[go: up one dir, main page]

US20190345365A1 - Composition and method of using perlite - Google Patents

Composition and method of using perlite Download PDF

Info

Publication number
US20190345365A1
US20190345365A1 US16/522,044 US201916522044A US2019345365A1 US 20190345365 A1 US20190345365 A1 US 20190345365A1 US 201916522044 A US201916522044 A US 201916522044A US 2019345365 A1 US2019345365 A1 US 2019345365A1
Authority
US
United States
Prior art keywords
adhesive
expanded perlite
powder
composition
mass
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US16/522,044
Inventor
David BAR MOAV
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SHAHAL BUILDING MATERIALS Ltd
Original Assignee
SHAHAL BUILDING MATERIALS Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by SHAHAL BUILDING MATERIALS Ltd filed Critical SHAHAL BUILDING MATERIALS Ltd
Priority to US16/522,044 priority Critical patent/US20190345365A1/en
Publication of US20190345365A1 publication Critical patent/US20190345365A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/005—Inorganic fillers with a shape other than granular or fibrous
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C04B14/04—Silica-rich materials; Silicates
    • C04B14/14—Minerals of vulcanic origin
    • C04B14/18—Perlite
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B16/00—Use of organic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of organic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B16/02—Cellulosic materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B16/00—Use of organic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of organic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B16/04—Macromolecular compounds
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B16/00—Use of organic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of organic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B16/04—Macromolecular compounds
    • C04B16/06—Macromolecular compounds fibrous
    • C04B16/0616—Macromolecular compounds fibrous from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B16/0625—Polyalkenes, e.g. polyethylene
    • C04B16/0633—Polypropylene
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B16/00—Use of organic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of organic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B16/04—Macromolecular compounds
    • C04B16/06—Macromolecular compounds fibrous
    • C04B16/0616—Macromolecular compounds fibrous from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B16/0641—Polyvinylalcohols; Polyvinylacetates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
    • C04B24/24—Macromolecular compounds
    • C04B24/38—Polysaccharides or derivatives thereof
    • C04B24/383—Cellulose or derivatives thereof
    • C04B24/386—Cellulose or derivatives thereof containing polyether side chains
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/04—Portland cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B7/00—Hydraulic cements
    • C04B7/02—Portland cement
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D1/00—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
    • C09D1/06—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances cement
    • C09D1/08—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances cement with organic additives
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J1/00—Adhesives based on inorganic constituents
    • C09J1/02—Adhesives based on inorganic constituents containing water-soluble alkali silicates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C04B14/04—Silica-rich materials; Silicates
    • C04B14/14—Minerals of vulcanic origin
    • C04B14/18—Perlite
    • C04B14/185—Perlite expanded
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/10—Accelerators; Activators
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00034—Physico-chemical characteristics of the mixtures
    • C04B2111/00086—Mixtures with prolonged pot-life
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00637—Uses not provided for elsewhere in C04B2111/00 as glue or binder for uniting building or structural materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00663—Uses not provided for elsewhere in C04B2111/00 as filling material for cavities or the like
    • C04B2111/00672—Pointing or jointing materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/40—Porous or lightweight materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/52—Sound-insulating materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
    • C04B2201/30—Mortars, concrete or artificial stone characterised by specific physical values for heat transfer properties such as thermal insulation values, e.g. R-values
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J11/00—Features of adhesives not provided for in group C09J9/00, e.g. additives
    • C09J11/02—Non-macromolecular additives
    • C09J11/04—Non-macromolecular additives inorganic
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J11/00—Features of adhesives not provided for in group C09J9/00, e.g. additives
    • C09J11/08—Macromolecular additives

