Cementitious veneer and laminate material

• US 7,740,700 B2
• Filed: 06/25/2008
• Issued: 06/22/2010
• Est. Priority Date: 12/27/2002
• Status: Active Grant

• Current Assignee: Ecomold Limited
• Original Assignee: Ecomold Limited
• Inventors: Wallner, Christine E.
• Primary Examiner(s): MARCANTONI, PAUL D
• Application Number:
  US12/146,237
• Publication Number:
  US 20080257222A1
• Time in Patent Office: 727 Days
• Field of Search: 106/685, 106/686, 106/705, 106/772, 106/778, 106/DIG.1, 428/325, 428/463, 428/513, 428/522, 428/697, 428/698, 428/699, 428/701, 428/703
• US Class Current: 106/685
• 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 cementitious veneer structure comprising:

a substrate to support a molded cementitious veneer layer, wherein the molded cementitious veneer layer is created by mixing;

a magnesium oxysulfate compound including magnesium sulfate, magnesium oxide, sodium hexametaphosphate, phosphoric acid, 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 polymer mixture,

and wherein the cementitious veneer layer is molded into a panel form and adhered to the substrate within a mold.

2. The cementitious veneer structure of claim 1 wherein the polyvinyl polymer mixture comprises polyvinyl alcohol fibers boiled in water with butylene carbonate.

3. The cementitious veneer structure of claim 2 wherein the cementitious veneer layer is molded into a sheet and adhered to the substrate through an adhesion layer.

4. The cementitious veneer structure of claim 2 wherein the cementitious veneer layer is molded into a tile form and adhered to the substrate through an adhesion layer.

5. The cementitious veneer structure of claim 2 wherein the magnesium oxysulfate compound comprises approximately sixty percent of the cementitious veneer mixture.

6. The cementitious veneer structure of claim 1 wherein the mold is lined with a material to impart a specific finish to the molded cementitious veneer layer.

7. The cementitious veneer structure of claim 1 wherein the mold is treated with a surface treatment to impart a specific surface characteristic to the molded

cementitious veneer layer.

8. A cementitious veneer structure produced by a process comprising:

providing a substrate to support a molded cementitious veneer layer;

applying an adhesion layer to the substrate;

creating a cementitious veneer layer by mixing;

a magnesium oxysulfate compound including magnesium sulfate, magnesium oxide, sodium hexametaphosphate, phosphoric acid, 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 polymer mixture, adhering the cementitious veneer layer to the substrate within a mold.

9. The cementitious veneer structure of claim 8 wherein the polyvinyl polymer mixture comprises polyvinyl alcohol fibers boiled in water with butylene carbonate.

10. The cementitious veneer structure of claim 8 wherein the cementitious veneer layer is molded into one of a tile or a sheet.

11. The cementitious veneer structure of claim 8 further comprising fibers added to the cementitious layer to enhance a functional or ornamental characteristic of the cementitious veneer layer.