NZ734212B - Concrete curing blanket and method - Google Patents
Concrete curing blanket and methodInfo
- Publication number
- NZ734212B NZ734212B NZ734212A NZ73421215A NZ734212B NZ 734212 B NZ734212 B NZ 734212B NZ 734212 A NZ734212 A NZ 734212A NZ 73421215 A NZ73421215 A NZ 73421215A NZ 734212 B NZ734212 B NZ 734212B
- Authority
- NZ
- New Zealand
- Prior art keywords
- layer
- wicking
- tissue
- super absorbent
- tissue layer
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims description 20
- 230000002745 absorbent Effects 0.000 claims abstract description 148
- 239000002250 absorbent Substances 0.000 claims abstract description 148
- 239000000463 material Substances 0.000 claims abstract description 98
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 48
- 230000004888 barrier function Effects 0.000 claims abstract description 40
- 239000007767 bonding agent Substances 0.000 claims abstract description 16
- 238000004519 manufacturing process Methods 0.000 claims abstract description 10
- 229920000433 Lyocell Polymers 0.000 claims description 13
- -1 polyethylene Polymers 0.000 claims description 11
- 239000000853 adhesive Substances 0.000 claims description 9
- 230000001070 adhesive effect Effects 0.000 claims description 9
- 239000004568 cement Substances 0.000 claims description 9
- 229920000297 Rayon Polymers 0.000 claims description 8
- 239000004698 Polyethylene Substances 0.000 claims description 7
- 229920001495 poly(sodium acrylate) polymer Polymers 0.000 claims description 7
- 229920000573 polyethylene Polymers 0.000 claims description 7
- NNMHYFLPFNGQFZ-UHFFFAOYSA-M sodium polyacrylate Chemical compound [Na+].[O-]C(=O)C=C NNMHYFLPFNGQFZ-UHFFFAOYSA-M 0.000 claims description 7
- 239000004743 Polypropylene Substances 0.000 claims description 4
- 238000003490 calendering Methods 0.000 claims description 4
- 229920001155 polypropylene Polymers 0.000 claims description 4
- 229920000728 polyester Polymers 0.000 claims description 3
- 238000002791 soaking Methods 0.000 claims description 2
- MYWUZJCMWCOHBA-VIFPVBQESA-N methamphetamine Chemical compound CN[C@@H](C)CC1=CC=CC=C1 MYWUZJCMWCOHBA-VIFPVBQESA-N 0.000 claims 1
- 230000036571 hydration Effects 0.000 abstract description 5
- 238000006703 hydration reaction Methods 0.000 abstract description 5
- 238000001704 evaporation Methods 0.000 abstract description 3
- 230000008020 evaporation Effects 0.000 abstract description 3
- 230000002452 interceptive effect Effects 0.000 abstract description 3
- 230000008901 benefit Effects 0.000 description 5
- 229920000247 superabsorbent polymer Polymers 0.000 description 4
- 239000004583 superabsorbent polymers (SAPs) Substances 0.000 description 4
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- 229920002678 cellulose Polymers 0.000 description 3
- 239000001913 cellulose Substances 0.000 description 3
- 238000010276 construction Methods 0.000 description 3
- 239000000835 fiber Substances 0.000 description 3
- 229920000642 polymer Polymers 0.000 description 3
- 239000007864 aqueous solution Substances 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 238000009472 formulation Methods 0.000 description 2
- 239000000499 gel Substances 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 239000002655 kraft paper Substances 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 239000004745 nonwoven fabric Substances 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 239000004831 Hot glue Substances 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- 230000018044 dehydration Effects 0.000 description 1
- 238000006297 dehydration reaction Methods 0.000 description 1
- 239000008367 deionised water Substances 0.000 description 1
- 239000012153 distilled water Substances 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 239000000017 hydrogel Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 1
- 239000003999 initiator Substances 0.000 description 1
- 239000000543 intermediate Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000004584 polyacrylic acid Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 230000008961 swelling Effects 0.000 description 1
Classifications
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- 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
- C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
- C04B40/04—Preventing evaporation of the mixing water
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
- E04G21/24—Safety or protective measures preventing damage to building parts or finishing work during construction
- E04G21/246—Safety or protective measures preventing damage to building parts or finishing work during construction specially adapted for curing concrete in situ, e.g. by covering it with protective sheets
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-
- 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
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/674—Nonwoven fabric with a preformed polymeric film or sheet
-
- 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
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/674—Nonwoven fabric with a preformed polymeric film or sheet
- Y10T442/678—Olefin polymer or copolymer sheet or film [e.g., polypropylene, polyethylene, ethylene-butylene copolymer, etc.]
