Inorganic phosphate compositions and methods

Abstract

Disclosed and described are multi-component inorganic phosphate formulations of acidic phosphate components and basic oxide/hydroxide components. Also disclosed are high solids, atomizable compositions of same, suitable for spray coating.

1 . An atomizable phosphate ceramic spray system comprising
 a first component cartridge comprising an aqueous solution of an acid-phosphate of chemical formula A m (H 2 PO 4 ) m .nH 2 O, where A is hydrogen ion, ammonium cation, metal cation, or mixtures thereof; where m=1-3, and n=0-6; the first component solution adjusted to a pH of about 2 to about 5;   a second component cartridge comprising an aqueous solution of an alkaline oxide or alkaline hydroxide represented by B 2m O m , B(OH) 2m , or mixtures thereof, where B is an element of valency 2m (m=1, 1.5, or 2) the second component solution adjusted to a pH of between 9-14; and   optionally, a rheology modifier/suspending agent in an amount capable of providing shear thinning of either the first component or the second component and further capable of suspending a high solids content of either the first component or the second component for atomization; and   high shear dispersion blade; and   a plural sprayer operably connected to a pump.   
     
     
         2 . The phosphate ceramic spray system of  claim 1 , wherein the second component is at least one of magnesium hydroxide and calcium hydroxide, and water. 
     
     
         3 . The phosphate ceramic spray system of  claim 1 , wherein the first component comprises about 2 to about 10 wt % phosphoric acid, water, and at least one of mono potassium phosphate and mono calcium phosphate. 
     
     
         4 . The phosphate ceramic spray system of  claim 1 , further comprising aluminum oxide present in an amount sufficient to increase the hardness of the phosphate ceramic. 
     
     
         5 . The phosphate ceramic spray system of  claim 1 , wherein the rheology modifier/suspending agent is at least one of guar gum, diutan gum, welan gum, and xanthan gum. 
     
     
         6 . The phosphate ceramic spray system of a  claim 5 , wherein the aggregate is present in an amount of at least about 1 wt % to about 60 wt %. 
     
     
         7 . The phosphate ceramic spray system of  claim 6 , wherein the aggregate is at least one of a resin coated silica and a naturally colored mineral aggregate. 
     
     
         8 . The phosphate ceramic spray system of  claim 6 , wherein the aggregate is of an average particle size of about 20 mesh micron to about 400 mesh. 
     
     
         9 . The phosphate ceramic spray system of  claim 6 , wherein the aggregate is of an average particle size of at least about 20 mesh or less and, after application of a coating of less than about 20 mil, substantially retains the aggregate in the coating on a vertical surface or an overhead surface. 
     
     
         10 - 48 . (canceled) 
     
     
         49 . An inorganic phosphate compound of the general formula:
 i) B s (A 3-m PO 4 ) s ; wherein A has a valency of m=1 or 2; and B has a valency of s=1, or 2;   ii) B s (A (2/m) )PO 4 ) s ; wherein A has a valency of m=1 or 2; B has a valency of s=1, or 2;   iii)  (2/m) A 3 B m (PO 4 ) 2 ; wherein A has a valency of m=1 or 2; B has a valency of 3; or   iv) B(AOPO 4 ) s ; wherein A has a valency of 4 and s=1 or 2; and B has a valency of 1, or 2;   
       wherein the inorganic phosphate i-iv has at least one of the following characteristics:
 a) a substantially reduced amount of calcined alkali/alkali earth oxide particles present as measured b x-ray diffraction; or 
 b) a reduced crystalline morphology as measured by x-ray diffraction relative to a compositionally similarly inorganic phosphate ceramic or ceramic or, 
 c) a reduced density, relative to a compositionally similarly inorganic phosphate ceramic. 
 
     
     
         50 . The inorganic phosphate compound of  claim 49 , wherein the density is less than 1.8 g/cm 3 . 
     
     
         51 . The inorganic phosphate compound of  claim 49 , wherein the density is less than 1.5 g/cm 3 . 
     
     
         52 . The inorganic phosphate compound of  claim 49 , wherein the compound is at least one ofthe following: MgKPO 4 ; Mg(ZnPO 4 ) 2 Mg(K 2 PO 4 ) 2 ; Mg 2 KPO 4 ; Mg(ZnPO 4 ) 2 ; Mg(K 2 PO 4 ) 2 ; Al 2 Mg 3 (PO 4 ) 2 ; Mg(ZrOPO 4 ) 2 ; Mg[Zr(OH) 2 PO 4 ) 2 ] 2 ; and calcium/magnesium phosphate. 
     
     
         53 - 64 . (canceled)