RU2117578C1 - Multilayer material for protective coatings of building structures - Google Patents

Abstract

FIELD: manufacture of building materials. SUBSTANCE: material has base covered on the both sides with bitumen layers and a protective overlay. Overlay formed from preliminarily agitated melt of at least one basic composition consisting of polyolefin and rubber powder is laid on molten bitumen at overlay temperature from melting point of thermoplastic to 90 C. Appearance of overlay may be improved by introducing different dyes in it. Its performance characteristics may be improved by introducing some fillers and modifiers. EFFECT: reused waste from large-scale polymer production and improved quality of material. 5 cl, 3 tbl

Description

 The invention relates to polymeric materials, in particular containing secondary polymers, and can find application in the industry for the production of materials for the protection of various building structures and structures, mainly in the production of waterproofing materials, roofing materials, floor coverings, that is, to protect foundations, roofs, floors of various building structures.

 Currently, a large number of protective materials (waterproofing, roofing and flooring) based on organic components are produced and used in industrial and individual construction. As a rule, roofing, waterproofing and floor organic materials have several advantages over traditional materials made of inorganic materials in terms of performance (much lighter, easier to lay, attractive appearance) and have a lower cost. However, scarce and expensive organic and polymer raw materials are used for their production, and the materials themselves are in most cases unsuitable for recycling.

 It is known that recently, in connection with an increase in the use of polymeric materials, the amount of secondary polymers (production and consumption waste of polymers and polymer products) has sharply increased. Thus, the share of polymers in the total municipal waste is up to 15 wt.% In developed countries, and up to 7 wt.% In large cities in Russia. At the same time, the volumes of polymer recycling significantly lag behind the volumes of polymer waste accumulation due to the fact that most of the secondary polymers cannot compete with primary ones according to the price-quality criteria. This leads to a sharp increase in the degree of environmental pollution by non-destructive polymer waste in natural conditions, and therefore the importance of technologies that allow the use of secondary, including polymeric materials to produce high-quality products that can compete with products from primary materials increases. Especially valuable from an environmental point of view, recently developed technologies for the production of materials and products that allow the use of waste large-capacity polymers, such as waste polyolefins and processed rubber products (shock-absorbed tires), in products and materials of mass demand.

 The most promising are materials containing a special low-melting layer, which allows the most productive laying of such materials. As a rule, this layer consists of bitumen, therefore, such materials contain at least one layer that keeps the product in shape at high temperature, and an additional layer that protects the bitumen from external influences and gives the product decorative properties.

 Known material [Europatent EP 0414143 A1, E 04 D 5/12, 1991], containing at least three layers (carrier, adhesive and decorative), which makes it easy to lay the material in the right place, well providing sealing joints. However, the presence of a special adhesive layer dramatically increases the cost of the material.

 Known material consisting of synthetic fabric coated on both sides with bitumen, and on one side of the bitumen is closed with a synthetic film of polypropylene or polyester [Europatent EP 0271727 B1, E 04 D 5/10, 1988]. The presence of an open bitumen layer makes it easy to lay the material on the surface, however, a polypropylene or polyester film does not differ in high weather resistance to ultraviolet radiation, which makes the use of such a film ineffective.

 Known material consisting of synthetic fabric coated on both sides with bitumen, with bitumen on one side covered with a perforated film of biaxially oriented polypropylene, and on the other hand with a powder of inorganic material [Europatent EP 0233488 B1, E 04 D 5/10, 1990] . The presence of an open bitumen layer makes it easy to lay the material on the surface, however, due to the perforated oriented polypropylene film, the material does not provide continuous adhesion to the material on which it is laid, and therefore the hydrolyzing properties of the material may be imperfect.

 A multilayer material is known, including a substrate layer, a bitumen layer, a cushioning layer and a protective layer, which consists of a polyolefin, glass flour and dye [Europatent EP 0287078 A2, B 32 B 11/10, 1988]. The presence of the lower bitumen layer allows the material to be laid well, however, the upper protective layer, despite the light color, is unstable to UV radiation due to the high content of polyolefin in it, in addition, the presence of a large amount of glass in the upper layer makes the material brittle.

 Known material consisting of several layers, the lower layer of bitumen, then a layer of fabric or non-woven fibrous material, a layer of polyolefin or rubber and an upper layer of a composition based on styrene-butadiene, ethylene-propylene rubber or butyl rubber or chlorinated polyethylene and bitumen or polypropylene [German Patent DE 3108473 C2, E 04 D 5/10, 1983]. The material has good weather resistance, but it is very expensive because it includes many primary polymers. The material has another serious drawback: the material of the upper layer absorbs dust and after a while, even if it was painted initially, it will have a gray unattractive surface.

