BRPI0618052A2 - binder composites having wood-like properties and manufacturing methods - Google Patents

Abstract

<B> BINDING COMPOSITES WITH WOOD-LIKE PROPERTIES AND MANUFACTURING METHODS <D> A method of making a binder composite includes: (1) forming the mixture of an extrusable binder composition first by forming a fibrous mixture comprising fibers, water and an agent modifying rheology and then adding hydraulic cement, (2) extruding the extrusable binder composition into a green extrudate, where the green extrudate is characterized by being stable and substantially retaining a predefined cross-sectional shape, (3) removing a portion of water by evaporation to reduce density and increase porosity and (4) cause, or allow, hydraulic cement to hydrate to form the binder composite. Such a process produces a binder composite that is suitable for use as a wood substitute. Wood-like construction products can be sawn, nailed and screwed like ordinary wood.

Description

"BINDING COMPOSITES OWNING LIKE WOOD AND MANUFACTURING METHODS"

I. The Field of the Invention

The present invention generally relates to binder building products containing reinforcing fibers, more particularly to extrusable binder compositions for use in the manufacture of binder building products having wood-like properties.

II. Related Technology

Lumber and other construction products obtained from trees have been an element of building structures throughout history. Wood is a source for many different building materials, because of its ability to be cut and formed into various shapes and sizes, its overall performance as a building material and its ability to be transformed into many different building structures. Not only can the trees be cut in two by four, one by ten, plywood, upholstery board and so on, but different pieces of lumber can be easily attached to the mulch, nails, dowels, screws and others. fixation devices. Lumber can easily be formed and combined with other products to produce a desired structure.

Although trees are a renewable resource, it may take many years for a tree to grow to a usable size. As such, trees can disappear faster than they can be grown, at least locally in various parts of the world. Additionally, deserts or other areas without an abundance of trees have to import sawn wood or deprive themselves of the building structures that require wood. Due to concerns about deforestation and other related environmental concerns such as tree felling, there has been an attempt to create "lumber substitutes" from other materials such as plastics and concretes. Although plastics have some favorable properties such as moldability and high tensile strength, they are weak in compressive strength; They are generally derived from non-renewable resources and are generally considered to be less environmentally friendly than natural products.

On the other hand, concrete is a building material that is essentially non-exhaustible because its constituents are as common as clay, sand, stones and water. Concrete usually includes hydraulic cement, water, and at least one aggregate, where water reacts with the cement to form the cement paste, which joins the aggregates. When hydraulic cement and water cure (ie hydrate) to bond with aggregates and other solid constituents, the resulting concrete can have extremely high compressive strength and flexural modulus, but is a brittle material with relatively high tensile strength. low compared to its compressive strength, with low hardness or deflection properties. However, by adding reinforcements such as reinforcement bar or solid building structures, the concretif is useful for road construction, building foundations and generally large solid structures.

Previous attempts to create substitutes for concrete sawnwood have not provided products with adequate characteristics. In part, this is because of traditional approaches to making concretes that require mixtures to be cast cured, and have not provided products with the appropriate hardness or bending strength to be a substitute for lumber. An attempt to make wood substitutes from concrete involves the "Hatschek process", which is a modification of the process used to make paper.

In the Hatschek process, construction products are made from a highly aqueous slurry containing up to 99% water, hydraulic cement, aggregates and fibers. Aqueous pastafluid has an extremely high water to cement ratio ("w / c") and is dehydrated to produce a composition that is capable of curing to form solid construction products. The aqueous slurry is applied in successive layers in a porous drum and dehydrated between subsequent layers. The fibers are added to prevent the solid cement particles from flowing with water and imparting a level of strength. When still in a damp, non-hardened condition, the dehydrated material is removed from the drum, optionally shaped and allowed to cure. The resulting products are layered. Although adequately comfortable when kept dry, they tend to separate or detach when exposed to excessive moisture over time. Because the products are layered, the components, particularly the fibers, are not homogeneously dispersed.

Other construction products manufactured using hydraulically fixable binders include artificial gypsum sheet and cement sheet. Artificial plasterboard is used extensively in the construction industry as a structural material for walls. Because it is very sensitive to moisture, it is generally unsuitable for use in showers and other areas having high humidity. Cement slab is more resistant to water effects and can be used as a substitute for artificial plasterboard. Artificial flame is typically made by placing an aqueous pastafluid between sheets of paper. Both the slab plate and the cement plate are highly brittle, which allows them to be notched and broken to produce sheets of a desired size. Although it is possible to insert nails and screws into such artificial plates, they have little nail and screw retention. This is because they easily fracture under the point load of nails and screws because they lack hardness. Thus, while artificial sheet can be nailed or bolted to underlying wooden or metal sheet, artificial sheet is not a good structural material in itself. In fact, when attaching mechanisms or other fittings to the artificial plate, it is generally necessary to use a softened iron or self-locking screw, since a nail or screw by itself will easily come out of the artificial plate.

Although the present inventors have previously invented methods for making paper-like flexible sheets using cement and fibers, such sheets were flexible as paper and could be curved, folded or rolled into a variety of different food or beverage containers such as paper. paper. Such sheets would not be suitable for use as a building material. For one thing, such sheets were made by rapidly drying a moldable composition on a heated Yankee roller within seconds or minutes of formation, which resulted in the hydraulic cement particles becoming mere fillers, with the rheology modification agent providing the most, if not all, of the bonding strength Because cement particles were acting merely as fillers, they were eventually replaced by cheaper calcium carbonate fillers.

Therefore, it would be advantageous to provide a binding composition and method for the preparation of wood-like building products that can be used as a substitute for lumber products and which could be manufactured without dehydrating a highly aqueous fluid paste. Moreover, it would be beneficial to provide binder building products that could be used as a substitute for wood, including a wide variety of wood building products such as structural and decorative products currently made of wood.

SUMMARY OF THE INVENTION

The present invention relates to binder building materials that can function as a substitute for lumber. Accordingly, the present invention is directed to the use of extrudable binder compositions which may be extruded or otherwise shaped into a wood-like construction product which may be used as a substitute for many known lumber products. Fibrous binder construction products may have similar properties to wood construction products. In some embodiments, the fibrous α-glutinating building products may be sawn, cut, drilled, hammered and fixed together as is generally made of wood building products and described in more detail below.

Ordinary concrete is generally much denser and harder than wood and therefore much harder to stick, nail or screw. In general, the ability of the construction glutinant to be sawed using standard wood saws, nailed using a hammer or screwed using a common screwdriver is a function of hardness, which is approximately proportional to density (ie. the lower the density, the lower the hardness as a regrageral). In cases where it will be desirable for binder-building products to be sawn, nailed and / or bolted using tools commonly found in the construction industry when using wood products, binder-building products will generally have a hardness that approximates that of wood. wood (that is, so as to be softer than conventional concrete). The inclusion of fibers and rheology modifying agent helps in the creation of products that are softer than conventional concrete. In addition, the inclusion of a substantial amount of well-dispersed dust helps to reduce the density which in turn , helps reduce hardness.

Although not strictly a measure of hardness, it has been found that the flexural modulus of a material correlates with hardness when it refers to the ability to serve, nail and / or screw together binder construction products. Ordinary concrete typically has a flexural modulus with an order of magnitude measured in hundreds of gigapascals (10 "11Pa), which translates to an order of magnitude of approximately 107 psi. In contrast, the flexural modulus of the wood ranges from approximately 500,000 psi to approximately 5,000,000 (approximately 3.5 to 35 gigapascals) .concrete is typically about 5 to 100 times harder than wood. softer woods such as pine which are more easily sawn, nailed and screwed than hardwoods are up to 100 times softer than concrete when approximated by the flexural modulus.

In one embodiment, the present invention includes a binder composite product for use as a sawn timber substitute. Such a product may include a cured binder composite comprised of hydraulic cement, rheology modification agent and fibers. The cured α-glutinant composite can be characterized by the following: It is capable of being sawn by hand with a wood saw; a flexure module in a range of approximately 1.4 x 10 9 Pa (200,000 psi) to approximately 3.4 x 10 10 Pa (5,000,000 psi); a bending force of up to approximately 2.8 x 10 7 7a (4,000 psi); a preferred density less than approximately 1.2 g / cm3, more preferably less than approximately 1.15 g / cm3, even more preferably less than about 1.1 g / cm3, and more preferably less than about 1.05 g / cm3, and fibers substantially evenly distributed across the cured binder composition, preferably in a concentration -traction greater than approximately 10% by dry weight Construction products made in accordance with the present invention are much harder than cement-like paper-like products, because the fibers are dispersed substantially homogeneously (i.e. not in layers, as in the Hatschek process), the building products do not separate or defoliate when exposed to moisture.

The cured binder composition is prepared by mixing an extrudable binder composition including water at a concentration of from about 25% to about 75% by weight, hydraulic cement at a concentration of from about 25% to about 75% by weight, a rheology modification in a concentration of about 0.25% to about 5% by weight wet and fiber at a concentration greater than about 5% by weight wet. The extruded compositions are characterized as having a clay-like consistency with high deformation stress, Binghamian plastic properties and immediate stability. Once mixed, the extrudable binder composition can be extruded into a green extrudate having a predefined cross-sectional area. The green extrudate is advantageously stable with the extrusion so as to be able to retain its cross-sectional area and shape so as not to lower after extrusion and to allow manipulation without disruption. After being extruded , the hydraulic cement within the green former may be cured to form the cured binder composite.

According to one embodiment, the amount of water that is initially used to form an extrusable composition is reduced by evaporation before, during or after hydration of the cement binder. This can be accomplished by drying in an oven, typically at a temperature below the boiling point of water to produce controlled drying while not interfering with cement hydration. There are at least two benefits that result from drying: (1) the water-to-cement ratio can be reduced, which increases the strength of the cement paste, and (2) the waterlessness leaves the porosity behind, which can substantially reduce especially the density and hardness of the resulting product without a concomitant reduction in strength.

The nominal or apparent water / cement ratio of the extrusable composition may initially be in a range approximately 0.8 to approximately 1.2. However, the actual water / cement ratio based on water that is actually available for cement hydration is typically much lower. For example, after removing a portion of water by evaporation, the resulting water / cement ratio is typically in the range of from about 0.1 to about 0.5. For example, preferably about 0.2 to about 0.4, more preferably about 0.25 to about 0.35, and most preferably about 0.3. It has been found that not all added water can be removed by evaporation by heating in a furnace at a temperature of 63 ° C (145 ° F), indicating that some of the water is able to react with and hydrate the cement while heating, making it chemically alloyed water instead of free water that can be evaporated. This process differs from steam curing processes in that no water is removed, or that heats a material above the boiling point of water, where water is removed very quickly to allow significant hydration of the particles. of cement.

The fibers used in the binder composites according to the invention may be one or more hemp fibers, cotton fibers, flat leaf or stem fibers, hardwood fibers, softwood fibers, glass fibers, graphite fibers, silica fibers, ceramic fibers, metal fibers, polymer fibers, polypropylene fibers and carbon fibers. The amount of fibers which are substantially evenly distributed through the cured binder composition is preferably greater than approximately 15% by dry weight, more preferably greater than approximately 20% by dry weight. Some fibers, such as wood or plant fibers, have a high affinity for water and are capable of absorbing substantial amounts of water. This means that some of the water added in a binder composition to make it extrusible can be bonded with the fibers, thereby reducing the effective water / cement ratio as fiber-bound water is not readily available to hydrate, cement binding agent.

The hydraulic cement binder used in the binder composites according to the invention may be one or more of Portland cements, MDF cements, DSP cements, Densit type cements, Pyrament cements, calcium aluminate cements, mortars, cements. of silicate, gypsum cements, phosphate cements, alumina altoteor cements, micro fine cements, slag cements, magnesium oxychloride cements and combinations thereof. The cement binder contributes at least approximately 50% of the binding strength of the construction product (eg in combination with the binding strength of the rheology modifying agent). Preferably, the hydraulic cement will contribute at least about 70% of the overall bonding force, more preferably at least about 80% and most preferably at least about 90% of the bonding strength. Because the hydraulic cement binder contributes substantially to the overall strength of construction materials, they are much stronger and have much higher flexural hardness compared to similar products using hydraulic cement mainly as a filler (ie , by heating to 150 ° C and above to rapidly remove all or substantially all water by evaporation).

The rheology modifying agent may be one or more of polysaccharides, proteins, celluloses, starches such as amylpectin, amylose, seagel, starch acetates, starch hydroxyethers, ionic starches, long chain alkyl starches, dextrins, amine starches, phosphate starches, dialdehyde starches, cellulosics such as methylhydroxyethylcellulose, hydroxymethylcellulose, carboxymethylcellulose, methylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose and clay. The rheology modifying agent is preferably included in an amount in a range of from about 0.25% to about 5% by weight of the binder composition, more preferably in a range of from about 0.5% to approximately. 4% by weight wet, and more preferably in a range of from about 1% to about 3% by wet weight. Like fibers, the rheology modifying agent can bind with water, thereby reducing the effective water / cement ratio compared to nominal reason based on actual water added rather than water that is available for hydration. Although the rheology demodifying agent may act as a binder, it will electically contribute less than approximately 50% of the overall binding strength.

Optionally, a fixation accelerator at a concentration of about 0.01% to about 15% by dry weight may be included, where the fixation accelerator may be one or more of Na2OH, KCO3, KOH, NaOH, CaCl2, CO2, magnesium chloride. triethanolamine, aluminates, inorganic HCl salts, inorganic HNO3 salts, inorganic H2SO4 salts, calcium silicate hydrates (CSH) and combinations thereof. Attachment accelerators may be especially useful where rapid force is desired for manipulation and / or where a portion of the water is removed by evaporation during initial hydration.

An aggregate material may also be included, which is one or more of sand, dolomite, gravel, stone, basal-to, granite, limestone, sandstone, glass beads, airgel, perlite, vermiculite, exfoliated stone, xerogels, mica, clay, synthetic clay, alumina, silica, ash particle, silica gas, tabular alumina, kaolin, glass microspheres, ceramic spheres, gypsum dihydrate, calcium carbonate, calcium aluminate and combinations thereof.

In one embodiment, the cured binder composite may receive a 10d nail being hammered into it with a hand hammer. The cured binder composite may have an extraction resistance of at least about 4380N / m (25 lbf / in) for the 10d nail, preferably at least about 8760 N / m (50 lbf / in) for the 10d nail. Additionally, the cured binder composite may have an extraction resistance of at least approximately 52χ 10 ^ 3 N / m (300 lbf / in) for a screw, preferably at least about 87600 N / m (500 lbf / in) for one screw. the screw. Extraction strength is generally related to the amount of fibers within the binder composite (i.e. increases with increasing fiber content, all things being equal). The fibers create greater localized fracture energy and hardness that resists fracture formation in and around a hole made by a nail or screw. The result is a spring-back effect in which the die retains the nail by frictional forces. or the bolt by both frictional and mechanical forces.

In one embodiment, the method of manufacturing the binder composite may include extruding the extrudable binder composition around at least one reinforcement member selected from the group consisting of reinforcement bar, wire, mesh and screen to provide a suitable composition. at least partially encapsulate the reinforcement element within the green extrudate.

In one embodiment, the method of manufacturing the binder composite product may include the following: extruded green extrudate having at least one continuous hole which is stable in form; inserting a reinforcement bar and a bonding agent into the continuous bore while the binder composite is in a stable green state or is at least partially cured and joining the reinforcement bar on a surface of the continuous hole with the bonding agent. Optionally, the bonding agent is applied to the reinforcement bar before inserting the reinforcement bar.

In one embodiment, the method of manufacturing the binder composite product may include configuring the binder composite in a construction product to be a substitute for a sawn timber construction product. As such, the construction product may be manufactured in a shape selected from the group consisting of a rod, rod, pipe, cylinder, plate, I-beams, general purpose pile, upholstery plate, two by four, one by eight, panel, Flat sheet, tile and a board having a hollow interior. Construction products are typically manufactured using a process that includes extrusion, but may also include one or more intermediate or finishing procedures. An intermediate procedure typically occurs while the composition is in a green, uncured state, while a finishing procedure typically occurs after the material has been cured or hardened.

Unlike wood, which cannot be appreciably softened except by damaging or weakening the timber structure, concrete is plastic and moldable before curing. Construction products made from it can be re-modeled (ie, bent or bent) while on a green state to produce shapes that are generally difficult or impossible to obtain using real wood. The binder surface or matrix of construction products can be treated to be waterproof using waterproofing agents such as silanes, siloxanes, latexes and other waterproofing agents known in the concrete industry, which is an added advantage over the wood. Such materials may be mixed and / or applied to the surface of the binder building products.

