WO2020223562A1 - Modificateur de faible densité pour fibro- ciment - Google Patents

Modificateur de faible densité pour fibro- ciment Download PDF

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Publication number
WO2020223562A1
WO2020223562A1 PCT/US2020/030862 US2020030862W WO2020223562A1 WO 2020223562 A1 WO2020223562 A1 WO 2020223562A1 US 2020030862 W US2020030862 W US 2020030862W WO 2020223562 A1 WO2020223562 A1 WO 2020223562A1
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Prior art keywords
cellulose fibers
fiber
fibers
weight
reinforced cement
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PCT/US2020/030862
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English (en)
Inventor
Michael John Julius
Hugh West
Janet WELCH
Brian MULDERIG
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International Paper Company
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Publication of WO2020223562A1 publication Critical patent/WO2020223562A1/fr

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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
    • 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
    • C04B28/06—Aluminous cements
    • 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
    • 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
    • C04B28/04—Portland cements
    • 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
    • C04B28/10—Lime cements or magnesium oxide cements
    • 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
    • C04B28/14—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 calcium sulfate cements
    • 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
    • C04B2103/0045—Polymers chosen for their physico-chemical characteristics
    • C04B2103/0062—Cross-linked polymers
    • 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
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00586—Roofing 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
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00603—Ceiling 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
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • 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

Definitions

  • Fiber cement building products combine the durability of cement and the flexibility of wood.
  • typical fiber cement boards have a high density of about 1.2-1.7 g/cm 3 , making them heavier than wood-based construction products, which typically have a density of 0.6-0.9 g/cm 3 . Therefore, fiber cement building products are more difficult to cut, machine, and nail than wood-based products. This in turn makes the installation of fiber cement products more labor-intensive.
  • LDAs Low Density Additives
  • very few manufacturers have been successful in incorporating such elements due to the technical challenges, increased costs of the materials, and concerns that the use of LDAs could lead to lower durability of the product.
  • the disclosure provides a fiber-reinforced cement composition
  • a fiber-reinforced cement composition comprising cement and modified cellulose fibers, such as crosslinked cellulose fibers.
  • the composition further comprises water, conventional cement additives, and/or one or more additional low density additives.
  • building materials such as panels, siding, roofing, trims, moldings, and boards, comprising fiber-reinforced cement compositions of the disclosure.
  • the building materials advantageously have lower density as compared to building materials having an equivalent fiber-reinforced cement composition that does not comprise modified cellulose fibers.
  • the building materials advantageously have similar moisture movement as while also having lower density as compared to building materials having an equivalent fiber-reinforced cement composition that does not comprise modified cellulose fibers.
  • FIG. 1 shows density, Modulus of Rupture (MoR) values, and energy (as determined by a 3 -point bending test) of sample prototypes having a constant 7 wt% unbleached kraft pulp (UKP) content and increasing levels of modified fibers (XL) from 0 wt% to 4 wt%.
  • MoR Modulus of Rupture
  • FIG. 2 shows density, Modulus of Rupture (MoR) values, and energy (as determined by a 3-point bending test) of sample prototypes having a decreasing UKP content from 4.5 wt% to 2.75 wt% and a constant 3 wt% XL. Also shown is a 7.5 wt% UKP and 0 wt% XL control sample pad for comparison.
  • MoR Modulus of Rupture
  • FIG. 3 shows density, Modulus of Rupture (MoR) values, and energy (as determined by a 3 -point bending test) of sample prototypes having varied UKP content from 7 wt% to 4 wt% and a varied modified fibers (X-Link) content from 3.5 wt% to 4.5 wt%. Also shown is a 7 wt% UKP and 0 wt% X-Link control sample pad for comparison.
  • MoR Modulus of Rupture
  • FIG. 4 shows density, Modulus of Rupture (MoR) values, and energy (as determined by a 3 -point bending test) of sample prototypes having a constant 7 wt% UKP content and increasing levels of XL from 0 wt% to 3.5 wt%. Also shown is a 9 wt% total cellulose fiber content (5.85 wt% UKP and 3.15 wt% XL; 65% of UKP and 35% of XL) sample pad for comparison, in which the two fibers were co-refmed before mixing in the composition.
