GB2460239A - Multilayer coating of a floor - Google Patents

Multilayer coating of a floor Download PDF

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Publication number
GB2460239A
GB2460239A GB0809149A GB0809149A GB2460239A GB 2460239 A GB2460239 A GB 2460239A GB 0809149 A GB0809149 A GB 0809149A GB 0809149 A GB0809149 A GB 0809149A GB 2460239 A GB2460239 A GB 2460239A
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resin
meth
acrylate
primer
substrate
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GB2460239B (en
GB0809149D0 (en
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Anthony Lehane
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    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D133/00Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
    • C09D133/04Homopolymers or copolymers of esters
    • C09D133/06Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, the oxygen atom being present only as part of the carboxyl radical
    • C09D133/10Homopolymers or copolymers of methacrylic acid esters
    • C09D133/12Homopolymers or copolymers of methyl methacrylate
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40Additives
    • C09D7/60Additives non-macromolecular
    • C09D7/63Additives non-macromolecular organic
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50Multilayers
    • B05D7/56Three layers or more
    • B05D7/57Three layers or more the last layer being a clear coat
    • B05D7/576Three layers or more the last layer being a clear coat each layer being cured, at least partially, separately
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D133/00Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
    • C09D133/04Homopolymers or copolymers of esters
    • C09D133/06Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, the oxygen atom being present only as part of the carboxyl radical
    • C09D133/08Homopolymers or copolymers of acrylic acid esters
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D133/00Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
    • C09D133/04Homopolymers or copolymers of esters
    • C09D133/06Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, the oxygen atom being present only as part of the carboxyl radical
    • C09D133/10Homopolymers or copolymers of methacrylic acid esters
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D7/1233
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40Additives
    • C09D7/60Additives non-macromolecular
    • C09D7/61Additives non-macromolecular inorganic
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40Additives
    • C09D7/66Additives characterised by particle size
    • C09D7/69Particle size larger than 1000 nm
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40Additives
    • C09D7/70Additives characterised by shape, e.g. fibres, flakes or microspheres
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2320/00Organic additives
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2451/00Type of carrier, type of coating (Multilayers)
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2502/00Acrylic polymers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2601/00Inorganic fillers
    • B05D2601/20Inorganic fillers used for non-pigmentation effect
    • B05D2601/22Silica
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50Multilayers
    • B05D7/56Three layers or more
    • B05D7/57Three layers or more the last layer being a clear coat
    • B05D7/574Three layers or more the last layer being a clear coat at least some layers being let to dry at least partially before applying the next layer
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00Use of inorganic substances as compounding ingredients
    • C08K3/34Silicon-containing compounds

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Wood Science & Technology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Electromagnetism (AREA)
  • Inorganic Chemistry (AREA)
  • Nanotechnology (AREA)
  • Paints Or Removers (AREA)
  • Floor Finish (AREA)

Abstract

The rigid substrate 1 is coated with a primer 3. The cured primer 4 layer is then coated 6 with a layer comprising a (meth)acrylate and dibenzoyl peroxide. A methacrylate or acrylate polymer coating containing a diphenylperoxy anhydride crosslinking agent and quartz filler is then applied 9 to previously crosslinked 7 coating. Flakes are then applied 12 onto this cured 10 coating before another coating 13 of a (meth)acrylate and dibenzoyl peroxide is applied. Each solution coat is cured before the next layer is applied. Viscosities, curing times and temperatures, compressive strength, and dimensions are specified. A further layer may be applied. Preferred compositions of many of the layers are specified. The substrate is preferably concrete, ceramic tiles, metal, asphalt, wood or PVC.