Construction products may be solid or they may be hollow. Providing continuous holes by extruding around a solid mandrel to produce a continuity produces lightweight construction products. One or more of such holes may be filled with barrel reinforcement (e.g., bonded with epoxy or other adhesive), they may provide a conduit for the electrical wires or they may be used to screw into the construction product as a pre-drilled hole. Construction products can comprise complex extruded structures. They can be virtually any size or cross-sectional shape. They can be formed into large sheets (eg by roller extrusion) or blocks (eg through large die openings) and then milled into smaller sizes such as wood. .

In one embodiment, a method of manufacturing the binder composite product may include stably processing the green extrudate and / or binder composite cured by at least one process selected from the group consisting of bending, stamping, impact molding, cutting, being - grinding, sanding, milling, textured finishing, planing, polishing, polishing, hole pre-drilling, dyeing and impregnation.

In one embodiment, a method of manufacturing the binder composite product may include recycling a portion of a leftover green extrudate or cut-out material from the main body of a construction product (e.g., by stamping), where recycling includes combining the waste material. spare green extruder with an extrusable binder composition.

In one embodiment, the process for curing the hydraulic cement may include thermal curing or autoclaving.

In one embodiment, the extrusion may be through a die opening. Alternatively, the extrusion may be by roller extrusion.

These and other embodiments and aspects of the present invention will become more fully apparent from the detailed description and appended claims, or may be learned from the practice of the invention as follows.

BRIEF DESCRIPTION OF DRAWINGS

To further clarify the above and other advantages and aspects of the present invention, a more particular description of the invention will be given by reference to its specific embodiments which are illustrated in the accompanying drawings. It is found that these drawings represent only typical embodiments of the invention and, therefore, should not be considered as limiting their scope. The invention will be described and explained with further specificity and detail using the accompanying drawings in which:

Figure 1A is a schematic diagram illustrating one embodiment of an extrusion process for the manufacture of a binder construction product.

Figure IB is a schematic diagram illustrating one embodiment of an extrusion die head for manufacturing a binder construction product having a continuous hole extending therethrough;

Figure IC is a perspective view illustrating details of the cross-sectional areas of extruded binder construction products.

Figure 2 is a schematic diagram illustrating one embodiment of a roller extrusion process for preparing a binder construction product;

Figures 3A-D are perspective views illustrating co-extrusion embodiments of a binder construction product with a structurally reinforcing element;

Figure 4 is a schematic diagram illustrating an embodiment of a process for structurally reinforcing a binder construction product;

Figure 5A is a perspective view showing a concrete illustration of the prior art and a nail inserted therein.

Figure 5B is a perspective view illustrating one embodiment of a binder construction product and a nail inserted therein;

Figure 6A is a longitudinal sectioned view of Figure 4,

Figure 6B is a view of the middle level cross section of Figure 6A,

Figure 7A is a longitudinal sectioned view of figure 5,

Figure 7B is a view of the middle level cross section of Figure 7A,

Figure 8 is a graph of the bending forces of the wood, one embodiment of a binder construction product and one embodiment of a binder reinforced binder construction product;

Figure 9 is a graph of a tensile force of one embodiment of a binder construction product and

Figure 10 is a graph of wood displacement and one embodiment of a binder construction product by a compressive force.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In general, the present invention relates to binder compositions and methods for preparing such compositions and fabricating α-glutinating construction products which have properties similar to wood-building products. The terminology used here is used for the purpose of describing particular embodiments only and is not intended to be limiting.

I. General Definitions

The term "multiple components" refers to fiber-reinforced binder compositions and extruded composites prepared therefrom, which typically include three or more chemically or physically disintegrated materials or phases. For example, such extrusable compositions and resulting construction products may include components such as rheology modifying agents, hydraulic cements, other hydraulically fixable materials, fastening accelerators, fibers, inorganic aggregate materials, organic aggregate materials, dispersants, water and other liquids. Each of these broad categories of materials provides one or more unique properties for the extruded mixtures prepared therefrom as well as the final article. Within these broad categories, it is also possible to include different components (such as two or more inorganic aggregates or fibers) which may impart different but complementary properties to the extruded article. The terms "hydraulically fixable composition" and " binder composition "are intended to refer to a broad category of compositions and materials that contain both a hydraulically fixable binder and water, as well as other components, despite the extent of hydration or cure that has occurred. As such, the binder materials include hydraulic pastes or hydraulically affixable compositions in a green (i.e. unhardened, molten, or moldable) state and a hardened or fixed binder construction product.

The term "homogeneous" is intended to refer to a composition to be equally mixed so that at least two random samples of the composition have approximately or substantially the same concentration and distribution of a component.

The terms "hydraulic cement", "hydraulically fixable binder", "hydraulic binder" or "cement" are intended to refer to the component or combination of components within an ouhydraulically fixable binder composition which is an inorganic binder such as, for example, Portland cement, ash particle, and thickening and curing after being exposed to water. These hydraulic cements develop greater mechanical properties such as hardness, compressive strength, bending force, bending force, and surface bonding. component (eg aggregate agglutination in cement) by chemically reacting with water.

The terms "hydraulic paste" or "cement paste" are intended to refer to a mixture of hydro-hydraulic cement and green water as well as hardened paste that results from hydration of the hydraulic binder. Overall, within a hydraulically fixable composition, the cement paste binds individual solid materials such as fibers, cement particles, aggregates and so on.

The terms "fiber" and "fibers" include both natural and synthetic fibers. Fibers typically having an aspect ratio of at least about 10: 1 are added in an extrusable binder composition to increase elongation, deflection, hardness and fracture energy, as well as bending and tensile forces of the resulting extruded composite or product. of finished building. Fibers reduce the likelihood that green extruded, extruded articles, and hardened or cured articles produced from them will break or break when forces are applied to them during handling, processing, and curing. Also, the fibers may provide wood-like properties to binder-building products such as nail retention, screw retention, pullout strength and the ability to be machine-sawed or hand-sawed and / or drilled with a wood drill. Fibers can absorb water and reduce the effective water / cement ratio.

The term "fiber reinforced" is intended to refer to fiber reinforced binder compositions that include fibers to provide some structural reinforcement to enhance the mechanical property associated with green extrusion, extruded articles and hardened or cured composites. as well as the construction products produced from them.

Additionally, the key term is "reinforced", which clearly comprises the extrudable, extruded green binder compositions and cured construction products of the present invention of the fixable compositions and conventional binder articles. Fibers act primarily as a reinforcing component to specifically add tensile strength, flexibility and hardness to construction products as well as to reinforce any cut or formed surfaces thereon. Because they are substantially homogeneously dispersed, construction products do not separate or deflate when exposed to moisture as can binder construction products made using the Hatschek process.

The term "mechanical property" is intended to include a property, variable or parameter that is used to identify or characterize the mechanical strength of a substance, composition or article of manufacture. Thus, a mechanical property may include the amount of elongation, deflection, or compression before rupture or rupture, stress and / or stress before rupture, compressive strength, compressive strength, Young's modulus, hardness, firmness, deformation, resistance, extraction resistance and so on.

The terms "extruded", "extruded form" or "extruded article" are intended to include any known or future projected form which is extruded using the extrudable compositions and methods of the present invention. For example, the extruded composite may be prepared from rods, rods, pipes, cylinders, plates, I-beams, general purpose pilings such as power poles, telephone poles, antenna poles, cable poles. and so on, two by four, one by four, panels, flat sheets, other traditional wood products, shingles, electrical tendon boards, and reinforcing bar reinforcement articles. Additionally, an extruded construction product may initially be extruded as an "unfinished form" and will then be shaped, milled or otherwise refined in a manufacturing article, which is intended to be included under these terms. For example, a slab or large block (for example a 16 by 16) may be cut or milled in a plurality of two by four.

The term "extrusion" may include a process where a material is processed or pressed through an opening or across an area having a certain size to shape the material to conform to the opening or area. A material through a die opening may be an extrusion form. Alternatively, roller extrusion, which includes pressing a composition between a set of rollers, may be another form of extrusion. Roller extrusion is described in more detail below in Figure 2. In any event, extrusion refers to a process that is used to model a blunt, milling, sawing or similar moldable composition, and generally includes compression or passage of the core. material through an opening having a predefined cross-sectional area.

The terms "hydrated" or "cured" are intended to refer to a level of a hydraulic reaction that is sufficient to produce a hardened binder construction product having obtained a substantial amount of its potential or maximum strength. However, the extruded binder compositions or construction products may continue to hydrate or cure long after they have achieved significant hardness and a substantial amount of their maximum strength.

The terms "green", "green material", "green extruded" or "green state" are intended to refer to the state of a binder composition that has not yet achieved a substantial amount of its ultimate strength; however, the "green state" is designed to identify that the binding composition is sufficiently cohesive to retain an extruded form before being hydrated or cured. As such, a freshly extruded former extruded comprised of hydraulic cement and water should be considered to be "green" before a substantial amount of hardening or curing has occurred. The green state is not necessarily a clear cut demarcation line for the amount of hardness or hardening that has occurred, but it must be interpreted as the state of the composition before being substantially cured. Thus, a binder composition is in the green state after extrusion and before it is substantially cured. The term "stably" is intended to refer to the condition of a green extrudate immediately with extrusion which is characterized by the extrudate having a structure. stable that does not deform under its own weight. As such, a green extrudate that is stably can retain its shape during handling and further processing.

The term "composite" is intended to refer to a stably composition that is composed of distinct components such as fibers, rheology modifiers, cement, aggregates, fixation accelerators, and so on. As such, a composite is formed when the hardness or shape stability of the green extrudate increases and can be prepared in a construction product.

The term "dry weight" is intended to be a composition being characterized without the presence of water or another equivalent solvent or hydration reagent. For example, when relative concentrations are expressed as dry weight percentages, relative concentrations are calculated as if there was no water. Thus, dry weight is unique to water.

The term "wet weight" is intended to refer to the composition being characterized by the moisture content that emerges from the presence of water. For example, the relative concentration for the wet weight of a component is measured by a total weight that includes water and all other decomposition components.

The term "nail acceptance" is intended to refer to the ease of hammering a nail into a binder-building product. Nail acceptance is described by a numerical range which is defined as follows: 1 refers to a building product into which a nail can be easily hammered without bending, 2 refers to a more firm construction product such as a nail can be hammered without curvature, but which gives greater expertise and substantially downward pressure to prevent curvature, 3 refers to a construction product having a high level of firmness such that a nail is typically bent or deformed using the normal hammering action (but which can take a straight nail if a conventional nail gun having high strength is used).

As used herein, the term "pullout resistance" is intended to refer to the amount of force or pressure required to extract a fastening rod, such as a pre-go or screw, from a substrate such as wood, concrete and the construction product. inventive binder. Also, the extraction strength can be calculated by the drift force to extract an IOd nail (e.g., a 10-penny nail) embedded 2.54 cm (1 inch) in the cured binder composite. Extraction resistance is proportional to fiber content, all things being equal.

As used herein, the term "anchor rod" is intended to refer to a nail, screw, bolt or the like which is formed to form a hole within a substrate while being inserted into it. Such inserts may be performed by hammering, screwing, ballistics and so on. Additionally, the clamping rod may be used to secure an element to another clamping element to form holes when it is being inserted into each element.

The construction products of the present invention may typically be drilled using common wood drills and / or sawed using standard wood saws, as opposed to conventional concrete products requiring masonry drills and saw blades.

In view of the foregoing definitions, the following discussion presents the inventive aspects of embodiments of the present invention.

II. Compositions Used to Make Extruded Construction Products

The extrudable binder compositions used to make the extruded construction products according to the present invention include water, hydraulic cement, fibers, a rheology modifying agent and optionally a setting accelerator and / or an aggregate. Binder-building products are formulated to have less firmness and compressive strength compared to ordinary concrete, and have greater flexibility, softness, elongation, hardness and bending to better mimic the properties of re-al wood. In general, the tensile strength ratio for inventive binder compressed composites will be much higher than conventional concrete.

In addition, extrusable binder compositions and extruded construction products prepared therefrom may have some components which are substantially the same as in other multi-component compositions discussed elsewhere. Accordingly, additional information on the individual components of such multi-component compositions and mixtures, as well as some aspects of the methods used to manufacture extruded articles and calendered articles thereof, can be obtained from US Patents 5,508,072, 5,549. 859, 5,580,409, 5,631,097 and 5,626,954 and US Patent Application 60 / 627,563, which are incorporated herein by reference.

It should be understood, however, that the construction products of the present invention are substantially stronger and have greater flexural hardness compared to paper-like sheet products made using hydraulic cement, but where such sheets have been completely dried in a manner of seconds or minutes. using a heated Yan-kee roller significantly above the boiling point of the water (eg 150-300 ° C). Rapid evaporation of water interferes with hydration of the hydraulic cement, thereby converting it into a particulate filler rather than a binder. Controlled evaporation of water over a period of several days (at least about 2 days) at a temperature below the boiling point of the water (eg 100-175 ° F or approximately 40-80 ° C) removes excessive water. while still allowing hydration of the hydraulic cement binder. The construction products according to the invention are as different from the manufacture of paper-like sheets using cement as the two-by-four construction bonding products, and others made of wood from ordinary tree paper.

In one embodiment, the calendering equipment and processes described in the incorporated references may be used with the compositions described herein. However, the tightness between the calenders can be adjusted to produce boards or other products which are of a size to be used as binder construction products (this is at least about 2 mm, preferably at least about 5 mm). mm, more preferably at least about 1.25cm and most preferably at least about 2.5cm (at least about 1/8 inch, preferably at least 1/4 inch, more preferably at least 1/4 inch). 2 inches and most preferably at least 1 inch). For example, the process described in US 5,626,954 may be modified to calender larger materials to yield wood-like boards, such as two four, one by ten and one by ten. Also, the benefits of the calendering process can be used to prepare wood-like boards of any length, such as lengths that are essentially impossible to obtain from real wood. allow inventive wood-like planks to be manufactured to have cross-sectional areas and custom lengths such as lengths of 2.6 m (8 ft 8 inches), 12.2 m (40 feet), 18.3 m ( 60 feet) and 24.4 m (80 feet).

A. Hydraulic Cement

The extrudable binder compositions and the binder construction products include one or more hydraulic decking types. As discussed below, while the rheology modifier can contribute most of the strength to the green extruded and extruded composition, the hydraulic cement can contribute most of the strength to the binder composite or construction product after curing or Hydration begins. Examples of hydraulic cements and associated properties and reactions throughout the manufacturing process as well as in the finished fiber reinforced construction product can be found in the incorporated references. For example, hydraulic cement may be white cement, gray cement, aluminate cement, type I-V cement, and so on.

The extrusable composition may include various amounts of hydraulic cement. In general, the amount of hydraulic cement in an extrusable composition is described as a wet percentage (eg wet weight% or wet volume%) to account for the water present. As such, the hydraulic cement may be from about 25% to about 75% by weight wet, more preferably from about 35% to about 65% by weight wet and more preferably from about 40 to 60% by weight. wet weight of extrudable composition.

Briefly, within the extruded product, the hydraulic cement forms a cement paste or gel reacting with water, where the speed of reaction can be greatly increased by the use of clamping accelerators and the physical properties of the binder construction product. are modulated by a high concentration of fibers. Generally, the amount of hydraulic cement in a cured binder composite is described as a dry percentage (eg% by dry weight or% by dry volume). The amount of hydraulic cement may range from about 40% to about 95% dry weight, more preferably about 50% to about 80% dry weight, and most preferably from about 60% to about 75% by weight. dry. It should be recognized that some products may use more or less hydraulic cement as required and depending on the other constituents.

Hydraulic cement, more specifically the hydraulic cement or paste formed by the reaction or hydration with water, will typically contribute at least about 50% of the general bond strength of the inventive construction products, preferably at least about 70%, more preferably at least about 50%. about 80% and even more preferably at least about 90% of the general agglutination force. This is a direct result of maintaining a relatively low water-to-cement ratio (for example, by one or more controlled early heating to slowly remove a portion of the water by evaporation and / or water absorption by the fibers and / or agent). rheology modification).

B. Water

In one embodiment, water may be used at relatively high amounts within the extrudable composition to increase the mixing rate, extrusion capacity, curing rate and / or porosity of the finished extruded products. Although the addition of more water has For the effect of reducing compressive strength, this can be a desirable byproduct in order to produce a product that can be sawn, sanded, nailed, bolted and otherwise used as wood or as a wood substitute. Additionally, high concentrations of water in the extruded or extruded composition may be reduced by evaporation or heating. When water is evaporated from the green extrudate, shape stability and aporosity can be increased simultaneously. This is in contrast to typical concrete compositions and methods, where increasing porosity decreases green strength and vice versa.

