Classifications

• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
  • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
  • C04B28/04—Portland cements
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
  • C04B26/02—Macromolecular compounds
  • C04B26/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • C04B26/06—Acrylates
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
  • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F15/00—Flooring
  • E04F15/12—Flooring or floor layers made of masses in situ, e.g. seamless magnesite floors, terrazzo gypsum floors
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
  • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/60—Flooring materials
  • C04B2111/62—Self-levelling compositions

Definitions

• This invention is in the field of floor coverings. More particularly, it relates to compositions and methods for renewing or restoring an old floor, especially old resilient floor coverings, e.g., of the embossed vinyl type, which contain noxious materials, such as asbestos.
• Replacement of an old, worn out resilient floor covering can be effected by peeling the old sheet material from the floor, cleaning the underlying floor, and applying a new floor covering.
• removing the old floor covering there is a danger that some of the asbestos may be liberated, with as yet unknown environmental consequences.
• a polymer-modified cement is disclosed in U.S. Parent 3,947,398 for use in flooring applications, including underlayment for tiles. That is, gypsum plaster is modified by adding to the gypsum a resin latex containing vinyl, acrylate, or methacrylate resins.
• the two-part composition is mixed prior to application and is said to be self-leveling.
• the resin is not chemically reactive in the composition.
• U.S. Patent 4,108,813 describes a cementitious floor covering composition containing Portland cement, a resin emulsion and spherical quartz sand. Although a wide range of resins is disclosed as being useful, resins which are chemically reactive in the composition are not included.
• a self-leveling flooring composition containing gypsum cement, Portland cement, sand, and water is disclosed in U.S. Patent 4,159,912; no polymeric constituent is included.
• this invention provides a leveling composition which is applied to the old floor covering and forms an interface between the exposed surface of the old floor covering and the backing of a new floor covering.
• the leveling composition is selected such that any embossed pattern in the old floor covering is not telegraphed into the new floor covering and so that, when the new floor covering is peeled from the floor, the leveling composition adheres preferentially to the new floor covering.
• the leveling composition is advantageously employed over an old, embossed vinyl floor covering, it may also be employed over non-embossed floor coverings, and over floor coverings which are other than vinyl, e.g., over ceramic tile and resilient tile, such as vinyl, asbestos, and vinyl/asbestos tile, and over strip wood flooring.
• this invention provides a method for safely renewing an old floor covering which may contain noxious material.
• this invention provides a floor covering per se, which includes both the old and the new floor coverings.
• the leveling composition of. this invention which includes a polymer-modified cement, a modified acrylic resin latex, and water, is a key element in each aspect.
• the leveling composition of this invention is readily applied over the old flooring and, within a short period of time, the new floor covering can be applied over the hardened composition. Thus, in a single working day, an old floor covering can be renewed.
• the leveling composition of this invention includes resin which is chemically reactive and cures in the composition.
• the leveling composition of this invention includes, as an inorganic component, a high-hydrate Portland or calcined gypsum cement.
• the cement is combined with an organic polymeric material, e.g., an ethylene/vinyl acetate copolymer.
• the resultant polymer-modified cement contains between about 2 and about 10 percent by weight of the organic polymeric material and may also contain a small amount of a dispersing agent, such as sodium citrate, for example. Because of its reactivity with water, the polymer-modified cement is stored in a dry state prior to its incorporation into the leveling composition.
• the leveling composition of this invention includes an acrylic resin which has been modified to contain chemically reactive functional groups, e.g., epoxide groups or precursors thereto which give rise to such functional groups in the composition.
• the reactive groups serve to cure the acrylic resin, e.g., by cross-linking it.
• the curing may be effected, or the reactive functional groups produced by, the addition of a catalyst.
• the modified acrylic resin can be " incorporated into the aforesaid dry polymer-modified cement
• suitable acrylic resins are commercially available as aqueous latexes, and when so employed, the aqueous modified acrylic resin is preferably mixed with the polymer-modified cement just prior to using the leveling composition.
• cross-linking can be effected with a basic catalyst, such as sodium bicarbonate, sodium hydroxide, magnesium oxide, or zinc oxide, for example.
• a preferred catalyst is sodium carbonate sesquihydrate. Between about 1 and about 5 percent of the latter, based upon the weight of the acrylic resin, is added at the time the components of the leveling composition are mixed.
• the catalyst may be present in the polymer-modified cement as a curing accelerator.
• the leveling composition will contain by weight about 2 to about 4 parts polymer-modified cement, about 1 part modified acrylic resin, about 1 to 3 parts water, and catalyst.
