# US 7,407,545 B2 · Cementitious veneer and laminate material

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- Number: US 7,407,545 B2
- Document ID: US7407545B2
- Status: Granted
- Kind: B2
- Application number: 11/091,648
- Filed: 2005-03-28
- Published: 2005-09-29
- Granted: 2008-08-05
- Earliest claimed: 2002-12-27
- Assignees: Stonelace
- Inventors: Christine E. Wallner
- Web page: https://patentgrep.com/patent/US7407545B2

## CPC

- E04F 15/02: Flooring or floor layers composed of a number of similar elements (of webs E04F15/16)
- C04B 28/02: containing hydraulic cements other than calcium sulfates
- C04B 28/04: Portland cements
- C04B 28/30: containing magnesium cements {or similar cements}(magnesium oxide cements C04B28/10)
- C04B 41/009: {characterised by the material treated}
- C04B 41/52: Multiple coating or impregnating {multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation}
- E04F 13/141: {with an outer layer of concrete (E04F13/147 takes precedence)}
- Y02W 30/91: Use of waste materials as fillers for mortars or concrete
- Y10S 106/01: Fly ash
- Y10T 428/252: Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]
- Y10T 428/31699: Ester, halide or nitrile of addition polymer
- Y10T 428/31855: Of addition polymer from unsaturated monomers
- Y10T 428/31902: Monoethylenically unsaturated
- Y10T 428/31935: Ester, halide or nitrile of addition polymer
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y10S: TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A cementitious veneer and laminate composition is provided. The cementitious laminate composition includes a substrate, a primer layer applied to the substrate, the primer layer comprising a mixture of polyvinyl alcohol catalyst, Portland cement, and sand; and a cementitious veneer layer applied to the primer layer, the veneer layer comprising a mixture of magnesium sulfate, filler, magnesium oxide, gypsum cement, and polyvinyl alcohol catalyst. The polyvinyl alcohol catalyst comprises a mixture of polyvinyl alcohol fibers dissolved in water and mixed with butylene carbonate. The veneer layer is applied to the substrate and primer layer by means including spraying and manual spreading. The veneer layer can be ornamentally manipulated either before or after curing of the veneer layer. The veneer composition can be formed into laminated tiles or panels for use in building applications.

## Claims

### Claim 1

A cementitious veneer comprising:
a magnesium oxysulfate compound including magnesium sulfate, magnesium oxide, sodium hexametaphosphate, phosphoric acid, and water; and
a cementitious composition mixed with the magnesium oxysulfate compound to form a cementitious veneer mixture, the cementitious composition including gypsum cement, filler, water, and a polyvinyl alcohol polymer mixture.

### Claim 2 (depends on 1)

The cementitious veneer layer of claim 1 wherein the polyvinyl polymer mixture comprises polyvinyl alcohol fibers boiled in water with butylene carbonate.

### Claim 3 (depends on 2)

The cementitious veneer layer of claim 2 wherein the water is distilled water.

### Claim 4 (depends on 2)

The cementitious veneer layer of claim 2 wherein the water is microclustered water.

### Claim 5 (depends on 2)

The cementitious veneer layer of claim 2 wherein the magnesium oxysulfate compound comprises approximately sixty volume percent of the cementitious veneer mixture.

### Claim 6 (depends on 1)

The cementitious veneer layer of claim 1, wherein the magnesium oxysulfate compound consists of, by percentage of volume, 0.04% to 0.08% sodium hexametaphosphate, 0.06% to 0.17% phosphoric acid at a concentration of 75% to 85%, 40% to 46% magnesium sulfate, 30% to 35% magnesium oxide, 1.3% to 1.4% distilled water, 2.5% to 3.25% hollow granular fly ash spheres, and the cementitious composition consists of, by percentage of volume, 1.2% to 1.9% hollow granular fly ash spheres, 77% to 85% Calcium Sulfate Hemihydrate and Portland Cement, 13.5% to 14% distilled water, and 1.25% to 2.5% of the mixture of polyvinyl polymer and butylene carbonate.