Thus, the amount of water within the various mixtures described here can be drastically varied over a wide range. For example, the amount of water in the green extruded and extruded composition may range from about 25 wt.% Wet to about 75 wt.% Wet, more preferably from about 35 wt.% To about 65 wt.% And more preferably from about 40 wt.%. about 60% by weight wet. On the other hand, the cured composite or hardened construction product may have free water in less than 10% wet weight, more preferably less than about 5% wet weight and more preferably less than about 2% wet weight. water by weight; however, additional water may be agglutinated with the rheology modifier, fibers or aggregates.

The amount of water in the extrudate during the rapid reaction period should be sufficient to cure or hydrate to provide the finished properties described here. However, maintaining a relatively low water to cement ratio (ie w / c) increases the strength. of the final binder construction products. Accordingly, the actual or nominal ratio of water to cement will typically initially range from about 0.75 to about 1.2. In some cases, the actual or nominal water to cement ratio may be greater than 1.5 or 1.75 to produce construction products having very high porosity and / or less firmness and greater sawmill, preaching capacity and / or bolting capacity.

The water to cement ratio affects the ultimate strength of the hydraulic cement binder. Controlled removal of water by evaporation (for example, over a period of days, such as at least about two days) not only increases the strength of green in the short term, it can increase the long-term strength of the cement binder by reducing water content. for cement. Additionally, water may be used to provide porosity for the finished product present during the forming process and then rapidly removing a portion of the water. Rapid removal of water may result in voids in the finished product to increase porosity. Also, this may decrease the amount of water, increase the strength of the binder and provide a correct ratio of water strength to binder. The water-to-cement ratio following heat-controlled evaporation will preferably be less than about 0.5 (i.e., in a range of from about 0.1 to about 0.5, preferably about 0, 2 to about 0.4, more preferably about 0.25 to about 0.35 and more preferably about 0.3).

The amount of water is also selected in order to produce a construction product having a desired density. Because the ability to saw, nail or screw together the binder construction products according to the invention is related to density (i.e., the smaller the density, the easier it is to saw, nail and / or screw on the composite using woodworking tools), the amount of water can be selected to produce a product having a desired level of porosity. In general, increasing the amount of water that is removed by evaporation before, during or subsequent to curing reduces the density of the final cured construction product.

In the case where it is desirable for building products to have properties similar to those of wood, it would be preferable that the density be less than about 1.2 g / cm3, more preferably less than about 1.15 g. / cm3, even more preferably less than about 1.1 g / cm3 and more preferably still less than about 1.05 g / cm3.

In addition to having wood-like properties that enable sawing, nailing and screwing using conventional woodworking tools, the construction materials according to the invention can be finished by using a milling cutter and planer.

C. FibersExtruded composition and extruded construction products include a relatively high fiber concentration compared to conventional concrete compositions. Moreover, the fibers are typically dispersed substantially homogeneously throughout the binding composition in order to maximize the beneficial properties afforded by the fibers. The fibers are present in order to provide structural reinforcement for the extruded, extruded green composition and the binder construction product. The screws also provide nail and bolt retention by providing a spring return effect, providing micro-level hardness, preventing the formation of cracks or catastrophic failure at or around the nail or bolt hole. Fibers that can absorb substantial amounts of water (eg wood, plant or other cellulose-based fibers) can be used to reduce the effective water / cement ratio (ie based on water that is actually available for hydration of cement).

Various types of fibers can be used to achieve specific characteristics. For example, the binder compositions may include naturally occurring organic fibers extracted from hemp, cotton, plant leaves or stems, hardwood, softwood or the like, fibers made from organic polymers, examples of which include nylon. polyester (i.e. polyamide, polyvinyl alcohol (PVA), polyethylene and polypropylene and / or inorganic fibers, examples of which include glass, graphite, silica, silicates, alkali-resistant micro-glass made using borax, ceramics, fiber carbon fibers, carbides, demetal materials, and so on Preferred fibers, for example, include fiberglass, woolastanite, abaca, bagasse, wood fiber (e.g. soft pine, southern pine, a-beto and eucalyptus), cotton, silica nitride, desilic carbide, silica nitride, tungsten carbide and Kevlar, however other types of fibers may be used.

Fibers used in the manufacture of α-glutinating compositions may have a high length-to-width ratio (or "aspect ratio") because longer, narrower fibers typically impart more strength per person to the finished construction product. The fibers may have an average aspect ratio of at least about 10: 1, preferably at least about 50: 1, more preferably at least about 100: 1 and most preferably even greater than about 200: 1. 1.

In one embodiment, the fibers may be used in various lengths such as, for example, from about 0.1cm to about 2.5cm, more preferably from about 0.2cm to about 2cm and most preferably. from about 0.3 cm to about 1.5 cm. In one embodiment, the fibers may be used in lengths of less than about 5 mm, more preferably less than about 1.5 mm and more preferably smaller than about Imm.

In one embodiment, very long or continuous fibers may be mixed in the binder compositions. As used herein, a "long fiber" is intended to refer to a thin long synthetic fiber that is longer than about 2.5 cm. As such, a continuous fiber may be present in lengths ranging from about 2.5 cm to about 10 cm, more preferably from about 3 cm to about 8 cm and most preferably from about 4 cm to about 5 cm.

The concentration of fibers within the extrudable binder compositions may vary widely in order to depress various properties for the extruded composition and the finished product. In general, the fibers may be present in the extrudable composition in the range of about 2% to about 50% by weight wet within the composition, more preferably from about 5% to about 40% and even more preferably. from about 8% to about 30% and more preferably from about 10% to about 25% by weight wet.

The concentration of the fibers within the cured binding composites may be in the range of about 3% to about 65% by dry weight, more preferably from about 5% to about 50% and even more preferably from about 8% to about 50%. 40% and more preferably from about 10% to about 30% by dry weight.

In another embodiment, the fibers may be present in more than about 10% by volume, preferably more than about 15% by volume, preferably more than 20% by volume, even more preferably. more than about 25% by volume and more preferably even more than about 30% by volume.

Additionally, specific types of fibers may vary in amount in the compositions. Accordingly, PVA may be present in a binder composition cured to about 5% by dry weight, more preferably from about 1% to about 4% and more preferably from about 2% to about 3.25%. Moles and / or woods may be present in a binder composition cured in amounts described above with respect to the general fibers or present up to about 10% dry weight, more preferably up to about 5% dry weight and most preferably up to about 3.5. % dry weight. Newspaper fibers may be present in a binder composition cured in amounts described above with respect to the general fibers or present up to about 35% dry weight, more preferably from about 10% to about 30% dry weight and most preferably about from 15% to about 25% by dry weight.

In one embodiment, the fiber type may be selected based on the desired structural aspects of the finished product comprised of the binder construction product, where it may be preferred to have dense synthetic fibers compared to light natural fibers or vice versa. Typically, the specific gravity of natural or wood fibers ranges from about 0.4 for cherry wood fibers to about 0.7 for birch or mahogany. On the other hand, synthetic fibers may have specific gravities ranging from about 1 for polyurethane fibers, about 1.5 for Kevlar fibers, about 2 for graphite and quartz glass, about 3.2 for silicon carbide. and desilicon nitride, about 7 to about 9 for most metals with about 8 for stainless steel fibers, about 5.7 for zirconium dioxide fibers, about 15 tungsten carbide parafibers. As such, natural fibers tend to have densities of less than 1 and synthetic fibers tend to have densities of from about 1 to about 15.

In one embodiment, various fibers of different densities may be used together within the α-glutinating compositions. For example, it may be beneficial to combine the properties of a cherry wood fiber with a silicon carbide fiber. Thus, a combined fiber / synthetic system may be used in ratios ranging from about 10 to about 0.1, more preferably about β to about 0.2, even more preferably about 5 to about 0.1. about 0.25 and more preferably about 4 to about 0.5.

In one embodiment, a mixture of regular or long length fibers such as pine, spruce or other natural fibers may be combined with micro-fibers such as woolastinite or glass fibers to provide unique properties including greater hardness. , flexibility and bending strength, with larger and smaller fibers acting at different levels within the binder matrix.

In view of the foregoing, the fibers are added in relatively high amounts to produce a binder construction product having greater tensile strength, elongation, deflection, deformability and flexibility. For example, the high amount of fiber produces a binder construction product that may have a defixing rod inserted therein, with an extraction resistance that is resistant to extraction. The fibers contribute to the ability of the binder construction product to be sawn, screwed, sanded and polished like wood, or the fluff of the fibers may be exposed by polishing to produce a suede-like or fabric-like surface.

Additionally, the extrusable binder composition and the cured binder composites may include powders. Although saw dust can be considered to be fibrous, it is generally comprised of a plurality of fibers held together with lignin or other natural aglomeration material. The fibers may provide characteristics for the extrusable binder composition or cured binder composites which differ somewhat from the characteristics provided by the true fibers. In some cases the dust spills can function as a filler. Saw dust can be obtained as a by-product of sawmills and other facilities where lumber or timber products are cut or milled. The extrudable binder composition may include saw dust up to 10% by weight, preferably up to 15% by weight, more preferably up to 20% by weight and most preferably from about 10% to about 20% by weight. Thus, the cured binder composites may include saw dust up to 12% by dry weight, preferably up to 18% by dry weight, more preferably up to 25% by dry weight and most preferably about 6% by dry weight. from 12 to about 20% dry weight.

D. Rheology Modifying Agent In preferred embodiments of the present invention, the extrudable binder compositions and the binder building products include a rheology modifying agent ("rheology modifier"). The rheology modifier may be mixed with water and fibers to aid in substantially uniform (or homogeneous) distribution of the fibers within the binder composition. Additionally, the rheology modifier may provide shape stability for an extruded. In part, this is because the rheology modifier acts as a binder when the composition is in a green state to increase early green strength so that it can be manipulated or otherwise processed without the use of molds or other retention devices. form. The rheology modification agent helps to control porosity (i.e. it produces evenly dispersed pores when water is removed by evaporation). In addition, the rheology demodifying agent may provide greater hardness and flexibility for a cured composite which may result in improved deflection characteristics. Thus, the dermatology modifier cooperates with other composition components in order to obtain a more deformable, flexible, bendable, compact, hard and / or elastic binder construction product.

For example, variations in the type, molecular weight, degree of branch, quantity and distribution of the rheology modifier may affect the properties of the extrudable composition, green extrudate and binder construction products. As such, the type of rheology modifier may be any polysaccharide, proteinaceous material and / or synthetic organic material which is capable of being or providing the rheological properties described herein. Examples of some suitable polysaccharides, particularly cellulosic ethers, include methylhydroxyethylcellulose, hydroxymethylcellulose, carboxymethylcellulose, methylcellulose, ethylcellulose, hydroxyethylcellulose and hydroxyethylpropylcellulose, starches such as amylpectin, amylose, amidoethyl amido amide acetate , ionic starches, long chain alkyl starches, dextrins, amine starches, phosphate starches and dedialdehyde starches, polysaccharide gums such as seagel, alginic acid, phycocolloids, agar, gum arabic, locust bean gum, karaia gum, gum tragacanth and so dian te te. Examples of some proteinaceous materials include collagen, caseins, biopolymers, biopolyesters and so on. Examples of synthetic organic materials that may yield rheology modification properties include petroleum-based polymers (e.g. polyethylene, polypropylene), latexes (e.g. styrene-butadiene) and biodegradable polymers (e.g. aliphatic polyesters). , polyhydroxyalkanoates, polylactic acid, polycaprolactone), polyvinyl chloride, polyvinyl alcohol and polyvinyl acetate. Clay may also act as a rheology modifier to aid in fiber dispersion and / or to provide shape stability for the green extruded composition.

The amount of rheology modifier within the extrudable composition and the binder construction product may vary from low to high concentrations depending on type, branch, molecular weight and / or interactions with other composition components. For example, the amount of rheology modifier present in the extrudable binder compositions may range from about 0.1% to about 10% by weight, preferably from about 0.25% to about 5% by weight, even more preferably from about 0.5% to about 5% and most preferably from about 1% to about 3% by weight wet. The amount of rheology modifier present in the cured binder compositions may range from about 0.1% to about 20% dry weight, more preferably from about 0.3% to about 10% dry weight, even more preferably from about 10%. from 0.75% to about 8% and most preferably from about 1.5% to about 5% by dry weight.

Additionally, examples of organosynthetic materials, which are plasticizers generally used together with the rheology modifier, include polyvinyl pyrrolidones, polyethylene glycols, polyvinyl alcohols, polyvinyl ethers, polyacrylic acid salts, polyvinylacrylic acids, polyvinylacrylic salts, polyvinylacrylic acid, polyacrylamides, ethylene oxide polymers, polylactic acid, synthetic clay, styrene-butadiene copolymers, latex, its copolymers, their mixtures and so on. For example, the amount of plasticizers in the composition may range from non-plasticizer to about 40% dry weight plasticizer, more preferably from about 1% to about 35% dry weight plasticizer, even more preferably about. from 2% to about 30%, and most preferably from about 5% to about 25% by dry weight.

The rheology modifying agent will typically yield less than 50% of the overall binding strength of inventive construction products. They may indirectly increase the strength of the cement paste, however, by reducing the effective water / cement ratio. Water that is agglutinated by the rheology modifying agent is generally not readily available for hydration of hydraulic cement agglutination, thereby reducing the general amount of water that is available for cement hydration.

E. Filling

In one embodiment, the extrudable composition, green extrudate and cured binder composite may include fillers. Alternatively, there are cases where fillers are specifically excluded. Fillers, if used anyway, are generally included in smaller quantities and mainly to reduce the cost of extruded products. Because it is desired to obtain extruded products in the form of wood-like building material having the properties of wood, fillers should be selected that do not produce a product that is very hard and difficult to work with. Examples of fillers include expanded clays, perlite, vermiculite, kaolin, wollastonite, diatomaceous earth, limestone, plastic beads, glass beads, granulated rubber, granulated plastic, exfoliated vermiculite, talc, mica, and coarse sand are more preferable because they decrease weight and weight. density of the binder construction product. Some fillers, such as vermiculite and plastic beads, have elasticity, and may provide spring return to provide better clamping force for a clamping rod. Others, such as perlite and glass beads, are friable, which causes or allows them to be crushed when introducing a fixing stick, thereby increasing or providing friction to resist extraction. Additional information on the types and quantities of fillers that can be used in the binder compositions can be obtained from the incorporated references. Fillers such as exfoliated vermiculite, talc and mica may be platelet-shaped, and may seal longitudinally within the green extrudate by the former extruder.

In one embodiment, the extrusable binder compositions may include a widely varying amount of fillers. Specifically, when used, each of the fillers may be independently present in less than about 10 wt.% Wet, preferably less than about 7 wt.% Wet, more preferably less than about 3 wt. even more preferably it is from about 2% to about 12% by weight wet.

In one embodiment, the prepared binder compositions may include a wide variety of fillers. Specifically, when used, each filler may be independently present in less than about 15% dry weight, preferably less than about 10% dry weight, more preferably less than about 5% dry weight. and most preferably still about 3% to about 15% by dry weight. In some cases, fillers such as limestone may be present up to about 70% dry weight. For example, when included in a cured binder composition, vermiculite may be present in from about 2% dry weight to about 20% dry weight and preferably about 3% dry weight to about 16% dry weight.

F. Other Materials

In one embodiment, a setting accelerator may be included in the extrudable, green extruded composition and binder construction product. As described herein and in the incorporated references, the fixation accelerator may be included to shorten the duration of the induction period or to accelerate the onset of the rapid reaction period. In this way, traditional clamping accelerators such as MgCl2, NaC03, KCO3, CaCl2 and so on may be used, but may result in a decrease in the compressive strength of the binder product; however, it may be a desirable byproduct in order to produce a product that can be sawn, sanded, nailed and bolted like wood.

For example, traditional clamping accelerators may be present in the green extrudate from about 0.001% to about 5% total dry weight, more preferably from about 0.05% to about 2.5% dry weight, and about 0.5%. more preferably from about 0.11% to about 1% dry weight.

In one embodiment, the fixation accelerator includes calcium silica hydrate (C-S-H). C-S-H can be prepared by forming a CaO-SiO2-H2O precipitate by adding aqueous Ca (NOa) 2 and NaSiO3 solutions at room temperature and forming a precipitate. Further details of the preparation and use of such a C-S-H clamping accelerator can be obtained in U.S. Provisional Application 60 / 627,563, previously incorporated by reference. Additionally, an increase in the amount of the C-S-H clamping accelerator may not substantially decrease the compressive strength of the binder construction product. For example, CSH may be present in the green extrudate from about 0.01% to about 15% by dry weight, more preferably from about 0.5% to about 10% dry weight, and most preferably from about 10%. 1% about 5% by dry weight. Thus, the amount of C-S-H clamping accelerator mixed in the extrudable composition may be greater than the amount of traditional clamping accelerators without compromising the strength of the finished product.

