Encapsulating material for asbestos tile

A self-levelling continuous coating composition is disclosed. The composition is adapted for application on a surface of flooring material which contains asbestos. The composition encapsulates the hazardous material there in the floor and allows the addition of another layer of flooring to be installed thereover. The composition is comprised of about 40-55 parts by weight of a latex emulsion binder; about 2-7 parts by weight antifreeze; about 38-53 parts by weight hollow ceramic microspheres; and about 6-16 parts by weight water. The resulting composition can be applied in a single step application and does not require mixing of separate ingredients at the workplace.

BACKGROUND OF THE INVENTION 
This invention pertains to the art of protective coatings, and more 
particularly to the art of protective coatings for flooring tiles 
containing hazardous materials. It will be appreciated, however, that the 
invention has broader applications and may be advantageously employed in 
other environments such as in connection with coating non-flooring 
surfaces. 
Many preexisting floors contain materials which have in recent years been 
determined to be hazardous. Asbestos, a known carcinogen, is among the 
more prevalent hazardous materials found in flooring. Removing asbestos 
materials from existing structures has become a rather undesirable 
undertaking for health, safety and economic reasons. Extreme care must be 
taken during its removal to avoid contact or ingestion by humans. 
In an effort to avoid the hazards and expense involved with removing 
asbestos flooring, it has become known to encapsulate asbestos-containing 
floors with encapsulating or coating materials having qualities which 
allow for safely maintaining existing flooring in place. While known 
encapsulating materials offer many benefits, as will be discussed below, 
prior art encapsulating materials are not without disadvantages. 
For example many of the encapsulants for coating existing materials must be 
mixed or prepared at the work site. This can lead to a lack of consistency 
of the encapsulant, and substantially reduce the encapsulant's 
effectiveness. 
In addition, encapsulating materials of the prior art typically require 
multiple steps in application. Those which have been known to require a 
single step application are comprised of an elastomeric polymer-moisture 
cured polyurethane. These, however, have proven to have a very short shelf 
life. Moreover, these moisture cured polyurethanes do not provide 
encapsulating properties until they are covered with a layer of sheet 
goods. 
The EPA has issued a number of minimum requirements which must be met for 
asbestos encapsulating materials. For example, the EPA requires that 
asbestos fibers be sealed or locked in by either bridging over the 
surface, or penetrating into the matrix of the asbestos containing 
material. The encapsulator is not to include any toxic substances, nor 
should it reduce significantly the fire retardant properties of the 
underlying material. The encapsulating materials are to be applied with a 
minimum of effort and technical skill, and must have a sufficient impact 
resistance, flexibility, and resistance to penetration in order to 
withstand moderate physical contact. In addition, it is important that the 
resulting encapsulating composition be water insoluble once it has been 
cured, and that it is non-toxic and without noxious fumes during 
application. Finally, among the requirements set forth by the EPA, the 
encapsulating compound should have aging characteristics which permit it 
to withstand normal atmosphere changes for a minimum of six years while 
still maintaining sufficient surface integrity to allow recoating. 
The material of the present invention meets and/or exceeds all of the 
requirements outlined above as propounded by the EPA. 
With the above requirements in mind, it is desirable that an encapsulating 
material be developed which offers ease of installation, i.e., one that 
permits a single step application. Since the existing flooring may be 
uneven and full of imperfections, dents and ridges, it is desirable that 
the encapsulating compound be self-levelling. Also, the encapsulant should 
be one that will permit the installation of a new layer of flooring 
thereon such that it will bond with the adhesive used in installing the 
new flooring. 
The encapsulating material should be capable of forming a continuous sheet 
to prevent asbestos exposure. Along these lines, the material should be 
sufficiently strong to prevent wear and, thus, re-exposure of asbestos. 
Finally, it is desirable to develop an encapsulating material having a 
reasonable shelf life. 
The present invention contemplates a new and improved encapsulating 
compound which overcomes all of the above-referred problems and others and 
provides a self-levelling, continuous asbestos encapsulating compound 
which is an economical alternative to removing existing flooring. 
The formulation provides a permanent coating which adheres firmly to the 
surface of flooring materials to seal in any hazardous materials such as 
asbestos. The formulation provides a strong, water resistant, nonporous 
coating which does not require combination with other products before use. 
