RU2307887C2 - Covering production method - Google Patents

Abstract

FIELD: construction, particularly coverings for sport and playing grounds, pavements, all-purpose mats and so on with the use of ecologically-friendly materials based on rubber and tire scrap, as well as artificial rubber.

SUBSTANCE: method involves preparing filler, namely rubber crumb, and binding material, namely polymeric mass; mixing thereof in mixer; pouring the obtained mix on base. The filler has 1.0-70.0 particle dimensions. Filler/binding material ratio is from 10:0.5 to 10:10. Filler and binding material are mixed at temperature exceeding 2°C in screw mixer having reversible drive up to homogenous mass obtaining. Binding material is added after filler introduction during mixing operation. Ready mix is unloaded by means of screw mixer. Before mix pouring base is cleaned of dirt and dust and covered with primer. The mix is poured after at least partial primer drying to reach mix layer thickness more than 2 mm on base. After that the mix is covered with film to prevent mix adhering to working tools. Then the covering is smoothed, compacted and cured for total hardening thereof.

EFFECT: increased productivity, decreased production costs, simplified technology and extended range of technical capabilities.

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Description

The invention relates to the field of construction, and in particular to a method for the manufacture of coatings using environmentally friendly materials based on the processing of waste from the tire and rubber industries, as well as artificial rubber.

The prior art known method is a porous coating (patent RU No. 2034808 C1, E01C 13/00, publ. 05/10/1995), which consists in preparing a plastic mass based on the filler in the form of crumb rubber and a binder in the form of a polymeric material, in addition bitumen, a fibrous filler, an antiseptic are introduced into the mixture, all this is mixed in a mixer. The resulting mixture is laid in an even layer on the base. In the manufacture of this coating requires mandatory heating of the material to 160-180 ° C. Another drawback of this solution is its limited technical capabilities, since it does not provide high-quality alignment of the unevenness of the base, it is necessary to align large irregularities first mechanically, which significantly increases the cost of the work on the manufacture of the coating, in addition, in the process of performing operations on the working surface of the tools, particles of the mixture stick to cover.

The problem to which the invention is directed is to increase productivity, reduce costs and simplify the technology of coating production by reducing operations during their manufacture and using advanced equipment while improving product quality, expanding technical capabilities by creating a technological one with an optimal combination of plastic and elastic properties in a large temperature range with a high coefficient of adhesion (anti-skid), wear-resistant coating.

The technical result consists in the fact that in the manufacture of the coating simple and environmentally friendly components are used that do not require heat treatment when mixing, which significantly reduces energy costs and cost, is relevant for areas with a cold climate. Another feature of the method is the exclusion of adhesion of the mass prepared for coating the tool, and the process parameters used — mixing temperature, fraction size of the components used, and their mass ratio — made it possible to form a broad-based coating of a single integral structure with high physical properties across the layers and in general. In addition, the technical result consists in combining the operations of mixing and mixing the components of the mixture with one working body - the screw, changing the direction of its rotation, with the operation of unloading the prepared mass along the axis of the screw shaft.

To achieve a technical result in solving the problem in the known method of manufacturing a coating, which consists in preparing a filler in the form of rubber crumb and a binder in the form of a polymer mass, they are mixed in a mixer, the resulting mass is laid on a base, the filler is used in fractions of 1.0 -70.0 mm, taken in relation to the binder in parts by weight of 10: 0.5-10.0, the mixing process is carried out at a temperature exceeding 2 ° C in a screw mixer with a reversible drive to obtain a single the bottom of the mass, while the binder is introduced after the filler during mixing, and the resulting mass is unloaded with a screw mixer, the foundation is cleaned of dirt and dust and primed before laying, and the prepared mixture is laid after the primer is partially or completely dried, the mixture is laid with a thickness of more than 2 mm , a film is placed on the decomposed mixture to prevent the mixture from sticking to the working tools, the coating material is leveled and compacted, then the prepared coating is maintained until completely hardened.

Other embodiments of the invention are possible, according to which it is necessary that:

- during the mixing process, dye would be added to the mixture in an amount of 0.03 to 0.1 parts by weight;

- mixing would be carried out in a screw mixer with a horizontal screw, the top loading of the mixture components and unloading along the axis of the screw;

- would use a film based on a polymer material;

- for laying the mixture on the surface of the base, a trowel or a spatula would be used, for leveling and initial compaction of the laid mass - at least one roller, and for compaction - ramming means in the form of a pest;

- all tools would be treated with a solution to prevent adhesion of particles to the coating mass;

- a layer of polymer material would be applied to the working surface of all tools to prevent adhesion of particles to the coating mass.

Signs are essential and interconnected causal relationship with the formation of a set of essential features sufficient to achieve a technical result.

Figure 1 shows the first embodiment of the coating.

Figure 2 - the second embodiment of the coating.

Figure 3 is a third embodiment of the coating.

