WO2008055906A2

WO2008055906A2 - Method of ceramic tiling using synthetic polymers for prefabricated swimming pools made of the same material

Info

Publication number: WO2008055906A2
Application number: PCT/EP2007/061943
Authority: WO
Inventors: Jesús López Martín; Susana Mancebo Montoro
Original assignee: Lopez Martin Jesus; Susana Mancebo Montoro
Priority date: 2006-11-06
Filing date: 2007-11-06
Publication date: 2008-05-15
Also published as: ES2299379B1; ES2299379A1; WO2008055906A3

Abstract

Method of lining prefabricated swimming pools made of reticulated synthetic polymers using ceramic material consisting of the application of a layer of adhesive on the surface of the swimming pool or on the back part of the ceramic material (the side that will not be in contact with the water in the pool). The adhesive used is biphasic in nature with a component A (with a specific composition based on an epoxy resin) that acts as a sticking agent and a component B (with another set composition) that acts as a hardening and reticulating agent. The mixture of components A and B of the adhesive makes up the adhesive layer that bonds the ceramic tiling to the reticulated synthetic polymer surface of the swimming pool. This document also describes a swimming pool created according to this method.

Description

METHOD OF CERAMIC TILING USING SYNTHETIC POLYMERS FOR PREFABRICATED SWIMMING POOLS MADE OF THE SAME MATERIAL.

Technical scope of the invention

This invention falls under the technical category of prefabricated swimming pools in the case where one would like to decorate the structural body, which contains the water, either totally or partially, with mosaic tile-style decorative elements made of ceramic materials.

State of the art

In the past and still today in select circumstances, e.g. in the case of large sports complexes, swimming pools have traditionally been built on site. That is to say, a blueprint design was prepared including the shape and dimensions (length, width and depth profile) of the swimming pool and any related facilities (showers, filters, pumps, drains, stairs, trampolines, etc.); the site was excavated in accordance with the agreed architectural plan; and the resulting hole was lined with concrete, typically with additional layers of minerals or synthetic textiles to better guarantee that the pool was watertight and to avoid any loss of water from the body of the pool. Then, the structural body was painted, usually with waterproof paints, and/or was decorated, usually with ceramic tiles. The bond between the concrete or other mineral layers that could be used to line it (plaster, etc.) and the ceramic tiling was relatively unproblematic, since it represented a bond between analog materials capable of interacting on a physical, mechanical and chemical level. It is sufficient to cite the lining of bathrooms and kitchens in private housing, where ceramic liners, such as tiles, are applied to the walls using mineral putties, plaster, etc. For the purposes of this document, the term should be understood in its broadest definition, which, by way of example, includes but is not limited to glazed tiles, flagstones, tesseras, mosaic tiles, plaques, paving stones, plates, etc. made from any ceramic material or fired clay or milled pieces of stone subjected to thermal processes, including assemblies of natural stone, such as marble, granite, slate, etc. as well as combinations of the same. The disadvantages of this traditional method for manufacturing swimming pools were their cost and the fact that they could not be reproduced on an industrial scale, since every design and assembly or installation was unique to each customer and to the plot of land available. Furthermore, this sort of "traditional" swimming pools exhibits the issue of cracking in the structure on account of expansion due to variations in seasonal (summer-winter) or day (night-day) temperature, being as they are exposed to the elements. This meant that expansion joints had to be included in the installation of any swimming pool project.

As a result of the increasing standard of living in Western countries, an ever- increasing percentage of the population has access to a second residence for leisure purposes. This type of second residence very frequently includes outdoor swimming pools, especially in warmer countries, for swimming in the hotter months of the year. As such, there was a need for creating swimming pools adapted to this new socio- economic reality that maintained all of the technical characteristics of their traditional counterparts, more specifically — and understandably — that the structural body of the pools did not leak the water contained in them. The technical solution that was chosen was prefabricated swimming pools made of reticulated — and preferably — reinforced synthetic polymers.

Prefabricated swimming pools made of polymers have been available for years. They imply considerable savings in the installation of pools in private residences, because they permit the standardization of the production process according to a selection of models produced by each manufacturer. Because they can be mass- produced in large batches, manufacturers can optimize their investments in the industrial processes, especially the molds, needed for their production. With such pools, the transition was made from traditional swimming pools made on site for each customer with a specific design and ad hoc assembly to a system of mass-produced factory production removed from the site of installation and standardized assembly, given that the process repeats itself for the varying models of swimming pool structures produced.