-
- 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
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/681—Spun-bonded nonwoven fabric
-
- 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
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/699—Including particulate material other than strand or fiber material
Abstract
concrete curing blanket (10) of the present invention seeks to solve problems of current concrete curing blankets which have poor water holding capacity, are expensive to manufacture, complicated to use, not durable or strong, easily tearable and poor hydration or poor water carrying characteristics which affects the strength and durability of concrete when cured. Also there is a need for preventing bonding agents from contaminating and interfering with the absorbing of water. Therefore concrete curing blanket of the present invention includes an absorbent sheet (22) having a wicking layer (20), super absorbent materials, and a tissue layer (26), which are laminated together to form the absorbent sheet (22). The absorbent sheet (22) is sized for being spread over a curing concrete slab (C). A vapor barrier (30) is bonded to the tissue layer (26) of the absorbent sheet (22) to inhibit evaporation from the concrete curing blanket (10), and includes a plurality of perforations. cs which affects the strength and durability of concrete when cured. Also there is a need for preventing bonding agents from contaminating and interfering with the absorbing of water. Therefore concrete curing blanket of the present invention includes an absorbent sheet (22) having a wicking layer (20), super absorbent materials, and a tissue layer (26), which are laminated together to form the absorbent sheet (22). The absorbent sheet (22) is sized for being spread over a curing concrete slab (C). A vapor barrier (30) is bonded to the tissue layer (26) of the absorbent sheet (22) to inhibit evaporation from the concrete curing blanket (10), and includes a plurality of perforations.
Description
Docket: 0987-02UA
TITLE: CONCRETE CURING BLANKET
CROSS-REFERENCE TO RELATED APPLICATIONS
This application for a utility patent claims the benefit of U.S. Provisional Application No.
62/110,526, filed Jan. 31, 2015.
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION:
This invention relates generally to a concrete curing blanket, and more particularly to a
concrete curing blanket that includes an absorbent sheet that includes a wicking layer, a super
absorbent material, and a tissue layer, laminated together, and which is covered with a vapor
barrier having a plurality of perforations.
DESCRIPTION OF RELATED ART:
Concrete strength and durability improves when the concrete is thoroughly hydrated during
curing. If the concrete is kept wet for the first 7-10 days after setting, strength and durability
thereof is increased 75% over ordinary aging of concrete in dry surface conditions.
Docket: 0987-02UA
To keep concrete hydrated, the concrete industry has come to rely on concrete curing blankets
for covering wetted concrete and extending the duration of damp conditions on the curing
surface of the concrete. An example of such a concrete curing blanket is disclosed in
McDonald, U.S. 7,572,525, which teaches a curing blanket that includes a vapor barrier, and
an airlaid layer consisting of a binder material and a natural cellulose bleached fluff pulp
fiber derived from wood through Kraft processing.
The prior art teaches the use of concrete curing blankets that include an airlaid layer that
includes natural cellulose bleached fluff pulp fiber derived from wood through Kraft
processing. However, the prior art does not teach a concrete curing blanket that includes an
absorbent sheet that includes a wicking layer, a super absorbent material, and a tissue layer,
laminated together, which is covered with a vapor barrier having a plurality of perforations.
The present invention fulfills these needs and provides further advantages as described in the
following summary.
All references, including any patents or patent applications cited in this specification are
hereby incorporated by reference.
