Ultra-stable cement-based material formulation, method of making same, and ultra-stable tile backer board formulation and method of making same

文档序号：913919 发布日期：2021-02-26 浏览：8次中文

阅读说明：本技术 超稳定水泥基材料配制物、其制造方法以及超稳定瓷砖背衬板配制物和其制造方法 (Ultra-stable cement-based material formulation, method of making same, and ultra-stable tile backer board formulation and method of making same ) 是由 J·A·万宝格 B·罗克纳于 2018-12-28 设计创作，主要内容包括：具有纳米分子贴面的超稳定水泥基材料通过以下方式来制造水泥基材料：共混基于所述水泥基材料的最终总重量29wt％至40wt％的含有80wt％至98wt％的氧化镁的氧化镁干粉与14wt％至18wt％的溶解于水中的氯化镁并反应形成液体悬浮液,混合2至10分钟,添加含磷材料,以及使所述液体悬浮液反应成无定形相水泥基材料,其中所述无定形相水泥基材料的一部分生长多个晶体。所述多个晶体由形成纳米分子贴面的所述无定形相水泥基材料包封。制造所述超稳定水泥基材料的方法。掺入所述超稳定水泥基材料中的瓷砖背衬板和制造所述瓷砖背衬板的方法。(The super-stable cement-based material with the nano-molecular veneers is prepared by the following steps: blending 29 to 40 wt% of a dry powder of magnesium oxide containing 80 to 98 wt% of magnesium oxide based on the total final weight of the cementitious material with 14 to 18 wt% of magnesium chloride dissolved in water and reacting to form a liquid suspension, mixing for 2 to 10 minutes, adding a phosphorus-containing material, and reacting the liquid suspension to an amorphous phase cementitious material, wherein a portion of the amorphous phase cementitious material grows multiple crystals. The plurality of crystals are encapsulated by the amorphous phase cement-based material forming a nano-molecular veneer. A method of making the ultra-stable cementitious material. A tile backer board incorporated into the ultra-stable cement-based material and a method of making the tile backer board.)

1. An ultra-stable cementitious material having a nano-molecular veneer, the ultra-stable cementitious material having a nano-molecular veneer comprising:

(i) 29 to 40 wt% of a dry powder of magnesium oxide containing 80 to 98 wt% of magnesium oxide based on the total final weight of the cementitious material, the magnesium oxide having a surface area of between 5 meters²Per gram to 50 m²(ii) in the range of/gram and having an average particle size in the range of about 0.3 to about 90 microns, wherein greater than about 90 weight percent of the magnesium oxide particles are less than or equal to about 40 microns;

(ii) 14 to 18 wt% magnesium chloride dissolved in water, based on the total final weight of the cementitious material;

(iii) 0.1 to 10 wt% based on the total final weight of the cementitious material of a stabilizing material having a phosphorus-containing compound comprising:

1. phosphorous acid (A) based on the final total weight of the cementitious material, wherein the phosphorous acid is from 55 wt% to 65 wt% H₃PO₃Composition of an aqueous solution of the concentrate; or

2. Phosphoric acid (B) based on the final total weight of the cementitious material, wherein the phosphoric acid is from 80 wt% to 90 wt% H₃PO₄Composition of an aqueous solution of the concentrate;

wherein a portion of the amorphous phase cement-based material grows a plurality of crystals, each crystal having a MW in the range of 280 to 709, the amorphous phase cement-based material encapsulating the plurality of crystals, wherein a majority of the stabilizing material with the phosphorus-containing compound is consumed into the nanomolecular overlay while the surface area of the plurality of crystals increases by 2% to 49% during curing, and wherein the nanomolecular elements of the cured nanomolecular overlay are insoluble in water and the cured nanomolecular overlay protects the plurality of crystals of the formed cement-based material from degradation in water at a temperature of 20 ℃ to 60 ℃ for 24 hours to 56 days.

2. The nano-molecular veneered super-stable cementitious material of claim 1, comprising: 0.1 to 30 wt% of an aggregate comprising particles having a diameter of 1nm to 10mm, based on the total final weight of the concrete, wherein the aggregate comprises at least one of: wood, perlite, styrene-based foam beads, calcium carbonate powder, glass particles, and combinations thereof.

3. The nano-molecular veneered super-stable cementitious material of claim 2, comprising: 0.1 to 2 wt% of a reinforcing material comprising a silica-containing non-woven or woven mat, a hydrocarbon-containing non-woven or woven mat, based on the final total weight of the cementitious material.

4. The ultra-stable cementitious material with nano-molecular veneering of claim 1, comprising adding 0.1 to 15 weight percent biomass added to the amorphous phase cementitious material based on the final total weight of the concrete and mixing for 3 to 10 minutes.

5. The ultra-stable cement-based material with nano-molecular veneering of claim 4, wherein the biomass is a member of the group comprising: rice hulls, corn husks and manure.

6. The ultra-stable cementitious material with nano-molecular veneering of claim 2, comprising adding 0.1 to 10 wt% of at least one surfactant to the cementitious material based on the final total weight of the concrete to reduce the porosity of the aggregate and prevent amorphous phase cementitious material from entering the pores of the aggregate.

7. The ultra-stable cement-based material with a nano-molecular veneer according to claim 6, wherein the surfactant is a detergent.

8. The ultra-stable cement-based material with nanomolecular facing of claim 2, comprising: adding 0.1 to 5 wt% of a redispersible powders polymer based on the final total weight of the concrete and mixing for 3 to 10 minutes.

9. The ultra-stable cement-based material with nanomolecular facing of claim 8, wherein the redispersible powders polymer is selected from the group consisting of: silicon, polyurethane dispersions, polyurethanes, alkyl carboxylic acid vinyl ester monomers, branched and unbranched alcohol (meth) acrylate monomers, vinyl aromatic monomers, olefin monomers, diene monomers and vinyl halide monomers or vinyl acetate ethylene "VAE".

10. The ultra-stable cementitious material with nano-molecular veneering of claim 8, further comprising adding 0.1 to 5 weight percent of acrylic or Styrene Butadiene Rubber (SBR) to the concrete based on the final total weight of the cementitious material while adding the redispersible powders polymer.

11. The ultra-stable cementitious material with nano-molecular veneers of claim 1, further comprising adding 0.1 wt% to 15 wt% of a reinforcing material based on the total final weight of the concrete, the reinforcing material comprising at least one of:

(i) silica-containing chopped fibers;

(ii) hemp-containing fibers;

(iii) nano-molecular carbon fiber bundles;

(iv) short-cut carbon fibers;

(v) chopped hydrocarbon fibers; and combinations thereof.

12. A method of making a hyperstable cement-based material with a nano-veneer; the method comprises the following steps:

(i) blending 29 to 40 wt% based on the total final weight of the cementitious material of a dry powder of magnesium oxide containing 80 to 98 wt% of magnesium oxide with 14 to 18 wt% based on the total final weight of the cementitious material of magnesium chloride dissolved in water, the magnesium oxide having a surface area of between 5 meters²Per gram to 50 m²In the range of about 0.3 to about 90 microns in average particle sizeWherein greater than about 90 weight percent of the magnesium oxide particles are less than or equal to about 40 microns, the magnesium chloride in aqueous solution comprising: 20 to 30 wt% aqueous magnesium chloride solution, wherein the magnesium oxide and the magnesium chloride in the water react to form a liquid suspension;

(ii) mixing the liquid suspension for 2 to 10 minutes while minimizing the addition of gas to the liquid suspension;

(iii) adding 0.1 to 10 wt% based on the final total weight of the cementitious material of a stabilizing material having a phosphorus-containing compound to the mixed liquid suspension, the stabilizing material having a phosphorus-containing compound comprising:

(iv) reacting the liquid suspension with stabilizing material into an amorphous phase cement-based material over a period of 1 to 4 minutes;

13. The method of claim 12, the method comprising: blending 35 to 79.9 wt% of the formed cementitious material with 0.1 to 30 wt% of an aggregate comprising particles having a diameter of 1nm to 10mm, based on the total final weight of the concrete, wherein the aggregate comprises at least one of: wood, perlite, styrene-based foam beads, calcium carbonate powder, glass particles, and combinations thereof.

14. The method of claim 13, the method comprising: pouring the concrete onto 0.1 wt% to 2 wt% of a reinforcing material comprising a silica-containing non-woven or woven mat, a hydrocarbon-containing non-woven or woven mat, based on the final total weight of the cementitious-based material, and curing to the cementitious-based material.

15. The method of claim 12, comprising adding 0.1 to 15 wt% biomass added to the amorphous phase cement-based material based on the final total weight of the concrete and mixing for 3 to 10 minutes.

16. The method of claim 15, wherein the biomass is a member of the group comprising: rice hulls, corn husks and manure.

17. A method as claimed in claim 13 which comprises adding to the cementitious material from 0.1 to 10 wt% based on the total final weight of the concrete of at least one surfactant to reduce the porosity of the aggregate and prevent amorphous phase cementitious material from entering the pores of the aggregate.

18. The method of claim 17, wherein the surfactant is a detergent.

19. The method of claim 13, the method comprising: adding 0.1 to 5 wt% of a redispersible powders polymer based on the final total weight of the concrete and mixing for 3 to 10 minutes.

20. The method of claim 19, wherein the redispersible powders polymer is selected from the group consisting of: silicon, polyurethane dispersions, polyurethanes, alkyl carboxylic acid vinyl ester monomers, branched and unbranched alcohol (meth) acrylate monomers, vinyl aromatic monomers, olefin monomers, diene monomers and vinyl halide monomers or vinyl acetate ethylene "VAE".

21. The method of claim 19, further comprising adding 0.1 to 5 wt% of acrylic or Styrene Butadiene Rubber (SBR) to the concrete, based on the final total weight of the cementitious material, with the addition of the redispersible powders polymer.

22. The method of claim 12, further comprising adding 0.1 wt% to 15 wt% of a reinforcing material based on the total final weight of the concrete, the reinforcing material comprising at least one of:

(i) silica-containing chopped fibers;

(ii) hemp-containing fibers;

(iii) nano-molecular carbon fiber bundles;

(iv) short-cut carbon fibers;

(v) chopped hydrocarbon fibers; and combinations thereof.

23. A tile backer board, comprising:

a. 35 to 79.9 wt%, based on the total final weight of the tile backing plate, of a cement-based material comprising:

(ii) 14 to 18 wt%, based on the total final weight of the cementitious material, of magnesium chloride dissolved in water, the magnesium chloride in the form of an aqueous solution comprising: 20 to 30 wt% aqueous magnesium chloride solution, wherein the magnesium oxide and the magnesium chloride in the water react to form a liquid suspension;

(iii) 0.1 to 10 wt% based on the total final weight of the cementitious material of a stabilising material with a phosphorous containing compound which when mixed with the liquid suspension reacts to an amorphous phase cementitious material comprising:

b. 0.1 to 30 wt% of an aggregate comprising particles having a diameter of 1nm to 10mm, based on the final total weight of the tile backing plate, wherein the aggregate comprises at least one of: wood, perlite, styrene-based foam beads, calcium carbonate powder, glass particles, and combinations thereof;

c. 0.1 to 2 wt% of a reinforcing material based on the final total weight of the tile backing plate, the reinforcement material comprises a non-woven or woven mat comprising silica, a non-woven or woven mat comprising hydrocarbons, wherein the amorphous phase cement-based material containing aggregate is poured onto the reinforcement material such that a portion of the amorphous phase cement-based material is capable of growing a plurality of crystals, each crystal having a MW in the range of 280 to 709, the amorphous phase cement-based material encapsulating the plurality of crystals, wherein a majority of the stabilizing material having the phosphorus-containing compound is consumed into the nano-molecular veneer while the surface area of the plurality of crystals increases by 2% to 49% during curing, and wherein the nanomolecular elements of the cured nanomolecular overlay are insoluble in water and the cured nanomolecular overlay protects the plurality of crystals of the formed tile backing plate from degradation in water at a temperature of 20 ℃ to 60 ℃ for 24 hours to 56 days.

24. The tile backing plate of claim 23, comprising from 0.1 to 15% by weight of biomass added to the amorphous phase cement-based material, based on the final total weight of the tile backing plate.

25. The tile backing plate of claim 23, comprising from 0.1 to 10 wt%, based on the final total weight of the tile backing plate, of at least one surfactant added to the cement-based material to reduce the porosity of the aggregate and prevent the amorphous phase cement-based material from entering the pores of the aggregate.

26. The tile backing plate of claim 23, comprising: from 0.1 to 5% by weight, based on the final total weight of the tile backing plate, of a redispersible powders polymer incorporated in the amorphous phase cement-based material.

27. The tile backing plate of claim 26, wherein the redispersible powders polymer is selected from the group consisting of: acrylic, silicon, polyurethane dispersions, polyurethanes, alkylcarboxylic acid vinyl ester monomers, branched and unbranched alcohol (meth) acrylate monomers, vinyl aromatic monomers, olefin monomers, diene monomers and vinyl halide monomers or vinyl acetate ethylene "VAE".

28. The tile backing plate of claim 23, further comprising from 0.1 to 5 weight percent of acrylic or Styrene Butadiene Rubber (SBR) blended with the redispersible powders polymer into the amorphous cement-based material, based on the final total weight of the tile backing plate.

29. The tile backing plate of claim 23, further comprising 0.1 to 15 wt%, based on the total final weight of the tile backing plate, of a reinforcing material comprising at least one of:

(i) silica-containing chopped fibers;

(ii) hemp-containing fibers;

(iii) nano-molecular carbon fiber bundles;

(iv) short-cut carbon fibers;

(v) chopped hydrocarbon fibers; and combinations thereof.

