Patent Application
20170057870
Concrete is used to form buildings and infrastructure worldwide including, for example, houses, airports, bridges, highways, rail systems, etc. Concrete has different properties when newly mixed and when hardened depending on the proportioning and mixing of ingredients including cement, water, and aggregates. Additional components or additives may also be added to concrete to reduce the cost of concrete construction; to modify the properties of hardened concrete; to ensure the quality of concrete during mixing, transporting, placing, and curing; and to overcome certain emergencies during concrete operations.
The present disclosure relates to a composition including a cement and an additive and methods of making a mixture that includes a cement and an additive. The additive may be used to modify the properties of the cement and/or mixture. In some embodiments, the mixture is a concrete mixture. For example, the additive may alter the viscosity of the mixture, the rate of curing, and/or the properties of hardened concrete (e.g., porosity, strength, water permeability). The additive may also affect, for example, the amount of water that it is necessary to add to a concrete mixture before it is formed and/or cured.
In some embodiments, the present disclosure relates to a method including combining a cement and an additive, wherein the additive includes a polymer chain segment including
wherein A is independently selected from SO3H, COOH, a sulfonic or carboxy salt of an alkali metal, ammonium, quaternary ammonium, an alkaline earth metal, Al3+, La3+, Ce3−, Fe3+, Cr3+, Mn2+, Cu2+, Zn2+, Pb2+, or Sn2+. In some embodiments, the additive and the cement are combined to form a concrete mixture including less than 5 weight percent (wt-%) of the additive, less than 2 wt-% of the additive, between 0.1 wt-% and 5 wt-% of the additive, or between 0.1 wt-% and 1 wt-% of the additive.
In some embodiments, the additive includes
wherein A is independently selected from SO3H, COOH, a sulfonic or carboxy salt of an alkali metal, ammonium, quaternary ammonium, an alkaline earth metal, Al3+, La3+, Ce3−, Fe3+, Cr3+, Mn2+, Cu2+, Zn2+, Pb2+, or Sn2+; and wherein n is an integer between 1 and 10,000.
In some embodiments, the additive includes
wherein A is independently selected from SO3H, COOH, a sulfonic or carboxy salt of an alkali metal, ammonium, quaternary ammonium, an alkaline earth metal, Al3+, La3+, Ce3−, Fe3+, Cr3+, Mn2+, Cu2+, Zn2+, Pb2+, or Sn2+; and wherein p is an integer greater than 1 and q is an integer greater than 1.
In some embodiments, the additive further includes an accelerator.
In some embodiments, the present disclosure relates to a composition including a cement and an additive, wherein the additive includes a polymer chain segment including
wherein A is independently selected from SO3H, COOH, a sulfonic or carboxy salt of an alkali metal, ammonium, quaternary ammonium, an alkaline earth metal, Al3+, La3+, Ce3−, Fe3+, Cr3+, Mn2+, Cu2+, Zn2+, Pb2+, or Sn2+.
In some embodiments, the additive includes
wherein A is independently selected from SO3H, COOH, a sulfonic or carboxy salt of an alkali metal, ammonium, quaternary ammonium, an alkaline earth metal, Al3+, La3+, Ce3−, Fe3+, Cr3+, Mn2+, Cu2+, Zn2+, Pb2+, or Sn2+; and wherein n is an integer between 1 and 10,000.
In some embodiments, the additive includes
wherein A is independently selected from SO3H, COOH, a sulfonic or carboxy salt of an alkali metal, ammonium, quaternary ammonium, an alkaline earth metal, Al3+, La3+, Ce3−, Fe3+, Cr3+, Mn2+, Cu2+, Zn2+, Pb2+, or Sn2+; and wherein p is an integer greater than 1 and q is an integer greater than 1.
In some embodiments, the additive is less than 5 wt-% of the composition, is less than 2 wt-% of the composition, is between 0.1 wt-% and 5 wt-% of the composition, or is between 0.1 wt-% and 1 wt-% of the composition.
In some embodiments, the composition is a concrete mixture.