Definitions

  • the present invention relates to the use of compositions containing expanded perlite. More particularly, the present invention relates to the use of compositions of expanded perlite for the construction industry.
  • Volcanic glass such as perlite
  • molten rock i.e. lava
  • Perlite is the lava that hardens immediately and contains 2-5% water.
  • Perlite is known in industry in two forms: crude and expanded. Crude perlite is prepared by the crushing and screening of perlite into various sized fractions. Expanded perlite is perlite after it has been heated. When heated, perlite can expand to as much as twenty times its original volume. This expansion is the result of heated water: when the glassy lava rock is heated to, for example, 890° C., the water molecules trapped in the rock turn into vapor which causes the rock to expand. That is similar to water that expands, when heated, in a corn kernel to create popcorn. It is the presence of these trapped water molecules in perlite which accounts for the physical properties of expanded perlite.
  • Expanded perlite can be manufactured to weigh between 32-240 kg/m 3 , making it adaptable for numerous applications in the construction, industrial, chemical, horticultural and petrochemical industries.
  • U.S. Pat. No. 7,736,574 discloses a method for the production of perlite products such as sheets, panels or bricks.
  • the disclosed method involves first providing a quantity of expanded perlite and treating the perlite by applying a cement binder thereto, so as to at least partially encapsulate the perlite with binder. Thereafter, an amount of cement is added to the binder-treated perlite and a mixture is created. The described mixture is then formed and allowed to harden to yield solid articles. Nevertheless, the disclosed method is used for yielding perlite based solid articles.
  • the present invention relates to a powder adhesive composition
  • a powder adhesive composition comprising: (a) cement; (b) a dispersible polymer powder; and (c) at least 10% volume of the powder adhesive is an expanded perlite; wherein said cement is at a ratio of between 600-1000% of the mass of the expanded perlite; and wherein the powder adhesive composition is an adhesive, and the adhesion strength of the adhesive, is over 0.4 MPa, after 28 days, and after water immersion for at least 20 days.
  • the composition further comprises a cellulose ethers compound.
  • the composition further comprises a defoamer.
  • the composition further comprises a fiber compound.
  • the cement is white cement.
  • the cement is Portland cement.
  • the composition further comprises an accelerator.
  • the expanded perlite comprises at least 1% of the total mass of the composition.
  • the dispersible polymer powder is a dispersible powder based on vinyl acetate.
  • the fiber compound is a polypropylene compound.
  • the adhesive composition is used for gluing a tile.
  • the adhesive composition is used for gluing a stone tile.
  • the adhesion strength of the adhesive is between 0.5-1.5 MPa, after 28 days, and after water immersion for at least 20 days.
  • the present invention also relates to a method of producing a powder adhesive comprising the steps of: mixing expanded perlite, cement, and a dispersible polymer powder, in any order; wherein at least 30% volume of the sand-free powder adhesive is the expanded perlite.
  • the present invention also relates to a powder adhesive composition which comprises: gypsum; a retarder; a dispersible polymer powder based on vinyl acetate; and wherein at least 30% volume of the powder adhesive is an expanded perlite.
  • the retarder is a modified polymer retardation.
  • Prior stone veneer powder adhesives such as Sika Ceram-202, manufactured by Sika AG of Switzerland, or Mr. Fix 116 manufactured by Carmit Mr. Fix Ltd., of the United Kingdom for gluing ceramic tiles, typically have a density of more than 1400 kg/m 3 .
  • the heavy weight of these prior adhesives is due, inter alia, to the weight of the sand in the adhesive.
  • the heavy weight of these prior adhesives is costly in terms of transportation and problematic in terms of handling, e.g. manual carrying.
  • the sand is not dried properly, before it is mixed into the adhesive, some of the adhesive's polymers can be ruined, effectively weakening the adhesive.
  • adheresive is meant to include hereinafter any composition that has an adhesion strength, after 28 days, of more than 0.4 megapascal (MPa).
  • An adhesive/plaster composition is proposed, for use in the construction industry, which uses expanded perlite. Unlike conventional adhesive compositions having sand as aggregate; in this embodiment, the volume of sand is substituted with an equal or equivalent volume of expanded perlite. In some versions, the adhesive is sand-free.
  • the composition, which comprises expanded perlite may be used for creating an adhesive, plaster, or any kind of material that hardens on drying and may be used for indoor and/or outdoor gluing on and/or coating walls, ceilings, floors, or for any other construction use.
  • the composition may be used as a powder adhesive, when mixed with water the resulting material can be used for gluing natural or synthetic stone tiles to a wall.
  • a powder adhesive composition for a stone veneer which uses expanded perlite instead of sand, may have a density of approximately 500 kg/m 3 , which results in a lighter weight, for the same volume, compared to a typical prior powder adhesive that may have a density greater than 1400 kg/m 3 .
  • the Density (dry mix) of the powder adhesive composition may be between 250-1500 kg/m 3 .
  • the Density (dry mix) of the powder adhesive composition may be between 350-1500 kg/m 3 .
  • the advantages of using expanded perlite instead of sand in powder adhesives or plaster in terms of improving the thermal and/or acoustic insulation properties of the adhesive and/or plaster are due to the expanded perlite's improved thermal and/or acoustic insulation properties that are discussed further at Table 1.
  • the adhesive composition, which comprises expanded perlite may have different consistencies such as powder, granular, cream, etc.
  • the adhesive or plaster composition, which comprises expanded perlite may be stored in sacks, bags, buckets, or any other known container.
  • the expanded perlite comprises:
  • expanded vermiculite may be used instead of expanded perlite as set forth in the above-identified paragraph regarding the adhesive/plaster compositions.
  • Vermiculite is a hydrous silicate mineral that (a) is classified as a phyllosilicate and (b) expands greatly when heated. Vermiculite may be formed by weathering or hydrothermal alteration of biotite or phlogopite.
  • a first powder, light weight, stone veneer adhesive has
  • a second powder, light weight, stone veneer adhesive has
  • the powder, light weight, stone veneer adhesive is a sand free adhesive.
  • a third powder, light weight, sand free, stone veneer adhesive has expanded perlite in at least 10% volume of the powder adhesive; cellulose ether compounds at a ratio of between 5-25% of the mass of the expanded perlite;
  • a defoamer at a ratio of between 0.1-65% of the mass of the expanded perlite
  • cement at a ratio of between 600-1000% of the mass of the expanded perlite.
  • the components of the instant adhesive can be mixed together in any order to obtain the desired adhesion strength, of the adhesive, which is over 0.4 MPa, after 28 days, and after water immersion for at least 20 days.
  • the adhesion strength is between 0.5-1.5 MPa, after 28 days, and after water immersion for at least 20 days.
  • a fourth powder, light weight, sand free, stone veneer adhesive has expanded perlite in at least 15% volume of the powder adhesive
  • a dispersible polymer at a ratio of between 10-305% of the mass of the expanded perlite
  • cement at a ratio of between 40-1505% of the mass of the expanded perlite.
  • the components of the instant adhesive can be mixed together in any order to obtain the desired adhesion strength, of the adhesive, which is over 0.3 MPa, after 28 days, and after water immersion for at least 20 days.
  • the adhesion strength is between 0.5-2.5 MPa, after 28 days, and after water immersion for at least 20 days