Description

"A Process for Applying a Moisture Tolerant Floor Coating"
Introduction
This invention relates to a process for applying a moisture tolerant floor coating to a substantially rigid substrate to provide a flooring. The invention also relates to a moisture tolerant rough surface flooring and smooth surface flooring prepared by that process. In the specification the term "moisture tolerant" refers to a material which is moisture impermeable and is furthermore not damaged during contact with moisture.
Various types of floor coatings are presently available, and their use can vary from domestic household areas such as bathrooms and garages to public areas such as supermarkets, exhibition halls, restaurants and industrial warehouses. Due to the nature of the use of these floor coatings it is essential that they have good wear and tear resistance, chemical resistance and most importantly are moisture tolerant.
Epoxy resin is commonly used to provide floor coatings and is produced by combining epoxide resin, fillers, aggregate and hardener. It has been found to have some favourable properties such as good bonding, chemical resistance and wear and tear resistance. The main drawback with the use of epoxy resin however is that it is not sufficiently moisture tolerant and thus can be damaged by the presence of moisture. Additionally, epoxy resin has not been found to be sufficiently flexible and thus has been found to crack after curing under certain conditions. Epoxy resin cures very slowly and generally can take up to 7 days before it is adequately cured.
Furthermore epoxy resin will not cure under very cold conditions and thus may need to be stored during cooler seasons which can increase costs.
Another floor coating commonly used is polyurethane which has been found to be more suitable as a floor coating than epoxy resin as it has increased flexibility.
Polyurethane, however, shares some drawbacks with epoxy resin in that it is not sufficiently moisture tolerant, has a very slow curing time and will not cure under certain conditions.
There is therefore a need for a process for applying a moisture tolerant floor coating to provide a moisture tolerant flooring with better bonding without compromising any other favourable properties.
Statements of Invention
According to the invention, there is provided a process for applying a moisture tolerant floor coating to a substantially rigid substrate to provide a flooring, the process comprising: preparing a surface of the substrate to be coated; applying to the prepared substrate a sufficient amount of a moisture tolerant primer having a primer viscosity of between lOmPa.s and 500mPa.s to provide a primer thickness of between 0.1mm and 0.5mm; curing the moisture tolerant primer at a curing temperature in the range of between 0°C and 35°C for between 0.5 and 24 hours to provide a primed substrate having a primer compressive strength of between 20 N/mm2 and N/mm2; obtaining a (meth)acrylate monomer-polymer solution and crosslinking a sufficient amount of the solution with a dibenzoylperoxide curing agent to form a flexible self levelling resin having a resin viscosity of between 200mPa.s and l500mPa.s; applying to the primed substrate a sufficient amount of the flexible self levelling resin to provide an intermediate resin coat having a thickness of between 1.0mm and 5.0mm; curing the intermediate resin coat at a curing temperature in the range of between 0°C and 35°C for between 0.5 and 1.5 hours to provide a resinated substrate having a resin elongation at break of between 20% and 150% and a resin compressive strength of between 5 N/mm2 and 30 N/mm2; crosslinking a sufficient amount of the (meth)acrylate monomer-polymer solution with a dibenzoylperoxide curing agent and a quartz based filler to form a medium flexible self levelling resin having a resin viscosity of between 200mPa.s and 1500mPa.s; applying to the resinated substrate a sufficient amount of a medium flexible self levelling resin to provide a main resin coat having a thickness of between 1.0mm and 5.0mm; curing the main resin coat at a curing temperature in the range of between 0°C and 35°C for between 0.5 and 1.5 hours to provide a substrate with a main coat of resin having a resin compressive strength of between 25N/mm2 and 75N/mm2; distributing to the main coat of resin on the substrate, resin compatible flakes having a particle size of between 1mm and 10mm and a flake thickness of between 5Opm and 300pm; crosslinking a sufficient amount of the (meth)acrylate monomer-polymer solution with a dibenzoylperoxide curing agent to form a sealer resin having a resin viscosity of between lOOm Pa.s and 300mPa.s; applying to the main coat of resin and flakes between 400g/m2 and 600g/m2 of the sealer resin and sufficient resin to entirely embed the flakes; and curing the sealer resin at a curing temperature in the range of between 0°C and 35°C for between 0.5 and 1.5 hours to provide a rough surface flooring.
It has surprisingly been found that the combination of the specific moisture tolerant primer and the (meth)acrylate based resins with these specific properties results in a floor coating with excellent properties. Specifically, the resultant flooring is moisture tolerant, has good bonding, excellent wear and tear and chemical resistance and can be either flexible or rigid. Additionally, the rough surface flooring has excellent skid resistance.
It has also surprisingly been found that it is possible to use faster curing conditions with this specific combination of primer and resin to provide the flooring. As a result of the fast curing, this allows a significant reduction in the time required to coat the substrate and it has been found that with some embodiments of the invention the flooring is complete after two hours.