Moreover, the coating formulation eliminates the need to dispose of 
hazardous waste and does not interfere with the drying of subsequent 
flooring layers added thereto. The composition requires a minimal effort 
to spread, and minimal surface preparation before application. Finally, 
the product provides an easy clean up. 
BRIEF DESCRIPTION OF THE INVENTION 
In accordance with the present invention, there is provided a 
self-levelling continuous coating composition adapted for application on a 
surface of flooring material containing a hazardous substrate, such as 
asbestos, in order to encapsulate the hazardous material therein. 
In accordance with a more limited aspect of the invention, a self-levelling 
continuous coating composition is provided. The coating composition can be 
applied in a single step to a surface of flooring material which contains 
asbestos. The encapsulating material coats the existing flooring and is 
sufficiently strong to prevent wearing away and re-exposure of asbestos. 
The composition permits the installation of a new layer of flooring 
material over the old asbestos-containing flooring. 
The composition comprises about 40-55 parts by weight of a liquid latex 
emulsion binder, about 2-7 parts by weight of antifreeze, about 38-53 
parts by weight of hollow ceramic microspheres and about 6-16 parts by 
weight of water. Additional components of the composition may include 
surfactants such as emulsifiers and wetting agents, an anti-foaming agent, 
a preservative, a coalescing agent and a plasticizer. The components are 
all mixed together and applied to a preexisting asbestos-containing floor 
in a single step application. 
A principal advantage of the invention is that it provides an economical 
method for asbestos abatement that ensures health and safety, and is 
economically desirable. 
Another advantage of the present invention is that it offers a simple 
alternative to asbestos removal. It can be applied to existing flooring in 
a single step, and new flooring can be installed thereon. 
Yet another advantage of the present invention is that it provides an 
encapsulating material that is continuous and self-levelling. 
Still other advantages and benefits of the invention will become apparent 
to those skilled in the art upon a reading and understanding of the 
following detailed description.

DETAILED DESCRIPTION OF THE INVENTION 
The present invention is directed to an asbestos encapsulator. The asbestos 
encapsulator could likewise be referred to as a tile encapsulator, 
embossing leveler or liquid underlayment for reasons which will become 
more apparent in the following discussion. 
As stated above, worn out tile or resilient floor covering which contains 
asbestos must be replaced. Since asbestos is a carcinogen, the 
Environmental Protection Agency has mandated that whenever asbestos is 
being handled, certain precautions must be taken to protect workers as 
well as the environment. Such safeguards apply to a number of situations 
including the removal of asbestos floor coverings. The removal and 
disposal of such hazardous material is very dangerous and expensive. 
Manufacturers of resilient floor coverings are, therefore, now recommending 
that existing asbestos-containing floors be left in place. They also 
suggest that an embossed asbestos-containing floor be filled with a skim 
coat of embossing leveller followed by sealing the asbestos with a layer 
of resilient floor covering. 
Unfortunately, when the new floor covering wears through, the original 
asbestos containing material is exposed. The asbestos encapsulator of the 
present invention prevents the re-exposure of the asbestos surface by 
forming a thick continuous film. The barrier film is then covered with new 
tile or resilient floor covering. 
The encapsulating material of the present invention provides for a single 
step application. Unlike many of the prior art compositions, mixing of two 
or more components is not required. 
In addition, the encapsulator of the present invention is self-levelling. 
It needs only to be spread to cover the surface. There is no need for 
troweling to form a smooth surface. The rheology of the product allows it 
to slowly flow to a smooth surface. 
Furthermore, the encapsulating product of the present invention can be 
applied in thick or thin coats. In areas where tiles are missing or the 
situation otherwise requires, a coating can be applied up to as thick as 
3/8 of an inch without adverse effect, except for an increase in drying 
time. 
The coating can be applied to thicknesses ranging from about 1/32 to 5/8 of 
an inch. At thicknesses over 3/8 of an inch, however, the coating should 
be allowed at least seventy two (72) hours of drying time. Applications 
over 1/2 inch may call for as much as seven days to set. Since prolonged 
drying times beyond seven days are impractical, it is recommended that 
thick coats be applied in separate layers. A desirable application 
thickness falls in the range of about 1/16 to 1/4 inch, although a wet 
film thickness of about 1/8 inch is preferred. Thickness can be increased 
economically by applying a latex modified cement product or underlayment 
cement on top of the encapsulator. 
