Solidia Technologies, Inc.

Asahi Kasei Construction Materials Corporation

David Vuong

Vahit Atakan

Sadananda Sahu

Omkar Deo

Deepak Ravikumar

Yoshihito Fukasawa

Hirotaka Takase

Takayuki Kamata

Katsuhiko Kanno

The invention provides novel aerated composite materials that possess excellent physical and performance characteristics of aerated concretes, and methods of production and uses thereof. These composite materials can be readily produced from widely available, low cost raw materials by a process suitable for large-scale production with improved energy consumption, desirable carbon footprint and minimal environmental impact.

Aerated composite materials, methods of production and uses thereof

An aerated composite material produced from carbonatable calcium silicate compositions (carbonation cured AAC) that has a compressive strength equivalent to autoclaved aerated concrete (ordinary AAC) at substantially the same density and a process of production of the same are provided. The composite material of the present invention comprises: a plurality of bonding elements, each including a core comprising calcium silicate, a first layer which partially or fully surrounds the core and is rich in SiO, and a second layer which partially or fully surrounds the first layer and is rich in CaCO; a plurality of filler particles having their particle sizes ranging from 0.1 &#x3bc;m to 1000 &#x3bc;m; and a plurality of voids; wherein the plurality of bonding elements and plurality of filler particles together form a bonding matrix and are substantially evenly dispersed in the matrix and bonded together, the plurality of voids are bubble-shaped and/or interconnected channels, a pore volume with a radius of 0.004 &#x3bc;m to 10.0 &#x3bc;m in the plurality of voids is 0.30 ml/composite material 1 g or less, and a estimated compressive strength expressed by the following formula (1): estimated compressive strength (absolute dry density=0.50)=compressive strength&#xd7;(0.50+absolute dry density)is 2.0 N/mmor greater.

Lightweight composite materials produced from carbonatable calcium silicate and methods thereof

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Piscataway, NJ, United States of America

David Vuong