US4118241A
Expired / Lapsed
US
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Mortar compositions and method of making same
Assignee: Tile Council of America Inc
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Filing: 1976-07-27
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Granted: 1978-10-03
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Expires: 1996-07-27
Abstract
Abstract This invention relates to improved hydraulic cement mortar compositions which have the advantages of dry-set mortars and which have superior compressive strength as well as bond strength to both vitreous and non-vitreous tile.
Inventors
- 👤 Frank E. Bernett
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 22:04
CPC Classifications
C; C04; C04B; C04B28/00; C04B28/02; C04B28/04
Claims Analysis
Total Claims: 51
Claim 1
Independent Claim
121 words
A dry composition capable of being mixed with water to form a mortar, said dry composition comprising in percentages by weight of the dry composition 40 to 70 percent of an inert filler, 0.2 to 1.0 percent of a water soluble cellulose ether having a viscosity of 4,000 cps to 30,000 cps in 2 percent solution, an antifoam component present in an amount from 0.05 to 1.0 percent based upon the weight of the composition wherein said antifoam component enables the dry composition to be mixed with water by machine to form a mortar having an air content of between 5 and 20 percent based upon the volume of the mixed mortar, and a hydraulic cement in an amount to balance.
Claim 2
Dependent Claim
121 words
A dry composition capable of being mixed with water to form a mortar, said dry composition comprising in percentages by weight of the dry composition 40 to 70 percent of an inert filler, 0.2 to 1.0 percent of a water soluble cellulose ether having a viscosity of 4,000 cps to 30,000 cps in 2 percent solution, an antifoam component present in an amount from 0.05 to 1.0 percent based upon the weight of the composition wherein said antifoam component enables the dry composition to be mixed with water by machine to form a mortar having an air content of between 5 and 20 percent based upon the volume of the mixed mortar, and a hydraulic cement in an amount to balance.
Claim 3
Dependent Claim
47 words
The dry composition defined in claim 1 wherein the antifoam component is present in sufficient amounts to enable said composition to be machine mixed with water to form a mortar having an air content between 10 and 15 percent based upon the volume of the mixed mortar.
Claim 4
Dependent Claim
13 words
The dry composition of claim 1 wherein said hydraulic cement is Portland Cement.
Claim 5
Dependent Claim
30 words
The dry composition of claim 1 wherein said cellulose ether is selected from the group consisting of methyl cellulose, methyl hydroxypropyl cellulose, hydroxyethyl cellulose, and hydroxypropyl cellulose, and mixtures thereof.
Claim 6
Dependent Claim
44 words
The dry composition of claim 1 wherein there is present from 0.1 to 1.0 percent based on the weight of the dry composition of a cold water soluble polyvinyl alcohol having a viscosity of about 35 cps or greater in 4 percent aqueous solution.
Claim 7
Dependent Claim
21 words
The dry composition of claim 5 wherein the cellulose ether component is present in the range from 0.2 to 0.6 percent.
Claim 8
Dependent Claim
157 words
A dry composition capable of being mixed with water to form a mortar, said composition comprising in weight percentages based on the dry composition 50 to 70 percent of an inert filler of a fine grain size, having an AFS grain fineness number of greater than about 50, 0.2 to 0.6 percent or a water soluble cellulose ether having a viscosity of 4,000 cps to 30,000 cps in 2 percent solution, 0.1 to 1.0 percent cold water soluble polyvinyl alcohol having a viscosity of about 35 cps or greater in 4 percent aqueous solution, an antifoam component present in an amount from 0.05 to 1.0 percent based upon the weight of the composition wherein said antifoam component enables the dry composition to be mixed with water by machine to form a mortar having an air content between 5 and 20 percent by volume based upon the volume of the mixed mortar, and a hydraulic cement to balance.
