Description:BACKGROUND
Field of Invention
[001] Embodiments of the present invention generally relate to construction materials and particularly to a formulation and a method for stabilizing foam in concrete.
Description of Related Art
[002] Foam concrete, also known as aerated concrete or cellular concrete, is a lightweight construction material. However, stabilizing the foam to maintain its uniformity and stability throughout the mixing and curing processes is a key challenge during the production of foam concrete. Instabilities in foam lead to inconsistencies in concrete density, compromising the structural integrity and overall performance of the resulting material. In addition, traditional concrete is also used as a construction material but often falls short in applications where reduced weight and enhanced insulation properties are required. In such cases, lightweight concrete with entrained air or foam is preferred due to its lower density and improved thermal insulation.
[003] Furthermore, lightweight concrete typically incorporates lightweight aggregates such as expanded clay, shale, or perlite, as well as air-entraining agents to create air voids within the mixture. However, this type of concrete offers benefits in terms of weight and thermal performance, it often faces challenges related to stability and consistency in foam content and distribution. These issues negatively affect the structural integrity and insulation properties of the final product, limiting its applicability in various construction scenarios.
[004] Additionally, the undesired drainage of the liquid from the foam structure leads to the collapse of foam bubbles. The phenomenon critically imparts the durability and performance of foam-based materials. In addition, with time foam bubbles tend to coarsen and grow larger, diminishing the foam’s stability, which makes the process detrimental to the longevity and effectiveness of foam in various applications.
[005] Moreover, there are various solutions available in prior art that address foam-enhanced and lightweight concrete formulations. However, they do not provide better stability and control over foam content, resulting in less reliable and efficient lightweight concrete products.
[006] There is thus a need for an improved and advanced formulation for stabilizing foam in concrete that can administer the aforementioned limitations in a more efficient manner.
SUMMARY
[007] Embodiments in accordance with the present invention provide a formulation for stabilizing foam in concrete. The formulation comprising: a non-ionic surfactant adapted to reduce surface tension and enhance a uniform distribution of air bubbles in the foam of the concrete. The non-ionic surfactant is selected from alkyl polyglycosides, alkoxylated alcohols, fatty acid esters, or a combination thereof. The formulation further comprising: a foaming additive adapted to influence bubble formation and structure to create a sustained and robust foam network, wherein the foaming additive is selected from organic polymers, protein-based foaming agents, and surfactant blends, or a combination thereof.
[008] Embodiments in accordance with the present invention further provide a method for preparing a formulation for stabilizing foam in concrete. The method comprising steps of: adding a non-ionic surfactant selected from alkyl polyglycosides, alkoxylated alcohols, fatty acid esters, or a combination thereof; incorporating a foaming additive selected from organic polymers, protein-based foaming agents, and surfactant blends, or a combination thereof; mixing a foam concrete mixture to ensure the homogeneous dispersion of the non-ionic surfactant and foaming additive; and allowing the foam concrete mixture to set and cure.
[009] Embodiments of the present invention may provide a number of advantages depending on their particular configuration. First, embodiments of the present application may provide a formulation for stabilizing foam in concrete.
[0010] Next, embodiments of the present application may provide a formulation for stabilizing foam in concrete that mitigates foam instability.
[0011] Next, embodiments of the present application may provide a formulation for stabilizing foam in concrete that comprises a balanced combination of surfactants, stabilizers, and additives.
[0012] Next, embodiments of the present application may provide a formulation for stabilizing foam in concrete that ensures consistent air void distribution in the concrete matrix.
[0013] Next, embodiments of the present application may provide a method for preparing a formulation for stabilizing foam in concrete that is easy to reproduce.
[0014] Next, embodiments of the present application may provide a method for preparing a formulation for stabilizing foam in concrete that improves thermal insulation properties.
[0015] These and other advantages will be apparent from the present application of the embodiments described herein.