30. A building having an interior building surface covered with the tile backer board of claim 23.

31. A tile backer board, comprising:

a. 35 to 79.9 wt%, based on the total final weight of the tile backing plate, of a cement-based material comprising:

2. Based onPhosphoric acid (B) of the final total weight of the cement-based material, wherein the phosphoric acid is from 80 wt% to 90 wt% H₃PO₄Composition of an aqueous solution of the concentrate;

b. 0.1 to 30 wt% of an aggregate comprising particles having a diameter of 1nm to 10mm, based on the total weight of the tile backing plate, wherein the aggregate comprises at least one of wood, perlite, styrene-based foam beads, calcium carbonate powder, and combinations thereof;

c. 0.1 to 15 wt% of a reinforcing material based on the final total weight of the tile backing plate, the reinforcing material comprising at least one of:

(i) silica-containing chopped fibers;

(ii) hemp-containing fibers;

(iii) nano-molecular carbon fiber bundles;

(iv) short-cut carbon fibers;

(v) chopped hydrocarbon fibers; and combinations thereof;

wherein a portion of the amorphous phase cement-based material grows a plurality of crystals, each crystal having a MW in the range of 283 to 709, the amorphous phase cement-based material encapsulating the plurality of crystals, wherein a majority of the stabilizing material with the phosphorus-containing compound is consumed into the nanomolecular overlay while the surface area of the plurality of crystals increases by 2% to 49% during curing, and wherein the nanomolecular elements of the cured nanomolecular overlay are insoluble in water and the cured nanomolecular overlay protects the plurality of crystals of the formed tile backing plate from degradation in water at a temperature of 20 ℃ to 60 ℃ for 24 hours to 56 days.

32. The tile backing plate of claim 31, comprising from 0.1 to 15% by weight of biomass based on the final total weight of the tile backing plate, said biomass being added to said amorphous phase cement-based material.

33. The tile backing plate of claim 31, comprising from 0.1 to 10 wt%, based on the final total weight of the tile backing plate, of at least one surfactant added to the amorphous phase cement-based material to reduce the porosity of the aggregate and prevent the amorphous phase cement-based material from entering the pores of the aggregate.

34. The tile backing plate of claim 31, comprising: from 0.1 to 5% by weight, based on the final total weight of the tile backing plate, of a redispersible powders polymer incorporated in the amorphous phase cement-based material.

35. The tile backing plate of claim 34, wherein the redispersible powders polymer is selected from the group consisting of: acrylic, silicon, polyurethane dispersions, polyurethanes, alkylcarboxylic acid vinyl ester monomers, branched and unbranched alcohol (meth) acrylate monomers, vinyl aromatic monomers, olefin monomers, diene monomers and vinyl halide monomers or vinyl acetate ethylene "VAE".

36. The tile backing plate of claim 31, further comprising from 0.1 to 5 weight percent of acrylic or Styrene Butadiene Rubber (SBR) blended with the redispersible powders polymer into the amorphous cement-based material, based on the final total weight of the tile backing plate.

37. A building having an interior building surface covered with the tile backer board of claim 31.

38. A method of manufacturing a tile backing plate, the method comprising:

a. forming a cementitious material comprising:

(i) blending 29 to 40 wt% based on the total final weight of the cementitious material of a dry powder of magnesium oxide containing 80 to 98 wt% of magnesium oxide with 14 to 18 wt% based on the total final weight of the cementitious material of magnesium chloride dissolved in water, the oxygenThe surface area of magnesium oxide is between 5 m²Per gram to 50 m²(ii) in the range of/gram and having an average particle size in the range of from about 0.3 to about 90 microns, wherein greater than about 90 weight percent of the magnesium oxide particles are less than or equal to about 40 microns, said magnesium chloride in aqueous solution comprising: 20 to 30 wt% aqueous magnesium chloride solution, wherein the magnesium oxide and the magnesium chloride in the water react to form a liquid suspension;

(ii) mixing the liquid suspension for 2 to 10 minutes while minimizing the addition of gas to the liquid suspension;

(iv) reacting the liquid suspension with stabilizing material into the amorphous phase cement-based material over a period of 1 to 4 minutes;

b. blending 35 to 79.9 wt%, based on the total final weight of the tile backing plate, of the formed cement-based material with 0.1 to 30 wt%, based on the total final weight of the tile backing plate, of an aggregate comprising particles having a diameter of 1nm to 10mm, wherein the aggregate comprises at least one of: wood, perlite, styrene-based foam beads, calcium carbonate powder, glass particles, and combinations thereof, thereby forming concrete;

c. pouring the concrete on a reinforcing material of 0.1 to 2 wt% based on the final total weight of the tile backing plate, curing into the tile backing plate, the reinforcing material comprising a non-woven or woven mat comprising silica, a non-woven or woven mat comprising hydrocarbons, and

wherein a portion of the amorphous phase cement-based material grows a plurality of crystals, each crystal having a MW in the range of 280 to 709, the amorphous phase cement-based material encapsulating the plurality of crystals, wherein a majority of the stabilizing material with the phosphorus-containing compound is consumed into the nanomolecular overlay while the surface area of the plurality of crystals increases by 2% to 49% during curing, and wherein the nanomolecular elements of the cured nanomolecular overlay are insoluble in water and the cured nanomolecular overlay protects the plurality of crystals of the formed tile backing plate from degradation in water at a temperature of 20 ℃ to 60 ℃ for 24 hours to 56 days.

39. A method as claimed in claim 38 which comprises adding 0.1 to 15% by weight of biomass added to the amorphous phase cement-based material based on the total final weight of the tile backing board and mixing for 3 to 10 minutes.

40. The method of claim 39, wherein the biomass is a member of the group comprising: rice hulls, corn husks and manure.

41. A method as claimed in claim 38 which comprises adding to the cement-based material from 0.1 to 10 wt% based on the final total weight of the tile backing plate of at least one surfactant to reduce the porosity of the aggregate and prevent amorphous phase cement-based material from entering the pores of the aggregate.

42. The method of claim 41, wherein the surfactant is a detergent.

43. The method of claim 38, the method comprising: adding 0.1 to 5% by weight based on the final total weight of the tile backing board of a redispersible powders polymer incorporated in the amorphous phase cement-based material and mixing for 3 to 10 minutes.

44. The method of claim 43, wherein the redispersible powders polymer is selected from the group consisting of: silicon, polyurethane dispersions, polyurethanes, alkyl carboxylic acid vinyl ester monomers, branched and unbranched alcohol (meth) acrylate monomers, vinyl aromatic monomers, olefin monomers, diene monomers and vinyl halide monomers or vinyl acetate ethylene "VAE".

45. The method of claim 38, further comprising adding 0.1 to 5 wt% of acrylic or Styrene Butadiene Rubber (SBR) based on the final total weight of the tile backing plate to the amorphous cement-based material while adding the redispersible powders polymer.

46. The method of claim 38, further comprising adding 0.1 wt% to 15 wt% of a reinforcing material based on the total final weight of the tile backing plate, the reinforcing material comprising at least one of:

(i) silica-containing chopped fibers;

(ii) hemp-containing fibers;

(iii) nano-molecular carbon fiber bundles;

(iv) short-cut carbon fibers;

(v) chopped hydrocarbon fibers; and combinations thereof.

47. An interior building surface covered with a tile backer board made by the method of claim 38.

48. A method of manufacturing a tile backing plate, the method comprising:

a. forming a cementitious material comprising:

(i) blending 29 to 40 wt% based on the total final weight of the cementitious material of a dry powder of magnesium oxide containing 80 to 98 wt% magnesium oxide with 14 to 18 wt% based on the total final weight of the cementitious material of magnesium chloride dissolved in water, the magnesium oxide having a surface area of between 5 meters²Per gram to 50 m²In the range of/gramAnd an average particle size in the range of from about 0.3 to about 90 microns, wherein greater than about 90 weight percent of the magnesium oxide particles are less than or equal to about 40 microns, the magnesium chloride in aqueous solution comprising: 20 to 30 wt% aqueous magnesium chloride solution, wherein the magnesium oxide and the magnesium chloride in the water react to form a liquid suspension;

(ii) mixing the liquid suspension for 2 to 10 minutes while minimizing the addition of gas to the liquid suspension;

(iii) adding 0.1 to 10 wt% based on the final total weight of the cementitious material of a stabilizing material having a phosphorus-containing compound to the liquid suspension, the stabilizing material having a phosphorus-containing compound comprising:

(iv) reacting the liquid suspension with stabilizing material into the amorphous phase cement-based material over a period of 1 to 4 minutes

b. Blending 35 to 79.9 wt%, based on the total final weight of the tile backing plate, of the formed amorphous phase cement-based material with 0.1 to 30 wt%, based on the total weight of the tile backing plate, of an aggregate comprising particles having a diameter of 1nm to 10mm, wherein the aggregate comprises at least one of wood, perlite, styrene-based foam beads, calcium carbonate powder, and combinations thereof;

c. mixing 0.1 wt% to 15 wt%, based on the total final weight of the tile backing plate, of a reinforcing material comprising at least one of:

(i) silica-containing chopped fibers;

(ii) hemp-containing fibers;

(iii) nano-molecular carbon fiber bundles;

(iv) short-cut carbon fibers;

(v) chopped hydrocarbon fibers; and combinations thereof; and is

Wherein a portion of the amorphous phase cement-based material grows a plurality of crystals, each crystal having a MW in the range of 283 to 709, the amorphous phase cement-based material encapsulating the plurality of crystals, wherein a majority of the stabilizing material with the phosphorus-containing compound is consumed into the nanomolecular overlay while the surface area of the plurality of crystals increases by 2% to 49% during curing, and wherein the nanomolecular elements of the cured nanomolecular overlay are insoluble in water and the cured nanomolecular overlay protects the plurality of crystals of the formed tile backing plate from degradation in water at a temperature of 20 ℃ to 60 ℃ for 24 hours to 56 days.

49. A method as claimed in claim 48 which includes adding from 0.1 to 15% by weight of biomass added to the amorphous phase cement-based material based on the total final weight of the tile backing board.

50. The method of claim 49, wherein the biomass is a member of the group comprising: rice hulls, corn husks and manure.

51. A method as claimed in claim 48 which includes adding from 0.1 to 10% by weight based on the total final weight of the tile backing plate of at least one surfactant which is added to the amorphous phase cement-based material to reduce the porosity of the aggregate and prevent the amorphous phase cement-based material from entering the pores of the aggregate.

52. The method of claim 51, wherein the surfactant is a detergent.

53. The method of claim 48, the method comprising: adding from 0.1 to 5% by weight based on the final total weight of the tile backing board of a redispersible powders polymer incorporated in the amorphous phase cement-based material.

54. The method of claim 53, wherein the redispersible powders polymer is selected from the group consisting of: acrylic, silicon, polyurethane dispersions, polyurethanes, alkylcarboxylic acid vinyl ester monomers, branched and unbranched alcohol (meth) acrylate monomers, vinyl aromatic monomers, olefin monomers, diene monomers and vinyl halide monomers or vinyl acetate ethylene "VAE".

55. The method of claim 48, further comprising adding 0.1 to 5 wt% of acrylic or Styrene Butadiene Rubber (SBR) blended with the redispersible powders polymer into the amorphous cement-based material, based on the total final weight of the tile backing plate.

56. A building having an interior building surface covered with a tile backer board made by the method of claim 48.

Technical Field

The present invention relates generally to a formulation for manufacturing an ultra-stable cement-based material, a method for manufacturing the same, an ultra-stable tile backer board formulation, and a method for manufacturing a tile backer board.

Background

There is a need for a building material free of crystalline silica having structural integrity, fire resistance, excellent insulating properties, and excellent mold, flour germ, and termite resistance.

There is also a need for building materials with high hot water stability.

The present embodiment meets these needs.

Drawings

The detailed description will be better understood in conjunction with the following drawings:

figures 1A-1D depict a step-wise process for manufacturing the ultra-stable cement-based material and tile backing board of the present invention.

Figure 2 depicts X-ray diffraction pre-and post-treatments of magnesium oxychloride with phosphoric acid.

Figures 3A-3H depict tables of cement-based material formulations of the present invention containing reinforcing components and aggregates and other additives, as well as physical properties of the formulations.

Figures 3I-3T depict tables of physical properties of ceramic tile backing boards and formulations of the present invention containing reinforcing components and aggregates and other additives.

Figure 4 is a table showing various additional formulations made according to the method of the present invention.

The present embodiments are described in detail below with reference to the listed figures.

Detailed Description

Before explaining the present method in detail, it is to be understood that the formulations and methods of the present invention are not limited to the particular embodiments and that they may be practiced or carried out in various ways.

The present invention relates to a method for manufacturing a super stable cementitious building material consisting of a crystalline fraction and an amorphous nanomolecular coating substantially free of crystalline silica.

The first step of the process involves forming a gel phase by blending together magnesium oxide and magnesium chloride in water, wherein the weight ratio of magnesium oxide to magnesium chloride is from 1.9:1 to 2.1: 1.

In the method, 2 to 30% by weight of aggregate is added to the gel phase to form an amorphous phase.

Phosphorous acid or phosphoric acid, or both, is then added to the amorphous phase, causing a portion of the amorphous phase to crystallize while forming a nanomolecular overlay that encapsulates the crystalline portion of the amorphous phase, is free of detectable magnesium phosphate, and has a 2% to 49% (e.g., 35% to 49%) increase in surface area compared to the non-overlaid crystalline portion, and wherein the crystalline portion with the nanomolecular overlay is configured to resist degradation in water at a temperature of 60 ℃ within 48 hours.

The benefits of this approach are as follows: when immersed in water at temperatures up to 60 ℃, the cement stability increases; this physical property determines the warm water stability of the above cement and no additional time is required for the present invention.

Benefits of cement-based material formulations include increased cement stability when immersed in water at temperatures up to 60 ℃.

The present invention provides a magnesium oxychloride cement having increased stability in high temperature and high moisture environments.