• Example 1 sets forth ingredients in a typical leveling composition of this invention.
• ROBOND LEC-58 available commercially as ROBOND LEC-58 from Rohm and Haas Company, Independence Mall West, Philadelphia, PA 19105.
• this invention provides a method for renewing an old floor covering which utilizes the leveling composition.
• the old floor covering should be firmly adhered to the floor. Then, if at some later date it is desired to again replace the floor covering, the topmost floor covering can be peeled from the floor, leaving the original, old floor covering behind, and another floor covering can be installed over a new application of the leveling composition.
• the old floor covering cannot be thoroughly cleaned, it is desirable to begin the renewal by applying a primer to the exposed surface of the old floor covering.
• a primer which includes a polymeric component and one or more surfactants is desirable.
• the polymeric component can include acrylic, vinyl/acrylic, and styrene/acrylic resins, for example.
• the primer is first applied to the old floor covering and dried.
• the next step in practicing the method is to select a leveling composition.
• This selection can be made from leveling compositions which are within the scope of this invention as described above.
• certain leveling compounds and compositions e.g. , cementitiou ⁇ compositions disclosed in the prior art, can be satisfactory.
• a leveling composition of this invention is applied to produce a smooth-faced stratum over the old floor covering, and the leveling composition is then cured. If a leveling composition of this invention has been selected, curing is generally effected by allowing the leveling composition to harden at ambient temperature, drying to some extent, during which the modified acrylic resin begins to cross-link. Sufficient hardening and curing generally take place at ambient temperature in about 1 to about 2 hours, and higher temperatures promote faster curing.
• the new floor covering is then adhered to the exposed surface of the hardened leveling composition.
• the new floor covering can be laid down using one of the latex adhesive ⁇ . commonly used in the flooring industry for such purposes.
• Example 2 The practice of the method of this invention is illustrated in Example 2.
• a piece of embossed, cushioned vinyl floor covering is taped down to a 2 ft. X 2 ft. panel of 1/2 in. plywood with double-faced tape to hold it flat.
• the leveling composition of Ex. 1 is applied and smoothed with a trowel. Prior to drying, 1 in. wide cotton cloth strips are embedded in the wet leveling compound. The composite is allowed to dry approximately 90 minutes. Then 1 in. wide by 6 in. long strips of the composite, which consists of the resilient flooring, the leveling compound, and the cloth strips are cut and subjected to tensile testing.
• a duplicate piece of resilient flooring is similarly taped down to another 2 ft. X 2 ft. panel and the same leveling compound is applied in the identical manner.
• a second piece of resilient flooring is adhered to the exposed face of the hardened leveling compound using techniques standard in the industry, including a multi-purpose latex adhesive made from a styrene-butadiene rubber (available from Congoleum Corporation, Trenton, New Jersey as No. 3033) .
• a multi-purpose latex adhesive made from a styrene-butadiene rubber (available from Congoleum Corporation, Trenton, New Jersey as No. 3033) .
• 1 in. X 6 in. strips of the composite are cut and similarly subjected to tensile testing.
• the composite strips are placed in a standard tensile testing machine and peeled apart at an angle of approximately 90°. The force required to peel the composites apart is recorded as is the failure mechanism. The results of such tests appear in Table 1.
• a 4 ft. X 4 ft. text floor panel is constructed from 2 in. X 4 in. studs and 1/2 in. thick plywood which is conditioned for six weeks at 85°F and 85% R.H. to swell them to a state simulating summer ambient structure conditions in a home.
• resilient flooring of various types is adhered to the plywood face.
• the leveling compound of Ex. 1 is applied to the resilient flooring and allowed to cure for 90 minutes. After the leveling compound has hardened, a new piece of resilient flooring is adhered to the exposed face of the leveling compound using various adhesives standard in the art.
• the composite is cured at ambient conditions for 72 hours and is then placed in a 110°F oven for six weeks to allow the deck to shrink to a state simulating winter ambient structure conditions in a home.
• the deck is removed after the six-week period and examined for buckles or loose spots as an indication of the shear resistance of the composite. The results of such tests appear in Table 2.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Structural Engineering (AREA)
• Materials Engineering (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Organic Chemistry (AREA)
• Architecture (AREA)
• Inorganic Chemistry (AREA)
• Civil Engineering (AREA)
• Floor Finish (AREA)
• Paints Or Removers (AREA)
• Adhesives Or Adhesive Processes (AREA)

Applications Claiming Priority (2)

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Citations (5)

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• 1989
  • 1989-07-13 KR KR1019900700585A patent/KR900701678A/ko not_active Application Discontinuation
  • 1989-07-13 EP EP19890908322 patent/EP0424446A4/en not_active Withdrawn
  • 1989-07-13 JP JP1508084A patent/JPH03506058A/ja active Pending
  • 1989-07-13 WO PCT/US1989/003034 patent/WO1990000530A1/en not_active Application Discontinuation

Patent Citations (5)

Non-Patent Citations (1)

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