This system of off-site production of swimming pool structures made of reticulated, reinforced synthetic polymers has made this type of facilities accessible to a broad range of different customers, for it implies a considerable reduction in the cost of production and installation. The insulation, defined as the impermeability of the pool to water leakage, is even better, because synthetic polymers possess a degree of flexibility, which makes the use of expansion joins unnecessary. Furthermore, this type of swimming pools has smooth edges that do not allow for grime to accumulate as easily, making them easier to clean. They also have shorter installation times, usually 4 to 5 days. However, the synthetic materials used to construct the bodies of prefabricated swimming pools, which is generally blue in color, exhibit some primary disadvantages:

a) They are slippery, with the corresponding risk for users as they walk along the slippery base of the pool or the risk of falling when entering or exiting swimming pools that include steps made of the same synthetic material that are integrated into the pool's structure. b) All of the structures are very similar, and customers demand personalized swimming pools according to their individual preferences as well as integration in the immediate vicinity of their homes or the natural environment surrounding the plot where the pool is to be installed.

The problem of keeping bathers from slipping was solved by means of a non- slip engraving added during the production of swimming pools of reticulated, reinforced synthetic polymers. This engraving is carried out on the surface of the pool's structure and constitutes and additional step in the production process, with the corresponding disadvantages in terms of increase cost and processing time.

For this reason, there have been different attempts to solve both problems without including any extra steps in process of producing structures of reticulated synthetic polymers, as is the case of adding a non-stick engraving to its surface. The solution would be to cover the prefabricated structures with a mineral material, such as small mosaics. For one, mosaics increase friction, thus avoiding undesired slipping and sliding. Because there are an infinite number of potential designs, dimensions, decorative themes, colors and combinations of the above, they also make it possible to personalize individual swimming pools. In the case of small mosaic tiles or tesseras, the increase in friction is sue to the elevated number of pieces per square meter of the surface of the swimming pool. Because they are individual pieces, they include divisions, which separate them from other pieces, such as furrows or height differences between them, which prevent bare feet from slipping when coming in contact with them as one swims. In the case of larger pieces (glazed tiles, paving stones, etc.), the general preference is for decorative tiling with rougher surfaces, even though they also exhibit such non-slip divisions, being as these increase friction and thereby prevent slippage. The problem that has been encountered in the various attempts to line the structure of prefabricated swimming pools of reticulated synthetic polymers using mineral compounds such as flagstones, glazed tiles or mosaic tiles is that these materials do not stay in place for long and end up becoming detached, resulting in, among others:

i. An undesirable look ii. Plugged filters iii. Cuts and injuries in pool users

For these reasons, it was necessary to find a lasting method for lining the structural bodies of swimming pools made from reticulated synthetic polymers using a decorative mineral material.

Document JP5321441 shows a method for sticking tiles to a swimming pool, using silicone rubber adhesive to attach tiles to fibre reinforced unsaturated polyester resin. Document JP2000328804 discloses a plastic board reinforced with glass fibre made of thermosetting urethane group resin or polyester, wherein ceramic tiles are affixed on the surface of plastic board using epoxy group adhesives.

Brief description of the invention

The method of the invention consists of adhering ceramic material, primarily in the form of mosaic tiles, using adhesives with technical characteristics that make them especially suited to the invention. These mosaic tiles may be adhered either individually or as plaques connected together by means of a mesh or net or on pieces of PVC, all of which serve as a support mechanism for the mosaic tiles and are impregnated with adhesive. These plaques may be placed whole, as supplied, or may be cut into sections or strips to adapt to the dimensions of different parts of the swimming pool or auxiliary installations (edges, overflow tanks, foot wash station, stairs, etc.). The surface of the prefabricated swimming pool structure does not need be pre- treated in order to apply the adhesive. The structure may be covered with the ceramic material in this invention exactly as it is; no prior mechanical or chemical surface treatment is necessary. This shortens the production time and costs. For this, a biphasic adhesive made up of the following two components was chosen:

A. - Epoxy resin

B. - Hardening agent + reticulating agent for the epoxy

Both components are mixed in set proportions and are applied directly to the surface of the swimming pool structure. Because it dries very quickly, the layers of mosaic tile are placed as the adhesive is spread. The preferred material for the mosaic tiles to be used is Gresite ®. Gresite ® is defined as mosaic tiles, which are usually small and square in shape (1 cm x 1 cm to 5 cm x 5 cm), made of vitrified ceramics, with a smooth or rough surface. The glass portion faces out in contact with the water or the air. The back is usually not vitrified.