In addition, it may be favorable to combine the properties of traditional clamping accelerators with CSH, where the ratio of traditional clamping accelerator to C-SH may range from about 0.2 to about 5, more preferably from about 0.25 to about 4, and most preferably from about 0.5 to about 2.

Alternatively, the amount of C-S-H-defix accelerator or the corresponding concentrations of calcium and silicate may be maintained or only slightly varied throughout the induction period and the rapid deriving period so as to remain substantially constant in the final cured binder construction product.

In one embodiment, the binder compositions may include an additive material. Alternatively, there are cases where additive materials are specifically excluded. Additives, if used in any way, are generally included in smaller quantities and mainly to reduce the cost of extruded products. In some cases, additives may be used to modify the strength of the product. Some examples of additives may be water-reactive polyolanic materials, have a high pH and are somewhat agglutinating. Examples of pozzolanic materials include pozzolanic ash, plowed earth, ash particle, silica gas and so on.

Additionally, the binder compositions may include dyes or pigments to change color or provide custom-colored binder composite binder construction products. Dyes or pigments that are routinely used in the binder compositions may be applied in the present invention.

Other specific materials which may be present in the binder compositions may include guar gum, darauair, TiO2, delvo, 30/30 glenium, LatexAc 100, pozzilithNC534 and other similar materials. For example, TiO 2 may be present from about 0.5% to about 1.5% by weight, preferably from about 0.7% to about 1.3% by dry weight; delvo may be present from about 0.05% to about 0.5% dry weight, preferably from about 0.06% to about 0.37% dry weight; 30/30 glycene may be present from about 0.25% to about 0.5% dry weight, preferably from about 0.3% to about 0.4% dry weight; LatexAc 100 may be present from about 0.75% to about 3% by dry weight, preferably from about 0.95% by dry weight to about 2.80% by dry weight and pozzilith NC534 may be present from about 1, 25% to about 2% dry weight, preferably from about 1.4% to about 1.5% dry weight.

In one embodiment, the binder compositions may include additional optional materials such as dispersants, polymeric binders, nucleating agents, volatile solvents, salts, buffering agents, acidifying agents, coloring agents and so on. Specifically, when used, such additional optional materials, some of which are discussed in the incorporated references, may each be independently present in less than about 10% dry weight, more preferably less than about 5%. dry weight and more preferably still less than about 1% dry weight.

In one embodiment, a substantially cured binder extrudate that is fiber reinforced may be overcoated with a protective or sealing material such as paint, coloring, varnish, texture coating and so on. As such, the coating may be applied to the binder construction product after it is substantially cured. For example, the binder construction product may be impregnated such that the fibers present on the surfaces are of a different tone than the rest of the binder construction and / or textured to resemble a wood product.

Known sealants in the concrete industry may be surface applied and / or incorporated into the binder matrix to provide waterproof properties.

These include silanes and siloxanes. In addition, C-S-H particles may be surface applied and / or mixed in the matrix to provide a waterproof appearance. Precipitated hydrated decement paste may also be applied to the surface to provide a waterproof or other protective appearance.

III. Construction Product Manufacturing

Figure 1 is a schematic diagram illustrating one embodiment of a manufacturing system and equipment that may be used during the formation of an extrusable, extruded green, binder composite and / or construction product composition. It should be recognized that this is only an illustrated example for the purpose of describing a general processing system and equipment, where various additions and modifications may be made therein to prepare inventive binder compositions and construction products. Also, the schematic representation is not shall be construed in any way limiting the presence, disposition, shape, orientation or size of any of the aspects described in conjunction therewith. With that said, a more detailed description of the system and equipment that can prepare the binder compositions as well as the binder construction products that are in accordance with the present invention is now provided. Referring now to Figure 1A, which represents an embodiment of an extrusion system 10. according to the present invention. Such an extrusion system 10 includes a first mixer 16, optional second mixer 18 and an extruder 24. The first mixer 16 is configured to receive at least one feed of materials through at least one first feed stream 12 to be mixed into a first blend 20. Then of the proper mix, which can be performed under high shear while maintaining a temperature below that which accelerates hydration, the first blend 20 is removed from the first mixer 16 as a flow of material ready for further processing.

By mixing the first mixture 20 apart from any additional components, the respective mixed components may be homogeneously distributed throughout the composition. For example, it may be advantageous to mix the fibers homogeneously with at least the rheology modifier and water before combining them with the additional components.

As such, the rheology modifier, fibers and / or water are mixed under high shear to increase the homogeneous distribution of the fibers therein. The rheology modifying agent and water form a plastic composition having high strain and viscosity that is capable of transferring the shear forces of the mixer downwardly to the fiber level. In this way, the fibers can be homogeneously dispersed throughout the mixture using much less water than required in Hatschek and traditional papermaking procedures, which typically require up to 99% water to disperse the fibers.

Optional second mixer 18 has a second feed stream 14 which supplies the material to be mixed into a second mixture 22, where such mixing may be improved by the inclusion of a heating element. For example, the second mixer 18 can receive and mix additional components such as additional water, fixing accelerators, hydraulic cement, plasticizers, aggregates, nucleating agents, dispersants, polymeric binders, volatile solvents, salts, buffering agents, acidifying agents, coloring agents, fillers and so on before combining them with other components to form an extrusable composition. The second mixer 18 is optional because additional components could be mixed with the fibrous blend in the first mixer 16.

As in the illustrated schematic diagram, extruder 24 includes an extruder thread 26, optional heating elements (not shown) and a die head 28 with a die opening 30. Optionally, the extruder may be a single screw, double screw and / or an extruder piston type. After the first blend 20 and the second blend 22 enter the extruder, they may be combined and mixed into an extrudable composition.

By mixing the components, an interface is created between the different components, such as the rheology and fiber demodifying agent, which allows the individual fibers to break. By increasing the viscosity and pull of deformation with the rheology modifying agent, more fibers can be substantially homogeneously distributed throughout the mixture and final cured product. Also, cohesion between the different can be increased to increase capillary and particle forces for improved shape mix and stability after extrusion. For example, the cohesion between the different components can be compared with clay, so that the green extruder can be placed on a ceramic wheel and worked similar to common clays that are made in pottery.

In one embodiment, additional feed streams (not shown) may be located anywhere along the length of the extruder 24. The availability of additional feed streams may enable the manufacturing process to add certain components. in any position to modify the characteristics of the extrudable composition during mixing and extrusion as well as the characteristics of the green extrudate after extrusion. For example, in one embodiment, it may be advantageous to supply the fixation accelerator in the composition within about 60 minutes to within about 1 second before being extruded, especially when it is CSH. More preferably, the fixation accelerator It is mixed in the composition within about 45 minutes to about 5 seconds before being extruded, even more preferably within about 30 minutes to about 8 seconds, and most preferably within about 20 minutes. about 10 seconds before being extruded. This can enable the green extrudate to be configured for greater shape stability and a reduced induction period before the rapid reaction period begins.

Thus, the induction period after extrusion may be substantially reduced so as to induce the onset of the rapid reaction period starting within about 30 seconds to about 30 minutes after extrusion, more preferably less than which is about 20 minutes, even more preferably less than about 10 minutes and most preferably still less than about 5 minutes after being extruded.

In another embodiment, the clamping accelerator may be separately supplied to the extruder from the other components so that the induction period has a duration of less than about 2 hours, more preferably less than 1 hour, even more preferably less than 1 hour. which is about 40 minutes and more preferably still less than 30 minutes.

Referring further to Figure 1A, as the binder assembly moves to the end of the extruder 24, it passes through the die head 28 before being extruded into the die opening 30. The die head 28 and the The die cover 30 can be configured in any shape or arrangement as long as it produces an extrudate that is capable of being further processed or finished into a construction product. In the illustrated embodiment, it may be advantageous for the die opening 30 to have a circular diameter such that the extrudate 32 has a rod-like shape. Other exemplary cross-sectional shapes are illustrated in Figure 1C, including hexagonal 42, rectangular 44, square 46, or beam 46.

Extruded construction products may be characterized as being immediately stable while in the green state. That is, the extrudate can be immediately processed without deforming, where processing can include cutting, sawing, shaping, milling, forming, drilling and so on. As such, the extrudate in the state-of-the-art need not be cured before being prepared to the size, shape or shape of the a-fit binder construction product. For example, green processing may include the following: (a) creating planks by milling, sawing, cutting or the like having specified dimensions such as width, thickness, length, radius, diameter and so on; (b) bending the extrudate to form a curved binder, which may be of any size and shape, such as a curved chair leg, curved arches and other ornamental and / or structural elements; (3) Creating boards having exceeded lengths are different from standard wood board lengths, which may include shorter or longer board lengths of 2.1 m, 2.6 m, 2.8 m, 8.2 m, 12.2 m, 12.5m, 18.3 m, 18.6 m, 24.4 m, 24.7 m (6 ft 9 in, 8 ft 8 in, 9 ft 1 in, 27 ft, 40 feet, 41 feet, 60 feet, 61 feet, 80 feet, 81 feet) and so on; (d) texture with rollers, which may provide surfaces similar to wood grain for the binder construction product; (e) have the surface painted, waterproof or otherwise coated, which may apply coatings comprised of signs, siloxanes, latex, CSH and so on; and (f) carried, shipped or otherwise. moved and / or handled form. Also, by-products that are produced from green processing can be placed in the feed compositions and reprocessed. Thus, green binder by-products can be recycled, which can significantly reduce manufacturing costs.

Figure IB is a schematic diagram of a die head 29 that can be used with the extrusion process of Figure IA. As such, the die head 29 includes a die opening 30 which has a hole forming element 31. The hole forming element 31 may be circular as shown, or have any shape of cross section. As such, the element The forming hole 31 may form a hole in the extrudate which is shown in FIG. Since the extrudate can be stably immediately extruded, the hole can retain the size and shape of the hole forming element 31. In addition, various die heads having hole forming elements that can produce annular extrusions are provided. Well-known in the art may be adapted or modified, if necessary, to be usable with the extrusion processes according to the present invention.

Referring now to Figure 1C, additional embodiments of extrudates 40 are shown. Thus, the die head and die aperture of FIG. IA or IB may be modified or altered to provide extrusions 40 having various cross-sectional areas, where the cross-sectional area of extrudate 40 may be substantially the same. same as the cross-sectional area of the die opening. For example, the cross-sectional area may be a hexagon 42, rectangle 44 (e.g., two by four, one by ten, etc.), square 46, beam I 48 or a cylinder 50, optionally having a continuous hole 49. Also, Additional cross-sectional shapes may be prepared via extrusion. More particularly, the die head and die opening of FIG. IB may be used such that hexagon 42, rectangle 44 (e.g., two by four, one by ten, etc.), square 46, beam I 48 or cylinder 50 may optionally include continuous circular holes 51, rectangular holes 53, square holes 57 or the like. Also, complex die heads and apertures may be used to prepare the cylinder 50 having the continuous bore 49 and a plurality of smaller holes 51. Moreover, any general cross-sectional shape may also be processed into a specific shape such as, for example. for example, one two by four in a four by four square shape. Alternatively, the die orifice can produce huge products that are later cut to desired specifications to ensure greater uniformity.

In this way, the foregoing processes may be usable for extruding construction products with one or more continuous holes. For example, a two by four or other board may be extruded having one or more holes within which the reinforcement bar may be inserted while in a green state or after curing. In the case of a chiseled board, the reinforcement bar may be held in place in the hole using epoxy or other adhesive to provide a strong bond between the reinforcement bar and the board. For example, the cylinder 50 of FIG. 1C, as well as the other shapes, can be manufactured in large building structures such as utility poles, telephone or power line. Such structures may optionally include a large interior opening49 to reduce mass and cost, along with smaller holes51 in the wall to allow insertion of the reinforcement bar for strengthening as shown. In one embodiment, a telephone pole has an outer diameter of about 35.6 cm (fourteen inches), a wall thickness of about 7.6 cm (three inches), and an inner hole diameter of about 20.3 cm (eight inches). inches). The plurality of separate 1.3 cm (half inch) holes may be provided within the 7.6 cm (three inch) wall to accommodate the placement of the reinforcement bar.

In one embodiment, the extrudable composition is withdrawn prior to being extruded. While some processes may utilize a specific air removal process to remove a substantial amount of air from the extrudable composition, other processes may remove air by the mixing process that occurs in the extruder. In any event, active or passive withdrawal may provide an extruder who does not have large air voids or cell formations. For example, an airless binder composite may have a dry porosity of from about 15% to about 60%, more preferably from about 20% to about 55%, and most preferably from about 25% to about 50%. . Thus, the extrudate and the resulting binder construction product may be manufactured to be substantially or completely devoid of any multicellular formations.

In one embodiment, the extrudable composition is aerated before being extruded. Some processes may utilize an active aeration process to increase the amount of air in the extrudable composition and thereby form air voids or multicellular formations, where such processes may include blowing pressurized air into the composition within the extruder or by mixing in open air. Other compositions can be passively ventilated simply by not actively removing air. Additionally, rapid removal of water from the extrudate may also increase the porosity of the finished product, which may be performed in a dryer or other heating chamber. In either event, active or passive ejection may provide an extruded and / or binder build product that has small air voids to large or cellular formations. For example, an aerated binder composite may have a porosity of from about 40% to about 75%, more preferably from about 45% to about 65%, and most preferably from about 50% to about 60%. Thus, aeration or withdrawal of the extrudable composition may provide the ability to increase or decrease the density of the gluing construction product. Thus, the porosity of a binder construction product may be suitable for specific needs. -cific and customized. This may allow the manufacturing process to be suitable for providing a porosity that correlates with the intended use of the binding construction product.

For example, wood-like boards may be configured to have higher porosities, which enable improved nailing, bolting, cutting, drilling, milling, sawing, and so on. As such, greater porosity can be used to improve the wood-like properties of the binder material. Thus, aporosity along with fiber content can be modified to correlate with intended uses.

In one embodiment, the extrudate may also be processed in a dryer or autoclave. The dryer may be useful for drying the extrudate to remove excessive water, which may increase porosity and / or deform stability. On the other hand, the extrudate can be processed through an autoclave to increase the cure rate.

Figure 2 is a schematic diagram depicting an alternative extrusion process that can be used to prepare the binder construction products according to the present invention. As such, the extrusion process may be considered to use a roller extrusion system 200 that uses rollers to extrude the wet binder material into a green extrudate. Such a roller extrusion system 200 includes a mixer 216 configured to receive at least one material feed through a feed stream 212 to be mixed into a mix 220. After suitable mixing, which can be performed as described herein, mixture 220 is removed from blender 216 as a flow of material ready for further processing.

Mixture 220 is then applied to a conveyor222 or other similar means of transport to move the material from the application site. This allows the mixture to be formed into a binder stream 224 which can be processed. As such, the binder flow 224 may be passed under a first roller 226 which is set at a predefined distance from the conveyor 222 and having a predefined cross-sectional area relative thereto which may press or form the binder flow 224 on a green extrudate 228. .

Optionally, the conveyor 222 may then deliver the green extrudate 228 through a first calender 230 comprised of an upper roller 230a and a lower roller 230b. The calender 230 may be configured to have a predefined cross-sectional area such that the green former extruded 228 is also formed and / or compressed into a green former extruded 242. Also, a second optional calender 240 comprised of a first roller 240a and a second roller 240b may be used in place of or beyond first calan-dr 230. A combination of calenders 230, 240 may be favorable to provide a green extrudate that is substantially formed as desired. Alternatively, the first roller 226 may be excluded and the binder flow 224 may be processed through any number of calipers 230, 240.

Additionally, the formed green extrudate 242 or other extrudate described herein, such as the process illustrated in Figure 1A, may also be processed by a processing apparatus 244. The processing apparatus 244 may be any type of equipment or system that is used to process the materials. green extruded materials as described here. As such, the processing apparatus 244 may saw, mill, cut, bend, coat, dry or otherwise further shape or process the formed green extrudate 242 into a processed extrudate 246. Also, the by-product 260 obtained from the processing apparatus 244 may be recycled. in feed composition 212 or applied to conveyor 222 together with the mixture 220. When the processing apparatus 244 is a dryer, the formed green extrudate 242 may be heated to a temperature that rapidly removes water to form. voids in the processed extrudate 246, which increases the porosity.

In one embodiment, the processed extrudate 246, or other extruded described herein, may be cured by processing through an autoclave 248 or dryer. As such, autoclave 248 or the dryer may raise the temperature of the processed extrudate 246 and ambient humidity to induce the onset of the hydration reaction. Thus, the autoclave 248or the dryer can rapidly cure the processed extrudate 246 into a 250 cured binder construction product. For example, the autoclave 248 can provide a steam cure when operated at a temperature of about 60-65Â ° C for about 24 hours. in order to get 75% of the final force. A conventional drier can then be used to remove the residual water.