SUMMARY OF THE INVENTION
Docket: 0987-02UA
The present invention teaches certain benefits in construction and use which give rise to the
objectives described below.
The present invention provides a concrete curing blanket that includes an absorbent sheet
comprising a wicking layer and a tissue layer with super absorbent materials positioned
therebetween. The absorbent sheet is sized for being spread over a curing concrete slab. A
vapor barrier is bonded to the tissue layer of the absorbent sheet to inhibit evaporation from
the concrete curing blanket.
In one embodiment, the concrete curing blanket is at least 1 meter wide and 5 meters long. In
one embodiment, the vapor barrier includes a plurality of perforations.
A primary objective of the present invention is to provide a concrete curing blanket having
advantages not taught by the prior art.
Another objective is to provide a concrete curing blanket that includes a combination of a
wicking layer, a super absorbent material, and a tissue layer, that are laminated together to
form an absorbent sheet.
Another objective is to provide a concrete curing blanket that has both superior wicking
capabilities from the wicking layer, and also includes superior water holding capacity due to
the inclusion of the super absorbent materials.
Docket: 0987-02UA
Another objective is to provide a concrete curing blanket that is sized and shaped to be spread
over concrete, either vertically or horizontally, over a large area of concrete during the curing
of the concrete.
Another objective is to provide a concrete curing blanket that has a vapor barrier having a
plurality of perforations for maintaining water within the absorbent sheet, while also allowing
the absorbent sheet to be soaked during installation, and also re-wetted periodically during
the course of the curing process.
A further objective is to provide a concrete curing blanket that is inexpensive to manufacture,
easy to use, resistant to tearing, and provides superior hydration for extended periods of time.
Other features and advantages of the present invention will become apparent from the
following more detailed description, taken in conjunction with the accompanying drawings,
which illustrate, by way of example, the principles of the invention.
The present invention provides a concrete curing blanket comprising:
an absorbent sheet comprising a wicking layer and a tissue layer with super absorbent
materials positioned between the wicking layer and the tissue layer;
wherein the wicking layer and the tissue layer are laminated together with a heat
activated bonding agent in the presence of heat and pressure to contain the super
Docket: 0987-02UA
absorbent materials between the wicking layer and the tissue layer, such that the
wicking layer draws water up into the super absorbent material of the absorbent sheet;
wherein the wicking layer comprises lyocell, and wherein the super absorbent
material comprises sodium polyacrylate;
a vapor barrier bonded to the tissue layer of the absorbent sheet; and
wherein the concrete curing blanket is at least 1 meter wide and 5 meters long.
In a further aspect the invention provides a concrete curing blanket comprising:
an absorbent sheet comprising a wicking layer and a tissue layer with super absorbent
materials positioned between the wicking layer and the tissue layer;
wherein the wicking layer and the tissue layer are laminated together with a heat
activated bonding agent in the presence of heat and pressure to contain the super
absorbent materials between the wicking layer and the tissue layer, such that the
wicking layer draws water up into the super absorbent material of the absorbent sheet;
wherein the wicking layer comprises lyocell, and wherein the super absorbent
material comprises sodium polyacrylate; and
a vapor barrier bonded to the tissue layer of the absorbent sheet, the vapor battier
having a plurality of perforations.
In a further aspect the invention provides a concrete curing blanket comprising:
an absorbent sheet consisting of a layer of lyocell and a tissue layer with super
absorbent materials positioned between the layer of lyocell and the tissue layer, the
Docket: 0987-02UA
layer of lyocell being laminated to the tissue layer with a heat activated bonding agent
in the presence of heat and pressure, such that the layer of lyocell draws water up into
the super absorbent material of the absorbent sheet; and
a vapor barrier bonded to the tissue layer of the absorbent sheet.
Preferably the super absorbent materials comprise sodium polyacrylate.
Preferably the concrete curing blanket is at least 1 meter wide and 5 meters long.
Preferably the vapor barrier has a plurality of perforations.