The present invention provides a cement-based material having a protective layer that is not exposed to crystals and therefore is not susceptible to dissolution by moisture or water at elevated temperatures.

The present invention stabilizes the concrete, thereby reducing the corrosive effects on other building materials in the assembly.

The present invention has improved water resistance over other types of magnesium oxychloride cements without the addition of polymers or other sealants that can compromise some of the excellent fire resistant properties of the magnesium oxychloride cement.

The present invention and the unexpected amorphous layer protecting the crystals of magnesium oxychloride cement, do less harm to the structural strength of the cement product than other uses for which phosphorus compounds have been demonstrated.

The present invention relates to a method for manufacturing a cement-based building material consisting of a crystalline fraction and an amorphous nanomolecular coating substantially free of crystalline silica.

In the method, 2 to 30% by weight of aggregate is added to the gel phase to form an amorphous phase.

Phosphorous acid or phosphoric acid, or both, is then added to the amorphous phase, causing a portion of the amorphous phase to crystallize while forming a nanomolecular overlay that encapsulates the crystalline portion of the amorphous phase, contains no detectable magnesium phosphate, and has a surface area that is increased by 2% to 49% compared to the non-overlaid crystalline portion, and wherein the crystalline portion with the nanomolecular overlay is configured to resist degradation in water at a temperature of 60 ℃ within 48 hours.

The benefits of this approach are as follows: when immersed in water at temperatures up to 60 ℃, the cement stability increases, which physical property determines the warm water stability of the above cement and no additional time is required for the present invention.

The invention relates to a method for manufacturing an ultra-stable cement-based material with a nano-molecular veneer and an ultra-stable cement-based material with a nano-molecular veneer.

The present invention also relates to a tile backer board formulation consisting of a crystalline portion and an amorphous nanomolecular coating that is substantially free of crystalline silica.

Benefits of the tile backer board formulation include increased cement stability when immersed in water at temperatures up to 60 ℃.

The present invention provides a tile backing plate with a protective layer that is not exposed to crystals and therefore is not susceptible to dissolution by moisture or water at elevated temperatures.

The following definitions are used herein:

the term "aggregate" means wood, perlite, foam beam, glass, calcium carbonate powder or carbon fiber bundle having a particle size of not more than 3 mm.

The term "amorphous phase" refers to a non-crystalline mixture of the final reaction product.

The term "amorphous nanomolecular coating" refers to a coating bonded to a crystalline moiety that has a material that is not visible as crystalline in X-ray diffraction testing and has a molecular density that is inert to water molecules.

The term "biomass" refers to organic materials such as wood flour, straw, ground pecan shells, and ground bagasse.

The term "cementitious building material" refers to a board or structure used for structural assembly to form facilities, offices, barns, houses, fences, and marine dormitories for marine vessels or oil platforms.

The term "crystalline fraction" refers to a fraction of the resulting cementitious building material having an activation energy of 70 kj/mole, having a monoclinic crystal structure, and including magnesium oxychloride in the present invention.

The term "crystalline silica" refers to silica molecules in a crystalline phase similar to glass, such as sand.

The term "dispersible polymer" is a water-dispersible ethylene-vinyl acetate copolymer.

The term "encapsulation" refers to the creation of a nano-molecular veneer on a crystalline surface where a surface coating can be attached, such as sandpaper comprising a plurality of silica particles adhered to a substrate with very small spaces between the silica particles. The dendritic nature of the plurality of crystals provides a coating that may be continuous or have small gaps.

The term "fiber" refers to needle-like materials not exceeding 3mm in length, but may include longer fibers woven into a mat.

The term "gel phase" refers to a phase in which molecules attract each other in the slurry without bonding.

The term "water-insoluble" refers to a compound that does not go into solution or degrade when exposed to water between ambient and 60 ℃ for 0 to 48 hours.

The term "magnesium chloride in water" refers to a liquid containing anhydrous magnesium chloride salts, for example water containing anhydrous magnesium chloride salts containing 20 to 35% by weight of salt in water, which may be distilled water, dirty water containing particulates and non-volatile organic matter, or clean tap water.

The term "magnesia" refers to a powder of MgO having a purity of 80% to 98%, the remainder being calcium carbonate, quartz or iron oxide or similar impurities naturally present in magnesite.

The term "magnesium phosphate crystals" refers to crystals formed by the reaction of magnesium oxide with phosphoric acid or phosphorous acid.

The term "nanomolecular element" refers to a newly identified water-insoluble, non-crystalline, phosphorus-containing substance; can be identified using Scanning Electron Microscopy (SEM) and elemental analysis. This material does not appear to be a phosphorous containing species on X-ray diffraction.

The term "phosphoric acid" refers to H having a density of 1.1g/ml to 1.85g/ml₃PO₄And (3) concentrating.

The term "phosphorous acid" refers to H having a density of 1.1g/ml to 1.65g/ml₃PO₃And (3) concentrating.

The term "plurality of crystals" refers to magnesium oxychloride crystals formed from a portion of the amorphous phase.

The term "predetermined temperature of water" refers to a temperature of from ambient temperature to 90 ℃.

The term "preset time period" refers to a time window of 10 hours to 90 hours, and specifically includes 24 hours to 72 hours.

The phrase "protecting the plurality of crystals from degradation in water" refers to the nanomolecular facing resulting in a loss of strength that is lower than the loss of strength without the nanomolecular facing when the cement-based material is exposed to water between ambient temperature and 60 ℃ for 0-48 hours.

The term "substantially free" means that the content of crystalline silica in the cement-based construction material is less than 3% by weight, based on x-ray diffraction testing.

The term "surface area" refers to the surface area as measured using the BET theoretical method.

The term "faceting" refers to a chemically bonded protective layer on the crystalline portion of the amorphous phase that is configured to resist water that may rise to 60 ℃ for extended periods of time.

The term "water" means H with less than 0.5% by weight impurities₂O。

Method for manufacturing ultra-stable cement-based materials

A method of making an ultra-stable cementitious material with nano-veneering involves blending 29 to 40 wt% of a dry powder of magnesium oxide containing 80 to 98 wt% of magnesium oxide based on the total final weight of the cementitious material with 14 to 18 wt% of magnesium chloride dissolved in water based on the total final weight of the cementitious material.

The surface area of the magnesium oxide is between 5 m²Per gram to 50 m²In the range of/gram and having an average particle size in the range of about 0.3 to about 90 microns, wherein greater than about 90 weight percent of the magnesium oxide particles are less than or equal to about 40 microns.

Magnesium chloride is in aqueous solution. The magnesium chloride may be a 20 wt% to 30 wt% aqueous solution of magnesium chloride.

The magnesium oxide reacts with magnesium chloride in water to form a liquid suspension.

The method involves mixing the liquid suspension for 2 minutes to 10 minutes while minimizing the addition of gas to the liquid suspension.

The method involves adding 0.1 wt% to 10 wt% of a stabilizing material having a phosphorus-containing compound to the mixed liquid suspension, based on the total final weight of the cementitious material.

The stabilizing material with the phosphorus-containing compound may be phosphorous acid (a) based on the final total weight of the cementitious material, wherein the phosphorous acid is from 55 wt% to 65 wt% H₃PO₃Composition of an aqueous solution of the concentrate; or phosphoric acid (B) based on the final total weight of the cement-based material, wherein the phosphoric acid is from 80 wt% to 90 wt% of H₃PO₄Aqueous solution composition of concentrate.

The next step of the process is to react the liquid suspension with the stabilizing material into an amorphous phase cement-based material over a period of 1 minute to 4 minutes.

A portion of the amorphous phase cement-based material grows a plurality of crystals, each crystal having a MW in the range of 280 to 709, the amorphous phase cement-based material encapsulates the plurality of crystals, wherein a majority of the stabilizing material with the phosphorus-containing compound is consumed into the nanomolecular coat while the surface area of the plurality of crystals increases by 2% to 49% during curing, and wherein the nanomolecular elements of the cured nanomolecular coat are insoluble in water and the cured nanomolecular coat protects the plurality of crystals of the formed cement-based material from degradation in water at a temperature of 20 ℃ to 60 ℃ for 24 hours to 56 days.

In embodiments, the method involves blending 35 wt% to 79.9 wt% of the formed cementitious material with 0.1 wt% to 30 wt% of aggregate comprising particles having a diameter of 1nm to 10mm, based on the final total weight of the concrete, wherein the aggregate comprises at least one of: wood, perlite, styrene-based foam beads, calcium carbonate powder, glass particles, and combinations thereof.

In embodiments, the method involves pouring concrete onto 0.1 wt% to 2 wt%, based on the total final weight of the cementitious material, of a reinforcing material, the reinforcing material comprising a silica-containing non-woven or woven mat, a hydrocarbon-containing non-woven or woven mat, and curing the concrete into the cementitious material.

In embodiments, the method involves adding 0.1 to 15 wt% biomass added to the amorphous phase cementitious material based on the final total weight of the concrete

And mixing for 3 to 10 minutes.

The biomass may be a member of the following group: rice hulls, corn husks and manure.

In embodiments, the method involves adding 0.1 to 10 wt%, based on the final total weight of the concrete, of at least one surfactant to the cementitious material to reduce the porosity of the aggregate and prevent the amorphous phase cementitious material from entering the pores of the aggregate.

The surfactant may be a detergent.

In embodiments, the method involves adding 0.1 to 5 wt% redispersible powder polymer based on the total final weight of the concrete and mixing for 3 to 10 minutes.

In embodiments, the redispersible powders polymer may be selected from the group consisting of: silicon, polyurethane dispersions, polyurethanes, alkyl carboxylic acid vinyl ester monomers, branched and unbranched alcohol (meth) acrylate monomers, vinyl aromatic monomers, olefin monomers, diene monomers and vinyl halide monomers or vinyl acetate ethylene "VAE".

In embodiments, the method involves adding 0.1 to 5 weight percent of acrylic or Styrene Butadiene Rubber (SBR) to the concrete, based on the final total weight of the cementitious material, along with a redispersible powder polymer.

In embodiments, the method involves adding 0.1 wt% to 15 wt% of a reinforcing material based on the total final weight of the concrete.

The reinforcing material may be at least one of: silica-containing chopped fibers; hemp-containing fibers; nano-molecular carbon fiber bundles; short-cut carbon fibers; chopped hydrocarbon fibers; and combinations thereof.

Ultra-stable cement-based materials

The ultra-stable cement-based material comprises 29 to 40 wt% based on the total final weight of the cement-based material of dry magnesium oxide powder comprising 80 to 98 wt% magnesium oxide, the magnesium oxide having a surface area of between 5 meters²Per gram to 50 m²In the range of/gram and having an average particle size in the range of about 0.3 to about 90 microns, wherein greater than about 90 weight percent of the magnesium oxide particles are less than or equal to about 40 microns.

The ultra-stable cementitious material contains 14 to 18 wt% magnesium chloride dissolved in water, based on the total final weight of the cementitious material.

The ultra-stable cementitious material contains 0.1 wt% to 10 wt% of a stabilizing material having a phosphorus-containing compound based on the total final weight of the cementitious material.

The stabilized material with the phosphorus-containing compound has phosphorous acid (A) based on the final total weight of the cementitious material, wherein the phosphorous acid is from 55 wt% to 65 wt% of H₃PO₃Composition of an aqueous solution of the concentrate; or phosphoric acid (B) based on the final total weight of the cement-based material, wherein the phosphoric acid is from 80 wt% to 90 wt% of H₃PO₄Aqueous solution composition of concentrate.

In an embodiment, an ultra-stable cement-based material with a nano-molecular veneer comprises: 0.1 to 30 wt% of an aggregate comprising particles having a diameter of 1nm to 10mm, based on the total final weight of the concrete, wherein the aggregate comprises at least one of: wood, perlite, styrene-based foam beads, calcium carbonate powder, glass particles, and combinations thereof.

In an embodiment, an ultra-stable cement-based material with a nano-molecular veneer comprises: 0.1 to 2 wt% of a reinforcing material based on the final total weight of the cementitious material, the reinforcing material comprising a silica-containing non-woven or woven mat, a hydrocarbon-containing non-woven or woven mat.

In an embodiment, an ultra-stable cement-based material with a nano-molecular veneer comprises: 0.1 to 15 wt% biomass added to the amorphous phase cement-based material, based on the total final weight of the concrete.

The biomass may be a member of the group comprising: rice hulls, corn husks and manure.

In an embodiment, an ultra-stable cement-based material with a nano-molecular veneer comprises: 0.1 to 10 wt% based on the total final weight of the concrete of at least one surfactant added to the cementitious material to reduce the porosity of the aggregate and prevent the amorphous phase cementitious material from entering the pores of the aggregate.

The surfactant may be a detergent.

In an embodiment, an ultra-stable cement-based material with a nano-molecular veneer comprises: from 0.1 to 5% by weight of a redispersible powders polymer based on the total final weight of the concrete.

The redispersible powders polymer is selected from the group consisting of: silicon, polyurethane dispersions, polyurethanes, alkyl carboxylic acid vinyl ester monomers, branched and unbranched alcohol (meth) acrylate monomers, vinyl aromatic monomers, olefin monomers, diene monomers and vinyl halide monomers or vinyl acetate ethylene "VAE".

In an embodiment, an ultra-stable cement-based material with a nano-molecular veneer comprises: 0.1 to 5% by weight, based on the final total weight of the cement-based material, of an acrylic or Styrene Butadiene Rubber (SBR) added to the concrete at the same time as the addition of the redispersible powders polymer.

In an embodiment, an ultra-stable cement-based material with a nano-molecular veneer comprises: 0.1 to 15 wt% of a reinforcing material based on the total final weight of the concrete.

The reinforcing material includes at least one of: silica-containing chopped fibers; hemp-containing fibers; nano-molecular carbon fiber bundles; short-cut carbon fibers; chopped hydrocarbon fibers; and combinations thereof.

