Compositions: coating or plastic – Coating or plastic compositions – Inorganic settable ingredient containing
Reexamination Certificate
1999-04-26
2001-04-17
Green, Anthony (Department: 1755)
Compositions: coating or plastic
Coating or plastic compositions
Inorganic settable ingredient containing
C106S716000, C106S730000, C106S676000
Reexamination Certificate
active
06217646
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to a cementitious compound which can be pumped, sprayed or troweled on wall surfaces.
BACKGROUND OF THE INVENTION
It is known to use fresh cementious compounds to apply same over worn out rigid wall surfaces, for resurfacing and/or levelling purposes. These known cementious compounds may be for example troweled by hand over the wall surface, or sprayed thereon by a compressed air gun at the end of a hose connected to a fresh cementious compound tank. However, once cured, these cementious compound having adhered to the wall surface cannot be thereafter surface shaped for aesthetic purposes, since the cement is completely rigid and cannot be hand- or trowel-fashioned for custom made individualized look. In addition, these cementious compounds may have structural weaknesses and/or aesthetically unappealing features brought about by through-borings generated by air bubbles that appeared during wall application and that became accidentally trapped therein during curing.
Examples of such known fresh cementious or cementious-like compounds include the following patents. U.S. Pat. No. 3,989,534, which discloses a cement having the appearance of a foam, which includes Portland cement, a defoaming agent and hollow silicate spherical bodies. U.S. Pat. No. 4,391,647, which discloses a compound to manufacture stucco and plaster joints with a trowel, having a large proportion of hollow silicium particles, mixed to lime. U.S. Pat. No. 3,023,116, which shows an ultralight concrete which is buoyant since it comprises a good quantity of spherical glass particles. U.S. Pat. No. 3,362,837, which discloses a thermally insulating concrete which is non absorbent and which includes Portland cement, sand, gravel and volcanic ash. U.S. Pat. No. 4,494,990, which discloses a cement mixed with gypsum, which is similar to hydraulic lime, but which further comprises accelerating agents to vary the curing time of the compound, and which further comprises a water reducing agent. U.S. Pat. No. 5,009,269, which is a mixture of Portland cement, of a polyvinyl and of calcium sulfate.
OBJECT OF THE INVENTION
The gist of this invention is to improve upon existing add-on cementitious compounds, by providing an economic cementitious composition which is both a breathable, porous mortar which can be sculpted in custom-made fashion following an initial cure.
SUMMARY OF TILE INVENTION
The invention consists of a cementitious mortar compound with the ability of being sprayed or troweled on wall surfaces. The mortar compound comprises as active ingredients the following three ingredients:
a) hydraulic lime;
b) Portland cement;
c) vinyl acetate dry polymer; and further comprising as filler and the main ingredient in weight of the total compound weight the following single ingredient:
d) a mineral filler; wherein upon having been sprayed over a surface to be levelled, said mortar compound boasts the unexpected result of remaining both permeable to water vapours throughout curing, while enabling scupturing thereof even after a 24 hour last leg curing stage thereof.
Each of said sphere is envisioned to be of the lightweight and hollow type, and of a size which may vary between 70 to 325 mesh (44 to 210 micrometers).
Various additives may be included to enhance the performance of the composition. These additives include:
1. a second filler, selected from the ground comprising glass spheres and ceramic-based spheres, wherein said spheres assist in reducing the overall density of the mortar compound and reduce binder level.
2. a defoaming agent, to assist in controlling the final amount of air on the sprayed compound during curing thereof.
3. a water retention agent (preferably cellulose ether), permitting applications on either high or low absorptive substrates.
4. a rheological aid (preferably polysaccharide) to the compound.
5. a water repellent agent (preferably calcium stearate)
6. a water reducing agent, to reduce the amount of water required while maintaining the plasticity of the mix.
7. an accelerator agent for the portland cement portion of the compound, preferably selected from the group comprising calcium formate and zinc formate.
The respective relative ratios of these ingredients may vary between the following ranges, as percentage in weight of the total compound:
a) hydraulic lime (preferably of moderate hydraulicity): between 2 and 30%; (preferably 5%)
b) portland cement: between 4 and 25%; (preferably 10%)
c) vinyl acetate dry polymer: between 1 to 8% (preferably 5%); and
d) mineral filler between: 50 to 80% (preferably about 73.33%)
e) glass/ceramic spheres: between 0 and 30% (preferably 7%)
f) defoaming agent: between NIL and 0.20% (preferably 0.15%)
g) water retention agent: between NIL and 0.40% (preferably 0.05%) (preferably methyl cellulose)
h) rheological aid: between NIL and 0.04% (preferably 0.03%) (preferably polysaccharide)
i) water repellent agent: ranges between NIL and 0.40% (preferably 0.10%) (preferably calcium stearate)
j) water reducing agent: between NIL and 0.40% (preferably 0.20%) (preferably ligno sulfanate)
k) accelerator agent: between NIL and 0.40% (preferably 0.14%) (preferably calcium formate)
For best performance, said mineral filler will be silica sand will have a particle size which may vary between about 16 to 325 mesh (44 to 1190 micrometers), and most preferably about #40 mesh. (420 micrometers).
When the applied mortar has initially cured, it can be sculpted to a limitless array of architectural designs. Once fully cured, it will have the capability of releasing entrapped moisture by transmitting vapors. These vapors will be released at such a rate that entrapped humidity will not damage or not internal structural components.
Conceptually, this specialty mortar would have the ability to be applied on wall surfaces by means of a pump spray unit or by trowel. Equally, this mortar will have a strong bond to most common construction materials. The application must be able to hold its own weight up to 2″ in thickness. Once this mortar has cured for approx. 24 hours, it can then be sculpted and designed to specification. Once fully cured, vapors can be released at a fast and efficient rate due to porosity of the dried mortar and the density of the hydraulic binders.
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Daubois Inc.
Green Anthony
Martineau François
LandOfFree
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