Detailed description of the invention

A lasting lining for the structure of a prefabricated swimming pool made of reticulated synthetic polymers, whose surface has not been pre-treated, is understood to be one whose ceramic elements, preferably mosaic-style tiling, do not come loose for a period of at least 5 years. One of the advantageous achievements of the invention is that it covers the structures of prefabricated swimming pools with Gresite ® made from isophthalic polyester resins reinforced with fibers and glass cloth.

One of the advantageous adhesives of the invention is biphasic in nature, consisting of two components (A+B) that must be mixed together in advance and applied to the surface of the swimming pool structure straight away, with no need to pre-treat the surface of the pool, a process carried out practically in unison or in a short interval of 2-5 minutes prior to the placement of the mosaic tiles. Lines of 4 to 8 meters of adhesive are spread out over the surface of the swimming pool and the vitrified ceramic tiles are then placed on it. A variant to this process is to apply the adhesive directly to the backside of the lining material, instead of on the surface of the swimming pool. Mosaic tiles have two sides: the front, which comes in contact with the water and is decorated, in terms of color, finish (enamel, roughness, channels, etc.), etc. The other side of the mosaic tile or tesseras does not usually contain such decoration and is attached to the meshwork that holds the tiles together in a plaque. This backside is the side that will be in contact with the adhesive.

The ration between components A and B is 9:1, respectively. Component A is an epoxy resin with the following composition:

Product of the reaction bispheno 1 A-epichlorhydrin; epoxy resin 2.5-10%

Diisobutyl phthalate 2.5-10%

Toluene 1-2.5% Aliphatic glycidyl ether 1-2.5 %

Nonylphenol 0.5-1.0%

Component B of the adhesive is a mixture of a hardening agent and a reticulating agent for the epoxy made up as follows:

Benzyl alcohol 10-25%

2,4,6-tri(dimethylaminomethyl)phenol 10-25% m-phenylenebis(methylamine) 10-25 %

3-aminomethyl-3,5,5-trimethylcyclohexylamine 10-25% Polyethylene polyamines 2.5-10%

Nonylphenol 2.5-10%

Benzyldimethylamine 1-2.5%

Component A of the adhesive is the component that works as the sticking agent, while component B acts as a hardening agent and reticulating agent for the adhesive applied to the back of the ceramic material used to line the pool. Surprisingly, whereas other adhesives were not able to guarantee the lasting adherence of mosaic tiles to the surface of prefabricated swimming pools made of reticulated synthetic polymers, findings show that the adhesive included in this invention provides for a lasting connection between the surface of the swimming pool and the Gresite ® lining.

Successful test results were also obtained with glues made of polyurethane and isocyanates or diisocyanates (Poliur Seal AS-734® and Flexipur®, respectively). In such cases, the adhesive is made up of just one component, obviating the need to pre- mix two components in set proportions. None of the adhesives described in here has been used before, and they were never intended for use in the joining of reticulated, reinforced synthetic polymers, such as those used to make prefabricated swimming pools, with ceramic materials — or mineral materials in general — such as Gresite ©-style glass mosaic tiles.

In general terms, the method of the invention was to try out different types of adhesives until finding those which, on account of their chemical composition, were capable of forming a lasting bond between two materials as chemically different as the surface of prefabricated swimming pools and the mineral material used to line them. The surface of prefabricated swimming pools is made of reticulated, reinforced synthetic polymers, i.e. organic polymers. The ceramic lining has a mineral basis, and is, as such, inorganic in nature. The bond between two substances that are physically so different and have widely disparate chemical compositions was only possible on account of the surprising characteristics of the chemical interrelation between these two materials exhibited by the adhesives used in the method of this invention. These characteristics are based on the chemical composition of each adhesive and their characteristics in the case of forming bonds between the organic composition of the swimming pool and inorganic composition of the lining, making their bond lasting in nature.