Optionally, the extrudate may be plastic coated and / or stored for a period of time to allow the extrudate to cure. This may allow the extrudate to harden over time to produce the required strength for the cured binder composite product. For example, after 28 days, the hardened binder composite may have about 80% of the final strength, and may be placed in a dryer to remove residual water.

In another option, the combined screening / drying process may be used to cure and dry the extruded a-glutinant composite. For example, the combined drying / drying process may be performed at a temperature of 60-65 ° C for 48 hours to obtain about 80% of the final force. However, larger blocks may take additional time in any curing and / or drying process.

According to FIGS. 3A-D, the extrusion system shown in FIG. IA may be modified to be able to extrude the extrudate around a complementary de-boiling element or reinforcing element such as reinforcing bar (metal or fiber). glass), wire, wire mesh, screen and the like. By coextruding the binder composition with a reinforcing wire, mesh or reinforcing bar, the resulting binder construction product can have greater deflection and bending force before breaking. Alternatively, the roller extrusion system 200 may be configured to prepare reinforced green bodies and binder construction products as described below.

Referring now to Fig. 3A, a mode of a co-extrusion system 300 is represented. The co-extrusion system 300 includes at least two or more screwdrivers 302a and 302b. The screwdrivers 302a and 302b are oriented such that the respective openings of the die 303a and 303b produce extrudates that blend into a uniform extruder 308. In addition, the co-extrusion system 300 includes a device for placing a holding element. such as reinforcement bar 304 within uniform extruder 308, where the device may include a conveyor, pulley, diving mechanism, movable screwdriver, reinforcement bar compression mechanism, reinforcement bar traction mechanism and so on. against.

As shown, the reinforcing bar 304 is passed between the first die opening 303a and the second die opening 303b. This allows the reinforcing bar 304 to be at least partially or completely encapsulated within uniform extrudate 308, where the encapsulated reinforcing bar 306 is shown by dashed lines. As shown, the reinforcement bar 304 may have a first end 310 that is oriented beyond die openings 303a and 303b before any extrudate is applied to the reinforcement bar 304, so that the first end 310 is not encapsulated. The bare reinforcement bar can enable the reinforcement bar to be pulled past die openings 303a and 303b and facilitates easy manipulation and manipulation after extrusion.

Referring now to Figure 3B, another embodiment of a co-extrusion system 320 is shown. Co-extrusion system 320 includes a taper holder 322 and a device for supplying a wire or screen mesh 324 to extruder 326 where the device may include a conveyor, pulley, diving mechanism, movable screwdriver, machine tool compression mesh, mesh traction mechanism and so on. As such, the device can continuously supply mesh 324 for opening die 321, so extrudate 326 is extruded around and encapsulates mesh 324. Encapsulated mesh 328 is represented by lines within extrudate 326. Additionally The mesh 324 may be supplied at a rate substantially equivalent to the extrusion rate so that the reinforced extrudate is also formed.

Referring now to Figure 3C, another embodiment of a co-extrusion system 340 is shown. Co-extrusion system 340 includes a screwdriver 342 with a die opening 348. The screwdriver 342 and the open die 348 are configured such that a complementary de-holding element 344 (i.e. at least one reinforcement barrel) can be The channel 346 allows the reinforcing bar 344 to be passed through the opening of the die 348 via a channel opening 350. When the reinforcing bar 344 passes through the opening of the channel 350, it is encapsulated. extruded 352 to form the encapsulated reinforcing bar 354.

Referring now to the 3D figure, another mode of a co-extrusion system 360 is represented. Co-extrusion system 360 includes a die holder 362 with a die opening 363 and an open die 364. The open die 364 is configured to include an open cavity 366 defined by the die body 368. In use, the open die 364 receives the die member. complementary support 370, such as a wire or mesh, a plurality of reinforcing bars or wires within open cavity 366. This allows extrudate 374 to be extruded over and around mesh 370 to form encapsulated mesh 376, as shown by dashed lines within extruded 374.

Although open mold 364 can be used to shape the shape of the extrudate 374, it does not necessarily do so. This is because co-extrusion system 360 can be configured such that the open mold 365 merely supports mesh 376 and passes mesh 370 beyond the opening of die 363. Thus, extrusion 374 can be self-supporting and encapsulate mesh 370 in. of the open molding 364 or in some other aspect such as a conveyor system, pulley, drive mechanism, movable screwdriver, reinforcement bar compression mechanism, reinforcement bar traction mechanism and so on (not shown).

Figure 4 is a schematic diagram illustrating another embodiment for structurally reinforcing a binder construction product having a reinforcing bar-like structure. As such, the reinforcing process 400 may use the prepared reinforcing bar 402 of any reinforcing material such as metal, ceramic, plastics and so on. The reinforcement bar 402 may then be processed by a processing apparatus 404 which applies an epoxy coating 406 to the reinforcement bar 402. A binder construction product 408 having the continuous bore 410 formed therein, as by the processes described. in conjunction with Figure 1B, can be obtained to receive the epoxy coated reinforcement bar 402 406. The epoxy coated reinforcement bar 402 is then inserted into bore 410. This may include driving force, compression or otherwise forcibly pushing. epoxy coated reinforcing bar 402 into the bore. In this way, the binder-building product 408 having the reinforcing bar 402 can be significantly strengthened and structurally reinforced. Alternatively, the epoxy may be inserted into the bore410 of the binder construction product 408 before the reinforcing tab 402 is inserted therein.

In one embodiment, the green extrudate with or without a complementary supporting element may also be processed by causing, or allowing, the hydraulic cement within the green extrude to hydrate or otherwise cure to form a construction product. solidified binder. As such, the binder construction product can be prepared to be immediately stable after being extruded to allow its handling without breakage. More preferably, the binder composition or the green extrudate may be stable in a period of 15 minutes, more preferably within 10 minutes, even more preferably within 5 minutes and most preferably within 1 minute after. be extruded. The most optimal and preferred composition and processing may result in a green extrudate which is stably extruded. The use of a rheology demodifying agent may be used to produce extrusions which are stably immediate even in the absence of hydration of the hydraulic cement binder.

In order to achieve shape stability, the manufacturing process may simply allow the green extruder to settle and set without any further processing or it may be induced to hydrate and / or set. Where manufacture includes causing the green extrudate to hydrate, otherwise set to cure, the manufacturing system may include a dryer, heater or autoclave. The dryer or heater may be configured to generate sufficient heat to draw or evaporate extrudate water to increase its stiffness and porosity or to induce the onset of the rapid reaction period. On the other hand, an autoclave can be pressurized to induce the onset of the rapid derating period.

In one embodiment, the green extrudate may be allowed or induced to initiate the rapid reaction period as described herein in addition to including a fixation accelerator within the binder composition. As such, the green extrudate may be induced to initiate the rapid reaction period by changing the temperature of the extrudate or by changing the pressure and / or relative humidity. Also, the rapid reaction period can be induced by setting the fixation accelerator to initiate reactions within a predetermined time period after being extruded.

In one embodiment, the preparation of a binder composite or construction product may include substantially hydrating or otherwise curing the extruded green binder construction product over a reduced period, or a faster reaction rate, compared to conventional or conventional compounds. other hydraulically fixable materials. As a result, the binder construction product may be substantially cured or hardened, depending on the type of binder that is used within about 48 hours, more preferably within about 24 hours, even more preferably within 12 hours and most preferably within 6 hours. Thus, the manufacturing system and process can be set up to obtain fast cure rates so that the binder construction product can also be processed or finished. .

In one embodiment, a cured or cured binder composition may also be processed or finished. Such processing may include sawing, sanding, cutting, drilling and / or shaping the binder composition into a desired shape, where the composition lends itself to such modeling. Thus, when a binder construction product is sawn, the fibers and rheology modifier can contribute to straight cut lines that can be formed without cracking or chipping the cut surface or internal aspects of the material. This enables the binding construction product to be a substitute for wood because a two by four shaped product can be purchased by a consumer and cut with standard equipment into the desired shapes and lengths.

In one embodiment, the green extrudably can be processed through a system that modifies the outer surface of the product. An example of such a modification is to pass the green extrudate through a calender or series of rollers which may give the wood a similar appearance. As such, the binder construction product may be a wood substitute having the aesthetic appearance and texture of the wood. Also, certain colorants, dyes and / or pigments may be applied to the surface or dispersed within the binder construction product to obtain the color of various types of wood.

Green extruded construction products may also be refurbished while in a green state to produce, for example, curved boards or other construction products having a desired radius. This is a significant advantage over traditional wood products that are difficult to bend and / or must be milled to have a curved profile.

In one embodiment, the binder construction product may be sanded and / or polished in a manner that exposes fibers to the surface. Due to the high percentage of fibran product, a large number of fibers may be exposed on the surface. This can provide interesting and creative textures that can enhance the aesthetic qualities of the product. For example, the binder construction product can be sanded and polished so that it looks and feels similar to suede or fabric.

IV. Construction Products

The present invention provides the ability to manufacture binder construction products having virtually any desired size and shape, whether extruded into the desired shape or subsequently cut, milled or otherwise formed to the desired size and shape. Examples include upholstery plate, two by four, other sizes of lumber, panel placement, imitation plywood, imitation fiber board, doors, slats, moldings, table tops, table legs, frame window, door sash, roof tiles, artificial sheet, grout plates, beams, I-beams, floor joists and so on. In this way, the binder construction product can be load-bearing (for example, two by four) or without load support (eg upholstery plate). Thus, the binder construction product can be used as a wood substitute for almost any building application.

The cured binder composite can be configured to have various properties to function as a substitute for lumber. An example of a cured bonding composite that can function as a substitute for lumber can have any of the following properties: capable of receiving hammer and / or ballistic nails;

able to retain or retain nails, especially when attached to another object; capable of receiving screwdrivers by screwdriver or mechanical screwdriver; able to retain or maintain screws, especially when being attached to another object; be similar in weight to a lumber product, but may be slightly heavier; strong enough not to fracture when rotated; strong enough not to significantly deviate at the ends or to fracture when held or supported in the middle and / or capable of being sawn or cut with a hand saw or other saw configured to cut wood.

In one embodiment, the green extrudate or binding compound may be prepared in a construction product as described above. As such, an airless embodiment of the cured binder composite material can be characterized by including a specific gravity including pores or cell formations which may be greater than 0.85 or range from 0.85 to about 2.0. more preferably from about 0.9 to about 1.75 and most preferably from about 0.95 to about 1.5. However, in some embodiments, an airless composite may have a higher specific gravity than 2.0 when synthetic fibers are used. On the other hand, when not airless, the specific gravity of the composite including of pores or cell formations may be greater than about 0.4 or range from about 0.4 to about 0.85, more preferably about 0, 5 to about 0.75 and most preferably from about 0.6 to about 0.75.

One embodiment of the cured composite may be characterized by having a compressive strength of greater than about 105.46 kg / cm2 (1,500 psi), more preferably greater than about 123.04 kg / cm2 (1,750 psi), and more preferably even greater. than about 2,000 psi (140.62 kg / cm2).

In one embodiment, the cured composite may have a bending force of from about 11.2 x 10 3 kg / cm2 (160,000 psi) to about 59.8 x 10 3 kg / cm2 (850,000 psi), preferably from about 14 , 1 χ 10 3 kg / cm2 (200,000 psi) to about 56,2 χ 10 ^ 3 kg / cm2 (800,000 psi), more preferably from about 2,909 kg / cm2 (3,000 psi) to about 49,2 χ 10 ^ 3 kg / cm2 (700,000 psi) and most preferably from about 28.1χ 10 ^ 3 kg / cm2 (400,000 psi) to about 42.2 χ 10 ^ 3 kg / cm2 (600,000 psi).

In one embodiment, the cured composite may have a flexural modulus of about 140.6 χ 10 ^ 3 kg / cm2 (200,000 psi) to about 351.5 χ 10 3 kg / cm2 (5,000,000 psi), more preferably. about 300,000 psi (21,1 χ 10 3 kg / cm2) to about 3,000,000 psi (210,9 χ 10 ^ 3 kg / cm2) and more preferably about 35,2 χ 10 ^ 3 kg / cm2 (500,000) at about 140.6 χ 10 3 kg / cm 2 (2,000,000 psi).

In one embodiment, the cured composite may have an elastic energy absorption of about 0.56 J (5 lbf-in) to about 5.65 J (50 lbf-in), preferably about 1.13 J (10 to about 3.39 J (30 lbf-in), more preferably from about 1.35 J (12 lbf-in) to about 2.82 J (25 lbf-in) and most preferably about from 1.69 J (15 lbf-in) to about 2.26 J (20 lbf-in).

Additionally, the binder construction product can be distinguished from previous concrete construction products. Fig. 5A is a representation of problems that may arise from the insertion (e.g., hammering, driving force, or ballistic force) of a fastening rod 64 (e.g., nail or bolt) into a surface 62 of such a prior concrete construction product 60 where the retaining rod 64 forms the bore 66 during insertion. Similar to ordinary concretes that are used in a variety of applications ranging from sinking roads, when concrete 60 has a retaining rod 64 inserted into it, the surface structure 62 is damaged. As depicted, concrete 60 and / or the surface 62 are prone to cracking 68 and scraping pieces 70 around the bore 66.

Since concrete 60 is damaged around hole 66, the surface of hole 66 may appear to have an irregular and fractured shape formed by substantial cracking, pieces and / or splinters. Additionally, the force required to insert a nail clamping rod 64 into the concrete with a hammer that repeatedly strikes the nail head 64 often damages or bends the nail 64 so that it is essentially useless. Additionally, when the deflection rod 64 is a screw, the bolting action may drill a hole 66 in the surface that is permeated with cracks and chips. Thus, prior concrete construction products 60 have not been suitable wood substitutes with respect to being able to receive a retaining rod 64 and have resembled and behaved similar to ordinary concrete, cracking and chipping during such an insertion.

Referring now to Figure 5B, a representation of a binder construction product 80 being used as a wood substitute according to the present invention is shown. Thus, the results of inserting a fixing rod 84 (e.g., nail or bolt) into the surface 82 of the bonding construction product 80 are more favorable compared to the common concrete of figure 5A. More specifically, when a clamping rod84 is inserted into surface 82, the resulting hole 86 formed by the clamping rod 84 may be substantially rounded. Although minor chips or cracks may exist as is usually the case during such wood insertions, the hole 86 is much rounder and less damaged compared to the results of ordinary concrete. Since the binder construction product 80 is configured as a wood substitute, a nail securing rod 84 may be hammered into it repeatedly by striking the nail head without damaging or bending nail 84.

In any event, the binder construction products described herein may be used as a wood substitute and may even have a fastening rod inserted into them. As such, inventive binder construction products can be used to connect multiple piece components together or be used for other typical nail or bolt applications.

Furthermore, Figures 6Δ and 6B represent another 90 representation of the common results that occur when a fixing rod 94 (e.g., nail or bolt) is inserted into a prior or common concrete construction product 92. When the anchor rod 94 is inserted into the surface 96 of the concrete 92, a hole 95 formed by the insert is fractured and notched as shown in figure 4. Thus, in figure 6A, the representation 90 represents a longitudinal cut-out view of the resulting damage in the concrete 92 and in Fig. 6B representation 90 represents a mid-level cross-sectional view of the resulting furodified 95.

As shown, the fixing rod 94 not only causes surface 96 to fracture or form pieces 98, but the inner surface 100 of the entire length of hole 95 is similarly damaged. More particularly, the davara clamping insert 94 causes the inner surface 100 to be permeated with cracks 102, crushed concrete 104 and chipped concrete 106. Even though it is possible to insert a clamping beam 94 into the concrete, this often requires some type of ballistics or cracks. explosive load rather than hammering or bolting because common hammering often results in the curvature of a nail securing rod 94 and bolting significantly damages the inner surface 100. Additionally, a securing rod 94 that has been inserted into the common concrete 92 can be easily extracted from it, often without the use of a tool or device as described above. Briefly, this is because damage to the inner surface 100 decreases the compressive forces applied against the anchor rod 94 that are required to hold it in place. As such, common concrete 92 has a low or low extraction resistance and a nail or bolt 94 can be easily extracted from it. This does not allow ordinary concrete 92 to be used as wood substitutes, and two such pieces cannot be properly nailed without easily being broken.

Moreover, Figures 7A and 7B show a common representation 110 of results for a fastening rod 112 being inserted into a fiber reinforced binder construction product 114 according to the present invention. In contrast to the representation in FIGS. 6A and 6B, when the anchor rod 112 is inserted into the surface 115 of the inventive construction product 114, a hole 116 formed by the insert is not damaged or substantially fractured, which is also shown in FIG. Thus Figure 7A represents a longitudinal cut-away view of the resulting hole 116 and Figure 7B represents an intermediate level cross-sectional view of the resulting hole116.

