Claims
- 1. An earthen plaster formulation comprising:
at least two clays; and at least one aggregate.
- 2. The plaster formulation of claim 1 wherein at least one of said clays comprises kaolin.
- 3. The plaster formulation of claim 2 wherein said kaolin comprises up to approximately 30% by weight.
- 4. The plaster formulation of claim 3 comprising between approximately 2.7 and 24% by weight of kaolin.
- 5. The plaster formulation of claim 4 comprising between approximately 5% and 19% by weight of kaolin.
- 6. The plaster formulation of claim 5 comprising between approximately 7.3% and 16% by weight of kaolin.
- 7. The plaster formulation of claim 6 comprising between approximately 8.7% and 15.2% by weight of kaolin.
- 8. The plaster formulation of claim 1 wherein at least one of said clays comprises ball clay.
- 9. The plaster formulation of claim 8 wherein said ball clay comprises up to approximately 30% by weight.
- 10. The plaster formulation of claim 9 comprising between approximately 2.7 and 24% by weight of ball clay.
- 11. The plaster formulation of claim 10 comprising between approximately 5% and 19% by weight of ball clay.
- 12. The plaster formulation of claim 11 comprising between approximately 7.3% and 16% by weight of ball clay.
- 13. The plaster formulation of claim 12 comprising between approximately 8.7% and 15.2% by weight of ball clay.
- 14. The plaster formulation of claim 1 wherein at least one of said clays comprises fireclay.
- 15. The plaster formulation of claim 14 wherein said fireclay comprises up to approximately 30% by weight.
- 16. The plaster formulation of claim 15 comprising between approximately 2.7 and 24% by weight of fireclay.
- 17. The plaster formulation of claim 16 comprising between approximately 5% and 19% by weight of fireclay.
- 18. The plaster formulation of claim 17 comprising between approximately 7.3% and 16% by weight of fireclay.
- 19. The plaster formulation of claim 18 comprising between approximately 8.7% and 15.2% by weight of fireclay.
- 20. The plaster formulation of claim 1 wherein at least one of said clays comprises an expanding clay.
- 21. The plaster formulation of claim 20 wherein said expanding clay comprises up to approximately 5% by weight.
- 22. The plaster formulation of claim 21 comprising between approximately 0.5% and 3.9% by weight of said expanding clay.
- 23. The plaster formulation of claim 22 comprising between approximately 1.3% and 3.4% by weight of said expanding clay.
- 24. The plaster formulation of claim 23 comprising between approximately 2.1% and 2.75% by weight of said expanding clay.
- 25. The plaster formulation of claim 2 further comprising ball clay.
- 26. The plaster formulation of claim 2 further comprising fireclay.
- 27. The plaster formulation of claim 2 further comprising an expanding clay.
- 28. The plaster formulation of claim 25 further comprising fireclay.
- 29. The plaster formulation of claim 25 further comprising an expanding clay.
- 30. The plaster formulation of claim 26 further comprising an expanding clay.
- 31. The plaster formulation of claim 28 further comprising an expanding clay.
- 32. The plaster formulation of claim 8 further comprising fireclay.
- 33. The plaster formulation of claim 32 further comprising an expanding clay.
- 34. The plaster formulation of claim 8 further comprising an expanding clay.
- 35. The plaster formulation of claim 14 further comprising an expanding clay.
- 36. The plaster formulation of claim 1 further comprising a color additive.
- 37. The plaster formulation of claim 36 wherein said color additive comprises a powder pigment.
- 38. The plaster formulation of claim 36 comprising between approximately 0.1% and 10% by weight of said color additive.
- 39. The plaster formulation of claim 36 wherein said color additive comprises at least one member selected from the group consisting of Burnt Sienna, Raw Sienna, Yellow Oxide, Black Earth, and Green Earth.
- 40. The plaster formulation of claim 1 further comprising an acid.
- 41. The plaster formulation of claim 40 wherein said acid comprises as least one, but is not limited to, acid selected from the group consisting of borax-decahydrate, boric acid, acetic acid, and citric acid.
- 42. The plaster formulation of claim 41 comprising between approximately 1% and 7% by weight of said acid.
- 43. The plaster formulation of claim 1 wherein said aggregate comprises at least one aggregate selected from the group consisting of sand, silt, silica, calcined clay, grog, marble dust, and shell sand.
- 44. The plaster formulation of claim 1 wherein said aggregate comprises calcium carbonate.
- 45. The plaster formulation of claim 1 wherein said aggregate has a size range of between approximately 1000 microns and 5 microns.
- 46. The plaster formulation of claim 1 comprises up to approximately 76% by weight of said aggregate.