In a yet further aspect the invention provides a method of curing concrete, the method
comprises the steps of:
providing a concrete curing blanket comprising:
an absorbent sheet comprising a wicking layer, super absorbent materials, and a tissue
layer, with the super absorbent materials being positioned between the wicking layer
and the tissue layer;
wherein the wicking layer is capable of wicking water from the concrete into the
super absorbent materials, the wicking layer comprising viscose;
wherein the super absorbent materials are capable of holding a volume of water that is
at least 30 times the volume of the super absorbent materials; and
wherein the tissue layer is a layer of tissue material that is capable of bonding with the
wicking layer ; bonding a vapor barrier to the tissue layer of the absorbent sheet;
covering the concrete with the concrete curing blanket; and
soaking the concrete and the concrete curing blanket with water.
Preferably the wicking layer further comprises polyethylene, polypropylene, or polyester.
Docket: 0987-02UA
In a further aspect of the invention provides a method of manufacturing a concrete curing
blanket, the method comprising the steps of:
providing a wicking layer, super absorbent materials, and a tissue layer, wherein the
wicking layer comprising viscose and is capable of wicking water from the concrete
into the super absorbent materials, wherein the super absorbent materials are capable
of holding a volume of water that is at least 30 times the volume of the super
absorbent materials, and wherein the tissue layer is a layer of tissue material that is
capable of bonding with the wicking layer;
positioning the super absorbent materials between the wicking layer and the tissue
layer;
bonding the wicking layer, the super absorbent materials, and the tissue layer together
to form an absorbent sheet;
bonding a vapor barrier to the tissue layer of the absorbent sheet; and
perforating the vapor barrier to form a plurality of perforations through the vapor
barrier.
Preferably the bonding of the wicking layer, the super absorbent materials, and the tissue
layer is performed by calendaring them together through a pair of rollers.
Preferably the bonding of the wicking layer, the super absorbent materials, and the tissue
layer is performed using an adhesive.
Preferably the bonding of the wicking layer, the super absorbent materials, and the tissue
layer is performed using an adhesive comprising a heat activated bonding agent or a contact
cement.
Docket: 0987-02UA
In a further aspect of the invention provides a method of manufacturing a concrete curing blanket,
the method comprising the steps of:
providing a wicking layer, super absorbent materials, and a tissue layer, wherein the wicking layer
comprises a combination of viscose and polyethylene that is capable of wicking water from the
concrete into the super absorbent materials, wherein the super absorbent materials are capable of
holding a volume of water that is at least 30 times the volume of the super absorbent materials, and
wherein the tissue layer is a layer of tissue material that is capable of bonding with the wicking
layer;
providing the super absorbent materials between the wicking layer and the tissue layer;
bonding the wicking layer, the super absorbent materials, and the tissue layer together to form
an absorbent sheet;
creating a plurality of the absorbent sheets by repeating the process described above;
positioning the plurality of the absorbent sheets adjacent each other;
positioning a vapor barrier so that it extends across all of the plurality of absorbent
sheets;
bonding the vapor barrier to the tissue layers of the plurality of the absorbent sheet so
that they together form the concrete curing blanket; and
perforating the vapor barrier to form a plurality of perforations through the vapor
barrier.
Preferably the bonding of the wicking layer, the super absorbent materials, and the tissue
layer is performed by calendaring them together through a pair of rollers.
Preferably the bonding of the wicking layer, the super absorbent materials and the tissue layer
is performed using an adhesive.