As shown, the anchor rod 112 does not cause any substantial damage to surface 115, or the inner surface 118 of the entire length of hole 116. More particularly, inserting the anchor rod 112 can cause fibers 120 on the inner surface 118 to become exposed and deformed or pushed apart by the clamping rod 112. As described, such fibers 120 are deformed or pushed apart to allow the clamping rod 112 to pass over but then exert a clamping force against the clamping rod 112 after insertion. . Additionally, the rheology modifier may allow the construction product to deform by the nail when it is being inserted, and then apply a clamping force against the nail after it is inserted.

Additionally, a hole 116 formed by a nail fastener 112 is not damaged and may provide sufficient compressive forces against the nail to resist its extraction. This is because the nail 112 does not damage the hole wall 116 during insertion by the fibers and other deforming materials during the formation of the hole 116. In addition, when the fixing rod 112 is a screw, the hole wall 116 may have sharp edges. and grooves that lock with teeth and grooves in the screw. In addition, a substantial amount of composite material within the bolt slots 112 may be secured to the wall to help provide greater extraction resistance. Thus, the hole wall 116 is sufficiently compressive to require the aid of a lever, screwdriver or other extractor to remove the nail or screw.

Binder construction products can be used as a wood substitute for applications where multiple construction products are nailed, bolted or screwed. Without limitation, it is thought that combining a high percentage of fiber weight and / or volume percentage, as described above, provides favorable interactions with nails, screws and / or dowels. The amount of fiber simulates the properties of the wood. More particularly, each individual fiber may deform when first influenced by a nail or screw, and then compress against the impact or screw to provide a clamping force thereon. This allows the nail or screw to be inserted into the binder construction product without causing substantial scraping or cracking.

Additionally, the use of a high concentration of rheology modifier may also help to provide this functionality. As with fibers, the rework modifier provides a feature for the agglutinating construction product that at least partially allows it to be deformed without substantial cracking or scraping. In part, the rheology modifier may grant a similar feature to plastic that holds materials together around a place being stressed, such as the point where a nail or screw is being inserted. As such, the nail or screw is capable of being inserted into the gluing construction product and the rheology modifier allows the required deformation without scraping or substantial cracking.

For example, the high concentration of fibers or other fillers may provide significant extraction resistance for the binder construction product. The pullout resistance for an IOd nail (for example, nail characterized by 9 or 3.2 mm (0.128 inch) diameter and 76.2 mm (3 inch) length) embedded in 25.4 mm (1 inch) in a binder compound may range from about 531.6 kgf / m (30lbf / in) to about 1860.6 kgf / m (105lbf / in), more preferably about 708.8 kgf / m m (40 lbf / in) to about 163.43 kgf / m (95 lbf / in) and most preferably still about 886.0 kgf / m (50 lbf / in) to about 1506.2 kgf / m (85). lbf / in). The extraction resistance for a more porous bonding composite may range from about 443.0 kgf / m (25 lbf / in) to about 1594.8 kgf / m (90 lbf / in), more preferably about 531. 0.6 kgf / m (30 lbf / in) to about 1240.4 kgf / m (70 lbf / in) and most preferably still about 708.8 kgf / m (40 lbf / in) to about 1063.2 kgf / m (60 lbf / in). Extraction resistance for a harder bonding composite may range from about 265.8 kgf / m (15 lbf / in) to about 1063.2 kgf / m (60 lbf / in), more preferably about 319 .0 kgf / m (18 lbf / in) to about 886.0 kgf / m (50 lbf / in) and most preferably about 354.4 kgf / m (20 lbf / in) to about 886.0 kgf / m (50lbf / in). However, it should be understood that the extraction resistance for a product at a given density may change by changing the amount of fiber, porosity, filler, nail type and so on.

Similarly, the extraction resistance for a 25.4 mm (one inch) bolt embedded in a glutinant composite can range from about 3544.0 kgf / m (200lbf / in) to about 17720.0 kgf / m (1,000 more preferably from about 5316.0 kgf / m (300 lbf / in) to about 16834.0 kgf / m (950 lbf / in) and most preferably about 7088.0 kgf / m (400 lbf / in) at about 15948.0 kgf / m (900 lbf / in). However, it should be understood that the extraction strength for a product at a given density may change by changing the amount of fiber, porosity, filler, nail type and so on.

Additionally, the binder composites primarily comprise inorganic materials that are less prone to rot when kept in a humid environment compared to wood. Even though organic fibers may have a tendency to degrade under certain conditions, the generally high alkalinity of the hydraulic cement will inhibit damage and rot under most circumstances.

EXAMPLES OF MODES OF THE INVENTION

Example 1

Various extrusable compositions having different component concentrations are prepared according to the present invention. All mixtures are mixed according to the normal mixing procedures described above and the references incorporated herein. Briefly, a fiber blend, rheology modifying agent and water is mixed for a 1 hour mixing time before additional components are added and mixed for an additional hour. The extrusable compositions are formulated as shown in tables 1-6. Table 1

<table> table see original document page 83 </column> </row> <table>

SW = softwood and HW = hardwood

Table 2

<table> table see original document page 83 </column> </row> <table>

Table 3

<table> table see original document page 83 </column> </row> <table> <table> table see original document page 84 </column> </row> <table>

SW = softwood and HW = hardwoodTable 4

<table> table see original document page 84 </column> </row> <table>

SW = softwood and HW = hardwoodTable 5 <table> table see original document page 85 </column> </row> <table>

Sw = softwood and HW = liewood

Table 6

<table> table see original document page 85 </column> </row> <table> SW = softwood and HW = hardwood

Following mixing, the compositions are extruded through a screwdriver having a rectangular aperture of about 50.8 mm (2 inches) by about 101.6 mm (4 inches). A binder construction product in the form of a two by four is prepared. It is heated at a temperature of about 63 ° C (145 ° F) for about 2 days to controllably remove a portion of the water while allowing or accelerating the hydration of Portland cement by water that is not removed. The construction product is characterized by being able to be sawn using a standard wood saw and drilled using a common wood drill. Nails can be hammered and screws can be screwed into construction products using conventional tools used to work with similar sized timber products.

Example 2

Various extrusable compositions having different component concentrations are prepared according to Example 1. The extrusable compositions are formulated as shown in Tables 7-8.

Table 7

<table> table see original document page 86 </column> </row> <table> <table> table see original document page 87 </column> </row> <table>

Table 8

<table> table see original document page 87 </column> </row> <table> Water 16 34% 20 39% 20 39%

Total 46, 54 100% 51.6 100% 51.1 100%

The binder compositions exemplified by mixtures 1-6 are extruded into a cured construction product (e.g., by early heating). The quantities of each component are then calculated on a basis basis, and provided in tables 9-10.

Table 9

<table> table see original document page 88 </column> </row> <table> Table 10

<table> table see original document page 89 </column> </row> <table>

Example 3

The flexural strength of extruded binder construction products has been tested and compared to wood.

More particularly, bending force was tested as a function of displacement in centimeters (inches) in response to an applied force in kg (pounds). As such, the wood displacement (x) was compared with an unreinforced extruded composite (solid diamond - ♦), extruded construction product reinforced with fiberglass reinforcement bar (solid square - ♦). ■) and an extruded construction product reinforced with steel reinforcement bar (solid triangle- ▲) as shown in figure 8. As shown, the extruded binder construction products mimicked the displacement of the wood to about 124.7 kg (275 pounds) of strength. Additionally, extruded construction products reinforced with fiberglass reinforcing bar and steel reinforcing bar showed more displacement for the same strength compared to wood. Thus, extruded binder construction products can mimic the wood at lower end forces and reinforcing bar reinforced binder construction products may actually have greater displacement for a given strength compared to wood.

Example 4

The tensile strength of one embodiment of the extruded binder-building product was tested. As such, the elongation percentage of the extruded binder construction product was measured as a function of the tensile strength in kg per square centimeter (pounds per square inch (psi)), which is depicted in Figure 9. Study results indicate that the extruded agglutinately constructed construction product is able to elongate to about 1.45% before deforming to tensile strength by about 35.15 kg / cm2 (500psi).

For comparative purposes, wood displacement in response to compressive pressure was measured and compared with displacement of one embodiment of the extruded binder construction product. The wood (solid diamond- ♦) and the extruded binder construction product (solid square - ■) were each tested as a 2.54 cm by 7.62 cm (1 "χ 3" article ( 1 inch for 3 legs)), with force being applied with the grain to the end surface of each beam. The results of the study are shown in Figure 10. Wood exhibited a large increase in displacement at lower pressures, but then shifted from about 10% of displacement to about 50% of displacement at about 309.32 kg / cm2 (4,400 psi), which is shown by the almost horizontal line. The extruded binder construction product exhibited a similar displacement tendency at a smaller compressive load of about 105.46 to 140.62 kg / cm2 (1,500 to about 2,000 psi), but began to resist displacement. after only being relocated by about 30%. Thus, when a force is applied to the extruded wood or binder construction product on the end surface, a large displacement may occur at a critical force before again resisting the compressive force.

Example 6

A binder composition (6-7-06-1) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 11A. The extrudate was covered in plastic and stored at room temperature until fixation. The fixed extrudate was then placed in an 8 day curing tank and kept at 55 ° C to controllably remove a portion of the water while accelerating hydration of the cement binder. The cured extrudate was then substantially completely dehydrated in a drying oven and the construction product was tested dry. The building product had the following dimensions: length of 12.91 cm, width of 8.64 cm, height of 1.92 cm and weight of 232.45g. The construction product exhibited the properties described in table 11B.

IlA table

Percent input Percentage excess (kg) mass of composition volume

<table> table see original document page 92 </column> </row> <table> Delvo: concrete stabilizer sold by BASF

Table IlB

<table> table see original document page 93 </column> </row> <table>

Example 7

A binder composition (6-8-06-1) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 12A. The extrudate was covered in plastic and stored at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated in a drying oven and the construction product was tested dry. The building product had the following dimensions: length 12.4 cm, width 8.8 cm, height 1.96 cm and weight 256.49 g. The construction product exhibited the properties described in table 12B.

Table 12a

Material Intake- Percent of Percent of vo-sa (kg) compost mass of total composition

<table> table see original document page 94 </column> </row> <table>

Table 12B

<table> table see original document page 94 </column> </row> <table> <table> table see original document page 95 </column> </row> <table>

Example 8

A binder composition (6-14-06-1) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 13A. The extrudate was covered in plastic and stored at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated in a drying oven and the construction product was tested dry. The building product had the following dimensions: length 12.53 cm, width 8.77 cm, height 1.96 cm and weight 228.08 g. The construction product exhibited the properties described in table 13B.

Table 13Material Percent Input Percent too much (kg) of mass wet volume of composition

<table> table see original document page 96 </column> </row> <table>

Table 13B

<table> table see original document page 96 </column> </row> <table>

Example 9

A binder composition (6-14-06-2) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 14A. The extrudate was covered in plastic and stored at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated in a drying oven and the construction product was tested dry. The building product had the following dimensions: length 12.57 cm, width 8.96 cm, height 2.06 cm and weight 242.88g. The construction product exhibited the properties described in table 14B.

Table 14A

Material Percent input Percent excess (kg) of mass wet volume of the composition

<table> table see original document page 97 </column> </row> <table>

Table 14B <table> table see original document page 98 </column> </row> <table>

Example 10

A binder composition (6-21-06-1) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 15A. The extrudate was covered in plastic and stored at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated in a drying oven and the construction product was tested dry. The building product exhibited the properties described in table 15B.

Table 15ΔMaterial Percent Input Percent of (component) mass (kg) of mass wet volume of composition

<table> table see original document page 99 </column> </row> <table>

Table 15B

<table> table see original document page 99 </column> </row> <table>

Example 11

A binder composition (6-27-06-1) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 16A. The extrudate was covered in plastic and stored at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated in a drying oven and the construction product was tested dry. The building product had the following dimensions: length of 12.93cm, width of 8.86cm, height of 4.33cm and weight of 550.03g. The construction product exhibited the properties described in table 16B.

Table 16A

Material Percent Input Percent (component) mass (kg) mass wet volume of the composition

<table> table see original document page 100 </column> </row> <table>

Table 16B <table> table see original document page 101 </column> </row> <table>

Example 12

A binder composition (6-29-06-1) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 17A. The extrudate was covered in plastic and stored at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated in a drying oven and the construction product was tested dry. The building product had the following dimensions: length of 12.64 cm, width of 8.87 cm, height of 2.03 cm and weight of 200.67g. The construction product exhibited the properties described in table 17B.

Table 17A

Material Percent Input Percent (component) mass (kg) mass wet volume of the composition

<table> table see original document page 102 </column> </row> <table>

Table 17B

<table> table see original document page 102 </column> </row> <table> Example 13

A binder composition (7-3-06-1) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 18A. The extrudate was covered in plastic and stored at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated in a drying oven and the construction product was tested dry. The building product had the following dimensions: length 12.4 cm, width 8.4 cm, height 1.86 cm and weight 197.580 g. The construction product exhibited the properties described in table 18B.

Table 18a

<table> table see original document page 103 </column> </row> <table> <table> table see original document page 104 </column> </row> <table>

Table 18Β

<table> table see original document page 104 </column> </row> <table>

Example 14

A binder composition (7-5-06-1) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 19A. The extrudate was covered in plastic and stored at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated in a drying oven and the construction product was tested dry. The building product had the following dimensions: length of 12.62 cm, width of 8.8 cm, height of 1.92 cm and weight of 313.34 g. The construction product exhibited the properties described in table 19B.

Table 19A

Composition Percent input Percent (component) mass (kg) mass wet volume

<table> table see original document page 105 </column> </row> <table>

Table 19B

<table> table see original document page 105 </column> </row> <table> <table> table see original document page 106 </column> </row> <table>

Example 15

A binder composition (7-7-06-1) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 20A. The extrudate was covered in plastic and stored at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated in a drying oven and the construction product was tested dry. The building product had the following dimensions: length 35.3 cm, width 8.8 cm, height 1.8 cm and weight 852.12 g. The construction product exhibited the properties described in table 20B.

Table 20A

<table> table see original document page 106 </column> </row> <table> <table> table see original document page 107 </column> </row> <table>

Table 20Β

<table> table see original document page 107 </column> </row> <table>

Example 16

A binder composition (7-13-06-1) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 21A. The extrudate was covered in plastic and stored at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated in a drying oven and the construction product was tested dry. The building product exhibited the properties described in table 21B.

Table 21A

Material Percent Input Percent (component) mass (kg) mass wet volume of the composition

<table> table see original document page 108 </column> </row> <table>

Table 21B

<table> table see original document page 108 </column> </row> <table> <table> table see original document page 109 </column> </row> <table>

Example 17

A binder composition (7-13-06-2) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 22A. The extrudate was covered in plastic and stored at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated in a drying oven and the construction product was tested dry. The building product exhibited the properties described in table 22B.

Table 22A

Material Percent Input Percent (component) mass (kg) mass wet volume_of the composition

<table> table see original document page 109 </column> </row> <table> <table> table see original document page 110 </column> </row> <table>

Table 22Β

<table> table see original document page 110 </column> </row> <table>

Example 18

A binder composition (7-14-06-1) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 23A. The extrudate was covered in plastic and stored at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated in a drying oven and the construction product was tested dry. The building product exhibited the properties described in table 23B.

Table 23A

Material Percent Input Percent (component) mass (kg) mass wet volume of the composition

<table> table see original document page 111 </column> </row> <table>

Table 23B

<table> table see original document page 111 </column> </row> <table> <table> table see original document page 112 </column> </row> <table>

Example 19

A binder composition (7-14-06-2) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 24A. The extrudate was covered in plastic and stored at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated in a drying oven and the construction product was tested dry. The building product had the following dimensions: length 15.2 cm, width 8.5 cm, height 1.8 cm and weight 211.82 g. The construction product exhibited the properties described in table 24B.

Table 24A

Material Percent Input Percent (component) mass (kg) mass wet volume of the composition

<table> table see original document page 112 </column> </row> <table> <table> table see original document page 113 </column> </row> <table>

Table 24Β

<table> table see original document page 113 </column> </row> <table>

Example 20

A binder composition (7-14-06-3) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 25A. The extrudate was covered in plastic and stored at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated in a drying oven and the construction product was tested dry. The building product had the following dimensions: length 15.4 cm, width 8.4 cm, height 1.8 cm and weight 212.15 g. The construction product exhibited the properties described in table 25B.