The aggregate comprises particles having a diameter of 1nm to 10mm based on the final total weight of the cement-based material.

The aggregate contains at least one of the following: wood, perlite, styrene-based foam beads, calcium carbonate powder, glass particles, and combinations thereof.

The cementitious material with aggregate is blended into the amorphous phase with 0.1 to 2 wt% of a reinforcing material based on the final total weight of the cementitious material.

The reinforcement material may be a non-woven or woven mat containing silica, a non-woven or woven mat containing hydrocarbons.

In other embodiments, the reinforcing material may be silica-containing chopped fibers; hemp-containing fibers; nano-molecular carbon fiber bundles; short-cut carbon fibers; chopped hydrocarbon fibers; and combinations thereof.

An amorphous phase cement-based material containing aggregate may be poured over the reinforcement material such that a portion of the amorphous phase cement-based material is capable of growing a plurality of crystals, each crystal having a MW in the range of 280 to 709, the amorphous phase cement-based material encapsulating the plurality of crystals.

Most stable materials with phosphorus-containing compounds can be consumed into the nanomolecular overlay while the surface area of the plurality of crystals increases by 2% to 49% during curing, and wherein the nanomolecular elements of the cured nanomolecular overlay are insoluble in water and the cured nanomolecular overlay protects the plurality of crystals of the formed cement-based material from degradation in water at a temperature of 20 ℃ to 60 ℃ for 24 hours to 56 days.

In embodiments of the cementitious material, 0.1 to 15 wt% of biomass based on the total final weight of the cementitious material may be added to the amorphous phase cementitious material.

In an embodiment of the cementitious material, 0.1 to 10 wt% of at least one surfactant, based on the final total weight of the cementitious material, is added to the cementitious material to reduce the porosity of the aggregates and prevent the amorphous phase cementitious material from entering the pores of the aggregates.

In embodiments of the cementitious material, 0.1 to 5% by weight of the redispersible powders polymer, based on the total final weight of the cementitious material, may be incorporated into the amorphous phase cementitious material.

In embodiments of the cement-based material, the redispersible powders polymer may be selected from the group consisting of: acrylic, silicon, polyurethane dispersions, polyurethanes, alkylcarboxylic acid vinyl ester monomers, branched and unbranched alcohol (meth) acrylate monomers, vinyl aromatic monomers, olefin monomers, diene monomers, and vinyl halide monomers.

In embodiments of the cementitious material, 0.1 to 5 weight percent of an acrylic or Styrene Butadiene Rubber (SBR) and a redispersible powders polymer, based on the total final weight of the cementitious material, may be blended into the amorphous cementitious material.

In embodiments of the cementitious-based material, 0.1 to 5 weight percent of a redispersible polymer powder, based on the total final weight of the cementitious-based material, may be added to the amorphous cementitious-based material, wherein the redispersible polymer powder is a member of the group consisting of: vinyl esters and ethylene, vinyl laurate vinyl chloride copolymers, vinyl ester monomers, (meth) acrylate monomers, vinyl aromatic monomers, olefin monomers, 1, 3-diene monomers, vinyl halide monomers, homopolymers or copolymers derived from one or more monomers selected from the group consisting of: vinyl acetate, vinyl esters of alpha-branched monocarboxylic acids having 9 to 11 carbon atoms, vinyl chloride, ethylene, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, propyl acrylate, propyl methacrylate, n-butyl acrylate, n-butyl methacrylate, 2-ethylhexyl acrylate.

The present invention relates to a building having an exterior building surface of cementitious material covered with the formulation of the independent claims of the present application.

FIG. 1A shows the steps of the present invention.

The method for manufacturing the cement-based building material comprises the following steps of 100: the gel phase is formed by blending together magnesium oxide and magnesium chloride in water.

Step 110 may involve adding at least one of the following to the gel phase while forming the amorphous phase: phosphorous acid and phosphoric acid.

Step 120 may entail adding 2 to 30 weight percent aggregate to the amorphous phase based on the total final weight of the cementitious building material.

Step 130 may involve crystallizing a portion of the amorphous phase into a plurality of crystals, thereby producing a nanomolecular element protruding from the plurality of crystals, encapsulating the plurality of crystals, forming a nanomolecular coating without detectable magnesium phosphate crystals, while increasing the surface area of the plurality of crystals by 2% to 49%, and wherein the nanomolecular element of the nanomolecular coating is insoluble in water and the nanomolecular coating protects the plurality of crystals from degradation in water at a predetermined temperature for a predetermined period of time.

In embodiments, the method of manufacturing a cementitious building material may include adding 0.1 wt% to 15 wt% of biomass to the gel phase based on the total final weight of the cementitious building material.

In embodiments, the method of making a cementitious building material may involve adding 0.1 to 5 wt% of a dispersible polymer to the gel phase based on the total final weight of the cementitious building material.

Figure 1B depicts the steps required to manufacture a tile backing plate.

Step 200 may comprise forming 35 wt% to 79.9 wt% of the cement-based material based on the total final weight of the tile backing plate.

Step 201 may involve blending 29 wt% to 40 wt% of a dry powder of magnesium oxide containing 80 wt% to 98 wt% of magnesium oxide, based on the final total weight of the cementitious material, into 14 wt% to 18 wt% of magnesium chloride dissolved in water, based on the final total weight of the cementitious material.

Step 202 may involve mixing magnesium oxide and magnesium chloride in water with a planetary mixer to form a liquid suspension while minimizing the addition of gases to the liquid suspension.

Step 204 may involve adding 0.1 wt% to 10 wt% of a stabilizing material having a phosphorus-containing compound to the mixed liquid suspension, based on the final total weight of the cementitious material.

Step 206 may involve reacting the mixed liquid suspension to an amorphous phase cement-based material within a predetermined unit time.

Step 208 may involve blending 0.1 wt% to 30 wt%, based on the final total weight of the tile backing plate, of aggregate comprising particles having a diameter of 1nm to 10mm into the amorphous phase cement-based material, wherein the aggregate comprises at least one of: wood, perlite, styrene-based foam beads, calcium carbonate powder, glass particles, and combinations thereof.

Step 210 may involve pouring flowable concrete onto 0.1 wt% to 2 wt% of a reinforcing material based on the total final weight of the tile backing plate to form a reinforced concrete.

Step 212 may involve forming a plurality of crystals of a defined molecular weight from the amorphous non-crystalline nanomolecular cement-based material encapsulating the plurality of crystals in a portion of the amorphous phase cement-based material within a predetermined unit time, resulting in a nanomolecular veneer that is free of detectable phosphorous-containing compounds, while increasing the surface area of the plurality of crystals.

Step 214 may include testing the stability of the resulting tile backing board in 60 ℃ water over 24 hours using Jet Products, LLC warm water stability test, as certified by the college of chemsen Chemical Engineering Department in 2017.

Fig. 1C depicts other steps used in the manufacture of cement-based materials in conjunction with the embodiment of fig. 1A.

FIG. 1C depicts:

step 220 may include adding 0.1 wt% to 15 wt% of biomass to the amorphous phase cement-based material based on the final total weight of the tile backing board.

Step 222 may comprise adding 0.1 to 10 wt%, based on the final total weight of the tile backing board, of at least one surfactant added to the cement-based material to reduce the porosity of the aggregate and prevent the amorphous phase cement-based material from entering the pores of the aggregate.

Step 224 may include adding 0.1 to 5 weight percent redispersible powder polymer to the amorphous phase cement-based material based on the total final weight of the tile backing board.

Step 226 may include blending 0.1 to 5 wt% of acrylic or Styrene Butadiene Rubber (SBR) with a redispersible powders polymer into the amorphous cement-based material, based on the final total weight of the tile backing board.

Figure 1D shows the steps of another embodiment of manufacturing a cementitious material.

Step 250 may include forming 55 wt% to 99.8 wt% of a cement-based material based on the total final weight of the tile backing board.

Step 252 may include forming 55 wt% to 99.8 wt% of the cementitious material by: blending 29 wt% to 40 wt%, based on the total final weight of the cementitious material, of a dry powder of magnesium oxide containing 80 wt% to 98 wt% of magnesium oxide with 14 wt% to 18 wt%, based on the total final weight of the cementitious material, of magnesium chloride dissolved in water to form a liquid suspension.

Step 254 may involve adding 0.1 wt% to 10 wt% of the stabilizing material with the phosphorus-containing compound to the liquid suspension, based on the final total weight of the cementitious material.

Step 256 may include reacting the liquid suspension to an amorphous phase cement-based material for a predetermined period of time.

Step 258 can involve adding 0.1 wt% to 30 wt% aggregate to the amorphous phase cement-based material based on the total weight of the tile backing board.

Step 260 may involve adding 0.1 to 15 wt% of a reinforcing material to the amorphous phase cement-based material based on the final total weight of the tile backing plate, wherein the reinforcing material is at least one of: silica-containing chopped fibers; hemp-containing fibers; nano-molecular carbon fiber bundles; short-cut carbon fibers; chopped hydrocarbon fibers; and combinations thereof.

Step 262 may involve growing a plurality of crystals from a portion of the amorphous phase cement-based material, each crystal having a MW in the range of 283 to 709, the amorphous phase cement-based material encapsulating the plurality of crystals, wherein a majority of the stabilizing material with the phosphorus-containing compound is consumed into the nanomolecular overlay while the surface area of the plurality of crystals increases by 2% to 49% during curing, and wherein the nanomolecular elements of the cured nanomolecular overlay are insoluble in water and the cured nanomolecular overlay protects the plurality of crystals of the formed tile backing plate from degradation in water at a temperature of 20 ℃ to 60 ℃ for 24 hours to 56 days.

In embodiments, the cement-based building material may produce a nanomolecular coating with a thickness of 1 to 3 microns.

In an embodiment, the cementitious building material may be used to produce a cementitious building material configured to support a load of at least 2.5 pounds per square foot.

In embodiments, the cementitious building material produces a product that can be used to create a home, office, warehouse, shed, dock, art, ditch, or other load-bearing support structure.

In embodiments, the water may be a brine or similar salt solution having a concentration of 2% to 30% salt.

In embodiments, the cementitious building material may contain fibers.

In a variation of the cement-based building material, other substrates may be introduced and coated with the cement-based building material with oriented strand board, plywood, waterproofing membrane, concrete and wood, and with the amorphous phase to increase fire resistance and hot water stability, before crystallizing the amorphous phase.

The cementitious building material may include at least one surfactant added to the amorphous phase to reduce the porosity of the aggregate and prevent the amorphous phase from entering the pores of the aggregate.

The surfactant may be any molecule that reduces the surface porosity of the aggregate used in the cement.

In embodiments, the amorphous phase may be crystallized using a temperature of 40 ℃ to 50 ℃ over a period of 3 to 24 hours at a relative humidity of 30% to 100%.

In embodiments, the cementitious building material may be formed using an exothermic reaction (e.g., 10 to 15 degrees of heat generated over the duration of the reaction).

In embodiments, the cementitious building material gel phase may be formed using fine mixing for at least 3 minutes prior to adding the aggregate.

Figure 2 shows the diffractogram of the cured sample generated from X-ray diffraction at 28 ℃. The main 5 phase peaks are marked. The four upper quadrants are phosphoric acid post-treatment and the lower quadrants are phosphoric acid pre-treatment.

The importance of this figure 2 is the area under the peak.

Ceramic tile back lining board

The present invention relates to a tile backer board formulation.

The tile backer board can be formed from 35 wt% to 79.9 wt% of a cement-based material, based on the total final weight of the tile backer board.

The cementitious material may be manufactured from 29 to 40 wt% of a dry powder of magnesium oxide containing 80 to 98 wt% of magnesium oxide, based on the total final weight of the cementitious material.

The surface area of the magnesium oxide may be between 5 meters²Per gram to 50 m²In the range of/gram and having an average particle size in the range of about 0.3 microns to about 90 microns, wherein greater than about 90 weight percent of the magnesium oxide particles are less than or equal to about 40 microns.

The cementitious material may be manufactured by mixing 14 wt% to 18 wt% of magnesium chloride dissolved in water with dry magnesium oxide powder based on the final total weight of the cementitious material.

The magnesium chloride in aqueous solution form may have a 20 wt% to 30 wt% aqueous magnesium chloride solution in which magnesium oxide and magnesium chloride in water react to form a liquid suspension.

The cementitious material may include 0.1 wt% to 10 wt% of the stabilizing material with the phosphorus-containing compound based on the total final weight of the cementitious material.

When mixed with the liquid suspension, the mixture reacts to form an amorphous phase cement-based material.

The cement-based material is blended from 0.1 wt% to 30 wt% aggregate into the amorphous phase.

The aggregate may comprise particles having a diameter of 1nm to 10mm, based on the final total weight of the tile backing plate.

The aggregate may contain at least one of the following: wood, perlite, styrene-based foam beads, calcium carbonate powder, glass particles, and combinations thereof.

The cement-based material with aggregate is blended into the amorphous phase from 0.1 to 2 wt% of reinforcing material based on the final total weight of the tile backing board.

The reinforcement material may be a non-woven or woven mat containing silica, a non-woven or woven mat containing hydrocarbons.

In other embodiments, the reinforcement material may be silica-containing chopped fibers, hemp-containing fibers, nano-molecular carbon fiber bundles, chopped carbon fibers, chopped hydrocarbon fibers, and combinations thereof.

The amorphous phase cement-based material containing the aggregate is poured over the reinforcement material such that a portion of the amorphous phase cement-based material is capable of growing a plurality of crystals, each crystal having a MW that may be in the range of 280 to 709, the amorphous phase cement-based material encapsulating the plurality of crystals.

Most of the stabilizing material with a phosphorous containing compound can be consumed into the nanomolecular overlay while the surface area of the plurality of crystals increases by 2% to 49% during curing, and wherein the nanomolecular elements of the cured nanomolecular overlay are insoluble in water and the cured nanomolecular overlay protects the plurality of crystals of the formed tile backing plate from degradation in water at a temperature of 20 ℃ to 60 ℃ for 24 hours to 56 days.