Docket: 0987-02UA
Preferably the bonding of the wicking layer, the super absorbent materials, and the tissue
layer is performed using an adhesive comprising a heat activated bonding agent or contact
cement.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate the present invention. In such drawings:
FIGURE 1 is a perspective view of a concrete curing blanket according to one
embodiment of the present invention, illustrating the concrete curing blanket being positioned
on a concrete slab while water is poured onto the concrete slab and into the concrete curing
blanket;
FIGURE 2 is a sectional view of the concrete curing blanket taken along line 2-2 in
Figure 1, illustrating the four layers of construction of the concrete curing blanket in the
embodiment of Fig. 1;
FIGURE 3 is a side elevational view of a first step of manufacture of the concrete curing
blanket, wherein a wicking layer and a tissue layer are laminated together to contain the super
absorbent polymers therebetween, and thereby form an absorbent sheet; and
Docket: 0987-02UA
FIGURE 4 is a perspective view of a second step of manufacture of the concrete curing
blanket, wherein the absorbent sheet formed in Fig. 3 is bonded to a vapor barrier to form the
concrete curing blanket of Figs. 1 and 2.
DETAILED DESCRIPTION OF THE INVENTION
The above-described drawing figures illustrate the invention, a concrete curing blanket 10
that is used for providing hydration to a concrete slab C during the curing process, to provide
concrete that has superior strength and durability.
FIGURE 1 is a perspective view of one embodiment of the concrete curing blanket 10,
illustrating the concrete curing blanket 10 being positioned on the concrete slab C. As
illustrated in Fig. 1, the concrete curing blanket 10 is manufactured in a roll that is sized for
being unrolled over the concrete slab C to effectively cover the concrete slab C. The concrete
curing blanket 10 is at least about 1 meter wide, and about 10 meters long. In a typical
embodiment, the concrete curing blanket 10 is 1-3 meters wide (in this case about 2.5 meters
wide), and about 30-60 (or more) meters long. In alternative embodiments, the
measurements may vary according to the needs of the user, but they will be sufficiently large
to be useful in covering concrete slabs, which may be of considerable size. As used in this
application, the term “about” is hereby defined to include +/- 10%.
Docket: 0987-02UA
As illustrated in Fig. 1, before and while the concrete curing blanket 10 is being positioned
on the concrete slab C, water is poured in large amounts onto the concrete slab C and into
and over the concrete curing blanket 10, so that the concrete slab C remains thoroughly
hydrated, and the concrete curing blanket 10 is thoroughly soaked. Once saturated, the
concrete curing blanket 10 maintains an optimal amount of water in contact with the surface
of the concrete slab C, which optimizes the strength and durability of the concrete when
cured.
While one form of concrete slab C is illustrated herein, the term “concrete slab” is hereby
defined to include any form of structure that may require this form of hydration, including
cement walls, pillars, and other structures known in the art. Indeed, due to the superior water
carrying characteristics of the present invention, the concrete curing blanket 10 is particularly
useful when used on angled or vertical cement structures, which might otherwise be difficult
to keep hydrated.
FIGURE 2 is a sectional view of the concrete curing blanket 10 taken along line 2-2 in Figure
1. Fig. 2 illustrates the four layers of construction of the concrete curing blanket 10 in the
embodiment of Fig. 1. As shown in Fig. 2, the concrete curing blanket 10 comprises an
absorbent sheet 22 comprising a wicking layer 20 and a tissue layer 26 with super absorbent
materials 24 laminated therebetween. The concrete curing blanket 10 further comprises a
vapor barrier 30 bonded to the tissue layer 26 of the absorbent sheet 22.
Docket: 0987-02UA
The wicking layer 24 of Fig. 2 is a layer of material that is able to quickly wick up water from
the pool of water formed on the concrete slab C (as shown in Fig. 1) as it is rolled onto the
concrete slab C, so that the water is quickly and efficiently drawn into the concrete curing
blanket 10. Water may also be poured directly onto the roll of the concrete curing blanket 10,
to assure that the concrete curing blanket 10 is thoroughly hydrated. In the current
embodiment, the wicking layer 20 is a nonwoven fabric, in this case a spunlaced nonwoven
fabric comprising viscose. The wicking layer 20 may further comprise a polymer such as
polyethylene, polypropylene, and/or polyester, which are useful in the bonding/lamination
process, as discussed in greater detail below. In one embodiment, the wicking layer 20
comprises a combination of viscose and polyethylene.