The product sets firm in about 4 to 5 hours, although it is recommended 
that 24-48 hours elapse before physical pressure (such as walking) is 
applied. Under normal conditions, new flooring such as tile, vinyl floor 
covering or carpeting, can be installed over the dried coating after 48 
hours of drying time. Conditions which inhibit the evaporation of water, 
such as low temperature, high humidity, thick film and lack of 
ventilation, will reduce the rate of drying. Conversely, conditions which 
promote evaporation of water will increase the rate of drying. 
The encapsulator is not prone to cracking, porosity or other film property 
deterioration which one might expect to see in the prior art encapsulating 
coatings. Moreover, the encapsulating composition of the present invention 
is both strong and flexible. While floor coating is typically strong 
enough to bear heavy loads, the encapsulator of the present invention 
offers added built-in impact resistance and flexibility. The ability of a 
thick film to be flexible enough to respond to normal expansion, 
contraction and twisting is the result of using a latex resin, and is 
augmented by ceramic microspheres present in the composition. 
Still further, the encapsulator product of the present invention does not 
interfere with the drying of pressure sensitive adhesives. That is, many 
pressure sensitive adhesives (PSAs) lose a substantial part of their dry 
tack when applied over cementitious products. The use of PSAs is preferred 
for installing tile over tile. 
Another important advantage of the encapsulating material of the present 
invention is that it provides a continuous film. Any discontinuities would 
be undesirable as they would provide areas where asbestos could be exposed 
and would be able to escape. In other words, unlike e.g., cement, the 
composition of the present invention is not prone to cracking and is not 
porous. 
The encapsulant can be applied to a variety of flooring materials including 
vinyl tile, vinyl sheet goods, rubber tile, wooden floors, and concrete or 
cement floors. It is recommended that the floor be thoroughly cleaned 
before applying the encapsulating coating. 
It is fully within the scope of the present invention to use the coating 
for a variety of purposes other than as an encapsulant. For instance, it 
can be used as a fire retardant coating, or as a thermal barrier to 
provide a low grade insulation. Another use for the composition is as an 
adhesive for use in connection with wood, vinyl or concrete, or simply as 
a coating for cement (e.g., for patching). Finally, the composition may 
find usefulness as a dip coating for wood, such as structural building 
timber. 
As stated, the encapsulating material of the present invention calls for a 
variety of ingredients including binders, antifreeze, hollow ceramic 
microspheres and water. Additional ingredients such as surfactants, 
anti-foaming agents, preservatives, coalescing agents and plasticizers can 
also be added in relatively small amounts. 
The encapsulator properties can be modified by altering the preparations of 
the ingredients over a wide range. The properties, which can be altered, 
include viscosity and flow, hardness and flexibility, color and 
appearance, filling properties, freeze-thaw stability, coalescence, 
cohesion, film toughness, film adhesion, density, freedom from bubbles and 
practical coating thickness. A modification of one property is likely to 
result in a change in other properties. 
Certain qualities of the encapsulator can be adjusted according to the 
material to be coated. For example, the composition can be made softer or 
more flexible if the flooring to be coated is wood. For concrete, it can 
be made harder by removing the plasticizer and/or changing to a polymer 
having a higher glass transistion temperature. Also, the coating can be 
made tougher and more impact resistant by switching to a more cohesive 
polymer such as Neoprene. The cost can be reduced by adding calcium 
carbonate which makes the coating harder and more brittle. 
The resulting formulation may be one having a solid color. In the 
alternative, it may be given a speckled appearance. The speckled 
appearance can be achieved by mixing two or more colors or blending with 
white. The speckled effect is unusual and probably results from a 
relatively large size of microspheres compared to normal paint pigments. 
This unusual property is noted for its artistic value only. For example, a 
mixture of five parts white to one part red creates a unique product which 
attracts the attention of future workers. That is, the pattern of the 
colors would provide a warning that a hazardous material such as asbestos 
is located underneath the coating. 
A binder is present in the formulation at an amount of about 40-55 weight % 
of the overall formulation. The binder is preferably a latex emulsion 
binder. A preferred binder is polyvinyl acetate homopolymer emulsion, 
although other latex binding materials such as polychloroprene, acrylics, 
ethylene vinyl acetate, vinyl acrylic, acrylonitrile, terpolymers and 
copolymeric compositions can be used. 
