Method of grouting using specific mortar composition

Claim 1

A method of setting and grouting tile which comprises employing at room temperature an aqueous non-hydraulic mortar composition having a viscosity of about 120,000 cps comprising about 10% by weight (solids) of a mixture of film-forming, room temperature cross-linkable polymers in the form of an emulsion, suspension, dispersion or partial solution consisting of an acrylic resin having methylol acrylamide and acid cross-linkable groups and about 77% by weight (solids) of a water-insoluble filler consisting of a mixture of silica, glass and alumina trihydrate.

Claim 2

A method of setting and grouting tile which comprises employing at room temperature an aqueous non-hydraulic mortar composition having a viscosity of about 120,000 cps comprising about 10% by weight (solids) of a mixture of film-forming, room temperature cross-linkable polymers in the form of an emulsion, suspension, dispersion or partial solution consisting of an acrylic resin having methylol acrylamide and acid cross-linkable groups and about 77% by weight (solids) of a water-insoluble filler consisting of a mixture of silica, glass and alumina trihydrate.

Claim 3

A method of setting and grouting tile which comprises employing at room temperature an aqueous non-hydraulic mortar composition having a viscosity of about 16,000 cps comprising about 5% by weight (solids) of a mixture of film-forming, room temperature, cross-linkable polymers in the form of an emulsion, suspension, dispersion or partial solution consisting of an acrylic resin having methylol acrylamide and acid cross-linkable groups and an acrylic polymer having acid cross-linkable groups and about 77% by weight (solids) of a water-insoluble filler consisting of a mixture of silica, glass and alumina trihydrate.

Claim 4

A method of setting and grouting tile which comprises employing at room temperature an aqueous non-hydraulic mortar composition having a viscosity of about 16,000 cps comprising about 5% by weight (solids) of a mixture of film-forming, room temperature, cross-linkable polymers in the form of an emulsion, suspension, dispersion or partial solution consisting of an acrylic resin having methylol acrylamide and acid cross-linkable groups and an acrylic polymer having acid cross-linkable groups and about 77% by weight (solids) of a water-insoluble filler consisting of a mixture of silica, glass and alumina trihydrate.

Claim 5

A method of setting and grouting tile which comprises employing at room temperature an aqueous non-hydraulic mortar composition comprising about 2.5% by weight (solids) of a mixture of film-forming, room temperature, cross-linkable polymers in the form of an emulsion, suspension, dispersion or partial solution consisting of an acrylic resin having methylol acrylamide and acid cross-linkable groups and an acrylic polymer having acid cross-linkable groups and about 77% by weight (solids) of a water-insoluble filler consisting of a mixture of silica, glass and alumina trihydrate.

Claim 6

A method of setting and grouting tile which comprises employing at room temperature an aqueous non-hydraulic mortar composition comprising about 2.5% by weight (solids) of a mixture of film-forming, room temperature, cross-linkable polymers in the form of an emulsion, suspension, dispersion or partial solution consisting of an acrylic resin having methylol acrylamide and acid cross-linkable groups and an acrylic polymer having acid cross-linkable groups and about 77% by weight (solids) of a water-insoluble filler consisting of a mixture of silica, glass and alumina trihydrate.

Claim 7

A method of setting and grouting tile which comprises employing at room temperature an aqueous non-hydraulic mortar composition having a viscosity of about 740,000 cps comprising about 7% by weight (solids) of a film-forming, room temperature, cross-linkable polymer in the form of an emulsion, suspension, dispersion or partial solution, said polymer being an acrylic resin having methylol acrylamide and acid cross-linkable groups and about 80% by weight (solids) of a water-insoluble filler consisting of silica, sand, limestone and alumina trihydrate.

Claim 8

A method of setting and grouting tile which comprises employing at room temperature an aqueous non-hydraulic mortar composition having a viscosity of about 740,000 cps comprising about 7% by weight (solids) of a film-forming, room temperature, cross-linkable polymer in the form of an emulsion, suspension, dispersion or partial solution, said polymer being an acrylic resin having methylol acrylamide and acid cross-linkable groups and about 80% by weight (solids) of a water-insoluble filler consisting of silica, sand, limestone and alumina trihydrate.

