WO2019222790A1

WO2019222790A1 - A concrete surface sealing system

Info

Publication number: WO2019222790A1
Application number: PCT/AU2019/000061
Authority: WO
Inventors: Brian KISSENBERGER; Jason MUSTUKAS
Original assignee: Water Based Sealers Pty Ltd
Priority date: 2018-05-21
Filing date: 2019-05-20
Publication date: 2019-11-28

Abstract

The invention provides a concrete surface sealing system including a first sealant composition for application to cover a concrete surface, including a preservative-free non- crosslinked water-soluble acrylic polymer; a second sealant composition for application to the first sealant composition-covered surface, including a preservative-free cross-linked water-soluble acrylic polymer; pressurised carbon dioxide for applying the first and second sealant compositions; and a spray assembly, the spray assembly including a trolley configured to support a gas canister containing the carbon dioxide and a container of one of the first or second sealant composition, the trolley including a planar base of irregular quadrilateral configuration in which a rim extends operably upward around at least part of the periphery of the base, the irregular quadrilateral configuration optimised to stabilise the canister and the container when in place.

Description

A CONCRETE SURFACE SEALING SYSTEM

FIELD OF THE INVENTION

Various embodiments of a concrete surface sealing system are described herein.

BACKGROUND TO THE INVENTION

Traditional standard sealing procedures for concrete generally use an oil- based system, where a completely dry concrete surface is required before application. Application of these systems exposes personnel to toxic chemicals including volatile organic compounds during application, which are hazardous to the personnel and the environment. Furthermore oil-based products can have lower than desired performance qualities with respect to UV stability, stain resistance and longevity. Application of oil-based products is generally labour intensive, and clean up can involve the use of further toxic chemicals, for example xylene. Responsible disposal of toxic chemicals is a serious and costly issue.

Water-based sealants are available, but can be prone to blushing, flaking and peeling caused by sunlight exposure and moisture damage. Pre-mixed water-based products require acidic preservatives to ensure acceptable shelf life of the product. When the preservative loses effectiveness, non-volatile organic compounds can affect the product’s composition and thereby the entire formulation. This can cause the product to fail due to its inability to polymerise as required. This results in a lack of clarity (blush) with moisture contact, and freeze/thaw cycles can cause further failure resulting in flaking and/or peeling.

Flaking is when a sealer appears opaque, similar to blushing, but in this case the sealer has aged and ruptured, and fragments that are not properly connected to the whole, detach from the surface.

Peeling is when the adhesion of the sealer is so weak that it is incapable of adhesion to the surface. Flaking is the prelude to peeling, and complete

removal/stripping is required in order to properly re-seal the surface.

SUMMARY OF THE INVENTION

According to one aspect of the invention, there is provided a concrete surface sealing system including: a first sealant composition for application to cover a concrete surface, including a preservative-free non-crosslinked water-soluble acrylic polymer;

a second sealant composition for application to the first sealant composition- covered surface, including a preservative-free cross-linked water-soluble acrylic polymer;

pressurised carbon dioxide for applying the first and second sealant compositions; and

a spray assembly, the spray assembly including a trolley configured to support a gas canister containing the carbon dioxide and a container of one of the first or second sealant compositions, the trolley including a planar base of irregular quadrilateral configuration in which a rim extends operably upward around at least part of the periphery of the base, the irregular quadrilateral configuration optimised to stabilise the canister and the container when in place.

The planar base of the trolley may be of trapezoidal configuration. At least one corner of the trapezoid may be outwardly curved.

The rim of the base may include an aperture defining a base handle in a front face of the rim. A cross-member may be positioned above a rear portion of the base, configured to accommodate each of the gas canister and the container of the first or second sealant composition. A bar may be attached to the base at each of two rear corners of the base, each bar extending operably upward from the base, and forming a trolley handle at a position above the base.

A crosspiece may be attached to the frame at a position between the trolley handle and the base, the crosspiece configured for further accommodation of at least one of the gas canister and the container of the first or second sealant composition.

A hose reel may be attached at a rear face of the crosspiece.

The trolley may include two wheels operably attached to either side of the cross-member. A tool caddy may be attached to the frame at a position between the trolley handle and the base. A hose reel may be attached at a rear face of the tool caddy.

The sealing system may include the cylinder of pressurised carbon dioxide and the container of the first or second sealant composition fitted to the base and crosspiece of the trolley, a first hose connecting the cylinder to the container, and a second hose connected to the container, the second hose configured for application of the first or second sealant composition to a concrete surface.