The invention is illustrated by specific examples of implementation, which, however, are not the only possible, but clearly demonstrate the possibility of achieving this set of essential features of a given technical result.

According to the invention, a method of manufacturing a coating consists in preparing a filler in the form of crumb rubber, which is obtained from waste from the tire and rubber industries or from artificial rubber. As a binder, a polymer-based mass is used. The filler is used in fractions of 1.0-70.0 mm, taken in the ratio to the binder in parts by weight of 10: 0.5-10.0. The filler and binder are mixed at a temperature exceeding 2 ° C in a screw mixer with a reversible drive until a homogeneous mass is obtained, while the binder is introduced after the filler in the mixing process. The resulting mass is also unloaded with a screw mixer. Preliminarily, the foundation before laying is cleaned of dirt and dust and primed with the types of primers known in construction, for example, based on PVA glue, and the laying of the prepared mixture is carried out after the primer is partially or completely dried. The mixture is laid with a thickness of at least 2 mm, the coating thickness is determined in each case separately on the basis of the destination conditions and the required properties of the coating, if necessary, the coating can be made with a thickness of about 70 mm. In order to prevent adhesion of the mixture particles to the tool on the decomposed mixture, a film is laid out to prevent the mixture from sticking to the tool, the coating is leveled and sealed.

After that, the prepared coating is maintained until completely hardened.

In order to expand the functionality and aesthetic features of the coating during mixing, the corresponding dye is introduced into the mixture in an amount of from 0.03 to 0.1 weight parts.

To improve the quality of the resulting mixture and reduce time, the mixing is carried out in a screw mixer with a horizontal screw, the top loading of the mixture components and unloading along the axis of the screw.

Also, an increase in productivity is affected by the use of a trowel or blade for laying the mixture on the surface of the base, for leveling and initial compaction of the laid mass - at least one roller, and for compaction - tamping means in the form of a pest. In this case, all tools are treated with a solution to prevent adhesion of the particles of the coating mass or their working surface is covered with a layer of polymer material to prevent adhesion of the particles of the coating mass.

Example No. 1. Coating 1 is (Fig. 1) a multilayer structure consisting of at least one layer 2 of polymeric material and at least one porous layer 3, which is a hardened binder 4 based on a polymeric material with a filler placed in it in the form of rubber crumb 5 fraction from 0.5 to 20 mm in a mass ratio, forming a porous structure, namely in the ratio of rubber crumb to a binder in weight parts of 10: 0.5-10.0.

The porous layer 3, depending on the purpose and operating conditions, can be located above or below, or between layers 2 made of a polymer material, while these layers 2 and 3 are interconnected with the possibility of the formation of a monolithic permanent coating.

Below are some examples of implementation depending on the purpose of the coating.

Example No. 2. Coating 1 (Fig. 2) with respect to flooring of livestock farming can consist of one porous layer 3, which is the lower layer placed on the base 6, and one layer 2, which is the upper layer made of a polymer material. Layers 2 and 3 are interconnected with the possibility of the formation of an integral structure with a high-strength working surface 7. For the technology of servicing ungulates, it is especially important that the floor covering is on one side relatively elastic, heat-insulating, not stone, and most importantly with a very strong working surface. The proposed solution satisfies these requirements. The implementation of the upper layer 2 of polyurethane allowed to increase the strength properties of the coating 1 for the floor of the premises for animals. It is especially worth noting that animals, in particular horses, while in stalls where the floor of the construction described above is placed on the floor, did not paint it with hooves, as was the case with the stone floor. Performing a floor covering on one floor is elastic, has a beneficial effect on animals, does not disturb their psyche and, as it were, “pacifies” their condition. In order to optimize the cost-strength characteristics, the coating 1 for the floor of livestock farms is performed with an upper layer 2 of a thickness "t" of at least 0.5-5.0 mm and a lower porous layer 3 of a thickness of "T" equal to 3.0-20, 0 mm

Example No. 3. The design of the coating 1 (Fig. 3), as applied to it as a deck coating, consists of one porous layer, which is the upper layer 3, and one layer, which is the lower layer 8, made of a polymeric material and connected to deck 9. Layers 3 and 8 are interconnected with the possibility of the formation of an integral structure.

The implementation of the upper layer 3 porous contributes to the effective removal of liquid from the surface, reduces vibration, provides noise absorption, in addition, this coating improves performance due to the prevention of sliding on the surface.

