GYPSUM CEMENT COMPOSITION AND ARTICLES FORMED THEREOF

Abstract

A composition for forming moulded mantels, columns and other decorative enhancement to fireplace openings is formed of a mixture of alpha hemihydrate gypsum plaster, cement, filler and milled fiber. By using this composition with water and acrylic binder a mixture is formed which sets and gains strength quickly and is an ideal material for manufacturing architectural and decorative structures. Advantageously, a casted piece can be removed from a mould within two to three hours after casting. The finished product has a desired finish that is similar to a casted gypsum cement, referred to sometimes as a honed finish which can withstand high heat, discoloration and cracking while maintaining suitable strength when exposed to typical temperatures of a fireplace surround in indoor applications.

Claims

1. A gypsum cement composition, comprising: gypsum plaster 10%-45% by weight; cement; micronized filler of at least 80 mesh; and, milled fibre, wherein the total amount of cement and filler combined is at least 50% by weight and less than or equal to 90% by weight, and wherein the amount of cement is at least 10% or more by weight, and wherein the amount of filler is less than or equal to 85% by weight.

2. A gypsum cement composition as defined in claim 1, including water and/or acrylic binder.

3. A gypsum cement composition as defined in claim 1, wherein the gypsum is alpha or beta gypsum hemihydrate.

4. A gypsum cement composition as defined in claim 3, wherein the milled fibre is milled cotton or milled glass fibres.

5. A gypsum cement composition as defined in claim 3, wherein the gypsum plaster is alpha or beta hemihydrate gypsum plaster and is about 25-38% by weight.

6. A gypsum cement composition as defined in claim 5, wherein the cement is about 20-50% by weight.

7. A gypsum cement composition as defined in claim 6, wherein the cement is calcium aluminate cement or Portland cement and is 25-40% by weight.

8. A gypsum cement composition as defined in claim 7, wherein the micronized filler in powder form has a mesh size greater or equal to about 120, and about 20-50% by weight.

9. A gypsum cement composition as defined in claim 7, wherein the milled glass or cotton fibres are of a length of about 1/32″-½″.

10. A gypsum cement composition as defined in claim 4, wherein the milled glass or cotton fibres are 1-6% by weight and wherein the composition excludes sand.

11. A gypsum cement composition as defined in claim 7, further comprising a set retarder.

12. A gypsum cement composition as defined in claim 7 wherein the gypsum plaster is 30% +/−6% by weight.

13. A gypsum cement composition as defined in claim 7, wherein the calcium aluminate cement or Portland cement is about 33.5%+/−5% by weight.

14. The gypsum cement composition as defined in claim 1, mixed with water or water and acrylic binder, wherein the water or acrylic binder to powder ratio is: one part water or water and acrylic binder with 3.45 to 6 parts of the composition by weight for preferred results.

15. The gypsum cement composition as defined in claim 12, wherein the filler in powder form has a mesh size of 140 or more and wherein the milled fibre is glass or cotton fibre is and is 3.5%+/−2% by weight.

16. The gypsum cement composition as defined in claim 13, wherein the filler in powder form has a mesh size of 140 or more and wherein the milled fibre is glass or cotton fibre is and is 3.5%+/−2.5% by weight, and wherein the composition is mixed with water or water and acrylic binder, wherein the water or acrylic binder to powder ratio is: one part water or water and acrylic binder with 3.45 to 6 parts of the composition by weight for preferred results.

17. The gypsum cement composition as defined in claim 16, wherein the filler is nepheline syenite.

18. The gypsum cement composition as defined in claim 13, in the absence of sand.

19. A method of forming an object comprising: providing a slurry of gypsum plaster 20% to 45%; cement; micronized filler; and, milled fibre into a mould to form a first layer, and after the first layer sets, applying a second backup layer over the set first layer.

20. The method as defined in claim 19, wherein the slurry is packed and wherein the gypsum plaster is alpha or beta hemihydrate gypsum plaster about 20-38% by weight, the cement is calcium aluminate cement or Portland cement about 20-50% by weight, the milled fibre is of a length of about 1/32″-½″ and is about 1-6% by weight, and wherein the filler has a mesh size of 120 or more.