In an embodiment of the tile backing board, 0.1 to 15 wt% of biomass based on the final total weight of the tile backing board is added to the amorphous phase cement-based material.

In an embodiment of the tile backing plate, 0.1 to 10 wt%, based on the final total weight of the tile backing plate, of at least one surfactant is added to the cement-based material to reduce the porosity of the aggregate and prevent the amorphous phase cement-based material from entering the pores of the aggregate.

In an embodiment of the tile backing board, 0.1 to 5% by weight of redispersible powder polymer, based on the final total weight of the tile backing board, can be incorporated into the amorphous phase cement-based material.

In embodiments of the tile backing plate, the redispersible powders polymer may be selected from the group consisting of: acrylic, silicon, polyurethane dispersions, polyurethanes, alkylcarboxylic acid vinyl ester monomers, branched and unbranched alcohol (meth) acrylate monomers, vinyl aromatic monomers, olefin monomers, diene monomers, and vinyl halide monomers.

In an embodiment of the tile backing board, 0.1 to 5% by weight of acrylic or Styrene Butadiene Rubber (SBR) based on the total final weight of the tile backing board may be blended with a redispersible powders polymer into the amorphous cement-based material.

In an embodiment of the tile backing plate, 0.1 to 5 wt% based on the final total weight of the tile backing plate of a redispersible polymer powder may be added to the amorphous cement-based material, wherein the redispersible polymer powder is a member of the group consisting of: vinyl esters and ethylene, vinyl laurate vinyl chloride copolymers, vinyl ester monomers, (meth) acrylate monomers, vinyl aromatic monomers, olefin monomers, 1, 3-diene monomers, vinyl halide monomers, homopolymers or copolymers derived from one or more monomers selected from the group consisting of: vinyl acetate, vinyl esters of alpha-branched monocarboxylic acids having 9 to 11 carbon atoms, vinyl chloride, ethylene, methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, propyl acrylate, propyl methacrylate, n-butyl acrylate, n-butyl methacrylate, 2-ethylhexyl acrylate.

The present invention relates to a building having an internal building surface covered with a tile backer board covered with the formulation of the independent claim of the present application.

Method for manufacturing ceramic tile backer board

The method involves blending 35 to 79.9 wt%, based on the total final weight of the tile backing plate, of the formed cement-based material with 0.1 to 30 wt%, based on the total final weight of the tile backing plate, of an aggregate comprising particles having a diameter of 1nm to 10mm, wherein the aggregate comprises at least one of: wood, perlite, styrene-based foam beads, calcium carbonate powder, glass particles, and combinations thereof, thereby forming concrete.

The process continues by pouring concrete onto 0.1 to 2% by weight, based on the final total weight of the tile backing plate, of a reinforcing material comprising a non-woven or woven mat containing silica, a non-woven or woven mat containing hydrocarbons, and curing into a tile backing plate.

A portion of the amorphous phase cement-based material grows a plurality of crystals, each crystal having a MW in the range of 280 to 709, the amorphous phase cement-based material encapsulates the plurality of crystals, wherein a majority of the stabilizing material with the phosphorus-containing compound is consumed into the nanomolecular overlay while the surface area of the plurality of crystals increases by 2% to 49% during curing, and wherein the nanomolecular elements of the cured nanomolecular overlay are insoluble in water and the cured nanomolecular overlay protects the plurality of crystals of the formed tile backing plate from degradation in water at a temperature of 20 ℃ to 60 ℃ for 24 hours to 56 days.

The method involves adding 0.1 to 15 wt% biomass added to the amorphous phase cement-based material based on the final total weight of the tile backing board and mixing for 3 to 10 minutes.

Biomass is a member of the group comprising: rice hulls, corn husks and manure.

The method comprises adding 0.1 to 10 wt%, based on the final total weight of the tile backing plate, of at least one surfactant to the cement-based material to reduce the porosity of the aggregate and prevent the amorphous phase cement-based material from entering the pores of the aggregate.

The surfactant may be a detergent.

The process may involve the addition of 0.1 to 5 wt% redispersible powder polymer incorporated in an amorphous phase cement-based material based on the final total weight of the tile backing board and mixing for 3 to 10 minutes.

The redispersible powders polymer may be selected from the group consisting of: silicon, polyurethane dispersions, polyurethanes, alkyl carboxylic acid vinyl ester monomers, branched and unbranched alcohol (meth) acrylate monomers, vinyl aromatic monomers, olefin monomers, diene monomers and vinyl halide monomers or vinyl acetate ethylene "VAE".

The method may comprise adding 0.1 to 5 wt% of acrylic or Styrene Butadiene Rubber (SBR) to the amorphous cement-based material based on the total final weight of the tile backing board, while adding the redispersible powder polymer.

The invention includes an interior building surface covered with a tile backer board made by the method.

Another embodiment of the method of manufacturing a tile backer board involves forming a cement-based material by blending 29 wt% to 40 wt%, based on the total final weight of the cement-based material, of a dry powder of magnesium oxide containing 80 wt% to 98 wt% of magnesium oxide with 14 wt% to 18 wt%, based on the total final weight of the cement-based material, of magnesium chloride dissolved in water.

The magnesium oxide reacts with magnesium chloride in water to form a liquid suspension.

The next step involves mixing the liquid suspension for 2 to 10 minutes while minimizing the addition of gas to the liquid suspension, and then adding 0.1 to 10 wt% of a stabilizing material having a phosphorus-containing compound to the liquid suspension, based on the final total weight of the cementitious material.

In this form of the method, the liquid suspension with the stabilising material reacts into the amorphous phase cement-based material over a period of 1 to 4 minutes.

The method comprises blending 35 to 79.9 wt% of the formed amorphous phase cement-based material based on the total final weight of the tile backing plate with 0.1 to 30 wt% of an aggregate comprising particles having a diameter of 1nm to 10mm based on the total weight of the tile backing plate, wherein the aggregate comprises at least one of wood, perlite, styrene-based foam beads, calcium carbonate powder, and combinations thereof.

The next step involves mixing 0.1 to 15 wt% of a reinforcing material based on the final total weight of the tile backing plate, the reinforcing material comprising at least one of: silica-containing chopped fibers, hemp-containing fibers; nano-molecular carbon fiber bundles; short-cut carbon fibers; chopped hydrocarbon fibers; and combinations thereof.

A portion of the amorphous phase cement-based material grows a plurality of crystals, each having a MW in the range of 283 to 709, the amorphous phase cement-based material encapsulates the plurality of crystals, wherein a majority of the stabilizing material with the phosphorus-containing compound is consumed into the nanomolecular overlay while the surface area of the plurality of crystals increases by 2% to 49% during curing, and wherein the nanomolecular elements of the cured nanomolecular overlay are insoluble in water and the cured nanomolecular overlay protects the plurality of crystals of the formed tile backing plate from degradation in water at a temperature of 20 ℃ to 60 ℃ for 24 hours to 56 days.

The method involves adding 0.1 to 15 wt% biomass added to the amorphous phase cement-based material, based on the total final weight of the tile backing board, wherein the biomass is a member of the group comprising: rice hulls, corn husks and manure.

Examples

Example 1

The method of making a cement-based building cementitious material follows:

the method produces a cement-based material having a 78% crystalline fraction and 12% amorphous nanomolecular coating that is substantially free of crystalline silica.

To produce a cement-based material, a gel phase was first formed by blending together magnesia powder having a purity of 85% by weight and magnesium chloride in brine having a density of 1.26.

Magnesium oxide was blended with magnesium chloride in a weight ratio of 2:1 based on the final total weight of the cementitious building material.

Then, 20 wt% of the aggregate of the wood was added to the gel phase, forming an amorphous phase.

To the amorphous phase 5 wt% phosphoric acid based on the final total weight of the cement based building material was added.

To complete the formation of the cement-based material, 65% of the amorphous phase was crystallized by extruding it between two layers of fiberglass on a carrier sheet. The sandwich-like material was cured at 45-55 ℃ for 12-24 hours at a relative humidity of greater than 55% to produce a panel with a thickness of 12 mm.

A nanomolecular overlay was formed on the crystalline portion with an overlay thickness of 1 micron encapsulating the portion of the crystalline portion but not producing detectable magnesium phosphate. The surface area of the nanomolecular overlay was increased by 30% compared to the non-overlay crystalline fraction.

The final crystalline portion with the nanomolecular facing was configured to resist degradation in water at a temperature of 60 ℃ for 48 hours.

Example 2

70% by weight of the cementitious material is used to form the cementitious material.

The cementitious material had 34 wt% dry powder of magnesium oxide containing 85 wt% pure magnesium oxide based on the total final weight of the cementitious material.

The new cement-based material was formed by combining 34 wt% of dry powder of magnesium oxide containing 85 wt% purity magnesium oxide, based on the total final weight of the cement-based material.

The surface area of the magnesium oxide used is between 5 m²Per gram to 50 m²In the range of/gram and having an average particle size in the range of about 0.3 to about 90 microns, wherein greater than about 90 weight percent of the magnesium oxide particles are less than or equal to about 40 microns.

16 wt% magnesium chloride based on the final total weight of the cement-based material is dissolved in water. The magnesium chloride in aqueous solution is: 29 wt% aqueous magnesium chloride solution. The magnesium oxide reacts with magnesium chloride in water to form a liquid suspension.

Then 1.3 wt% of the stabilizing material with the phosphorous containing compound based on the final total weight of the cementitious material is mixed with the liquid suspension and the mixture is reacted to amorphous phase cementitious material.

The stabilizing material with the phosphorus-containing compound is phosphoric acid (B) based on the final total weight of the cement-based material, wherein the phosphoric acid consists of 85 wt% of H₃PO₄Aqueous solution composition of concentrate. The mixture reacts to form an amorphous phase cement-based material.

The amorphous phase cement-based material grows a plurality of crystals, each having a MW of 530, thereby producing a nano-molecular element protruding from the plurality of crystals, encapsulating the plurality of crystals, wherein a majority of the stabilizing material having the phosphorus-containing compound is consumed into the non-molecular veneer while the surface area of the plurality of crystals increases by 49%, and wherein the nano-molecular element of the nano-molecular veneer is insoluble in water and the nano-molecular veneer protects the plurality of crystals forming the cement-based material from degradation in water at 60 ℃ for 24 hours.

Example 3

The cementitious material of this example had 35 wt% dry powder of magnesium oxide containing 80 wt% pure magnesium oxide based on the total final weight of the cementitious material.

Magnesium chloride dissolved in water at 15 wt% based on the final total weight of the cement-based material was mixed with magnesium oxide.

In this example, the magnesium chloride in the form of an aqueous solution was a 27 wt% aqueous magnesium chloride solution. Magnesium oxide and magnesium chloride in water are mixed and reacted to form a liquid suspension.

2.5 wt% based on the final total weight of the cementitious material of the stabilising material with the phosphorus containing compound is mixed with the liquid suspension and the mixture is reacted to an amorphous phase cementitious material, the stabilising material with the phosphorus containing compound containing phosphorous acid (a) based on the final total weight of the cementitious material. Phosphorous acid from 60 wt% H₃PO₃Aqueous solution composition of concentrate.

A portion of the amorphous phase cement-based material grows a plurality of crystals, each resulting in a MW of 283, 413, 530, or 709, thereby producing a nano-molecular element protruding from the plurality of crystals, encapsulating the plurality of crystals.

Most of the phosphorus-containing compound from the stabilizing material with the phosphorus-containing compound is consumed into the non-molecular facer while the surface area of the plurality of crystals increases by 2% to 49%.

The nanometer molecular elements of the nanometer molecular veneers are insoluble in water and serve as cement-based materials, and the nanometer molecular veneers protect the plurality of crystals from being degraded in water at 60 ℃ for 24 hours.

Figures 3A-3H show a number of samples of cement-based material formulations and their associated physical properties.

Sample 1 contained 29 wt% dry powder of magnesium oxide based on the final total weight of the cement-based material used. The dry magnesium oxide powder contained 85 wt% pure magnesium oxide.

The magnesium oxide was blended with 14 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 1, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

For this sample, the next step involved adding 0.1 wt% of stabilizing material with a phosphorus-containing compound to the mixed liquid suspension, based on the final total weight of the cementitious material.

For sample 1, the stabilizing material with the phosphorus-containing compound was phosphorous acid based on the final total weight of the cement-based material, where phosphorous acid was composed of 60 wt% of H₃PO₃Aqueous solution composition of concentrate.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

The flowable uncured cement-based material is then poured onto a mold to cure and form the cement.

For this sample 1, a portion of the amorphous phase cement-based material formed multiple crystals, each referred to as a "magnesium oxychloride cement crystal," having a MW of 530.7, wherein the amorphous, noncrystalline, nanomolecular cement-based material encapsulated multiple crystals, thereby creating a nanomolecular overlay free of detectable phosphorus-containing compounds, as well asThe surface area of the plurality of crystals is increased by 2 to 20m²/g。

The cured material of sample 1 formed a cement-based material that was stabilized in water at 60 ℃ for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample 2

Sample 2 contained 40 wt% of dry magnesia powder containing 85 wt% of magnesia, based on the final total weight of the cement-based material used.

The magnesium oxide was blended with 18 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 2, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

For this example, the next step involves adding 10 wt% of the stabilizing material with the phosphorus-containing compound to the mixed liquid suspension, based on the final total weight of the cementitious material.

For sample 2, the stabilizing material with the phosphorus-containing compound was phosphoric acid based on the final total weight of the cement-based material, where the phosphoric acid was from 80 wt% to 90 wt% H₃PO₄Aqueous solution composition of concentrate.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

The flowable uncured cement-based material is then poured onto a mold and cured to form the cement.