In order to obtain the optimal cost-strength characteristics of the deck covering, taking into account the operating conditions of the vessel (sea, river, latitude, longitude, etc.), the lower layer 8, connected to the top of the deck 9 and made of polymer material, has a thickness of "t", equal to 0.5-3.7 mm, and the upper layer 8 is a thickness of "T" equal to 3.0-27.0 mm

For the implementation of high-quality layout of the mixture using a set of tools for laying the coating, made on the basis of a polymer material with rubber crumb. The kit includes a means for applying the mass from which the coating is made on the surface of the base. The specified tool is made, for example, in the form of a trowel or scapula, with which the mass is laid out on the base. One or two rollers may be used in the kit. If there is one roller in the set, it provides a seal of the decomposed mass and smoothing of the coating surface. If there are two rollers in the set, they are made different in weight, one of which is made of greater weight in order to effectively compact the mass spread on the base and pre-align the coating, and the other is of less weight in order to level the surface of the coating with it. In addition, the kit includes a ramming tool.

In this case, the ramming means can be made in the form of a pest and a coating is made on its working surface to prevent sticking of particles of the rammed mass. All tools immediately before laying the coating can be treated with a solution to prevent adhesion of particles of the coating mass, for example with a polymeric material or turpentine.

The coating is made as follows.

The manufacturing technology of the coating is as follows.

Wastes from the tire and rubber industry, crushed to a crumb with a fraction of up to 10 mm in the amount of 3 parts by weight, a binder, which is a substance based on polyurethane, in the amount of 1 part by weight, and a dye representing iron oxide, in the amount of 0.06 parts by weight they are mixed in a screw mixer with a horizontal screw and with a reversible drive, which compacts the mixture during mixing. The components of the mixture are loaded from above. In this case, the binder is introduced after the filler and dye in the mixing process, which is carried out at a temperature exceeding 2 ° C, until a homogeneous mass is obtained. Mixing is carried out alternately in one and in the other direction by rotating the screw until a mass is uniform in color. In addition, with stirring, you can enter the catalyst in an amount of 1% by weight of the mixture to enable the process to be carried out at low temperatures.

When preparing the mixture, it is necessary that the filler is always dry, and that water does not get into the binder, as this will spoil the binder and the mixture as a whole. The fraction of rubber crumb should be the same, since its different sizes will cause heterogeneity in the color of the mixture as well as non-observance of the proportions of the weight parts in the mixture and spoil the appearance of the product.

The resulting mass is discharged by a screw mixer into a prepared container. Before the layout, the surface is cleaned of dust and dirt and primed, for example with a solution based on PVA glue. After the primer has dried, the resulting mixture is laid out on an uneven surface with an even layer of thickness exceeding 2 mm, the resulting coating is leveled, compacted by ramming, rolled with a light roller and maintained until it completely hardens, since the mixture hardens when the coating comes in contact with water vapor .

When laying the coating on concrete or asphalt, it is first necessary to treat them with a primer or primer for better adhesion and to avoid moisture. The coating thickness in this case should be at least 4-5 mm. When laying on the ground or sand and gravel, it should be spilled with water and carefully packed for less consumption of the mixture. The coating thickness should be at least 15 mm. Geotextile fabric can be attached to the ground before laying the mixture to protect the mixture from contact with the ground.

The resulting product meets the specified requirements.

As a result, using this method, it is possible to obtain a colored durable porous material from rubber crumb, a polyurethane binder and pigments that give a color, which is laid by the method of self-leveling floors and leveled on work tables or on any surface: soil, sand, concrete, asphalt, granite dusting and etc. In this case, the binder provides a strong connection with a solid surface.

Claims (7)

1. A method of manufacturing a coating, which consists in preparing a filler in the form of rubber crumb and a binder in the form of a polymer mass, mixing them in a mixer, the resulting mass is laid on a base, characterized in that they use a filler fraction of 1.0-70.0 mm, taken in relation to the binder in parts by weight of 10: 0.5-10.0, the mixing process is carried out at a temperature exceeding 2 ° C in a screw mixer with a reversible drive until a homogeneous mass is obtained, while the binder is introduced after the filler into percent mixing, and the resulting mass is unloaded with a screw mixer, the foundation is cleaned from dirt and dust and primed before laying, and the prepared mixture is laid after the primer is partially or completely dried, the mixture is laid with a thickness of more than 2 mm, a film is laid out on the decomposed mixture to prevent the mixture from sticking to working tools, level and compact the coating, then maintain the prepared coating until completely hardened. 2. The method according to claim 1, characterized in that during the mixing process, dye is introduced into the mixture in an amount from 0.03 to 0.1 parts by weight. 3. The method according to claim 1, characterized in that the mixing is carried out in a screw mixer with a horizontal screw, the top loading of the mixture components and unloading along the axis of the screw. 4. The method according to claim 1, characterized in that they use a film based on a polymeric material. 5. The method according to claim 1, characterized in that a trowel or a spatula is used to lay the mixture on the surface of the base, at least one roller is used for leveling and initial compaction of the laid mass, and tamping means in the form of a pest is used for compaction. 6. The method according to claim 5, characterized in that all the tools are treated with a solution to prevent adhesion of the particles of the coating mass. 7. The method according to claim 5, characterized in that on the working surface of all the tools a layer of polymer material is applied to prevent adhesion of particles of the coating mass.

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