CA2439698A1 - Fiber reinforced cement composite materials using chemically treated fibers with improved dispersibility - Google Patents

Fiber reinforced cement composite materials using chemically treated fibers with improved dispersibility Download PDF

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Publication number
CA2439698A1
CA2439698A1 CA 2439698 CA2439698A CA2439698A1 CA 2439698 A1 CA2439698 A1 CA 2439698A1 CA 2439698 CA2439698 CA 2439698 CA 2439698 A CA2439698 A CA 2439698A CA 2439698 A1 CA2439698 A1 CA 2439698A1
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CA
Canada
Prior art keywords
fibers
building material
chemically treated
fiber
dispersant
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA 2439698
Other languages
French (fr)
Other versions
CA2439698C (en
Inventor
Caidian Luo
Donald J. Merkley
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
James Hardie Technology Ltd
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Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US09/969,742 external-priority patent/US6676745B2/en
Application filed by Individual filed Critical Individual
Publication of CA2439698A1 publication Critical patent/CA2439698A1/en
Application granted granted Critical
Publication of CA2439698C publication Critical patent/CA2439698C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/10—Coating or impregnating
    • C04B20/1018—Coating or impregnating with organic materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04—Waste materials; Refuse
    • C04B18/18—Waste materials; Refuse organic
    • C04B18/24—Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper, cork
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04—Waste materials; Refuse
    • C04B18/18—Waste materials; Refuse organic
    • C04B18/24—Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper, cork
    • C04B18/241—Paper, e.g. waste paper; Paper pulp
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/0048—Fibrous materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/10—Coating or impregnating
    • C04B20/1051—Organo-metallic compounds; Organo-silicon compounds, e.g. bentone
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/10—Coating or impregnating
    • C04B20/1055—Coating or impregnating with inorganic materials
    • C04B20/107—Acids or salts thereof
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L1/00—Compositions of cellulose, modified cellulose or cellulose derivatives
    • C08L1/02—Cellulose; Modified cellulose
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21C—PRODUCTION OF CELLULOSE BY REMOVING NON-CELLULOSE SUBSTANCES FROM CELLULOSE-CONTAINING MATERIALS; REGENERATION OF PULPING LIQUORS; APPARATUS THEREFOR
    • D21C9/00—After-treatment of cellulose pulp, e.g. of wood pulp, or cotton linters ; Treatment of dilute or dewatered pulp or process improvement taking place after obtaining the raw cellulosic material and not provided for elsewhere
    • D21C9/001—Modification of pulp properties
    • D21C9/002—Modification of pulp properties by chemical means; preparation of dewatered pulp, e.g. in sheet or bulk form, containing special additives
    • D21C9/005—Modification of pulp properties by chemical means; preparation of dewatered pulp, e.g. in sheet or bulk form, containing special additives organic compounds
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/40—Surface-active agents, dispersants
    • C04B2103/408—Dispersants
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2933—Coated or with bond, impregnation or core
    • Y10T428/2938—Coating on discrete and individual rods, strands or filaments
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2933—Coated or with bond, impregnation or core
    • Y10T428/2964—Artificial fiber or filament
    • Y10T428/2965—Cellulosic

Abstract

A fiber-reinforced building material in one embodiment incorporates cellulose fibers that are chemically treated with a dispersant to impart improved dispersibility to the fibers. The fibers are treated with a dispersant which deactivates the hydroxyl sites of the fiber surfaces and in some cases, making the fiber surface more hydrophobic. The dispersant inhibits the hydroxyl groups on the cellulose fiber surface from bonding with hydroxyl groups of other fibers and from bonding with hydroxyl groups of the same fiber, thereby significantly reducing inter-fiber and intra-fiber hydrogen bonding. The chemically treated fibers with improved dispersibility improve the fiber distribution and reinforcing efficiency, which in turn improves key physical and mechanical properties of the material such as the modulus of rupture, z-direction tensile strength, and toughness, and surface finishes.