  • the described adhesives may be mixed with water for creating a glue having cream like texture, which hardens on drying. Due to the expanded perlite's intrinsic characteristics, water may be added to the powder adhesive composition in the mass ratio of approximately 0.8:1, for example, meaning, that approximately 0.8 liter of water may be added for each 1 kg of powder; 0.9:1; 0.7:1; 0.6:1; or 1:1. Water could also be added to the powder adhesive composition in the ratio of between 60-100% of the mass of the powder adhesive composition. The ration of water added to the adhesive powder may also be a function of the specific ingredients of the adhesive powder.
  • the adhesive, with or without cement, may be used for gluing any stone tiles as a protective and/or decorative covering for exterior or interior horizontal or vertical surfaces.
  • the composition, comprising expanded perlite, is used for creating a lightweight powder veneer adhesive.
  • veneer is meant to include any protective or ornamental facing which can be adhesively attached to any horizontal or vertical surface.
  • the adhesive may be used for adhesively attaching stone such as granite, porcelain, ceramic, mosaic, porcelain, marble, brick, or any other synthetic or natural stone to a wall, ceiling, floor or any other surface.
  • the powder adhesive is mixed with water for creating a cream like textured glue, which hardens on drying.
  • the glue may be used for adhesively attaching any stone tiles as a protective and/or decorative covering for exterior or interior horizontal or vertical surfaces.
  • the powder adhesive composition, for attaching stone veneer comprises
  • the expanded perlite, used in the adhesive composition has the following characteristics:
  • the expanded perlite, used in the adhesive composition can be derived from different sources, and have other physical properties.
  • expanded perlite instead of sand in construction compositions may also benefit the environment as the perlite is a natural and ecological substance.
  • the use of expanded perlite instead of sand in powder adhesives or plaster can also improve the thermal and/or acoustic insulation properties of the adhesive and/or plaster due to the expanded perlite's improved thermal and/or acoustic insulation properties.
  • a cellulose ethers compound preferably, Mecellose FMC 21010 manufactured by Samsung Chemical; Methocel, which is water-soluble methylcellulose and has hydroxypropyl methylcellulose polymers, any other cellulose ether that is made for use with cement and mixtures thereof.
  • the cellulose ethers compound enhances some of the qualities of the adhesive composition such as providing workable quality to the composition and/or extending the open time of the composition, and/or improving the water saturation of the composition, where open time is the time after the adhesive is applied during which a serviceable bond can be made.
  • the cellulose ethers are added to the adhesive composition at a ratio of between
  • a dispersible polymer preferably, Wacker's Vinnapas 5025L, which is a leveling dispersible powder based on vinyl acetate and ethylene, or may be any other dispersible powder based on vinyl acetate, or any other hydroscopic compound which is dispersible in water, such as SBR-based adhesives, vinyl acetate, acryl, etc.
  • the dispersible polymer is added to the adhesive composition at a ratio of between
  • a defoamer e.g. an anti-foam agent, such as Vinapor® DF 9010 F, or any other chemical additive that reduces and hinders the formation of foam.
  • an anti-foam agent such as Vinapor® DF 9010 F
  • Commonly used agents are insoluble oils, polydimethylsiloxanes and other silicones, certain alcohols, stearates and glycols.
  • the additive is used to prevent formation of foam or is added to break a foam already formed.
  • the fiber compound may be added to the adhesive composition at a ratio of between
  • a fiber compound such as Adfil construction fibers or any other polypropylene compound having a fiber length of 6 mm or any other chemical or synthetic fiber compound which may be used for cement based adhesives, or any other fiber that is used with cement such as nylon fiber.
  • the fiber compound may be added to the adhesive composition at a ratio of between
  • cement such as white cement, Portland cement, or any type of cement or aluminous cement.
  • the cement may be added to the adhesive composition at a ratio of between
  • the adhesive composition comprising expanded perlite, may be free of cement.
  • the resulting adhesive composition free of cement is a light weight adhesive used for indoors gluing.
  • This adhesive may be sold as a cream adhesive.
  • Gypsum and a retarder such as HYCON R 7200, manufactured by BASF, or any other modified polymer retardation instead of cement.
  • the gypsum may be added to the adhesive composition at a ratio of between 600-900% of the mass of the expanded perlite, and the retarder may be added in relations to the desired open time.
  • the adhesive for attaching veneer may also comprise an additive for accelerating the bonding time of the adhesive, referred to hereinafter as accelerator.
  • the accelerator may be Calcium Formate, Calcium Chloride, or any other additive that can be used for accelerating the bonding time of the adhesive.
  • the accelerator may be added to the adhesive composition at a ratio of between 5-15% of the mass of the expanded perlite.
  • the expanded perlite and all the other component ingredients, mentioned above, of the adhesive composition may be mixed together in any order to form a powder adhesive composition.
  • the above-identified powder adhesive composition may be mixed with water to create glue for gluing any synthetic or natural stone tile to any surface. Due to the expanded perlite's intrinsic characteristics, water may be added to the powder adhesive composition in the mass ratio of approximately 0.7:1, meaning that approximately 0.7-1 liter of water can be added for each 1 kg of powder, to approximately 1:1. That means, water may be added to the powder adhesive composition in the ratio of between 70-100% of the mass of the powder adhesive composition. Alternatively, water may be added to the powder adhesive composition in the mass ratio of approximately 0.6:1 to approximately 1:1. In other words, water may be added to the powder adhesive composition in the ratio of between 60-100% of the mass of the powder adhesive composition.
  • the resulting adhesive composition that complies with this disclosure has an adhesion strength
  • the resulting adhesive composition that complies with this disclosure has a wet density of:
  • An adhesive example is set forth at Table 2, with ingredients and their approximated amounts for creating a powder adhesive composition, which comprises expanded perlite, for attaching stone tiles:
  • a powder adhesive composition of about 9 kg is created.
  • the powder adhesive composition weighs less than the typical prior art powder adhesive. That decreased weight reduces costs of transportation and handling.
  • the use of expanded perlite instead of sand in the powder adhesives prolongs the open time of the adhesive, after the water is added, effectively making the perlite based adhesive more comfortable for use.
  • Table 4 conveys the described adhesive complies with the known adhesive properties of: C1, C1 T, C1 TE, C1 TE S1, C1 TE S2, C2, C2 T, C2 TE, C2 TE S1, or C2 TE S2 of any of the European standards such as: EN 1346 (2007), EN 1308 (2007), EN 1347 (2007), EN 1348 (2007), or EN 12002 (2008) available on http://www.techstreet.com or http://shop.bsigroup.com.
  • Jieru described a mortar composition.
  • Jieru's mortar composition is compared with this application's claimed adhesive composition.
  • Jieru discloses an insulation mortar for use in masonry or plastering.
  • Jieru's mortar is based on the composition disclosed in the abstract and in the summary of CN 101279833 A while the proposed adhesive is based on one of the embodiments, with the understanding that both compositions have the same total volume for comparison purposes:
  • GB 1225755 discloses a cement-based adhesive.
  • the compositions comprised the following amounts of components:

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Structural Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Civil Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Nanotechnology (AREA)
  • Adhesives Or Adhesive Processes (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Processes Of Treating Macromolecular Substances (AREA)
  • Solid-Sorbent Or Filter-Aiding Compositions (AREA)
  • Porous Artificial Stone Or Porous Ceramic Products (AREA)

Abstract

The present invention relates to a powder adhesive composition comprising: (a) cement; (b) a dispersible polymer powder; and (c) at least 10% volume of the powder adhesive is an expanded perlite; wherein said cement is at a ratio of between 600-1000% of the mass of the expanded perlite; and wherein the powder adhesive composition is an adhesive, and the adhesion strength of the adhesive, is over 0.4 MPa, after 28 days, and after water immersion for at least 20 days.

Description

    TECHNICAL FIELD
  • The present invention relates to the use of compositions containing expanded perlite. More particularly, the present invention relates to the use of compositions of expanded perlite for the construction industry.
    • BACKGROUND
  • Volcanic glass, such as perlite, forms when molten rock, i.e. lava, pours out of a volcano and rapidly cools. That rapid cooling inhibits crystal formation and permitting water to escape. Perlite is the lava that hardens immediately and contains 2-5% water.
  • Perlite is known in industry in two forms: crude and expanded. Crude perlite is prepared by the crushing and screening of perlite into various sized fractions. Expanded perlite is perlite after it has been heated. When heated, perlite can expand to as much as twenty times its original volume. This expansion is the result of heated water: when the glassy lava rock is heated to, for example, 890° C., the water molecules trapped in the rock turn into vapor which causes the rock to expand. That is similar to water that expands, when heated, in a corn kernel to create popcorn. It is the presence of these trapped water molecules in perlite which accounts for the physical properties of expanded perlite.
  • Expanded perlite can be manufactured to weigh between 32-240 kg/m3, making it adaptable for numerous applications in the construction, industrial, chemical, horticultural and petrochemical industries.
  • U.S. Pat. No. 7,736,574 discloses a method for the production of perlite products such as sheets, panels or bricks. The disclosed method involves first providing a quantity of expanded perlite and treating the perlite by applying a cement binder thereto, so as to at least partially encapsulate the perlite with binder. Thereafter, an amount of cement is added to the binder-treated perlite and a mixture is created. The described mixture is then formed and allowed to harden to yield solid articles. Nevertheless, the disclosed method is used for yielding perlite based solid articles.
    • SUMMARY
  • It is an object of the present invention to provide a light weight composition for use in the construction industry.
  • It is another object of the present invention to provide a light weight adhesive, for attaching any natural or synthetic stone veneer.
  • It is still another object of the present invention to provide an ecological adhesive for gluing stone tiles, which has a long open time.
  • It is still another object of the present invention to provide an adhesive or plaster which has improved thermal and acoustic insulating properties.
  • Other objects and advantages of the invention will become apparent as the description proceeds.
  • The present invention relates to a powder adhesive composition comprising: (a) cement; (b) a dispersible polymer powder; and (c) at least 10% volume of the powder adhesive is an expanded perlite; wherein said cement is at a ratio of between 600-1000% of the mass of the expanded perlite; and wherein the powder adhesive composition is an adhesive, and the adhesion strength of the adhesive, is over 0.4 MPa, after 28 days, and after water immersion for at least 20 days.
  • Preferably, the composition further comprises a cellulose ethers compound.
  • Preferably, the composition further comprises a defoamer.
  • Preferably, the composition further comprises a fiber compound.
  • Preferably, the cement is white cement.
  • In one embodiment, the cement is Portland cement.
  • In one embodiment, the composition further comprises an accelerator.
  • Preferably, the expanded perlite comprises at least 1% of the total mass of the composition.
  • Preferably, the dispersible polymer powder is a dispersible powder based on vinyl acetate.
  • Preferably, the fiber compound is a polypropylene compound.
  • Preferably, the adhesive composition is used for gluing a tile.
  • Preferably, the adhesive composition is used for gluing a stone tile.
  • Preferably, the adhesion strength of the adhesive, is between 0.5-1.5 MPa, after 28 days, and after water immersion for at least 20 days.
  • The present invention also relates to a method of producing a powder adhesive comprising the steps of: mixing expanded perlite, cement, and a dispersible polymer powder, in any order; wherein at least 30% volume of the sand-free powder adhesive is the expanded perlite.
  • The present invention also relates to a powder adhesive composition which comprises: gypsum; a retarder; a dispersible polymer powder based on vinyl acetate; and wherein at least 30% volume of the powder adhesive is an expanded perlite.
  • Preferably, the retarder is a modified polymer retardation.
    • DETAILED DESCRIPTION
  • Prior stone veneer powder adhesives, such as Sika Ceram-202, manufactured by Sika AG of Switzerland, or Mr. Fix 116 manufactured by Carmit Mr. Fix Ltd., of the United Kingdom for gluing ceramic tiles, typically have a density of more than 1400 kg/m3. The heavy weight of these prior adhesives is due, inter alia, to the weight of the sand in the adhesive. The heavy weight of these prior adhesives is costly in terms of transportation and problematic in terms of handling, e.g. manual carrying. Furthermore, if the sand is not dried properly, before it is mixed into the adhesive, some of the adhesive's polymers can be ruined, effectively weakening the adhesive.
  • The term “adhesive” is meant to include hereinafter any composition that has an adhesion strength, after 28 days, of more than 0.4 megapascal (MPa).
    • Adhesive/Plaster Composition
  • An adhesive/plaster composition is proposed, for use in the construction industry, which uses expanded perlite. Unlike conventional adhesive compositions having sand as aggregate; in this embodiment, the volume of sand is substituted with an equal or equivalent volume of expanded perlite. In some versions, the adhesive is sand-free. The composition, which comprises expanded perlite, may be used for creating an adhesive, plaster, or any kind of material that hardens on drying and may be used for indoor and/or outdoor gluing on and/or coating walls, ceilings, floors, or for any other construction use. For example, the composition may be used as a powder adhesive, when mixed with water the resulting material can be used for gluing natural or synthetic stone tiles to a wall. Thus, for example, a powder adhesive composition for a stone veneer, which uses expanded perlite instead of sand, may have a density of approximately 500 kg/m3, which results in a lighter weight, for the same volume, compared to a typical prior powder adhesive that may have a density greater than 1400 kg/m3. In one embodiment the Density (dry mix) of the powder adhesive composition may be between 250-1500 kg/m3. In another embodiment the Density (dry mix) of the powder adhesive composition may be between 350-1500 kg/m3. The advantages of using expanded perlite instead of sand in powder adhesives or plaster in terms of improving the thermal and/or acoustic insulation properties of the adhesive and/or plaster are due to the expanded perlite's improved thermal and/or acoustic insulation properties that are discussed further at Table 1. The adhesive composition, which comprises expanded perlite, may have different consistencies such as powder, granular, cream, etc. The adhesive or plaster composition, which comprises expanded perlite, may be stored in sacks, bags, buckets, or any other known container. In particular, the expanded perlite comprises:
      • at least 10% of the total volume of the adhesive/plaster composition;
      • at least 30% of the total volume of the adhesive/plaster composition
      • at least 70% of the total volume of the adhesive/plaster composition;
      • at least 80% of the total volume of the adhesive/plaster composition; or
      • at least 90% of the total volume of the adhesive/plaster composition.
        Examples of the above total volume of the adhesive/plaster compositions are described in greater detail below.
    Adhesive/Plaster Composition With Vermiculite
  • Alternatively, expanded vermiculite may be used instead of expanded perlite as set forth in the above-identified paragraph regarding the adhesive/plaster compositions. Vermiculite is a hydrous silicate mineral that (a) is classified as a phyllosilicate and (b) expands greatly when heated. Vermiculite may be formed by weathering or hydrothermal alteration of biotite or phlogopite.
    • Powder, Light Weight Stone Veneer Adhesive
  • A first powder, light weight, stone veneer adhesive has
      • (a) expanded perlite in at least 70 volume percent of the adhesive;
      • (b) cellulose ether compounds at a ratio of between 7-15% of the mass of the expanded perlite;
      • (c) a dispersible polymer at a ratio of between 17%-180% of the mass of the expanded perlite;
      • (d) a defoamer at a ratio of between 0.5-20% of the mass of the expanded perlite;
      • (e) a fiber compound at a ratio of between 0.9-1.1% of the mass of the expanded perlite;
