Cement-based tile

1. A method for manufacturing a cement-based tile comprising:

mixing a cement in the range of about 0.1 to 88% by wet weight percent, a secondary material in the range of about 0.1 to 50% by wet weight percent, a reinforcement fiber in the range of about 0.5 to 20% by wet weight percent, and a rheology modifying agent in the range of about 0.5 to 10% by wet weight percent with a water in the range of 10 to 60% of a total wet material weight at a same time, wherein the secondary material comprises limestone, sand, silica sand, gypsum, silica fume, fumed silica, Plaster of Paris, calcium carbonate, fly ash, slag, rock, or a combination thereof, and the reinforcement fiber comprises cellulose fiber, glass fiber, plastic fiber, polypropylene fiber, polyvinyl alcohol (PVA) fiber, homopolymer acrylic fiber, alkali-resistant fiber, or a combination thereof;

extruding the mixture through a die using an extruder or molding the mixture using one or more molds; and

allowing the extruded or molded mixture to set.

2. The method as recited in claim 1 , wherein the cement contains gypsum.

3. The method as recited in claim 1 , wherein the mixing further comprises a color pigment in the range of about 0.1 to 5% by wet weight percent.

4. The method as recited in claim 1 , wherein the mixing further comprises a retarder in the range of 0.1 to 8% by wet weight percent.

5. The method as recited in claim 1 , wherein the mixture has a clay-like consistency.

6. The method as recited in claim 1 , wherein the rheology modifying agent comprises a polysaccharide, a polysaccharide derivative, a protein, a protein derivative, a synthetic organic material, a synthetic organic material derivative, or a combination thereof.

7. The method as recited in claim 1 , wherein the cement-based tile has a density in the range of about 1.4 to 2.4 g/cm3, a compressive strength in the range of about 5 MPa to 100 MPa, and a flexural strength in the range of about 5 to 35 MPa.

8. The method as recited in claim 1 , wherein the secondary material is calcium carbonate or silica sand.

9. The method as recited in claim 1 , wherein the reinforcement fiber is PVA fiber.

10. The method as recited in claim 1 , wherein the cement-based tile comprises a roofing tile, a wall tile or a floor tile.

11. The method as recited in claim 1 , wherein:

the cement is in the range of about 40 to 55% by wet weight percent;

the secondary material is in the range of about 20 to 40% by wet weight percent;

the reinforcement fiber is in the range of about 1 to 5% by wet weight percent;

the rheology modifying agent is in the range of about 0.5 to 2.5 by wet weight percent; and

the water in the range of 15 to 25% of the total wet material weight.

12. The method as recited in claim 1 , wherein:

the cement is in the range of about 45 to 50% by wet weight percent;

the secondary material is in the range of about 28 to 30% by wet weight percent;

the reinforcement fiber is in the range of about 1.9 to 2.1% by wet weight percent;

the rheology modifying agent is in the range of about 1.5 to 1.7 by wet weight percent; and

the water in the range of 18 to 20% of the total wet material weight.

13. The method as recited in claim 1 , wherein extruding the mixture through the die using the extruder comprising:

conveying the mixture through a barrel using an auger; and

continuously forming the mixture into a final shape having form stability through the die using the extruder.

14. The method as recited in claim 1 , wherein the extruded mixture comprises an elongated sheet and further comprising rolling the elongated sheet through one or more sets of calenders.

15. The method as recited in claim 14 , further comprising:

cutting the elongated sheet into a set of individual sheets having a specified length;

stacking the set of individual sheets onto a pallet;

covering the stack with a plastic and an insulating material;

curing the stack by allowing the covered stack to sit for a specified time period; and

squaring up and sanding each individual sheet.

16. The method as recited in claim 15 , wherein the specified time period is approximately 24 to 48 hours.

17. The method as recited in claim 1 , wherein the extruded mixture or the molded mixture is allowed to set for up to 2 to 3 hours.

18. The method as recited in claim 1 , further comprising curing the extruded mixture or the molded mixture.

19. The method as recited in claim 1 , further comprising drying the extruded mixture or the molded mixture.

20. The method as recited in claim 1 , further comprising cutting, trimming, sanding or routing the extruded mixture or the molded mixture into a specified shape.

21. The method as recited in claim 1 , further comprising spraying the extruded mixture or the molded mixture with a water repellent.

22. The method as recited in claim 1 , further comprising applying one or more coatings or inks to extruded mixture or the molded mixture.

23. The method as recited in claim 22 , wherein the one or more coatings or inks comprise a UV coating, a fire resistant coating, a color, an image, a texture or a combination thereof.

