VISCOSE MATERIALS AND METHOD TO PRODUCE
Cross Reference with Related Requests This is a non-provisional application of provisional application No. 60 / 583,672 of Matthew Piazza filed on June 29, 2004. Field of the Invention The present invention relates generally to building materials and, more particularly, a composition for producing construction materials and a method for producing the composition. BACKGROUND OF THE INVENTION DESCRIPTION OF THE PRIOR ART To date cementitious building materials are heavy and have limited strength. These materials are usually produced using vermiculite and / or other lightweight fibrous materials, water and cement. In order to produce these construction materials, a large amount of water is required since the vermicuite and other lightweight fibrous matepals are very absorbent and capable of absorbing huge amounts of water used to produce the construction mat. The water absorbed by vermiculite and other lightweight fibrous materials is necessary to moisten and reinforce the cement. The use of water in cementitious construction materials is added to the weight of the construction material and although it is used to create the construction material it causes stress fractures to form in the material
Cementitious construction when it is frozen and thawed. It is desirable, then, to produce a composition that is capable of reducing the amount of water needed to produce the building materials. It is also desirable to produce a mixture capable of being added to the cement with vermicu / ita and other lightweight fibrous materials to produce a construction material that includes a minimum amount of water. In addition it is desirable to produce a building material where a liquid or gel wetting agent is added to saturate the vermiculite and other lightweight fibrous materials used in the material so that the need to use water is obviated. It is also desirable to combine certain reactive elements in a manner capable of minimizing or eliminating any reaction occurring between them by addition to the building material. Brief Description of the Present Invention The present invention relates generally to construction materials and, more specifically, to a composition for producing construction materials and a method for producing the composition. The composition includes a plurality of chemicals that are undesirably reactive with each other. It is a primary object of the present invention to produce a viscous composition to produce a construction material that overcomes the limitations of prior art construction materials. It is a further object of the present invention to produce a viscous material that is formed by combining a mixture with at least one
of cementitious materials, rubber, plastics. Another object of the present invention is to produce a viscous material wherein the mixture includes certain reactive elements in a manner to reduce or eliminate / react with each other. A still further object of the present invention is to produce a viscous material wherein the mixture is capable of increasing the strength and reducing the weight of the resulting building material. A still further object of the present invention is to produce a viscous material wherein the properties associated with each element are imparted to the resulting building material. Still another object of the present invention is to produce a building material that includes at least one of nanoparticles and nanotubules to provide additional attributes to the additional building material. A further object of the present invention is to provide a method for minimizing reactions among a plurality of reactive chemicals. The method includes the activities of adding a first chemical and adding a first layer of barrier, the first barrier layer that rests on top of the first chemical. A second chemical is added and the second chemical rests on top of the first barrier layer. A second barrier layer is added which rests on top of the second chemical. One more chemical is added and the additional chemical composition rests on top of the second barrier layer. The chemicals and the layers of
The barrier is uniformly mixed, so that each of the first, second and second chemicals is evenly distributed to form a mixture where the chemicals are added in order to decrease the density. Another objective of the present invention is to provide a composition comprising a first chemical product, a second chemical; and at least one barrier layer placed between the first chemical and the second chemical to avoid interaction between them. By mixing the composition according to predetermined rules a mixture is produced which has each of said first chemical product and second chemical product evenly distributed perfectly. Still another object of the present invention is to provide a composition comprising at least one of a substrate and a casting material and a mixture. The mixture includes super-plasticizer, self-consolidating, shrinkage reducers and a ality of barrier layers. When the mixing occurs, one of the ality of barrier layers is provided between each adjacent element of the mixture which prevents intermixing between the elements so that the reactions between the elements are minimized and allows each respective element to maintain the properties associated with it. When said mixture is combined with the substrate and mixed to form the composition, the mixture is evenly distributed throughout the composition causing the at least one of the substrate and the casting material and each element
the mixture join with each other. Still a further object of the present invention is to provide a method for producing a composition. The method includes combining a predetermined amount of at least one of a substrate and a casting material with at least one of water and a wetting agent in order to saturate the at least one of the substrate and the casting material. Then, combine a mixture with e) saturated substrate and the casting material. The mixture includes superplasticizer, self-consolidator, shrinkage reducers and a ality of barrier layers. One of the ality of barrier layers is provided between each element of the mixture that prevents inter-mixing between the elements, whereby each respective element is allowed to maintain the properties associated therewith. The method provides the continuous mixing of the mixture of at least one of the substrate and the casting material and mixes and forms a composition wherein each respective element of the mixture is evenly distributed throughout the composition causing the elements of the mixture join with each of the at least one of the substrate and casting material and having properties associated with the elements of the mixture. Another object of the present invention is to produce a mixture and construction material that is simple and easy to use. Still another objective of the present invention is to produce a construction material that is economical in manufacturing cost.