      • (f) an accelerator at a ratio of between 5-15% of the mass of the expanded perlite; and,
      • (g) optionally, cement at a ratio of between 600%-900% of the mass of the expanded perlite.
        The components of the instant adhesive can be mixed together in any order to obtain the desired adhesion strength, of the adhesive, which is over 0.4 MPa, after 28 days, and after water immersion for at least 20 days. Preferably, the adhesion strength is between 0.5-1.5 MPa, after 28 days, and after water immersion for at least 20 days.
  • A second powder, light weight, stone veneer adhesive has
      • (a) expanded perlite in at least 1% of the mass of the adhesive;
      • (b) cellulose ether compounds at a ratio of between 5-25% of the mass of the expanded perlite;
      • (c) a dispersible polymer at a ratio of between 10-250% of the mass of the expanded perlite;
      • (d) a defoamer at a ratio of between 0.1-65% of the mass of the expanded perlite;
      • (e) a fiber compound at a ratio of between 0.6-15% of the mass of the expanded perlite;
      • (f) an accelerator at a ratio of between 3-25% of the mass of the expanded perlite; and,
      • (g) optionally, cement at a ratio of between 600-1000% of the mass of the expanded perlite.
        The components of the instant adhesive can be mixed together in any order to obtain the desired adhesion strength, of the adhesive, which is over 0.4 MPa, after 28 days, and after water immersion for at least 20 days. Preferably, the adhesion strength is between 0.5-1.5 MPa, after 28 days, and after water immersion for at least 20 days.
  • In some embodiments, the powder, light weight, stone veneer adhesive is a sand free adhesive.
  • A third powder, light weight, sand free, stone veneer adhesive has expanded perlite in at least 10% volume of the powder adhesive; cellulose ether compounds at a ratio of between 5-25% of the mass of the expanded perlite;
  • a dispersible polymer at a ratio of between 10-250% of the mass of the expanded perlite;
  • a defoamer at a ratio of between 0.1-65% of the mass of the expanded perlite;
  • a fiber compound at a ratio of between 0.6-15% of the mass of the expanded perlite;
  • an accelerator at a ratio of between 3-25% of the mass of the expanded perlite; and,
  • optionally, cement at a ratio of between 600-1000% of the mass of the expanded perlite.
  • The components of the instant adhesive can be mixed together in any order to obtain the desired adhesion strength, of the adhesive, which is over 0.4 MPa, after 28 days, and after water immersion for at least 20 days. Preferably, the adhesion strength is between 0.5-1.5 MPa, after 28 days, and after water immersion for at least 20 days.
  • A fourth powder, light weight, sand free, stone veneer adhesive has expanded perlite in at least 15% volume of the powder adhesive;
  • a dispersible polymer at a ratio of between 10-305% of the mass of the expanded perlite;
  • a defoamer at a ratio of between 0.1-65% of the mass of the expanded perlite; and,
  • optionally, cement at a ratio of between 40-1505% of the mass of the expanded perlite.
  • The components of the instant adhesive can be mixed together in any order to obtain the desired adhesion strength, of the adhesive, which is over 0.3 MPa, after 28 days, and after water immersion for at least 20 days. Preferably, the adhesion strength is between 0.5-2.5 MPa, after 28 days, and after water immersion for at least 20 days
  • The described adhesives may be mixed with water for creating a glue having cream like texture, which hardens on drying. Due to the expanded perlite's intrinsic characteristics, water may be added to the powder adhesive composition in the mass ratio of approximately 0.8:1, for example, meaning, that approximately 0.8 liter of water may be added for each 1 kg of powder; 0.9:1; 0.7:1; 0.6:1; or 1:1. Water could also be added to the powder adhesive composition in the ratio of between 60-100% of the mass of the powder adhesive composition. The ration of water added to the adhesive powder may also be a function of the specific ingredients of the adhesive powder. The adhesive, with or without cement, may be used for gluing any stone tiles as a protective and/or decorative covering for exterior or interior horizontal or vertical surfaces.
  • The composition, comprising expanded perlite, is used for creating a lightweight powder veneer adhesive. The term veneer is meant to include any protective or ornamental facing which can be adhesively attached to any horizontal or vertical surface. The adhesive may be used for adhesively attaching stone such as granite, porcelain, ceramic, mosaic, porcelain, marble, brick, or any other synthetic or natural stone to a wall, ceiling, floor or any other surface. The powder adhesive is mixed with water for creating a cream like textured glue, which hardens on drying. The glue may be used for adhesively attaching any stone tiles as a protective and/or decorative covering for exterior or interior horizontal or vertical surfaces. The powder adhesive composition, for attaching stone veneer, comprises
  • First Component:
      • at least 1% of expanded perlite of its total mass;
      • at least 3% of expanded perlite of its total mass;
      • at least 6% of expanded perlite of its total mass; or
      • at least 9% of expanded perlite of its total mass.
  • Preferably, the expanded perlite, used in the adhesive composition, has the following characteristics:
      • (A) a granular size of between 0.01 to 2 mm, and a density that includes and is between 50-115 kg/m3;
      • (B) a granular size of between 2 to 6 mm and a density that includes and is between 40-50 kg/m3;
      • (C) a granular size of between 0.01 to 6 mm and having a density that includes and is between 40-115 kg/m3.
  • For example, the physical properties of the expanded perlite that can be used for creating a powder adhesive composition for attaching stone tiles is disclosed at Table 1:
  • TABLE 1
    Spatial weight 40-115 kg/m3
    Color White
    Refractive Index 1.4-1.5
    Granular Size From fine powder to 6 mm
    pH 7-8
    Softening Point 890-1100° C.
    Fusion Point 1280-1350° C.
    Specific Heat 387 J/kg · K
    Thermal Conductivity 0.04 W/m · K
  • In practice, the expanded perlite, used in the adhesive composition, can be derived from different sources, and have other physical properties.
  • The use of expanded perlite instead of sand in construction compositions may also benefit the environment as the perlite is a natural and ecological substance. The use of expanded perlite instead of sand in powder adhesives or plaster can also improve the thermal and/or acoustic insulation properties of the adhesive and/or plaster due to the expanded perlite's improved thermal and/or acoustic insulation properties.
  • Second Component:
  • A cellulose ethers compound, preferably, Mecellose FMC 21010 manufactured by Samsung Chemical; Methocel, which is water-soluble methylcellulose and has hydroxypropyl methylcellulose polymers, any other cellulose ether that is made for use with cement and mixtures thereof. The cellulose ethers compound enhances some of the qualities of the adhesive composition such as providing workable quality to the composition and/or extending the open time of the composition, and/or improving the water saturation of the composition, where open time is the time after the adhesive is applied during which a serviceable bond can be made. The cellulose ethers are added to the adhesive composition at a ratio of between
      • 5-25% of the mass of the expanded perlite,
      • 7%-15% of the mass of the expanded perlite;
      • 30-40% of the mass of the expanded perlite.
  • Third Component
  • A dispersible polymer, preferably, Wacker's Vinnapas 5025L, which is a leveling dispersible powder based on vinyl acetate and ethylene, or may be any other dispersible powder based on vinyl acetate, or any other hydroscopic compound which is dispersible in water, such as SBR-based adhesives, vinyl acetate, acryl, etc. The dispersible polymer is added to the adhesive composition at a ratio of between
      • 10%-250% of the mass of the expanded perlite;
      • 200-250% of the mass of the expanded perlite;
      • 5-300% of the mass of the expanded perlite.
  • Fourth Component
  • A defoamer, e.g. an anti-foam agent, such as Vinapor® DF 9010 F, or any other chemical additive that reduces and hinders the formation of foam. Commonly used agents are insoluble oils, polydimethylsiloxanes and other silicones, certain alcohols, stearates and glycols. The additive is used to prevent formation of foam or is added to break a foam already formed. Preferably, the fiber compound may be added to the adhesive composition at a ratio of between
      • 0.1-65% of the mass of the expanded perlite; or
      • 0.5-30% of the mass of the expanded perlite.
  • Fifth Component
  • A fiber compound such as Adfil construction fibers or any other polypropylene compound having a fiber length of 6 mm or any other chemical or synthetic fiber compound which may be used for cement based adhesives, or any other fiber that is used with cement such as nylon fiber. Preferably, the fiber compound may be added to the adhesive composition at a ratio of between
      • 0.6-15% of the mass of the expanded perlite; or
      • 0.6-0.9% of the mass of the expanded perlite.
  • Sixth Component—Optional
  • Cement such as white cement, Portland cement, or any type of cement or aluminous cement. Preferably, the cement may be added to the adhesive composition at a ratio of between
      • 600-1000% of the mass of the expanded perlite;
      • 800-950% of the mass of the expanded perlite;
      • 250-1700% of the mass of the expanded perlite;
      • 350-900% of the mass of the expanded perlite; or
      • 350-1700% of the mass of the expanded perlite.