24. A method for manufacturing a cement-based tile comprising:

mixing a cement in the range of about 0.1 to 88% by wet weight percent with a water in the range of 10 to 60% of a total wet material weight;

blending the cement-water mixture with a secondary material in the range of about 0.1 to 50% by wet weight percent and a reinforcement fiber in the range of about 0.5 to 20% by wet weight percent, wherein the secondary material comprises limestone, sand, silica sand, gypsum, silica fume, fumed silica, Plaster of Paris, calcium carbonate, fly ash, slag, rock, or a combination thereof, and the reinforcement fiber comprises cellulose fiber, glass fiber, plastic fiber, polypropylene fiber, polyvinyl alcohol (PVA) fiber, homopolymer acrylic fiber, alkali-resistant fiber, or a combination thereof;

adding a rheology modifying agent in the range of about 0.5 to 10% by wet weight percent;

extruding the mixture through a die using an extruder or molding the mixture using one or more molds; and

allowing the extruded or molded mixture to set.

25. The method as recited in claim 24 , wherein the cement contains gypsum.

26. The method as recited in claim 24 , further comprising adding a color pigment in the range of about 0.1 to 5% by wet weight percent.

27. The method as recited in claim 24 , further comprising adding a retarder in the range of 0.1 to 8% by wet weight percent.

28. The method as recited in claim 24 , wherein the mixture has a clay-like consistency.

29. The method as recited in claim 24 , wherein the rheology modifying agent comprises a polysaccharide, a polysaccharide derivative, a protein, a protein derivative, a synthetic organic material, a synthetic organic material derivative, or a combination thereof.

30. The method as recited in claim 24 , wherein the cement-based tile has a density in the range of about 1.4 to 2.4 g/cm3, a compressive strength in the range of about 5 MPa to 100 MPa, and a flexural strength in the range of about 5 to 35 MPa.

31. The method as recited in claim 24 , wherein the secondary material is calcium carbonate or silica sand.

32. The method as recited in claim 24 , wherein the reinforcement fiber is PVA fiber.

33. The method as recited in claim 24 , wherein the cement-based tile comprises a roofing tile, a wall tile or a floor tile.

34. The method as recited in claim 24 , wherein:

the cement is in the range of about 40 to 55% by wet weight percent;

the secondary material is in the range of about 20 to 40% by wet weight percent;

the reinforcement fiber is in the range of about 1 to 5% by wet weight percent;

the rheology modifying agent is in the range of about 0.5 to 2.5 by wet weight percent; and

the water in the range of 15 to 25% of the total wet material weight.

35. The method as recited in claim 24 , wherein:

the cement is in the range of about 45 to 50% by wet weight percent;

the secondary material is in the range of about 28 to 30% by wet weight percent;

the reinforcement fiber is in the range of about 1.9 to 2.1% by wet weight percent;

the rheology modifying agent is in the range of about 1.5 to 1.7 by wet weight percent; and

the water in the range of 18 to 20% of the total wet material weight.

36. The method as recited in claim 24 , wherein extruding the mixture through the die using the extruder comprising:

conveying the mixture through a barrel using an auger; and

continuously forming the mixture into a final shape having form stability through the die using the extruder.

37. The method as recited in claim 24 , wherein the extruded mixture comprises an elongated sheet and further comprising rolling the elongated sheet through one or more sets of calenders.

38. The method as recited in claim 37 , further comprising:

cutting the elongated sheet into a set of individual sheets having a specified length;

stacking the set of individual sheets onto a pallet;

covering the stack with a plastic and an insulating material;

curing the stack by allowing the covered stack to sit for a specified time period; and

squaring up and sanding each individual sheet.

39. The method as recited in claim 38 , wherein the specified time period is approximately 24 to 48 hours.

40. The method as recited in claim 24 , wherein the extruded mixture or the molded mixture is allowed to set for up to 2 to 3 hours.

41. The method as recited in claim 24 , further comprising curing the extruded mixture or the molded mixture.

42. The method as recited in claim 24 , further comprising drying the extruded mixture or the molded mixture.

43. The method as recited in claim 24 , further comprising cutting, trimming, sanding or routing the extruded mixture or the molded mixture into a specified shape.

44. The method as recited in claim 24 , further comprising spraying the extruded mixture or the molded mixture with a water repellent.

45. The method as recited in claim 24 , further comprising applying one or more coatings or inks to extruded mixture or the molded mixture.

46. The method as recited in claim 24 , wherein the one or more coatings or inks comprise a UV coating, a fire resistant coating, a color, an image, a texture or a combination thereof.