US5643359A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Dispersion of plant pulp in concrete and use thereof
Assignee: DPD Inc
•
Filing: 1995-11-15
•
Granted: 1997-07-01
•
Expires: 2015-11-15
Abstract
Abstract Pulp fibers derived from wood or non-wood plants or recycled paper products, which are about 0.1-30 mm long and about 0.001-0.1 mm in diameter with length-to-diameter ratio of about 30-3000, are dispersed in conventional concrete mixtures using conventional mixing equipment for effectively improving fresh and hardened concrete properties at relatively low cost. Dispersion is achieved by individualizing the plant pulp fibers so that they are not fully bonded to each other, and dispersing the individual fibers in concrete at relatively low dosages of about 0.3-30 kg per cubic meter. Once individualized, the affinity of plant pulp fibers for water facilitates their dispersion in conventional concrete mixtures. Fresh concrete mixtures incorporating the dispersed individualized plant pulp fibers possess desirable workability, resistance to segregation and bleeding, pumpability, finishability, and reduced rebound when pneumatically applied. Hardened concrete materials incorporating the dispersed individualized plant pulp fibers provide improved crack resistance, toughness characteristics, impact resistance, fatigue life, abrasion resistance, and other mechanical, physical and durability characteristics. Precast and cast-in-pace concrete as well as plain and reinforced concrete and shotcrete benefit from such improvements in fresh and hardened material properties rendered by dispersed plant pulp fibers.
Inventors
- 👤 Parviz Soroushian
- 👤 Jer-Wen Hsu
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 12:06
CPC Classifications
C; C04; C04B; C04B18/00; C04B18/04; C04B18/18; C04B18/24; C04B18/241; Y; Y02; Y02W; Y02W30/00; Y02W30/50; Y02W30/91
Claims Analysis
Total Claims: 40
Claim 1
Independent Claim
150 words
A process for making a cellulose fiber reinforced cement-based material using cellulose pulp derived through at least one of mechanical, thermal and chemical pulping methods, the process comprising the steps of: a. drying the wet cellulose pulp resulting from the pulping methods under conditions to achieve a dried fluff pulp with low fiber-to-fiber bonding therein; b. mechanically separating the dried fluff pulp into substantially individual fibers by breaking the fiber-to-fiber bonds between the individual fibers; c. adding the separated, substantially individual fibers to a cement-based material at a dosage ranging from about 0.3-30.0 kg per cubic meter, said cement-based material further including about 50-1500 kg per cubic meter of cement, about 50-1000 kg per cubic meter of water, and about 100-3600 kg per cubic meter of aggregate; and d. mixing the separated, substantially individual fibers into the cement-based material so as to disperse the fibers uniformly throughout the cement-based material.
Claim 2
Dependent Claim
150 words
A process for making a cellulose fiber reinforced cement-based material using cellulose pulp derived through at least one of mechanical, thermal and chemical pulping methods, the process comprising the steps of: a. drying the wet cellulose pulp resulting from the pulping methods under conditions to achieve a dried fluff pulp with low fiber-to-fiber bonding therein; b. mechanically separating the dried fluff pulp into substantially individual fibers by breaking the fiber-to-fiber bonds between the individual fibers; c. adding the separated, substantially individual fibers to a cement-based material at a dosage ranging from about 0.3-30.0 kg per cubic meter, said cement-based material further including about 50-1500 kg per cubic meter of cement, about 50-1000 kg per cubic meter of water, and about 100-3600 kg per cubic meter of aggregate; and d. mixing the separated, substantially individual fibers into the cement-based material so as to disperse the fibers uniformly throughout the cement-based material.
Claim 3
Dependent Claim
27 words
The process of claim 1, wherein the separated, substantially individual fibers are added to the cement-based material at a dosage ranging from 0.5-5.0 kg per cubic meter.
Claim 4
Dependent Claim
32 words
The process of claim 1, wherein said addition step involves addition of the separated, substantially individual plant fibers with other components of the cement-based material at any stage during the mixing step.
Claim 5
Dependent Claim
22 words
The process according to claim 3, wherein the mixing of the separated, substantially individual fibers into the cement-based material exceeds 20 seconds.
Claim 6
Dependent Claim
40 words
The process according to claim 1, wherein said aggregate of said cement-based material comprises at least one of mineral, synthetic, metallic, and organic sources, with about 0.05-5 mm minimum aggregate particle size and about 10-100 mm maximum aggregate particle size.
Claim 7
Dependent Claim
28 words
The process according to claim 1, wherein said drying step limits pressing of the wet cellulose pulp to produce the dried fluff pulp with low fiber-to-fiber bonding therein.