  • As indicated above, the adhesive composition, comprising expanded perlite, may be free of cement. The resulting adhesive composition free of cement is a light weight adhesive used for indoors gluing. This adhesive may be sold as a cream adhesive.
  • Seventh Component—Optional
  • Gypsum and a retarder such as HYCON R 7200, manufactured by BASF, or any other modified polymer retardation instead of cement. The gypsum may be added to the adhesive composition at a ratio of between 600-900% of the mass of the expanded perlite, and the retarder may be added in relations to the desired open time.
  • Eighth Component—Optional
  • The adhesive for attaching veneer may also comprise an additive for accelerating the bonding time of the adhesive, referred to hereinafter as accelerator. The accelerator may be Calcium Formate, Calcium Chloride, or any other additive that can be used for accelerating the bonding time of the adhesive. The accelerator may be added to the adhesive composition at a ratio of between 5-15% of the mass of the expanded perlite.
    • Process Steps
  • The expanded perlite and all the other component ingredients, mentioned above, of the adhesive composition, may be mixed together in any order to form a powder adhesive composition.
  • The above-identified powder adhesive composition may be mixed with water to create glue for gluing any synthetic or natural stone tile to any surface. Due to the expanded perlite's intrinsic characteristics, water may be added to the powder adhesive composition in the mass ratio of approximately 0.7:1, meaning that approximately 0.7-1 liter of water can be added for each 1 kg of powder, to approximately 1:1. That means, water may be added to the powder adhesive composition in the ratio of between 70-100% of the mass of the powder adhesive composition. Alternatively, water may be added to the powder adhesive composition in the mass ratio of approximately 0.6:1 to approximately 1:1. In other words, water may be added to the powder adhesive composition in the ratio of between 60-100% of the mass of the powder adhesive composition.
  • The resulting adhesive composition that complies with this disclosure has an adhesion strength
      • (A) over 0.5 MPa, after 28 days;
      • (B) over 1 MPa, after 28 days;
      • (C) between 0.5-1.5 MPa, after 28 days,
      • (D) between 0.5-1 MPa, after 28 days,
      • (E) between 0.5-2.5 MPa, after 28 days,
      • (F) (i) over 0.5 MPa, after 28 days; over 1 MPa, after 28 days; between 0.5-1.5 MPa, after 28 days, or between 0.5-1 MPa, after 28 days and (ii) after the adhesive has been immersed in water;
      • (G) (i) over 0.5 MPa, after 28 days; over 1 MPa, after 28 days; between 0.5-1.5 MPa, after 28 days, or between 0.5-1 MPa, after 28 days and (ii) after the adhesive has been immersed in water for at least 1 day; and
      • (H) (i) over 0.5 MPa, after 28 days; over 1 MPa, after 28 days; between 0.5-1.5 MPa, after 28 days, or between 0.5-1 MPa, after 28 days and (ii) after the adhesive has been immersed in water for at least 20 days.
  • The resulting adhesive composition that complies with this disclosure has a wet density of:
      • (A) between 700-1400 kg/m3;
      • (B) between 800-1600 kg/m3;
      • (C) between 700-1500 kg/m3.
    EXAMPLES
  • An adhesive example is set forth at Table 2, with ingredients and their approximated amounts for creating a powder adhesive composition, which comprises expanded perlite, for attaching stone tiles:
  • TABLE 2
    Perlite 820 g
    White Cement 7.38 Kg
    Methocel 100 g
    Vinaps 5025L 0.6 Kg
    poly propylene 10 g
    Vinapor DF 9010 F 50 g
  • By mixing the exemplified ingredients and amounts, of Table 2, then a powder adhesive composition of about 9 kg is created. Water, for example and not limited to 7.5 liters, is added to this powder adhesive composition to create a glue that is used to adhere the stone veneer or tiles to a surface after which the glue cures and the tiles stay attached to the surface henceforth.
  • The mixing of the exemplified ingredients and amounts identified at table 2 create an adhesive that complies with the properties C2 TE S1 of any of the European adhesive standards: EN 1346 (2007), EN 1308 (2007), EN 1347 (2007), EN 1348 (2007), or EN 12002 (2008). Those standards are available on http://www.techstreet.com or http://shop.bsigroup.com.
  • Lab tests of the above disclosed example powder adhesive composition reveal the following characteristics of the composition:
  • TABLE 3
    Density (wet) 700-1400 kg/m3
    Preferred Water to powder relation 0.9 liter water for 1 kg powder
    Effective work time 90 minutes
    Open time 30 minutes
    Cover capability 2.6 Kg/m2 for 5 mm thickness
    adhesion strength after 28 days 0.5-1.5 megapascal MPa
    Working temperature 5° C.-35° C.
  • Thus, as conveyed at Table 3, the powder adhesive composition weighs less than the typical prior art powder adhesive. That decreased weight reduces costs of transportation and handling. In addition, the use of expanded perlite instead of sand in the powder adhesives prolongs the open time of the adhesive, after the water is added, effectively making the perlite based adhesive more comfortable for use.
  • Lab tests that use the above-identified powder adhesive composition reveal the following characteristics of the composition:
  • TABLE 4
    Density (dry mix) 250-1500 kg/m3
    Preferred Water to powder relation 1 liter water for 1 kg powder
    Effective work time 90 minutes
    Open time 45 minutes
    Cover capability 2.6 Kg/m2 for 5 mm thickness
    adhesion strength after 28 days 0.5-1.5 megapascal MPa
    Working temperature 5° C.-35° C.
  • Table 4 conveys the described adhesive complies with the known adhesive properties of: C1, C1 T, C1 TE, C1 TE S1, C1 TE S2, C2, C2 T, C2 TE, C2 TE S1, or C2 TE S2 of any of the European standards such as: EN 1346 (2007), EN 1308 (2007), EN 1347 (2007), EN 1348 (2007), or EN 12002 (2008) available on http://www.techstreet.com or http://shop.bsigroup.com.
    • Experimental Reports: Experiment Mo. 1:
  • At CN 101279833 A, Jieru described a mortar composition. Jieru's mortar composition is compared with this application's claimed adhesive composition. In particular, Jieru discloses an insulation mortar for use in masonry or plastering. Jieru's mortar is based on the composition disclosed in the abstract and in the summary of CN 101279833 A while the proposed adhesive is based on one of the embodiments, with the understanding that both compositions have the same total volume for comparison purposes:
  • TABLE 5
    Proposed
    ingredients Jieru's composition adhesive
    cement 4.5 Kg 50% 7.240 Kg 83%
    coal ash 1.44 Kg 16% 0
    dispersible 0.225 Kg 2.5% 0.6 Kg 6.8%
    polymer + defoamer
    wood fiber 0.027 Kg 0.3% 0
    fiber compound 0.009 Kg 0.1% 0.015 Kg 0.17%
    calcium formate 0.045 Kg 0.5% 0
    cellulose ethers 0.054 Kg 0.6% 0.1 Kg 1.1%
    sulphonated 0.036 Kg 0.4% 0
    polycondensahon
    (water repellent +
    multifunctional
    additives)
    expanded perlite 2.7 Kg 30% 0.82 Kg 9.3%
    • Results:
  • Jieru's composition is an insulation mortar composition that has an adhesion strength between 0.07-0.1 MPa (as measured in accordance to the EN 998-1:2016 standard available at http://www.techstreet.com/standards/bs-an-998-1-2016?product id=1936338). In contrast, the adhesion strength of the proposed adhesive is between 0.5-1.5MPa, after 28 days, and after water immersion for at least 20 days as measured in accordance to the EN 1348:2007 standard available at http://www.techstreet.com/standards/be-en-1348-2007?product id=1533195). Accordingly, Jieru's composition does not and cannot meet the minimum requirements of the claimed invention.
    • Experiment No. 2:
  • GB 1225755 discloses a cement-based adhesive. For the sake of brevity, the Comparative Examples A-C of GB 1225755 have been tested. The compositions comprised the following amounts of components:
  • TABLE 6
    Example A (kg) B (kg) C (kg)
    White Portland “Snowcrete” 4.41 4.470 4.450
    Cement cimbeton cimbeton cimbeton
    Expanded unmilled perlite 0.360 0.540 0.720
    grade 100/28 agrikal agrikal agrikal
    Powdered Limestone 3.915 3.915 3.915
    stone&lime stone&lime stone&lime
    Vinyl acetate copolymer 0.225 0.225 0.225
    5044 5044 5044
    vinapas vinapas vinapas
    Methyl hydroxypropyl 0.090 0.090 0.090
    cellulose Mp75 h Mp75 h Mp75 h
    weikem weikem weikem
    Water 8.0-9.0 lt 8.0-9.0 lt 8.0-9.0 lt
    Cement:perlite mass ratio (%) 1225 780 560
  • The compounds disclosed in Table 6 were compared to an example according to the present invention having the following amounts of components that conform to the teachings of the claimed invention (see Table 7):
  • TABLE 7
    Proposed adhesive Components:
    White Cement 7380 g
    Expanded perlite 850 g
    Vinnaps 5025L 600 g
    Methocel 100 g
    Polypropylene 10 g
    Water 6.5-7.0 lt
    Cement:perlite mass ratio (%) 870
    • Analysis of Compositions:
  • The adhesive strength of the compositions prepared above were analysed according to the standard EN 1348 august 2007. The extended open time of the compositions prepared above were analysed according to the standard EN 1346 august 2007
    • Results:
  • TABLE 8
    Adhesive strength Extended open time
    Example (MPa) (minutes)
    Comparative A 0.2 in water 18 (failed)
    (failed all test)
    Comparative B 0.17 in water 19 (failed)
    (failed all test)
    Comparative C 0.14 in water 19 (failed)
    (failed all test)
    Present invention 1.1 in water 30 m (as necessary)
  • As conveyed at Table 8, GB 1225755's cement-based adhesive fails to meet the minimum requirements of the claimed invention.
  • While the above description discloses many embodiments and specifications of the invention, these were described by way of illustration and should not be construed as limitations on the scope of the invention. The described invention may be carried into practice with many modifications which are within the scope of the appended claims.