In one embodiment, the wicking layer 20 comprises a cellulose precipitated from an organic
solution in which no substitution of the hydroxyl groups takes place and no chemical
intermediates are formed (e.g, Lyocell). In alternative embodiments, alternative or equivalent
wicking materials may also be used, using formulations that would be known to those skilled
in the art, and such alternative or equivalent formulations should be considered within the
scope of the present invention.
The super absorbent materials 24 may include super absorbent polymers, super absorbent
fibers, or other similar or equivalent materials. As used in the present application, the term
“super absorbent polymers” (“SAP”) is defined to include polymers that can absorb and
retain extremely large amounts of liquid relative to their own mass. Water absorbing SAP,
Docket: 0987-02UA
classified as hydrogels, when cross linked, absorb aqueous solutions through hydrogen
bonding with water molecules. A SAP’s ability to absorb water is a factor of the ionic
concentration of the aqueous solution. In deionized and distilled water, a SAP may absorb
500 times its weight (30-60 times its own volume), although this ability drops to only about
10% of this amount when salt is present.
The total absorbency and swelling capacity are controlled by the type of and degree of cross-
links used to make the gel. Low density cross-linking have a higher absorbency, which
higher cross-link density exhibits lower absorbent capacity and swell, but greater gel strength
and firmness.
SAPs are commonly made from the polymerization of acrylic acid bended with sodium
hydroxide in the presence of an initiator to form a poly-acrylic acid sodium salt, sometimes
referred to as sodium polyacrylate. Other materials known in the art may also be used in this
manner. In the present embodiment, the super absorbent materials 24 include a sodium
polycarbonate polymer, and may further include additional additives, as discussed in greater
detail below.
As shown in Fig. 2, the concrete curing blanket 10 further includes the tissue layer 26, which
in the present embodiment is a tissue fabric that is suitable forming a bond between the
absorbent sheet 22 and the vapor barrier 30. The tissue layer 26 is a good surface for forming
a good, strong, stable bond, and for preventing any bonding agents (glues, cements, bonding
Docket: 0987-02UA
agents, etc.) from contaminating the super absorbent materials 24, and interfering with the
ability of the super absorbent materials 24 from absorbing water. For purposes of this
application, the term “tissue layer” is defined to include tissue fabric, and also any other
materials known to those skilled in the art that is able to provide a good bonding attachment
between the absorbent sheet and the vapor barrier.
The vapor barrier 30 of Fig. 2 is a film comprising polyethylene or polypropylene or other
material that is substantially vapor impervious, to prevent dehydration of the concrete curing
blanket 10. The vapor barrier 30 may include perforations 32 so that water may be added
from the top of the concrete curing blanket 10, so long as the perforations 32 are not large
enough to enable excessive drying of the concrete curing blanket 10.
FIGURE 3 is a side elevational view of a first step of manufacture of the concrete curing
blanket 10, wherein the wicking layer 20 and the tissue layer 26 are laminated together to
contain the super absorbent polymers therebetween, and thereby form the absorbent sheet 22.
In this embodiment, the super absorbent materials 24 further include a heat activated bonding
agent, which facilitates the lamination of the three sheets together in the presence of heat and
pressure. In this embodiment, the wicking layer 20, the super absorbent materials 24, and the
tissue layer 26 are all laminated together under heat and pressure, such as via one or more
rollers 40. Either the rollers 40 themselves may be heated, or a separate heater (not shown)
may be included to apply suitable heat to the substrate moving through the rollers 40.
Docket: 0987-02UA
While the present embodiment uses heat, other forms of bonding agents (e.g., contact cement,
hot melt adhesive, etc.) may be used during rolling of the substrate, and may include rollers
40 that are not heated, or may omit the rollers entirely, so that the different layers are
assembled in another manner known in the art.