The advantage of using a self levelling resin is that it can flow and spread quickly onto a surface thus preventing problems associated with bad levelling such as trowel marks. It has the ability to level any uneven surface on the substrate thus providing excellent surface evenness. Additionally, as the resin is self levelling it provides a fast working speed thus reducing the overall processing time.
Furthermore, as the resin is flexible, it has the ability to absorb impacts and thus prevents cracking of the flooring. Due to the thermal elongation of the flexible resin, it can also move when it is thermally stretched by heat and cold, thus if the substrate used has the ability to expand and contract at differing temperatures, the flexible coating can follow these movements and does not curl, crack or become loose in adhesion.
The flexible self levelling resin which forms the intermediate coat can correct an uneven surface or can fill up voids in the surface of the substrate. It works as a flexible membrane underneath the main coat and in the event that the main coat cracks, the flexibility of the intermediate coat allows it to remain intact thus preventing the penetration of water. A further advantage of the intermediate coat is that it provides an excellent interlink between the substrate, primer and the medium flexible resin and this is achieved by the flexible self levelling resin having the ability to dissolve some of the primer and/or medium flexible resin. The medium flexible self levelling resin which forms the main coat is less flexible in order to prevent it being marked or scratched. The advantage of the sealer resin is that it provides protection for the resin compatible flakes and also when cured provides a surface with good grip.
In one embodiment of the invention, the process further comprises: sanding the rough surface flooring at a sanding speed in the range of between 150 and 200 rpm to provide a sanded flooring; applying to the sanded flooring between 400 gIm2 and 600g/m2 of the sealer resin to form an additional layer of sealer resin; and curing the additional layer of sealer resin at a cunng temperature in the range of between 0°C and 35°C for between 0.5 and 1.5 hours to provide a smooth surface flooring.
It has surprisingly been found that a sanding speed in the range of between 150 and 200 rpm and preferably of the order of 168 rpm is an optimum speed for achieving a smooth flooring and significantly better than previously used higher sanding speeds. Specifically, this sanding speed is more efficient than lower sanding speeds of less than 150rpm, in that with a higher sanding speed it takes a shorter time to sand a larger area. More surprisingly, however, it has been found that a sanding speed of between 150 and 200rpm is also more efficient than a sanding speed in excess of 200rpm. Specifically, it has been found that if the speed is higher than 200rpm, this creates friction and causes the sealer resin to melt from the heat created thus reducing the sanding efficiency. This can also lead to marks within the sanded surface.
The function of the moisture tolerant primer is to impart moisture tolerant properties to the resultant flooring and to provide an interface for the resin layers. It has also been found that these particular primers have excellent bonding to any conventional substrate.
In one embodiment of the invention and prior to applying the moisture tolerant primer, the process further comprises preparing the primer by the steps of: obtaining a (meth)acrylate monomer-polymer solution as a resin base; crosslinking the resin base with between 10% and 30% of an isocyanate prepolymer curing agent by weight of the resin base to form a crosslinked resin base; adding to the crosslinked resin base between 0.05% and 0.3% of an adhesion promoter by weight of the crosslinked resin base to form a final resin; and adding to the final resin between 0.5% and 5% of a peroxide by weight of the final resin to form the moisture tolerant primer.
The main advantage of this (meth)acrylate primer is that it has an extremely fast curing time of less than 2 hours and due to the presence of isocyanate has been found to chemically react with the moisture thus preventing its penetration.
Preferably, the process further comprises preparing the (meth)acrylate monomer-polymer solution by the steps of: dissolving in a (meth)acrylate monomer between 10% and 50% of a polymethylmethacrylate or a polymethylmethacrylate/copolymer by weight of the (meth)acrylate monomer; adding between 5% and 25% of either a polyol, a hydroxyalkyl(meth)acrylate, or a polyol/hydroxyalkyl(meth)acrylate mixture in the presence of between 0.3% and 3% of an accelerator, between loppm and 200ppm of a stabiliser and between 0.1% and 2% of paraffin wax to provide the solution.
Ideally, the (meth)acrylate monomer is selected from the group comprising one or more of 2-component methyl(meth)acrylate, ethyl(meth)acrylate, n-butyl(meth)acrylate, ethyltriglycol(meth)acrylate, 2-ethylhexyl(meth)acrylate, triethylenglykoldi(meth)acrylate and butandioldi(meth)acrylate.
Preferably, the polyol is selected from the group comprising one or more of polyester polyol, polyether polyol, hydroxypoly(meth)acrylate and castor oil modified polymers.
Further preferably, the hydroxyalkyl(meth)acrylate is selected from the group comprising one or more of hydroxyethyl(meth)acrylate and hydroxypropyl(meth)acrylate.
Still further preferably, the accelerator is a tertiary amine selected from the group comprising one or more of dimethylparatoluidine, diethoxyethylparatoluidine, dipropoxyparatoluidine and dimethylaniline Ideally, the stabiliser is selected from the group comprising one or more of hydrochinone, hydrochinone monomethylether and trialkylphosphines.
