FIELD OF INVENTION
The present invention relates to polymer cement composites having enhanced
compressive strength, tensile strength and abrasion resistance, useful for various
applications. Method of manufacture of the same is also provided herewith.
5 BACKGROUND OF INVENTION
This section is intended to provide information relating to the field of the
invention and thus any approach/functionality described below should not be
assumed to be qualified as a prior art merely by its inclusion in this section.
Cement is a multi-component product that is generally manufactured by using a
10 variety of materials/components/minerals including, but not limiting to, calcium,
silicon, aluminium, iron, limestone, shells, and chalk. Further, cement hydration
is a continuous process by which the cement minerals are replaced by new
hydration products. The manufacturing of cement involves a complex hydration
process that consists of a series of chemical reactions producing anhydrous
15 materials such as Alite (C3S), Belite (C2S), Tricalcium Aluminate (C3A) and
Tetracalcium Aluminoferrite (C4AF). Said chemical reactions occur at different
stages of cement raw material burning inside a kiln at a temperature of 1450
degree Centigrade. Also, the reaction of cement and water involves both
hydrolysis and hydration processes and proceed at different rates for different
20 mineral phases such that the anhydrous materials C3A and C4AF hydrate at very
early stages of hydration as compared to the anhydrous materials C3S and C2S
that need additional time for hydration. In conventional techniques, when the
cement is mixed with sand, mortar is produced, while if the cement and sand are
mixed with larger aggregates the end product are concrete and other chemical
25 and mineral admixtures as performance enhancers. The conventional cement,
manufactured by the conventional techniques, has a compressive strength
ranging from 20 MPa to 150 MPa, however, the conventional cement, being a
brittle material, has less tensile strength (approximately one tenth of its
compressive strength) due to which the conventional techniques of
3
manufacturing the conventional cement possess various challenges while
bending, warping, buckling, twisting, etc. Another limitation of the conventional
cements, when laid on floors, lies in the inability to provide walking comfort due
to hard and unpliant surfaces i.e. the conventional cement when used in
5 aesthetics, granite, marble and other building stones may provide good
durability but the quality and performance of the conventional cement is a
challenge since the same depend on many factors such as the quality of the rock
quarry, the quality of transportation etc. Yet another limitation associated with
the conventional cement is its unreproducible appealing designs. Another
10 limitation of the conventional technique relates to over-engineered conventional
materials used for manufacturing conventional cement for various applications
such as floor coverings, wall coverings, counter-tops and many such applications.
In light of the abovementioned drawbacks along with drawbacks inherent in the
existing arts, there exists a substantial need of an efficient and dynamic method
15 for manufacturing an optimised product of polymer cement that not only has
better compressive and tensile strength and abrasion resistance but can also
retain its characteristics efficiently in compression, tension and abrasion.
OBJECTS OF THE INVENTION
This section is intended to introduce certain objects of the disclosed invention in
20 a simplified form, and is not intended to identify the key advantages or features
of the present invention.
The primary objective of the invention is to provide a polymer cement composite
with enhanced compressive strength, tensile strength, abrasion resistance,
sound absorption, and ability to be moulded into thinner sections while retaining
25 its characteristics.
Another object of the invention is to provide a method for manufacturing a
polymer cement composite with enhanced compressive strength, tensile
strength, abrasion resistance, sound absorption, and ability to be moulded into
thinner sections while retaining its characteristics.
4
Yet another object of the present invention is to provide a method for
manufacturing a polymer cement composite with a reproducible appearance.
SUMMARY OF THE INVENTION
In an aspect of the present invention, there is provided a polymer cement
5 composite comprising: (a) cement; (b) silica sand; (c) stone chips; (d) epoxy resin;
and (e) hardener.
In another aspect of the present invention, there is provided a method of
manufacturing a polymer cement composite comprising: (a) cement; (b) silica
sand; (c) stone chips; (d) epoxy resin; and (e) hardener, said method comprising
10 the steps of: (i) mixing epoxy resin and hardener to obtain a first mixture; (ii)
mixing cement, stone chips and silica sand to obtain a second mixture; (iii) mixing
first and second mixture to obtain a third mixture; (iv) pouring the third mixture
in a mould; and (v) releasing the solidified mixture from the mould to obtain said
polymer cement composite.