For this sample 2, a portion of the amorphous phase cement-based material formed multiple crystals, each of which was referred to as a "magnesium oxychloride cement crystal," MW 530.7, wherein the amorphous phase was amorphousThe nanomolecular cement-based material encapsulates the plurality of crystals, thereby creating a nanomolecular veneer that is free of detectable phosphorous-containing compounds, while the surface area of the plurality of crystals increases by 49% to 29m²/g。

The cured material of sample 2 formed a cement-based material that was stabilized in water at 60 ℃ for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample 3

Sample 3 contained 32 wt% of dry magnesia powder containing 85 wt% of magnesia, based on the final total weight of the cement-based material used.

The magnesium oxide was blended with 17 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 3, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

For this example, the next step involves adding 0.1 wt% of a stabilizing material having a phosphorus-containing compound to the mixed liquid suspension, based on the total final weight of the cementitious material.

For sample 3, the stabilizing material with the phosphorus-containing compound was phosphoric acid based on the final total weight of the cement-based material, where the phosphoric acid was from 80 wt% to 90 wt% H₃PO₄Aqueous solution composition of concentrate.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

The reinforcing component is a non-woven mat containing silica. The reinforcing component is 0.1 wt% based on the total final weight of the cementitious material.

For this sample 3, it is indefiniteForming a portion of the phase-forming cement-based material into a plurality of crystals, each of the crystals being referred to as a "magnesium oxychloride cement crystal," having a MW of 530.7, wherein the amorphous, noncrystalline, nanomolecular cement-based material encapsulates the plurality of crystals, thereby creating a nanomolecular veneer that is free of detectable phosphorus-containing compounds, while increasing the surface area of the plurality of crystals by 2% to 20m²/g。

The cured material of sample 3 formed a cement-based material that was stabilized in water at 60 ℃ for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample No. 4

Sample 4 contained 31 wt% of dry magnesia powder containing 85 wt% of magnesia, based on the final total weight of the cement-based material used.

The magnesium oxide was blended with 16 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 4, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

For this sample, the next step involved adding 1 wt% of stabilizing material with a phosphorus-containing compound to the mixed liquid suspension, based on the final total weight of the cementitious material.

For sample 4, the stabilizing material with the phosphorus-containing compound was phosphoric acid based on the final total weight of the cement-based material, where the phosphoric acid was from 80 wt% to 90 wt% H₃PO₄Aqueous solution composition of concentrate.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

The reinforcing component is 2 wt% of chopped silica fibers based on the total final weight of the cement-based material.

For this sample 4, a portion of the amorphous phase cement-based material formed multiple crystals, each referred to as a "magnesium oxychloride cement crystal," having a MW of 530.7, wherein the amorphous non-crystalline nanomolecular cement-based material encapsulated the multiple crystals, thereby creating a nanomolecular veneer free of detectable phosphorus-containing compounds, while the surface area of the multiple crystals increased by 23% to 24m²/g。

The cured material of sample 4 formed a cement-based material that was stabilized in water at 60 ℃ for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample No. 5

Sample 5 contained 32.5 wt% of dry magnesia powder containing 85 wt% of magnesia, based on the final total weight of the cement-based material used.

The magnesium oxide was blended with 17.5 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 5, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

For this example, the next step involved adding 1.75 wt% of the stabilizing material with the phosphorus-containing compound to the mixed liquid suspension, based on the total final weight of the cementitious material.

For sample 5, the stabilizing material with the phosphorus-containing compound was phosphoric acid based on the final total weight of the cement-based material, where the phosphoric acid was from 80 wt% to 90 wt% H₃PO₄Aqueous solution composition of concentrate.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

Sample 5 contained 0.1 wt% of an aggregate component called wood perlite: styrene based foam beads (ratio 30:8:1) based on the final total weight of the cementitious material, which was added to the amorphous phase cementitious material to form a flowable concrete.

The flowable uncured concrete is then poured over the mold and cured to produce the finished concrete.

For this sample 5, a portion of the amorphous phase cement-based material formed multiple crystals, each referred to as a "magnesium oxychloride cement crystal," having a MW of 530.7, wherein the amorphous non-crystalline nanomolecular cement-based material encapsulated the multiple crystals, thereby creating a nanomolecular veneer free of detectable phosphorus-containing compounds, while the surface area of the multiple crystals increased by more than 38% to 27m²/g。

The cured material of sample 5 formed a cement-based material that was stabilized in water at 60 ℃ for 24 hours using Jet Products, llc.

Sample No. 6

Sample 6 contained 33 wt% of dry magnesia powder containing 85 wt% of magnesia, based on the final total weight of the cement-based material used.

The magnesium oxide was blended with 18 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 6, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

For this example, the next step involved adding 2.5 wt% of the stabilizing material with the phosphorus-containing compound to the mixed liquid suspension, based on the final total weight of the cementitious material.

For sample 6, the stabilizing material with the phosphorus-containing compound was phosphoric acid based on the final total weight of the cement-based material, where the phosphoric acid was from 80 wt% to 90 wt% H₃PO₄Aqueous solution composition of concentrate.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

Sample 6 contained 30 wt% wood to perlite to styrene based foam bead aggregate component based on the total final weight of the cementitious material in a ratio of 30:8:1, which was added to the amorphous phase cementitious material to form a flowable concrete.

The flowable uncured concrete is then poured into a mold and cured to produce the finished concrete.

For this sample 6, a portion of the amorphous phase cement-based material formed multiple crystals, each referred to as a "magnesium oxychloride cement crystal," having a MW of 530.7, wherein the amorphous non-crystalline nanomolecular cement-based material encapsulated the multiple crystals, thereby producing a nanomolecular veneer free of detectable phosphorus-containing compounds, while the surface area of the multiple crystals increased by more than 49% to 29m²/g。

The cured material of sample 6 formed a cement-based material that was stabilized in water at 60 ℃ for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample 7

Sample 7 contained 33 wt% of dry magnesia powder containing 85 wt% of magnesia, based on the final total weight of the cement-based material used.

The magnesium oxide was blended with 19 wt% magnesium chloride dissolved in water based on the final total weight of the cement-based material.

For sample 7, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

For this example, the next step involved adding 3.75 wt% of the stabilizing material with the phosphorus-containing compound to the mixed liquid suspension, based on the total final weight of the cementitious material.

For sample 7, the stabilizing material with the phosphorus-containing compound was phosphoric acid based on the final total weight of the cement-based material, where the phosphoric acid was from 80 wt% to 90 wt% H₃PO₄Aqueous solution composition of concentrate.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

Sample 7 contained 0.1 wt% biomass based on the total final weight of the cement-based material. The biomass of this sample was rice hulls.

For this sample 7, a portion of the amorphous phase cement-based material formed multiple crystals, each referred to as a "magnesium oxychloride cement crystal," having a MW of 530.7, wherein the amorphous non-crystalline nanomolecular cement-based material encapsulated the multiple crystals, thereby producing a nanomolecular veneer free of detectable phosphorus-containing compounds, while the surface area of the multiple crystals increased by 49% to 29m²/g。

The cured material of sample 7 formed a cement-based material that was stabilized in water at 60 ℃ for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample 8

Sample 8 contained 32 wt% of dry magnesia powder containing 85 wt% of magnesia, based on the final total weight of the cement-based material used.

The magnesium oxide was blended with 17 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 7, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

For this example, the next step involved adding 5 wt% of the stabilizing material with the phosphorus-containing compound to the mixed liquid suspension, based on the final total weight of the cementitious material.

For sample 8, the stabilizing material with the phosphorus-containing compound was phosphoric acid based on the final total weight of the cement-based material, where the phosphoric acid was from 80 wt% to 90 wt% H₃PO₄Aqueous solution composition of concentrate.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

Sample 8, which contained 15 wt% biomass based on the total final weight of the cementitious material, was added to an amorphous phase cementitious material to form a flowable concrete. The biomass is corn husks.

The flowable uncured concrete is then poured into a mold, and the finished material forms the concrete.

For this sample 8, a portion of the amorphous phase cement-based material formed multiple crystals, each referred to as a "magnesium oxychloride cement crystal," having a MW of 530.7, wherein the amorphous non-crystalline nanomolecular cement-based material encapsulated the multiple crystals, thereby creating a nanomolecular veneer free of detectable phosphorus-containing compounds, while the surface area of the multiple crystals increased by more than 44% to 28m²/g。

The cured material of sample 8 formed a cement-based material that was stabilized in water at 60 ℃ for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample 9

Sample 9 contained 35 wt% of dry magnesia powder containing 85 wt% magnesia, based on the final total weight of the cementitious material used.

The magnesium oxide was blended with 16 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 9, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

For this example, the next step involved adding 6.25 wt% of the stabilizing material with the phosphorus-containing compound to the mixed liquid suspension, based on the total final weight of the cementitious material.

For sample 9, the stabilizing material with the phosphorus-containing compound was phosphoric acid based on the final total weight of the cement-based material, where the phosphoric acid was from 80 wt% to 90 wt% H₃PO₄Aqueous solution composition of concentrate.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

(i) A certain weight% of a surfactant (i.e. a detergent) based on the total final weight of the cementitious material is added to the amorphous phase cementitious material.

The flowable uncured concrete is then poured into a mold to form the finished concrete.

For this sample 9, a portion of the amorphous phase cement-based material formed multiple crystals, each referred to as a "magnesium oxychloride cement crystal," having a MW of 530.7, wherein the amorphous non-crystalline nanomolecular cement-based material encapsulated the multiple crystals, thereby producing a nanomolecular veneer free of detectable phosphorus-containing compounds, while the surface area of the multiple crystals increased by 23% to 24m²/g。

The cured material of sample 9 formed a cement-based material that was stabilized in water at 60 ℃ for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample 10

Sample 10 contained 30 wt% dry powder magnesium oxide containing 85 wt% magnesium oxide based on the final total weight of the cementitious material used.

The magnesium oxide was blended with 18 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 10, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

For this example, the next step involved adding 7.5 wt% of the stabilizing material with the phosphorus-containing compound to the mixed liquid suspension, based on the final total weight of the cementitious material.

For sample 10, the stabilizing material with the phosphorus-containing compound was phosphoric acid based on the final total weight of the cement-based material, where the phosphoric acid was from 80 wt% to 90 wt% H₃PO₄Aqueous solution composition of concentrate.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

Sample 10 contained 10 wt% sodium stearate, based on the total final weight of the cementitious material, as a surfactant that was added to the amorphous phase cementitious material to form a flowable concrete.

The flowable uncured concrete is then poured into a mold to form the finished concrete.

For this sample 10, a portion of the amorphous phase cement-based material formed multiple crystals, each crystalReferred to as "magnesium oxychloride cement crystals", MW 530.7, wherein the amorphous nanomolecular cement-based material encapsulates a plurality of crystals, thereby creating a nanomolecular coating free of detectable phosphorus-containing compounds, while the surface area of the plurality of crystals increases by more than 38% to 27m²/g。

The cured material of sample 10 formed a cement-based material that was stabilized in water at 60 ℃ for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample 11

Sample 11 contained 33 wt% of dry magnesia powder containing 85 wt% magnesia, based on the final total weight of the cementitious material used.

The magnesium oxide was blended with 15 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 11, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

For this example, the next step involved adding 8.75 wt% of the stabilizing material with the phosphorus-containing compound to the mixed liquid suspension, based on the total final weight of the cementitious material.

For sample 11, the stabilizing material with the phosphorus-containing compound was phosphoric acid based on the final total weight of the cement-based material, where the phosphoric acid was from 80 wt% to 90 wt% H₃PO₄Aqueous solution composition of concentrate.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

(i) A certain weight percent of a redispersible polymer, i.e. Vinyl Acetate Ethylene (VAE), based on the total final weight of the cementitious material, is added to the amorphous phase cementitious material.

The flowable uncured concrete is then poured into a mold to form the finished concrete.

For this sample 11, a portion of the amorphous phase cement-based material formed multiple crystals, each referred to as a "magnesium oxychloride cement crystal," having a MW of 530.7, wherein the amorphous non-crystalline nanomolecular cement-based material encapsulated the multiple crystals, thereby producing a nanomolecular veneer free of detectable phosphorus-containing compounds, while the surface area of the multiple crystals increased by more than 49% to 29m²/g。

The cured material of sample 11 formed a cement-based material that was stabilized in water at 60 ℃ for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample 12

Sample 12 contained 32 wt% of dry magnesia powder containing 85 wt% magnesia, based on the final total weight of the cementitious material used.

The magnesium oxide was blended with 19 wt% magnesium chloride dissolved in water based on the final total weight of the cement-based material.

For sample 12, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

For sample 12, the stabilizing material with the phosphorus-containing compound was phosphoric acid based on the final total weight of the cement-based material, where the phosphoric acid was from 80 wt% to 90 wt%H₃PO₄Aqueous solution composition of concentrate.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

Sample 12 contained 5 wt% vinyl acetate ethylene based on the total final weight of the cementitious material, which was added to the amorphous phase cementitious material to form a flowable concrete.

The flowable uncured concrete is then poured into a mold to form the finished concrete.

For this sample 12, a portion of the amorphous phase cement-based material formed multiple crystals, each referred to as a "magnesium oxychloride cement crystal," having a MW of 530.7, wherein the amorphous non-crystalline nanomolecular cement-based material encapsulated the multiple crystals, thereby producing a nanomolecular veneer free of detectable phosphorus-containing compounds, while the surface area of the multiple crystals increased by 49% to 29m²/g。

The cured material of sample 12 formed a cement-based material that was stabilized in water at 60 ℃ for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Example 4

The method for manufacturing the cement-based building tile backer board follows:

this process produced a tile backing plate with 78% crystalline fraction and 12% amorphous nanomolecular finish substantially free of crystalline silica.

