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(12) United States Patent (10) Patent No.: US 9,353,009 B2 Dantin Et Al

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(12) United States Patent (10) Patent No.: US 9,353,009 B2 Dantin Et Al US009353009B2 (12) United States Patent (10) Patent No.: US 9,353,009 B2 Dantin et al. (45) Date of Patent: May 31, 2016 (54) DRY COMPOSITION BASED ON MINERAL (56) References Cited BNDER AND INTENDED FOR THE PREPARATION OF A HARDENABLE WET U.S. PATENT DOCUMENTS FORMULATION FOR THE CONSTRUCTION 7,288,147 B2 10/2007 Christensen et al. INDUSTRY 2003. O144386 A1 7/2003 Pakusch et al. 2010, O190888 A1 7/2010 Gaeberlein et al. (75) Inventors: Véronique Dantin, Saint-Quentin Fallavier (FR); Paulo Goncalo, FOREIGN PATENT DOCUMENTS Saint-Quentin Fallavier (FR); Stéphanie FR 2955103 T 2011 Persoz, Saint-Quentin Fallavier (FR) FR 2955 104 T 2011 OTHER PUBLICATIONS (73) Assignee: PAREXGROUP SA, Issy les Portland Cement Wikipedia (downloaded Feb. 3, 2015).* Moulineaux (FR) “Portland Cement Hydration” by Dr. Kimberly Kurtis, published online in 2007 at http://people.ce.gatech.edu/~kk92/hyd07.pdf.* (*) Notice: Subject to any disclaimer, the term of this "Appendix A: Overview of Portland Cement and Concrete” (May 11, patent is extended or adjusted under 35 2015) http://www.epa.gov/epawaste/conserve?tools/cpg/pdf app-a. U.S.C. 154(b) by 0 days. pdf. “Cement Chemist Notation” (May 11, 2015)http://en.wikipedia.org/ wiki/Cement chemist notation. (21) Appl. No.: 13/513,498 “Portland cement” (Feb. 3, 2015) http://en.wikipedia.org/wiki/Port land cement. Zhu, H.; "Computer Simulated Crystal Structures of Major Chemical (22) PCT Fled: Mar. 9, 2012 Compounds in Portland Cement” Presentation at University of Mas sachusetts-Lowell, Jul. 20, 2009. (86) PCT NO.: PCT/EP2012/054166 S371 (c)(1), * cited by examiner (2), (4) Date: Jul. 20, 2012 Primary Examiner — Vu A Nguyen (74) Attorney, Agent, or Firm — Vedder Price P.C.; Thomas (87) PCT Pub. No.: WO2O13/131583 J. Kowalski; Deborah L. Lu (57) ABSTRACT PCT Pub. Date: Sep. 12, 2013 The invention relates to a dry composition for the preparation of a wet formulation for the construction industry. (65) Prior Publication Data The aim of the invention is to provide a dry composition that US 2014/O371351A1 Dec. 18, 2014 results in hardened products for the construction industry having an excellent compromise between its lightweight properties and mechanical properties; optimizing the hydra (51) Int. C. tion of the binder; and making possible a stable lightweight C04B 28/04 (2006.01) property without excessive increase in Volume. C04B 28/06 (2006.01) To this end, the composition according to the invention is C04B 24/26 (2006.01) based on a mineral binder (a) and incorporates at least one BOIF 3/12 (2006.01) SuperAbsorbent Polymer (SAP) (b) and an accelerator com C04B 28/10 (2006.01) ponent (c), characterized in that it comprises at least one C04B 28/02 (2006.01) Source of aluminum ions and, optionally, (d) a setting CO4B 103/OO (2006.01) retarder, (e) an additional setting accelerator, (f) a water (52) U.S. C. retaining agent, (g) a filler: (h) a lightweight filler, (i) a water CPC ............... C04B 28/10 (2013.01); B01F3/1214 repellent; (ii) a coloring agent; (k) fibers: (1) an anti-foaming (2013.01); B0IF 3/1228 (2013.01); C04B agent; (m) a redispersible powder resin, (n) a rheological 24/2641 (2013.01); C04B 24/2652 (2013.01); agent; (O) an air-entraining or foaming agent, (p) a gas-gen C04B 28/02 (2013.01); C04B 28/04 (2013.01); erating agent; (q) a fire retardant. B01F 2215/006 (2013.01); B01 F 2215/0047 The wet formulation obtained by mixing this dry composition (2013.01); C04B 2103/0051 (2013.01); C04B with water, the methods for preparing this dry composition 220 1/32 (2013.01) and the corresponding wet formulation, the construction (58) Field of Classification Search products obtained from the wet formulation and the structures CPC ... CO4B 28/04: CO4B 28/06; C04B 24/2641; produced with these products, are other subjects of the inven CO4B 24/2652 tion. See application file for complete search history. 13 Claims, No Drawings US 9,353,009 B2 1. 2 DRY COMPOSITION BASED ON MINERAL mopierre blocks, which have a lambda value close to 0.12 BNDER AND INTENDED FOR THE W/m Kt and mechanical strength of 3-5 MPa approximately) PREPARATION OF A HARDENABLE WET or as non-bearing cladding elements, contributing additional FORMULATION FOR THE CONSTRUCTION thermal insulation (in the case of Multipor R cladding, which INDUSTRY has a lambda value close to 0.048 W/m'K and mechanical strength of 0.5 MPa). Obtaining these elements requires alu CROSS REFERENCE TO RELATED minium powder to be handled, which requires particular pre APPLICATIONS cautions in view of its explosive nature. Moreover, a costly autoclaving stage is necessary to confer the necessary This application is a S371 National Stage Application of 10 mechanical strength on these elements. This technique there PCT/EP2012/0541.66, filed