15 DESCRIPTION OF THE DRAWING
The preferred embodiments of the present invention can be best understood
when read in conjunction with the following drawing
Figure 1 illustrates an exemplary method flow diagram [100] comprising the
method for manufacturing an optimised product of polymer cement composite
20 having enhanced characteristics, in accordance with an embodiment of the
present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, for the purposes of explanation, specific details have
been set forth in order to provide a brief description of the invention. It will be
25 apparent, however, that the invention may be practiced without these specific
details and features.
The present invention relates to a unique composition of polymer cement
composite that enables to achieve the objective of the present invention to
5
provide a polymer cement composite having enhanced compressive and tensile
strength, abrasion resistance, and improved noise absorption capability. The
polymer cement composite may comprise different types of minerals, metal
alloys, compounds or any such manufacturing material as may be obvious to
5 person skilled in the art.
In an embodiment, the polymer cement composite comprises at least one of
white/grey cement, silica sand, stone chips, preferably granite, epoxy resin
(transparent ER 105 & EH 620) along with hardener and optionally concrete color
pigment in a percentage as illustrated in below table:
Mineral/Manufacturing
Material
Percentage
White/Grey Cement 25-35%
Silica Sand 15-25%
Stone chips 0-20%
Epoxy Resin 20-40%
Hardener 10-15%
Concrete color pigment Based on
requirement
10
In an embodiment of the present invention, cement weight concentration in said
composite is in the range of 25-35%, silica sand weight concentration in said
composite is in the range of 15-25%, stone chips weight concentration in said
composite is in the range of 0-20%, epoxy resin weight concentration in said
15 composite is in the range of 20-40%, and hardener weight concentration in said
composite is in the range of 10-15%.
In an embodiment of the present invention, cement weight concentration in said
composite is in the range of 25-30%, 26-31%, 27-32%, 28-33%, 29-34%, or 30-
6
35%; silica sand weight concentration in said composite is in the range of 16-
21%, 17-22%, 18-23%, 19-24%, or 20-25%; stone chips weight concentration in
said composite is in the range of 0-5%, 1-6%, 2-7%, 3-8%, 4-9%, 5-10%, 6-11%, 7-
12%, 8-13%, 9-14%, 10-15%, 11-16%, 12-17%, 13-17%, 14-18%, 15-19%, or 16-
5 20%; epoxy resin weight concentration in said composite is in the range of 20-
25%, 21-26%, 22-27%, 23-28%, 24-29%, 25-30%, 26-31%, 27-32%, 28-33%, 29-
34%, 30-35%, 31-36%, 32-37%, 33-38%, 34-39%, or 35-40%; hardener weight
concentration in said composite is in the range of 10-11%, 11-12%, 12-13%, 13-
14%, or 14-15%.
10 In an embodiment of the present invention, the composite compressive strength
is 0.1-10-fold more than standard conventional composite. In an embodiment,
the composite compressive strength is 0.1-1-fold, 1-2-fold, 2-3-fold, 3-4-fold, 4-5-
fold, 5-6-fold, 6-7-fold, 7-8-fold, 8-9-fold, or 9-10-fold more than standard
conventional composite.
15 In an embodiment of the present invention, the composite tensile strength is
0.1-10-fold more than standard conventional composite. In an embodiment, the
composite tensile strength is 0.1-1-fold, 1-2-fold, 2-3-fold, 3-4-fold, 4-5-fold, 5-6-
fold, 6-7-fold, 7-8-fold, 8-9-fold, or 9-10-fold more than standard conventional
composite.
20 In an embodiment of the present invention, the composite abrasion resistance is
is 0.1-10-fold more than standard conventional composite. In an embodiment,
the composite abrasion resistance is 0.1-1-fold, 1-2-fold, 2-3-fold, 3-4-fold, 4-5-
fold, 5-6-fold, 6-7-fold, 7-8-fold, 8-9-fold, or 9-10-fold more than standard
conventional composite.
25 In an embodiment of the present invention, the composite noise absorption
capability is 0.1-10-fold more than standard conventional composite. In an
embodiment, the composite noise absorption capability is 0.1-1-fold, 1-2-fold, 2-
3-fold, 3-4-fold, 4-5-fold, 5-6-fold, 6-7-fold, 7-8-fold, 8-9-fold, or 9-10-fold more
than standard conventional composite.