In the following detailed description, examples are provided and reference is made to the accompanying figures that form a part hereof by way of illustration of several specific embodiments. It is to be understood that other embodiments are contemplated and may be made without departing from the scope or spirit of the present disclosure. The following detailed description, therefore, is not to be taken in a limiting sense.
All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are to facilitate understanding of certain terms used frequently herein and are not meant to limit the scope of the present disclosure.
Unless otherwise indicated, all numbers expressing feature sizes, amounts, and physical properties used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that can vary depending upon the properties sought to be obtained by those skilled in the art utilizing the teachings disclosed herein.
The recitation of numerical ranges by endpoints includes all numbers subsumed within that range (e.g. 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5) and any range within that range.
As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” encompass embodiments having plural referents, unless the content clearly dictates otherwise.
As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
As used herein, “have,” “having,” “include,” “including,”, “comprise,” “comprising,” or the like are used in their open ended sense, and generally mean “including, but not limited to.” It will be understood that “consisting essentially of,” “consisting of,” and the like are subsumed in “comprising,” and the like. The term “consisting of” means including, and limited to, whatever follows the phrase “consisting of” That is, “consisting of” indicates that the listed elements are required or mandatory, and that no other elements may be present. The term “consisting essentially of” indicates that any elements listed after the phrase are included, and that other elements than those listed may be included provided that those elements do not interfere with or contribute to the activity or action specified in the disclosure for the listed elements.
As used herein, “concrete” is a composition prepared from components including filler material, water, and cement. The filler material may include any suitable material including, for example, sand, stone, gravel, etc.
The present disclosure describes a composition including a cement and an additive and methods for forming such compositions. The additive includes a polymer chain segment including:
wherein A is independently selected from SO3H, COOH, a sulfonic or carboxy salt of an alkali metal, ammonium, quaternary ammonium, an alkaline earth metal, Al3+, La3+, Ce3+, Fe3+, Cr3+, Mn2+, Cu2+, Zn2+, Pb2+, or Sn2+. In some embodiments the segment is preferably cross-linked to additional segments through covalent bonds. The cement and additive may be included in a concrete mixture. In some embodiments, the additive is a polymer.
While the present disclosure is not so limited, an appreciation of various aspects of the disclosure will be gained through a discussion of the examples provided below.
A cement may include a non-hydraulic cement or a hydraulic cement. In some embodiments, the cement is a Portland cement, including, for example, Type I, Type II, Type III, Type IV, Type V, Type Ia, Type IIa, Type IIIa, Type II(MH), Type II(MH)a, white Portland cement, etc. The cement may be normal or quick hardening.
The additives of the present disclosure include a polymer chain segment including
wherein A is independently selected from SO3H, COOH, a sulfonic or carboxy salt of an alkali metal, ammonium, quaternary ammonium, an alkaline earth metal, Al3+, La3+, Ce3+, Fe3+, Cr3+, Mn2+, Cu2+, Zn2+, Pb2+, or Sn2+. In some embodiments the segment is preferably cross-linked to additional segments through covalent bonds. The cement and additive may be included in a concrete mixture. In some embodiments, the additive is a polymer.
In some embodiments, the additive includes a polymer that includes a segment including the following formula:
wherein A is independently selected from SO3H, COOH, a sulfonic or carboxy salt of an alkali metal, ammonium, quaternary ammonium, an alkaline earth metal, Al3+, La3+, Ce3+, Fe3+, Cr3+, Mn2+, Cu2+, Zn2+, Pb2+, or Sn2+; and wherein n is an integer between 2 and 10,000. In some embodiments, n is at least 5.
In one embodiment, A can be SO3− and/or COO−, wherein 3 percent (%), 4%, 5%, 8%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 60%, 70%, 80%, 90%, 95%, or 100% of A is SO3− and 97%, 96%, 95%, 92%, 90%, 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 40%, 30%, 20%, 10%, 5%, or 0% of A is COO−.