Table 25A

<table> table see original document page 114 </column> </row> <table>

Table 25B <table> table see original document page 115 </column> </row> <table>

Example 21

A binder composition (7-17-06-1-0) was pre-prepared and processed into a binder construction product. The construction product was tested to determine physical properties. Briefly, the binding product was prepared by mixing and extruding the composition described in table 26A. The extrudate was immediately placed in a drying oven after extrusion. After complete dehydration, the extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The building product had the following dimensions: length 16.6 cm, width 8.8 cm, height 1.95 cm and weight 261.57 g. The construction product exhibited the properties described in table 26B.

Table 26A

<table> table see original document page 116 </column> </row> <table>

Table 26B

<table> table see original document page 116 </column> </row> <table> <table> table see original document page 117 </column> </row> <table>

Example 22

A binder composition (7-17-0 6-1-1) was pre-prepared and processed into a binder construction product. The construction product was tested to determine physical properties. Briefly, the binding construction product was prepared by mixing and extruding the composition described in table 27A. The extrudate was immediately placed in a drying oven 1 hour after extrusion. After complete dehydration, the extrudate was then placed in a curing tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 16.6 cm, width 8.8 cm, height 1.95 cm and weight 261.57 g. The construction product exhibited the properties described in table 27B.

Table 27A

Material (component)

Inlet (kg) of

wet

percent percent too much wet volume of the <table> table see original document page 118 </column> </row> <table>

Table 27Β

<table> table see original document page 118 </column> </row> <table>

Example 23

A binder composition (7-17-0 6-1-2) was pre-prepared and processed into an agglutinant building product the building product was tested to determine physical properties. Briefly, the binding product was prepared by mixing and extruding the composition described in table 28A. The extrudate was placed in a drying oven 2 hours after extrusion. After complete dehydration, the extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 16.9 cm, width 8.7 cm, height 1.94 cm and weight 272.91 g. The construction product exhibited the properties described in table 28B.

Table 28A

Material Percent Input Percent (component) mass (kg) mass wet volume of the composition

<table> table see original document page 119 </column> </row> <table> <table> table see original document page 120 </column> </row> <table>

Table 28Β

<table> table see original document page 120 </column> </row> <table>

Example 24

A binder composition (7-17-06-1-3) was pre-prepared and processed into a binder construction product the construction product was tested to determine physical properties. Briefly, the binding product was prepared by mixing and extruding the composition described in table 29A. The extrudate was placed in a drying oven 3 hours after extrusion. After complete dehydration, the extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 14.3 cm, width 8.7 cm, height 1.94 cm and weight 238.98 g. The construction product exhibited the properties described in table 29B.

Table 29A

Material Percent Input Percent (of component) mass (kg) of mass wet_ volume of composition

<table> table see original document page 121 </column> </row> <table>

Table 29B

<table> table see original document page 121 </column> </row> <table> <table> table see original document page 122 </column> </row> <table>

Example 2 5

A binder composition (7-17-06-1-4) was pre-prepared and processed into an agglutinant building product the building product was tested to determine physical properties. Briefly, the binding construction product was prepared by mixing and extruding the composition described in table 30A. The extrudate was placed in a drying oven 4 hours after extrusion. After complete dehydration, the extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 15.2 cm, width 8.7 cm, height 1.96 cm and weight 245.57 g. The construction product exhibited the properties described in table 30B.Table 30A

Material Percent Input Percent (component) mass (kg) mass wet volume_of the composition

<table> table see original document page 123 </column> </row> <table>

Table 30B

<table> table see original document page 123 </column> </row> <table> Example 2 6

A binder composition (7-17-06-1-5) was prepacked and processed into a binder construction product. The construction product was tested to determine physical properties. Briefly, the binding construction product was prepared by mixing and extruding the composition described in table 31A. The extrudate was placed in a drying oven 5 hours after extrusion. After complete dehydration, the extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 15.2 cm, width 8.7 cm, height 1.93 cm and weight 250.77 g. The build product exhibited the properties described in table 31B.

Table 31A

Material Percent Input Percent (component) mass (kg) mass wet volume of the composition

<table> table see original document page 124 </column> </row> <table> <table> table see original document page 125 </column> </row> <table>

Table 31Β

<table> table see original document page 125 </column> </row> <table>

Example 27

A binder composition (7-17-06-1-6) was pre-prepared and processed into a binder construction product. The construction product was tested to determine physical properties. Briefly, the binding product was prepared by mixing and extruding the composition described in table 32A. The extrudate was placed in a drying oven 6 hours after extrusion. After complete dehydration, the extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 15.8 cm, width 8.7 cm, height 1.96 cm and weight 250.77 g. The construction product exhibited the properties described in table 32B.

Table 32A

Material Percent Input Percent (of component) mass (kg) of mass wet_ volume of composition

<table> table see original document page 126 </column> </row> <table>

Table 32B

<table> table see original document page 126 </column> </row> <table> <table> table see original document page 127 </column> </row> <table>

Example 28

A binder composition (7-17-06-1-28) was pre-prepared and processed into a binder construction product. The construction product was tested to determine physical properties. Briefly, the binding product was prepared by mixing and extruding the composition described in table 33A. The extrudate was covered in plastic and kept at room temperature. The extrudate was then placed in a drying oven 28 days hours after extrusion. After complete dehydration, the extrudate was covered in plastic and kept at room temperature. The cured extrudate was substantially dehydrated completely again in a drying oven until completely dehydrated on the day prior to testing and the construction product was dried. The construction product exhibited the properties described in table 33B.

Table 33Material Percent Input Percent of (component) mass (kg) mass wet volume of composition

<table> table see original document page 128 </column> </row> <table>

Table 33B

<table> table see original document page 128 </column> </row> <table> Example 29

A binder composition (7-17-06-2) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 34A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 35.7 cm, width 8.9 cm, height 1.9 cm and weight 547.09 g. The construction product exhibited the properties described in table 34B.

Table 34A

Material Percent Input Percent (component) Mass (kg) Wet Mass Wet Volume

of composition

total total volume vol (%)

(%)

<table> table see original document page 129 </column> </row> <table> <table> table see original document page 130 </column> </row> <table>

Table 34Β

<table> table see original document page 130 </column> </row> <table>

Example 30 A binder composition (7-18-06-1) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 35A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 35.72 cm, width 8.7 cm, height 2 cm and weight 580.88 g. The construction product exhibited the properties described in table 35B.

Table 35A

<table> table see original document page 131 </column> </row> <table> Table 35Β

<table> table see original document page 132 </column> </row> <table>

Example 31

A binder composition (7-20-06-1) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 36A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 35.4 cm, width 8.9 cm, height 1.9 cm and weight 560.28 g. The construction product exhibited the properties described in table 36B.Table 36A

Material Percent Input Percent (component) mass (kg) mass wet volume_of the composition

<table> table see original document page 133 </column> </row> <table>

Table 36B

<table> table see original document page 133 </column> </row> <table> <table> table see original document page 134 </column> </row> <table>

Example 32

A binder composition (7-21-06-1) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 37A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 35.1 cm, width 8.9 cm, height 2.0 cm and weight 817.17 g. The construction product exhibited the properties described in table 37B.

Table 37A Material Percent Input Percent of (component mass (kg) of mass wet moist volume of

<table> table see original document page 134 </column> </row> <table> <table> table see original document page 135 </column> </row> <table>

Table 37Β

<table> table see original document page 135 </column> </row> <table>

Example 33

A binder composition (7-21-06-2) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 38A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 29 cm, width 8.8 cm, height 2.0 cm and weight 451.38 g. The construction product exhibited the properties described in table 38B.

Table 38A

<table> table see original document page 136 </column> </row> <table> <table> table see original document page 137 </column> </row> <table>

Example 34

A binder composition (7-24-06-1) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 39A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 19 cm, width 8.3 cm, height 1.9 cm and weight 264.14 g. The construction product exhibited the properties described in table 39B.

Table 39A

Material Percent Input Percent (of component) mass (kg) mass wet volume of composition total composition (%) vol (%)

<table> table see original document page 138 </column> </row> <table>

Table 39B

<table> table see original document page 138 </column> </row> <table> <table> table see original document page 139 </column> </row> <table>

Example 35

A binder composition (7-24-06-1-0) was pre-

Stopped and processed in a construction product aglutinantee The construction product has been tested to determine physical properties. Briefly, the binding product was prepared by mixing and extruding the composition described in table 40A. The extrudate was covered in plastic at room temperature and then placed in a drying oven on the same day as the extrusion. The dried extrudate was then placed in plastic and stored at room temperature. The extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 19.5 cm, width 9 cm and height 2 cm. The building product exhibited the properties described in table 40B.Table 40A

Material (com- Incomponent) mass (kg)

percent percent percent too wet humid volumeof the total composition total vol (%)

(%)

<table> table see original document page 140 </column> </row> <table>

Table 4 OB

<table> table see original document page 140 </column> </row> <table> <table> table see original document page 141 </column> </row> <table>

Example 36

A binder composition (7-24-06-1-1) was prepacked and processed into a binder construction product. The binder composition was tested to determine physical properties. Briefly, the binding product was prepared by mixing and extruding the composition described in table 41A. The extrudate was covered in plastic at room temperature, and then placed in a drying oven one day after extrusion. The dried extrudate was then placed in plastic and stored at room temperature. The extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 19.5 cm, width 9 cm and height 2 cm. The building product exhibited the properties described in table 41B.

Table 41 Percent Input Percent Percent

(component) mass (kg) wet mass wet volume

of the composition

total tion totalation

(%) vol (%)

<table> table see original document page 142 </column> </row> <table>

Table 41B

<table> table see original document page 142 </column> </row> <table> <table> table see original document page 143 </column> </row> <table>

Example 37

A binder composition (7-2 4-06-1-2) was prepacked and processed into a binder construction product the binder construction was tested to determine physical properties. Briefly, the binding product was prepared by mixing and extruding the composition described in table 42A. The extrudate was covered in plastic at room temperature, and then placed in a drying oven two days after extrusion. The dried extrudate was then placed in plastic and stored at room temperature. The extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 19.5 cm, width 9 cm and height 2 cm. The construction product exhibited the properties described in table 42B.

Table 42a

Material Percent Input Percent of

(component) mass (kg) mass wet volume of total composition total composition (%) vol (%) <table> table see original document page 144 </column> </row> <table>

Table 42Β

<table> table see original document page 144 </column> </row> <table>

Example 38

A binder composition (7-24-06-1-4) was pre-prepared and processed into a binder construction product the construction product was tested to determine physical properties. Briefly, the binding construction product was prepared by mixing and extruding the composition described in table 43A. The extrudate was covered in plastic at room temperature, and then placed in a drying oven four days after extrusion. The dried extrudate was then placed in plastic and stored at room temperature. The extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 19.5 cm, width 9 cm and height 2 cm. The construction product exhibited the properties described in table 43B.

Table 43A

<table> table see original document page 145 </column> </row> <table> Table 43Β

<table> table see original document page 146 </column> </row> <table>

Example 39

A binder composition (7-24-06-1-8) was pre-prepared and processed into a binder construction product the construction product was tested to determine physical properties. Briefly, the binding construction product was prepared by mixing and extruding the composition described in table 44A. The extrudate was covered in plastic at room temperature, and then placed in a dry oven eight days after extrusion. The dried extrudate was then placed in plastic and stored at room temperature. The extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 19.5 cm, width 9 cm and height 2 cm. The construction product exhibited the properties described in table 44B.

Table 44A

Material Percent Input Percent of

(component) mass (kg) mass wet volume

of the composition

total total composition (%) vol (%)

<table> table see original document page 147 </column> </row> <table>

Table 44B

<table> table see original document page 147 </column> </row> <table> <table> table see original document page 148 </column> </row> <table>

Example 40

A binder composition (7-2 4-0 6-1-22) was pre-prepared and processed into a binder construction product the binder product was tested to determine physical properties. Briefly, the binding product was prepared by mixing and extruding the composition described in table 45A. The extrudate was covered in plastic at room temperature, and then placed in a drying oven twenty-two days after extrusion. The dried extrudate was then placed in plastic and stored at room temperature. The extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 19.5 cm, width 9 cm and height 2 cm. The construction product exhibited the properties described in table 45B.

Table 45A

Material Percent Input Percent (component) mass (kg) mass wet volume of the composition

<table> table see original document page 148 </column> </row> <table> <table> table see original document page 149 </column> </row> <table>

Table 45Β

<table> table see original document page 149 </column> </row> <table>

Example 41

A binder composition (7-24-06-1-32) was pre-prepared and processed into a binder construction product the construction product was tested to determine physical properties. Briefly, the binding product was prepared by mixing and extruding the composition described in table 46A. The extrudate was covered in plastic at room temperature and then placed in a drying oven thirty-two days after extrusion. The dried extrudate was then placed in plastic and stored at room temperature. The extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 19.5 cm, width 9 cm and height 2 cm. The construction product exhibited the properties described in table 46B.

Table 46A

Material Percent Input Percent of

(component) mass (kg) mass wet volume

of total composition total composition (%) vol (%) _

<table> table see original document page 150 </column> </row> <table> Table 46Β

<table> table see original document page 151 </column> </row> <table>

Example 42

A binder composition (7-24-06-2) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 47A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 17.4 cm, width 8.5 cm and height 1.9 cm. The construction product exhibited the properties described in table 47B.

Table 47A

Material Percent Input Percent of

(component) mass (kg) mass wet volume

of the composition

total total composition (%) vol (%)

<table> table see original document page 152 </column> </row> <table>

Table 47B

<table> table see original document page 152 </column> </row> <table> <table> table see original document page 153 </column> </row> <table>

Example 4 3

A binder composition (7-24-06-3) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 48A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 17.9 cm, width 8.4 cm, height 1.9 cm and weight 232.8 g. The construction product exhibited the properties described in table 48B.

Table 48Material Percent Input Percent of

(component) mass (kg) mass wet volume

of the composition

total total composition (%) vol (%)

<table> table see original document page 154 </column> </row> <table>

Table 48B

<table> table see original document page 154 </column> </row> <table> <table> table see original document page 155 </column> </row> <table>

Example 4 4

A binder composition (7-31-06-7) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 49A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 16.6 cm, width 8.4 cm, height 1.95 cm and a weight of 199.64 g. The construction product exhibited the properties described in table 49B.

Table 49A

<table> table see original document page 155 </column> </row> <table> <table> table see original document page 156 </column> </row> <table>

Table 49Β

<table> table see original document page 156 </column> </row> <table>

Example 45

A binder composition (7-31-06-8) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 50A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 16.6 cm, width 8.4 cm, height 1.95 cm and a weight of 199.64 g. The construction product exhibited the properties described in table 50B.

Table 50A

Material Percent Input Percent (component) mass (kg) mass wet volume

of total composition total composition (%) vol (%)

<table> table see original document page 157 </column> </row> <table> <table> table see original document page 158 </column> </row> <table>

Table 50Β

<table> table see original document page 158 </column> </row> <table>

Example 46

A binder composition (8-1-06-4) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 51A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 16.13 cm, width 8.4 cm, height 1.96 cm and a weight of 204.17 g. The construction product exhibited the properties described in table 51B.

Table 5IA

<table> table see original document page 159 </column> </row> <table>

Table 51B

<table> table see original document page 159 </column> </row> <table> <table> table see original document page 160 </column> </row> <table>

Example 47

A binder composition (8-1-06-9) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 52A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 17.04 cm, width 8.58 cm, height 1.99 cm and a weight of 255.36 g. The construction product exhibited the properties described in table 52B.

Table 52Material Percent Input Percent of

(component) mass (kg) mass wet volume

of the composition

total total composition (%) vol (%)

<table> table see original document page 161 </column> </row> <table>

Table 52B

<table> table see original document page 161 </column> </row> <table> Percentage Composition

<table> table see original document page 162 </column> </row> <table>

Example 4 8

A binder composition (8-2-06-1) was prepared

Processed and processed into a binder construction product and construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 53A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length of 16.34 cm, width of 7.66 cm, height of 1.86 cm and a weight of 215.51 g. The construction product exhibited the properties described in table 53B.

Table 53A

Material (in Percent Percent Input deponent) mass (kg) wet mass wet volume

of total composition total composition vol (%) (%)

<table> table see original document page 162 </column> </row> <table> <table> table see original document page 163 </column> </row> <table>

Table 53Β

<table> table see original document page 163 </column> </row> <table>

Example 49

A binder composition (8-2-06-2) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 54A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 16.1 cm, width 7.87 cm, height 1.87 cm and a weight of 226.8 g. The construction product exhibited the properties described in table 54B.

Table 54A

Material Percent Input Percent (component) Mass (kg) Wet Mass Wet Volume

of total composition total composition (%) vol (%)

<table> table see original document page 164 </column> </row> <table> <table> table see original document page 165 </column> </row> <table>

Table 54Β

<table> table see original document page 165 </column> </row> <table>

Example 50

A binder composition (8-2-06-3) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 55A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 35 cm, width 8.81 cm, height 1.98 cm and a weight of 660.44 g. The construction product exhibited the properties described in table 55B.