The choice of latex emulsion binder is determinative of many of the final 
properties of the encapsulant, such as adhesion to vinyl tile, cement or 
wood. Generally, binders having a glass transition temperature (T.sub.g) 
in a range of -5.degree. C. to 55.degree. C. serve to provide ample 
hardness in relation to flexibility. Binders having lower glass transition 
temperatures are relatively flexible, while those of higher glass 
transition temperatures are more brittle. Water resistance, toughness, 
chemical resistance, impact resistance, shelf life and durability of the 
coating are a function of the chemical composition of the binder. 
Microspheres such as hollow ceramic microspheres comprise about 38-53% by 
weight of the overall encapsulating formulation. The microspheres act 
analagously to ball bearings in that they offer the encapsulant desired 
flexibility. Microspheres are hollow ceramic spheres which are chosen 
because they provide the most desirable level of flow at the highest 
solids content. The inert composition, particle size, strength and low oil 
absorption qualities are important attributes which make the microspheres 
desirable. Microspheres range from 0-300 microns in diameter and have a 
compression strength of about 3500 psi. If desired, conventional pigments 
can be substituted for the microspheres. 
Pigmentation determines to a large extent the solids volume of the coating. 
By selecting pigments having low oil absorption, a greater amount of 
pigment can be added to the encapsulating composition while still 
maintaining a reasonable viscosity and a suitable dry film. Ceramic 
microspheres and glass beads have very low oil absorption and offer such 
desirable properties as strength, crush resistance, inertness, tight 
packing, and uniformity in size. Glass beads are often used in conjunction 
with other pigments as certain adhesives do not bond well with glass. 
Other pigments may be used to lower cost, change color, adjust viscosity, 
reduce gloss, and conceal surface imperfections. 
Antifreeze is present in about 2-7% by weight of the overall composition. 
Antifreeze products assist in stabilizing the finish coating during 
freeze-thaw cycles by lowering the temperature at which a coating will 
freeze. They also influence the rate of drying. 
Glycols perform the dual purpose of acting as freeze/thaw additives and 
assisting to maintain a wet edge on the coating. Ethylene glycol is 
generally considered the most effective antifreeze component for the 
coating composition, although it is comparitively expensive. 
It is important that excessive amounts of glycol are not added. Too much 
glycol tends to slow the thorough drying of a thick coating and will 
sometimes leave an oily film on the coating surface, particularly in humid 
conditions. 
Aside from ethylene glycol, the most commonly used antifreezes are 
propylene glycol, glycol ethers, glycol ether acetates and alcohols. 
Water comprises roughly 6-16% by weight of the encapsulating formulation. 
The purpose of water is to decrease the viscosity of the resulting 
composition to enable the encapsulating coating to spread across a floor 
with relative ease. One could, of course, conceivably eliminate water as a 
part of the formulation and just include additional antifreeze. Thus the 
material would comprise only binder, microspheres and antifreeze. However, 
it is anticipated that with this type of formulation the coating would 
take too long to dry. In addition, the coating may not flow very well and 
thus may not be completely self-levelling. In other words, the water helps 
to speed the drying process of the composition and also enables the 
composition to flow better. 
In addition to the above components, the formulation may include 0-2% by 
weight of an emulsifier surfactant such as 
octylphenoxy-polyethoxy-ethanol. Also, about 0-2% by weight of a wetting 
agent surfactant such as sodium zinc phosphate inorganic polymer may be 
included. Surfactants aid in wetting and dispersing the pigment and 
wetting the surface of the substrate. Some surfactants improve wetting by 
emulsifying residual grease, oils and waxes which may remain after 
cleaning the floor. Excessive amounts of surfactants may cause foaming and 
loss of water. 
A defoamer or anti-foam agent such as petroleum hydrocarbon may be present 
up to about 2% by weight of the overall formulation. As the name implies, 
defoamers reduce the foam or bubbles entrapped in the composition. 
Excessive amounts may promote adhesion loss, so it is desirable to use the 
least amount of defoamer which is effective. Some defoaming agents lose 
strength upon aging. 
