US 10,815,149 B2 · Hydrophobic finish compositions with extended flow time retention and building products made thereof

Abstract

Disclosed are hydrophobic finish compositions and cementitious articles made with the hydrophobic finish compositions. In some embodiments, the article is a waterproof gypsum panel surface reinforced with inorganic mineral fibers that face a flexible and hydrophobic cementitious finish possessing beneficial waterproofing properties. The waterproof gypsum panels of the invention have many uses, such as, tilebacker board in wet or dry areas of buildings, exterior weather barrier panel for use as exterior sheathing, and roof cover board having water durability and low surface absorption. The flexible and hydrophobic cementitious finish can include fly ash, film-forming polymer, silane compound (e.g., alkyl alkoxysilane), an extended flow time retention agent including either one or more carboxylic acids, salts of carboxylic acids, or mixtures thereof, and other optional additives.

Claims26

Dependent claims

A hydrophobic finish composition comprising:

(i) hydraulic component comprising fly ash;
(ii) film-forming polymer;
(iii) at least one silane compound selected from the group consisting of:
(a) silane compounds having a molecular weight of at least about 150,
(b) silane compounds having a general chemical formula (I):
(R1O)mSi—X4-m (I)
wherein R1O is an alkoxy group, X is an organofunctional group, and m ranges from 1 to 3, and
(c) mixtures of silane compounds (a) and (b);
and
(iv) an extended flow time retention agent comprising at least one member selected from the group consisting of carboxylic acids, salts of carboxylic acids, and mixtures thereof;
wherein said carboxylic acids have the chemical formula (II):
wherein R is an organofunctional group;
wherein the salts of carboxylic acid have the chemical formula (III)
wherein R is as defined in formula (II) and X+ is a cation,
wherein there is an absence of calcium sulfate.

12 more elements

An article comprising:

a cementitious layer;
and
a hydrophobic finish composition facing the cementitious layer, the hydrophobic finish comprising:
(i) hydraulic component comprising fly ash;
(ii) film-forming polymer;
(iii) at least one silane compound selected from the group consisting of:
(a) silane compounds having a molecular weight of at least about 150,
(b) silane compounds having a general chemical formula (I):
(R1O)m—Si—X4-m (I)
wherein R1O is an alkoxy group, X is an organofunctional group, and m ranges from 1 to 3, and
(c) mixtures of silane compounds (a) and (b);
and
(iv) an extended flow time retention agent comprising at least one member selected from the group consisting of carboxylic acids, salts of carboxylic acids, and mixtures thereof:
wherein said carboxylic acids have the chemical formula (II):
wherein R is an organofunctional group;
wherein the salts of carboxylic acid have the chemical formula (III)
wherein R is as defined in formula (II) and X+ is a cation.

14 more elements

A mat-faced cementitious board comprising:

a cementitious core;
a fibrous mat having an inner surface facing at least one face of the cementitious core, and an opposite outer mat surface;
and
a hydrophobic finish composition facing the opposite outer mat surface of the fibrous mat, the hydrophobic finish comprising:
(i) hydraulic component comprising fly ash;
(ii) film-forming polymer;
(iii) at least one silane compound selected from the group consisting of:
(a) silane compounds having a molecular weight of at least about 150,
(b) silane compounds having a general chemical formula (I):
(R1O)m—Si—X4-m (I)
wherein R1O is an alkoxy group, X is an organofunctional group, and m ranges from 1 to 3, and
(c) mixtures of silane compounds (a) and (b);
and
(iv) an extended flow time retention agent comprising at least one member selected from the group consisting of carboxylic acids, salts of carboxylic acids, and mixtures thereof;
wherein said carboxylic acids have the chemical formula (II):
wherein R is an organofunctional group;
wherein the salts of carboxylic acid have the chemical formula (III)
wherein R is as defined in formula (II) and X+ is a cation.

15 more elements

Dependencies are inferred from the claim text.

Hydrophobic finish compositions with extended flow time retention and building products made thereof

Life of this patent

Hydrophobic finish compositions with extended flow time retention and building products made thereof

Life of this patent

Abstract

Claims26