|Title of Invention||
A MORTAR COMPOSITION
|Abstract||The present invention relates to a composition of the material for the production of fly ash pre polymerized resin composites. More particularly the invention relates to polymeric binding compositions and particularly to coating compositions useful as an adhesive for clay bricks, Fly ash bricks, aerated concrete blocks, cement blocks etc., used as building blocks for civil construction activities, as plaster/render for building surfaces, as a crack filler, as a repair plaster, as a fire and heat resistant plaster/mastic etc. The product is designed to be used in building / construction industry as self-curing, crack resistant, eco friendly, ready to use composite useful as a brick / block laying adhesive, render/plaster, crack filler, repair plaster, etc. The composition composed of ultra fine pulverized fly ash, a low viscosity Poly vinyl acetate (VAM), styrene acrylic, pure acrylic, CNSL (cashew nut shell liquid), Silicon, Shellac type emulsion polymer as a binder and water. The composition also preferably contains one or more of a dispersant, a defoamer, a plasticizer, a thickener, a drying agent, preservative, a fungicide, silica or quartz fillers of different mesh and an ingredient to control the pH of the composition.|
|Full Text|| FORM - 2
THE PATENTS ACT, 1970
(39 OF 1970)
"Composition of materials for production of fly ash pre polymerized cement less eco-friendly morter and methods thereof."
1. Joshi Pradeep Vasant
2. Joshi Shilpa '
80/85, 'OM Laxmi Niwas',
1st floor, Prabhat road,
Erandwane, Pune- 411 004
Both Indian Nationals
The following specification describes the nature of the invention
FIELD OF INVENTION
The present invention relates in general to compositions and a method of use of such compositions to produce eco-friendly cement less product, which are resistant to corrosion and is designed to use in civil engineering and construction industry.
BACKGROUND OF THE INVENTION
The formulation of high-performance materials that are stronger and more durable than conventional cement-based materials has emerged as an issue of considerable importance in the construction industry.
The most common practice of plastering masonry work is an 'on site' mixing of cement, sand and water in the defined ratio. Commonly used plaster preparation technology comprises of combination of cement plus lime. Mixture of these materials is applied mechanically between the brick surfaces for binding and giving strength. All the plastering materials are cement based with additives of varied nature in order to impart crack reduction, strength, ease in application, weathering etc. However, the cement based plaster needs post curing which is affected by sprinkling of water thereby causing expansion of cement particle thus forming a compact strong structure. In humid atmosphere the curing temperature conditions normally in the range of 20°C -30°C. However there is negative effect of curing at low temperature conditions.
Cement based products as used traditionally are pre-designed for short pot life and difficult for handling. An adhesion and curing rate drastically gets affected due to hydrolysis reaction between cement- sand mixture which gets thicker in case of slow working conditions.
During the application process the mason has to apply the cement based plaster with great pressure in order to get strong adhesion of adjacent bricks however; half of the cement based products fall on the ground which results in to waste up to 10%-15% mass basis.
U.S. Pat. No. 5,601,643 to Silverstrim et al. relates to a cementitious mixture comprising Class F fly ash and an alkali metal or alkaline earth metal silicate, which sets rapidly and gives high strength under elevated temperature. U.S. Pat. No. 6,296,699 to Jin relates to the production of a binder using waste glasses activated by sodium silicate with a Si02 :Na2 O weight ratio between about 1.6:1 to about 2.0:1. however the weight ratio of Si02 :Na2 O should be below 2, otherwise, the activated cementing material will set too fast to be useful [Jolicoeur et al., Advances in Concrete Technology, Natural Resources Canada, pp. 483-514, 1992]. Although those binders can give high strength, they are not stable in moist conditions. Also, they display serious effluence problems because of low Si02: Na2 O ratios.
BRIEF DESCRIPTION OF THE INVENTION
The present inventors have focused on the excellent workability, water resistance and weatherability of construction cement free product that is plaster and made a diligent study to improve the defects of this traditionally used cement based products, dry contraction and adhesion. As a result, they have found that the above defects can be overcome by using styrene acrylic emulsion polymer of small particle size containing styrene and acrylic monomers in the ratio 5:95 to 95:05 along with fly ash in appropriate proportions which finding has led to this invention.
The emulsion contains additional stabilizers for long life both indoor and outdoor constructions. The particle size varies from 1-50 micron which is compatible with all types of pigments and fillers. The total composition is filled with graded quality of fly ash / pozzocrete. The settling rate and time controlled by adjusting natural and synthetic thickeners. The eco-plasters can set at temperatures starting from 5°C and above.
The present invention also employ addition of different types of inorganic fillers like silicates, oxides and carbohydrates and silica in varying particle size gradation in order to facilitate settling time and provide good flow of materials, adjusted setting in thick layers from 100 micron to 10cm.
The eco plaster as disclosed in the present invention offers solution on various problems arising during and after plastering of the walls. The product is designed to offer total replacement to conventional cement based plasters.
The eco plaster as disclosed herein is a ready to use material and needs no mixing on site. This enables control on quality. There is no need of water, which not only saves water but also prevents on site contamination.
The eco plaster as disclosed herein is completely free from cement and needs no curing. This saves water as well as time in construction. It is most suitable replacement to conventional plaster in today's world, which is facing cement shortage.
The eco plaster as disclosed herein has excellent resistance to cracks, which arise in all plasters over a period of time due to various reasons. It is a crackles plaster. The product has excellent adhesion to the substrate. The product is hence lifelong use.
The eco plaster as disclosed herein is very easy to apply. It needs very less time compared to conventional plasters. It is a bio friendly product, which contains ingredients that reduce the environmental pollution. On demolition it can be simply used for land filling and is absolutely harmless. It is possible to apply any paint /texture /coating on the plasters. It has excellent water resistance, and does not permit growth any fungus or mildew growth.
Dated this 25th day of April, 2007.
M.S.KHADILKAR (Agent for Applicant)
|Indian Patent Application Number||832/MUM/2007|
|PG Journal Number||24/2012|
|Date of Filing||27-Apr-2007|
|Name of Patentee||JOSHI PRADEEP VASANT|
|Applicant Address||FLAT NO. 4,"AKSHAY SANKUL", UNITED WESTERN HSG. SOC., KARVE NAGAR, PUNE 411 052, MAHARASHTRA, INDIA|
|PCT International Classification Number||B03D1/02|
|PCT International Application Number||N/A|
|PCT International Filing date|