Composite materials formed of at least partially cured cement-containing particles dispersed through polymeric matrix, applications using same, and methods of making
Composite materials including at least partially cured cement-containing particles dispersed through a polymeric matrix and applications utilizing such composite materials such as a floor tile, decking profile, roof profile, stair tread, railings, siding, and interior and exterior trim. Methods of fabricating the composite materials and products are also disclosed.
1 . A composite material, comprising:
a polymeric matrix; and
a plurality of at least partially cured cement-containing particles dispersed through the polymeric matrix.
2 . The composite material of claim 1 wherein at least some of the at least partially cured cement-containing particles comprise cured fiber-cement particles.
3 . The composite material of claim 1 wherein at least some of the at least partially cured cement-containing particles comprise concrete particles.
4 . The composite material of claim 1 wherein the plurality of at least partially cured cement-containing particles comprises cured fiber-cement particles and concrete particles.
5 . The composite material of claim 1 , further comprising wood particles dispersed through the polymeric matrix.
6 . The composite material of claim 1 wherein the polymeric matrix comprises a reinforced polymeric material.
7 . The composite material of claim 1 wherein the polymeric matrix comprises a non-reinforced polymeric material.
8 . The composite material of claim 1 wherein the polymeric matrix is selected from the group consisting of high density polyethylene (HDPE), polyvinyl chloride (PVC), nylon, acrylonitrile styrene acrylate (ASA), fiber-glass, and an epoxy.
9 . The composite material of claim 1 wherein the polymeric matrix comprises an additive selected from the group consisting of a UV inhibitor, a biocide, a dye, and combinations thereof.
10 . The composite material of claim 1 wherein the polymeric matrix is about 30 to about 35 weight percent of the composite material.
11 . A building product, comprising:
a member formed of a composite material, the composite material comprising:
a polymeric matrix; and
a plurality of at least partially cured cement-containing particles dispersed through the polymeric matrix.
12 . The building product of claim 11 wherein at least some of the at least partially cured cement-containing particles comprise cured fiber-cement particles.
13 . The building product of claim 11 wherein at least some of the at least partially cured cement-containing particles comprise concrete particles.
14 . The building product of claim 11 wherein the plurality of at least partially cured cement-containing particles comprises cured fiber-cement particles and concrete particles.
15 . The building product of claim 11 , further comprising wood particles dispersed through the polymeric matrix.
16 . The building product of claim 11 wherein the polymeric matrix comprises a reinforced polymeric material.
17 . The building product of claim 11 wherein the polymeric matrix comprises a non-reinforced polymeric material.
18 . The building product of claim 11 wherein the polymeric matrix is selected from the group consisting of high density polyethylene (HDPE), polyvinyl chloride (PVC), nylon, acrylonitrile styrene acrylate (ASA), fiber-glass, and an epoxy.
19 . The building product of claim 11 wherein the polymeric matrix comprises an additive selected from the group consisting of a UV inhibitor, a biocide, a dye, and combinations thereof.
20 . The building product of claim 11 wherein the polymeric matrix is about 30 to about 35 weight percent of the composite material
21 . The building product of claim 11 wherein the member is configured as a floor tile.
22 . The building product of claim 11 wherein the member is configured as a decking piece.
23 . The building product of claim 11 wherein the member is configured as a stair tread.
24 . The building product of claim 11 wherein the member is configured as a railing.
25 . The building product of claim 11 wherein the member is configured as a siding piece.
26 . The building product of claim 11 wherein the member is configured as a roofing shingle.
27 . The building product of claim 11 wherein the member is configured as a trim piece.
28 . The building product of claim 11 wherein the member comprises an extruded member.
29 . The building product of claim 11 wherein the member comprises a molded member.
30 . The building product of claim 11 wherein the member comprises a cast member.
31 . A method of manufacturing a composite material, comprising:
mixing a polymeric binder material and a plurality of cement-containing particles together; and
curing the polymeric binder material.
32 . The method of claim 31 wherein the plurality of at least partially cured cement-containing particles were ground from cement waste product.
33 . The method of claim 31 , further comprising forming the at least partially cured cement-containing particles by grinding cement waste product.
34 . The method of claim 33 wherein the act of forming the at least partially cured cement-containing particles by grinding cement waste product comprises grinding fiber-cement waste product.
35 . The method of claim 33 wherein the act of forming the at least partially cured cement-containing particles by grinding cement waste product comprises grinding concrete waste product.
36 . The method of claim 31 , further comprising extruding the polymeric binder material and the at least partially cured cement-containing particles to form an article.
37 . The method of claim 31 , further comprising injection molding the polymeric binder material and the at least partially cured cement-containing particles to form an article.
38 . The method of claim 31 , further comprising casting the polymeric binder and the at least partially cured cement-containing particles to form an article.
39 . The method of claim 31 , further comprising mixing wood particles with the polymeric binder material and the at least partially cured cement-containing particles.
40 . The method of claim 31 wherein the act of curing the polymeric binder material comprises curing the polymeric binder material to form the composite material having a cured polymeric matrix with the plurality of at least partially cured cement-containing particles dispersed therethrough.