FIGURE 4 is a perspective view of a second step of manufacture of the concrete curing
blanket 10, wherein the absorbent sheet 22 formed in Fig. 3 is bonded to a vapor barrier 30 to
form the concrete curing blanket 10 of Figs. 1 and 2. In this embodiment, three of the
absorbent sheets 22 are arranged side-by-side (or slightly overlapping) to be bonded to the
vapor barrier 30, in this case also using rollers 40, although this is not necessarily required, as
discussed above. As described above, heat, a heat activated bonding agent, contact cement,
or other suitable adhesive or bonding element may be used to bond these two elements
together to form the final concrete curing blanket 10.
In use, the wicking layer 24 picks up water from the concrete slab C, as shown in Fig. 1, and
from the wicking layer 24 the water is picked up (more slowly) by the super absorbent
materials 24. While the wicking layer 20 can pick up the water quickly, it cannot store as
much water, and while the super absorbent materials 24 take longer to absorb the water, they
can in the end act as a reservoir for much larger amounts of water.
Docket: 0987-02UA
Following installation, if the wicking layer 20 dries, water wicks from the super absorbent
materials 24 back into the wicking layer 20, to maintain the proper hydration of the wicking
layer 20 and the concrete slab C.
As used in this application, the words “a,” “an,” and “one” are defined to include one or more
of the referenced item unless specifically stated otherwise. Also, the terms “have,” “include,”
“contain,” and similar terms are defined to mean “comprising” unless specifically stated
otherwise. Furthermore, the terminology used in the specification provided above is hereby
defined to include similar and/or equivalent terms, and/or alternative embodiments that
would be considered obvious to one skilled in the art given the teachings of the present patent
application.
Docket: 0987-02UA
Claims (16)
- CLAIMS 5 1. A concrete curing blanket comprising: an absorbent sheet comprising a wicking layer and a tissue layer with super absorbent materials positioned between the wicking layer and the tissue layer; wherein the wicking layer and the tissue layer are laminated together with a heat activated bonding agent in the presence of heat and pressure to contain the super 10 absorbent materials between the wicking layer and the tissue layer, such that the wicking layer draws water up into the super absorbent material of the absorbent sheet; wherein the wicking layer comprises lyocell, and wherein the super absorbent material comprises sodium polyacrylate; a vapor barrier bonded to the tissue layer of the absorbent sheet; and 15 wherein the concrete curing blanket is at least 1 meter wide and 5 meters long.
- 2. A concrete curing blanket comprising: an absorbent sheet comprising a wicking layer and a tissue layer with super absorbent materials positioned between the wicking layer and the tissue layer; 20 wherein the wicking layer and the tissue layer are laminated together with a heat activated bonding agent in the presence of heat and pressure to contain the super Docket: 0987-02UA absorbent materials between the wicking layer and the tissue layer, such that the wicking layer draws water up into the super absorbent material of the absorbent sheet; wherein the wicking layer comprises lyocell, and wherein the super absorbent material comprises sodium polyacrylate; and 5 a vapor barrier bonded to the tissue layer of the absorbent sheet, the vapor battier having a plurality of perforations.
- 3. A concrete curing blanket comprising: an absorbent sheet consisting of a layer of lyocell and a tissue layer with super 10 absorbent materials positioned between the layer of lyocell and the tissue layer, the layer of lyocell being laminated to the tissue layer with a heat activated bonding agent in the presence of heat and pressure, such that the layer of lyocell draws water up into the super absorbent material of the absorbent sheet; and a vapor barrier bonded to the tissue layer of the absorbent sheet.
- 4. The concrete curing blanket of claim 3, wherein the super absorbent materials comprise sodium polyacrylate.
- 5. The concrete curing blanket of claim 3, wherein the concrete curing blanket is at least 1 20 meter wide and 5 meters long. Docket: 0987-02UA
- 6. The concrete curing blanket of claim 3, wherein the vapor barrier has a plurality of perforations.