  • MoR Modulus of Rupture
  • FIG. 5 shows density, Modulus of Rupture (MoR) values, and energy (as determined by a 3 -point bending test) of sample prototypes having a constant 7 wt% UKP content and comparisons with a low level (at 3 wt%) and a high level (at 6 wt%) of either XL or Southern bleached softwood kraft pulp (SBSK). Also shown is a 7 wt% UKP and 0 wt% XL or SBSK control sample pad.
  • MoR Modulus of Rupture
  • FIG. 6 shows density, Modulus of Rupture (MoR) values, and energy (as determined by a 3 -point bending test) of sample prototypes having a constant UKP content and increasing levels of either modified fibers (Crosslink) or Pearlite 2000 from 2 wt% to 6 wt%. Also shown is a 7 wt% UKP and 0 wt% XL or Pearlite 2000 control sample pad.
  • the UKP has a CSF of 418.
  • FIG. 7 shows density, Modulus of Rupture (MoR) values, and energy (as determined by a 3 -point bending test) of sample prototypes having a constant UKP content and increasing levels of either modified fibers (Crosslink) or Pearlite 2000 from 2 wt% to 6 wt%. Also shown is a 7 wt% UKP and 0 wt% XL or Pearlite 2000 control sample pad.
  • the UKP has a CSF of 218.
  • FIG. 8 shows moisture movement (percent change in dimensional length) of sample prototypes having a constant UKP content and increasing levels of either modified fibers (Crosslink) or Pearlite 2000 from 2 wt% to 6 wt%. Also shown is a 7 wt% UKP and 0 wt% XL or Pearlite 2000 control sample pad.
  • the UKP has a CSF of 418.
  • FIG. 9 shows density, Modulus of Rupture (MoR) values, and energy (as determined by a 3 -point bending test) of sample prototypes having a constant UKP content (at 7 wt%) and various levels (at about 2 wt% or about 4 wt%) of either modified fibers without debonder treatment (XL 530) and with debonder treatment (XL 535) or Pearlite 100 at about 4 wt%. Also shown is a 7 wt% UKP and 0 wt% XL or Pearlite 100 control sample pad.
  • MoR Modulus of Rupture
  • Fiber cement is a dense product (1.2-1.7 gm/cm 3 ).
  • the density limits the thickness of the product, due to weight and workability concerns.
  • the current industry practice is to use Low Density Additives (LDAs) to reduce the density of fiber reinforced cement compositions and products; however, the use of LDAs can increase the manufacturing costs of these products and could lead to decreased durability.
  • LDAs Low Density Additives
  • modified cellulose fibers such as crosslinked cellulose fibers
  • replacement of a portion of cellulose pulp with such modified cellulose fibers in reinforced fiber cement compositions unexpectedly led to reinforced fiber cement compositions with lower density (e.g., lower by up to 20-30%), lower weight, decreased energy for cutting the cured fiber cement products (i.e., scoring and snapping), and better nail- ability than the control compositions.
  • Moisture movement for these compositions was also comparable to or better than existing fiber cement products.
  • modified cellulose fibers e.g., crosslinked cellulose fibers
  • use of modified cellulose fibers has the potential to reduce overall cellulose fiber requirement in the manufacture of reinforced fiber cement compositions and building materials, thus decreasing the manufacturing costs while increasing durability due to reduced fiber content and one or more other LDAs.
  • compositions of the present invention may include modified cellulose fibers as an LDA with or without other cellulose fiber additives. Also, the compositions of the present invention may include modified cellulose fibers as an LDA with or without additional known LDAs, for example, polymer spheres, hollow ceramic microspheres, and expanded volcanic ash.
  • the disclosure provides a fiber-reinforced cement composition
  • a fiber-reinforced cement composition comprising cement and modified cellulose fibers (MCF), such as crosslinked cellulose fibers.
  • the modified cellulose fibers are crosslinked cellulose fibers.