Mar. 9, 2012. fore cannot be used on site. Moreover, with respect to the production of prefabricated parts, there is a demand for alter BACKGROUND OF THE INVENTION native technologies for the production of prefabricated ele ments having the same types of mechanical and thermal insu 1. Field of the Invention 15 lation performance, which avoid the use of aluminium The technical field of the invention is that of powder com powder (eliminating the potential problems of explosion) and positions intended for the preparation of wet formulations for which avoid the costly autoclaving stage: energy cost, low the construction industry, for example renders, mortars, con productivity and specific investments. cretes or adhesives for construction. Air-entraining admixtures are also known for renders, mor These wet formulations can be obtained: tars and concrete, the purpose of which is to trap the Surround directly by mixing the powder compositions on site (e.g. ing air, during blending with water (mixing) of the dry com renders, mortars, concretes or adhesives for construc positions of renders, mortars or concrete. These air-entraining tion), agents are for example surfactants, fatty acids and alkali Salts by mixing the powder compositions on industrial sites to of fatty acids such as Sodium lauryl Sulphate. Such known produce prefabricated parts Such as for example plates, 25 air-entraining admixtures are capable of improvement. concrete blocks or monomer blocks. In fact, all of the difficulty of this route of production of More precisely, the invention relates to dry compositions foams by air-entrainment lies in the stabilization of the air based on mineral binders and a Super Absorbent Polymer trapped within the wet matrix of render, mortar or concrete. (SAP) that are capable, after mixing with water at high mix This stabilization is even more problematical in that it must ing ratios, for example greater than 50%, of producing wet 30 not be obtained to the detriment of the standard properties formulations that make it possible to produce lightweight (e.g. ease of use) of the wet forms of render, mortar or con hardened articles, such as exterior or interior coverings or crete foams, or to the detriment of the properties (in particular renders (e.g. exterior thermal insulation system (ETI)/deco mechanical) expected for the hardened forms of these foams. ration/protection/waterproofing), adhesives, solid objects, Moreover, the stability of the foam must also be present at etc. 35 each stage of the preparation and application processes. This 2. Description of Related Art must be embodied by a density that does not vary during each In this technical field, there is a constant need for a “foam’ stage, whether in the mixing vat, after passing through the system that incorporates air into the wet or hardened renders, pipes (lance output density 1.o.d.) or during spraying, when mortars and concretes, so as to make them lighter and give the application is carried out in this way. Conversely, this them beneficial properties in particular as regards Sound and/ 40 density can be different between each stage. The reproduc orthermal insulation and thermal resistance or fire resistance. ibility and reliability of the method of producing these foams, These low-density wet render, mortar or concrete foams must although problematical in an industrial environment, pose a also have good workability or handling. The Sound and/or real problem of robustness when use directly on site by thermal insulation properties of these render, mortar or con undualified operators is envisaged. In practice, their use on crete foams would be particularly acceptable for floor cover 45 site is very limited as it requires highly qualified labour. ings or resurfacing, exterior renders for protecting facades In order to improve this route of production of air-entrain and firestop mortars, among others. ing foams, FR2955103A proposes a dry composition for the A certain number of admixtures for render, mortar or con preparation of render, mortar or concrete foams for the con crete compositions are already known, the function of which struction industry, which become porous once hardened, so is to generate gases in situ and therefore to form a foam after 50 that they are lightweight, thermally and/or sound insulating, mixing and porosity after hardening. This is the case in par both in paste form and hardened form, and which are obtained ticular for aluminium powders capable of producing hydro by air-entrainment during mixing. This composition includes gen in an aqueous oralkaline medium, as well as for hydrogen a foaming admixture comprising: peroxide, which quickly releases oxygen when it comes into A. a modified starch ether having a Brookfield viscosity contact with catalysts such as silver or potassium permanga 55 comprised between 500 and 25,000 mPas.; nate. Other families of admixtures that generate gas in situ in B.
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