Protective coating system

• US 4,349,398 A
• Filed: 12/08/1980
• Issued: 09/14/1982
• Est. Priority Date: 12/08/1980
• Status: Expired due to Term

• Current Assignee: Edward C. Kearns
• Original Assignee: Edward C. Kearns
• Inventors: Kearns, Thomas R., Kearns, Richard F., Kearns, Timothy P.
• Primary Examiner(s): Kimlin, Edward C.
• Assistant Examiner(s): Wine, F. K.
• Application Number:
  US06/214,122
• Time in Patent Office: 645 Days
• Field of Search: 04B/1/00, 156/91, 156/94, 156/71, 156/303.1, 156/280, 428/247, 428/255, 428/256, 428/310, 428/703, 428/63, 428/140, 428/86, 264/DIG. 57, 264/309, 264/255, 264/256, 264/257, 264/259, 264/333, 264/121, 264/171, 264/174, 264/271.1, 264/34, 264/36, 52/720, 52/434, 52/309.12, 427/140, 427/403, 404/70
• US Class Current: 156/71
• CPC Class Codes: E04D 7/00 Roof covering exclusively consisting of sealing masses applied in situ; Gravelling of flat roofs
• CPC Class Codes: E04F 15/12 Flooring or floor layers made of masses in situ, e.g. seamless magnesite floors, terrazzo gypsum floorsinorganic or bituminous masses C04B; organic plastic masses C08L
• CPC Class Codes: Y10T 428/20 Patched hole or depression
• CPC Class Codes: Y10T 428/24996 With internal element bridging layers, nonplanar interface between layers, or intermediate layer of commingled adjacent foam layers
• CPC Class Codes: Y10T 428/249968 Of hydraulic-setting material
• CPC Class Codes: Y10T 428/249985 Composition of adhesive or bonding component specified
• CPC Class Codes: Y10T 428/24999 Inorganic
• CPC Class Codes: Y10T 442/131 Including a coating or impregnation of synthetic polymeric material
• CPC Class Codes: Y10T 442/183 Synthetic polymeric fiber

Abstract

Protective coating systems are reinforced by first laying a suitable mesh screen of plastic, metal or the equivalent on the surface to be protected. Thereafter, a thin layer of a coating composition, e.g., a latex cement, is poured over the mesh and allowed to set. In this operation the mesh is bonded by means of the coating composition to said surface. The screen also protrudes to the upper surface of said layer and when the latter has been allowed to set, a second layer is applied resulting in a system in which the reinforcing mesh not only aids in forming a durable bond between said first layer and said surface, but also likewise renders the two layers thus formed resistant to spalling or separating caused from expansion or contraction of said surface.

Claims

1. A method for applying an outer protective waterproof coating of latex cement to a continuous surface comprising first laying down a layer of screen over said surface, said screen having typically from about 5 to 15 holes per linear inch, next overlaying said screen with a readily flowable coating composition of said latex cement effective to cause said screen to float to the top of said coating, thereafter permitting said coating to form a set surface, thus bonding said screen and said set surface to said continuous surface, then applying a second layer of said coating material to said set surface and allowing said second layer to set whereby said layers are reinforced by means of said screen situated essentially between said layers, both of said layers in a set condition being from about 1/16 to about 1/4 inch in thickness.

2. The method of claim 1 wherein said continuous surface is an insulating material selected from the group consisting of natural substances and synthetic organic polymers in the form of a substantially rigid foam.

3. The method of claim 2 wherein said insulating material is a polyurethane foam.

4. The method of claim 1 wherein said coating consists essentially of separate layers of a thin, hard concrete having high impact, flexural, and tensile strength, said concrete being made with hydraulic cement modified with a minor amount of a synthetic resin latex cement modifier and a fine aggregate.

5. The method of claim 1 wherein the reinforcing screen employed is a plastic screen.

6. The method of claim 5 wherein the screen employed is a nylon screen.

7. The method of claim 1 wherein the coating composition employed is a hydraulic cement modified with a synthetic resin latex cement and a fine aggregate.

8. The method of claim 3 wherein the screen employed is a nylon screen.