- 47. The plaster formulation of claim 46 wherein said aggregate comprises between approximately 5% and 75% by weight of said aggregate.
- 48. The plaster formulation of claim 47 comprising between approximately 10% and 74% by weight of said aggregate.
- 49. The plaster formulation of claim 48 comprising between approximately 15% and 73% by weight of said aggregate.
- 50. The plaster formulation of claim 49 comprising between approximately 18.4% and 72% by weight of said aggregate.
- 51. The plaster formulation of claim 1 further comprising a fiber.
- 52. The plaster formulation of claim 51 wherein said fiber comprises at least one member selected from the group consisting of straw, hair, plant fibers, organic fibers and non-organic fibers.
- 53. The plaster formulation of claim 51 comprising up to approximately 5% by weight of said fiber.
- 54. The plaster formulation of claim 53 comprising between approximately 0.5% and 4% by weight of said fiber.
- 55. The plaster formulation of claim 54 comprising between approximately 1% and 3.5% by weight of said fiber.
- 56. The plaster formulation of claim 55 comprises between approximately 1.4% and 3.1% by weight of said fiber.
- 57. The plaster formulation of claim 1 comprises between approximately 0% and 30% by weight of kaolin, between approximately 0% and 30% by weight of ball clay by weight, between approximately 0% and 30% by weight of fireclay, between approximately 0% and 5% by weight of said expanding clay, between approximately 0% and 76% by weight of said aggregate, and between approximately 0% and 5% by weight of said fiber, wherein at least two clays present in said formulation are greater than 0% by weight.
- 58. The plaster formulation of claim 57 comprising between approximately 2.7% and 24% by weight of kaolin, between approximately 2.7% and 24% by weight of ball clay, between approximately 2.7% and 24% by weight of fireclay, between approximately 0.5% and 3.9% by weight of said expanding clay, between approximately 5% and 75% by weight of said aggregate, and between approximately 0.5% and 4% by weight of said fiber.
- 59. The plaster formulation of claim 58 comprising between approximately 5% and 19% by weight of kaolin, between approximately 5% and 19% by weight of ball clay, between approximately 5% and 19% by weight of fireclay, between approximately 1.3% and 3.4% by weight of said expanding clay, between approximately 10% and 74% by weight of said aggregate, and between approximately 1% and 3.5% by weight of said fiber.
- 60. The plaster formulation of claim 59 comprising between approximately 7.3% and 16% by weight of kaolin, between approximately 7.3% and 16% by weight of ball clay, between approximately 7.3% and 16% by weight of fireclay, between approximately 1.7% and 2.9% by weight of said expanding clay, between approximately 15% and 73% by weight of said aggregate, and 1.4% and 3.1% of said fiber.
- 61. The plaster formulation of claim 60 comprising between approximately 8.7% and 15.2% by weight of kaolin, between approximately 8.7% and 15.2% by weight of ball clay, between approximately 8.7% and 15.2% by weight of fireclay, between approximately 2.1% and 2.75% by weight of said expanding clay, between approximately 18.4% and 72% by weight of said aggregate, and up to approximately 1.4% by weight of said fiber.
- 62. The plaster formulation of claim 1 further comprising a decorative element.
- 63. The plaster formulation of claim 1 further comprising a sealant.
- 64. The plaster formulation of claim 63 wherein said sealant comprises at least one member selected from the group consisting of modern chemical plaster sealants, natural sealants, cactus juice, and milk paint.
- 65. A method for the application of an earthen plaster formulation, the method comprising the steps of:
providing a plaster comprising of at least two clays and at least one aggregate; and applying the plaster to a surface.
- 66. The method of claim 65 wherein the step of applying the plaster to a surface comprises applying it to a new surface.
- 67. The method of claim 65 wherein the step of applying the plaster to a surface comprises applying it to an existing surface.
- 68. The method of claim 65 wherein the step of applying the plaster to a surface comprises applying the plaster to an interior surface.
- 69. The method of claim 65 wherein the step of applying the plaster to a surface comprises applying the plaster to an exterior surface.
- 70. The method of claim 65 wherein the step of applying the plaster to a surface comprises using at least one plastering technique selected from the group consisting of hand troweling, floating with a sponge or brush, and traditional drywalling techniques.
- 71. The method of claim 65 wherein the step of applying the plaster to a surface further comprising the step of finishing.
- 72. The method of claim 65 wherein the step of applying the plaster to a surface further comprising the step of applying a base layer.
- 73. The method of claim 65 wherein the step of applying the plaster to a surface further comprising the step of applying a bonding layer.
- 74. The method of claim 65 wherein the step of applying the plaster to a surface further comprising the step of applying a coarse layer.
