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US 10,167,230 B1Granted
Ultra stable tile backer board formulation
OwnerJames Allen Wambaugh, Brett Rochnerinventors
Life of this patent
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Abstract
A tile backer board has 29 wt % to 40 wt % of a magnesium oxide dry powder containing 80 wt % to 98 wt % of magnesium oxide, 14 wt % of 18 wt % of a magnesium chloride dissolved in water; 0.1 wt % to 10 wt % of a stabilizing material with a phosphorus-containing compound, reacting into an amorphous phase cementitious material. The phosphorus-containing compound is a phosphorous acid (A) or a phosphoric acid (B). 0.1 wt % to 30 wt % of an aggregate is added and then a reinforcing component is mixed in or the cement is poured onto the reinforcing component forming a tile backer board.
Claims15
A tile backer board comprising the product of:
- a. forming a cementitious material that is the product of:
- (i) blending
- a) 29 wt. % to 40 wt. %, based on the final total weight of the cementitious material, of a magnesium oxide dry powder containing 80 wt. % to 98 wt. % of magnesium oxide, the magnesium oxide powder having a surface area of from 5 m2/g to 50 m2/g and an average particle size of from about 0.3 μm to about 90 μm, and wherein more than about 90 wt. % of the particles of the magnesium oxide powder have a particle size of less than or equal to about 40 μm, with
- b) 14 wt. % to 18 wt. %, based on the final total weight of the cementitious material, of an aqueous solution of magnesium chloride, the aqueous solution of magnesium chloride comprising 20 wt. % to 30 wt. % of magnesium chloride,
- and reacting the magnesium oxide and the magnesium chloride to form a liquid suspension;
- (ii) mixing the liquid suspension for from 2 minutes to 10 minutes;
- (iii) adding 0.1 wt. % to 10 wt. %, based on the final total weight of the cementitious material, of a stabilizing material to the mixed liquid suspension, wherein the stabilizing material is:
- 1) an aqueous solution comprising 55 wt. % to 65 wt. % of phosphorous acid (H3PO3);
- or
- 2) an aqueous solution comprising 80 wt. % to 90 wt. % of phosphoric acid (H3PO4);
- and
- (iv) allowing the liquid suspension with the stabilizing material to react for from 1 minute to 4 minutes to form an amorphous phase cementitious material;
- b. blending 35 wt. % to 79.9 wt. %, based on the final total weight of the tile backer board, of the formed amorphous phase cementitious material with 0.1 wt. % to 30 wt. %, based on the final total weight of the tile backer board, of an aggregate comprising particles having a diameter from 1 nm to 10 nm, wherein the aggregate comprises at least one selected from the group consisting of wood, perlite, styrene-based foam beads, calcium carbonate powder, and glass particulates, thereby forming a concrete;
- and
- c. pouring the formed concrete over 0.1 wt. % to 2 wt. %, based on the final total weight of the tile backer board, of a reinforcing material that cures into the tile backer board, the reinforcing material comprising a non-woven or woven silica-containing mat or a non-woven or woven hydrocarbon-containing mat;
- wherein a portion of the amorphous phase cementitious material grows a plurality of crystals, each crystal having a molecular weight of from 280 to 709 and being encapsulated by the amorphous phase cementitious material;
- wherein a majority of the stabilizing material is consumed during curing into a nano-molecular veneer over the crystals while increasing the surface area of the plurality of crystals by 2% to 49%;
- and
- wherein the nano-molecular veneer is insoluble in water and protects the plurality of crystals from degradation in water at temperatures of from 20° C. to 60° C. for from 24 hours to 56 days.
16 more elements
A tile backer board comprising the product of:
- a. forming a cementitious material that is the product of:
- (i) blending
- a) 29 wt. % to 40 wt. %, based on the final total weight of the cementitious material, of a magnesium oxide dry powder containing 80 wt. % to 98 wt. % of magnesium oxide, the magnesium oxide powder having a surface area of from 5 m2/g to 50 m2/g and an average particle size of from about 0.3 μm to about 90 μm, and wherein more than about 90 wt. % of the particles of the magnesium oxide powder have a particle size of less than or equal to about 40 μm, with
- b) 14 wt. % to 18 wt. %, based on the final total weight of the cementitious material, of an aqueous solution of magnesium chloride, the aqueous solution of magnesium chloride comprising 20 wt. % to 30 wt. % of magnesium chloride,
- and reacting the magnesium oxide and the magnesium chloride to form a liquid suspension;
- (ii) mixing the liquid suspension for from 2 minutes to 10 minutes;
- (iii) adding 0.1 wt. % to 10 wt. %, based on the final total weight of the cementitious material, of a stabilizing material to the mixed liquid suspension, wherein the stabilizing material is:
- 1) an aqueous solution comprising 55 wt. % to 65 wt. % of phosphorous acid (H3PO3);
- or
- 2) an aqueous solution comprising 80 wt. % to 90 wt. % of phosphoric acid (H3PO4);
- and
- (iv) allowing the liquid suspension with the stabilizing material to react for from 1 minute to 4 minutes to form an amorphous phase cementitious material;
- b. blending 35 wt. % to 79.9 wt. %, based on the final total weight of the tile backer board, of the formed amorphous phase cementitious material with
- i) 0.1 wt. % to 30 wt. %, based on the final total weight of the tile backer board, of an aggregate comprising particles having a diameter from 1 nm to 10 nm, wherein the aggregate comprises at least one selected from the group consisting of wood, perlite, styrene-based foam beads, calcium carbonate powder, and glass particulates, and
- ii) 0.1 wt. % to 15 wt. %, based on the final total weight of the tile backer board, of at least one reinforcing material selected from the group consisting of chopped silica-containing fibers, hemp-containing fibers, nano-molecular carbon fiber strands, chopped carbon fibers, and chopped hydrocarbon fibers;
- wherein a portion of the amorphous phase cementitious material grows a plurality of crystals, each crystal having a molecular weight of from 283 to 709 and being encapsulated by the amorphous phase cementitious material;
- wherein a majority of the stabilizing material is consumed during curing into a nano-molecular veneer over the crystals while increasing the surface area of the plurality of crystals by 2% to 49%;
- and
- wherein the nano-molecular veneer is insoluble in water and protects the plurality of crystals from degradation in water at temperatures of from 20° C. to 60° C. for from 24 hours to 56 days.
16 more elements
Dependencies are inferred from the claim text.