To produce a tile backing board, the gel phase was first formed by blending together magnesium oxide powder of 85% purity by weight and magnesium chloride in saline having a density of 1.26.

Magnesium oxide was blended with magnesium chloride in a weight ratio of 2:1 based on the final total weight of the cementitious building material.

Then, 20 wt% of the aggregate of the wood was added to the gel phase, forming an amorphous phase.

To the amorphous phase 5 wt% phosphoric acid based on the final total weight of the cement based building material was added.

To complete the formation of the tile backing sheet, 65% of the amorphous phase was crystallized by extruding it between two layers of fiberglass on a carrier sheet. The sandwich-like material was cured at 45-55 ℃ for 12-24 hours at a relative humidity of greater than 55% to produce a panel with a thickness of 12 mm.

The final crystalline portion with the nanomolecular facing was configured to resist degradation in water at a temperature of 60 ℃ for 48 hours.

Example 5

A tile backer board was formed using 70 wt% cement-based material.

The cementitious material had 34 wt% dry powder of magnesium oxide containing 85 wt% pure magnesium oxide based on the total final weight of the cementitious material.

Then 14 wt% of aggregate containing particles with a diameter of 1nm to 10mm is added to the amorphous phase cement-based material.

The aggregate contains perlite.

In addition, 1.5 wt% of reinforcing material based on the total weight of the tile backing plate formed was used.

The reinforcing material is a woven mat containing silica.

Pouring an amorphous phase cement-based material containing aggregate over the reinforcement material such that a portion of the amorphous phase cement-based material is capable of growing a plurality of crystals, each having a MW of 530, thereby producing a nanomolecular element protruding from the plurality of crystals, encapsulating the plurality of crystals, wherein a majority of the stabilizing material with a phosphorous-containing compound is consumed into the non-molecular veneer while the surface area of the plurality of crystals is increased by 49%, and wherein the nanomolecular element of the nanomolecular veneer is insoluble in water and the nanomolecular veneer protects the plurality of crystals forming the tile backing plate from degradation in water at 60 ℃ for 24 hours.

Example 6

A tile backer board was formed using 65 wt% cement-based material.

The cementitious material has 35 wt% dry magnesia powder containing 80 wt% pure magnesia, based on the total final weight of the cementitious material.

Magnesium chloride dissolved in water at 15 wt% based on the final total weight of the cement-based material was mixed with magnesium oxide.

12% by weight of aggregate containing particles having a diameter of 1nm to 10mm is added to the amorphous phase cement-based material. The aggregate is a mixture of styrene-based foam beads and calcium carbonate powder.

In addition, 7 wt% of reinforcing material based on the total weight of the tile backing plate formed was added together with the aggregate. The reinforcement material contains chopped fibers containing silicon dioxide; hemp-containing fibers; nano-molecular carbon fiber bundles; short-cut carbon fibers; and chopped hydrocarbon fibers; in a ratio of 1:1:1:1:1 to each other.

Upon addition of a portion of the amorphous phase cement-based material to the aggregate, a plurality of crystals are produced, each having a MW of 283, 413, 530, or 709, thereby producing a nano-molecular element protruding from the plurality of crystals, encapsulating the plurality of crystals.

The nanomolecular elements of the nanomolecular overlay are insoluble in water and serve as a tile backing plate, and the nanomolecular overlay protects the plurality of crystals from degradation in water at 60 ℃ for 24 hours.

Figures 3I-3T show a number of samples of the formulation of the tile backer board and its associated physical properties.

Sample 1 (this reference to "sample 1" and the following reference to "sample" refers to one of figures 3I-3T) contains 29 wt% dry powder of magnesium oxide based on the final total weight of the cementitious material used. The dry magnesium oxide powder contained 85 wt% pure magnesium oxide.

The magnesium oxide was blended with 14 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 1, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

Sample 1 contained 0.1 wt% of an aggregate component called wood (fiber), based on the final total weight of the tile backer board, which was added to the amorphous phase cement-based material to form a flowable concrete.

The flowable uncured concrete is then poured over the reinforcing component to form the reinforced concrete.

The reinforcing component is a non-woven mat containing silica, which is weighed at 0.1 wt% based on the final total weight of the formed tile backing board.

For this sample 1, a portion of the amorphous phase cement-based material formed multiple crystals, each referred to as a "magnesium oxychloride cement crystal," having a MW of 530.7, wherein the amorphous non-crystalline nanomolecular cement-based material encapsulated the multiple crystals, thereby creating a nanomolecular veneer free of detectable phosphorus-containing compounds, while the surface area of the multiple crystals increased by 2% to 20m²/g。

The cured material of sample 1 formed a tile backing board that was stabilized in 60 ℃ water for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample 2

Sample 2 contained 40 wt% of dry magnesia powder containing 85 wt% of magnesia, based on the final total weight of the cement-based material used.

Magnesium oxide has a surface area between5 m²Per gram to 50 m²In the range of/gram and having an average particle size in the range of about 0.3 to about 90 microns, wherein greater than about 90 weight percent of the magnesium oxide particles are less than or equal to about 40 microns.

The magnesium oxide was blended with 18 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 2, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

For this example, the next step involved adding 10 wt% of stabilizing material with a phosphorus-containing compound to the mixed liquid suspension, based on the final total weight of the tile backing plate.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

Sample 2 contained 30 wt% of an aggregate component called wood (fiber), based on the final total weight of the tile backer board, which was added to the amorphous phase cement-based material to form a flowable concrete.

The flowable uncured concrete is then poured over the reinforcing component to form the reinforced concrete.

The reinforcing component is a woven mat containing silica. The reinforcing component is 2 wt% based on the final total weight of the tile backing board.

For this sample 2, a portion of the amorphous phase cement-based material formed multiple crystals, each referred to as a "magnesium oxychloride cement crystal," having a MW of 530.7, wherein the amorphous non-crystalline nanomolecular cement-based material encapsulated the multiple crystals, thereby producing a nanomolecular veneer free of detectable phosphorus-containing compounds, while the surface area of the multiple crystals increased by 49% to 29m²/g。

The cured material of sample 2 formed a tile backing board that was stabilized in 60 ℃ water for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample 3

Sample 3 contained 32 wt% of dry magnesia powder containing 85 wt% of magnesia, based on the final total weight of the cement-based material used.

The magnesium oxide was blended with 17 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 3, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

Sample 3 contained 15 wt% of an aggregate component called perlite, based on the final total weight of the tile backer board, which was added to an amorphous phase cement-based material to form a flowable concrete.

(i) A certain weight percent of biomass called rice hulls, based on the final total weight of the tile backer board, is added to the amorphous phase cement-based material.

The flowable uncured concrete is then poured over the reinforcing component to form the reinforced concrete.

The reinforcing component is a hydrocarbon-containing non-woven mat. The reinforcing component is 0.1 wt% based on the final total weight of the tile backing board.

For this sample 3, a portion of the amorphous phase cement-based material formed multiple crystals, each referred to as a "magnesium oxychloride cement crystal," having a MW of 530.7, wherein the amorphous non-crystalline nanomolecular cement-based material encapsulated the multiple crystals, thereby producing a nanomolecular veneer free of detectable phosphorus-containing compounds, while the surface area of the multiple crystals increased by 2% to 20m²/g。

The cured material of sample 3 formed a tile backing board that was stabilized in 60 ℃ water for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample No. 4

Sample 4 contained 31 wt% of dry magnesia powder containing 85 wt% of magnesia, based on the final total weight of the cement-based material used.

The magnesium oxide was blended with 16 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 4, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

For this example, the next step involved adding 1 wt% of the stabilizing material with the phosphorus-containing compound to the mixed liquid suspension, based on the final total weight of the cementitious material.

For sample 4, the stabilizing material with the phosphorus-containing compound was based on the final total weight of the cement-based materialPhosphoric acid, wherein the phosphoric acid is 80 to 90 weight percent of H₃PO₄Aqueous solution composition of concentrate.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

Sample 4 contained 15 wt% of an aggregate component called perlite, based on the final total weight of the tile backer board, which was added to an amorphous phase cement-based material to form a flowable concrete.

15% by weight of biomass called corn husks, based on the final total weight of the tile backer board, was added to the amorphous phase cement-based material.

The flowable uncured concrete is then poured over the reinforcing component to form the reinforced concrete.

The reinforcing component is a woven mat containing hydrocarbons. The reinforcing component is 0.1 wt% based on the total final weight of the cementitious material.

The cured material of sample 4 formed a tile backing board that was stabilized in 60 ℃ water for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample No. 5

Sample 5 contained 32.5 wt% of dry magnesia powder containing 85 wt% of magnesia, based on the final total weight of the cement-based material used.

The magnesium oxide was blended with 17.5 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 5, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

Sample 5 contained 15 wt% based on the final total weight of the tile backing board of an aggregate component called styrene based foam beads, which was added to an amorphous phase cement-based material to form a flowable concrete.

Sample 5 contained 0.1 wt% detergent as a surfactant added to the amorphous phase cement-based material to reduce the porosity of the aggregate and prevent the amorphous phase cement-based material from entering the pores of the aggregate, based on the final total weight of the tile backer board.

Sample 5 contained 1 wt% silica-containing chopped fibers based on the final total weight of the tile backing board.

The flowable uncured concrete is then poured over the reinforcing component to form the reinforced concrete.

The reinforcing component is a non-woven mat containing silica. The reinforcing component is 0.1 wt% based on the final total weight of the tile backing board.

For this sample 5, a portion of the amorphous phase cement-based material formed multiple crystals, each of which was referred to as a "magnesium oxychloride cement crystal," MW 530.7, wherein the amorphous nanomolecular cement-based material encapsulated the multiple crystals, thereby producing a non-crystalline cementThe detected nano-molecule of the phosphorus-containing compound is coated, and the surface area of a plurality of crystals is increased by more than 38 percent to 27m²/g。

The cured material of sample 5 formed a tile backing board that was stabilized in 60 ℃ water for 24 hours using Jet Products, llc.

Sample No. 6

Sample 6 contained 33 wt% of dry magnesia powder containing 85 wt% of magnesia, based on the final total weight of the cement-based material used.

The magnesium oxide was blended with 18 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 6, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

Sample 6 contained 15 wt% of an aggregate component called glass particles, based on the final total weight of the tile backing board, which was added to an amorphous phase cement-based material to form a flowable concrete.

Sample 6 contained 10 wt% sodium stearate based on the final total weight of the tile backing board as a surfactant added to the amorphous phase cement-based material to reduce the porosity of the aggregate and prevent the amorphous phase cement-based material from entering the pores of the aggregate.

Sample 6 contained 10 wt% silica-containing chopped fibers based on the final total weight of the tile backing board.

The flowable uncured concrete is then poured over the reinforcing component to form the reinforced concrete.

The reinforcing component is a woven mat containing silica. The reinforcing component is 0.1 wt% based on the final total weight of the tile backing board.

The cured material of sample 6 formed a tile backing board that was stabilized in 60 ℃ water for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample 7

Sample 7 contained 33 wt% of dry magnesia powder containing 85 wt% of magnesia, based on the final total weight of the cement-based material used.

The magnesium oxide was blended with 19 wt% magnesium chloride dissolved in water based on the final total weight of the cement-based material.

For sample 7, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

Sample 7 contained 11 wt% aggregate component based on the final total weight of the tile backing board, the ratio of wood, perlite and styrene foam beams was 30:8:1, which was added to the amorphous phase cement-based material to form a flowable concrete.

(i) A certain weight% of redispersible powders polymer based on the final total weight of the tile backing plate is added to the amorphous phase cement-based material. The redispersible powder polymer is vinyl acetate ethylene.

The flowable uncured concrete is then poured over the reinforcing component to form the reinforced concrete.

The reinforcing component is a woven mat containing hydrocarbons. The reinforcing component is 0.1 wt% based on the final total weight of the tile backing board.

The cured material of sample 7 formed a tile backing board that was stabilized in 60 ℃ water for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample 8

Sample 8 contained 32 wt% of dry magnesia powder containing 85 wt% of magnesia, based on the final total weight of the cement-based material used.

The magnesium oxide was blended with 17 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 7, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

Sample 8 contained 12 wt% aggregate component based on the final total weight of the tile backer board, the ratio of wood, perlite and styrene foam beams was 30:8:1, which was added to the amorphous phase cement-based material to form a flowable concrete.

A redispersible powders polymer of 5% by weight based on the final total weight of the tile backing board was added to the amorphous phase cement-based material. The redispersible powder polymer is vinyl acetate ethylene.

The flowable uncured concrete is then poured over the reinforcing component to form the reinforced concrete.

The reinforcing component is a non-woven mat containing silica. The reinforcing component is 0.1 wt% based on the final total weight of the tile backing board.

The cured material of sample 8 formed a tile backing board that was stabilized in 60 ℃ water for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample 9

Sample 9 contained 35 wt% of dry magnesia powder containing 85 wt% magnesia, based on the final total weight of the cementitious material used.

The magnesium oxide was blended with 16 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 9, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

Sample 9 contained 13 wt% aggregate component based on the final total weight of the tile backing board, the ratio of wood, perlite and styrene foam beams was 30:8:1, which was added to the amorphous phase cement-based material to form a flowable concrete.

(i) A certain weight% of acrylic acid based on the final total weight of the tile backer board is added to the amorphous phase cement-based material.

The flowable uncured concrete is then poured over the reinforcing component to form the reinforced concrete.

The reinforcing component is a woven mat containing silica. The reinforcing component is 0.1 wt% based on the final total weight of the tile backing board.

The cured material of sample 9 formed a tile backing board that was stabilized in 60 ℃ water for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample 10

Sample 10 contained 30 wt% dry powder magnesium oxide containing 85 wt% magnesium oxide based on the final total weight of the cementitious material used.