- 7. A method of curing concrete, the method comprises the steps of: 5 providing a concrete curing blanket comprising: an absorbent sheet comprising a wicking layer, super absorbent materials, and a tissue layer, with the super absorbent materials being positioned between the wicking layer and the tissue layer; wherein the wicking layer is capable of wicking water from the concrete into the 10 super absorbent materials, the wicking layer comprising viscose; wherein the super absorbent materials are capable of holding a volume of water that is at least 30 times the volume of the super absorbent materials; and wherein the tissue layer is a layer of tissue material that is capable of bonding with the wicking layer ; bonding a vapor barrier to the tissue layer of the absorbent sheet; 15 covering the concrete with the concrete curing blanket; and soaking the concrete and the concrete curing blanket with water.
- 8. The method of claim 7, wherein the wicking layer further comprises polyethylene, polypropylene, or polyester.
- 9. A method of manufacturing a concrete curing blanket, the method comprising the steps Docket: 0987-02UA providing a wicking layer, super absorbent materials, and a tissue layer, wherein the wicking layer comprising viscose and is capable of wicking water from the concrete into the super absorbent materials, wherein the super absorbent materials are capable of holding a volume of water that is at least 30 times the volume of the super 5 absorbent materials, and wherein the tissue layer is a layer of tissue material that is capable of bonding with the wicking layer; positioning the super absorbent materials between the wicking layer and the tissue layer; bonding the wicking layer, the super absorbent materials, and the tissue layer together
- 10 to form an absorbent sheet; bonding a vapor barrier to the tissue layer of the absorbent sheet; and perforating the vapor barrier to form a plurality of perforations through the vapor barrier. 15 10. The method of claim 9, wherein the bonding of the wicking layer, the super absorbent materials, and the tissue layer is performed by calendaring them together through a pair of rollers.
- 11. The method of claim 9, wherein the bonding of the wicking layer, the super absorbent 20 materials, and the tissue layer is performed using an adhesive. Docket: 0987-02UA
- 12. The method of claim 11, wherein the bonding of the wicking layer, the super absorbent materials, and the tissue layer is performed using an adhesive comprising a heat activated bonding agent or a contact cement. 5
- 13. A method of manufacturing a concrete curing blanket, the method comprising the steps providing a wicking layer, super absorbent materials, and a tissue layer, wherein the wicking layer comprises a combination of viscose and polyethylene that is capable of wicking water from the concrete into the super absorbent materials, wherein the super 10 absorbent materials are capable of holding a volume of water that is at least 30 times the volume of the super absorbent materials, and wherein the tissue layer is a layer of tissue material that is capable of bonding with the wicking layer; providing the super absorbent materials between the wicking layer and the tissue layer; 15 bonding the wicking layer, the super absorbent materials, and the tissue layer together to form an absorbent sheet; creating a plurality of the absorbent sheets by repeating the process described above; positioning the plurality of the absorbent sheets adjacent each other; positioning a vapor barrier so that it extends across all of the plurality of absorbent 20 sheets; bonding the vapor barrier to the tissue layers of the plurality of the absorbent sheet so that they together form the concrete curing blanket; and Docket: 0987-02UA perforating the vapor barrier to form a plurality of perforations through the vapor barrier.
- 14. The method of claim 13, wherein the bonding of the wicking layer, the super absorbent 5 materials, and the tissue layer is performed by calendaring them together through a pair of rollers.
- 15. The meth of claim 13, wherein the bonding of the wicking layer, the super absorbent materials and the tissue layer is performed using an adhesive.
- 16. The method of claim 15, wherein the bonding of the wicking layer, the super absorbent materials, and the tissue layer is performed using an adhesive comprising a heat activated bonding agent or contact cement.
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201562110526P | 2015-01-31 | 2015-01-31 | |
US62/110,526 | 2015-01-31 | ||
US14/709,747 US9739068B2 (en) | 2015-01-31 | 2015-05-12 | Concrete curing blanket |
US14/709,747 | 2015-05-12 | ||
PCT/US2015/068312 WO2016122831A1 (en) | 2015-01-31 | 2015-12-31 | Concrete curing blanket and method |
Publications (2)
Publication Number | Publication Date |
---|---|
NZ734212A NZ734212A (en) | 2019-07-26 |
NZ734212B true NZ734212B (en) | 2019-10-30 |
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