Preferably, the isocyanate prepolymer curing agent is selected from the group comprising one or more of di-phenylmethanediisocyanate (MDI), hexamethylendiisocyante (HDI); toluylendiisocyanate (TDI) and isophorondiisocyante (IPDI).
Further preferably, the adhesion promoter is selected from the group comprising one or more of methacryloyloxiethyl-phosphate, hydroxyethylmethacrylate-phosphate, hydroxyethylacrylate-phosphate, hydroxypropylmethacrylate-phosphate and hydroxypropylacrylate-phosphate.
In another embodiment of the invention, the moisture tolerant primer is a solvent free 2-component epoxy primer consisting of a short molecular epoxy glycidylether crosslinked with a hexamethylendiamine hardener. The main advantage of the epoxy primer it has been found that it can physically penetrate deep into a porous substrate such as concrete thus strengthening the substrate and blocking the ability of the moisture to penetrate. The epoxy primer is also extremely moisture tolerant and can withstand water pressure up to 5 bar.
Ideally, the substrate is selected from a group comprising concrete, ceramic tiles, metal, asphalt, wood, and polyvinyl chloride plastic.
Preferably, the flexible self-levelling resin further comprises a quartz based filler. The quartz filler is a bulking agent and increases the compressive strength of the coating layers. When used as a broadcast aggregate, it provides a good grip and skid resistance and is attractive.
Further preferably, the quartz based filler comprises a mixture of quartz powder and/or calcium carbonate, barite, dolomite and quartz sand.
Preferably, the quartz based filler has a particle size of between 3pm and l800pm.
Further preferably, the quartz based filler has a particle size of between 10pm and 500pm. Still further preferably, the ratio of self-levelling resin to quartz based filler is between 1:1 and 1:3 Ideally, the resin compatible flakes are based on a water emulsion binder resin derived from one or more of acrylic, vinyl and acrylic-styrene, mineral powder fillers and inorganic pigments. The advantage of using resin compatible flakes is that they do not influence the chemical curing of the resin. Specifically, these flakes are resistant to the monomers in both the self levelling and sealer resins and thus will not absorb any of the monomers from these materials and dissolve in these monomers and curl. Additionally, the flakes are easy to broadcast or distribute, and do not comprise any additives which would lead to the slowing down or inhibition of the curing reactions. Preferably, the flake thickness is between 6Opm and 200pm.
According to the invention, there is also provided a moisture tolerant flooring provided by the process of the invention.
Detailed Description of the Invention
Before further discussion a definition of the following terms will aid in the understanding of the present invention: In the specification the term "(meth)acrylate" refers to all compounds comprising a methacrylate group. The abbreviation MMA refers to one specific compound within that family, namely methylmethacrylate.
In the specification the term "isocyanate prepolymer" refers a substance formed by pre-reacting an isocyanate with some or all of a polyol. A final amount of polyol and I or extender (referred to as the "curative") is added to the prepolymer to complete the reaction.
The invention will be more thoroughly understood from the following description of some embodiments thereof, given by way of example only, in which: Fig. 1 is a flow diagram of a process for applying a moisture tolerant floor coating on a substantially rigid surface to provide a rough surface flooring, according to the invention; and Fig. 2 is a flow diagram of a process for applying a moisture tolerant floor coating on a substantially rigid surface to provide a smooth surface flooring, according to the invention.
All of the equipment used in carrying out the process is well known equipment and accordingly does not require any further description.
Referring to Fig 1, in step 1 a surface of the substrate to be coated is prepared. In step 2 a moisture tolerant primer is obtained and a sufficient amount of the moisture tolerant primer is applied to the prepared substrate in step 3 to provide a primer thickness of between 0.1mm and 0.5mm. The moisture tolerant primer is cured in step 4 at a curing temperature in the range of between 0°C and 35°C for between 0.5 and 24 hours to provide a primed substrate in step 5. In step 6, a sufficient amount of a flexible self levelling resin is applied to the primed substrate to provide an intermediate resin coat having a thickness of between 1mm and 5mm. The intermediate resin coat is cured in step 7 at a curing temperature in the range of between 0°C and 35°C for between 0.5 and 1.5 hours to provide a resinated substrate in step 8.
In step 9, a sufficient amount of a medium flexible self levelling resin is applied to the resinated substrate to provide a main resin coat having a thickness of between 1mm and 5mm. The main resin coat is cured in step 10 at a curing temperature in the range of between 0°C and 35°C for between 0.5 and 1.5 hours to provide a substrate with a main coat of resin in step 11.
In step 12 resin compatible flakes are distributed to the main coat of resin. In step 13 between 400g/m2 and 600g/m2 of sealer resin is applied to the main coat of resin and flakes so as to entirely embed the flakes. The sealer resin is cured in step 14 at a curing temperature in the range of between 0°C and 35°C for between 0.5 and 1.5 hours to provide a rough surface flooring in step 15.