 The closest to the claimed one is a material consisting of several layers, including a substrate - a layer of material resistant to perforation and stretching, for example, various kinds of fabric coated on both sides with a waterproofing, including bitumen composition, and at least one top layer consisting of granules of elastic material attached to a multilayer material using adhesive [Europatent EP 0405546 B1, E 04 D 5/12, 1991]. The material must have good atmospheric resistance due to the granule layer, however, the surface of the material is uneven due to the large size of the dispersed material (1 - 20 mm), in addition, the material can be painted only as a result of using colored granules, which is very expensive for a rubber material . In the case of the use of granules from worn rubber, the material as a whole can have almost only black color due to the high content of soot in bulk polymer waste.

 The objective of the present invention was the creation of a protective material for coating various building structures and structures: foundations, roofing floors (material for gyro-insulating, roofing and flooring), which includes the most massive polymer waste: secondary polyolefins and shock-absorbing rubbers and being material not inferior or superior to known materials in terms of operational or consumer properties: strength, resistance to transmission of water under pressure it, frost resistance, water absorption, resistance to acids and alkalis, a wide range of color shades.

 The task was also to create materials for various purposes: waterproofing, roofing and floor in the form of high quality rolls with the required surface design. At the same time, for its laying one could use the simplest, most productive, and non-laborious methods.

 The problem is solved in that the multilayer material containing the substrate, bitumen layers and the upper protective layer, as the upper layer contains a layer formed from a mixture preliminarily mixed in the melt, consisting of at least the main composition - thermoplastic and rubber powder. In this case, for example, polyvinyl chloride (PVC) or low density polyethylene (LDPE), a mixture of low density polyethylene or secondary low density polyethylene (a mixture of secondary low density polyethylene) or a mixture of polyolefins containing low density polyethylene in an amount mainly from 95 to 70 wt.%, Having a melt flow rate of the mixture (MFR) of from 0.2 to 10.0 g / 10 min. As a rubber powder, the main composition of the protective layer may contain a grinding product of worn tires, as well as crumb rubbers based on butyl rubber and (or) ethylene propylene rubbers, etc., predominantly up to 1 mm in size, mainly 40 to 90 wt. hours per 100 wt. including the main composition - a mixture of thermoplastic and rubber powder.

 The use of polyolefins with a certain melt flow index and rubber crumb of various rubbers as the main composition allows to obtain a top layer material with a high level of resistance to external influences, high deformation-strength properties and good processability in products, as well as with high ability to introduce various kinds of additives without loss of processability and manufacturability.

 Additionally, the material of the upper layer may contain 100 wt. including the main composition: mainly up to 20 wt. including pigments and / or dyes; mainly up to 30.0 parts by weight a modifier or a mixture of modifiers selected mainly from the group: butyl rubber (waste butyl rubber), ethylene propylene rubber (waste ethylene propylene rubber), stearic acid; mainly up to 10.0 wt. including a stabilizer or a mixture of stabilizers, mainly based on phosphoric acid esters; mainly up to 60.0 wt. including at least one of the dispersed fillers selected from the group: chalk, kaolin, aerosil, glass beads; mainly up to 50.0 parts by weight at least one of the fibrous fillers, with a fiber length predominantly up to 10 mm, selected from the group: chopped fiberglass, shredded cord waste from tire processing, shredded rubber-cord waste from tire processing, wood fibers, shredded waste from the production of synthetic and artificial fibers.

 The use of various additives (pigments and dyes, modifiers, stabilizers, dispersed and fibrous fillers) allows to obtain the material of the upper layer with the required level of consumer properties (color, texture) for a wide range of applications: waterproofing, roofing roll and sheet, floor coverings roll and sheet.

 The material of the top layer may also have a different surface design, while the amount of surface relief is comparable to the thickness of the material of the top layer.

 The lower layers of the material essentially represent a material similar to the well-known "hydroglass glass", which ensures the reliability of sealing the joints of the material, as well as the simplicity and adaptability of laying the material on the surface using known technologies.

The production of the proposed multilayer material for protective coatings of building structures and structures can be carried out by the following well-known techniques: passing the substrate through molten bitumen, followed by applying the upper protective layer by knurling and cooling the material. In contrast to the known methods, the temperature of the molten bitumen ranges from 100 ^o C to T _pl + 40 ^o C, and the temperature of the upper layer when applied is from T _pl - 90 to T _pl - 5 ^o C, where T _pl is the melting temperature thermoplastic contained in the top layer.

 The multilayer material can be produced on conventional standard equipment, which is used to obtain a material such as hydrostekloizol. In this case, the fiberglass tape after unwinding, drying and impregnation with hot bitumen is fed to the squeeze rolls simultaneously with the layer of the molded upper layer, where the materials are bonded, then the material is cooled as a whole and goes through the whole technological scheme for producing hydroglass glass.

The invention is illustrated by the following examples:
Example 1
The upper (first) layer of the material 1 mm thick consists of crumb rubber up to 0.5 mm in size (50 parts by weight), low density polyethylene (PTR 2 g / 10 min, 50 parts by weight). The second and fourth layers of material consist of bitumen with a thickness of 1.5 mm each, the third layer of material consists of fiberglass with a mesh size of 1.5 mm. Furthermore, the color of the upper layer of the material is black.

