Sprayable phosphate cementitious coatings and a method and apparatus for the production thereof
First Claim
1. A sprayed-on phosphate cement coating on a surface, the phosphate cement coating produced through a process comprising the steps of:
- a) providing a first cementitious constituent;
b) providing a second cementitious constituent adapted to combine with the first cementitious constituent to produce a phosphate cement coating;
c) spraying the surface with the first cementitious constituent;
d) spraying the surface with the second cementitious constituent; and
e) reacting the first and second cementitious constituents to produce a phosphate cement coating.
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Abstract
A sprayed-on phosphate cement coating formed from the combination and reaction of a phosphoric acid solution and a base metal solution. The acid solution and base solution may be intermixed prior to spraying, during spraying, or on a substrate. The curing reaction rate of the phosphate cement coating and its final physical properties may be controlled by adding various retardants, accelerants, reducers, wetting agents, superplasticizers, buffers, water reducers, adhesive agents, hardening agents, and/or sequestrants to the precursor solutions. The curing rate and properties of the cement coating may be further controlled by adjusting the temperature of the precursor solutions and/or the target substrate.
137 Citations
42 Claims
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1. A sprayed-on phosphate cement coating on a surface, the phosphate cement coating produced through a process comprising the steps of:
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a) providing a first cementitious constituent;
b) providing a second cementitious constituent adapted to combine with the first cementitious constituent to produce a phosphate cement coating;
c) spraying the surface with the first cementitious constituent;
d) spraying the surface with the second cementitious constituent; and
e) reacting the first and second cementitious constituents to produce a phosphate cement coating. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A phosphate cement coating for a substrate produced by the following method:
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aa) providing a first phosphoric acid liquid component;
bb) providing a second metallic base liquid component adapted to reactively combine with the first phosphoric acid liquid component to produce a phosphate cement coating;
cc) providing a cooling agent;
dd) spraying the substrate with the first phosphoric acid liquid component;
ee) spraying the substrate with the second metallic base liquid component;
ff) spraying the substrate with the cooling agent;
gg) mixing the first phosphoric acid liquid component, the second metallic base liquid component and the cooling agent to form a phosphate cement coating; and
hh) curing the phosphate cement coating. - View Dependent Claims (18, 19, 20, 21, 22)
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23. A phosphate cement, comprising:
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a substrate;
a phosphoric acid portion;
a metallic base portion; and
a reaction-temperature controlling means;
wherein the phosphoric acid portion and the metallic base portion are applied to the substrate; and
wherein the phosphoric acid portion and the metallic base portion are reacted to form a phosphate cement material. - View Dependent Claims (24, 25, 26, 27, 28, 29)
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30. A method of toughening paint, comprising the steps of:
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a) dissolving a phosphate source in the paint;
b) applying the paint to a surface; and
c) reacting the phosphate with a anions present in the paint to form a dispersed phosphate cement phase in the paint. - View Dependent Claims (31, 32, 33, 35, 36, 37, 38)
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34. A method of tuckpointing a substrate with phosphate cement slurry, comprising the steps of:
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a) imparting an electrical charge to the substrate;
b) imparting an opposite electrical charge to the phosphate cement slurry; and
c) applying the phosphate cement slurry to the substrate.
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39. A method of forming a laminate, comprising the steps of:
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a) forming a first non-phosphate cement layer;
b) depositing a second, phosphate cement layer over the first non-phosphate cement layer;
c) depositing a third non-phosphate cement layer over the phosphate cement layer. - View Dependent Claims (40, 41, 42)
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Specification