In one embodiment, the polymer segment includes a segment including the following formula:
wherein n is an integer between 2 and 10,000. Examples of a synthesis of this molecule where n is at least 2, poly(2,2′-disulfo-4,4′-benzidine terephthalamide), are described in U.S. Pat. No. 8,512,824. In one embodiment, the number-average molecular weight is about 10,000 to about 150,000. In another embodiment, the number-average molecular weight is about 50,000 to about 150,000.
In an alternative embodiment, the polymer segment includes a segment including (2,2′-dicarboxy)-4,4′-benzidine terephthalamide) or poly((2,2′-dicarboxy)-4,4′-benzidine terephthalamide):
wherein n is an integer between 2 and 10,000. In one embodiment, the number-average molecular weight is about 50,000 to about 150,000.
In some embodiments, the additive includes a copolymer that includes a segment including the following general formula:
and a segment including the following general formula:
wherein A is independently selected from SO3H, COOH, a sulfonic or carboxy salt of an alkali metal, ammonium, quaternary ammonium, an alkaline earth metal, Al3+, La3+, Ce3+, Fe3+, Cr3+, Mn2+, Cu2+, Zn2+, Pb2+, or Sn2+; and wherein at least one segment of formula (X-1a) and one segment of formula (X-2a) are connected by a covalent bond. The polymer segment may include a single segment of formula (X-1a) bonded to a single segment of formula (X-2a) or mixed segments of formula (X-1a) and formula (X-2a). In one embodiment, the ratio of segments of formula (X-1a) to segments of formula (X-2a) is about 73:27. In other embodiments, the ratio of segments can be 0:100, 1:99, 5:95, 10:90, 15:85, 20:80, 25:75, 30:70, 35:65, 40:60, 45:55, 50:50, 55:45, 60:40, 65:35, 70:30, 75:25, 80:20, 85:15, 90:10, 95:5, 99:1, 100:0 or any ratio in between, or a range of these ratios. In some embodiments, the number-average molecular weight can be between 2,000 and 50,000, between 2,000 and 10,000, or between 4,000 and 6,000, or the number-average molecular weight can be about 5000.
In some embodiments, the additive includes
wherein A is independently selected from SO3H, COOH, a sulfonic or carboxy salt of an alkali metal, ammonium, quaternary ammonium, an alkaline earth metal, Al3+, La3+, Ce3+, Fe3+, Cr3+, Mn2+, Cu2+, Zn2+, Pb2+, or Sn2+; p is an integer greater than or equal to 1; and q is an integer greater than or equal to 1.
In one embodiment, A can be SO3− and/or COO−, wherein 0%, 3%, 4%, 5%, 8%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 60%, 70%, 80%, 90%, 95%, or 100% of A is SO3− and 100%, 97%, 96%, 95%, 92%, 90%, 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 40%, 30%, 20%, 10%, 5%, or 0% of A is COO−.
For example, in one embodiment the polymer segment includes a segment including the following formula:
and a segment including the following formula:
wherein at least one segment of formula (X-1) and one segment of formula (X-2) are connected by a covalent bond. For example, the polymer segment can include a segment including the following formula:
wherein p is an integer greater than or equal to 1 and q is an integer greater than or equal to 1.
Examples of synthesis of a polymer including these segments, 2,2′-disulfo-4,4′-benzidine terephthalamide-isophthalamide copolymer, are described in U.S. Publication No. 2010/0190015. In one embodiment, the ratio of segments of formula (X-1) to segments of formula (X-2) is about 73:27. In other embodiments, the ratio of segments can be 0:100, 1:99, 5:95, 10:90, 15:85, 20:80, 25:75, 30:70, 35:65, 40:60, 45:55, 50:50, 55:45, 60:40, 65:35, 70:30, 75:25, 80:20, 85:15, 90:10, 95:5, 99:1, 100:0 or any ratio in between, or range of these ratios. In some embodiments, the number-average molecular weight can be between 2,000 and 50,000, between 2,000 and 10,000, or between 4,000 and 6,000, or the number-average molecular weight can be about 5000.
For example, in one embodiment the polymer segment includes a segment including the following formula:
and a segment including the following formula:
wherein at least one segment of formula (X-1b) and one segment of formula (X-2b) are connected by a covalent bond.