Claim 9

A method of setting and grouting tile which comprises employing at room temperature an aqueous non-hydraulic mortar composition having a viscosity in the range of 10,000 to 1,200,000 cps comprising a film-forming, room temperature cross-linkable polymer in the form of an emulsion, suspension, dispersion or partial solution, having reactive substituents on the polymer chain selected from the group consisting of epoxy, hydroxy, methylol, carboxy, ester, α-olefin, isocyanate, methylol acrylamide, amino, N-methylol amide, internal double bond and combinations thereof wherein said reactive substituents are capable of reacting at room temperature to cross-link said polymers, a water-insoluble filler selected from the group consisting of glass, quartz, silica, limestone, barytes, wollastonite, mica, flint powder, kryolite, alumina trihydrate, talc, pyrophyllite, zinc oxide and mixtures thereof, and an acid catalyst cross-linking aid which is ammonium chloride, said polymer comprising from 2% to 16% by weight, and said filler from 50% to 90% by weight, and said cross-linking aid from 0.03% to 2.0% by weight of the total aqueous composition.

Claim 10

A method of setting and grouting tile which comprises employing at room temperature an aqueous non-hydraulic mortar composition having a viscosity in the range of 10,000 to 1,200,000 cps comprising a film-forming, room temperature cross-linkable polymer in the form of an emulsion, suspension, dispersion or partial solution, having reactive substituents on the polymer chain selected from the group consisting of epoxy, hydroxy, methylol, carboxy, ester, α-olefin, isocyanate, methylol acrylamide, amino, N-methylol amide, internal double bond and combinations thereof wherein said reactive substituents are capable of reacting at room temperature to cross-link said polymers, a water-insoluble filler selected from the group consisting of glass, quartz, silica, limestone, barytes, wollastonite, mica, flint powder, kryolite, alumina trihydrate, talc, pyrophyllite, zinc oxide and mixtures thereof, and an acid catalyst cross-linking aid which is ammonium chloride, said polymer comprising from 2% to 16% by weight, and said filler from 50% to 90% by weight, and said cross-linking aid from 0.03% to 2.0% by weight of the total aqueous composition.

Claim 17

A method of setting and grouting tile which comprises employing at room temperature an aqueous mortar composition having a viscosity in the range of 10,000 to 1,200,000 cps comprising a film-forming, room temperature cross-linkable polymer in the form of an emulsion, suspension, dispersion or partial solution, having reactive substituents on the polymer chain selected from the group consisting of epoxy, hydroxy, methylol, carboxy, ester, α-olefin, isocyanate, methylol acrylamide, amino, N-methylol amide, internal double bond and combinations thereof wherein said reactive substituents are capable of reacting at room temperature to cross-link said polymers, a water-insoluble filler selected from the group consisting of glass, quartz, silica, limestone, barytes, wollastonite, mica, flint powder, kryolite, alumina trihydrate, talc, pyrophyllite, zinc oxide and mixtures thereof, and an acid catalyst cross-linking aid selected from the group consisting of inorganic and organic salts, organic acids, and amine acid-addition salts, said polymer comprising from 2% to 16% by weight, and said filler from 50% to 90% by weight of the total aqueous composition and wherein said composition is a non-hydraulic mortar.

Claim 18

A method of setting and grouting tile which comprises employing at room temperature an aqueous mortar composition having a viscosity in the range of 10,000 to 1,200,000 cps comprising a film-forming, room temperature cross-linkable polymer in the form of an emulsion, suspension, dispersion or partial solution, having reactive substituents on the polymer chain selected from the group consisting of epoxy, hydroxy, methylol, carboxy, ester, α-olefin, isocyanate, methylol acrylamide, amino, N-methylol amide, internal double bond and combinations thereof wherein said reactive substituents are capable of reacting at room temperature to cross-link said polymers, a water-insoluble filler selected from the group consisting of glass, quartz, silica, limestone, barytes, wollastonite, mica, flint powder, kryolite, alumina trihydrate, talc, pyrophyllite, zinc oxide and mixtures thereof, and an acid catalyst cross-linking aid selected from the group consisting of inorganic and organic salts, organic acids, and amine acid-addition salts, said polymer comprising from 2% to 16% by weight, and said filler from 50% to 90% by weight of the total aqueous composition and wherein said composition is a non-hydraulic mortar.