Claims (35)

1. A building material incorporating fibers, wherein at least a portion of the fibers are at least partially treated with a dispersant to form chemically treated fibers with improved dispersibility, wherein the dispersant binds hydroxyl groups on the fiber surface so as to substantially inhibit bonding between hydroxyl groups of different fibers, thereby substantially reducing inter-fiber hydrogen bonding so that the chemically treated fibers can be more readily dispersed in the building material.
2. The building material of Claim 1, wherein the dispersant binds hydroxyl groups on the fiber surface so as to substantially inhibit bonding between hydroxyl groups of the same fiber, thereby substantially reducing intra-fiber hydrogen bonding.
3. The building material of Claim 1 wherein the dispersant physically blocks the hydroxyl groups from bonding with hydroxyl groups of different fibers.
4. The building material of Claim 1 wherein the dispersant comprises at least one functional group that chemically bonds to the hydroxyl groups on the fiber surface in a manner so as to substantially prevent the hydroxyl groups from bonding with hydroxyl groups of different fibers.
5. The building material of Claim 1 wherein the dispersant comprises a surfactant that imparts the fibers improved dispersibility in an aqueous environment.
6. The building material of Claim 1, wherein the dispersant comprises organic compounds selected from the group consisting of polyamine compounds, cationic quaternaryamine surfactants, cationic surfactants, anionic surfactants, non-ionic surfactants, alkylalkoxylsilane, alkoxylsilane, halide organosilane, or mixtures thereof.
7. The building material of Claim 1, wherein the dispersant comprises approximately 0.001%-20% of the oven dry weight of the fibers.
8. The building material of Claim 1, wherein the dispersant comprises a debonder.
9. The building material of Claim 1, wherein the fibers are cellulose fibers.
10. The building material of Claim 1, wherein the building material comprises a polymeric matrix, wherein the chemically treated fibers with improved dispersibility are incorporated in the polymeric matrix.
11. The building material of Claim 1, wherein the building material comprises a cementitious matrix, wherein the chemically treated fibers with improved dispersibility are incorporated in the cementitious matrix.
12. The building material of Claim 11, wherein the chemically treated fibers are cellulose fibers.
13. The building material of Claim 12, wherein the cellulose fibers are individualized fibers.
14. The building material of Claim 11, wherein the chemically treated fibers comprise about 0.5% - 20% of the building material by weight.
15. The building material of Claim 14, wherein the chemically treated fibers comprise approximately 4-12% by weight of the building material.
16. The building material of Claim 11, wherein the chemically treated fibers with improved dispersibility increase the toughness of the building material by approximately 20% as compared to a building material made from an equivalent formulation without chemically treated fibers with improved dispersibility.
17. The building material of Claim 11, wherein the chemically treated fibers with improved dispersibility increase the strain of the building material by more than about 5% as compared to a building material made from an equivalent formulation without chemically treated fibers with improved dispersibility.
18. The building material of Claim 11, wherein the chemically treated fibers with improved dispersibility increase the modulus of rupture of the building material by more than about 5% as compared to a building material made from an equivalent formulation without chemically treated fibers with improved dispersibility.
19. The building material of Claim 11, wherein the chemically treated fibers with improved dispersibility increase the Z-direction tensile strength of the building material by more than about 10% as compared to a building material made from an equivalent formulation without chemically treated fibers with improved dispersibility.
20. The building material of Claim 11, wherein the chemically treated fibers with improved dispersibility reduce the fiber dosage of the building material by about 5%
as compared to a building material made from an equivalent formulation without chemically treated fibers with improved dispersibility.
21. The building material of Claim 11, wherein the chemically treated fibers with improved dispersibility comprise fibers having a length-weighted average length of longer than about 1 mm.
22. The building material of Claim 11, wherein the building material comprises a fiber cement formulation comprising about 20%-80% cement, about 20%-80%
aggregate, about 0.5%-20% fibers, and about 0%-50% additives.
23. A method of manufacturing a building material, comprising:
providing fibers;
treating at least a portion of the fibers with a dispersant to form chemically treated fibers with improved dispersibility, wherein the dispersant imparts improved fiber dispersibility in the aqueous phase;
mixing the chemically treated fibers with a binder and other ingredients to form a mixture;
forming the mixture into an article of a pre-selected shape and size; and curing the article so as to form a fiber reinforced composite building material.
24. The method of Claim 23, wherein providing the fibers comprises providing cellulose fibers.
25. The method of Claim 23, wherein treating the fibers comprises treating the fibers in a solution containing surfactants.
26. The method of Claim 23, wherein treating the fibers comprises applying between about 0.001%-20% of dispersants to the fibers by fiber mass.
27. The method of Claim 23, wherein treating the fibers comprises chemically bonding a dispersant to the fiber surface in a manner such that the dispersant substantially blocks at least a portion of the hydroxyl groups on the fiber surface.
28. The method of Claim 23, wherein treating the fibers comprises using a dry spray process to deposit dispersants on the fiber surface.
29. The method of Claim 23, wherein mixing the chemically treated fibers with a binder comprises mixing the chemically treated fibers with a cementitious binder so as to form a fiber cement mixture.
30. The method of Claim 23, wherein mixing the chemically treated fibers with a binder comprises mixing the chemically treated fibers with a polymeric binder.
31. The method of Claim 23, wherein providing the fibers comprises fiberizing the fibers.
32. The method of Claim 24, wherein providing the fibers comprises chemically removing the lignin of the fibers so as to individualize the fibers.
33. The method of Claim 29, wherein forming the fiber cement mixture into an article comprises using the extrusion, molding, Hatchek, and other processes.
34. A method of manufacturing a building material, comprising:
mixing fibers that have been chemically treated with a dispersant with a binder and other ingredients to form a mixture;
forming the mixture into an article of a pre-selected shape and size; and curing the article so as to form a fiber reinforced composite building material.
35. The method of Claim 34 wherein mixing fibers that have been chemically treated with a dispersant comprises mixing fluff pulps with a cementitious binder and other ingredients to form a fiber cement mixture.
CA 2439698 2001-03-09 2002-02-22 Fiber reinforced cement composite materials using chemically treated fibers with improved dispersibility Expired - Lifetime CA2439698C (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US27441401P 2001-03-09 2001-03-09
US60/274,414 2001-03-09
US09/969,742 2001-10-02
US09/969,742 US6676745B2 (en) 2000-10-04 2001-10-02 Fiber cement composite materials using sized cellulose fibers
PCT/US2002/006152 WO2002072499A2 (en) 2001-03-09 2002-02-22 Fiber reinforced cement composite materials using chemically treated fibers with improved dispersibility