[0016] The preceding is a simplified summary to provide an understanding of some embodiments of the present invention. This summary is neither an extensive nor exhaustive overview of the present invention and its various embodiments. The summary presents selected concepts of the embodiments of the present invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the present invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The above and still further features and advantages of embodiments of the present invention will become apparent upon consideration of the following detailed description of embodiments thereof, especially when taken in conjunction with the accompanying drawings, and wherein:
[0018] FIG. 1A illustrates a block diagram of a formulation for stabilizing foam in concrete, according to an embodiment of the present invention; and
[0019] FIG. 2 depicts a flowchart of a method for preparing the formulation for stabilizing foam in concrete, according to an embodiment of the present invention.
[0020] The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims. As used throughout this application, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include”, “including”, and “includes” mean including but not limited to. To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures. Optional portions of the figures may be illustrated using dashed or dotted lines, unless the context of usage indicates otherwise.
DETAILED DESCRIPTION
[0021] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the scope of the invention as defined in the claims.
[0022] In any embodiment described herein, the open-ended terms "comprising", "comprises”, and the like (which are synonymous with "including", "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of", “consists essentially of", and the like or the respective closed phrases "consisting of", "consists of”, the like.
[0023] As used herein, the singular forms “a”, “an”, and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.
[0024] FIG. 1A illustrates a block diagram of a formulation 100 for stabilizing foam in concrete, according to an embodiment of the present invention. In an embodiment of the present invention, the formulation 100 may comprise a non-ionic surfactant 102, and a foaming additive 104 based on the total weight of the formulation 100. In an embodiment of the present invention, the formulation 100 may comprise a viscosity modifier to control a rheological behavior of the foam. In an embodiment of the present invention, the viscosity modifier may be, but not limited to, a cellulose derivative, a hydroxyethyl cellulose, a xanthan gum, and so forth. Embodiments of the present invention are intended to include or otherwise cover any type of the viscosity modifier, including known, related art, and/or later developed technologies.
[0025] According to an embodiment of the present invention, the foam concrete mixture may be prepared by mixing the formulation 100 with concrete ingredients. In an embodiment of the present invention, the concrete ingredients may be, but not limited to, a cement, a water, aggregates, and so forth. Embodiments of the present invention are intended to include or otherwise cover any type of the concrete ingredients, including known, related art, and/or later developed technologies.
[0026] In an embodiment of the present invention, the foam concrete mixture may be mechanically mixed at a specific mixing time and speed to achieve optimal foam stability and uniformity. In an embodiment of the present invention, the foam in the concrete may be stabilized by incorporating the formulation 100 into a concrete mix in a ratio of 0.1 percentage (%) to 2 percentage (%) by weight of the concrete mix.
[0027] In an embodiment of the present invention, the formulation 100 may comprise the non-ionic surfactant 102 adapted to reduce surface tension. In another embodiment of the present invention, the non-ionic surfactant 102 may be adapted to enhance a uniform distribution of air bubbles in the foam of the concrete. In an embodiment of the present invention, the formulation 100 may comprise the non-ionic surfactant 102 based on the total weight of the formulation 100. In an embodiment of the present invention, the formulation 100 may comprise the non-ionic surfactant 102 in a range from 0.1% to 5% by weight.
[0028] According to an embodiment of the present invention, the non-ionic surfactant 102 may be, but not limited to, alkyl polyglycosides, alkoxylated alcohols, fatty acid esters, and so forth. Embodiments of the present invention are intended to include or otherwise cover any type of the non-ionic surfactant 102, including known, related art, and/or later developed technologies.
[0029] In an embodiment of the present invention, the formulation 100 may comprise the foaming additive 104 adapted to influence bubble formation. In another embodiment of the present invention, the formulation 100 may be further adapted to structure a sustained and robust foam network. In an embodiment of the present invention, the formulation 100 may comprise the foaming additive 104 based on the total weight of the formulation 100. In an embodiment of the present invention, the formulation 100 may comprise the foaming additive 104 in a range from 0.5% to 10% by weight.
[0030] According to an embodiment of the present invention, the foaming additive 104 may be, but not limited to, organic polymers, surfactant blends, a hydrogen peroxide, detergent blends, and so forth. In a preferred embodiment of the present invention, the foaming additive 104 may be a protein-based foaming agent derived from natural sources. Embodiments of the present invention are intended to include or otherwise cover any type of the foaming additive 104, including known, related art, and/or later developed technologies.