Claim 34

A method of grouting tile which comprises: assembling on a substrate a plurality of ceramic tiles in edge-to-edge relationship with spaces between the tiles; and filling the spaces between the tiles with an aqueous grouting composition having a viscosity in the range of 10,000 to 1,200,000 cps comprising 1. a film-forming, room temperature cross-linkable polymer in the form of an emulsion, suspension, dispersion or partial solution, having reactive substituents on the polymer chain selected from the group consisting of epoxy, hydroxy, methylol, carboxy, ester, α-olefin, isocyanate, methylol acrylamide, amino, N-methylol amide, internal double bond and combinations thereof wherein said reactive substituents are capable of reacting at room temperature to cross-link said polymer, 2. a water-insoluble filler, and 3. an acid catalyst cross-linking aid selected from the group consisting of inorganic and organic salts, organic acid, and amine-acid addition salts, said polymer comprising from 2% to 16% by weight, and said filler from 50% to 90% by weight of the total aqueous composition and wherein said composition is a non-hydraulic mortar.

Claim 35

A method of grouting tile which comprises: assembling on a substrate a plurality of ceramic tiles in edge-to-edge relationship with spaces between the tiles; and filling the spaces between the tiles with an aqueous grouting composition having a viscosity in the range of 10,000 to 1,200,000 cps comprising 1. a film-forming, room temperature cross-linkable polymer in the form of an emulsion, suspension, dispersion or partial solution, having reactive substituents on the polymer chain selected from the group consisting of epoxy, hydroxy, methylol, carboxy, ester, α-olefin, isocyanate, methylol acrylamide, amino, N-methylol amide, internal double bond and combinations thereof wherein said reactive substituents are capable of reacting at room temperature to cross-link said polymer, 2. a water-insoluble filler, and 3. an acid catalyst cross-linking aid selected from the group consisting of inorganic and organic salts, organic acid, and amine-acid addition salts, said polymer comprising from 2% to 16% by weight, and said filler from 50% to 90% by weight of the total aqueous composition and wherein said composition is a non-hydraulic mortar.

Claim 36

A method of setting ceramic tile which comprises applying to a substrate and/or the backs of ceramic tiles a mortar composition having a viscosity in the range of 10,000 to 1,200,000 cps comprising 1. a film-forming, room temperature cross-linkable polymer in the form of an emulsion, suspension, dispersion or partial solution, having reactive substituents on the polymer chain selected from the group consisting of epoxy, hydroxy, methylol, carboxy, ester, α-olefin, isocyanate, methylol acrylamide, amino, N-methylol amide, internal double bond and combinations thereof wherein said reactive substituents are capable of reacting at room temperature to cross-link said polymers, 2. a water-insoluble filler, and 3. an acid catalyst cross-linking aid selected from the group consisting of inorganic and organic salts, organic acid, and amine acid-addition salts, said polymer comprising from 2% to 16% by weight, and said filler from 50% to 90% by weight of the total aqueous composition and wherein said composition is a non-hydraulic mortar; and placing a plurality of said ceramic tiles in an edge-to-edge relationship over said substrate.

Claim 37

A method of setting ceramic tile which comprises applying to a substrate and/or the backs of ceramic tiles a mortar composition having a viscosity in the range of 10,000 to 1,200,000 cps comprising 1. a film-forming, room temperature cross-linkable polymer in the form of an emulsion, suspension, dispersion or partial solution, having reactive substituents on the polymer chain selected from the group consisting of epoxy, hydroxy, methylol, carboxy, ester, α-olefin, isocyanate, methylol acrylamide, amino, N-methylol amide, internal double bond and combinations thereof wherein said reactive substituents are capable of reacting at room temperature to cross-link said polymers, 2. a water-insoluble filler, and 3. an acid catalyst cross-linking aid selected from the group consisting of inorganic and organic salts, organic acid, and amine acid-addition salts, said polymer comprising from 2% to 16% by weight, and said filler from 50% to 90% by weight of the total aqueous composition and wherein said composition is a non-hydraulic mortar; and placing a plurality of said ceramic tiles in an edge-to-edge relationship over said substrate.