Publications (2)

Publication Number Publication Date
CA2439698A1 true CA2439698A1 (en) 2002-09-19
CA2439698C CA2439698C (en) 2011-04-19

Family

ID=26956792

Family Applications (1)

Application Number Title Priority Date Filing Date
CA 2439698 Expired - Lifetime CA2439698C (en) 2001-03-09 2002-02-22 Fiber reinforced cement composite materials using chemically treated fibers with improved dispersibility

Country Status (16)

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US (2) US7344593B2 (en)
EP (1) EP1368285B1 (en)
JP (1) JP4384411B2 (en)
CN (1) CN1247487C (en)
AR (1) AR032978A1 (en)
AT (1) ATE359245T1 (en)
AU (1) AU2002240552B2 (en)
CA (1) CA2439698C (en)
CZ (1) CZ20032693A3 (en)
DE (1) DE60219443T2 (en)
ES (1) ES2284820T3 (en)
MX (1) MXPA03007956A (en)
NZ (1) NZ528310A (en)
PL (1) PL370668A1 (en)
TW (1) TW553915B (en)
WO (1) WO2002072499A2 (en)

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MXPA03007956A (en) 2003-12-04
WO2002072499A2 (en) 2002-09-19
JP2004524254A (en) 2004-08-12
CN1247487C (en) 2006-03-29
WO2002072499A3 (en) 2003-03-20
EP1368285A2 (en) 2003-12-10
TW553915B (en) 2003-09-21
EP1368285B1 (en) 2007-04-11
PL370668A1 (en) 2005-05-30
ATE359245T1 (en) 2007-05-15
US20020170468A1 (en) 2002-11-21
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CZ20032693A3 (en) 2004-07-14
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US7857906B2 (en) 2010-12-28
CA2439698C (en) 2011-04-19
US20080148999A1 (en) 2008-06-26
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CN1462261A (en) 2003-12-17
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