of claim 14 , wherein the one or more additives are selected from plasticizers, retarders, accelerators, and dispersants.

16. The pervious composite material of claim 15 , wherein the one or more additives account for less than about 0.5 wt. % of the pervious composite material.

17. The pervious composite material of claim 1 , further comprising one or more pigments.

18. The pervious composite material of claim 1 , wherein the pigment comprises one or more of black iron oxide, cobalt oxide and chromium oxide.

19. The pervious composite material of claim 1 , further comprising one or more of silica fume, fly ash and blast furnace slag, cement-kiln dust, and crusher dust.

20. An article of manufacture made from the pervious composite material of claim 1 .

21. The article of manufacture of claim 20 , selected from the group consisting of pavements, driveways, parking lots, sidewalks, pathways, tennis courts, well linings, patios, swimming pool decks, noise barriers, and walls.

Assignees

• Kuppler John
• Patten Devin
• Ravikumar Deepak
• Deo Omkar
• Atakan Vahit
• Solidia Technologies Inc

Inventors

• Kuppler John
• Patten Devin
• Ravikumar Deepak
• Deo Omkar
• Atakan Vahit

Classifications

• Y10T428/249975

  Void shape specified [e.g., crushed, flat, round, etc.] · CPC title

• C04B38/0058

  open porosity · CPC title

• C04B38/0067

  characterised by the density of the end product · CPC title

• C04B2111/00284

  Materials permeable to liquids · CPC title

• Y10T428/249986

  Void-containing component contains also a solid fiber or solid particle · CPC title