Referring now to Fig. 2, in step 20 the rough surface flooring from Fig. 1 is obtained and is sanded in step 21 at a sanding speed in the range of between 150 and 200rpm to provide a sanded flooring in step 22. In step 23, between 400g/m2 and 600g/m2 of sealer resin is applied to the sanded flooring. In step 24 the additional sealer resin is cured at a curing temperature in the range of between 0°C and 35°C for between 0.5 and 1.5 hours to provide a smooth surface flooring in step 25.
The moisture tolerant floor coating is suitable to be applied to any conventional substrate such as concrete either in the form of slabs or screeds, ceramic tiles, metal such as stainless steel, normal steel, aluminium and zinc plated steel, asphalt such as bituminous screeds, wood such as parquet, plywood or chip board and polyvinyl chloride plastic in rigid form such as vinyl tiles. Preparation of the substrate to be coated is carried out by cleaning the surface to be coated to ensure that it is free of dust, oil, loose particles, laitance or old paint, and other contaminations or coatings.
Cleaning may be carried out by any conventional method and in the case of concrete cleaning is generally carried out by one or more of shot blasting, sanding, grinding, scarifying, applying high water pressure, steam cleaning, and washing with detergents.
Two types of primer can be used to achieve the moisture tolerant primer of the invention. The first of these primers is a (meth)acrylate primer having a viscosity of between 300 and 500 mPa.s and when cured a compressive strength of between 40 and 100 N/mm2. The viscosity can be varied by varying the amount of polymer in the primer and the compressive strength depends of the ratio of the monomers in the primer. The second of these primers is an epoxy primer having a viscosity of between and 200 mPa.s and when cured a compressive strength of between 20 and 40 N/mm2.
The primer can be applied to the substrate by any conventional application implement such as a paint roller, brush, rubber squeegee, or blade. In the case of the (meth)acrylate primer, the primer is generally spread on the substrate and forms a film layer and cures on the substrate as a thin layer. In the case of the epoxy primer, the primer should penetrate into the pores of the substrate by a minimum of 1 50g/m2, and -11 -the primer application should be continued until full saturation of the substrate.
Additionally, excess epoxy primer on the substrate should be removed prior to forming a film.
The resins are generally applied by means of a trowel or rake. The intermediate coat is more flexible that the main coat of resin, thus when cured the main coat becomes more rigid so as to provide surface scratch resistance and to avoid picking-up dirt.
When cured the sealer resin is generally 50% harder than the main coat. It is not advisable to put an extremely hard sealer coat on top of a very flexible main coat as hair cracks might appear in the sealer coat when stressed. Thus a moderate step up in flexibility is preferable.
The quartz based filler comprises a mixture of fine quartz and/or calcium carbonate powder and coarser powders or sand. The fine powders should generally have a particle size of between 3 and 20 pm while the coarser particles or sand normally have a particle size of up to 500 pm. Preferably the quartz based filler should comprises particles of a range of different sizes in order to get compact filling and good self levelling properties.
The flakes can either be the same colour or a mixture of colours and sizes. The resin compatible flakes must not contain any additives which could interrupt the polymerisation or inhibit or retard the curing reaction. Such detrimental additives include hydrochinone derivatives, phenolic derivatives, kresol derivatives, silicon derivatives, phosphates and other antioxidants, carbon black or epoxy hardeners or other amines.
The curing times required to provide the flooring are substantially shorter than those previously achieved. The curing times can be further modified and reduced on the basis of the type of primer chosen. For example, if (meth)acrylate primer is chosen the curing time will generally be in the region of 2 hours and can be as short as 1.5 hours. For other types of primers such as the epoxy primer the curing time will be longer i.e. up to 24 hours but nonetheless significantly shorter than conventional curing times of -7 days.
Some examples of the types of coatings prepared are shown in Table 1.
Table 1: Coatings
Coating A B C Primer MMA MMA Epoxy Primerthickness 0.1mm 0.3mm 0.5mm Primer viscosity 300 mPa.s 500 mPa.s 10 mPa.s Primer compressive strength 20 N/mm2 40 N/mm2 100 N/mm2 Flexible self levelling resin (Meth)acrylate -(Meth)acrylate -(Meth)acrylate -based resin based resin based resin Intermediate resin coat thickness 5 mm 3 mm 1 mm Resin viscosity 1500 mPa.s 1000 mPa.s 200 mPa.s Resin elongation at break 150 % 100 % 20 % Resin compressive strength 30 N/mm2 15 N/mm2 5 N/mm2 Medium flexible self levelling (Meth)acrylate -(Meth)acrylate -(Meth)acrylate -resin based resin based resin based resin Main resin coat thickness 1mm 5 mm 3 mm Resin viscosity 800 mPa.s 1500 mPa.s 200 mPa.s Resin compressive strength 45 N/mm2 75 N/mm2 25 N/mm2 Flake particle size 10 mm 3 mm 1 mm Flake thickness 300 pm 150 pm 50 pm Sealer resin (Meth)acrylate -(Meth)acrylate -(Meth)acrylate -based resin based resin based resin Sealer resin load 600g/m2 500g/m2 400g/m2 Sealer resin viscosity 100 mPa.s 200 mPa.s 300 mPa.s
Example I
Analysis of moisture tolerance, flexibility and chemical resistance of rough flooring as compared to conventional floorings prepared with coatings of epoxy and polyurethane.
The properties of a rough surface flooring are generally the same as that of a corresponding smooth surface flooring.
A rough surface flooring was prepared by the method outlined using the primers and resins as outlined in Table 2.