In many embodiments, the polymer has a number average molecular weight in a range of 3,000 to 30,000, in a range of 3,500 to 10,000, or in a range of 5,000 to 7,000, for example.
The additives of the present disclosure can be provided as water-based solutions. The additives can be added to a mixture at up to 5 wt-%, up to 4 wt-%, up to 3 wt-%, up to 2 wt-%, up to 1 wt-%, or up to 0.5 wt-%. In some embodiments, the additive and the cement are combined to form a mixture including between 0.1 wt-% and 5 wt-% of the additive, between 0.1 wt-% and 2 wt-% of the additive, between 0.1 wt-% and 1 wt-% of the additive, between 0.1 wt-% and 0.7 wt-% of the additive, or between 0.1 wt-% and 0.5 wt-% of the additive.
In some embodiments, a cement and an additive are mixed combined to form a concrete mixture.
The concrete mixture may be used for any purpose including, for example, as a construction material including, for example, as architectural and decorative concrete, as stucco, as pervious concrete, etc. The concrete may be used in 3D printing.
The additives of the present disclosure may be added to alter the properties of a concrete mixture including, for example, the properties of hardened concrete; the quality of concrete during mixing, transporting, placing, and/or curing; the amount of water required to be added to the concrete mixture; the rate of cement hardening, setting, and/or hydration; the stability of the concrete mixture; the viscosity of the concrete mixture; the entrainment of air in the concrete mixture, etc.
In some embodiments, a cement and an additive may be combined. In some embodiments, the cement and the additive form a concrete mixture. In some embodiments, the additive may be combined with water and the mixture containing water and additive may be mixed with cement. In some embodiments, the concrete mixture also includes chemical admixtures, reinforcement materials, and/or mineral admixtures.
In some embodiments, the chemical admixture can include an accelerator that increases the setting time, including, for example, calcium nitrate (Ca(NO3)2), calcium chloride (CaCl2), sodium nitrate (NaNO3), etc. In some embodiments, the chemical admixture can include an air-entraining admixture, a water-reducing admixture, a retarding admixture, and/or a plasticizer.
Objects and advantages of this disclosure are further illustrated by the following examples, but the particular materials and amounts thereof recited in these examples, as well as other conditions and details, should not be construed to unduly limit this disclosure.
The following equipment and material was used in the following representative Procedures and Examples unless otherwise indicated.
All reagents, starting materials, and solvents used in the following examples were purchased from commercial suppliers (such as Sigma-Aldrich Chemical Company, St. Louis, Mo.) and were used without further purification unless otherwise indicated.
Mixing Procedure
Slump Test Procedure
10.0 grams (g) (0.029 mol) of 4,4′-diaminobiphenyl-2,2′-disulfonic acid was mixed with 3.1 g (0.029 mol) of sodium carbonate and 160 ml of water and stirred until the solid completely dissolved. Then 50 ml of toluene was added. Upon stirring the obtained solution, a solution of 4.3 g (0.021 mol) of terephthaloyl chloride and 1.6 g (0.008 mol) of isophthaloyl chloride and 0.7 g (0.005 mol) of benzoyl chloride in 30 ml of toluene were added followed by addition of 3.4 g (0.033 mol) of sodium carbonate in 50 ml of water. The resulting mixture thickened in about 30 minutes. It was heated to boiling and toluene distilled out. The resulting water solution was ultrafiltered using a PES membrane with MW cut-off 5K Dalton. Yield of the copolymer was 200 g of 7% water solution.
Gel permeation chromatography (GPC) analysis of the sample was performed with Hewlett Packard 1260 chromatograph with diode array detector (λ=230 nm), using Varian GPC software Cirrus 3.2 and TOSOH Bioscience TSKgel G5000 PW-XLcolumn and 0.2 M phosphate buffer (pH=7) as the mobile phase. Poly(para-styrenesulfonic acid) sodium salt was used as GPC standard. The calculated number average molecular weight, Mn, weight average molecular weight, Mw, and polydispersity, PD. were found as 5.3×104, 1.6×105, and 3.0 respectively.