Additional objects of the present invention will be apparent as the description proceeds. Brief Description of the Drawings Various other objects, aspects and inherent advantages of the present invention will be more fully appreciated as it is better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same parts or similar in all the various views. Figure 1 is a flow diagram illustrating the process for producing the mixture. Figure 2 is a cross-sectional view showing a tank showing the placement of layers of the elements forming the mixture before mixing. Figure 3 is a flow diagram showing the process for producing a construction material that includes the mixture. Figure 4 is a perspective view of a static mixer used to mix the elements that make up the building material. Figure 5 is a flow diagram illustrating the process for producing an alternative embodiment of the mixture of the present invention; and Figure 6 is a cross-section showing the placement of layers of an alternative embodiment of the mixture. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT The present invention describes a chemical mixture for
produce a material that is capable of being used as a material for building and construction. The resulting material is capable of being used for ornamental decoration as well as for structural support of a structure. Thus, the chemical mixture can be used with at least one of a cement-based matepal, a plastic material and a rubber material and when using the mixture, the resulting material has improved properties that we were not able to perform until now . The resulting material therefore includes the mixture, vermiculite and a substrate to empty the material in a desired form. Thus, the following description of cement-based construction material should not be considered as limiting since the mixture can be used in additional areas with additional benefits which will be indicated through the following description. When producing a construction material that includes cement and vermiculite and / or lightweight fibrous materials, the vermiculite or lightweight materials should be placed in a mixture first before the addition of water. The chemistry or mixture of the present invention does not react with lightweight materials. The mixture will react only with cementitious materials, therefore when a light weight mixture is made with this material the vermiculite should be first cemented with water. The present invention is a process for mixing elements that normally react with each other in an undesirable way and conventional knowledge indicates that they should not be mixed
jointly. This method was discovered when a liquid or gel is placed directly on the vermiculite or light weight raw materials in the mix. The method for mixing the elements together which would react normally in contact concerns the elements that are normally used in the production of building materials, especially cementitious building materials. This method can also be used in the mixing of other chemicals that would normally react in contact with one another. The elements used in the method of the present invention to produce the mixture of the invention include: * Carboxylated polyether such as Superplasterizerolymer. * Carboxylated propyxene as an auto-consolidator; and * Aliphatic propylene, glycoethers such as shrinkage reducers. * Surfactant, preferably non-ionic surfactant. Additional elements added to the mixture may include: * Water reducing agents - aqueous carboxylated polyether solution, calcium, nitrate and glycosamines; * Viscosity control agent to reduce segregation; * Shrinkage control agents; * Water repellent agents; and * Air entrainment agents. Additional elements added to the mixture include: * nanoparticles formed from an oxide based on
silicon. * napotubules formed from an oxide based on itself.