  • the modified cellulose fibers, e.g., crosslinked cellulose fibers are included in the composition in the amounts from about 0.5 wt% to about 15 wt%, from about 1 wt% to about 10 wt%, from about 2 wt% to about to 8 wt%, or from about 2 wt% to about 5 wt%.
  • the crosslinked cellulose fibers are prepared from fibers derived from wood and non-wood fibers, wood cellulose (including softwood and hardwood fibers), refined and unrefined kraft or other chemically pulped fiber, bleached or unbleached cellulose fibers, cotton, mercerized fibers, and combinations thereof.
  • the modified cellulose fibers are fibers that are mechanically and/or chemically curled, with or without further crosslinking or other chemical treatment.
  • such fibers can be temporary curled via mechanical treatment via, e.g., curlator, refiner, extruder, and the like, and/or made durable via treatment with/addition of additives, such as starch, wet or dry strength resins, and combinations thereof.
  • Suitable modified cellulose fibers include partially crosslinked cellulose fibers (e.g., fibers that have levels of chemical crosslinking agent of less than about 4 wt%, using esterification or etherification crosslinking process) and fully crosslinked cellulose fibers (e.g., fibers that have levels of chemical crosslinking agent of greater than about 4 wt%, using esterification or etherification crosslinking process).
  • Modified cellulose fibers delivered in a bale or roll form and fibers coming as individual fibers or as a formed media can be used in the compositions disclosed herein.
  • crosslinking is achieved via chemical application to sheet or pulp slurries from low to medium and high consistency pulp or pulp fragments.
  • the compositions disclosed herein comprise modified cellulose fibers such as mercerized or caustic treated pulp, e.g., in fiber or sheet form.
  • the modified cellulose fibers include modified cellulose fibers disclosed in U.S. Patents 7,419,568; 7,320,740; 7,312,297; 7,288, 167; 7,195,695; 7,094,318; 7,074,301; 7,018,511; 6,844,066; and 6,620,293; and U.S. Patent Applications No. 20040234760; 20040206464; and 20030155087, the disclosures of each of which are incorporated herein by reference.
  • the compositions disclosed herein comprise modified cellulose fibers such as cured fibers (prepared by mechanical means and/or chemical means) or fibers that have been treated to reduce the yellowing of fibers.
  • the modified cellulose fibers are prepared by forming fiber bundles and then opening the bundles in a manner that encourages curl (e.g., flash drying).
  • the modified cellulose fibers are chemically crosslinked, mechanically curled fibers that have been swollen with an intra-crystalline swelling agent.
  • the modified cellulose fibers are fibers modified by the use of steam explosion, e.g., by first creating curl in any fiber to produce mechanically curled fibers and then steam exploding.
  • the modified cellulose fibers include modified cellulose fibers disclosed in U.S. Patents 7,364,639; 6,984,447; 6,780,201; 6,506,282; 6,413,362; 6,372,085; 6,329,565; and 6,197, 154 and U.S. Patent Application No. 2004011545, the disclosures of each of which are incorporated herein by reference.
  • the modified cellulose fibers include fibers prepared after pulping and before the pulp or paper machine, such as fibers disclosed in U.S. Patents 8,277,606; 7,390,378; 7,291,247; 6,899,790; 6,627,041; and AU Patent 614717B2, the disclosures of each of which are incorporated herein by reference.
  • the modified cellulose fibers are crosslinked cellulose fibers which comprise between about 0.5 weight % and about 10.0 weight %, about 1 weight % and about 7 weight %, or about 2 weight % and about 5 weight % of a crosslinking agent calculated on a dry fiber weight basis. Any suitable crosslinking agent can be used to prepare the modified cellulose fibers of the disclosed compositions.
  • the crosslinking agent is a polyacrylic acid crosslinking agent.
  • the polyacrylic acid crosslinking agent comprises dialkyl phosphinate.
  • the modified cellulose fibers are crosslinked cellulose fibers disclosed in U.S. Patents 8,722,797; 9,458,297; and 10, 156,042; and U.S. Patent Application US 2018/0087216 Al, the disclosures of which are incorporated herein by reference.
  • Crosslinked cellulose fibers can be prepared in any suitable manner.