[0031] FIG. 2 depicts a flowchart of a method 200 for preparing the formulation 100 for stabilizing foam in concrete, according to an embodiment of the present invention.
[0032] At step 202, the formulation 100 may be prepared by adding the non-ionic surfactant 102 selected from alkyl polyglycosides, alkoxylated alcohols, fatty acid esters, or a combination thereof.
[0033] At step 204, the formulation 100 may be prepared by incorporating the foaming additive 104 selected from organic polymers, protein-based foaming agents, surfactant blends, or a combination thereof.
[0034] At step 206, the formulation 100 may be prepared by mixing the foam concrete mixture to ensure a homogeneous dispersion of the non-ionic surfactant (102) and the foaming additive (104).
[0035] At step 208, the formulation 100 may be obtained by allowing the foam concrete mixture to set and cure. The obtained formulation 100 has enhanced stability and reduced susceptibility to environmental variations.
[0036] While the invention has been described in connection with what is presently considered to be the most practical and various embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
[0037] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined in the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements within substantial differences from the literal languages of the claims. , Claims:CLAIMS
I/We Claim:
1. A formulation (100) for stabilizing foam in concrete, the formulation (100) comprises:
a non-ionic surfactant (102) adapted to reduce surface tension and enhance a uniform distribution of air bubbles in the foam of the concrete, wherein the non-ionic surfactant (102) is selected from alkyl polyglycosides, alkoxylated alcohols, fatty acid esters, or a combination thereof; and
a foaming additive (104) adapted to influence bubble formation and structure to create a sustained and robust foam network, wherein the foaming additive (104) is selected from organic polymers, protein-based foaming agents, and surfactant blends, or a combination thereof.
2. The formulation (100) as claimed in claim 1, wherein a foam concrete mixture is prepared by mixing the formulation (100) with concrete ingredients selected from a cement, a water, and aggregates, or a combination thereof.
3. The formulation (100) as claimed in claim 1, wherein the formulation (100) comprises 0.1 percentage (%) to 5 percentage (%) by weight of the non-ionic surfactant (102) based on the total weight of the formulation (100).
4. The formulation (100) as claimed in claim 1, wherein the formulation (100) comprises 0.5 percentage (%) to 10 percentage (%) by weight of the foaming additive (104) based on the total weight of the formulation (100).
5. The formulation (100) as claimed in claim 1, wherein the foaming additive (104) is a protein-based foaming agent derived from natural sources.
6. The formulation (100) as claimed in claim 1, wherein the formulation (100) further comprises a viscosity modifier to control a rheological behaviour of the foam.
7. The formulation (100) as claimed in claim 6, wherein the viscosity modifier is selected from a cellulose derivative, a hydroxyethyl cellulose, a xanthan gum, or a combination thereof.
8. The formulation (100) as claimed in claim 1, wherein the foam in the concrete is stabilized by incorporating the formulation (100) into the concrete mix in a ratio of about 0.1 percentage (%) to 2 percentage (%) by weight of the concrete mix.
9. A method (200) of stabilizing foam in concrete, characterized in that the method (200) comprises steps of:
adding a non-ionic surfactant (102) selected from alkyl polyglycosides, alkoxylated alcohols, fatty acid esters, or a combination thereof;
incorporating a foaming additive (104) selected from organic polymers, protein-based foaming agents, surfactant blends, or a combination thereof;
mixing a foam concrete mixture to ensure a homogeneous dispersion of the non-ionic surfactant (102) and the foaming additive (104); and
allowing the foam concrete mixture to set and cure.
10. The method (200) as claimed in claim 9, wherein the foam concrete mixture is mechanically mixed at a specific mixing time and speed to achieve optimal foam stability and uniformity.

Date: Novemver 29, 2023
Place: Noida

Dr. Keerti Gupta
Agent for the Applicant
(IN/PA-1529