Up to about 2% by weight of a preservative such as dimethoxane may likewise 
be included in the encapsulating compositon. The preservative acts as a 
bacteriostat or fungistat. Bacteria, enzymes and fungus attempt to grow on 
or in a coating while the coating is stored in its container, or after it 
has been applied and dried. In addition, the preservative serves to 
improve the shelf life of the encapsulator. The compound has a shelf life 
of at least one year, although it is estimated that the shelf life may be 
as great as ten or twenty years. 
The choice of which preservative to use depends on the selection of binder, 
economics, and government regulations. Any preservative or combination of 
preservatives that provides desired results is likely to be satisfactory 
for use in the encapsulant composition. Sodium benzoate and benzoic acid, 
for example, are both effective at pHs of about 3-4. Mercurials, although 
toxic, provide desired results. Phenylmercuric acetate is an example of a 
mercurial which provides desired results. 
In addition, phenols can be used as preservatives. Such phenols include 
sodium-O-phenylphenate and O-phenylphenol. However, both of these products 
lose their potency upon storage. Pentachlorophenyl and 2,2 methylene bis 
(4-chlorophenol) can be effective in certain formulas. 
Halogen containing compounds can also be used as preservatives. Bromine 
compounds, though effective, are expensive. An example of a chlorine 
containing preservative product is hexachlorodimethylsulfone. Products 
containing iodine such as 3-iodo-2-propenyl butyl carbamate and 
di-iodomethyl-p-tolysufone have limited toxicology. 
Nitrogen containing compounds such as 2-(hydroxmethyl) amino ethanol, 
2-[(hydroxymethyl)amino]-2-methyl propanol, 1-(3-chloroally-3, 5, 
7-triaza-1-azoniaadamantane chloride and 1,2,-dibromo-2,4-dicyanobutane 
can be cost effective preservatives. 
Dimethoxanes such as 6-actoxy-2,4-dimethyl-m-dioxane are also useful as 
preservatives though expensive. 
Formaldehyde and products which release formaldehyde are also effective 
preservatives. Formaldehyde is, however, a suspected mutagen and 
carcinogen, and is increasingly becoming subject to government regulation. 
For these reasons, formaldehyde may be a less desirable preservative. 
Coalescing agents are materials which aid the latex emulsion particles in 
flowing together to form a complete or continuous film. A variety of 
coalescents, each having its own evaporation rate and solvency, are 
available for use in the encapsulating composition. The selected 
coalescent should be strong enough to cause the particles of emulsion to 
flow together. In addition, a suitable amount of the coalescent should 
remain after nearly all the water has evaporated. Too much or too strong a 
coalescent may cause gellation during freeze-thaw or upon aging. 
Coalescents become increasingly important as the glass transition 
temperature (T.sub.g) of the binder increases. They are available in many 
forms such as esters, alcohols, aliphatic hydrocarbons, aromatic 
hydrocarbons, ethers, etc. Up to about 3% by weight of a coalescing agent 
such as a combination of ethylene glycol phenyl ether (90%) and diethylene 
glycol phenyl ether (10%) may be present in the resulting compositon. 
Surfactants provide a broad class of compounds which can be used alone or 
in combination to modify the surface of the pigment and the surface of the 
product being coated. Surfactants can include, among others, phosphate 
esters, alkyl phenols, salts of polymeric carboxylic acid and alkyl aryl 
polyether alcohols. This list does not include all the possibilities and 
is only provided by way of example. 
Plasticizers provide an optional ingredient to the encapsulator formula. Up 
to about 3% by weight of a plasticizer such as dipropylene glycol 
dibenzoate may be added to give the coating a degree of flexibility. It 
should be noted that any plasticizing product which is compatible with the 
binder can be used in any amount which does not produce unwanted side 
effects. Plasticizers which may be used include, but are not limited to, 
glycerine, soft latexes, diethylene glycol dibenzoate, dipropylene glycol 
dibenzoate, nondrying oils, etc. 
A thickener can be added to the formulation to create a product which can 
be applied to sloped or uneven surfaces where retention of the slope is 
desired. Any thickener which serves to provide desired thickening results 
can be used. Thickeners can be included to up to 3 percent of the 
composition. Of course, one way to thicken the product is to decrease the 
water content of the product. As the viscosity increases, flow decreases. 
High viscosity produces a product which can be applied to inclined 
surfaces. 