  • polyacrylic acid-crosslinked cellulosic fibers can be prepared by applying polyacrylic acid to the cellulosic fibers in an amount sufficient to effect intra-fiber crosslinking.
  • the amount applied to the cellulosic fibers can be from about 1 to about 10 percent by weight based on the total weight of fibers.
  • crosslinking agent in an amount from about 4 to about 6 percent by weight based on the total weight of dry fibers.
  • polyacrylic acid-crosslinked cellulosic fibers can be prepared using a crosslinking catalyst.
  • Suitable catalysts can include acidic salts, such as ammonium chloride, ammonium sulfate, aluminum chloride, magnesium chloride, magnesium nitrate, and more preferably alkali metal salts of phosphorous-containing acids, like phosphoric, polyphosphoric, phosphorous, and hypophosphorous acids.
  • the crosslinking catalyst is sodium hypophosphite. The amount of catalyst used can vary from about 0.1 to about 5 percent by weight based on the total weight of dry fibers.
  • the crosslinking agent is a dialdehyde crosslinking agent (e.g., a C2-C9 dialdehyde such as glyoxal or glutaraldehyde), or a polycarboxylic acid (e.g., citric acid) crosslinking agent.
  • the crosslinked cellulose fibers are intrafiber crosslinked cellulosic fibers obtainable from cellulosic fibers by treatment with a crosslinking agent in the presence of a polyol.
  • the modified cellulose fibers are crosslinked cellulose fibers disclosed in U.S. Patents 6,748,671; 6,986,793; 4,822,453; and 5, 137,537, the disclosures of which are incorporated herein by reference.
  • Cellulosic fibers useful for making the crosslinked cellulose fibers can be derived primarily from wood pulp.
  • Suitable wood pulp fibers can be obtained from well-known chemical processes such as the kraft and sulfite processes, with or without subsequent bleaching.
  • the pulp fibers may also be processed by thermomechanical, chemithermomechanical methods, or combinations thereof.
  • the pulp fiber is produced by chemical methods. Ground wood fibers, recycled or secondary wood pulp fibers, and bleached and unbleached wood pulp fibers can be used.
  • a preferred starting material is prepared from long-fiber coniferous wood species, such as southern pine, Douglas fir, spruce, and hemlock.
  • wood pulp fibers Details of the production of wood pulp fibers are well-known to those skilled in the art. Suitable fibers are commercially available from a number of companies, including the International Paper Company. In any and all of the above-mentioned useful modified fibers, the wood pulp fibers may be optionally treated with a debonder without negatively impacting the performance of the derived fiber cement product. Debonders and debonder treatment of wood pulp fibers is well-known in the art of wood pulp fiber manufacturing.
  • the compositions of the disclosure comprise cementitious binder (e.g., Portland cement), modified cellulose fibers, and water.
  • cementitious binder e.g., Portland cement
  • modified cellulose fibers e.g., modified cellulose fibers
  • water e.g., water
  • cementitious binder e.g., Portland cement
  • Any type of cement suitable for preparation of fiber-reinforced cement products can be used in the compositions of the disclosure, including high alumina cement, lime, and other known cements and plasters.
  • the cement is Portland Type 1 or Type 2 cement.
  • compositions of the disclosure further comprise one or more components selected from conventional additives, such as known aggregates, silica, calcium carbonate, aluminum-tri-hydrate, low density additives (LDAs), cellulose pulp, natural fibers or fibrous materials, polymer fibers, glass fibers, metal fibers, silica fume, volcanic ash, clay, minerals, slags, pozzolanic material, spherical and amorphous polymer fillers, inorganic fillers, mineral oxides, and combinations thereof.
  • LDAs low density additives
  • the compositions comprise low density additives disclosed in U.S. Patent 8, 182,606, the disclosure of which is incorporated herein by reference.
  • LDAs typically used in the preparation of fiber- reinforced cement compositions
  • LDAs selected from microspheres (e.g., hollow ceramic microspheres), volcanic ash (such as expanded volcanic ash with a bulk density of about 2 to 25 lbs/cu. ft or about 32 to about 400 kg/m 3 ), low bulk density calcium silicate hydrate, pearlite, and combinations thereof.