Table 2: Rough Surface flooring Parameter Primer Conventional MMA Epoxy Epoxy-primer (bisphenolic) Primer thickness 0.4mm 0.4mm 0.2mm Primer viscosity 800 mPa.s 200 mPa.s 20 mPa.s Primer compressive strength 80 N/mm2 70 N/mm2 20 N/mm2 Flexible self levelling resin Epoxy non-(Meth)acrylate (Meth)acrylate flexible resin -based resin -based resin Intermediate resin coat thickness 1 mm 1 mm 1 mm Resin viscosity 2000 mPa.s 500 mPa.s 500 mPa.s Resin elongation at break 5 % 120 % 120 % Resin compressive strength 80 N/mm2 15 N/mm2 15 N/mm2 Medium flexible self levelling Epoxy non flexible (Meth)acrylate (Meth)acrylate resin Resin -based resin -based resin Main resin coat thickness 1mm 1mm 1mm Resin viscosity 2000 mPa.s 200 mPa.s 200 mPa.s Resin compressive strength 80 N/mm2 40 N/mm2 40 N/mm2 Flake particle size 3 mm 3 mm 3 mm Flake thickness 120 pm 120 pm 120 pm Sealer resin Epoxy non flexible (Meth)acrylate (Meth)acrylate Resin -based resin -based resin Sealer resin load 500g/m2 500g/m2 500g/m2 Sealer resin viscosity 500 mPa.s 150 mPa.s 150 mPa.s Samples of four other types of flooring were also obtained. Two of the types of flooring used conventional primers and one was coated with an epoxy coating and the second with a polyurethane coating. A further two types of flooring were prepared using a moisture tolerant primer and again with coatings of epoxy and polyurethane. Both of the epoxy and polyurethane coatings were applied using conventional application methods and were cured for 7 days at 20°C.
Moisture content The moisture content of each of the floorings was measured by the Calcium carbide Method (CM-Method). Concrete powder was obtained by crushing some of the concrete flooring and the powder was mixed with a defined amount of calcium carbide. A chemical reaction occurred between the water (moisture) and the calcium carbide which resulted in the release of ethylene gas. The reaction took place in a closed steel bottle with a manometer and thus the increase in pressure caused by the release of ethylene gas can be correlated to the scale of moisture content.
In order to measure the moisture tolerance of each of the floorings, water was poured onto the concrete of each of the floorings and was left for an hour giving the water an opportunity to permeate the concrete. After an hour, any remaining water was wiped away. The moisture tolerant floor coating of the present invention was then applied to the concrete. After complete curing the coating was chipped away from the flooring to expose the concrete underneath. A sample of the concrete was then taken from each of the floorings and the moisture content of each of the samples was measured by the calcium carbide method as outlined above.
Curing time The coating time for each of the floorings was measured manually by pressing finger tips onto the coating surface in order to determine if they were tack free.
Flexibility The flexibility of each of the floorings was calculated by measuring the compressive strength or E-modulus of each of the floorings according to DIN 1164, the calculations being based on the reverse values of these measurements.
Chemical Resistance The chemical resistance of each of the floorings was measured according to DIN The analysis for each of the different floorings is shown in Table 3 wherein: Column MMA coating: Convent = Conventional MMA primer MMA = Moisture tolerant MMA primer Epoxy Moisture tolerant Epoxy primer Column Eroxy coating: Convent = Conventional Epoxy primer Moist. Tol. = Moisture tolerant Epoxy primer Column Polyurethane coating: Convent = Conventional Polyurethane primer Moist. Tol. = Moisture tolerant Epoxy primer A generally acceptable moisture tolerant level is 6% or greater (water/substrate ratio by weight).
Table 3
MMA coating Epoxy coating Polyurethane coating Primer Convent MMA Epoxy Convent Moist. Tol. Convent Moist. Tol.
<0 bar <0 bar 5bar <0 bar 5bar <0 bar 5bar Moisture 4% 6% 12% 4% 12% 4% 12% tolerance Fullycured 2h 2h 14h 7d 7d 7d 7d Flexibility 25-75 25-75 25-75 70-110 70-110 25-75 25-75 range N/mm2 N/mm2 N/mm2 N/mm2 N/mm2 N/mm2 N/mm2 Chem. Resist.
a) Solvent No No No Yes Yes Yes Yes b) org. acid Yes Yes Yes No No No No c) inorg. acid Yes Yes Yes Yes Yes Yes Yes d) alkalines Yes Yes Yes Yes Yes Yes/No Yes/No e) salts Yes Yes Yes Yes Yes Yes Yes f) fat/oil Yes Yes Yes Yes Yes Yes Yes g) food stuff Yes Yes Yes Yes Yes Yes Yes h) cleaners Yes Yes Yes Yes Yes Yes Yes As shown in Table 3, the most favourable types of flooring were the MMA coated having either an MMA or epoxy primer as these displayed the best results for moisture tolerance and flexibility as well as having sufficient resistance to a number of solvents. Surprisingly however in addition to having such favourable properties, it was found that this specific combination of primers and resins could cure very quickly thus providing a moisture tolerant flooring within a number of hours.
The floorings prepared using a combination of moisture tolerant primer with either an epoxy or polyurethane coating also displayed moisture tolerance however took a significantly longer time to prepare. The present invention provides an improved multi-layered floor coating that is moisture tolerant, has excellent wear and tear, resistance to chemicals and can be prepared in just a few hours.
In the specification the terms "comprise, comprises, comprised and comprising" or any variation thereof and the terms "include, includes, included and including" or any variation thereof are considered to be totally interchangeable and they should all be afforded the widest possible interpretation and vice versa.
The invention is not limited to the embodiment hereinbefore described, but may be varied in both construction and detail within the scope of the appended claims.

