Fiber reinforced mineral-based materials and methods of making the same

Abstract

The present invention relates to a method for reinforcing mineral-based materials using reinforced fiber material. More particularly, the present invention relates a method for more uniformly dispensing a fiber material with a mineral-based material, such as cement paste.

1 - 35 . (canceled)  
     
     
         36 . A reinforced fiber material capable of dispersion in and/or bonding with a mineral-based material, comprising at least one cellulosic fiber material, at least one coordinating material, and water, wherein the at least one coordinating material separates the fibers of the at least cellulosic fiber material.  
     
     
         37 . The reinforced fiber material of  claim 36 , wherein the cellulosic fiber material comprises at least one of woody fibers, non-woody fibers, recycled fibers, and mechanical pulp.  
     
     
         38 . The reinforced fiber material of  claim 37 , wherein the woody fibers are chosen from at least one of hardwood fibers and softwood fibers.  
     
     
         39 . The reinforced fiber material of  claim 36 , wherein the coordinating material is chosen from at least one of: silica-rich materials including fly ash and silica fume; slag; aluminosilicates including heat-treated clay, metakaolin, and clay; fines from crushed rock; fine sand; silica gel; talc; calcium carbonates including precipitated calcium carbonate and grounded calcium carbonate; aluminum sulfate; wood ash; polymers that can absorb or bond to fiber material including anionic polymers and cationic polymers including potato starch and corn starch; surfactants; water; and saw dust.  
     
     
         40 . The reinforced fiber material of  claim 39 , wherein the coordinating material is at least one cationic polymer and at least one of fly ash and silica fume.  
     
     
         41 . The reinforced fiber material of  claim 36 , wherein the fiber material reduces early-age cracking or shrinkage cracking when added to a mineral-based composition.  
     
     
         42 . The reinforced fiber material of  claim 36 , wherein the fiber material improves the ductility and/or the toughness of a mineral-based composition to which it is added.  
     
     
         43 . The reinforced fiber material of  claim 36 , wherein the at least one coordinating material is adsorbed to the surface of the fibers of the at least one cellulosic fiber material.  
     
     
         44 . The reinforced fiber material of  claim 36 , wherein the at least one cellulosic fiber material is fibrillated.  
     
     
         45 . The reinforced fiber material of  claim 36 , wherein the reinforced fiber material is dry.  
     
     
         46 . A method for reinforcing a mineral based material, comprising: 
 mixing at least one cellulosic fiber material, at least one coordinating material, and water;    drying the mixture; and,    introducing the dry mixture into at least one mineral based material.    
     
     
         47 . The method of  claim 46 , wherein the cellulosic fiber material comprises at least one of woody fibers, non-woody fibers, recycled fibers, and mechanical pulp.  
     
     
         48 . The method of  claim 47 , wherein the woody fibers are chosen from at least one of hardwood fibers and softwood fibers.  
     
     
         49 . The method of  claim 46 , wherein the coordinating material is chosen from at least one of: silica-rich materials including fly ash and silica fume; slag; aluminosilicates including heat-treated clay, metakaolin, and clay; fines from crushed rock; fine sand; silica gel; talc; calcium carbonates including precipitated calcium carbonate and grounded calcium carbonate; aluminum sulfate; wood ash; polymers that can absorb or bond to fiber material including anionic polymers and cationic polymers including potato starch and corn starch; surfactants; water; and saw dust.  
     
     
         50 . The method of  claim 49 , wherein the coordinating material is at least one cationic polymer and at least one of fly ash and silica fume.  
     
     
         51 . The method of  claim 46 , wherein the mineral based material reduced early-age cracking or shrinkage cracking.  
     
     
         52 . The method of  claim 46 , wherein the mineral based material exhibits improved ductility and/or toughness.  
     
     
         53 . The method of  claim 46 , further comprising fibrillating the at least one cellulosic fiber material during or after mixing with the at least one coordinating material and water.  
     
     
         54 . The method of  claim 46 , wherein the introducing the dry mixture into the at least one mineral based material results in the uniform dispersion of the mixture in the at least one mineral based material.  
     
     
         55 . A method for reinforcing a mineral based material, comprising introducing to a mineral based material a dried reinforced fiber material made from at least one cellulosic fiber material, at least one coordinating material, and water.  
     
     
         56 . The method of  claim 55 , wherein the at least one cellulosic fiber material is chosen from at least one of hardwood and softwood fibers, and the at least one coordinating material is chosen from at least one cationic polymer and at least one of fly ash and silica fume.