Water resistant cementitious article and method for preparing same

• US 8,070,895 B2
• Filed: 04/20/2007
• Issued: 12/06/2011
• Est. Priority Date: 02/12/2007
• Status: Active Grant

• Current Assignee: United States Gypsum Company (GEBR Knauf Verwaltungsgesellschaft KG)
• Original Assignee: United States Gypsum Company (GEBR Knauf Verwaltungsgesellschaft KG)
• Inventors: Engbrecht, Dick C., Liu, Qingxia, Shake, Michael P., Wang, Xuming, Miller, David Paul, Reed, Paul, Roelfs, Donald L., Bury, Rafael, Bolind, Michael L.
• Primary Examiner(s): Tucker, Philip
• Assistant Examiner(s): Orlando, Michael N
• Application Number:
  US11/738,316
• Publication Number:
  US 20080190062A1
• Time in Patent Office: 1,691 Days
• Field of Search: 156/39, 156/41, 156/45
• US Class Current: 156/39
• CPC Class Codes: B32B 13/14 next to a fibrous or filamentary layer
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 2103/105 for reactions involving organo-silicon compounds
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/00629 the covering sheets being made of material other than paper
• CPC Class Codes: C04B 2111/27 Water resistance, i.e. waterproof or water-repellent materials
• CPC Class Codes: C04B 22/066 Magnesia; Magnesium hydroxide
• CPC Class Codes: C04B 22/16 containing phosphorus in the anion, e.g. phosphates
• CPC Class Codes: C04B 24/08 Fats; Fatty oils; Ester type waxes; Higher fatty acids, i.e. having at least seven carbon atoms in an unbroken chain bound to a carboxyl group; Oxidised oils or fats
• CPC Class Codes: C04B 24/42 Organo-silicon compounds
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/14 containing calcium sulfate cements gypsum-paper plates E04C
• CPC Class Codes: C04B 38/10 by using foaming agents C04B38/02 takes precedenceor by using mechanical means, e.g. adding preformed foam
• CPC Class Codes: C04B 7/02 Portland cement
• CPC Class Codes: E04C 2/043 of plaster E04C2/049 takes precedence
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10T 428/249921 Web or sheet containing structurally defined element or component
• CPC Class Codes: Y10T 442/2164 Coating or impregnation specified as water repellent

Abstract

A fibrous mat-faced cementitious article comprising (a) a cementitious core, and (b) a first fibrous mat comprising polymer or mineral fibers and a hydrophobic finish on at least one surface thereof, wherein the hydrophobic finish is in contact with the cementitious core, and a method of preparing a fibrous mat-faced cementitious article, as well as a method of preparing a water-resistant cementitious article comprising (a) preparing an aqueous siloxane dispersion, wherein the dispersion comprises about 4 wt. % to about 8 wt. % siloxane, (b) combining the siloxane dispersion with a cementitious mixture to provide a cementitious slurry, (c) depositing the cementitious slurry onto a substrate, and (d) allowing the cementitious slurry to harden, thereby providing a cementitious article.

Claims

1. A method of preparing a water-resistant cementitious article comprising

(a) preparing an aqueous siloxane dispersion comprising from about 4 wt. % to about 8 wt. % siloxane in water, wherein the aqueous siloxane dispersion comprises dispersed siloxane particles having an average particle size of less than about 50 microns, and does not comprise an emulsifier or dispersant;

(b) combining the siloxane dispersion with a cementitious mixture to provide a cementitious slurry,

(c) depositing the cementitious slurry onto a substrate, and

(d) allowing the cementitious slurry to harden, thereby providing a water-resistant cementitious article.

2. The method of claim 1, wherein the siloxane particles, have, an average particle size of less than about 30 microns.

3. The method of claim 1, wherein the aqueous siloxane dispersion is added to the cementitious mixture in an amount sufficient to provide about 0.3 wt. % to about 2 wt. % siloxane based on the weight of the hardened, dried cementitious slurry.

4. The method of claim 1, wherein the cementitious mixture comprises solid components and liquid components, and the siloxane dispersion is first combined with a liquid component of the cementitious mixture and subsequently combined with the solid components of the cementitious mixture.

5. The method of claim 1, wherein the substrate is a first fibrous mat comprising polymer or mineral fibers.

6. The method of claim 5, wherein the first fibrous mat comprises a hydrophobic finish and the cementitious slurry is deposited on the hydrophobic finish.

7. The method of claim 5, wherein the method further comprises depositing a hydrophobic finish on the fibrous mat before depositing the cementitious slurry on the first fibrous mat.

8. The method of claim 7, wherein the method further comprises drying the hydrophobic finish before depositing the cementitious slurry on the first fibrous mat.

9. The method of claim 6, wherein the hydrophobic finish comprises talc, wax, a hydrophobic resin, a silicone-based compound, a fatty acid or salt thereof, polyethylene glycol, a hydrocarbon or fluorocarbon surfactant having 12 or more carbon atoms, or a combination thereof.

10. The method of claim 6, wherein the hydrophobic finish provides a layer having a thickness of at least about 25 microns.

11. The method of claim 5, wherein the polymer or mineral fibers are glass fibers, polyester fibers, or a combination thereof.

12. The method of claim 5 further comprising contacting the cementitious slurry with a second fibrous mat prior to allowing the cementitious slurry to harden, wherein the cementitious slurry is disposed between the first fibrous mat and the second fibrous mat.

13. The method of claim 1, wherein the cementitious slurry is substantially free of paper or mineral fibers.

14. The method of claim 1, wherein the cementitious slurry is mixed in a mixer comprising a discharge conduit, and foam is added to the cementitious slurry in the discharge conduit prior to depositing the slurry on the substrate.

15. The method of claim 1, wherein the cementitious slurry comprises pre-blended unstable and stable soaps.

16. The method of claim 1, wherein the cementitious slurry comprises a polyphosphate.

17. The method of claim 16, wherein the polyphosphate is sodium trimetaphosphate.

18. The method of claim 1, wherein preparing the aqueous siloxane dispersion comprises the use of a high shear mixer with a tip-speed of about 9,000 to about 15,000 feet per minute (FPM).

19. The method of claim 1, wherein combining the siloxane dispersion with the cementitious mixture comprises adding the siloxane dispersion to gauging water that is subsequently combined with the cementitious mixture in a board mixer.

20. The method of claim 19, wherein preparing the siloxane dispersion comprises continuously supplying the siloxane and the water to an in-line mixer.