Table 55A

Material Percent Input Percent (component) mass (kg) mass wet volume

<table> table see original document page 166 </column> </row> <table> <table> table see original document page 167 </column> </row> <table>

Example 51

A binder composition (8-2-06-5) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 56A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 15.4 cm, width 8.35 cm, height 2.04 cm and a weight of 197.18 g. The construction product exhibited the properties described in table 56B.

Table 56Material Percent Input Percent of

(component) mass (kg) mass wet volume

of the composition

total composition

total (%) vol (%)

<table> table see original document page 168 </column> </row> <table>

Table 56B

<table> table see original document page 168 </column> </row> <table> <table> table see original document page 169 </column> </row> <table>

Example 52

A binder composition (8-2-06-6) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 57A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 17.1 cm, width 8.62 cm, height 2.03 cm and a weight of 248.32 g. The construction product exhibited the properties described in table 57B.

Table 57A

<table> table see original document page 169 </column> </row> <table> <table> table see original document page 170 </column> </row> <table>

Table 57Β

<table> table see original document page 170 </column> </row> <table>

Example 53

A binder composition (8-16-06-1) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 58A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length of 15.83 cm, width of 6.9 cm, height of 0.99 cm and a weight of 128.6 g. The construction product exhibited the properties described in table 58B.

Table 58A

<table> table see original document page 171 </column> </row> <table> <table> table see original document page 172 </column> </row> <table>

Table 58Β

<table> table see original document page 172 </column> </row> <table>

Example 54

A binder composition (9-6-06-1-5) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 59Δ. The extrudate was covered in plastic at room temperature until. fixation. The fixed extrudate was then placed in a cure tank for 5 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 16.7 cm, width 8.97 cm, height 2.03 cm and a weight of 312.42 g. The construction product exhibited the properties described in table 59B.

Table 59A

Material Percent Input Percent (component) Mass (kg) Wet Mass Wet Volume

of total composition total composition vol (%)

<table> table see original document page 173 </column> </row> <table>

Table 59B <table> table see original document page 174 </column> </row> <table>

Example 55

A binder composition (9-6-06-1-6) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 60A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a curing tank for 6 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 15.9 cm, width 8.91 cm, height 2.03 cm and a weight of 296.28 g. The construction product exhibited the properties described in table 60B.Table 60A

<table> table see original document page 175 </column> </row> <table>

Table 60B

<table> table see original document page 175 </column> </row> <table> <table> table see original document page 176 </column> </row> <table>

Example 56

A binder composition (9-6-06-1-7) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 61A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a curing tank for 7 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 11.1 cm, width 8.91 cm, height 2.05 cm and a weight of 211.26 g. The construction product exhibited the properties described in table 61B.

Table 61A

Material Percent Input Percent (component) mass (kg) mass wet volume

of the composition

total composition

total (%) vol (%) <table> table see original document page 177 </column> </row> <table>

Table 61Β

<table> table see original document page 177 </column> </row> <table>

Example 57

A binder composition (9-6-06-1-8) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 62A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 16.6 cm, width 8.63 cm, height 1.95 cm and a weight of 199.64 g. The construction product exhibited the properties described in table 62B.

Table 62A

Material Percent Input Percent (component) mass (kg) wet mass wet volume of composition total total composition vol (%) (%)

<table> table see original document page 178 </column> </row> <table> <table> table see original document page 179 </column> </row> <table>

Table 62Β

<table> table see original document page 179 </column> </row> <table>

Example 58

A binder composition (9-8-06-1) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 63A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length of 10.95 cm, width of 8.65 cm, height of 1.87 cm and a weight of 189.67 g. The construction product exhibited the properties described in table 63B.

Table 63A

<table> table see original document page 180 </column> </row> <table> <formula> formula see original document page 181 </formula>

Table 63Β

<formula> formula see original document page 181 </formula>

Example 59

A binder composition (9-8-06-2) was prepared and processed into a binder construction product and the construction product was tested to determine physical properties. Briefly, the binder construction product was prepared by mixing and extruding the composition described in table 64A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product had the following dimensions: length 11.7 cm, width 8.6 cm, height 1.9 cm and a weight of 202.8 g. The construction product exhibited the properties described in table 64B.

Table 64A

<table> table see original document page 182 </column> </row> <table> <table> table see original document page 183 </column> </row> <table>

Table 64Β

<table> table see original document page 183 </column> </row> <table>

Example 60

A binder composition (9-18-06-1-1) was prepared

Stopped and processed in a construction product aglutinantee The construction product has been tested to determine physical properties. Briefly, the binding product was prepared by mixing and extruding the composition described in table 65A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in an 8-day curing tank and maintained at 55 ° C. The cured extrudate was removed from the curing tank and tested wet. The wet construction product had the following dimensions: length 12 cm, width 9 cm, height 2 cm and a weight of 308.57 g. Additionally, the construction product was dried to have the following dry properties: length of 10.63 cm, width of 8.54 cm, height of 1.8 cm and weight of 179.3 g. The construction product exhibited the properties described in table 65B.

Table 65A

Percent input Percent too much (kg) wet mass wet volume of composition total total composition vol (%)

<table> table see original document page 184 </column> </row> <table> Table 65Β

<table> table see original document page 185 </column> </row> <table>

Example 61

A binder composition (9-18-06-1-2) was pre-prepared and processed into a binder construction product the construction product was tested to determine physical properties. Briefly, the binding construction product was prepared by mixing and extruding the composition described in Table 66A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in a cure tank for 8 days and kept at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product exhibited the properties described in table 66B.

Table 66A

Material Percent Input Percent

(component) mass (kg) wet mass wet volume

of total composition total composition vol (%) (%)

<table> table see original document page 186 </column> </row> <table>

Table 66B

<table> table see original document page 186 </column> </row> <table> <table> table see original document page 187 </column> </row> <table>

Example 62

A binder composition (9-18-06-1-3) was pre-prepared and processed into a binder construction product. The binder construction product was tested to determine physical properties. Briefly, the binding product was prepared by mixing and extruding the composition described in table 67A. The extrudate was covered in plastic at room temperature until fixation. The fixed extrudate was then placed in an 8-day curing tank and maintained at 55 ° C. The cured extrudate was substantially completely dehydrated again in a drying oven until completely dehydrated and the construction product was tested dry. The construction product exhibited the properties described in table 67B.

Table 67A <table> table see original document page 188 </column> </row> <table>

Table 67B

<table> table see original document page 188 </column> </row> <table> <table> table see original document page 189 </column> </row> <table>

Example 63

The binder construct of Example 6 has been tested to determine nail retention force according to the standard ASTM methods described in designation: D 1761 - 88 (re-approved 2000), published by ASTM. The binder build product was determined to have a nail retention force of 1280.1 kgf / m (72.24lbf / in).

Example 64

The binder construction product of example 9 has been tested to determine nail retention force and screw retention force according to the ASTM methods standards described in designation: D 1761 - 88 (approved in 2000), published by ASTM. The binder construction product was determined to have a retention force of 1539.9 kgf / m (86.9 lbf / in) and a bolt retention force of 15.3 χ 103 kgf / m (862.16 lbf / in).

Example 65

The binder construction product of example 10 has been tested to determine nail retention force and screw retention force according to standard ASTM methods. The binder construction product was determined to have a nail retention force of 635.4 kgf / m (35.86 lbf / in) and a bolt retention force of 7077.2 kgf / m (399.39 lbf / in) .

The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments should be considered in all respects only as illustrative and not restrictive. The scope of the invention, therefore, is indicated by the appended claims rather than by the preceding description. All changes that fall within the meaning and equivalence range of the claims should be covered within its scope.

Claims (29)

1. A binder composite product for use as a lumber substitute, the product comprising: a cured binder composite comprised of hydraulic wetting, a rheology modifying agent and substantially evenly distributed fibers through the cured binder composition and included in a quantity greater than approximately 10% by weight of the cured binder composite, said cured binder composite CHARACTERIZED by: a cross-sectional thickness of at least 2mm, a flexural hardness in a range of approximately 200,000 psi (1.4 χ 109 Pa) to 5,000,000psi (3.4 χ 1010 Pa), accept standard wood nails using a marshal or standard wood nail gun and bolts using a screwdriver, a lesser hair removal nail resistance approximately 25 lbf / in (4380 N / m) using the standard ASTM method and at least 300 lbf / in (5 2 χ 10 3 N / m) using the standardASTM method, said cured binder composition being prepared by a process comprising: mixing water, fibers and a rheology modifying agent to form a fibrous mixture in which the fibers are substantially homogeneously dispersed, add hydraulic cement to the fiber mixture to produce an extrusable binder composition having a plastic consistency that includes water at a concentration of from about 25% to about 75% wet weight, hydraulic cement at a suitable concentration. 25% to approximately 75% by weight wet, rheology modification agent at a concentration of approximately 0.1% to approximately 10% by weight wet and fibers at a concentration greater than approximately 8% by weight wet, extrude the extrudable binder composition in a green intermediate extrudate having a predefined cross-sectional area, the green extrudate being stably extruded and capable of substantially retaining the cross-sectional area to allow break-free handling, causing, or allowing, the hydraulic cement to cure to form the binder composite in a manner such that the hydraulic cement contributes to an agglutination force that is at least about 50% of the overall agglutination strength of the binder composite. Binder composite product according to claim 1, characterized in that the hydraulic cement is cured by heating the intermediate extrudate to remove a portion of the water by evaporation and reducing the density of the extrudate. Binder composite product according to claim 1, characterized in that the extrusable composition has a nominal water / cement ratio of greater than approximately 0.75 before heating and an actual water / cement ratio of less than approximately 0.5 after evaporation of the water portion. Binder composite product according to claim 1, characterized in that it also comprises at least one reinforcement member selected from the group consisting of reinforcement bars, wire, mesh and telapel less partially encapsulated by the binder composite. Binder composite product according to claim 4, characterized in that at least one reinforcing member is joined in the binder composite by a bonding agent. Binder composite product according to claim 1, characterized in that the fiber fibers are included in an amount greater than approximately 15% by dry weight of the binder composite. Binder composite product according to claim 1, characterized in that the fiber fibers are included in an amount greater than approximately 20% by dry weight of the binder composite. Binder composite product according to claim 1, characterized in that the binder composite is configured in an upholstery plate. Binder composite product according to claim 1, characterized in that the binder composite comprises a construction product which is a substitute for a lumber construction product. Binder composite product according to claim 1, characterized in that the binder composite has a density of less than approximately 1.2 g / cm3. Binder composite product according to claim 1, characterized in that the binder composite can be sawed using a standard sawdust. Binder composite product according to claim 9, characterized in that the construction product is in a shape selected from the group consisting of a rod, bar, pipe, cylinder, plate, beams I, piling general purpose, upholstery plate, two by four, structural plate, one by eight, panel, flat sheet, tile and plate having a hollow interior. Binder composite product according to claim 9, characterized in that the construction product is capable of receiving an IOd nail being hammered into it with a hand hammer without significant curvature. Binder composite product according to claim 9, characterized in that the construction product has a nail extraction resistance of at least approximately 50 lbf / in (8760 N / m) for a 10d nail. Binder composite product according to claim 9, characterized in that the construction product has a screw extraction resistance of at least approximately 500 lbf / in (87600 N / m). Binder composite product according to claim 1, characterized by at least one of the following: fibers being selected from the group consisting of hemp fibers, cotton fibers, plant or leaf fibers, hardwood fibers, madeiramole, glass fibers, graphite fibers, silica fibers, ceramic fibers, metal fibers, polymer fibers, polypropylene fibers, carbon fibers and combinations thereof, the hydraulic cement being selected from the group consisting of Portland cement. , MDF cements, DSP cements, Densit type cements, Pyrament type cements, calcium aluminate cements, mortars, silicate cements, gypsum cements, phosphate cements, alumina content cements, micro fine cements, slag cements, magnesium oxychloride cements and combinations thereof, the rheology modifying agent being selected from the group consisting of polysaccharides, proteins, cell starches, starches, methylhydroxyethylcellulose, hydroxymethylethylcellulose, carboxymethylcellulose, methylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, amylpectin, a-milose, seagel, starch acetates, starch hydroxyethers, ionic starches, long chain alkyl starches, dextrins, dextrins amine, phosphate starches, dialdehyde starches, arogila and combinations thereof, including a fixation accelerator selected from the group consisting of Na2OH, KCO3, KOH, NaOH, CaCl2, CO2, magnesium chloride, triethanolamine, aluminates, inorganic salts -cos HCl, inorganic salts HNO3, inorganic salts H2SO4, calcium silicate hydrates (CSH) and combinations thereof including a filler material selected from the group consisting of sand, dolomite, gravel, stone, heel, granite, limestone, sandstone, glass beads, aerogels, xerogels, seagel, mica, clay, synthetic clay, alumina, silica, ash particle, silica gas, aluminatabular, kaolin, glass microspheres o, ceramic spheres, plaster dihydrate, calcium carbonate, calcium aluminate and combinations thereof. A method of manufacturing a binder composite having properties suitable for use as a lumber substitute, comprising: mixing water, fibers and a rheology modifying agent to form a fibrous mixture in which the fibers are substantially dispersed of lumber. homogeneously, add hydraulic cement to the fiber mixture to produce an extrusable binder composition having a plastic consistency that includes water at a concentration of from about 25% to about 75% wet weight, hydraulic cement at a concentration of approximately 25%. % to approximately 75 wt.%, rheology modification agent at a concentration of approximately 0.1% to approximately 10 wt.% and fibers at a concentration greater than approximately 5 wt.%, extrude the composition extrudable binder in a green intermediate extrudate having a predisposable cross-sectional area defined, the green extrudate being stably extruded and capable of substantially retaining the cross-sectional area so as to allow rupture manipulation to cause, or allow, the hydraulic cement to cure to form the binder composite in one manner. so that the hydraulic cement contributes to an agglutination force that is at least about 50% of the general agglutination strength of the binder composite, which is CHARACTERIZED by one or more of the following: a cross-sectional thickness of at least 2mm, a bending hardness of a range of approximately 200,000 psi (1.4 χ 10 9 Pa) to approximately 5,000,000psi (3.4 χ 10 10 Pa), accept standard wood nails using a marshaling gun or standard wood nails and screws using -of a screwdriver, a menopausal nail extraction resistance approximately 25 lbf / in (4380 N / m) using the standard ASTM method, a screwdriver extraction resistance approximately 300 lbf / in (52 χ 103 N / m) using the standard ASTM method or can be sawed using a standard timber saw. A method according to claim 17, characterized in that the fibers are included in an amount greater than approximately 10% by weight of the extrudable binder composition. A method according to claim 17, characterized in that the fibers are included in an amount greater than approximately 15% by weight of the extrudable binder composition. Method according to claim 17, characterized in that the hydraulic cement is cured by heating the intermediate extrudate to remove a portion of the water by evaporation and reducing the density of the extrudate. Method according to claim 20, characterized in that the extrusable composition has a nominal water / cement ratio of greater than approximately 0.75 before heating and a real water / cement ratio of less than approximately 0.5 after evaporation of the water portion. A method according to claim 17, characterized in that it also comprises extruding extrudable binder composition around at least one reinforcement element selected from the group consisting of reinforcement bar, wire, mesh and screen so as to at least least partially encapsulate the reinforcement element within the green extrudate. A method according to claim 22 which further comprises: extruding a green extrudate having at least one continuous hole which is stably inserting a reinforcing bar and a continuous hole bonding agent while the binder composite It is in a stably green state or is at least partially cured and joining the reinforcement bar on a surface of the continuous hole with the bonding agent, optionally applying the bonding agent to the reinforcement bar before inserting the reinforcement bar. A method according to claim 17, characterized in that it also comprises configuring the binder composite in an upholstery plate. A method according to claim 17, characterized in that it also comprises processing the binder composite into a construction product to be a substitute for a timber construction product having a shape selected from the group consisting of a rod, bar, pipe, cylinder, plate, beams I, general purpose pile, upholstery plate, two by four, structural plate, one by eight, panel, flat sheet, tile and a plate having a hollow interior. A method according to claim 17, characterized in that it also comprises stably processing the green extrudate and / or the binder composite cured by at least one group process consisting of bending, cutting, sawing, sanding, milling, texture finishing, planing, polishing, polishing, hole pre-drilling, painting and impregnation. A method according to claim 17, characterized in that it also comprises recycling a portion of a spare green extrudate obtained from the processing of the green extrudate, wherein recycling includes combining the spare green extrudate with the composition. binderxtrusible. A method according to claim 17, characterized in that the binder composition is extruded through a die opening and / or by roller extrusion. A method according to claim 17, characterized in that it also comprises stamping or impact shaping the intermediate green extrudate.