  • compositions disclosed herein comprise from about 15 wt% to about 85 wt% cement (e.g., Portland cement); from about 1 wt% to about 10 wt% cellulose pulp; from about 0.5 wt% to about 15 wt% modified cellulose fibers (such as crosslinked cellulose fibers); from about 0 wt% to about 70 wt% silica; from about 0 wt% to about 70 wt% calcium carbonate; from about 0 wt% to about 10 wt% LDAs, and optionally from about 0 wt% to about 10 wt% optional components, such as colorants or metal hydroxides.
  • cement e.g., Portland cement
  • modified cellulose fibers such as crosslinked cellulose fibers
  • silica from about 0 wt% to about 70 wt% silica
  • from about 0 wt% to about 70 wt% calcium carbonate from about 0 wt% to about 10 wt% LDAs,
  • compositions disclosed herein comprise from about 20 wt% to about 40% wt% cement (e.g., Portland cement); from about 3 wt% to about 9 wt% cellulose pulp; from about 1 wt% to about 10 wt% modified cellulose fibers (such as crosslinked cellulose fibers); from about 35 wt% to about 65 wt% silica; from about 0 wt% to about 10 wt% calcium carbonate; from about 0 wt% to about 10 wt% LDAs, and optionally from about 0 wt% to about 5 wt% optional components.
  • cement e.g., Portland cement
  • modified cellulose fibers such as crosslinked cellulose fibers
  • silica from about 0 wt% to about 10 wt% calcium carbonate
  • from about 0 wt% to about 10 wt% LDAs optionally from about 0 wt% to about 5 wt% optional components.
  • compositions disclosed herein comprise from about 20 wt% to about 40% wt% cement (e.g., Portland cement); from about 3 wt% to about 9 wt% cellulose pulp; from about 1 wt% to about 6 wt% modified cellulose fibers (such as crosslinked cellulose fibers); from about 35 wt% to about 65 wt% silica; from about 0 wt% to about 10 wt% calcium carbonate; from about 0 wt% to about 10 wt% LDAs, and optionally from about 0 wt% to about 5 wt% optional components.
  • cement e.g., Portland cement
  • modified cellulose fibers such as crosslinked cellulose fibers
  • silica from about 0 wt% to about 10 wt% calcium carbonate
  • from about 0 wt% to about 10 wt% LDAs optionally from about 0 wt% to about 5 wt% optional components.
  • compositions disclosed herein comprise from about 20 wt% to about 40% wt% cement (e.g., Portland cement); from about 3 wt% to about 9 wt% cellulose pulp; from about 2 wt% to about 4 wt% modified cellulose fibers (such as crosslinked cellulose fibers); from about 35 wt% to about 65 wt% silica; from about 0 wt% to about 10 wt% calcium carbonate; from about 0 wt% to about 10 wt% LDAs, and optionally from about 0 wt% to about 5 wt% optional components.
  • cement e.g., Portland cement
  • modified cellulose fibers such as crosslinked cellulose fibers
  • silica from about 0 wt% to about 10 wt% calcium carbonate
  • from about 0 wt% to about 10 wt% LDAs optionally from about 0 wt% to about 5 wt% optional components.
  • compositions disclosed herein comprise from about 20 weight % to about 90% weight % cement; from about 2 weight % to about 9 weight % cellulose pulp; from about 0.5 weight % to about 8 weight % modified cellulose fibers; from about 0 weight % to about 5 weight % non-cellulose fibers; from about 0 weight % to about 65 weight % silica; from about 0 weight % to about 30 weight % calcium carbonate; and from about 0 weight % to about 12 weight % low density additives (LDAs).
  • LDAs low density additives
  • the density of the fiber-reinforced cement compositions disclosed herein is about 1.7 g/cm 3 or lower, about 1.3 g/cm 3 or lower, about 1.2 g/cm 3 or lower, about 1.1 g/cm 3 or lower, 1.05 g/cm 3 or lower, 1 g/cm 3 or lower, 0.95 g/cm 3 or lower, or 0.90 g/cm 3 or lower.
