Method for producing efflorescence resistant coating on cementitious substrate
First Claim
1. A method of producing an efflorescence resistant coating on a cementitious substrate comprising:
- foaming an efflorescence resistant coating composition comprising an aqueous evaporable carrier containing a latex binder having a Tg in range varying from -20°
C. to 100°
C., a weight average molecular weight in the range varying from 500 to 5,000,000, and a foaming agent selected from the group consisting of alkali metal, ammonium and amine salts of C12 -C24 aliphatic carboxylic acids, and mixtures thereof;
applying a foamed layer of said efflorescence resistant coating composition on the surface of said cementitious substrate;
collapsing said foamed layer on said surface of said cementitious substrate to form said efflorescence resistant coating thereon.
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Accused Products
Abstract
The present invention is directed to producing an efflorescence resistant sealer coating on a cementitious substrate, such as, a roof tile. A foamed layer of an efflorescence resistant coating composition is preferably applied on the surface of a wet cementitious substrate. The wet cementitious substrate is then hydrated to produce the cementitious substrate having the efflorescence resistant coating thereon. If desired, the efflorescence resistant coating composition is provided with a pigment to produce a pigmented efflorescence resistant coating on the cementitious substrate or a clear efflorescence resistant coating of the present invention may be applied over pigmented cementitious substrate. The efflorescence resistant coating produced in accordance with the process of the present invention substantially reduces the formation of esthetically unpleasant efflorescent layer on cementitious substrate surfaces.
63 Citations
22 Claims
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1. A method of producing an efflorescence resistant coating on a cementitious substrate comprising:
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foaming an efflorescence resistant coating composition comprising an aqueous evaporable carrier containing a latex binder having a Tg in range varying from -20°
C. to 100°
C., a weight average molecular weight in the range varying from 500 to 5,000,000, and a foaming agent selected from the group consisting of alkali metal, ammonium and amine salts of C12 -C24 aliphatic carboxylic acids, and mixtures thereof;applying a foamed layer of said efflorescence resistant coating composition on the surface of said cementitious substrate; collapsing said foamed layer on said surface of said cementitious substrate to form said efflorescence resistant coating thereon. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 16, 17, 18, 19, 20, 21, 22)
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9. A method of producing an efflorescence resistant coating on a cementitious substrate comprising:
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foaming an efflorescence resistant coating composition comprising an aqueous evaporable carrier containing a latex binder having a Tg in range varying from -20°
C. to 100°
C., a weight average molecular weight in the range varying from 500 to 5,000,000;
a foaming agent;
a coalescent; and
a wetting agent in the range of from 0.1 weight percent to 10 weight percent based on emulsion solids for reducing surface tension;applying a foamed layer of said efflorescence resistant coating composition on the surface of a wet cementitious substrate without physically disturbing said surface, said wetting agent in said composition enhancing surface contact between said foamed layer and said surface; collapsing said foamed layer on said surface of said wet cementitious substrate; and hydrating said wet cementitious substrate having said efflorescence resistant coating thereon. - View Dependent Claims (10)
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11. A method of producing an efflorescence resistant coating comprising:
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foaming an efflorescence resistant coating composition into a foam having substantially uniform cell size, said composition comprising an aqueous evaporable carrier containing a latex binder having a Tg in range varying from -20°
C. to 100°
C., a weight average molecular weight in the range varying from 500 to 5,000,000;
a foaming agent;
a coalescent;
a homogenizing agent and a wetting agent;uniformly distributing on the surface of a wet or green cementitious substrate, a foamed layer of said efflorescence resistant coating composition to substantially contact said surface without physically disturbing said surface; collapsing said layer on said surface to form said efflorescence resistant coating thereon; and hydrating said wet or green cementitious substrate. - View Dependent Claims (14, 15)
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12. A method of producing an efflorescence resistant coating comprising:
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foaming an efflorescence resistant coating composition into a foam having substantially uniform cell size, said composition comprising an aqueous evaporable carrier containing a latex binder having a Tg in range varying from -20°
C. to 100°
C., a weight average molecular weight in the range varying from 500 to 5,000,000;
a foaming agent selected from the group consisting of alkali metal, ammonium and amine salts of C12 -C24 aliphatic carboxylic acids, and mixtures thereof;
a coalescent;
a homogenizing agent and a wetting agent;uniformly distributing on the surface of a hydrated cementitious substrate, a foamed layer of said efflorescence resistant coating composition to substantially contact the surface of said hydrated cementitious substrate; and collapsing said layer on said surface to form said efflorescence resistant coating thereon.
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13. A method of producing an efflorescence resistant coating comprising:
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foaming an efflorescence resistant coating composition into a foam having substantially uniform cell size, said composition comprising an aqueous evaporable carrier containing a latex binder having a Tg in range varying from -20°
C. to 100°
C., a weight average molecular weight in the range varying from 500 to 5,000,000;
a foaming agent;
a coalescent;
a homogenizing agent and a wetting agent;uniformly distributing on the surface of a slurry, a foamed layer said efflorescence resistant coating composition to substantially contact said surface without physically disturbing said surface; collapsing said layer on said surface to form said efflorescence resistant coating thereon; and hydrating said slurry.
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Specification