Associative thickeners (of up to 2% of the composition) are among those 
which provide desired results. Associative thickeners are liquids which 
can be added at the job site or during manufacture. The addition of a 
thickener to the formulation creates a product having a troweling 
consistency. Other thickeners which could be used include protein 
thickeners such as Casein, and certain cellulose derivatives (of up to 1% 
of the composition) such as hydroxyethylcellulose. Acrylic polymers such 
as sodiumpolyacrylate and polyacrylic acid, polysaccharides, fumed silicas 
and expandable clays such as montmorillonite (MMT) and attapulgite may 
likewise be added. 
Some prior art coatings retard the spread of flames by not continuing to 
burn when the source of ignition is removed. Intumescent coatings add the 
property of keeping the coated surface from burning by forming a thermal 
barrier. The result is that a charred coating must be removed when the 
fire is extinguished. 
The encapsulator material of the present invention has flame retardant 
properties and shows signs of acting as a thermal barrier without the need 
to char. While the encapsulator compound does not contain any of the 
typical fire retarding agents known in the art, it has been found through 
testing to provide flame retardant properties. More specifically, a 
propane blow torch was held on the composition for thirty seconds. As soon 
as the blow torch was removed, the fire in the composition went out. While 
there was some charring of the material, there was no continuation of the 
burn. Accordingly, it is believed that the composition has fire resistant 
or fire retardant properties. 
Enhanced fire retardant properties can be obtained, if desired, with the 
addition of antimony oxide and a chlorine source like a chlorinated 
hydrocarbon. Pigments often found in fire retardant coatings are zinc 
borate, sodium borate, antimony silicon oxide, antimony oxide, halogenated 
hydrocarbon, alumina trihydrate, phosphates, phosphate esters, halogenated 
resins, monoammonia phosphate, melamine, pentaerythritol, etc. The theory 
and suggested formulas for making products fire retardant can be found in 
many texts on the subject or obtained from the manufacturer of one of the 
ingredients. Any of these techniques may be used to enhance fire retardant 
properties of the encapsulator of the present invention. Thorough testing 
is recommended since side effects are likely to occur. These side effects 
include increased smoke generation or toxic fume generation. 
The encapsulating composition of the present invention is applied to 
flooring surfaces according to a single step application. It is 
unnecessary to mix separate components at a work site. The coating can be 
troweled on or applied with a roller or even simply poured on. The film 
has cold flow properties which can be enhanced or decreased by the 
percentages of water and thickeners in the composition. 
The present invention will be more fully understood by the following 
examples: 
EXAMPLE I 
An asbestos encapsulating compound was prepared by mixing the various 
components together beginning with the liquids and ending by slowly adding 
pigment materials. The resulting material had the following composition: 
______________________________________ 
Ingredients % By Weight 
______________________________________ 
Polyvinyl Acetate Homopolymer Emulsion 
46.59% 
Octylphenoxypolyetthoxyethanol 
.14 
Sodium zinc phosphate inorganic polymer 
.14 
Petroleum hydrocarbon .27 
Dimethoxane .14 
Ethylene Glycol 2.43 
Ethylene glycol phenyl ether 90%) 
.27 
Diethylene glycol phenyl ether 10%) 
Dipropylene glycol dibenzoate 
.82 
Microspheres (white-ceramic) 
34.26 
Microspheres (red-ceramic) 
6.85 
Water 8.09 
100.00% 
______________________________________ 
The above formulation has good volume solids. 
A suspended flooring panel was coated with a 3/16" thick film of the 
encapsulator having the above composition. The panel was conditioned by 
allowing 7 days drying at ambient temperature and relative humidity. The 
coated panel was then subjected to 10 passes with a 400 lb. load on a 
crowned hard wheel having dimensions of 3" by 1 3/16". This weight 
normally ruins tile, but the encapsulator material of the above 
composition showed only minor indentation. Having passed the minimum 
requirement, the test was repeated using an 850 lbs. load. The panel by 
itself normally fails at 750 lbs. The encapsulator showed no signs of 
cracking and only minor indentations at 850 lbs. 