  • Density can be measured following the method published in the ASTM Cl 185 - 08 (2016) methods for Sampling and Testing Non- Asbestos Fiber-Cement Flat Sheet, roofing and Siding Shingles, and Clapboards (see Section 6; referred to hereafter as“ASTM Cl 185”). For the purposes of the data presented herein, all density measurements were obtained by using Archimedes’ principle.
  • addition of modified cellulose fibers results in about 10% to about 30% decrease in density for every 2-5% addition of modified cellulose fibers, and significant improvements in nailing.
  • addition of modified cellulose fibers, such as crosslinked cellulose fibers results in about 7% to about 10% decrease in density for every 2% addition of modified cellulose fibers, either with untreated or debonded fiber feedstock, with significant improvement in nailing.
  • the addition of modified cellulose fibers, such as crosslinked cellulose fibers can advantageously be used to reduce the density of fiber-reinforced cement building material by more than about 10%, or more than about 30%, as compared to an equivalent formulation without modified cellulose fibers.
  • the flexural strength or Modulus of Rupture can be measured by ASTM C 1185 (see Section 5).
  • the fiber-reinforced cement compositions of the disclosure have a Modulus of Rupture (MoR) of about 9.0 MPa or lower, 8.5 MPa or lower, about 8 MPa or lower, about 7.5 MPa or lower, about 7 MPa or lower, about 6 MPa or lower, about 5 MPa or lower, about 4 MPa or lower, or about 3 MPa or lower, e.g., when the samples tested were prepared for the two test conditions - Drying condition and Saturated condition.
  • the fiber-reinforced cement compositions of the disclosure have a moisture movement of less than 1.0% as compared to an equivalent formulation without modified cellulose fibers.
  • the moisture movement is less than 0.5%, and still more preferred is less than 0.25%, and most preferred is less than about 0.2%.
  • Moisture movement is a percent measure of linear dimensional change (expansion and / or shrinkage) in the fiber cement pad (or prototype / product) after period of being wet and subsequent drying.
  • Moisture movement testing was performed following a modified version published in the ASTM Cl 185 (see Section 8). The modifications are creating a moisture saturated condition where the method calls for a 90% relative humidity condition and an oven dry condition in place of a 30% relative humidity condition in the method. These testing condition changes are routinely used in the relevant art.
  • the fiber-reinforced cement compositions of the disclosure have an energy of about 1.0 J or lower, about 0.9 J or lower, about 0.8 J or lower, about 0.7 J or lower, about 0.6 J or lower, about 0.5 J or lower, about 0.4 J or lower, about 0.3 J or lower, or about 0.2 J or lower.
  • Energy measured and reported in Joules herein, is the energy absorption capacity of a pad (or prototype / product) and is a measure of the toughness of the article. A decreased energy value allows for some embodiments to have improved score and snap performance as compared to a comparable formulation without modified fibers.
  • the cellulose fiber-reinforced compositions disclosed herein can be used in the manufacture of building materials. In some embodiments, the compositions disclosed herein can be used to prepare an interior wall panel, an exterior wall panel, a ceiling panel, a siding, a roofing, a trim, a molding, or a board (such as a backer board).
  • a building material comprising the fiber-reinforced cement compositions described above.
  • the building material has a lower density as compared to a building material having an equivalent fiber- reinforced cement composition that does not comprise modified cellulose fibers.
  • the density of the building materials comprising a fiber-reinforced cement composition disclosed herein is about 1.7 g/cm 3 or lower, about 1.3 g/cm 3 or lower, about 1.2 g/cm 3 or lower, about 1.1 g/cm 3 or lower, 1.05 g/cm 3 or lower, 1 g/cm 3 or lower, 0.95 g/cm 3 or lower, or 0.90 g/cm 3 or lower.
  • the building materials disclosed herein maintain the advantageous properties of comparable reinforced fiber cement materials, which do not comprise modified cement fibers, such as durability.