Claims (10)

1. A sand-free powder adhesive composition comprising:
cement;
a dispersible polymer powder; and
expanded perlite, wherein at least 10% volume of the sand-free powder adhesive is expanded perlite;
characterized in that
said cement is at a ratio of between 600-1000% of the mass of said expanded perlite.
2. The composition according to claim 1, wherein said expanded perlite has a density of between 50-115 kg/m3, and a granular size of between 0-2 mm.
3. The composition according to claim 1, wherein said dispersible polymer powder is at a ratio of between 5-300% of the mass of said expanded perlite.
4. The composition according to claim 1, further comprising a cellulose ethers compound.
5. The composition according to claim 1, further comprising a fiber compound.
6. The composition according to claim 1, wherein the cement is white cement.
7. The composition according to claim 1, wherein the cement is Portland cement.
8. The composition according to claim 1, further comprising an accelerator.
9. The composition according to claim 5, wherein the fiber compound is a polypropylene compound.
10. The composition according to claim 1, wherein the perlite comprises at least 1% of the total mass of the adhesive composition.
US16/522,044 2014-02-24 2019-07-25 Composition and method of using perlite Abandoned US20190345365A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US16/522,044 US20190345365A1 (en) 2014-02-24 2019-07-25 Composition and method of using perlite

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
IL231135A IL231135B (en) 2014-02-24 2014-02-24 A composition and method of using perlite
IL231135 2014-02-24
US14/527,085 US20150239780A1 (en) 2014-02-24 2014-10-29 Composition and method of using perlite
US15/637,185 US10399900B2 (en) 2014-02-24 2017-06-29 Composition and method of using perlite
US16/522,044 US20190345365A1 (en) 2014-02-24 2019-07-25 Composition and method of using perlite

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
US15/637,185 Continuation-In-Part US10399900B2 (en) 2014-02-24 2017-06-29 Composition and method of using perlite

Publications (1)

Publication Number Publication Date
US20190345365A1 true US20190345365A1 (en) 2019-11-14

Family

ID=51418080

Family Applications (3)

Application Number Title Priority Date Filing Date
US14/527,085 Abandoned US20150239780A1 (en) 2014-02-24 2014-10-29 Composition and method of using perlite
US15/637,185 Expired - Fee Related US10399900B2 (en) 2014-02-24 2017-06-29 Composition and method of using perlite
US16/522,044 Abandoned US20190345365A1 (en) 2014-02-24 2019-07-25 Composition and method of using perlite

Family Applications Before (2)

