Cement-based thin-set mortar
AssigneeLaticrete International, Inc.
InventorRezvan Rooshenas
Life of this patent
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Abstract
A cement mortar is provided which is mixed with a liquid media, preferably either water or aqueous latex, for use as a thin-set mortar, medium bed mortar, underlayment mortar and/or grout (pointing mortar). The mortar or grout contains cement, sand and a water retaining agent and is improved by employing an aramid fiber in the mortar. A p-aramid fiber is preferred and it is highly preferred to use the polymer fiber in a pulp form which has a fibrillated structure. The overall performance properties of a cement-based mortar or grout such as a thin-set mortar are significantly improved including sag resistance, open time, bond strength, flexibility, heat aging and water immersion strength.
Claims33
A cement-based thin set mortar or medium bed mortar for installing tile, stone and other masonry products over concrete, masonry, brick and plywood substrates by troweling the composition on the substrate in a thickness up to about ¾ inch and placing the masonry product on the trowelled composition, the composition having enhanced overall performance properties including sag resistance, high tensile bond and shear bond strength, long open time, flexibility, water immersion strength, heat aging and freeze and thaw resistance comprising:
- cement;
- a filler;
- a water retaining agent;
- and
- an effective amount of a fiber selected from the group consisting of poly(p-phenylene terephthalamide) polymer fiber and a poly(m-phenylene terephthalamide) polymer fiber in the mortar to improve the overall performance properties of the mortar.
A cement-based grout for filling in spaces between set tiles having enhanced sag resistance and reduced void spaces comprising:
- cement;
- a filler;
- a water retaining agent;
- cement accelerator;
- defoamer;
- and
- an effective amount of a fiber selected from the group consisting of poly(p-phenylene terephthalamide) polymer fiber and poly(m-phenylene terephthalamide) polymer fiber in the grout to improve the overall performance properties of the grout.
A cement-based underlayment mortar for preparing uneven substrates to receive tile installed using a thin-set or medium-set mortar the underlayment mortar having enhanced flexural resistance, workability and reduced slumping or shrinkage comprising:
- cement;
- an accelerator;
- a filler;
- a defoamer;
- a retarder;
- and
- an effective amount of a fiber selected from the group consisting of poly(p-phenylene terephthalamide) polymer fiber and poly(m-phenylene terephthalamide) polymer fiber in the underlayment to improve the overall performance properties of the underlayment.
A method for setting tiles comprising the steps of:
- supplying a thin-set mortar or medium bed mortar composition having enhanced sag resistance, high tensile and shear bond strength, long open time, flexibility, water immersion strength, heat aging and freeze and thaw resistance comprising:
- cement;
- a filler;
- a water retaining agent;
- and
- an effective amount of a fiber selected from the group consisting of poly(p-phenylene terephthalamide) polymer fiber and a poly(m-phenylene terephthalamide) polymer fiber in the mortar to improve the overall performance properties of the mortar;
- adding a liquid and forming a plastic and trowable wet mortar;
- forming a layer of the wet mortar in a thickness up to about ¾ inch on a substrate to be tiled;
- placing tiles on the layer of wet mortar in the desired configuration;
- and curing the mortar to set the tile.
A method for setting tiles comprising the steps of:
- supplying a grout having enhanced sag resistance and reduced void spaces
- comprising:
- cement;
- a water retaining agent;
- cement accelerator;
- defoamer;
- and
- an effective amount of a fiber selected from the group consisting of poly(p-phenylene terephthalamide) polymer fiber and a poly(m-phenylene terephthalamide) polymer fiber in the grout to improve the overall performance properties of the grout;
- adding a liquid and forming a plastic and trowable grout;
- forming a grout joint in the spaces between tiles which have been set in the desired configuration;
- and
- curing the grout.
A method for applying an underlayment mortar to a substrate to provide an even surface for the setting of tiles comprising the steps of:
- supplying an underlayment mortar having enhanced flexural resistance,
- workability and reduced slumping or shrinkage comprising:
- cement;
- an accelerator;
- a filler;
- a defoamer;
- a retarder;
- and
- an effective amount of a fiber selected from the group consisting of 12 poly(p-phenylene terephthalamide) polymer fiber and a poly(m-phenylene terephthalamide) polymer fiber in the underlayment mortar to improve the overall performance properties of the underlayment mortar;
- adding a liquid and forming a plastic and trowable wet underlayment mortar;
- distributing the underlayment mortar on the substrate to form an even surface;
- and
- setting tiles in a thin-set or medium-set mortar composition on the underlayment mortar surface.
Dependencies are inferred from the claim text.