  • the fiber-reinforced cement materials have a Modulus of Rupture (MoR) of about 9.0 MPa or lower, about 8.5 MPa or lower, about 8 MPa or lower, about 7.5 MPa or lower, about 7 MPa or lower, about 6 MPa or lower, about 5 MPa or lower, about 4 MPa or lower, or about 3 MPa or lower.
  • MoR Modulus of Rupture
  • the fiber-reinforced cement compositions of the disclosure have an energy of about 1.0 J or lower, about 0.9 J or lower, about 0.8 J or lower, about 0.7 J or lower, about 0.6 J or lower, about 0.5 J or lower, about 0.4 J or lower, about 0.3 J or lower, or about 0.2 J or lower.
  • the fiber-reinforced cement materials disclosed herein e.g., materials comprising crosslinked cellulose fibers, can be easier to cut via a score and snap method than comparable materials that do not comprise crosslinked cellulose fibers.
  • the fiber-reinforced cement compositions of the disclosure have a moisture movement of less than 1.0% as compared to an equivalent formulation without modified cellulose fibers. In preferred embodiments, the moisture movement is less than 0.5%, and still more preferred is less than 0.25%, and most preferred is less than about 0.2%. In some embodiments, the building material disclosed herein have comparable moisture movement of materials that contain other LDAs, such as hollow ceramic microspheres, volcanic ash, or pearlite microspheres.
  • the building material disclosed herein includes an interior wall panel, an exterior wall panel, a ceiling panel, a siding, a roofing, a trim, a molding, or a board (such as a backer board).
  • the building material disclosed herein can be used for any applications wherein a reinforced fiber cement material is desirable, such as siding, backer boards, trim, molding, interior wall paneling, roofing and ceilings.
  • the materials disclosed herein are backer boards.
  • compositions of the disclosure and/or building materials comprising the compositions disclosed herein can be prepared or manufactured as follows:
  • pre-cure the article Prior to Autoclaving, in certain embodiments, it is preferred to pre-cure the article for a short time (e.g., from about 1 hr to about 24hrs).
  • the compositions prepared from crosslinked cellulose fibers co-refmed with other fibers and compositions prepared from crosslinked cellulose fibers directly added to the compositions at the same ratio provided similar mechanical properties.
  • the modified cellulose fibers are co-refmed with regular cellulose pulp (e.g., unbleached Kraft pulp) at various ratios, e.g., from about 1% to about 60% of crosslinked cellulose fiber loading) prior to use in the preparation of the compositions and materials disclosed herein.
  • Air curing can be done at ambient temperatures, i.e., between 0 degree Celsius and 55 degrees Celsius.
  • Exemplary building materials comprising compositions of the disclosure comprising various amounts of crosslinked cellulose fiber were prepared as described above in pad form for testing, and their properties were compared to those of a control material that did not include any crosslinked cellulose fibers. Pads and prototypes in the form of pads are routinely used in the art to test the various performance characteristics of equivalent fiber cement products.
  • sample prototypes (n>3) were prepared at 7 mm thickness, autoclaved, and cut prior to testing.
  • Sample prototypes having about 7 wt% unbleached kraft pulp (UKP) were prepared with 0 wt%, about 2 wt%, and about 4 wt% modified cellulose fibers (XL).
  • the prototypes were tested for Density, Modulus of Rupture (MoR) values, and Energy (as determined by a 3-point bending test), see FIG. 1. All three values were found to decrease as modified fiber increased. In comparison to leading products containing LDAs, the sample prototypes showed decreases in energy and density (not shown).
  • the samples containing about 2% and about 4% of crosslinked cellulose fibers demonstrated about 29% to about 50% decrease in Modulus of Rupture (MoR), as determined by a 3 -point bending test using autoclave dried samples that were saturated for testing, about 8% to about 20% decrease in density compared to the control samples, and about 30% to about 70% decrease in energy.
  • MoR Modulus of Rupture
  • Sample prototypes were then made to investigate decreasing amounts of UKP from about 4.5 wt% to about 2.75 wt% with a stable content of about 3 wt% of modified cellulose fibers.
  • the control sample pads comprised about 7.5 wt% UKP and 0.0 wt% modified fibers (see FIG. 2).
  • Sample prototypes were also made with varying content of both UKP and modified cellulose fibers (see FIG. 3).
  • the UKP varied from about 4 wt% to about 7 wt%.
  • the modified fibers content varied in range of 0 wt% to about 4.5 wt%.
  • the data shows that varied levels of different types of cellulose fibers alters the base performance functions in ways that can be tuned to particular product application needs, including as LDA performance of modified cellulose fibers and energy values, discussed further below. Also tested was the ability to co-refine UKP and modified cellulose fibers prior to blending.
  • FIG. 3 The UKP varied from about 4 wt% to about 7 wt%.
  • the modified fibers content varied in range of 0 wt% to about 4.5 wt%.
  • modified cellulose fibers from about 3 wt% to about 6 wt % was compared to market SBSK pulp from about 3 wt% to about 6 wt%. All sample composition formulations comprised UKP at about 7 wt%, including the control with 0 wt% added modified cellulose fibers or SBSK pulp. The tests confirm the LDA performance and the decreased energy property values of modified cellulose fiber (see FIG. 5).
  • modified cellulose fibers as an LDA in fiber cement sample prototypes was compared to a conventional LDA material, Pearlite 2000 (DICAPERL HP2000 from Dicalite Management Group, Inc.). An equivalent or better decrease in density, MoR, and energy values at each step increase in modified cellulose fibers as compared to the DICAPERL HP2000 (see FIG. 6). The Canadian Standard Freeness values of the UKP did not significantly affect the results (see FIG. 7).
  • Moisture movement was found to be comparable between materials that contain different levels of cellulose pulp and modified cellulose fiber, and only minimally greater than similarly prepared compositions containing conventional materials as an LDA (see FIG. 8).
  • the lower addition amounts of modified cellulose fibers (about 2 wt% and about 4 wt%) were comparable to other sample prototype results with LDAs or increased cellulose fiber content.
  • modified cellulose fiber grades made from stock wood pulp fiber that is untreated (CMF530 from International Paper Co.) and treated with a debonder prior to crosslinking (CMF535 from International Paper Co.) did not have significantly different results in the tests of sample prototypes compared to each other (see FIG. 9).
  • the two sample prototype sets at about 4 wt% modified cellulose fibers performed comparably to or better than the same additional amount of conventional materials as an LDA (DICAPERL HP 100 from Dicalite Management Group, Inc.).
  • the decreased energy data seen throughout the various modified fiber containing sample prototypes indicate that the compositions comprising this form of LDA can be easier to cut via a score and snap method typically used for cutting fiber-reinforced cement materials.
  • the exemplary samples decreased density, while at the same time had decreased energy, which is indicative of the toughness of the fiber cement board sample.
  • toughness of fiber-reinforced cement increases with the increase in the fiber content, thus making the fiber-reinforced cement more difficult to score and snap.
  • addition of crosslinked cellulose fiber while resulting in increased overall cellulose fiber content, resulted in decreasing toughness of the material as modified cellulose fiber content increased.
  • building materials comprising crosslinked cellulose fibers disclosed herein, e.g., backer boards can be easier to cut by scoring and snapping the board down the score line than comparable building materials that do not comprise crosslinked cellulose fibers.

Abstract

L'invention concerne des compositions renforcées de fibres de cellulose cimentaires comprenant des additifs à base de fibres de cellulose modifiées et des matériaux de construction comprenant les compositions. L'ajout de fibres de cellulose modifiées permet d'obtenir des matériaux de ciment renforcés par des fibres avec une densité inférieure, une maniabilité améliorée et des coûts potentiellement réduits. Les compositions sont appropriées pour être utilisées dans des produits de construction tels que des parements, des panneaux, des toitures, des planches d'appui, des garnitures, des moulages et d'autres produits en fibro-ciment.
PCT/US2020/030862 2019-04-30 2020-04-30 Modificateur de faible densité pour fibro- ciment WO2020223562A1 (fr)

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CN112777975A (zh) * 2020-12-31 2021-05-11 乌兰浩特市圣益商砼有限公司 一种利用改性火山灰岩粉制备的超高性能混凝土
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