Claims (22)

  1. CLAIMS1. A process for applying a moisture tolerant floor coating to a substantially rigid substrate to provide a flooring, the process comprising: preparing a surface of the substrate to be coated; applying to the prepared substrate a sufficient amount of a moisture tolerant primer having a primer viscosity of between lOmPa.s and 500mPa.s to provide a primer thickness of between 0.1mm and 0.5mm; curing the moisture tolerant primer at a curing temperature in the range of between 0°C and 35°C for between 0.5 and 24 hours to provide a primed substrate having a primer compressive strength of between 20 N/mm2 and 100 N/mm2; obtaining a (meth)acrylate monomer-polymer solution and crosslinking a sufficient amount of the solution with a dibenzoylperoxide curing agent to form a flexible self levelling resin having a resin viscosity of between 200mPa.s and l500mPa.s; applying to the primed substrate a sufficient amount of the flexible self levelling resin to provide an intermediate resin coat having a thickness of between 1.0mm and 5.0mm; curing the intermediate resin coat at a curing temperature in the range of between 0°C and 35°C for between 0.5 and 1.5 hours to provide a resinated substrate having a resin elongation at break of between 20% and 150% and a resin compressive strength of between 5 N/mm2 and 30 N/mm2; crosslinking a sufficient amount of the (meth)acrylate monomer-polymer solution with a dibenzoylperoxide curing agent and a quartz based filler to form a medium flexible self levelling resin having a resin viscosity of between 200mPa.s and l500mPa.s; applying to the resinated substrate a sufficient amount of a medium flexible self levelling resin to provide a main resin coat having a thickness of between 1.0mm and 5.0mm; curing the main resin coat at a curing temperature in the range of between 0°C and 35°C for between 0.5 and 1.5 hours to provide a substrate with a main coat of resin having a resin compressive strength of between 25N/mm2 and 75N1mm2; distributing to the main coat of resin on the substrate, resin compatible flakes having a particle size of between 1mm and 10mm and a flake thickness of between 5Opm and 300pm; crosslinking a sufficient amount of the (meth)acrylate monomer-polymer solution with a dibenzoylperoxide curing agent to form a sealer resin having a resin viscosity of between lOOmPa.s and 300mPa.s; applying to the main coat of resin and flakes between 400g/m2 and 600g/m2 of the sealer resin and sufficient resin to entirely embed the flakes; and curing the sealer resin at a curing temperature in the range of between 0°C and 35°C for between 0.5 and 1.5 hours to provide a rough surface flooring.
  2. 2. A process as claimed in claim 1, the process further comprising: sanding the rough surface flooring at a sanding speed in the range of between 150 and 200rpm to provide a sanded flooring; applying to the sanded flooring between 400g/m2 and 600g/m2 of the sealer resin to form an additional layer of sealer resin; and curing the additional layer of sealer resin at a curing temperature in the range of between 0°C and 35°C for between 0.5 and 1.5 hours to provide a smooth surface flooring.
  3. 3. A process as claimed in any preceding claim, wherein prior to applying the moisture tolerant primer, the process further comprises preparing the primer by the steps of: obtaining a (meth)acrylate monomer-polymer solution as a resin base; crosslinking the resin base with between 10% and 30% of an isocyanate prepolymer curing agent by weight of the resin base to form a crosslinked resin base; adding to the crosslinked resin base between 0.05% and 0.3% of an adhesion promoter by weight of the crosslinked resin base to form a final resin; and adding to the final resin between 0.5% and 5% of a peroxide by weight of the final resin to form the moisture tolerant primer.
  4. 4. A process as claimed in any preceding claim wherein the process further comprises preparing the (meth)acrylate monomer-polymer solution by the steps of: dissolving in a (meth)acrylate monomer between 10% and 50% of a polymethylmethacrylate or a polymethylmethacrylate/copolymer by weight of the (meth)acrylate monomer; adding between 5% and 25% of either a polyol, a hydroxyalkyl(meth)acrylate, or a polyol/hydroxyalkyl(meth)acrylate mixture in the presence of between 0.3% and 3% of an accelerator, between loppm and 200ppm of a stabiliser and between 0.1% and 2% of paraffin wax to provide the solution.
  5. 5. A process as claimed in claim 4, wherein the (meth)acrylate monomer is -20 -selected from the group comprising one or more of 2-component methyl(meth)acrylate, ethyl(meth)acrylate, n-butyl(meth)acrylate, ethyltriglycol(meth)acrylate, 2-ethylhexyl(meth)acrylate, triethyleneglykol-di(meth)acrylate and butandioldi(meth)acrylate.
  6. 6. A process as claimed in any of claims 4 or 5, wherein the polyol is selected from the group comprising one or more of polyester polyol, polyether polyol, hydroxypoly(meth)acrylate and castor oil modified polymers.