The magnesium oxide was blended with 18 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 10, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

Sample 10 contained 14 wt% aggregate component based on the final total weight of the tile backing board, the ratio of wood, perlite and styrene foam beams was 30:8:1, which was added to the amorphous phase cement-based material to form a flowable concrete.

Acrylic acid was added to the amorphous phase cement-based material in an amount of 5% by weight based on the final total weight of the tile backer board.

The flowable uncured concrete is then poured over the reinforcing component to form the reinforced concrete.

The reinforcing component is a woven mat containing hydrocarbons. The reinforcing component is 0.1 wt% based on the final total weight of the tile backing board.

For this sample 10, a portion of the amorphous phase cement-based material formed multiple crystals, each referred to as a "magnesium oxychloride cement crystal," having a MW of 530.7, wherein the amorphous non-crystalline nanomolecular cement-based material encapsulated the multiple crystals, thereby creating a nanomolecular veneer free of detectable phosphorus-containing compounds, while the surface area of the multiple crystals increased by more than 38% to 27m²/g。

The cured material of sample 10 formed a tile backing board that was stabilized in 60 ℃ water for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample 11

Sample 11 contained 33 wt% of dry magnesia powder containing 85 wt% magnesia, based on the final total weight of the cementitious material used.

The magnesium oxide was blended with 15 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 11, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

Sample 11 contained 16 wt% aggregate component based on the final total weight of the tile backing board, the ratio of wood, perlite and styrene foam beams was 30:8:1, which was added to the amorphous phase cement-based material to form a flowable concrete.

(i) A certain weight percent of styrene butadiene rubber based on the final total weight of the tile backer board is added to the amorphous phase cement-based material.

The flowable uncured concrete is then poured over the reinforcing component to form the reinforced concrete.

The reinforcing component is a non-woven mat containing silica. The reinforcing component is 0.1 wt% based on the final total weight of the tile backing board.

The cured material of sample 11 formed a tile backing board that was stabilized in 60 ℃ water for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample 12

Sample 12 contained 32 wt% of dry magnesia powder containing 85 wt% magnesia, based on the final total weight of the cementitious material used.

The magnesium oxide was blended with 19 wt% magnesium chloride dissolved in water based on the final total weight of the cement-based material.

For sample 12, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

For sample 12, the stabilizing material with the phosphorus-containing compound was phosphoric acid based on the final total weight of the cement-based material, where the phosphoric acid was from 80 wt% to 90 wt% H₃PO₄Aqueous solution composition of concentrate.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 2 minutes.

Sample 12 contained 17 wt% aggregate component based on the final total weight of the tile backer board, with a ratio of wood, perlite and styrene foam beams of 30:8:1, added to the amorphous phase cement-based material to form a flowable concrete.

Styrene butadiene rubber was added to the amorphous phase cement-based material in an amount of 5% by weight based on the final total weight of the tile backing board.

The flowable uncured concrete is then poured over the reinforcing component to form the reinforced concrete.

The reinforcing component is a woven mat containing silica. The reinforcing component is 0.1 wt% based on the final total weight of the tile backing board.

The cured material of sample 12 formed a tile backing board that was stabilized in 60 ℃ water for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample 13

Sample 13 had 29 wt% dry powder of magnesium oxide containing 85 wt% magnesium oxide based on the total final weight of the cement-based material.

The magnesium oxide was blended with 14 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 13, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

For sample 13, the stabilizing material with the phosphorus-containing compound was phosphorous acid (a) based on the final total weight of the cement-based material, where phosphorous acid was composed of 60 wt% H₃PO₃Aqueous solution composition of concentrate.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 3 minutes.

Then, to form the tile backer board of this sample 13, 0.1 wt% of an aggregate component, referred to as wood fiber, based on the final total weight of the tile backer board, was added to the amorphous phase cement-based material to form a flowable concrete.

The flowable uncured concrete is then mixed with the reinforcing component to form the reinforced concrete.

The reinforcing component was 0.1 wt% silica-containing chopped fibers.

In this sample, a portion of the amorphous phase cement-based material forms a plurality of crystals, each of which is referred to as a "magnesium oxychloride cement crystal," having a MW of 530.7, wherein the amorphous, non-crystalline nanomolecular cement-based material encapsulates the plurality of crystals, forming a nanomolecular veneer that is free of detectable phosphorus-containing compounds, while the surface area of the plurality of crystals increases by 2% to 20m²/g。

The cured material formed a tile backing sheet that was stabilized in water at 60 ℃ for 24 hours using Jet Products, LLC warm water stability test as certified by the chemical engineering system of the university of claimson in 2017.

Sample 14

Sample 14 had 40 wt% dry powder of magnesium oxide containing 85 wt% magnesium oxide based on the formed cementitious material.

The surface area of the magnesium oxide is between 5 m²Per gram to 50 m²In the range of/gramAnd has an average particle size in the range of about 0.3 to about 90 microns, wherein greater than about 90 weight percent of the magnesium oxide particles are less than or equal to about 40 microns.

The magnesium oxide was blended with 18 wt% magnesium chloride dissolved in water based on the total final weight of the cement-based material.

For sample 14, the magnesium chloride in aqueous solution was a 28 wt% aqueous magnesium chloride solution.

After 3 minutes of mixing with the planetary mixer, the magnesium oxide and magnesium chloride in the water form a liquid suspension while minimizing the addition of gas to the liquid suspension.

For this example, the next step involves adding 0 wt% of a stabilizing material having a phosphorus-containing compound to the mixed liquid suspension, based on the final total weight of the cementitious material.

For sample 14, the stabilizing material with the phosphorus-containing compound was phosphoric acid based on the final total weight of the cement-based material, where the phosphoric acid was from 80 wt% to 90 wt% H₃PO₄Aqueous solution composition of concentrate.

The liquid suspension with the stabilizing material may react into an amorphous phase cement-based material over a period of 3 minutes.

Then, to form the tile backer board of this sample 14, 30 wt% of an aggregate component, referred to as wood fiber, based on the final total weight of the tile backer board, was added to the amorphous phase cement-based material to form a flowable concrete.

The flowable uncured concrete is then mixed with the reinforcing component to form the reinforced concrete.

The reinforcing component is 15 wt% of nano-molecular carbon fiber bundles.

In this sample, a portion of the amorphous phase cement-based material formed a plurality of crystals, each of which was termed a "magnesium oxychloride cement crystal," having a MW of 530.7, wherein the amorphous, non-crystalline, nanomolecular cement-based material encapsulated the plurality of crystals, forming a nanomolecular overlay free of detectable phosphorus-containing compounds, while the surface area of the plurality of crystals increased by 49% to 29m²/g。

Fig. 3P-3T also show samples 15-24 produced in the same manner as samples 1-14, which exhibit other formulations and physical properties of tile backing board samples produced using chopped fibers as a reinforcing component and different additives, including biomass, surfactants, redispersible polymer powders, acrylic and styrene butadiene rubbers.

Figure 4 shows a first example of a magnesium oxychloride cement board using U.S. raw materials and 0% phosphoric acid.

Figure 4 shows a second example of a magnesium oxychloride cement board using U.S. raw materials and 1.25% phosphoric acid.

Figure 4 shows a third example of a magnesium oxychloride cement board using U.S. raw materials and 2.5% phosphoric acid.

Fig. 4 shows a fourth example of a magnesium oxychloride cement board using chinese raw materials and 0% phosphoric acid.

Fig. 4 shows a fifth example of a magnesium oxychloride cement board using chinese raw materials and 1.5% phosphoric acid.

Fig. 4 shows a sixth example of a magnesium oxychloride cement board using chinese raw materials and 3% phosphoric acid.

Detailed description of the preferred embodiments

For further explanation, other non-limiting embodiments of the invention are set forth below.

Embodiment a is a magnesia-based cementitious material comprising (i) magnesium oxychloride crystals at least partially surrounded by a phosphorus-containing amorphous layer, and/or (ii) crystalline magnesium oxychloride overcoated with amorphous nanomolecules substantially free of crystalline silica.

Embodiment a1 is the cement-based material of embodiment a, wherein the nano-molecular veneer comprises a non-crystalline phosphorus-containing substance identifiable by elemental analysis using a Scanning Electron Microscope (SEM), but not by X-ray diffraction (XRD) analysis.

Embodiment a2 is the cementitious material of embodiment a, wherein the material is substantially free of magnesium phosphate.

Embodiment a3 is the cement-based material of embodiment a, wherein at least a portion of the nano-molecular veneer is insoluble in water.

Embodiment a4 is the cementitious material of embodiment a, wherein the material is characterized by one or more of the following:

(i) a magnesium crystal content of about 45 wt% to about 85 wt%, as determined by quantitative X-ray diffraction;

(ii) the phosphorus-containing amorphous layer is from 10 wt% to about 50 wt% as determined by X-ray diffraction;

(iii) a magnesium crystal content of about 2 wt% to about 50 wt% after soaking in water at a temperature of 60 ℃ for 24 hours, as determined by X-ray diffraction;

(iv) BET surface area of about 20m²G to about 30m²/g。

Embodiment a5 is the cementitious material of embodiment a, further comprising 0.1 wt% to 30 wt% of an aggregate material selected from the group consisting of: wood, perlite, styrene-based foam beads, calcium carbonate powder, glass particles, or combinations thereof.

Embodiment a6 is the cementitious-based material of embodiment a, further comprising 0.1 wt% to 2 wt% of a reinforcing material selected from the group consisting of: a silica-containing non-woven mat, a silica-containing woven mat, a hydrocarbon-containing non-woven mat, a hydrocarbon-containing woven mat, or a combination thereof.

Embodiment a7 is the cementitious-based material of embodiment a, further comprising a reinforcing material selected from the group consisting of: silica-containing chopped fibers, hemp-containing fibers, nano-molecular carbon fiber bundles, chopped carbon fibers, chopped hydrocarbon fibers, and combinations thereof.

Embodiment A8 is the cementitious material of embodiment a, further comprising 0.1 wt% to 5 wt% of a redispersible polymer.

Embodiment B is a load-bearing support structure constructed using a cementitious building material comprising (i) magnesium oxychloride crystals at least partially surrounded by a phosphorus-containing amorphous layer, and/or (ii) crystalline magnesium oxychloride overcoated with amorphous nanomolecular coatings substantially free of crystalline silica.

Embodiment B1 is the structure of embodiment B selected from a residence, an office, a warehouse, a shed, a deck, an artwork, or a trench.

Embodiment C is a building comprising an exterior surface covered by a cementitious-based material comprising (i) magnesium oxychloride crystals at least partially surrounded by a phosphorus-containing amorphous layer, and/or (ii) crystalline magnesium oxychloride encapsulated by an amorphous nanomolecular overlay that is substantially free of crystalline silica.

Embodiment D is a building material comprising a substrate coated with a cementitious building material, wherein:

a cementitious building material comprising (i) magnesium oxychloride crystals at least partially surrounded by a phosphorus-containing amorphous layer, and/or (ii) crystalline magnesium oxychloride overcoated with amorphous nanomolecules substantially free of crystalline silica; and is

The substrate is selected from the group consisting of oriented strand board, plywood, waterproof film, concrete, and wood.

Embodiment E is a method of making an amorphous cement-based building material, comprising:

blending magnesium oxide and magnesium chloride in water and reacting the magnesium oxide and magnesium chloride, thereby forming a liquid suspension comprising magnesium oxychloride crystals;

adding a stabilizing material to the liquid suspension, wherein the stabilizing material is selected from the group consisting of phosphorous acid (H) comprising 55 wt% to 65 wt%₃PO₃) And an aqueous solution containing 80 to 90 wt% of phosphoric acid (H)₃PO₄) An aqueous solution of (a); and

the magnesium oxychloride crystals of the liquid suspension are reacted with the stabilizing material for a time period of from 1 minute to 4 minutes, thereby forming an amorphous phase cement-based material.

Embodiment E1 is the method of embodiment E, wherein the magnesium oxide and the magnesium chloride are blended in a weight ratio of 1.9:1 to 2.1: 1.

Embodiment E2 is the method of embodiment E, wherein the liquid suspension comprises an amorphous phase and the addition thereto of a stabilizing material promotes crystallization of a portion of the amorphous phase while forming a nano-molecular veneer encapsulating the formed crystalline amorphous phase.

Embodiment E3 is the method of embodiment E2, wherein the crystalline portion of the amorphous phase is free of magnesium phosphate.

Embodiment E4 is the method of embodiment E2, wherein the surface area of the crystalline amorphous phase encapsulated by the nanomolecular overlay is 25% to 35% higher than the crystalline amorphous phase that is not encapsulated by the nanomolecular overlay.

Embodiment E5 is the method of embodiment E, wherein the magnesium oxide and magnesium chloride are reacted to form the liquid suspension under conditions that minimize the addition of gas to the liquid suspension.

Embodiment E6 is the method of embodiment E, wherein the magnesium oxide and the magnesium chloride are mixed using a planetary mixer.

Embodiment E7 is the method of embodiment E, wherein the magnesium oxide and the magnesium chloride are blended for a period of 2 minutes to 10 minutes to form the liquid suspension.

Embodiment F is a method of making a building material, the method comprising pouring a cementitious building material over a reinforcing material, wherein:

The reinforcing material is selected from oriented strand board, plywood, waterproof film, concrete and wood.

Embodiment G is a method of making a concrete building material, the method comprising:

pouring a cementitious building material into the mold, wherein the cementitious building material comprises (i) magnesium oxychloride crystals at least partially surrounded by the phosphorus-containing amorphous layer, and/or (ii) crystalline magnesium oxychloride overcoated with amorphous nanomolecules that are substantially free of crystalline silica; and

the cement-based construction material is cured.

68页详细技术资料下载

上一篇：一种医用注射器针头装配设备

下一篇：包含至少一种微生物的组合物及其用途

Ultra-stable cement-based material formulation, method of making same, and ultra-stable tile backer board formulation and method of making same

相关技术

网友询问留言