* latexes * at least one yttrium oxide, aluminum oxide, silicon aluminum oxide, silicon barium oxide, zirconium barium oxide, cerium oxide, magnesium oxide and zirconium oxides. All of the above are not brand names, but are defined by their functions when placed in the cement mix individually. There are disadvantages associated with the production of a construction matepal with the above mixture together with cement and vermiculite. Specifically, the vermiculite will absorb a significant amount of water. 9.08 kilograms of vermiculite will absorb up to 18.9 liters of water and will result in a composition that has the consistency of wet sand. Therefore, it is not desirable to add the mixture directly to the vermiculite because the vermiculite will absorb the components of the mixture and thus avoid uniform distribution within the mixture containing the cementitious materials. The mixture is added to the cement mixture with additional water. The use of the mixture substantially reduces the amount of and potentially eliminates the need for water to be added to produce the construction material. Additionally, a light weight fiber may be added to the composition to reinforce the resulting building material. Alternatively, instead of water, an agent can be added
Moisturizing liquid or gel to the vermiculite to moisten the vermiculite without water. Due to the properties of known wetting agents, a substantially smaller amount of wetting agent is needed to saturate the vermiculite or lightweight fibrous materials to produce the composition. Additionally, known wetting agents weigh much less than water and thus reduce the weight of saturated vermiculite or lightweight fibrous materials. Additionally, the liquid or gel wetting agent can be mixed into the mixture used when any material that may be necessary to react the product is mixed. The liquid or gel wetting agent can be used to form layers between the reactive elements of the mixture whereby the amount of water is reduced and thus the weight of any product produced using the mixture is reduced. Therefore, as will be discussed later herein, the building material produced by the composition of the present invention allows the typically reactive chemical elements to be combined by a layer placement process of the invention which avoids any interaction between them. . The composition is formed using a mixture in which a layer of one of water and liquid or gel wetting agent is formed on top of one of the heavier chemical elements before adding the next heavier of the elements so that it is prevented from a reaction occurs between them. Thus, as the combination of the chemicals continues, a layer of one of water is formed and
liquid or gel wetting agent between a previous and subsequent element added to the mixture. Instead of water, a liquid or gel wetting agent can be added to the vermiculite to moisten the vermiculite without water. Due to the properties of known wetting agents, a substantially smaller amount of wetting agent is needed to saturate the vermiculite or and lightweight fibrous matting. Additionally, known wetting agents weigh much less than water and thus reduce the weight of saturated vermiculite or lightweight fibrous materials. Additionally, the liquid or gel wetting agent can be mixed into the mixture used when any material that may be necessary to react the product is mixed. The liquid or gel wetting agent can be used to form layers between the reactive elements of the mixture whereby the amount of water is reduced and thus the weight of any product produced using the mixture is reduced. Also, a liquid or gei wetting agent can be added to the cement instead of water in order to make the cementitious material without water. The cementitious material produced will have the characteristics of the finished product as if it had been mixed with water. Due to the removal of water, the cementitious materials will be stronger than the conventional concrete mix. A preferred wetting agent for use in the preparation of the mixture is a nonionic surfactant. A surfactant is a compound
which has a hydrophilic section and a hydrophobic section. The chemistry of a surfactant allows the substance to reduce the surface tension of the system, thereby allowing the surfactant to be used as a wetting agent. The hydrophilic segment of a surfactant is graded by the number of moles of ethylene oxide. The ethylene oxide chains form the hydrophilic portion of the surfactant molecule. The longer this portion of the molecule is, the more soluble in water is the nonionic surfactant. Additionally, the surfactants, and their functionality, are graded using an arbitrary scale that represents their Hydrophilic / Lipophilic Balance (HLB). A low HLB value means a surfactant more soluble in oil, while a higher HLB represents a surfactant with good solubility in water. The value of HLB is a numerical value that is calculated based on the molecular structure of the surfactant. IdeallyThe nonionic surfactants have an HLB value ranging from 7 to 9. Preferably, the nonionic surfactant is an octyl phenol ethoxylate which is produced by the addition of ethylene oxide to octyl phenol. The resulting octyl phenol ethoxylate is effective over a wide range of temperature and pH and forms strong gels and viscous solutions which are used as low foaming wetting agents in agricultural applications. However, its chemistry is such that it allows use in the mixture of the present invention. The non-ionic surfactant is placed between layers of additional materials such as plasticizers and shrinkage control agents for
