Method of producing opaque adherent coating on the surface of substantially hydrated cementitious substrate

• US 6,045,871 A
• Filed: 05/22/1997
• Issued: 04/04/2000
• Est. Priority Date: 06/07/1996
• Status: Expired due to Fees

• Current Assignee: Rohm and Haas Company (Dow, Inc.)
• Original Assignee: Rohm and Haas Company (Dow, Inc.)
• Inventors: Reilly, Joseph Clark, Matt, Richard Barry
• Primary Examiner(s): Beck, Shrive
• Assistant Examiner(s): Strain, Paul D.
• Application Number:
  US08/862,023
• Time in Patent Office: 1,048 Days
• Field of Search: 427/388.4, 427/393.4, 427/393.5, 427/393.6, 428/703
• US Class Current: 427/388.4
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/108 Shale, slate colliery shale C04B18/125
• CPC Class Codes: C04B 14/38 Fibrous materials; Whiskers
• CPC Class Codes: C04B 18/26 Wood, e.g. sawdust, wood shavings
• CPC Class Codes: C04B 2103/0058 Core-shell polymers
• CPC Class Codes: C04B 2103/56 Opacifiers
• CPC Class Codes: C04B 2111/00594 Concrete roof tiles
• CPC Class Codes: C04B 2111/21 Efflorescence resistance
• CPC Class Codes: C04B 2111/60 Flooring materials
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/48 Macromolecular compounds
• CPC Class Codes: C04B 41/502 Water
• CPC Class Codes: C04B 41/63 Macromolecular compounds
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

A method of producing an opaque adherent coating on the surface of a substantially hydrated cementitious substrate is provided. A waterborne storage stable sealer comprising an aqueous medium containing a binder polymer and an opacifying polymer is applied on the surface of such a cementitious substrate. Upon drying the layer substantially hides the primary efflorescence typically present on the surface of the cementitious substrate. Applicants have unexpectedly discovered that by optimally adjusting the thickness of the coating a weight amount of waterborne storage stable sealer solids in the waterborne storage stable sealer and a pigment volume content of the opacifying polymer in the storage stable sealer the opaque adherent coating is produced on the surface of the substantially hydrated cementitious substrate.

Claims

1. A method of producing an opaque adherent coating on a surface of a substantially hydrated cementitious substrate, said method consisting essentially of the steps of:

applying a layer of a waterborne storage stable sealer comprising an aqueous medium containing a binder polymer and an opacifying polymer on said surface of said cementitious substrate; and

drying said layer to substantially hide primary efflorescence on said surface of said cementitious substrate to produce said opaque adherent coating having a desired degree of opacity and adhesion to said cementitious substrate surface.

2. The method of claim 1, wherein thickness of said adherent opaque layer is adjusted to produce said desired degree of opacity and adhesion to said substantially hydrated cementitious substrate.

3. The method of claim 2, wherein the thickness of said adherent opaque layer is adjusted to be in the range of from 0.1 mils to 1.5 mils.

4. The method of claim 1, wherein a pigment volume content of said opacifying polymer in said storage stable sealer is adjusted to produce said desired degree of opacity and adhesion to said substantially hydrated cementitious substrate.

5. The method of claim 4, wherein of said pigment volume content is adjusted to be in the range of from 5 percent to 40 percent of opaque polymer solids, all percentages being in volume percentages based on the total volume of said storage stable sealer.

6. The method of claim 1, wherein a weight amount of waterborne storage stable sealer solids in said waterborne storage stable sealer is adjusted to produce said desired degree of opacity and adhesion to said substantially hydrated cementitious substrate.

7. The method of claim 6, wherein said weight amount of waterborne storage stable sealer solids is adjusted to be in the range of from 10 percent to 40 percent weight, all weight percentages being based on the total weight of said waterborne storage stable sealer.

15. The method of claim 1, 8, 9 or 10, wherein said opacifying polymer comprises dispersion of polymer particles in an aqueous medium, said polymer particles comprising sequentially polymerized heteropolymer having a base swelled core.

8. A method of producing an opaque adherent coating on a surface of a substantially hydrated cementitious substrate, said method consisting essentially of the steps of:

applying a layer of a waterborne storage stable sealer comprising an aqueous medium containing a binder polymer and an opacifying polymer on said surface of said cementitious substrate;

drying said layer to substantially hide primary efflorescence on said surface of said cementitious substrate; and

applying a topcoat of a paint composition thereon to produce said opaque adherent coating having a desired degree of opacity and adhesion to said cementitious substrate surface.

9. A method of producing an opaque adherent coating on a surface of a substantially hydrated cementitious substrate, said method consisting essentially of the steps of:

applying a layer of a waterborne storage stable sealer comprising an aqueous medium containing a binder polymer and an opacifying polymer on said surface of said cementitious substrate; and

drying said layer to substantially hide primary efflorescence on said surface of said cementitious substrate, wherein a weight amount of waterborne storage stable sealer solids in said waterborne storage stable sealer, thickness of said adherent opaque layer, and various permutations thereof are optimally adjusted to produce said opaque adherent coating having a desired degree of opacity and adhesion to said substantially hydrated cementitious substrate.

10. A method of producing an opaque adherent coating on a surface of a cementitious article, said method consisting essentially of the steps of:

forming said cementitious article;

applying a layer of a waterborne storage stable sealer comprising an aqueous medium containing a binder polymer and an opacifying polymer on said surface of said cementitious article; and

drying said layer to substantially hide primary efflorescence on the surface of said cementitious article; and

to produce said opaque adherent coating having a desired degree of opacity and adhesion to said cementitious article.

11. The method of claim 10, wherein said forming step comprises:

introducing a slurry into a mold of a desired shape to produce a preform therefrom, said slurry comprising water, cement and reinforcing material;

subjecting said preform to steam under high pressure in an autoclave to substantially hydrate said preform into said cementitious article.

12. The method of claim 11, wherein said reinforcing material is selected from the group consisting of sand, wood chips, wood fibers, silica, mineral fibers, glass fibers, expanded shale aggregates, other light weight aggregates, synthetic fibers, mineral wool and mixtures thereof.

13. The method of claim 10, further comprising applying a topcoat of a paint composition on said opaque adherent coating.

14. A cementitious article in the form of a lap siding, roof tile, floor tile, wall tile, wall panel, roof shingle, roof slate, or a patio floor produced in accordance with the method of claim 10.