Claim 9
Dependent Claim
157 words
A dry composition capable of being mixed with water to form a mortar, said composition comprising in weight percentages based on the dry composition 50 to 70 percent of an inert filler of a fine grain size, having an AFS grain fineness number of greater than about 50, 0.2 to 0.6 percent or a water soluble cellulose ether having a viscosity of 4,000 cps to 30,000 cps in 2 percent solution, 0.1 to 1.0 percent cold water soluble polyvinyl alcohol having a viscosity of about 35 cps or greater in 4 percent aqueous solution, an antifoam component present in an amount from 0.05 to 1.0 percent based upon the weight of the composition wherein said antifoam component enables the dry composition to be mixed with water by machine to form a mortar having an air content between 5 and 20 percent by volume based upon the volume of the mixed mortar, and a hydraulic cement to balance.
Claim 10
Dependent Claim
13 words
The dry composition of claim 7 wherein the hydraulic cement is Portland Cement.
Claim 11
Dependent Claim
45 words
The dry composition of claim 7 wherein the antifoam component is present in sufficient amount to enable the dry composition, when mixed with water by machine, to have an air content of between 10 and 15 percent based upon the volume of the mixed mortar.
Claim 12
Dependent Claim
30 words
The dry composition of claim 7 wherein the cellulose ether is selected from the group consisting of methyl cellulose, methyl hydroxypropyl cellulose, hydroxyethyl cellulose and hydroxypropyl cellulose, and mixtures thereof.
Claim 13
Dependent Claim
28 words
The dry composition of claim 9 wherein the weight ratio of the cellulose ether component to said polyvinyl alcohol component is in the range of 1:5 to 1:1.
Claim 14
Dependent Claim
12 words
The dry composition of claim 7 wherein said inert filler is silica.
Claim 15
Dependent Claim
27 words
The dry composition of claim 12 wherein the silica component is present in an amount from 55 to 66 percent based on the weight of the composition.
Claim 16
Dependent Claim
119 words
An aqueous mortar composition for use in setting vitreous and non-vitreous tile over porous and non-porous substrates, said composition comprising (A) a dry composition which comprises the following in weight percentages based on the dry composition: 40 to 70 percent of an inert filler, 0.2 to 1.0 percent of a water soluble cellulose ether having a viscosity of 4,000 cps to 30,000 cps in 2 percent solution, and a hydraulic cement in an amount to balance said dry composition, and (B) water wherein the air content of the aqueous composition is between 5 and 20 percent by volume and wherein the water is present in sufficient amount to give the aqueous mortar composition a workable consistency for setting tile.
Claim 17
Dependent Claim
119 words
An aqueous mortar composition for use in setting vitreous and non-vitreous tile over porous and non-porous substrates, said composition comprising (A) a dry composition which comprises the following in weight percentages based on the dry composition: 40 to 70 percent of an inert filler, 0.2 to 1.0 percent of a water soluble cellulose ether having a viscosity of 4,000 cps to 30,000 cps in 2 percent solution, and a hydraulic cement in an amount to balance said dry composition, and (B) water wherein the air content of the aqueous composition is between 5 and 20 percent by volume and wherein the water is present in sufficient amount to give the aqueous mortar composition a workable consistency for setting tile.
Claim 18
Dependent Claim
19 words
The aqueous mortar composition of claim 14 wherein said air content is between 10 and 15 percent by volume.
Claim 19
Dependent Claim
21 words
The aqueous mortar composition of claim 14 additionally comprising an antifoam component in an amount sufficient to provide said air content.
Claim 20
Dependent Claim
29 words
The aqueous mortar composition of claim 16 wherein said antifoam component is present in an amount from 0.05 to 1.0 percent based upon the weight of the dry composition.
Claim 21
Dependent Claim
14 words
The aqueous mortar composition of claim 14 wherein the hydraulic cement is Portland Cement.
Claim 22
Dependent Claim
31 words
The aqueous mortar composition of claim 14 wherein the cellulose ether is selected from the group consisting of methyl cellulose, methyl hydroxypropyl cellulose, hydroxyethyl cellulose and hydroxypropyl cellulose, and mixtures thereof.
Claim 23
Dependent Claim
45 words
The aqueous mortar composition of claim 14 wherein there is present from 0.1 to 1.0 percent based on the weight of the dry composition, of a cold water soluble polyvinyl alcohol having a viscosity of about 35 cps or greater in 4 percent aqueous solution.