21. An object formed of the composition defined in claim 1, wherein the gypsum is alpha or beta hemihydrate gypsum plaster about 25-38% by weight; the cement is calcium aluminate cement or Portland cement 20-50% by weight; the filler is in powder form having a mesh size from about 120 or greater and about 20-50% by weight, and wherein the milled fibre is milled glass or cotton having a fibre length of about 1/32″-½″ and is about 1-6% by weight.

22. An object as defined in claim 21, wherein the composition is absent sand.

Description

DETAILED DESCRIPTION

[0038] A composition described hereafter can be used to mould articles and these moulded articles, such as fireplace mantles can withstand heat of at least 400 degree Fahrenheit.

[0039] It should be understood that using different fillers can generate different attribution. The particular form of glass fibre, which can be in numerous forms, can affect the finished surface.

[0040] This composition is recommended for indoor use only.

[0041] Milled fibre is preferable to regular chopped fibre. Chopped fibre, which can be seen at the surface is deleterious to the appearance of the finished product. I have discovered that it takes less effort to mix the composition when milled fibres are used compared to chopped fibre, as the milled fibres are already substantially separated.

[0042] Glass fibers are preferred because there is a strong chemical bond between glass fibre and cement. In situations where glass is not desired, cotton fibre is a suitable choice.

[0043] The cross sectional diameter of a single strand of milled fibre is 5 to 13 microns, which are very difficult if not impossible to see, while the cross sectional diameter of a regular chopped fibre when it is not separated, can be up to 2 mm. Therefore, milled fibres are preferred.

[0044] Three aspects specific to this invention comprise:

[0045] a) The use of micronized filler, preferably nepheline syenite instead of rough sand. This fine nepheline syenite assists in providing a very smooth finish similar to pure alpha gypsum plaster. Nepheline syenite is also relatively safe if inhaled compared to other fillers.

[0046] b) The use of milled fibre instead of chopped fibre so as to substantially invisibly reinforce while preventing cracking.

[0047] c) Adding gypsum in the cement base slurry to set fast and let de-moulding the piece in a very short cycle.

[0048] It is preferred that no sand is added to the mixture of this invention, as it is deleterious to the finish.

[0049] Using more than about 40% by weight of gypsum can result in discoloration in the presence of heat at high temperatures. If the gypsum is less than about 20% by weight, de-moulding and polish-ability will be poor; the more gypsum, the more product-ability and early strength. I have discovered that alpha gypsum yields a much better result than beta gypsum. I have also found that the best finish comes from the fine nepheline syenite filler. It is the synergistic combination of these elements that provides a product having a preferred look, feel and strength and longevity not found elsewhere. Thus it is preferred to have the percent by weight of gypsum no more than about 38% and no less than about 25%.

[0050] Of course pigment can be added to the mixture, for example iron oxide to change the color, however the mixture with pigment added will itself not change color in the presence of heat when used, for example as a fireplace surroundings.

[0051] There are several advantages using the mixture of this invention. After casting, there is little to no expansion or shrinkage, wherein alpha and beta gypsum plaster expands after setting and GFRC or other cement base casts generally shrink. Using about 30% gypsum, and not significantly more, appears to prevent expansion, and using not significantly less than 30% gypsum appears to prevent shrinkage.

[0052] Another advantage of this invention is that it allows packing to be done in two steps. Typically, when using alpha gypsum plaster, a first slurry with pigment is mixed and is packed into the mould and this is called the face. Because a hollow product is made and the slurry is not poured, it is packed using a dough-like thick slurry. Immediately after the first face layer sets, usually within 15-20 minutes, a second layer called backup layer is applied. A mesh and other supporting material is placed in or on the second layer; this second layer is comprised of the same material without pigment added. This cannot be done using GFRC easily, or at all, as the first layer is not strong enough in the same day to do the backup layer. Therefore in the instant composition of this invention allows packing the same way as with alpha gypsum. I have also found, that because super plasticizer is not used for required in the mix, the workability is improved.

[0053] Adding milled fibre in the mixture improves the bending strength and allows thinner and lighter products to be made. Advantageously, use of the fine filler prevents or lessens efflorescence. nd yet another advantage of this invention is that most cement base concrete, including GFRC, will face hairline cracks several months after casting even without heating, but the composition of the instant invention is substantially crack resistant.

[0054] Numerous other embodiments may be envisaged without departing from the spirit and scope of the invention.