Application Number Title Priority Date Filing Date
US14/527,085 Abandoned US20150239780A1 (en) 2014-02-24 2014-10-29 Composition and method of using perlite
US15/637,185 Expired - Fee Related US10399900B2 (en) 2014-02-24 2017-06-29 Composition and method of using perlite

Country Status (12)

Country Link
US (3) US20150239780A1 (en)
EP (2) EP3495336A1 (en)
CY (1) CY1121918T1 (en)
DK (1) DK2910535T3 (en)
ES (1) ES2732324T3 (en)
HR (1) HRP20191190T1 (en)
HU (1) HUE044655T2 (en)
IL (1) IL231135B (en)
PL (1) PL2910535T3 (en)
PT (1) PT2910535T (en)
SI (1) SI2910535T1 (en)
TR (1) TR201909878T4 (en)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IL231135B (en) * 2014-02-24 2019-07-31 Shahal Building Materias Ltd A composition and method of using perlite
WO2020200889A1 (en) * 2019-03-29 2020-10-08 Sika Technology Ag Adhesive composition
FR3096365B1 (en) * 2019-05-24 2021-09-03 Saint Gobain Weber Dry composition of mortar, especially adhesive mortar for tile adhesive
AU2019204874B1 (en) * 2019-07-08 2020-02-06 Shahal Building Materials Ltd A light weight adhesive composition
US11739026B2 (en) * 2020-05-15 2023-08-29 TPI Polene Public Company Limited Lightweight fiber-reinforced cement material
CN111635188B (en) * 2020-05-19 2022-02-22 广东东鹏文化创意股份有限公司 Fireproof light inorganic plate and preparation process thereof

Family Cites Families (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1225755A (en) * 1967-07-28 1971-03-24
US5277712A (en) 1992-08-20 1994-01-11 Louisiana-Pacific Corporation Dry mix-type joint compounds, compositions therefrom and methods for filling drywall joints with same
DE19540273A1 (en) * 1995-10-28 1997-04-30 Dennert Poraver Gmbh Pumpable lightweight wall mortar, class LM 21
DE29615484U1 (en) 1996-09-05 1998-01-08 Krämer, Walter, 49577 Eggermühlen Non-combustible thermal insulation boards based on expanded Perlite grit
DE19645231A1 (en) * 1996-11-02 1998-05-07 Dennert Poraver Gmbh Lightweight mortar class LM 21
US20050092209A1 (en) 2003-10-30 2005-05-05 Garner Van D. Lime-free admixture compositions for hydraulic cements and methods thereof
WO2007056634A2 (en) 2005-11-03 2007-05-18 Michael Heiman Perlite composition and method of making the same
GB0715414D0 (en) 2007-08-07 2007-09-19 Cursham Henry C Lime motar composition
CN101139186A (en) 2007-08-20 2008-03-12 宁波荣山建筑节能科技有限公司 Expanded perlite-polyurethane composite insulating board and manufacturing technique thereof
CN101279833B (en) * 2008-05-29 2010-09-01 邱氏（湖北）涂料有限公司 Construction heat-insulating mortar
US9266778B2 (en) * 2008-11-21 2016-02-23 Usg Interiors, Llc Multi-layer acoustical plaster system
CN102190464A (en) 2010-03-12 2011-09-21 古金盛 Inorganic lightweight grouting material and its manufacturing method
KR101025429B1 (en) 2010-05-14 2011-03-25 채민호 Insulation waterproofing method of building with enhanced insulation effect
CN101857410A (en) * 2010-06-01 2010-10-13 武汉威尔博科技发展有限公司 Single-component inorganic heat-insulating mortar and preparation method thereof
IL231135B (en) * 2014-02-24 2019-07-31 Shahal Building Materias Ltd A composition and method of using perlite

Also Published As

Publication number Publication date
CY1121918T1 (en) 2020-10-14
PT2910535T (en) 2019-07-10
EP2910535B1 (en) 2019-04-03
US20150239780A1 (en) 2015-08-27
SI2910535T1 (en) 2019-08-30
US10399900B2 (en) 2019-09-03
HRP20191190T1 (en) 2019-10-04
IL231135A0 (en) 2014-08-31
DK2910535T3 (en) 2019-07-01
US20170297959A1 (en) 2017-10-19
HUE044655T2 (en) 2019-11-28
ES2732324T3 (en) 2019-11-21
PL2910535T3 (en) 2019-10-31
TR201909878T4 (en) 2019-07-22
EP2910535A1 (en) 2015-08-26
EP3495336A1 (en) 2019-06-12
IL231135B (en) 2019-07-31

Similar Documents

Publication Publication Date Title
US10399900B2 (en) Composition and method of using perlite
CA1326310C (en) Lightweight joint compound having improved paintability
US9932271B2 (en) Gypsum composites containing cementitious materials and methods
RU2471738C1 (en) Repair-waterproofing composition and additive in form of wollastonite complex for repair-waterproofing composition, mortar, concrete and articles based thereon
US12139438B2 (en) Fire resistant compositions and articles and methods of preparation and use thereof
CN107646025A (en) Composition for metakaolin construction material, the correlation technique for manufacturing the composition and the purposes for producing Constracture unit
CN101549978A (en) Sepiolite fiber modified vitrification bead thermal insulation mortar
AU2010100046A4 (en) A composition suitable for use in building construction
WO2009058558A1 (en) High hydroxyethylated starch and high dispersant levels in gypsum wallboard
CA2657612A1 (en) Sprayable and pumpable phosphate cement
RU2204540C1 (en) Dry mortar mix
US20200031716A1 (en) Hydrophobized fiber cement products, methods for production, and uses thereof
MX2013013835A (en) Cellulose ether compounds for improved hot temperature performance in external insulation finishing systems (eifs) mortars.
JP2009096657A (en) Cement mortar for plaster work
RU2262493C1 (en) Dry pack mortar
CN110698125A (en) Double-component polymer ceramic tile adhesive and preparation method thereof
WO2022177450A1 (en) Adhesive and pointing mortar
AU2019204874B1 (en) A light weight adhesive composition
EA017880B1 (en) Dry decorative finishing mixture
JP2023511351A (en) Formulations containing hydraulic binders and cellulose ethers
IL275043A (en) A composition and method of using perlite
CN112239338A (en) Light weight adhesive composition
HU227933B1 (en) Dry mix for making indoor stucco
KR100874883B1 (en) Flame Retardant Floor Finish Composition
Hayilu et al. Tile adhesive production by Inorganic materials

Legal Events

Date Code Title Description
STPP Information on status: patent application and granting procedure in general

Free format text: APPLICATION DISPATCHED FROM PREEXAM, NOT YET DOCKETED

STPP Information on status: patent application and granting procedure in general

Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION

STPP Information on status: patent application and granting procedure in general

Free format text: NON FINAL ACTION MAILED

STPP Information on status: patent application and granting procedure in general

Free format text: FINAL REJECTION MAILED

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION