CEMENT-BASED TILE
A cement-based tile formed from a mixture comprising: 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, the secondary material comprising limestone, sand, silica sand, gypsum, silica fume, fumed silica, Plaster of Paris, calcium carbonate, fly ash, slag, rock, or a combination thereof; a reinforcement fiber in the range of about 0.5 to 20% by wet weight percent, the reinforcement fiber comprising cellulose fiber, glass fiber, plastic fiber, polypropylene fiber, polyvinyl alcohol (PVA) fiber, homopolymer acrylic fiber, alkali-resistant fiber, or a combination thereof; a rheology modifying agent in the range of about 0.5 to 10% by wet weight percent; a water in the range of 10 to 60% of a total wet material weight; and wherein the mixture is extruded or molded to form the cement-based tile.
1 . A method for manufacturing a cement-based tile comprising:
mixing a cement, a secondary material, a reinforcement fiber and a rheology modifying agent with water at a same time, wherein:
the cement is in a range of about 0.1 to 88% by weight based on a total wet material weight of the mixture,
the secondary material is in a range of about 0.1 to 50% by weight based on the total wet material weight of the mixture,
the reinforcement fiber is in a range of about 0.5 to 20% by weight based on the total wet material weight of the mixture,
the rheology modifying agent is in a range of about 0.5 to 10% by weight based on the total wet material weight of the mixture, and
the water is in a range of 10 to 60% by weight based on the total wet material weight of the mixture;
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 , further comprising a color pigment in the range of about 0.1 to 5% by weight based on a total wet material weight of the mixture.
4 . The method as recited in claim 1 , further comprising a retarder in the range of 0.1 to 8% by weight based on a total wet material weight of the mixture.
5 . The method as recited in claim 1 , wherein the mixture has a consistency similar to clay.
6 . The method as recited in claim 1 , wherein the secondary material comprising limestone, sand, silica sand, gypsum, silica fume, fumed silica, Plaster of Paris, calcium carbonate, fly ash, slag, rock, or a combination thereof.
7 . The method as recited in claim 1 , wherein the reinforcement fiber comprising cellulose fiber, glass fiber, plastic fiber, polypropylene fiber, polyvinyl alcohol (PVA) fiber, homopolymer acrylic fiber, alkali-resistant fiber, or a combination thereof.
8 . 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.
9 . 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/cm 3 , 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.
10 . The method as recited in claim 1 , wherein the secondary material is calcium carbonate or silica sand.
11 . The method as recited in claim 1 , wherein the reinforcement fiber is PVA fiber.
12 . The method as recited in claim 1 , wherein the cement-based tile comprises a roofing tile, a wall tile or a floor tile.
13 . The method as recited in claim 1 , wherein:
the cement is in the range of about 40 to 55% by weight based on a total wet material weight of the mixture;
the secondary material is in the range of about 20 to 40% by weight based on a total wet material weight of the mixture;
the reinforcement fiber is in the range of about 1 to 5% by weight based on a total wet material weight of the mixture;
the rheology modifying agent is in the range of about 0.5 to 2.5 by weight based on a total wet material weight of the mixture; and
the water in the range of 15 to 25% by weight based on a total wet material weight of the mixture.
14 . The method as recited in claim 1 , wherein:
the cement is in the range of about 45 to 50% by weight based on a total wet material weight of the mixture;
the secondary material is in the range of about 28 to 30% by weight based on a total wet material weight of the mixture;
the reinforcement fiber is in the range of about 1.9 to 2.1% by weight based on a total wet material weight of the mixture;
the rheology modifying agent is in the range of about 1.5 to 1.7 by weight based on a total wet material weight of the mixture; and
the water in the range of 18 to 20% by weight based on a total wet material weight of the mixture.
15 . 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.
16 . 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.
17 . The method as recited in claim 16 , 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.
18 . The method as recited in claim 17 , wherein the specified time period is approximately 24 to 48 hours.
19 . 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.
20 . The method as recited in claim 1 , further comprising curing the extruded mixture or the molded mixture.
21 . The method as recited in claim 1 , further comprising drying the extruded mixture or the molded mixture.
22 . 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.
23 . The method as recited in claim 1 , further comprising spraying the extruded mixture or the molded mixture with a water repellent.
24 . The method as recited in claim 1 , further comprising applying one or more coatings or inks to extruded mixture or the molded mixture.
25 . 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.
26 . A method for manufacturing a cement-based tile comprising:
mixing a cement with a water, wherein the cement is in a range of about 0.1 to 88% by weight based on a total wet material weight of the mixture, and the water is in a range of 10 to 60% by weight based on the total wet material weight;
blending the cement-water mixture with a secondary material and a reinforcement fiber, wherein the secondary material is in a range of about 0.1 to 50% by weight based on a total wet material weight of the mixture and the reinforcement fiber is in a range of about 0.5 to 20% by weight based on a total wet material weight of the mixture;
adding a rheology modifying agent, wherein the rheology modifying agent is in a range of about 0.5 to 10% by weight based on a total wet material weight of the mixture;
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.
27 . The method as recited in claim 26 , wherein the cement contains gypsum.
28 . The method as recited in claim 26 , wherein the mixing further comprises a color pigment in the range of about 0.1 to 5% by weight based on a total wet material weight of the mixture.
29 . The method as recited in claim 26 , wherein the mixing further comprises a retarder in the range of 0.1 to 8% by weight based on a total wet material weight of the mixture.
30 . The method as recited in claim 26 , wherein the mixture has a consistency similar to clay.
31 . The method as recited in claim 26 , wherein the secondary material comprising limestone, sand, silica sand, gypsum, silica fume, fumed silica, Plaster of Paris, calcium carbonate, fly ash, slag, rock, or a combination thereof.
32 . The method as recited in claim 26 , wherein the reinforcement fiber comprising cellulose fiber, glass fiber, plastic fiber, polypropylene fiber, polyvinyl alcohol (PVA) fiber, homopolymer acrylic fiber, alkali-resistant fiber, or a combination thereof.
33 . The method as recited in claim 26 , 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.
34 . The method as recited in claim 26 , wherein the cement-based tile has a density in the range of about 1.4 to 2.4 g/cm 3 , 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.
35 . The method as recited in claim 26 , wherein the secondary material is calcium carbonate or silica sand.
36 . The method as recited in claim 26 , wherein the reinforcement fiber is PVA fiber.
37 . The method as recited in claim 26 , wherein the cement-based tile comprises a roofing tile, a wall tile or a floor tile.
38 . The method as recited in claim 26 , wherein:
the cement is in the range of about 40 to 55% by weight based on a total wet material weight of the mixture;
the secondary material is in the range of about 20 to 40% by weight based on a total wet material weight of the mixture;
the reinforcement fiber is in the range of about 1 to 5% by weight based on a total wet material weight of the mixture;
the rheology modifying agent is in the range of about 0.5 to 2.5 by weight based on a total wet material weight of the mixture; and
the water in the range of 15 to 25% by weight based on a total wet material weight of the mixture.
39 . The method as recited in claim 26 , wherein:
the cement is in the range of about 45 to 50% by weight based on a total wet material weight of the mixture;
the secondary material is in the range of about 28 to 30% by weight based on a total wet material weight of the mixture;
the reinforcement fiber is in the range of about 1.9 to 2.1% by weight based on a total wet material weight of the mixture;
the rheology modifying agent is in the range of about 1.5 to 1.7 by weight based on a total wet material weight of the mixture; and
the water in the range of 18 to 20% by weight based on a total wet material weight of the mixture.
40 . The method as recited in claim 26 , 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.
41 . The method as recited in claim 26 , wherein the extruded mixture comprises an elongated sheet and further comprising rolling the elongated sheet through one or more sets of calenders.
42 . The method as recited in claim 41 , 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.
43 . The method as recited in claim 42 , wherein the specified time period is approximately 24 to 48 hours.
44 . The method as recited in claim 26 , wherein the extruded mixture or the molded mixture is allowed to set for up to 2 to 3 hours.
45 . The method as recited in claim 26 , further comprising curing the extruded mixture or the molded mixture.
46 . The method as recited in claim 26 , further comprising drying the extruded mixture or the molded mixture.
47 . The method as recited in claim 26 , further comprising cutting, trimming, sanding or routing the extruded mixture or the molded mixture into a specified shape.
48 . The method as recited in claim 26 , further comprising spraying the extruded mixture or the molded mixture with a water repellent.
49 . The method as recited in claim 26 , further comprising applying one or more coatings or inks to extruded mixture or the molded mixture.
50 . The method as recited in claim 49 , 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.