Claim 8
Dependent Claim
29 words
The process according to claim 6, wherein said drying step further involves chemically treating the cellulose pulp to produce a dried, softened fluff pulp with low fiber-to-fiber bonding therein.
Claim 9
Dependent Claim
26 words
The process of claim 7, wherein said chemical treating involves use of at least one of a surfactant, a high bulk additive, and a sizing agent.
Claim 10
Dependent Claim
17 words
The process according to claim 1, wherein said mechanical separating step involves milling the dried fluff pulp.
Claim 11
Dependent Claim
17 words
The process according to claim 1, wherein said mechanical separating step involves fillibrating the dried fluff pulp.
Claim 12
Dependent Claim
31 words
The process according to claim 1, wherein said mechanical separating step involves carrying the dried fluff pulp in a high-speed airstream and impacting the airstream and pulp against a solid surface.
Claim 13
Dependent Claim
21 words
The process of claim 1, wherein said mechanical separating step involves wet processing of the dried fluff pulp with mechanical action.
Claim 14
Dependent Claim
14 words
The process of claim 1, wherein the wet cellulose pulp comprises waste paper products.
Claim 15
Dependent Claim
22 words
A process of claim 1, wherein said cement-based material is mortar with maximum aggregate particle size of less than about 5 mm.
Claim 16
Dependent Claim
46 words
A process of claim 1, wherein said mixing step involves mixing said separated, substantially individual fibers with at least one other dry ingredient of said cement-based material as a dry mix, and subsequently mixing the dry mix with the water and other ingredients of the mix.
Claim 17
Dependent Claim
48 words
The process of claim 1, wherein said mixing step involves mixing said separated, substantially individual fibers with the cement and the aggregate cement-based material as a dry mix, and subsequently mixing the dry mix with the water in a shotcrete process during pneumatic application of the dry mix.
Claim 18
Dependent Claim
39 words
The process of claim 1, wherein the adding step involves adding the separated, substantially individual fibers into the cement-based material together with a container therefor which disintegrates in the cement-base material through at least one of dissolution and dispersion.
Claim 19
Dependent Claim
27 words
The process according to claim 1, wherein said cement-based material further includes at least one of chemical admixtures, mineral admixtures, polymeric admixtures, and an air entraining agent.
Claim 20
Dependent Claim
27 words
The process according to claim 1, wherein said cement-based material is further subjected to at least one of the pumping, casting, consolidating, pneumatic application, and finishing processes.
Claim 21
Dependent Claim
39 words
A fresh concrete mixture incorporating dispersed cellulose pulp fibers, which is workable, pumpable, resistant to segregation and excess bleeding, possesses desirable finishability, and offers resistance to the loss of materials through rebound when pneumatically applied, the concrete mixture comprising:
Claim 22
Dependent Claim
39 words
A fresh concrete mixture incorporating dispersed cellulose pulp fibers, which is workable, pumpable, resistant to segregation and excess bleeding, possesses desirable finishability, and offers resistance to the loss of materials through rebound when pneumatically applied, the concrete mixture comprising:
Claim 23
Dependent Claim
92 words
3-30 kg per cubic meter of substantially individual cellulose fibers which have been derived from a wet cellulose pulp dried under conditions to achieve a fluff pulp with reduced fiber-to-fiber bonding therein, and subsequent, mechanical separation of the dried fluff pulp into the substantially individual fibers; about 50-1500 kg per cubic meter of cement; about 50-1000 kg per cubic meter of water; about 100-3600 kg per cubic meter of aggregate; and wherein the substantially individual fibers are dispersed uniformly throughout the cement-based material through mixing for a sufficiently long period of time.
Claim 24
Dependent Claim
92 words
3-30 kg per cubic meter of substantially individual cellulose fibers which have been derived from a wet cellulose pulp dried under conditions to achieve a fluff pulp with reduced fiber-to-fiber bonding therein, and subsequent, mechanical separation of the dried fluff pulp into the substantially individual fibers; about 50-1500 kg per cubic meter of cement; about 50-1000 kg per cubic meter of water; about 100-3600 kg per cubic meter of aggregate; and wherein the substantially individual fibers are dispersed uniformly throughout the cement-based material through mixing for a sufficiently long period of time.
Claim 25
Dependent Claim
23 words
A fresh concrete mixture according to claim 20, wherein said mixture comprises 0.5-5.0 kg per cubic meter of the substantially individual cellulose fibers.
Claim 26
Dependent Claim
25 words
A fresh concrete mixture according to claim 20, further including at least one of chemical admixtures, mineral admixtures, polymeric admixtures, and an air entraining agent.
