GB2386572A

GB2386572A - Synthetic floor covering

Info

Publication number: GB2386572A
Application number: GB0301835A
Authority: GB
Inventors: Mark Harcourt Newman
Original assignee: Altro Ltd
Current assignee: Altro Ltd
Priority date: 2002-01-26
Filing date: 2003-01-27
Publication date: 2003-09-24
Anticipated expiration: 2023-01-27
Also published as: GB0201833D0; GB2386572B; GB0301835D0

Abstract

A synthetic floor covering includes a resin and decorative particles and an upper surface free from imperfections. The floor covering may be made by applying a layer of resin e.g. epoxy resin, to the floor surface, applying decorative particles to the layer of resin such that at least part of the particles protrude from the upper surface of the layer of resin (130), allowing the resin to cure and grinding down the protruding particles (140) to the level of the upper surface of the layer of resin. The resin may include a degassing agent and/or a defoaming agent. A kit for laying down floor covering may include at least one gauging bar (120) having an upper surface, a floor engaging surface, wherein at least some of the decorative particles have a principal dimension which is greater than the height of the bar.

Description

IMPROVED FLOORING METHOD

The present invention relates to synthetic flooring, a kit for use in laying synthetic flooring and a method for laying synthetic flooring and in 5 particular, though not exclusively, to synthetic flooring formed from a synthetic resin having particles embedded within it.

Resin based synthetic or cementitious flooring is highly durable and is generally used in supermarkets and public buildings. Cementitious 10 flooring has the problem that generally it can only be applied at a thickness of upward of 70 millimetres. A problem with synthetic resin based flooring is that the known method of laying the flooring is labour intensive and takes a long time.

15 A known method of laying synthetic resin based flooring is illustrated by Figures la-c. Figure la shows a floor 10 in cross-section. The first step of the known method for laying synthetic flooring comprises cleaning and preparing the floor. Figure lb shows the floor 10 having a layer 20 of resin containing particles 30. The second step of the known method 20 comprises applying an epoxy resin having particles 30 of silica sand and/or flint mixed with it. The resin is then allowed to cure for 24 hours.

Figure lo shows known synthetic flooring where the reference numerals have the same meaning as in Figure lb. The synthetic flooring is 25 obtained by grinding down the product of the second step illustrated in Figure lb. Grinding the layer of resin and particles results in imperfections in the upper surface of the product which are filled by grouting 40 in the final step of the known method.

30 Laying cementitious resin based flooring is also relatively complicated as it involves first applying a sand/cement bedding screed to a concrete

subfloor and then cementitious resin based tiles. The joins between the tiles need to be filled or grouted to give a finished product. This final step is particularly labour intensive. The combination of the tiles and the bedding screed results in a relatively thick flooring which is inconvenient 5 in some locations.

It is an aim of the present invention to ameliorate the above disadvantages. 10 According to the invention there is provided a method of laying synthetic floor covering to a floor surface which method includes the steps of: applying a predetermined thickness of resin to the floor surface, applying decorative particles to the resin wherein the decorative particles include large particles having a principal dimension which is 15 greater than the predetermined thickness such that at least a part of the decorative particles protrudes from the upper surface of the layer of resin, allowing the resin to cure, and grinding down the protruding decorative particles to the level of 20 the upper surface of the layer of resin.

The advantages of the method according to the invention include that in the grinding step, only the protruding parts of the particles are ground.

This does not create a waste problem unlike with the known method 25 where the waste from the grinding step is a mixture of ground resin and ground particles. Since it is a wet ground system to prevent dusting, the waste is in the form of a slurry which is hard to dispose of and which adds to the cost of laying the known synthetic floor. Also the resin is very hard which adds to the grinding cost because it takes longer and is 30 more wearing on the grinding device. Thus the grinding cost of the method of the invention is estimated to be from ú12 to ú15 per square

metre whereas the grinding cost for the known synthetic flooring is generally from ú20 to ú25 per square metro.

A further advantage of the method of the invention is that a grouting step 5 is not required because the upper surface of the layer of resin is not subjected to grinding. This means that less time is required to lay the synthetic flooring according to the invention and results in a more attractive product. Another advantage of the invention is that it can be laid to a thickness of at least 6mm.

