Settable composition containing aluminum phosphate and method for preparing same

Claim 1

Process for preparing settable composition comprising: (A) providing aluminum phsophate; (B) providing solid organic carboxylic acid; (C) providing oxygen-containing alkaline earth compound; (D) providing water; and (E) admixing said aluminum phosphate, said solid organic carboxylic acid, said alkaline earth material, and water provided that said solid organic carboxylic acid and said alkaline earth material are not precontacted with each other prior to contact of the alkaline earth material with the aluminum phosphate; and (F) wherein said aluminum phosphate contains 0 to about 40 mole % of boron based upon the moles of aluminum and contains a mole ratio of phosphorus to total moles of aluminum and boron of at least about 2:1; (G) said solid organic carboxylic acid being soluble in aqueous solutions of the aluminum phosphate and containing at least two substituents selected from the group consisting of at lease two carboxylic acid groups; and at lease one carboxylic acid group, and at least one hydroxyl group, or keto tautomers thereof; (H) said alkaline earth metal compound contains alkaline earth metal and an oxide; and is capable of reacting with the aluminum phosphate; and (I) wherein the amount of aluminum phosphate is from about 50 to about 95% by weight based upon the total weight of aluminum phosphate and alkaline earth compound; the amount of alkaline earth compound is from about 50 to about 5% by weight based upon the total weight of aluminum phosphate and alkaline earth compound; the amount of water is from about 15 to about 50% by weight based upon the total weight of aluminum phosphate and water; and the amount of said acid is from about 0.5 to about 25% by weight based upon the total weight of aluminum phosphate, and acid.