Claim 27
Dependent Claim
33 words
A fresh concrete mixture according to claim 20, wherein said cellulose fibers have lengths ranging from about 0.1-30 mm, diameters ranging from about 0.001-0.1 mm, and mean length-to-diameter ratios ranging from about 30-3000.
Claim 28
Dependent Claim
19 words
A fresh concrete mixture according to claim 20, wherein said drying conditions limits pressing of the wet cellulose pulp.
Claim 29
Dependent Claim
30 words
A fresh concrete mixture according to claim 20, wherein said drying conditions involve addition of a chemical to the cellulose pulp so that the fluff pulp is softened fluff pulp.
Claim 30
Dependent Claim
26 words
A fresh concrete mixture according to claim 25, wherein said chemical includes at least one of a surfactant, a high hulk additive, and a sizing agent.
Claim 31
Dependent Claim
111 words
A hardened cellulose fiber reinforced cement structure comprising: about 0.3-30 kg per cubic meter of substantially individual cellulose fibers derived by initially drying a wet cellulose pulp under conditions to form a dried fluff pulp having low fiber-to-fiber bonding therein, and subsequently mechanically separating the dried fluff pulp into the substantially individual fibers; about 50-1500 kg per cubic meter of cement; about 50-1000 kg per cubic meter of water; about 100-3600 kg per cubic meter of aggregate; and said substantially individual cellulose fibers being uniformly dispersed throughout the hardened structure through mixing of the fibers together with the cement, water and aggregate for a sufficient length of time prior to curing.
Claim 32
Dependent Claim
111 words
A hardened cellulose fiber reinforced cement structure comprising: about 0.3-30 kg per cubic meter of substantially individual cellulose fibers derived by initially drying a wet cellulose pulp under conditions to form a dried fluff pulp having low fiber-to-fiber bonding therein, and subsequently mechanically separating the dried fluff pulp into the substantially individual fibers; about 50-1500 kg per cubic meter of cement; about 50-1000 kg per cubic meter of water; about 100-3600 kg per cubic meter of aggregate; and said substantially individual cellulose fibers being uniformly dispersed throughout the hardened structure through mixing of the fibers together with the cement, water and aggregate for a sufficient length of time prior to curing.
Claim 33
Dependent Claim
23 words
A hardened cellulose fiber reinforced structure according to claim 27, wherein the structure comprises 0.5-5.0 kg per cubic meter of the cellulose fibers.
Claim 34
Dependent Claim
41 words
The hardened cellulose fiber reinforced cement structure of claim 27, wherein said cellulose fibers comprise at least one of softwood and hardwood craft with lengths ranging from 0.1-30 mm, diameters ranging from 0.001-0.1 mm, and mean length-to-diameter ratios ranging from 30-3000.
Claim 35
Dependent Claim
24 words
The hardened cement structure according to claim 27, further including at least one of chemical admixtures, mineral admixtures, polymeric admixtures, and air entraining agents.
Claim 36
Dependent Claim
16 words
The hardened cement structure of claim 27, further including a gas-forming agent and air bubbles therein.
Claim 37
Dependent Claim
24 words
The hardened cement structure according to claim 27, further including at least one of continuous and discrete reinforcement in addition to the cellulose fibers.
Claim 38
Dependent Claim
19 words
The hardened cement structure according to claim 27, wherein said drying conditions limits pressing of the wet cellulose pulp.
Claim 39
Dependent Claim
30 words
The hardened cement structure according to claim 27, wherein said drying conditions involve addition of a chemical to the cellulose pulp so that the fluff pulp is softened fluff pulp.
Claim 40
Dependent Claim
26 words
The hardened cement structure according to claim 34, wherein said chemical includes at least one of a surfactant, a high bulk additive, and a sizing agent.
References Cited (Backward Citations)
US1046913A
Cited
US1349901A
Cited
US1633219A
Cited
US1913707A
Cited
US2677955A
Cited
GB891945A
Cited
US3753749A
Cited
US4188454A
Cited
US4310478A
Cited
US4263365A
Cited
US4287020A
Cited
US4400217A
Cited
US4369201A
Cited
US4483727A
Cited
US4524101A
Cited
EP0225404A1
Cited
EP0235577A2
Cited
US4861812A
Cited
US4968561A
Cited
US5000824A
Cited
US4985119A
Cited
US5196061A
Cited
US5399195A
Cited
US5102596A
Cited
US5453310A
Cited
US5362562A
Cited
US5385978A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2000-06-30 | 2000-12-30 | 2001-07-01 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2004-06-30 | 2004-12-30 | 2005-07-01 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2008-06-30 | 2008-12-30 | 2009-07-01 | $7700.00 | Window Closed / Lapsed |