avoid normal interaction, but not desired among them. When added, the surfactant acts as a barrier layer between the components of the mix added sequentially. The surfactant is combined in the mixture when all the aggregated components are mixed together. Alternatively, latex layers can be added to the mixture in place of the nonionic surfactant. In a similar manner to the surfactant, the latex layers are placed between the aggregate components of the mixture sequentially and act as barrier layers which prevent any premature and / or undesirable reaction between the components. Latex functions as a carrier agent that helps disperse the various components when mixed together. The latex also acts as a wetting agent by replacing the water typically used in building and architectural materials used in the prior art. An additional reinforcing component to be added to the mixture is a silicon-based oxide. Silicon-based oxides are excellent additives that work as agents that improve hardening. In addition, silicon-based oxides are used to increase the scratch resistance of a compound. Based on the improvement in hardness and scratch resistance, silicates have a specific utility as an additive in bricks and building materials. It is preferable that the silicon-based oxide that is added to the mixture be in the form of nanoparticles or nanotubules, such as
PU ENANO® which is produced by NanoProducts Corporation. The nanoparticles of these silicon-based oxides provide non-agglomerated nanoscale materials that are capable of being homogenously distributed in a mixture. As in the mixture of the claimed invention. The aspects of improvement of nanoparticles are the result of their training. Specifically, the combination of silica, at the grid level, with one or more metals allows the modification of the mechanical, optical, thermal, surface, structural and other properties. Thus, silicon-based oxide nanoparticles can be specifically tailored for use in the mixture of the present invention. Examples of various silicon-based oxides that can be used are silicon aluminum oxides, zirconium silicon oxides and other silicon multiple metal oxides. How to Prepare the Mixture Example: A Mixture of 18.9 Liters Pour mixture of super-plasticizers into a 1 8.9-liter enclosure using normal tap water and emptying enough water to put approximately 0.317 centimeters of water / surfactant barrier layer in the part superior of the super-plasticizer. The water / surfactant layer acts as a barrier since the water / surfactant is lighter than the super plasticizer and remains on top of the superplasticizer. When the next element is poured, for example a self-consolidator (or self-compactor), at the top of the water / surfactant layer a reaction will not be created
chemistry. The process is then repeated by placing a layer of substantially the same amount of water / surfactant on top of the second layer and adding a third element, for example a shrinkage control agent. This process is repeated afterwards for each additional element to be added to the mixture. In the above example mixture, there are substantially 4.7 liters of super plasticizer, substantially 9.46 liters of self-consolidating and substantially 2.83 liters of shrinkage controlling agent. The above-described mixture further contains substantially 1.9 liters of water barrier layer / surfactant which is inter-dispersed between each of the super plasticizer layers, the self-consolidator and the shrinkage control agent. In addition, as described above, each respective water barrier layer / surfactant is present in substantially equal amounts. The above was created for a mixture with many attributes to be added to cementitious products. The same method can be used for other chemical mixtures. The method described above can be used to produce mixtures useful for many different purposes including elements that normally react with each other. The use of the above described mixture is for example purposes only and is not intended to limit the method of the claimed invention. Alternatively, the mixture instead of the water barrier / surfactant layer, can be placed at least one of water, a
liquid wetting agent, a gel wetting agent and a wetting agent in gel form between each adjacent layer of chemical additives. When a lightweight concrete mix is made, materials such as vermiculite, pur / ita, miera, etc., are usually combined with cement. However, the use of these raw materials is problematic since the lightweight materials are highly water absorbent. The mixture will then require a large amount of water in order to function as desired. Mixing large amounts of water with cement decreases cement strength as well as increases the weight of the resulting concrete product. The mixture of the present invention works to reduce the amount of water needed by Jo which increases the strength of the resulting construction material as well as decreases the weight of the same. An exemplary formulation of the mixture of the present invention is shown below as Formulation A. Formulation A * 2 parts of carboxylated polyether such as Superplasterizerzermer; * 1 part of carboxylated propylene such as an Auto-consolidator; * 1 part of aliphatic propylene, glycol ethers such as shrinkage reducers; * 1 part of surfactant. In addition to the elements listed in Formulation A,
they can include other additional chemicals in the mixture to confer additional properties to it. These additional elements include at least a part of air entrainers, a part of nanoparticles of a silicon-based oxide and a part of latex. The depletion of nanoparticles which are formed as a silicon-based oxide for example purposes only and any type of nanoparticles having desirable properties associated therewith can be used with the mixture and / or viscous material of the present invention. The chemicals listed above are layered in a mixing tank and include a water layer and / or wetting agent between adjacent layers. This layer avoids the unwanted and undesirable interaction between the component elements of the mixture of the present invention. Alternatively, the mix can use a plurality of latex parts as a carrier / wetting agent that is placed between each respective component identified above. Thus, the latex can be one of the components in the mixture layer or it can be used as a barrier layer between the components added sequentially thereof. Also, the nanoparticles formed from silicon-based oxide can be their own sequentially added aggregate layer placed between two layers of wetting agent. Alternatively, the nanoparticles can be combined with another of the component layers added sequentially, before
identified. Additionally, the nanoparticles can be injected into the mixture and / or composition immediately before or during the emptying process. The nanoparticles have at least one predetermined attribute to be added to the composition for use in the production of a building material. These attributes include, but are not limited to, increased strength, increased durability, reduced thermal expansion, increased color and increased hardness. The construction material of the present invention is produced when the above mixture is combined in the method of the invention discussed hereinafter with specific reference to Figures 3 and 4. Upon mixing, a finished cement mixture is produced which is It can empty that it has all the concrete attributes and none of the disadvantages. The resulting building material has a substantially reduced weight, increased flexibility and increased tensile strength that can be more than four times that of conventional concrete. For example, conventional concrete will generally have up to 90.8 kilograms of tensile strength and flexible while the construction material of the present invention will have from 295.1 to 385.9 kilograms of tensile strength and flexible. The construction material of the present invention includes a combination of raw materials as shown in Table 1 below. These raw materials are generally dry powder materials and are combined with the mixture discussed above as
Formulation A to produce the construction matepal. Table 1: Raw Materials ° Cement. ° Sand or silica. ° Matepal Metakatolin - apozzo - lanie. Vermiculite or substitutes - purlite, mica, etc. Fiber. Polypropylene. ° Polyethylene. ° Fiberglass or any other fibrous material. ° at least one of nanotubes and nanopowders. The amounts of the above raw materials used to produce the construction material of the present invention may vary depending on the needs of the user. In order to produce the construction material of the present invention, an example combination of certain raw materials from Table 1 to Formulation A hereinafter is discussed as Formulation B. Formulation B includes: Formulation B ° 1 cement bag - approximately 42.68 kilograms. ° 22.7 kilograms of sand. 9.08 kilograms of vermiculite. 2.27 kilograms of metakatolin. ° 0.1 1 35 kilograms of polypropylene microfiber. ° 0.454 kilograms of polypropylene structural fiber.
° 1 mixing room of Formulation A. ° 30.28 liters of water. The above raw materials in combination with the mixture of Formulation A produces a complete stable monolithic viscous cementitious mixture which can be used to form a plurality of different cementitious products. The resulting building material is a concrete material that has a tensile strength and flexible and a decreased weight. Additionally, the strength of the cementitious materials produced can be increased and the weight reduced by eliminating the addition of water to the mixture by replacing the water with a liquid or gel wetting agent normally used in the agricultural field to wet the soil. This will also eliminate the problem of over-wetting of the cement, and thus produce a homogeneous mixture much more stable. In addition, when a lightweight material, such as vermiculite in the cement mixture, having absorbing qualities is used, the moisture trapped within the lightweight material is released over time to the cementitious material which reinforces the cementitious material continuously over a period of time. longer than normal conventional concrete due to this the hydration of the cementitious materials is stabilized to allow the material to cure constantly and also to heal stronger. The mixture and the methods described above can also be used to mix cement slurries, stuccoes and any other cement mixture.
In addition, the above mixing technique can be used in conjunction with rubber and plastic forming matepal. For example, a viscous composition formed from acetate, PVC, polyethylene fibers and polypropylene fibers can be produced by using a gel emulsion barrier layer placed between each respective element added during the mixing process. This prevents the reaction between the elements before uniform mixing thereof. Additionally, at least one of nanoparticles, nanopowders and nanotubules, as described hereinabove, can also be added to the mixture in the manner described. The accompanying Figures will now be discussed to show and describe the methods of the invention presented herein and the compositions of the invention produced using the methods of the invention. Figure 1 is a flow chart illustrating the method for producing the mixture of the invention or producing a mixture formed from elements that would normally react with each other. As can be seen from this figure, the mixture is formed by adding a predetermined amount of carboxylated polyether, such as a superplasticizer, as discussed in step S2. Next, a layer of at least one of water, liquid wetting agent or gel wetting agent on top of the super plasticizer that forms a barrier layer thereon, as set forth in step S4. Above the layer of at least one of water, liquid wetting agent or gel wetting agent, a layer of carboxylated propylene is placed such as a self-consolidating agent, as described in
