Cement-based tile

Abstract

A cement-based tile formed from a mixture comprising: a cement in the range of about 0.1 to 88% by wet weight percent; a secondary material in the range of about 0.1 to 50% by wet weight percent, the secondary material comprising limestone, sand, silica sand, gypsum, silica fume, fumed silica, Plaster of Paris, calcium carbonate, fly ash, slag, rock, or a combination thereof; a reinforcement fiber in the range of about 0.5 to 20% by wet weight percent, the reinforcement fiber comprising cellulose fiber, glass fiber, plastic fiber, polypropylene fiber, polyvinyl alcohol (PVA) fiber, homopolymer acrylic fiber, alkali-resistant fiber, or a combination thereof; a rheology modifying agent in the range of about 0.5 to 10% by wet weight percent; a water in the range of 10 to 60% of a total wet material weight; and wherein the mixture is extruded or molded to form the cement-based tile.

What is claimed is: 
     
         1 . A cement-based tile formed from a mixture comprising:
 a cement in the range of about 0.1 to 88% by wet weight percent;   a secondary material in the range of about 0.1 to 50% by wet weight percent, the secondary material comprising limestone, sand, silica sand, gypsum, silica fume, fumed silica, Plaster of Paris, calcium carbonate, fly ash, slag, rock, or a combination thereof;   a reinforcement fiber in the range of about 0.5 to 20% by wet weight percent, the reinforcement fiber comprising cellulose fiber, glass fiber, plastic fiber, polypropylene fiber, polyvinyl alcohol (PVA) fiber, homopolymer acrylic fiber, alkali-resistant fiber, or a combination thereof;   a rheology modifying agent in the range of about 0.5 to 10% by wet weight percent;   a water in the range of 10 to 60% of a total wet material weight; and   wherein the mixture is extruded or molded to form the cement-based tile.   
     
     
         2 . The cement-based tile as recited in  claim 1 , wherein the cement contains gypsum. 
     
     
         3 . The cement-based tile as recited in  claim 1 , further comprising a color pigment in the range of about 0.1 to 5% by wet weight percent. 
     
     
         4 . The cement-based tile as recited in  claim 1 , further comprising a retarder in the range of 0.1 to 8% by wet weight percent. 
     
     
         5 . The cement-based tile as recited in  claim 1 , wherein the mixture has a clay-like consistency. 
     
     
         6 . The cement-based tile as recited in  claim 1 , wherein the rheology modifying agent comprises a polysaccharide, a polysaccharide derivative, a protein, a protein derivative, a synthetic organic material, a synthetic organic material derivative, or a combination thereof. 
     
     
         7 . The cement-based tile as recited in  claim 1 , wherein the cement-based tile has a density in the range of about 1.4 to 2.4 g/cm 3 , a compressive strength in the range of about 5 MPa to 100 MPa, and a flexural strength in the range of about 5 to 35 MPa. 
     
     
         8 . The cement-based tile as recited in  claim 1 , wherein the secondary material is calcium carbonate or silica sand. 
     
     
         9 . The cement-based tile as recited in  claim 1 , wherein the reinforcement fiber is PVA fiber. 
     
     
         10 . The cement-based tile as recited in  claim 1 , wherein the cement-based tile comprises a roofing tile, a wall tile or a floor tile. 
     
     
         11 . The cement-based tile as recited in  claim 1 , wherein:
 the cement is in the range of about 40 to 55% by wet weight percent;   the secondary material is in the range of about 20 to 40% by wet weight percent;   the reinforcement fiber is in the range of about 1 to 5% by wet weight percent;   the rheology modifying agent is in the range of about 0.5 to 2.5 by wet weight percent; and   the water in the range of 15 to 25% of the total wet material weight.   
     
     
         12 . The cement-based tile as recited in  claim 1 , wherein:
 the cement is in the range of about 45 to 50% by wet weight percent;   the secondary material is in the range of about 28 to 30% by wet weight percent;   the reinforcement fiber is in the range of about 1.9 to 2.1% by wet weight percent;   the rheology modifying agent is in the range of about 1.5 to 1.7 by wet weight percent; and   the water in the range of 18 to 20% of the total wet material weight.   
     
     
         13 . A cement-based tile formed from a mixture consisting essentially of:
 a cement in the range of about 0.1 to 88% by wet weight percent;   a secondary material in the range of about 0.1 to 50% by wet weight percent, the secondary material comprising limestone, sand, silica sand, gypsum, silica fume, fumed silica, Plaster of Paris, calcium carbonate, fly ash, slag, rock, or a combination thereof;   a reinforcement fiber in the range of about 0.5 to 20% by wet weight percent, the reinforcement fiber comprising cellulose fiber, glass fiber, plastic fiber, polypropylene fiber, polyvinyl alcohol (PVA) fiber, homopolymer acrylic fiber, alkali-resistant fiber, or a combination thereof;   a rheology modifying agent in the range of about 0.5 to 10% by wet weight percent;   a water in the range of 10 to 60% of a total wet material weight; and   wherein the mixture is extruded or molded to form the cement-based tile.   
     
     
         14 . The cement-based tile as recited in  claim 13 , wherein the cement contains gypsum. 
     
     
         15 . The cement-based tile as recited in  claim 13 , further comprising a color pigment in the range of about 0.1 to 5% by wet weight percent. 
     
     
         16 . The cement-based tile as recited in  claim 13 , further comprising a retarder in the range of 0.1 to 8% by wet weight percent. 
     
     
         17 . The cement-based tile as recited in  claim 13 , wherein the mixture has a clay-like consistency. 
     
     
         18 . The cement-based tile as recited in  claim 13 , wherein the rheology modifying agent comprises a polysaccharide, a polysaccharide derivative, a protein, a protein derivative, a synthetic organic material, a synthetic organic material derivative, or a combination thereof. 
     
     
         19 . The cement-based tile as recited in  claim 13 , wherein the cement-based tile has a density in the range of about 1.4 to 2.4 g/cm 3 , a compressive strength in the range of about 5 MPa to 100 MPa, and a flexural strength in the range of about 5 to 35 MPa. 
     
     
         20 . The cement-based tile as recited in  claim 13 , wherein the secondary material is calcium carbonate or silica sand. 
     
     
         21 . The cement-based tile as recited in  claim 13 , wherein the reinforcement fiber is PVA fiber. 
     
     
         22 . The cement-based tile as recited in  claim 13 , wherein the cement-based tile comprises a roofing tile, a wall tile or a floor tile. 
     
     
         23 . The cement-based tile as recited in  claim 13 , wherein:
 the cement is in the range of about 40 to 55% by wet weight percent;   the secondary material is in the range of about 20 to 40% by wet weight percent;   the reinforcement fiber is in the range of about 1 to 5% by wet weight percent;   the rheology modifying agent is in the range of about 0.5 to 2.5 by wet weight percent; and   the water in the range of 15 to 25% of the total wet material weight.   
     
     
         24 . The cement-based tile as recited in  claim 13 , wherein:
 the cement is in the range of about 45 to 50% by wet weight percent;   the secondary material is in the range of about 28 to 30% by wet weight percent;   the reinforcement fiber is in the range of about 1.9 to 2.1% by wet weight percent;   the rheology modifying agent is in the range of about 1.5 to 1.7 by wet weight percent; and   the water in the range of 18 to 20% of the total wet material weight.