Sprayable phosphate cementitious coatings and a method and apparatus for the production thereof
OwnerDavid M. Goodsoninventor
Life of this patent
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Abstract
A sprayed-on phosphate cement coating formed from the combination and reaction of a phosphoric acid solution and a base metal solution. The acid solution and base solution may be intermixed prior to spraying, during spraying, or on a substrate. The curing reaction rate of the phosphate cement coating and its final physical properties may be controlled by adding various retardants, accelerants, reducers, wetting agents, superplasticizers, buffers, water reducers, adhesive agents, hardening agents, and/or sequestrants to the precursor solutions. The curing rate and properties of the cement coating may be further controlled by adjusting the temperature of the precursor solutions and/or the target substrate.
Claims31
A method of forming a phosphate cement coating, comprising the steps of:
- a) dissolving a phosphate source in a volume of liquid paint;
- b) applying a portion of the volume of liquid paint to a surface;
- and
- c) reacting the phosphate with anions present in the paint to form a dispersed phosphate cement phase in the paint;
- wherein the phosphate source also includes silica;
- and
- wherein step a) includes applying a charged solution to the substrate.
A method of forming a phosphate cement coating on a substrate comprising the steps of:
- a) precoating the substrate with an alkali coating;
- b) dissolving a phosphate source in a volume of liquid paint;
- c) applying a portion of the volume of liquid paint to a surface;
- and
- d) reacting the phosphate with anions present in the paint to form a dispersed phosphate cement phase in the paint;
- wherein the phosphate cement slurry contains ferromagnteic particles;
- and
- wherein the alkali coating is an aqueous solution including at least one of the following in solution:
- NaOH, KOH, caustic soda, and soda ash.
A method for forming a phosphate cement coating on a surface, comprising the steps of:
- a) providing a first cementitious constituent;
- b) providing a second cementitious constituent adapted to combine with the first cementitious constituent to produce a phosphate cement coating;
- c) spraying the surface with the first cementitious constituent;
- d) spraying the surface with the second cementitious constituent;
- and
- e) reacting the first and second cementitious constituents to produce a phosphate cement coating;
- wherein at least one cementitious constituent includes au accelerant.
A method for coating a substrate with a phosphate cement, comprising the steps of:
- aa) providing a first phosphoric acid liquid component;
- bb) providing a second metallic base liquid component adapted to reactively combine with the first phosphoric acid liquid component to produce a phosphate cement coating;
- cc) providing a cooling agent;
- dd) spraying the substrate with the first phosphoric acid liquid component;
- ee) spraying the substrate with the second metallic base liquid component;
- ff) spraying the substrate with the cooling agent;
- gg) mixing the first phosphoric acid liquid component, the second metallic base liquid component and the cooling agent to form a phosphate cement coating;
- and
- hh) curing the phosphate cement coating.
A method of repairing cementitious surfaces, comprising the steps of:
- identifying a surface flaw;
- spraying the flaw with a phosphoric acid solution;
- spraying the flaw with a metallic base solution;
- mixing the phosphoric acid solution and the metallic base solution;
- reacting the phosphoric acid solution and metallic base solution to form a phosphate cement bonded to the cementitious surface;
- and
- accelerating the reaction of the phosphoric acid solution and metallic base solution.
Dependencies are inferred from the claim text.