Step S6. Normally, when a carboxylated polyether is combined with a carboxylated polypropylene, a chemical reaction, such as foaming, occurs. However, the placement of the barrier layer of at least one of water, liquid wetting agent or gel wetting agent therebetween, minimizes or eliminates any reaction between the carboxylated polyether and the carboxylated propylene A. Another barrier layer of at least one of water, liquid wetting agent or gel wetting agent can then be placed on top of the carboxylated propylene layer, as described in step S8. Then a layer of aliphatic propylene, glycol ethers, such as shrinkage reducers can be placed on top of the carboxylated propylene, as set out in step S 10. The mixture formed by the combination of these elements can then be mixed without any reaction forming among the elements for use in the production of construction mater. Additional mater, such as an air entrainer, can be added to the mixture by first placing an additional barrier layer of at least one of water, liquid wetting agent or gel wetting agent, as discussed in step S 12. An additional barrier layer of at least one of water, liquid wetting agent or gel wetting agent can then be placed on top of the air entrainer, as described in step S14 before adding a layer of an aqueous solution of carboxylated polyether, calcium, nitrate and glycosamines, such as a water reducing agent on top of the barrier layer, as set forth in
Step S 16. Barrier layers can also be placed between the last layer and an additional layer, such as self-compaction agents, as discussed in step S 18, shrinkage control agents, as set forth in step S20, and water repellent agents, as deciphered in step S22. A cross-sectional view of a tank, which includes the elements in layer, is shown in Figure 2 and is generally indicated by the reference number 10. As can be seen from this figure, the barrier layers 28 of at least one of water, liquid wetting agent or gel wetting agent separate each element within the mixture whereby any reactions between the elements are reduced or avoided. As can be seen from this figure, the mixture is formed with a predetermined amount of carboxylated polyether, such as a superplasticizer 12, forming a bottom layer. A layer of carboxylated propylene 14, such as a self-consolidator, is placed on top of the carboxylated polyether 14 with a barrier layer 28 of at least one of water, liquid wetting agent or gel wetting agent therebetween. Another barrier layer 28 of at least one of water, liquid wetting agent or gel wetting agent is then placed on top of the carboxylated propylene layer and a layer of aliphatic propylene, glycol ethers 16, such as shrinkage reducers, is then placed on top of the barrier layer. The mixture formed by the combination of these elements can then be mixed without any reaction forming between the elements, for use in the
production of construction mater. Additional mater, such as an air entrainer 18, can be added to the mixture by first placing an additional barrier layer 28 of at least one of water, liquid wetting agent or gel wetting agent on top of the aliphatic propylene layer, glycol ethers 16. An additional barrier layer 28 of at least one of water, liquid wetting agent or gel wetting agent can then be placed on top of the air entrainer and a layer of an aqueous solution of carboxylated polyether, calcium, nitrate and glycosamines 20, such as a water reducing agent, can be placed on top of the barrier layer. Barrier layers can also be placed between the last layer and an additional layer, such as self-compaction agents 22, shrinkage control agents 24 and water repellent agents. The order in which the elements are added is provided as an example order. In practice, these elements can be added in any order as long as a layer formed of water or wetting agent is placed between the layers and is able to maintain the separation between the layers until mixing to form the mixture. Figure 3 is a flow diagram showing the method for producing a building material using the mixture discussed above with reference to Figures 1 and 2. In order to produce the construction material of the present invention, a desired amount of Light weight fillers, such as vermiculite, are combined with at least one of water and a wetting agent in an amount capable of
substantially saturate the vermiculite, as discussed in step S100. Additionally, microfibers can be added to the vermiculite, as desired. A measured quantity of cement is then added to the saturated vermiculite and microfibers, as set out in step S 102. Together with the cement, sand, silica and other elements, such as fiberglass or other fibers, can be added. . The mixture, as discussed above, is then added to the cement and the vermiculite / microfiber combination, as described in step S 104. At this point, the metakatolin, for example a pozzolanic material, can be added to the composition, as necessary, as discussed in step S 1 06. Structural fiber may then be added, as desired, as set forth in step S108. Metakatolin and structural fiber can be added continuously, as indicated by the arrow labeled with the number 1 10, as needed or to obtain the desired consistency. This entire process is carried out inside a mixing device and is constantly mixed during the entire process. After the addition of the cement it may be necessary to add additional water or wetting agents. Alternatively, this process can be performed in a static mixer 400, as shown in Figure 4. As can be seen from this figure, the elements 402 necessary to produce the construction material are added in the top / funnel 404 of the mixer 400 and allowed to flow along the lanes 406, 408 where the elements are constantly mixed. Added to the mixer through a tube 410 placed on the
There are also amounts of the inventive mixture, water or wetting agent 414 to saturate light weight fillers, such as vermiculite and wet cement. The mixture can be provided either separately or in combination with the water or the wetting agent provided to the cement. The mixture and the water or the wetting agent are placed in a pump of the containment tank and supplied to the static mixer 400 under pressure to react with the cement to produce a substance such as cloth, pasty, sticky. As the elements 402 of the composition pass through the static mixer 400 they are constantly mixed to form a homogeneous mixture. A pressure 418 is applied to the elements 402 placed in the static mixer 400 whereby the feeding of the elements to the static mixer 400 is forced and the elements 402 are caused to be pushed through it. Pressure 41 8 can be applied by anything capable of creating sufficient pressure, such as nitrogen or air. The mixed composition is then cleaned at the base of the static mixer 400 to remove the pressure-inducing agent. The mixture of the present invention allows light weight materials to be produced with all the characteristics of the pre-cast concrete without any of the disadvantages. The materials produced using the mixture and method discussed above are lighter in weight, stronger and more resistant to fracture than concrete. The process creates a new material by combining
of raw materials in a unique way. The materials, such as concrete, sand, metakatolin, vermiculite, fibers, etc. , are combined with the mixture to join those elements that normally do not join together to produce a product that has a matrix with a flexural and tensile strength that is substantially greater than the flexural and stress resistance of the concrete conventional. In addition to producing superior bonding components, the mixture allows the incorporation of high amounts of metakatolin, a Pozzolanic material, into the mixture. Such a thing has not been possible in the past. Puzolanas are natural or industrially produced materials that react with soda released from the hydration of Portland cement. Through this reaction the addition of metakatolin effectively eliminates free soda and converts the final material into a stable cementitious product. Puzolanas also reduce the permeability of cement paste. This helps prevent the entry of aggressive substances into the solution that cause effervescence and results in low permeability in a durable cementitious mixture that is able to withstand sulfate attack, acids, freezing and thawing conditions, de-icing salts and seawater. In addition, light weight loads, such as vermiculite, added to the mix not only help reduce the weight of the final product, but also soak up liquids and water as well. The materials cure slowly and consistently because the vermiculites act as a time-release in the
evaporation of water in the mixture. Thus, the final cementitious product is constantly supplied with liquid, which minimizes the possibility of fracture and reinforces the final product. Additionally, the mixture of the claimed invention can be combined with a second mixture having at least one of nanoparticles and nanotubules contained therein to produce a cementitious material. The nanoparticles and / or nanotubules provide increased resistance to the resulting cementitious material. In addition, the weight of the resulting cementitious matepal is substantially less than the conventional cementitious material. Alternatively, the construction matepal of the present invention may include nanoparticles and / or nanotubules that are evenly distributed throughout the mixture during the mixing process as will be discussed hereinbelow with specific reference to Figures 5 and 6. Figure 5 It is a flow chart that shows how an alternative mode of mixing is produced. In a manner similar to Figure 1, the superplasticizer is added to a tank as shown in step S500. Next, it is important to form a barrier layer, as discussed in step S502. However, unlike the mixture produced in Figure 1, the barrier layer formed in step S502 is formed from a wetting agent which is a nonionic surfactant having an HLB value between 7 and 9. Then, As shown in step S504, a predetermined amount of shrinkage control agent is added on top of the
first barrier layer. The first barrier layer of nonionic surfactant prevents the superplasticizer and shrinkage control agents from interacting with each other. A second barrier layer is formed by adding a nonionic surfactant over the layers of the shrinkage control agent and the superplasticizer, as shown in step S506. A nanoparticle layer formed from silicon-based oxides is then added on top of the second barrier layer, as shown in step S508. The silicon-based oxides in nanoparticles provide an increased hardness and improved structural support to the mixture that will later be combined with cementitious materials to produce the resulting mixture. A third layer of nonionic surfactant barrier is added to the top of the nanoparticle material layer, the shrinkage control agent and the super plasticizer, as in step S510. Step S512 then requires that a layer of latex material be added to the mixture on top of the third nonionic surfactant barrier layer. A fourth non-ionic surfactant final barrier layer is to be added to the top of the latex layer, as required by step S514. This completes the alternative embodiment of the mixture of the claimed invention. Then, in step S516, the layered mixture is completely blended with the previously identified cementitious materials in order to produce the resulting mixture for use in the production of building materials having a tensile strength and hardness
increased, as well as structural characteristics that make a material for construction and for superior architecture. Alternatively, steps S502, S506, S510 and S514 may include the use of latex as the barrier layer to be placed between the superplasticizer, the shrinkage control agents and the nanoparticles. Additionally, the layer of nanoparticles formed from silicon oxides may be interspersed within another layer of the mixture. Specifically, the nanoparticles can be combined with at least one of the latex, super-plasticizer and shrinkage control agents of the mixture of the invention. The proportions of each respective component used to form the mixture of the present invention can be varied. Nevertheless, changing the quantities of each element changes the characteristics of the final product, such as weight, strength, durability and hardness. Therefore, the proportions can be altered based on the desired characteristics of the product to be produced. This variant proportionality of the components to be used with the mixture of the present invention also applies to the resulting mixture with cementitious material, as discussed hereinabove. By altering the proportions of the components, the resulting characteristics of the building material or architecture will be changed. Thus, the material can be formed based on the desired desired characteristics of the construction or architectural material. Figure 6 is a cross-sectional view of a tank