10.0 g (0.029 mol) of 4,4′-diaminobiphenyl-2,2′-disulfonic acid was mixed with 3.1 g (0.029 mol) of sodium carbonate and 700 ml of water and stirred till dissolution. While stirring, the obtained solution a solution of 6.5 g (0.032 mol) of terephthaloyl chloride in 700 ml of toluene was added followed by a solution of 6.1 g of sodium carbonate in 100 g of water. The stirring was continued for 3 hours. Then the emulsion was heated to boiling and toluene distilled out. The resulting water solution was ultrafiltered using PES membrane with MW cut-off 20K Dalton. Yield of the polymer was 180 g of 8% water solution.
Gel permeation chromatography (GPC) analysis of the sample was performed with a Hewlett Packard 1260 chromatograph with diode array detector (λ=230 nm), using Varian GPC software Cirrus 3.2 and TOSOH Bioscience TSKgel G5000 PWXLcolumn and 0.2 M phosphate buffer (pH=7) as the mobile phase. Poly(para-styrenesulfonic acid) sodium salt was used as GPC standard. The calculated number average molecular weight, Mn, weight average molecular weight. Mw, and polydispersity, PD, were found as 1.1×105, 4.6×105, and 4.2 respectively.
The components shown in Table 1 were mixed:
The resulting mixture was tested using the Slump Test Procedure. Results are shown in
The components shown in Table 2 were mixed to form concrete that included 0.18 wt-% poly(2,2′-disulfo-4,4′-benzidine terephthalamide) and 0.3 wt-% poly(2,2″-disulfo-4,4′-benzidine terephthalamide):
The resulting mixtures were tested using the Slump Test Procedure. Results are shown in
The components shown in Table 3 were mixed to form concrete mixtures including 0.1 wt-%, 0.18 wt-%, 0.3 wt-%, 0.35 wt-%, or 0.7 wt-% 2,2′-disulfo-4,4′-benzidine terephthalamide-isophthalamide:
The resulting mixtures were tested using the Slump Test Procedure. Results are shown in
The components shown in Table 4 were mixed:
The resulting mixture was tested using the Slump Test Procedure. Results are shown in
The components shown in Table 5 were mixed:
The resulting mixture was tested using the Slump Test Procedure. Results are shown in Table 6 and
A water to cement ratio of 0.62 is equivalent to a 5% reduction in water compared to a water to cement ratio of 0.65. Compared to the control mixture having 0.65 and 0.62 water to cement ratio, the slump is higher with 2,2′-disulfo-4,4′-benzidine terephthalamide-isophthalamide copolymer added to the mixture.
Laboratory testing work was performed by Element Materials Technology, St. Paul, MN. ASTM test standards were used to determine slump (ASTM C143), air content (ASTM C231), unit weight (ASTM C138), time of set (ASTM C403), and compressive strength (ASTM C39)
Comparative test mixtures and procedures are outlined in ASTM C494 Sections 11-15.
The Following materials were used
Component amounts of each mixture are summarized in Tables 7 and 8. The mixture including 0.1% admixture (Mix Number 2) had a final concentration of 0.7 wt-% poly(2,2′-disulfo-4,4′-benzidine terephthalamide); the mixture including 0.05% admixture (Mix Number 4) had a final concentration of 0.35 wt-% poly(2,2′-disulfo-4,4′-benzidine terephthalamide).
2Total water including water in admixture
2Total water including water in admixture
Results are summarized in Table 9 and
1
1
Thus, embodiments of CONCRETE FORMULATION AND METHODS OF MAKING are disclosed.
All references and publications cited herein are expressly incorporated herein by reference in their entirety into this disclosure, except to the extent they may directly contradict this disclosure. Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations can be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this disclosure be limited only by the claims and the equivalents thereof. The disclosed embodiments are presented for purposes of illustration and not limitation.
| Number | Date | Country | |
|---|---|---|---|
| 62209544 | Aug 2015 | US |