7
In an embodiment of the present invention, the composite flexural strength is
0.1-10-fold more than standard conventional composite. In an embodiment, the
composite flexural strength is 0.1-1-fold, 1-2-fold, 2-3-fold, 3-4-fold, 4-5-fold, 5-
6-fold, 6-7-fold, 7-8-fold, 8-9-fold, or 9-10-fold more than standard conventional
5 composite.
In an embodiment of the present invention, the composites are capable of being
molded into thinner sections while retaining its characteristics.
As illustrated in Figure 1, the present invention encompasses an exemplary
method [100] for manufacturing polymer cement composite having enhanced
10 characteristics, in accordance with at least an embodiment of the present
disclosure. The following includes detailed steps involved in said method [100]
for manufacturing of the polymer cement composite.
At step 104, epoxy resin and hardener is mixed to obtain a first mixture.
At step 106, the cement, stone chips and silica sand are mixed with first mixture
15 of step 104 to obtain a second mixture. The stone chips and silica said may be
pre-mixed previously and then subsequently mixed with the cement in step 106
to obtain the second mixture.
At step 108, the first and second mixture are mixed thoroughly until a fairly
homogenous third mixture is obtained. In an embodiment, the compound is
20 mixed manually while in another embodiment the compound is mixed using a
mechanical mixer.
At step 110, the third mixture is poured into at least one pre-waxed mould and is
left idle for curing/treated for few hours based on ambient temperature.
At step 112 and on completion of the curing process, a polymer cement
25 composite is released from the at least one pre-waxed mould. Further, the
reverse side of the polymer concrete is sanded and left open to dry for achieving
a smooth surface. Thus, the polymer cement composite has a reproducible
appearance.
8
At step 114, the smooth surface of the polymer cement composite may be oiled
to enhance the smoothness. The method [100] terminates at step 116 where the
polymer cement composite having enhanced compressive and tensile strength
and abrasion resistance is manufactured.
5 Thus, the present invention encompasses manufacturing of a polymer cement
composite that not only has enhanced characteristics/properties but also has the
capability to retain its characteristics at every phase i.e. compression, tension
and abrasion. Also, the polymer cement composite possess improved noiseabsorption capability. Additionally, the polymer cement composite has a
10 capability to meld into thinner sections without breaking and losing its
characteristics/properties. Also, the polymer cement composite has varied
number of applications (such as vitrified tiles, cement, floor coverings, wall
coverings, counter-tops, etc.) due to the smooth surface and reproducible
appearance of the polymer cement composite.
15 However, a person skilled in the art may be cognizant of the fact that the
materials/minerals and the percentages thereof used in the manufacturing the
polymer cement composite may vary.
While the present invention has been described in detail with reference to
certain preferred embodiments and examples thereof, other embodiments,
20 equivalents and modifications are possible. Even though characteristics and
advantages of the present invention have been set forth in the foregoing
description, the invention is illustrative only, and changes may be made in detail.
Thus, various modifications are possible of the presently disclosed system and
process without deviating from the intended scope and spirit of the present
25 invention.

We claim:
1. A polymer cement composite comprising:
a. cement;
b. silica sand;
5 c. stone chips;
d. epoxy resin; and
e. hardener.
2. The polymer cement composite as claimed in claim 1, wherein said stone
chips are preferably granite.
10 3. The polymer cement composite as claimed in claim 1, further comprising at
least one coloring pigment.
4. The polymer cement composite as claimed in claim 1, wherein cement
weight concentration in said composite is in the range of 25-35%, silica sand
weight concentration in said composite is in the range of 15-25%, stone
15 chips weight concentration in said composite is in the range of 0-20%, epoxy
resin weight concentration in said composite is in the range of 20-40%, and
hardener weight concentration in said composite is in the range of 10-15%.
5. The polymer cement composite as claimed in claim 1, wherein said
composite compressive strength is 0.1-10-fold more than standard
20 conventional composite.
6. The polymer cement composite as claimed in claim 1, wherein said
composite tensile strength is 0.1-10-fold more than standard conventional
composite.
7. The polymer cement composite as claimed in claim 1, wherein said
25 composite abrasion resistance is 0.1-10-fold more than standard
conventional composite.
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8. The polymer cement composite as claimed in claim 1, wherein said
composite noise absorption capability is 0.1-10-fold more than standard
conventional composite.
9. The polymer cement composite as claimed in claim 1, wherein said
5 composite flexural strength is 0.1-10-fold more than standard conventional
composite.
10. A method of preparing a polymer cement composite as claimed in claims 1-
9