As a result of the time savings of the method of the invention, it has been found that about 300 square metres of the synthetic flooring according to the invention can be laid in the time it took to lay 40 square metres of the known synthetic flooring making it more cost effective.

According to the invention there is further provided a synthetic floor covering having an upper surface, which floor includes a resin and decorative particles wherein the upper surface of the floor is substantially free from imperfections.

The upper surface of the synthetic floor covering according to the invention is preferably substantially free from filler or grouting materials.

The resin used in the method according to the invention preferably includes a flow levelling agent in a quantity sufficient to increase the 25 flowability of the resin such that it is able to receive decorative particles without forming air pockets or holes. It preferably also contains a degassing agent and/or a de-foaming agent.

The resin used in the invention is preferably an epoxy resin. Before the 30 resin is applied to the surface in the method of the invention, it is

preferably mixed with a hardener. The hardener used in the invention is preferably a polyamide.

Examples of suitable flowing agents include polyether siloxane co-

5 polymers. An example of a suitable resin composition for use in the invention includes about 100 parts by weight of an epoxy resin binder (for example bisphenol-A/epichlorhydrin and/or bisphenol-F/epichlorhydrin reaction product), O to 20 parts by weight of a reactive diluent (for example mono-epoxidised alcohol), O to 30 parts by weight of a non 10 reactive diluent (e.g. benzyl alcohol), 0.1 to 2 parts by weight of an anti-

foaming agent, 0.1 to 2 parts by weight of a flow and levelling agent, 0 to 20 parts by weight of a pigment and 0 to 30 parts by weight of a filler.

The resin composition is used with a polyamine hardener at the appropriate stochiometric ratio.

According to the invention there is also provided a kit for use in laying a synthetic floor covering which includes decorative particles and at least one gauging bar wherein the at least one gauging bar has an upper surface, a floor engaging surface and a height which is the distance 20 between the two said surfaces and wherein at least some of the decorative particles have a principal dimension which is greater than the height of the gauging bar.

The kit optionally also includes a resin. The kit may further optionally 25 include a hardener. The gauging bar is optionally of square, rectangular or L-shaped cross-section. The principal dimension of the decorative particles is for example the length or the diameter of the particles.

In use, the gauging bar is generally laid on the surface to be covered by 30 the floor covering in an array to sub-divide the surface into smaller areas and to define the height of the upper surface of the floor covering to be

laid. The gauging bar is preferably formed from a material which is resistant to grinding such as metal, for example copper or brass. The first step of the method of the invention preferably is to provide at least one said gauging bar on the surface.

The decorative particles may organic or inorganic particles. Examples of the decorative particles used in the invention include particles of flint, silica sand, quartz, granite or marble. The decorative particles are optionally covered. The size of the decorative particles to be used in the 10 invention depends upon the intended thickness of the floor covering. For a floor covering thickness of about 6mm, optionally the decorative particles have a principal dimension or length which is up to 10 her;; millimetres, for example up to 8 millimetres. The decorative particles are optionally applied in an amount by weight of up to 22kg/m2.

The present invention will now be described by means of example only with reference to the drawings in which: Figures la-c illustrate a known method of laying synthetic flooring 20 from a cross-sectional view of a floor as described above; and Figures 2a-d illustrate a method according to the invention of laying the synthetic flooring according to the invention from a cross-sectional view of a floor.

Figure 2a shows in cross-section a floor to which has placed on it brass gauging bars 20. Gauging bars 20 are placed five metres apart and so line 5 is used to show that much of the cross-section of the flooring has been omitted. Each gauging bar 20 is six millimetres high. In the 30 method of the invention, the floor is prepared first before the gauging bars are laid on it. Generally this preparation includes cleaning the floor

but may optionally include applying an anti-static primer coating to the floor. In Figure 2b, there is a layer 30 of resin between the gauging bars 20 and 5 otherwise the reference numerals have the same meaning as described above with reference to Figure 2a. In the method of the invention, a layer 30 of resin prepared according to Example 1 or Example 2 is applied to prepared floor 10 between the gauging bars 20 to a depth of four millimetres. A spike roller is then applied to vent air from the layer 10 30.

In Figure 2c, the layer 30 of resin includes particles 40 and otherwise the reference numerals have the same meaning as described above with reference to Figure 2b. In the method of the invention, the next step is to 15 apply a sufficient volume of particles 40 to the layer 30 of resin 30 so that the depth of layer 30 is increased to six millimetres which is the height of the gauging bars 20. The particles 40 are generally applied to layer 30 by an operator wearing spike shoes. Since the resin used in layer 30 contains a flowing agent, the layer 30 receives the particles 40 20 without the formation of air holes as the resin flows around each particle.

The length or principal dimension of particles 40 is up to about eight millimetres such that part of some of the particles 40 protrudes from the surface of layer 30.

25 Figure 2d illustrates synthetic flooring according to the invention wherein the reference numerals have the same meaning as described above with reference to Figure 2c. The synthetic flooring shown in Figure 2d is prepared by the final steps of the method of the invention which are to allow the resin to cure, usually for 24 hours, and then to grind down the 30 part of some of the particles 40 which protruded from the surface of layer

30. The gauging bars are used to determine the level to which the synthetic flooring is ground down.

EXAMPLE 1

5 A resin for use in the invention was prepared by mixing the following base resin, filler and hardener which are as follows.

The base resin was prepared by mixing the following ingredients: 10 Parts by weight Epikote 215 (Shell Chemicals) 98 Benzyl alcohol 7 = Epikote 240 (Shell Chemicals) 40 Kronos 2057 (titanium dioxide pigment, 15 NL Chemical Europe) 56.6 Bayrerrox 318 (iron oxide pigment, Bayer AG) 3.4 Wacker SL (silicone flow agent, Wacker Chemie GmbH) 0.3 i 20 Tegopren B1484 (flow and levelling agent, Tego Chemie) 0.6 Xylene 2.1 Methyl isobutyl carbinol (anti-foaming agent) 3 25 wherein Epikote 215 is a mixture of mono-epoxidised alcohol with an - epoxy resin having an average molecular weight of greater than 100 which is the reaction product of Bisphenol-A and epichlorhydrin; Epikote 240 is a mixture of mono-epoxidised alcohol with an epoxy resin having an average molecular weight of greater than 100 which is the reaction 30 product of Bisphenol- F and epichlorhydrin.

The filler was 207 parts by weight of Sibelco M10 (which is a quartz flour) and 50 parts by weight of Blancfixe N (barium sulphate).

47 parts by weight of DX 207 (which is a cycloaliphatic amine based 5 hardener proprietary to Shell Chemicals) was used as the hardener.

EXAMPLE 2

A resin for use in the invention was prepared by mixing the following base resin, filler and hardener which are as follows.

The base resin was prepared by mixing the following ingredients: Parts by weight Epoxy resin DER 331 98 15 Epoxy resin DER 736 7 BYK 354 (polyacrylate solution, Byk-Chemie GmbH) 1 BYK 055 (Byk-Chemie GmbH) 0.75 BYK 051 (Byk-Chemie GmbH) 0.25 wherein DER 331 is a mixture of monoepoxidised alcohol with an epoxy resin having an average molecular weight of greater than 100 which is the reaction product of Bisphenol-A and epichlorhydrin; DER 736 is a short chain aliphatic proprietary di-epoxide; BYK 354 is a levelling additive 25 having a degassing and de-foaming action; BYK 055 and BYK 051 are foam destroying polymers.

The filler was 276 parts by weight of ground quartz.

30 The hardener was 58 parts by weight of the following hardener:

Parts by weight Isophorone diamine 55 Trimethylhexamethylene diamine 45 Benyl alcohol 88 5 Salicylic acid 12 DER 331 (as above) 40

Claims

1. A synthetic floor covering having an upper surface, which floor covering includes a resin and decorative particles wherein the upper 5 surface of the floor covering is substantially free from imperfections.

2. A floor covering according to claim 1 wherein the upper surface of the floor covering is substantially free from filler or grouting materials.

10 3. A floor covering according to claim 1 or claim 2 wherein the resin includes a flow levelling agent in a quantity sufficient to increase the flowability of the resin such that it is able to receive decorative particles without formation of an air pocket or hole.

15 4. A floor covering according to any one of the preceding claims wherein the resin includes a degassing agent and/or a de-foaming agent.

5. A floor covering according to any one of the preceding claims wherein the resin is an epoxy resin.

6. A floor covering according to any one of the preceding claims wherein the resin includes a hardener.

7. A floor covering according to claim 6 wherein the hardener is a 25 polyamide.

8. A floor covering according to any one of the preceding claims wherein the resin includes about 100 parts by weight of an epoxy resin binder, O to 20 parts by weight of a reactive diluent, 0 to 30 parts by 30 weight of a non-reactive diluent, 0.1 to 2 parts by weight of an anti

9. A floor covering according to any one of the preceding claims 5 which includes a gauging bar having an upper surface, a floor engaging surface and a height which is the distance between the two said surfaces, wherein the height of the gauging bar is the second predetermined thickness. 10 10. A floor covering according to claim 9 wherein the gauging bar is of square, rectangular or L-shaped cross-section..; 11. A method of laying synthetic floor covering as defined in any one of the preceding claims to a floor surface which method includes the steps 15 of: applying a layer of resin having a first predetermined thickness to the floor surface wherein the layer has an upper surface, applying decorative particles to the layer of resin wherein the decorative particles include large particles having a principal dimension 20 which is greater than a second predetermined thickness of the layer of resin such that at least a part of the decorative particles protrudes from the upper surface of the layer of resin wherein the second predetermined thickness of the layer of resin is the thickness of the resin including the decorative particles, 25 allowing the resin to cure, and grinding down the protruding decorative particles to the level of the upper surface of the layer of resin.

12. A method according to claim 11 wherein the resin includes a flow 30 levelling agent in a quantity sufficient to increase the flowability of the

resin such that it is able to receive decorative particles without formation of an air pocket or hole.

13. A method according to claim 11 or claim 12 wherein the resin 5 includes a degassing agent and/or a de-foaming agent.

14. A method according to any one of claims 11 to 13 wherein the resin is an epoxy resin.

10 15. A method according to any one of claims 11 to 14 wherein the resin includes a hardener.

16. A method according to claim 15 wherein the hardener is a polyamide. 17. A method according to any one of claims 11 to 16 wherein the resin includes about 100 parts by weight of an epoxy resin binder, 0 to 20 parts by weight of a reactive diluent, O to 30 parts by weight of a non-

reactive diluent, 0.1 to 2 parts by weight of an anti-foaming agent, 0.1 to 20 2 parts by weight of a flow and levelling agent, 0 to 20 parts by weight of a pigment and O to 30 parts by weight of a filler.

18. A method according to any one of claims 11 to 17 wherein the second predetermined thickness is determined using a gauging bar having 25 an upper surface, a floor engaging surface and a height which is the distance between the two said surfaces, wherein the height of the gauging bar is the second predetermined thickness.

19. A method according to claim 18 wherein the gauging bar is of 30 square, rectangular or L-shaped cross-section.

20. A method substantially as hereinbefore described with reference to Figures 2a-2d and/or Examples 1 and/or 2.

5 21. A kit for use in laying a synthetic floor covering as defined in any one of claims 1 to 10 which kit includes decorative particles and at least one gauging bar wherein the at least one gauging bar has an upper surface, a floor engaging surface and a height which is the distance between the two said surfaces and wherein at least some of the decorative 10 particles have a principal dimension which is greater than the height of the gauging bar.

22. A kit according to claim 21 which includes a resin preferably as defined in any one of claims 3 to 8.

23. A kit according to claim 21 or claim 22 wherein the gauging bar is of square, rectangular or L-shaped cross-section.

24. A synthetic floor covering according to any one of claims 1 to 10 20 obtainable by the method as defined in any one of claims 11 to 20.

25. A kit substantially as hereinbefore described with reference to Figures 2a-2d and/or Examples 1 and/or 2.

25 26. A synthetic floor covering substantially as hereinbefore described with reference to Figures 2a-2d and/or Examples 1 and/or 2.