One-Component Cementitious Coating for Tile Adhesion
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Solution Overview
Problem
Current two-component cementitious compositions for tile adhesives and water-proofing slurries are cumbersome to mix and apply, generate waste, and often fail to meet stringent performance criteria like extended open time and reduced slip, especially under water immersion and freeze-thaw conditions.
Innovation Solution
A one-component aqueous cementitious composition comprising calcium aluminate cement, organic latex polymer, and polysaccharides, which hardens upon application to a basic substrate surface, eliminating the need for a hardener and allowing for a stable, adhesive, and water-impermeable coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two-component cementitious compositions are used to meet stringent performance criteria, then adhesion strength and durability are improved, but device complexity and ease of operation deteriorate due to separate storage and mixing requirements
Solution Approach 1:
The patent combines the polymer component and cementitious binder into a single one-component composition, eliminating the need for separate storage and mixing of multiple components. The polymer is incorporated directly into the cementitious matrix, allowing the composition to be applied as a single material while still achieving the adhesive strength and durability of two-component systems.
Solution Approach 2:
The one-component composition serves multiple functions simultaneously: it acts as both the adhesive binder and the structural matrix, eliminating the need for separate polymer and cement components. This multi-functional design simplifies the application process while maintaining the performance benefits of polymer-modified cementitious adhesives.
2Duration of action of moving object
If two-component compositions are used to achieve extended open time, then duration of action is improved, but ease of operation worsens due to mixing requirements and potential waste generation
Solution Approach 1:
The patent merges the polymer modification and cementitious binder into a single pre-mixed composition that requires no field mixing. The polymer is incorporated into the cementitious matrix during manufacturing, ensuring homogeneous distribution and eliminating the complexity of mixing multiple components on-site, thereby extending open time while simplifying application.
3Reliability
If polymer modification is used to meet C2 classification, then adhesion strength under ageing and water immersion is improved, but manufacturing precision and formulation complexity increase
Solution Approach 1:
The patent combines the polymer and cementitious binder into a single integrated composition, eliminating the need for precise field mixing of separate components. The polymer is incorporated into the cementitious matrix during manufacturing, ensuring homogeneous distribution and reducing formulation complexity while maintaining the adhesion strength and durability required for C2 classification.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a stable, adhesive, and water-impermeable coating that meets the C2TE classification criteria for tile adhesives, offering extended open time and reduced slip resistance, while reducing waste and application complexity.
Implementation Method 1
the basicity of the substrate initiates the hardening of that composition
Implementation Method 2
applying said aqueous composition to said first substrate surface
Implementation Method 3
allowing for a stable, adhesive, and water-impermeable coating
Data Source
AI summary
The present application is directed to a method of forming a coated substrate, said method comprising: i) providing a one-component (1K) aqueous composition comprising, based on the total weight of non-volatile constituents in the composition: from 15 to 30 wt.% of a) calcium aluminate cement; from 15 to 30 wt.% of b) at least one organic latex polymer; from 0.01 to 2 wt.% of c) at least one polysaccharide; and, from 30 to 60 wt.% of d) substantially inert filler; ii) providing a substrate comprising a first substrate surface; iii) applying said aqueous coating composition to said first substrate surface; and; iv) allowing said aqueous coating composition to harden, wherein said method is characterized in that said first substrate surface possesses basicity as determined by the pH measurement method of ASTM F710-11. The method has particular utility in applying an adhesive coating to a first substrate to enable the bonding of a second substrate thereto: that second substrate is desirably a floor covering or a tile.