Once the mosaic tiles have been adhered in place, the space between them must be made water and airtight in order to avoid the formation of gaps or separations, which could permit the entry of water or — in the case of extremely low temperatures — ice, which, in turn, could respectively erode or serve as a wedge, causing the mosaic tiles to become detached and fall away and provoke the consequences described above. For this, the final step in lining prefabricated swimming pools made of reticulated synthetic polymers consists of filling in the spaces between the mosaic tiles. There are several methods for doing so, including:

a) Grout with cement b) Elastic joint cover, with optional color c) Porcelain joint cover d) Latex joint cover, which is the preferred method for this invention.

Claims

C L A I M S

1. - Method of lining prefabricated swimming pools made of reticulated synthetic polymers using ceramic material consisting of: the application of a layer of adhesive on the surface of the swimming pool the application of a layer of adhesive on the back part of the ceramic material

(the side that will not be in contact with the water in the pool), whereby the adhesive used is biphasic in nature with a component A that acts as a sticking agent and a component B that acts as a hardening and reticulating agent, characterized in that components A and B of the adhesive exhibit the following compositions: component A:

Product of the reaction bispheno 1 A-epichlorhydrin; epoxy resin 2.5-10% Diisobutyl phthalate 2.5-10% Toluene 1-2.5%

Aliphatic glycidyl ether 1-2.5 %

Nonylphenol 0.5-1.0% component B:

Benzyl alcohol 10-25% 2,4,6-tri(dimethylaminomethyl)phenol 10-25% m-phenylenebis(methylamine) 10-25 %

3-aminomethyl-3,5,5-trimethylcyclohexylamine 10-25%

Polyethylene polyamines 2.5-10%

Nonylphenol 2.5-10% Benzyldimethylamine 1-2.5% and the mixture of components A and B of the adhesive makes up the adhesive layer that bonds the ceramic tiling to the reticulated synthetic polymer surface of the swimming pool.

2. - Method as per claim 1, where components A and B of the adhesive are mixed in a 9:1 ratio.

3. - Method as per either of the previous two claims, where the lining of ceramic material is selected among mosaic tiles, glazed tiles, flagstones, tesseras, paving stones, or any combination of these materials.

4. - Method as per any of the previous claims, where the reticulated synthetic polymer of the swimming pool to be lined is an isophthalic polyester resin reinforced with fibers and/or glass cloth.

5. - Method as per any of the previous claims, where once adhered in place, the creaming lining is made air and watertight in order to prevent the formation of gaps or separations, which could permit the entry of water or ice, by filling in the spaces in the ceramic lining with one of the following methods:

- Grout with cement,

- Elastic joint cover, with optional color, - Porcelain joint cover, or

- Latex joint cover.

6. - Prefabricated swimming pool made from reticulated synthetic polymers, where the part of its structure which contains the water is covered, either totally or partially, by a ceramic material with lasting adherence to the synthetic polymer surface of the swimming pool by means of a biphasic adhesive with component A, which acts as a sticking agent, and component B, which acts as a hardening and reticulating agent, characterized in that components A and B of the adhesive exhibit the following compositions: component A:

Product of the reaction bispheno 1 A-epichlorhydrin; epoxy resin 2.5-10% Diisobutyl phthalate 2.5-10%

Toluene 1-2.5%

Aliphatic glycidyl ether 1-2.5% Nonylphenol 0.5-1.0% component B:

3-aminomethyl-3,5,5-trimethylcyclohexylamine 10-25%

Polyethylene polyamines 2.5-10% Nonylphenol 2.5-10%

Benzyldimethylamine 1-2.5% and the mixture of components A and B of the adhesive makes up the adhesive layer that bonds the ceramic tiling to the reticulated synthetic polymer surface of the swimming pool.

7. - Swimming pool as per claim 6, where components A and B of the adhesive are mixed in a 9: 1 ratio.

8. - Swimming pool as per either of claims 6 or 7, where the lining of ceramic material is selected among mosaic tiles, glazed tiles, plates, flagstones, plaques of mineral material, tesseras, paving stones, or any combination of these materials.

9. - Swimming pool as per any of claims 6 through 8, where the reticulated synthetic polymer of the swimming pool to be lined is an isophthalic polyester resin reinforced with fibers and/or glass cloth.