Next, a static load test was run to determine the failure point of the 
encapsulator. Failure is defined as the point at which the film cracks. As 
long as the film does not crack, asbestos cannot escape. Up to 1200 psi, 
the compression noted could be attributed to the underlying tile. The 
weight was then increased to 5000 lbs. psi, the limit of the static load 
machine. There was some compression, but no sign of failure of the 
encapsulator coating. In practice, a load of 1000 psi is considered 
excessive and impractical. Accordingly, the encapsulator compound of the 
present invention provides a safety factor of at least about 5 times the 
maximum expected in service. 
EXAMPLE II 
Another encapsulating composition was mixed and prepared. The resulting 
encapsulant had the following composition: 
______________________________________ 
Ingredients % By Weight 
______________________________________ 
Ethylene Vinyl Acetate Emulsion 
46.6% 
Octylphenoxypolyethoxyethanol 
.1 
Sodium zinc phosphate inorganic polymer 
.1 
Petroleum hydrocarbon .4 
Dimethoxane .1 
Ethylene glycol 2.4 
Ethylene glycol phenyl ether 90% 
.3 
Diethylene glycol phenyl ether 10% 
Dipropylene glycol dibenzoate 
.3 
Microspheres (white-ceramic) 
33.9 
Microspheres (red-ceramic) 
6.8 
Water 9.0 
100.00% 
______________________________________ 
The above formulation provides desirable results over a broad range of 
conditions. It contains a relatively soft resin with a good adhesion to 
vinyl. 
EXAMPLE III 
The following encapsulating composition was prepared: 
______________________________________ 
Ingredients % By Weight 
______________________________________ 
Carboxylated polychloroprene emulsion 
39.3% 
Dispersed hydrocarbon resin (tackifier) 
4.0 
Dispersed zinc oxide (stabilizer) 
1.2 
Octylphenoxypolyethoxyethanol 
.1 
Sodium zinc phosphate inorganic polymer 
.1 
Petroleum hydrocarbon .4 
Dimethoxane .1 
Ethylene glycol 2.3 
Ethylene glycol phenyl ether 90% 
.3 
Diethylene glycol phenyl ether 10% 
Microspheres (white-ceramic) 
44.5 
Red iron oxide 1.1 
Water 6.6 
100.00% 
______________________________________ 
This formulation makes a uniform red coating instead of giving a dotted 
appearance. It is representitive of a formula which provides desired 
results over a broad range of conditions. This formula contains a 
Neoprene-type resin with good adhesion to vinyl. The double bonds (pi 
bonds) in this resin are said to tie up free asbestos. 
The shelf life of this formulation depends upon the state of the art in 
manufacturing of the polychloroprene resin emulsion. For the present, the 
useful shelf life is roughly 6 months to 5 years, though this may change 
as the method of manufacturing the polychloroprene resin emulsion changes. 
EXAMPLE IV 
The following formulation is representitive of an encapsulating compound 
which would have poor flow and leveling. The lack of flow makes it well 
suited to application on inclined surfaces where a self leveling product 
may run. This formula contains a vinyl acrylic resin and a thickener. 
______________________________________ 
Ingredients % By Weight 
______________________________________ 
Acrylic emulsion (44% to 50% solids) 
43.0% 
Octylphenoxypolyethoxyethanol 
.1 
Sodium zinc phosphate inorganic polymer 
.1 
Petroleum hydrocarbon .4 
Dimethoxane .1 
Ethylene glycol 2.8 
Thickener 5.8 
Ethylene glycol phenyl ether 90% 
.3 
Diethylene glycol phenyl ether 10% 
Dipropylene glycol dibenzoate 
.8 
Microspheres (white-ceramic) 
33.0 
Microspheres (red-ceramic) 
6.5 
Water 7.1 
100.00% 
______________________________________ 
As previously noted, however, the protective coating can also be described 
by the list of qualities which are important to the final film. These 
qualities are: 
a) a one step coating 
b) a continuous coating 
c) a strong yet flexible coating 
d) a self-levelling coating 
e) a coating which is not prone to cracking, and 
f) a coating which can be applied in thin or thick coats. 
The coating detailed above is advantageous in comparison to the 
conventional coatings because of the properties or qualities detailed 
above. 
The invention has been described with reference to the preferred 
embodiment. Obviously, modifications and alterations will occur to others 
upon a reading and understanding of the preceding detailed description. It 
is intended that the invention be construed as including all such 
alterations and modifications insofar as they come within the scope of the 
appended claims and the equivalents thereof.