  7. 7. A process as claimed in any of claims 4 to 6, wherein the hydroxyalkyl(meth)acrylate is selected from the group comprising one or more of hyd roxyethyl(meth)acrylate and hydroxypropyl(meth)acrylate.
  8. 8. A process as claimed in any of claims 4 to 7 wherein the accelerator is a tertiary amine selected from the group comprising one or more of dimethylparatoluidine, diethoxyethylparatoluidine, dipropoxyparatoluidine and dimethylaniline
  9. 9. A process as claimed in any of claims 4 to 8 wherein the stabiliser is selected from the group comprising one or more of hydrochinone, hydrochinone monomethylether and trialkylphosphines.
  10. 10. A process as claimed in any of claims 3 to 9, wherein the isocyanate prepolymer curing agent is selected from the group comprising one or more of di-phenylmethanediisocyanate (MDI), hexamethylendiisocyante (HD I); toluylendiisocyanate (TDI) and isophorondiisocyante (I PDI).
  11. 11. A process as claimed in any of claims 3 to 10, wherein the adhesion promoter is selected from the group comprising one or more of methacryloyloxiethyl- phosphate, hydroxyethylmethacrylate-phosphate, hydroxyethylacrylate- phosphate, hydroxypropylmethacrylate-phosphate and hydroxypropylacrylate-phosphate.
  12. 12. A process as claimed in any of claims 1 or 2, wherein the moisture tolerant primer is a solvent free 2-component epoxy primer consisting of a short molecular epoxy glycidylether crosslinked with a hexamethylendiamine -21 -hardener.
  13. 13. A process as claimed in any preceding claim wherein the substrate is selected from a group comprising concrete, ceramic tiles, metal, asphalt, wood, and polyvinyl chloride plastic.
  14. 14. A process as claimed in any preceding claim, wherein the flexible self-levelling resin further comprises a quartz based filler.
  15. 15. A process as claimed in any preceding claim, wherein the quartz based filler comprises a mixture of quartz powder and/or calcium carbonate, barite, dolomite and quartz sand.
  16. 16. A process as claimed in any preceding claim, wherein the quartz based filler has a particle size of between 3pm and 1 800pm.
  17. 17. A process as claimed in any preceding claim, wherein the quartz based filler has a particle size of between 10pm and 500pm.
  18. 18. A process as claimed in any preceding claim, wherein the ratio of self-levelling resin to quartz based filler is between 1:1 and 1:3.
  19. 19. A process as claimed in any preceding claim, wherein the resin compatible flakes are based on a water emulsion binder resin derived from one or more of acrylic, vinyl and acrylic-styrene, mineral powder fillers and inorganic pigments.
  20. 20. A process as claimed in any preceding claim, wherein the flake thickness is between 6Opm and 200pm.
  21. 21. A process substantially as described hereinbefore with reference to the accompanying examples and drawings.
  22. 22. A moisture tolerant flooring provided by the process as claimed in any preceding claim. -22-23. A moisture tolerant flooring substantially as described hereinbefore with reference to the accompanying examples and drawings.
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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012089120A1 (en) * 2010-12-31 2012-07-05 Saint-Gobain Weber S.A. Sealing combination and its application in a self-leveling floor product
CN104151950A (en) * 2014-08-29 2014-11-19 苏州圣谱拉新材料科技有限公司 Colored crystal coating
CN114395278A (en) * 2021-12-07 2022-04-26 汇克涂料(湖南)有限公司 Water-based floor coating, preparation method and application thereof

Families Citing this family (1)

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Publication number Priority date Publication date Assignee Title
CN115160918B (en) * 2022-08-03 2023-11-03 宁波惠之星新材料科技股份有限公司 Raw material composition for preparing hardened film, hardened film and hardened film assembly

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EP0461320A1 (en) * 1990-06-13 1991-12-18 Gencorp Inc. In mold coating compositions
WO2004112482A2 (en) * 2002-09-09 2004-12-29 Mcdaniel Steven C Biological active coating components, coatings, and coated surfaces

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EP0461320A1 (en) * 1990-06-13 1991-12-18 Gencorp Inc. In mold coating compositions
WO2004112482A2 (en) * 2002-09-09 2004-12-29 Mcdaniel Steven C Biological active coating components, coatings, and coated surfaces

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012089120A1 (en) * 2010-12-31 2012-07-05 Saint-Gobain Weber S.A. Sealing combination and its application in a self-leveling floor product
CN104151950A (en) * 2014-08-29 2014-11-19 苏州圣谱拉新材料科技有限公司 Colored crystal coating
CN114395278A (en) * 2021-12-07 2022-04-26 汇克涂料(湖南)有限公司 Water-based floor coating, preparation method and application thereof

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