- 75. The method of claim 65 wherein the step of applying the plaster to a surface further comprising the step of applying a finish layer.
- 76. The method of claim 65 further comprising the steps of storing the plaster and rewetting and applying the stored plaster to the surface at a later date.
- 77. The method of claim 76 wherein the step of applying the stored plaster to the surface at a later date resulting in no substantial color difference from the prior applied clay plaster.
- 78. The method of claim 76 wherein the step of storing the plaster formulation comprises storing between approximately weeks, months and years.
- 79. The method of claim 65 wherein the step of applying the plaster comprises wetting previously applied plaster and applying the rewetted plaster to the surface.
- 80. The method of claim 65 wherein the step of applying the plaster to a surface comprises directly applying the plaster to plaster board.
- 81. The method of claim 65 wherein the step of applying the plaster to a surface comprises directly applying the plaster to a breathable wall system as a bonding layer.
- 82. The method of claim 65 wherein the step of applying the plaster to a surface further comprises directly applying the plaster to a breathable wall system as a finish layer.
- 83. The method of claim 65 wherein the step of applying the plaster to a surface comprises applying the plaster to a painted base.
- 84. The method of claim 65 wherein the step of applying the plaster to a surface comprises applying the plaster to a painted base used in conjunction with a sanded primer.
- 85. The method of claim 84 wherein the sanded primer comprises a commercially available primer with sanded texture.
- 86. The method of claim 65 wherein the step of applying the plaster to a surface comprises directly applying the plaster to porous masonry.
- 87. The method of claim 65 further comprising the step of adding calcined plaster to the plaster formulation.
- 88. The method of claim 65 further comprising the step of adding a sealant to the plaster formulation.
- 89. The method of claim 65 further comprising the step of adding fiber to the plaster formulation.
- 90. The method of claim 65 further comprising the step of adding a color pigment to the plaster formulation.
- 91. The method of claim 65 further comprising the step of adding an acid to the plaster formulation.
- 92. The method of claim 65 further comprising the step of adding an artistic detail to the applied plaster.
- 93. The method of claim 92 wherein the step of adding an artistic detail comprises stamping the applied plaster.
- 94. The method of claim 92 wherein the step of adding and artistic detail further comprises the step of building up the applied plaster.
- 95. The method of claim 65 wherein the step of providing the plaster formulation comprises providing between approximately 0% and 30% by weight of kaolin, between approximately 0% and 30% by weight of ball clay, between approximately 0% and 30% by weight of fireclay, between approximately 0% and 5% by weight of the expanding clay, up to approximately 76% by weight of the aggregate, and between approximately 0% and 5% by weight of the fiber, wherein at least two clays present in said formulation are greater than 0% by weight.
- 96. The method of claim 95 wherein the step of providing the plaster formulation comprises providing between approximately 2.7% and 24% by weight of kaolin, between approximately 2.7% and 24% by weight of ball clay, between approximately 2.7% and 24% by weight of fireclay, between approximately 0.5% and 3.9% by weight of the expanding clay, between approximately 5% and 75% by weight of the aggregate, and between approximately 0.5% and 4% by weight of the fiber.
- 97. The method of claim 96 wherein the step of providing the plaster formulation comprises providing between approximately 5% and 19% by weight of kaolin, between approximately 5% and 19% by weight of ball clay, between approximately 5% and 19% by weight of fireclay, between approximately 1.3% and 3.4% by weight of the expanding clay, between approximately 10% and 74% by weight of the aggregate, and between approximately 1% and 3.5% by weight of the fiber.
- 98. The method of claim 97 wherein the step of providing the plaster formulation comprises providing between approximately 7.3% and 16% by weight of kaolin, between approximately 7.3% and 16% by weight of ball clay, between approximately 7.3% and 16% by weight of fireclay, between approximately 1.7% and 2.9% by weight of the expanding clay, between approximately 15% and 73% by weight of the aggregate, and between approximately 1.4% and 3.1% by weight of the fiber.
- 99. The method of claim 98 wherein the step of providing the plaster formulation comprises providing between approximately 8.7% and 15.2% by weight of kaolin, between approximately 8.7% and 15.2% by weight of ball clay, between approximately 8.7% and 15.2% by weight of fireclay, between approximately 2.1% and 2.75% by weight of the expanding clay, between approximately 18.4% and 72% by weight of the aggregate, and up to approximately 1.4% by weight of the fiber.
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing of U.S. Provisional Patent Application Serial No. 60/389,562, entitled “Clay Plaster”, filed on Jun. 17, 2002 and the specification thereof is incorporated herein by reference.
Provisional Applications (1)
|
Number |
Date |
Country |
|
60389562 |
Jun 2002 |
US |