Cementitious veneer and laminate material

• US 6,913,819 B2
• Filed: 12/27/2002
• Issued: 07/05/2005
• Est. Priority Date: 12/27/2002
• Status: Active Grant

• Current Assignee: Ecomold Limited
• Original Assignee: Christine E. Wallner
• Inventors: Wallner, Christine E.
• Primary Examiner(s): Kruer, Kevin R.
• Application Number:
  US10/330,767
• Publication Number:
  US 20040126602A1
• Time in Patent Office: 921 Days
• Field of Search: 428/703, 428/500, 428/511, 428/513, 428/522, 428/325, 428/327, 428/330, 428/697, 428/699, 428/701, 428/711, 428/713, 428/772, 524/44, 524/414, 524/417, 524/418, 524/433, 524/459, 524/650, 524/803, 524/847, 106/685, 106/686, 106/687, 106/688, 106/689, 106/778, 106/783, 106/737, 523/081.7, 523/087, 523/091.7
• US Class Current: 428/325
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 16/0641 Polyvinylalcohols; Polyvinylacetates
• CPC Class Codes: C04B 18/082 Cenospheres
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 22/16 containing phosphorus in the anion, e.g. phosphates
• CPC Class Codes: C04B 22/165 Acids
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: C04B 28/14 containing calcium sulfate cements gypsum-paper plates E04C
• CPC Class Codes: C04B 28/30 containing magnesium cements or similar cementsmagnesium oxide cements C04B28/10
• CPC Class Codes: C04B 33/00 Clay-wares monolithic refractories or refractory mortars C04B35/66; porous products C04B38/00
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/4869 Polyvinylalcohols, polyvinylacetates
• CPC Class Codes: C04B 41/5079 Portland cements
• CPC Class Codes: C04B 41/52 Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
• CPC Class Codes: E04F 13/141 with an outer layer of concrete E04F13/147 takes precedence
• CPC Class Codes: E04F 15/02 Flooring or floor layers composed of a number of similar elements of webs E04F15/16
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10S 106/01 Fly ash
• CPC Class Codes: Y10T 428/252 Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]
• CPC Class Codes: Y10T 428/31699 : Ester, halide or nitrile of addition polymer
• CPC Class Codes: Y10T 428/31855 : Of addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31902 : Monoethylenically unsaturated
• CPC Class Codes: Y10T 428/31935 : Ester, halide or nitrile of addition polymer

Abstract

A cementitious veneer and laminate composition is provided. The cementitious laminate composition includes a substrate, a primer layer applied to the substrate, the primer layer comprising a mixture of polyvinyl alcohol catalyst, Portland cement, and sand; and a cementitious veneer layer applied to the primer layer, the veneer layer comprising a mixture of magnesium sulfate, filler, magnesium oxide, gypsum cement, and polyvinyl alcohol catalyst. The polyvinyl alcohol catalyst comprises a mixture of polyvinyl alcohol fibers dissolved in water and mixed with butylene carbonate. The veneer layer is applied to the substrate and primer layer by means including spraying and manual spreading. The veneer layer can be ornamentally manipulated either before or after curing of the veneer layer. The veneer composition can be formed into laminated tiles or panels for use in building applications.

Claims

1. A structure comprising:

a substrate comprising a stiff material;

a primer layer applied to the substrate, the primer layer comprising a mixture of polyvinyl alcohol catalyst, Portland cement, and sand;

and a veneer layer applied to the primer layer, the veneer layer comprising a mixture of magnesium sulfate, filler, magnesium oxide, gypsum cement, and polyvinyl alcohol catalyst.

2. The structure of claim 1, wherein the substrate is selected from the group consisting of cardboard, wood, metal, masonry, fiberglass, gypsum board, plastics, fiberboard, cement fiberboard, and ceramics.

3. The structure of claim 1, wherein the primer layer comprises, on a volume basis, 1.5% to 3.6% Portland Cement, 68% to 75% resin coated sand, and 29% to 30% polyvinyl alcohol catalyst which comprises polyvinyl alcohol polymer mixed with butylene carbonate in a ratio of 16:

1.

4. The structure of claim 3, wherein the polyvinyl alcohol polymer mixed with butylene carbonate is produced by dissolving polyvinyl alcohol fibers in boiling distilled water to form a polyvinyl alcohol mixture, and mixing the polyvinyl alcohol mixture with butylene carbonate, in a ratio of 16 parts of polyvinyl alcohol mixture with one part butylene carbonate.