The material is prepared as follows:
Bitumen layers are applied to fiberglass from both sides. The material obtained, which is at a temperature of 130 ^o C, is applied to the material of the upper layer, the temperature of which is 98 ^o C. The resulting multilayer material has a thickness of the upper layer of 1.1 mm and a total thickness of bitumen layers of 3.5 mm

Thus obtained material has a rough outer surface, is intended for waterproofing and has the following deformation-strength and physico-mechanical properties:
Breaking strength - 5.0 MPa.

 Elongation at break - 55%.

 Resistance to transmission of water under pressure (sample d = 190 mm, water pressure 1.52 MPa, mesh with a size of 2.5 mm, for 16 hours) - no water transmission.

 Water absorption - less than 1.5%.

Frost resistance (bending method, spike d = 5.0 mm) - (-) 30 ^o C.

 The coefficient of resistance (the ratio of tensile elongation after aging in acid to the initial tensile elongation) to acids (sulfuric acid, 50 wt.%, 240 hours) is 0.93.

 The coefficient of resistance (the ratio of tensile elongation after exposure to alkali to the initial tensile elongation) to alkalis (NaOH, 20 wt.%, 240 h) is 0.96.

The coefficient of thermal stability (the ratio of tensile elongation after holding at temperature to the initial tensile elongation, temperature 75 ^o C, 240 h) - 0.97.

Example 2
The upper (first) layer of the material 1 mm thick consists of crumb rubber up to 0.5 mm in size (80 parts by weight), low density polyethylene (PTR 2 g / 10 minutes, 20 parts by weight). The second and fourth layers of material consist of bitumen with a thickness of 1.5 mm each, the third layer of material consists of fiberglass with a mesh size of 1.5 mm. Furthermore, the color of the upper layer of the material is black.

The material is prepared as follows:
Bitumen layers are applied to fiberglass from both sides. The material obtained, which is at a temperature of 130 ^o C, is applied to the material of the upper layer, the temperature of which is 14 ^o C. The resulting multilayer material has a thickness of the upper layer of 1.1 mm and the total thickness of the bitumen layers of 3.5 mm

Thus obtained material has a rough outer surface, is intended for waterproofing and has the following deformation-strength and physico-mechanical properties:
Breaking Strength - 2.0 MPa
Elongation at break - 55%.

 Resistance to transmission of water under pressure - no water transmission.

 Water absorption - less than 1.5%.

Frost resistance - (-) 32 ^o C.

 The coefficient of resistance to acids is 0.92.

 The alkali resistance coefficient is -0.97.

 The coefficient of thermal resistance is 0.91.

 Examples 3 to 9 The composition of the material of the upper layer is shown in table. 1, the material properties of the upper layer of the multilayer material in table. 2, the conditions for applying the upper layer and the thickness of the layers of the multilayer material are shown in table 3.

 The proposed material has the following advantages: firstly, the production of the proposed multilayer material is a method of recycling polymer rubber waste, which significantly improves the environmental situation. Secondly, the use of a rubber-thermoplastic layer in a multilayer material makes the coating of such a material significantly more durable, since the protective layer is not only highly resistant to weathering, but also to acids, alkalis, oils and various organic solvents. Thirdly, the proposed material is very technologically advanced in use, since it contains a low-melting layer and can be laid according to the technology of a conventional waterproofing material - hydroglass glass. Fourthly, the protective layer of the material can be colored in bulk, which gives the material an attractive appearance that preserves the entire service life of the coating.

Claims (5)

1. A multilayer material for protective coatings of building structures and structures, containing a substrate coated on both sides with bitumen layers, and an upper protective layer, characterized in that the upper layer is previously prepared from melt-mixed components of the composition, consisting of at least a thermoplastic and rubber powder deposited on molten bitumen at a temperature of the upper layer of 5 - 90 ^o C below the melting temperature (glass transition) of the thermoplastic.  2. The material according to claim 1, characterized in that the top layer of the material as a thermoplastic contains low-density polyethylene or a mixture of low-density polyethylene in an amount of mainly 20 to 50 wt.h. based on 100 parts by weight mixtures of polyolefin (polyolefins) and rubber powder.  3. The material according to claims 1 and 2, characterized in that the upper layer of the material as a rubber powder contains a powder of predominantly a size of up to 1 mm in an amount of mainly 50 to 80 parts by weight based on 100 parts by weight mixtures of thermoplastic and rubber powder.  4. The material according to claims 1 to 3, characterized in that the top layer of the material further comprises at least one stabilizer, and / or one modifier, and / or one filler, and / or one dye with a total content of up to 72.5 wt. .h. based on 100 parts by weight mixtures of thermoplastic and rubber powder.  5. The material according to claims 1 to 4, characterized in that the substrate contains a fabric or non-woven material based on natural and / or synthetic and / or glass fibers or paper.

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