Claim 24
Dependent Claim
22 words
The aqueous mortar composition of claim 20 wherein the cellulose ether component is present in the range from 0.2 to 0.6 percent.
Claim 25
Dependent Claim
26 words
The aqueous mortar composition of claim 14 wherein the water is present in an amount from 20 to 40 percent by weight of the dry composition.
Claim 26
Dependent Claim
158 words
An aqueous mortar composition for use in setting vitreous and non-vitreous tile over porous and non-porous substrates, said composition comprising (A) a dry composition which comprises the following in weight percentages based on the dry composition: 50 to 70 percent of an inert filler of a fine grain size, having an AFS grain fineness number of greater than about 50, 0.2 to 0.6 percent of a water soluble cellulose ether having a viscosity of 4,000 cps to 30,000 cps in 2 percent solution, 0.1 to 1.0 percent cold water soluble polyvinyl alcohol having a viscosity of about 35 cps or greater in 4 percent aqueous solution, and a hydraulic cement in an amount to balance said dry composition, and (B) water wherein the air content of the aqueous composition is between 5 and 20 percent by volume and wherein the water is present in sufficient amounts to give the aqueous mortar composition a workable consistency for setting tile.
Claim 27
Dependent Claim
158 words
An aqueous mortar composition for use in setting vitreous and non-vitreous tile over porous and non-porous substrates, said composition comprising (A) a dry composition which comprises the following in weight percentages based on the dry composition: 50 to 70 percent of an inert filler of a fine grain size, having an AFS grain fineness number of greater than about 50, 0.2 to 0.6 percent of a water soluble cellulose ether having a viscosity of 4,000 cps to 30,000 cps in 2 percent solution, 0.1 to 1.0 percent cold water soluble polyvinyl alcohol having a viscosity of about 35 cps or greater in 4 percent aqueous solution, and a hydraulic cement in an amount to balance said dry composition, and (B) water wherein the air content of the aqueous composition is between 5 and 20 percent by volume and wherein the water is present in sufficient amounts to give the aqueous mortar composition a workable consistency for setting tile.
Claim 28
Dependent Claim
19 words
The aqueous mortar composition of claim 23 wherein said air content is between 10 and 15 percent by volume.
Claim 29
Dependent Claim
21 words
The aqueous mortar composition of claim 23 additionally comprising an antifoam component in an amount sufficient to provide said air content.
Claim 30
Dependent Claim
29 words
The aqueous mortar composition of claim 25 wherein said antifoam component is present in an amount from 0.05 to 1.0 percent based upon the weight of the dry composition.
Claim 31
Dependent Claim
14 words
The aqueous mortar composition of claim 23 wherein the hydraulic cement is Portland cement.
Claim 32
Dependent Claim
31 words
The aqueous mortar composition of claim 23 wherein the cellulose ether is selected from the group consisting of methyl cellulose, methyl hydroxypropyl cellulose, hydroxyethyl cellulose and hydroxypropyl cellulose, and mixtures thereof.
Claim 33
Dependent Claim
26 words
The aqueous mortar composition of claim 23 wherein the water is present in an amount from 20 to 40 percent by weight of the dry composition.
Claim 34
Dependent Claim
29 words
The aqueous mortar composition of claim 23 wherein the weight ratio of the cellulose ether component to said polyvinyl alcohol component is in the range of 1:5 to 1:1.
Claim 35
Dependent Claim
13 words
The aqueous mortar composition of claim 23 wherein said inert filler is silica.
Claim 36
Dependent Claim
28 words
The aqueous mortar composition of claim 31 wherein the silica component is present in an amount from 55 to 66 percent based on the weight of the composition.
Claim 37
Dependent Claim
22 words
The aqueous mortar composition of claim 30 wherein the density of the aqueous mortar composition is between 1.6 gms/cc and 1.9 gms/cc.
Claim 38
Dependent Claim
22 words
The aqueous mortar composition of claim 33 wherein the density of the aqueous mortar composition is between 1.7 gms/cc and 1.8 gms/cc.
Claim 39
Dependent Claim
40 words
A method of installing both vitreous and non-vitreous tile, said method comprising the steps of preparing the aqueous mortar composition of claim 23, covering a substrate with a bed of said mortar, and pressing dry tile into the resulting bed.
Claim 40
Dependent Claim
20 words
The method of claim 35 wherein the bed of mortar has a thickness of from 1/32 inch to 1/4 inch.
Claim 41
Dependent Claim
23 words
The method of claim 35 wherein the bed of mortar is formed by applying the mortar to the substrate with a notched trowel.
Claim 42
Dependent Claim
27 words
The method of claim 35 wherein the aqueous mortar composition is additionally applied to the back of the dry tile before pressing it into the mortar bed.
Claim 43
Dependent Claim
46 words
A method of installing both vitreous and non-vitreous tile, said method comprising the steps of preparing the aqueous mortar composition of claim 23, applying the aqueous mortar composition to the dry backs of tile, and pressing said tile with mortar on its back onto the substrate.
Claim 44
Dependent Claim
25 words
The method of claim 39 wherein the aqueous mortar composition is applied to the dry tile back with a flat trowel or a notched trowel.
Claim 45
Independent Claim
167 words
A method of manufacturing an aqueous mortar capable of setting both vitreous and non-vitreous tile over porous and non-porous substrates, said method comprising the steps of (A) forming a dry composition comprising: 50 to 70 percent of an inert filler of fine grain size, having an AFS grain fineness number of greater than about 50, 0.2 to 0.6 percent of a water soluble cellulose ether having a viscosity of 4,000 cps to 30,000 cps in 2 percent solution, 0.1 to 1.0 percent cold water soluble polyvinyl alcohol having a viscosity of about 35 cps or greater in 4 percent aqueous solution, and a hydraulic cement in an amount to balance said dry composition, wherein said percentages are by weight of the dry mix, and (B) mixing the dry composition with water by machine to yield a homogeneous aqueous composition having an air content in the range of 5 to 20 percent based on the volume of the aqueous mortar composition and a workable consistency for setting tile.
Claim 46
Independent Claim
167 words
A method of manufacturing an aqueous mortar capable of setting both vitreous and non-vitreous tile over porous and non-porous substrates, said method comprising the steps of (A) forming a dry composition comprising: 50 to 70 percent of an inert filler of fine grain size, having an AFS grain fineness number of greater than about 50, 0.2 to 0.6 percent of a water soluble cellulose ether having a viscosity of 4,000 cps to 30,000 cps in 2 percent solution, 0.1 to 1.0 percent cold water soluble polyvinyl alcohol having a viscosity of about 35 cps or greater in 4 percent aqueous solution, and a hydraulic cement in an amount to balance said dry composition, wherein said percentages are by weight of the dry mix, and (B) mixing the dry composition with water by machine to yield a homogeneous aqueous composition having an air content in the range of 5 to 20 percent based on the volume of the aqueous mortar composition and a workable consistency for setting tile.
Claim 47
Dependent Claim
18 words
The method of claim 41 wherein said air content is in the range of 10 to 15 percent.
Claim 48
Dependent Claim
14 words
The method of claim 41 wherein the dry composition further comprises an antifoam component.
Claim 49
Dependent Claim
27 words
The method of claim 41 wherein the inert filler is silica and it is present in the dry mix in an amount between 55 and 66 percent.
Claim 50
Dependent Claim
20 words
The method of claim 41 wherein the aqueous mortar composition has a density of between 1.6 gms/cc and 1.9 gms/cc.
Claim 51
Dependent Claim
20 words
The method of claim 41 wherein the density of the aqueous mortar composition is between 1.7 gms/cc and 1.8 gms/cc.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1981-10-02 | 1982-04-03 | 1982-10-03 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1985-10-02 | 1986-04-03 | 1986-10-03 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1989-10-02 | 1990-04-03 | 1990-10-03 | $7700.00 | Window Closed / Lapsed |