Nonwoven cementitious composite for in-situ hydration

Abstract

A cementitious composite includes a structure layer, cementitious material, a first layer, and a second layer. The structure layer defines a plurality of open spaces. The cementitious material is disposed within the plurality of open spaces of the structure layer. The first layer is disposed along a first side of the structure layer. The second layer is disposed along an opposing second side of the structure layer. The second layer is positioned to prevent at least a portion of the cementitious material from migrating out of the structure layer.

1 . A cementitious composite comprising:
 a structure layer defining a plurality of open spaces;   cementitious material disposed within the plurality of open spaces of the structure layer;   a first layer disposed along a first side of the structure layer; and   a second layer disposed along an opposing second side of the structure layer, the second layer positioned to prevent at least a portion of the cementitious material from migrating out of the structure layer.   
     
     
         2 . The cementitious composite of  claim 1 , wherein the first layer and the second layer are coupled to the structure layer without puncturing the first layer and the second layer. 
     
     
         3 . The cementitious composite of  claim 1 , wherein the first layer is a water-impermeable layer. 
     
     
         4 . The cementitious composite of  claim 1 , wherein the first layer is integrally formed with the structure layer. 
     
     
         5 . The cementitious composite of  claim 1 , wherein the second layer is water soluble such that the second layer disintegrates upon hydration. 
     
     
         6 . The cementitious composite of  claim 1 , wherein the second layer is biodegradable. 
     
     
         7 . The cementitious composite of  claim 1 , wherein the second layer defines a retaining surface and an aperture that facilitates a fluid flow into the cementitious material, wherein the aperture has an area of between 0.001 square millimeters and 3.0 square millimeters. 
     
     
         8 . The cementitious composite of  claim 7 , wherein the aperture is a plurality of apertures spaced at a frequency of between one aperture per square inch and twelve thousand apertures per square inch. 
     
     
         9 . The cementitious composite of  claim 1 , wherein the second layer includes at least one of a sheet or a coating. 
     
     
         10 . The cementitious composite of  claim 9 , wherein the second layer includes the sheet and the coating, and wherein the coating is disposed along the sheet. 
     
     
         11 . The cementitious composite of  claim 9 , wherein the second layer is or includes the sheet, and wherein the sheet is removable before hydration or after hydration. 
     
     
         12 . The cementitious composite of  claim 9 , wherein the second layer includes the coating. 
     
     
         13 . The cementitious composite of  claim 12 , wherein the coating is positioned to prevent at least the portion of the cementitious material from migrating out of the structure layer. 
     
     
         14 . The cementitious composite of  claim 12 , wherein the coating defines a retaining surface and a plurality of apertures, and wherein the plurality of apertures are positioned to facilitate a fluid flow through the retaining surface into the cementitious material. 
     
     
         15 . The cementitious composite of  claim 1 , wherein the structure layer includes a plurality of fibers. 
     
     
         16 . The cementitious composite of  claim 15 , wherein the plurality of fibers are arranged to form a plurality of discrete nodes spaced relative to one another such that the plurality of fibers cooperatively define the plurality of open spaces between the plurality of discrete nodes. 
     
     
         17 . The cementitious composite of  claim 1 , wherein the structure layer includes a first portion including fibers arranged with a first density and a second portion including fibers arranged with a second density different than the first density. 
     
     
         18 . A cementitious composite comprising:
 a first layer;   a second layer;   a structure layer positioned between the first layer and the second layer; and   cementitious material positioned between the first layer and the second layer;   wherein the second layer defines (i) a retaining surface positioned to prevent at least a portion of the cementitious material from migrating out of the structure layer and (ii) a plurality of apertures positioned to facilitate a fluid flow through the retaining surface into the cementitious material.   
     
     
         19 . The cementitious composite of  claim 18 , wherein at least one of:
 (i) each of the plurality of apertures has an area of between 0.001 square millimeters and 3.0 square millimeters;   (ii) the plurality of apertures are positioned at a frequency of between one aperture per square inch and twelve thousand apertures per square inch; or   (iii) the second layer includes a coating that defines the retaining surface and the plurality of apertures.   
     
     
         20 . A cementitious composite comprising:
 a first layer;   a second layer;   a structure layer positioned between the first layer and the second layer; and   cementitious material positioned between the first layer and the second layer;   wherein the structure layer includes fibers arranged with varying density in at least one of a longitudinal direction, a lateral direction, or a thickness direction.