5. The structure of claim 4, wherein the primer layer is applied to the substrate to form an adhesion layer for the veneer layer, the primer layer having a thickness of between approximately {fraction (1/16)} inch and approximately ½

inch.

6. The structure of claim 1, wherein the veneer layer comprises a first mixture consisting primarily of, on a volume basis, 0.04% to 0.08% sodium hexametaphosphate, 0.06% to 0.17% phosphoric acid at a concentration of 75% to 85%, 40% to 46% magnesium sulfate, 30% to 35% magnesium oxide, 1.3% to 1.4% distilled water, 2.5% to 3.25% hollow silicate spheres, and a second mixture comprising primarily gypsum cement.

7. The structure of claim 6, wherein the mixture comprises, on volume basis, 1.2% to 1.9% hollow silicate spheres, 77% to 85% gypsum cement, 13.5% to 14% distilled water, and 1.25% to 2.5% of the polyvinyl alcohol catalyst which comprises a 16:

1 mixture of polyvinyl alcohol polymer and butylene carbonate.

8. The structure of claim 7, wherein the veneer layer further comprises embedded fibers to increase a strength characteristic of the structure.

9. The structure of claim 7, wherein the veneer layer further comprises pigment or stains to enhance an appearance characteristic of the structure.

10. The structure of claim 7, wherein the veneer layer is ornamentally manipulated prior to drying.

11. The structure of claim 7, wherein the mixture of polyvinyl alcohol polymer and butylene carbonate is produced by dissolving polyvinyl alcohol fibers in boiling distilled water to form a polyvinyl alcohol mixture, and mixing the polyvinyl alcohol mixture with butylene carbonate, in a ratio of 16 parts of polyvinyl alcohol mixture with one part butylene carbonate.

12. The structure of claim 11, wherein the first mixture and second mixture are combined in a ratio of one part first mixture to one and one-half parts second mixture.

13. A cementitious laminate comprising:

a substrate comprising a stiff material;

a primer layer applied to the substrate, the primer layer comprising a mixture of polyvinyl alcohol catalyst, Portland cement, and sand;

and a veneer layer applied to the primer layer, the veneer layer comprising

a magnesium oxysulfate compound including magnesium sulfate, magnesium oxide, sodium hexametaphosphate, phosphoric acid, fillers, and water, and

a cementitious composition mixed with the magnesium oxysulfate compound to form a cementitious veneer mixture, the cementitious composition including gypsum cement, filler, water, and a polyvinyl alcohol catalyst.

14. The cementitious laminate of claim 13, wherein the veneer layer further comprises at least one member selected from the group consisting of embedded fibers to increase a strength characteristic of the cementitious laminate, and pigment to enhance an appearance characteristic of the cementitious laminate.

15. The cementitious laminate of claim 13, wherein the primer layer comprises, on a volume basis, 1.5% to 3.6% Portland Cement, 68% to 75% resin coated sand, and 29% to 30% polyvinyl alcohol catalyst which comprises polyvinyl alcohol polymer mixed with butylene carbonate in a ratio of 16:

1.

16. The cementitious laminate of claim 15, wherein the veneer layer comprises a first mixture consisting primarily of, on a volume basis, 0.04% to 0.08% sodium hexametaphosphate, 0.06% to 0.17% phosphoric acid at a concentration of 75% to 85%, 40% to 46% magnesium sulfate, 30% to 35% magnesium oxide, 1.3% to 1.4% distilled water, 2.5% to 3.25% hollow silicate spheres,

and a second mixture comprising, on volume basis, 1.2% to 1.9% hollow silicate spheres, 77% to 85% gypsum cement, 13.5% to 14% distilled water, and 1.25% to 2.5% of the polyvinyl alcohol catalyst which comprises a 16:

1 mixture of polyvinyl polymer and butylene carbonate.

17. The cementitious laminate of claim 16, wherein the polyvinyl alcohol catalyst is produced by dissolving polyvinyl alcohol fibers in boiling distilled water to form a polyvinyl alcohol mixture, and mixing the polyvinyl alcohol mixture with butylene carbonate, in a ratio of 16 parts of polyvinyl alcohol mixture with one part butylene carbonate.

18. The cementitious laminate claim 17, wherein the first mixture and second mixture are combined in a ratio of one part first mixture to one and one-half parts second mixture.