600 having the alternative embodiment of the mixture of the present invention. One layer of each superplasticizer 602 is placed in the base of the tank 600. The tank also includes a layer of shrinkage control agent 608, an oxide layer 61 0 based on silicon in nanoparticles and a layer of latex material 612. Positioned between each of the layers 602, 608, 610, 612 is a barrier layer 604 formed from a nonionic surfactant. The placement of the barrier layer is important as it prevents undesired mixing of the individual components of the mixture prior to combining with the cementitious material in the production of the building material of the invention. It is important to keep the elements separate and combine them only in the presence of the cementitious matepal in order to ensure that each respective element is uniformly incorporated into the mixture when the construction material is produced. This uniform combination allows each of the inherent properties of each respective element to be applied to the resulting mixture. Alternatively, the particulate silicon-based oxide layer can be removed and combined with at least the layer of latex material 612 and the layers in non-ionic 604 surfactants. The mixture described in Figures 5 and 6 can be combined with cementitious material in the manner described hereinabove, with specific reference to Figures 3 and 4. The mixture of the invention as has the silicon-based oxide in nanoparticles, once uniformly mixed with the cementitious materials before
described creates a building or architectural material that has superior strength and hardness associated with it. Silicon-based oxide nanoparticles, which are infused with a predetermined metal at the grid level, allow bonding with the cementitious material, thereby increasing the hardness and structural support of the resulting mixture. In addition, with the inclusion of the non-ionic surfactant, the weight of the resulting building material is significantly reduced while maintaining the strength of the same. The blend of the present invention allows lightweight materials with all of the characteristics of the pre-cast concrete to be produced without any of the disadvantages. The materials produced using the mixture and method discussed above are lighter in weight, stronger and more resistant to fracture than concrete. The process creates a new material by combining raw materials in a unique way. Materials such as concrete, sand, metakatolin, vermiculite, fiber, etc. , are combined with the mixture to join those elements that normally do not coalesce together to produce a product having a matrix with a multiple flexural strength and tensile stress of the flexural strength and the compressive stress of conventional concrete. The mixed material formed by the method described using the mixture of the invention allows the creation of new finished products. For example, the mixed material can be used to produce a thin, lightweight panel that can be used to
cover foam, metal and / or wood at a very low cost and provides an appearance of cut stone, marble, limestone, wood, etc. , very expensive. Thus, with the silicon-based oxide in nanoparticles in the resulting mixture, the improved scratch resistance of the material is equally important. Having improved scratch resistance, the material is highly resistant to the incidental and deliberate contact of other objects that could degrade the construction material and detrimentally affect the structural integrity thereof. Additionally, the mixture of the present invention allows the viscosity of the material that is produced to be varied to allow the addition of at least one of vermiculite, nanoparticles, nanotubules and fibrous material. This viscosity is further increased by the addition of a viscosity control agent which allows the viscosity of the composition to be varied in order to achieve different objectives. A) Yes, this mixture is usable in many fields including cementitious materials as well as plastics. For the achievement of the above and related objectives, this invention can be incorporated in the manner illustrated in the accompanying drawings, however, attention should be drawn to the fact that the drawings are illustrative only, and that changes can be made to the specific construction illustrated and described within the scope of the appended claims. It will be understood that each of the elements described above, or
two or more together can also find a useful application in other types of methods that differ from the type described above. Although certain novel aspects of this invention have been shown and described and pointed out in the appended claims, they are not intended to be limited to the foregoing details, since it will be understood that various omissions, modifications, substitutions and changes in the forms may be made. and the details of the illustrated device and its operation by those skilled in the art without departing in any way from the spirit of the present invention. Without further analysis, the foregoing will so completely reveal the fundamental of the present invention that others, through the application of ordinary knowledge, will easily adapt it for various applications without omitting aspects which, from the point of view of the prior art, constitute just the essential characteristics of the generic or specific aspects of this invention.