The non-crosslinked water-soluble acrylic polymer may be any appropriate polymer, including poly(methyl methacrylate).

The first sealant composition promotes adhesion of the sealing system to the concrete surface and increases the strength of the sealing system. This composition also promotes colour stabilisation of oxide coloured surfaces.

The crosslinked polymer may be any appropriate crosslinked polymer, including crosslinked polyacrylates.

This second composition provides the system with high wear properties and high stain resistance.

According to another aspect of the invention, there is provided a method of sealing a concrete surface using the sealing system described above, the method including:

applying, using the carbon dioxide as propellant, the first sealant composition to cover an area of the concrete surface;

applying, using the carbon dioxide as propellant, the second sealant composition to cover the area of the concrete surface covered by the first sealant composition.

The method may include applying a layer of water to the concrete surface before application of the first sealant composition. The water may be applied under high pressure of from 3000-3500 psi at from 10-20 litres water per minute.

The method may include diluting the first sealant composition with water before application to concrete surface. The first composition may be diluted to a solids content of from about 20% to about 50%.

The method may include applying a layer of water to the concrete surface covered by the first sealant composition before application of the second

composition. The water may be applied under high pressure of from 3000-3500 psi at from 10-20 litres water per minute.

The method may include diluting the second sealant composition with water before application to the concrete surface covered by the first composition. The second composition may be diluted to a solids content of from about 20% to about 50%.

The first sealant composition may be an aqueous solution of poly(methyl methacrylate) and the second sealant composition may be an aqueous solution of a mixture of poly(methyl methacrylate) and 2-(2-butoxyethoxy)ethyl acetate.

The first and second compositions may be applied in multiple layers.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a front perspective view of an assembly of the invention.

Figure 2 is a front perspective of a trolley for use in an assembly of the invention.

Figure 3 is a rear view of a trolley for use in an assembly of the invention.

Figure 4 is a top view of a trolley for use in an assembly of the invention.

Figure 5 is a left side view of a trolley for use in an assembly of the invention.

Figure 6 is a top rear perspective view of a trolley base for use in an assembly of the invention.

Figure 7 is a top perspective view of a wheel base for use in an assembly of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS

Figure 1 shows a front perspective view of a spray assembly 10 according to an aspect of the invention. A cylinder of gas 12, for example CO2, and a container of sealant 14 are accommodated on the base 16 of the trolley 18. Not shown in Figure 1 are the hoses which connect the cylinder 12 to the sealant container 14, and the hose connected to the sealant container 14 which permits delivery of the sealant-gas mixture.

Figure 2 shows the features of a trolley 18 in accordance with an aspect of the invention more clearly, in the absence of the cylinder 12 and container 14. The trolley includes a base 16 of trapezoidal configuration. Attached to the base 16 is a frame 22 which extends up from the base 16 by two arms 23, 25 to form a trolley handle 24. The frame 22 can be manufactured from any material, such as for example aluminium, stainless steel, galvanised steel, but is preferably manufactured from lightweight aluminium. The frame 22 defines the height of the trolley, which can be any practicable height, and in this example is from about 120cm to about 125cm high.

The frame 22 also assists in securing the wheel base 34 to the trolley 18. This is effected by passing each arm 23, 25 through a respective aperture 31 (not shown), 33 in a curved member 36. The curved member 36 is fitted above the base 16 and curved to accommodate a lower portion of the cylinder 12 and container 14. The wheels 20 are mounted to the wheel base 34 with a rod 38. The curved member 36 can be secured at any practical position above the base 16. In this example, the curved member 36 is configured to accommodate an Australian size‘D’ C0₂ cylinder 12 and a 19Litre pressurised, stainless steel or aluminium, solution container 14 in . The wheel base 34 and curved member 36 are shown in isolation as a top rear view in Figure 7.

The trolley 18 also includes a crosspiece 26 at a practicable position between the trolley handle 24 and the base 16. In this example, the crosspiece 26 is located about 30cm-40cm from the base 16. The front face of the cross piece is curved to accommodate an upper portion of the cylinder 12 and container 14. The crosspiece can be manufactured from any material, such as for example plastic, aluminium, stainless steel, galvanised steel, but is preferably manufactured from lightweight aluminium.

The crosspiece 26 can be secured to the trolley 18 in any suitable manner. In Figure 2, the crosspiece is secured to the trolley by passing the arms 23, 25 through respective apertures 41 , 43 in the crosspiece 26.

A tool caddy 28 is also included in this embodiment of the invention. The caddy 28 can be secured to the arms 23, 25 by bolting, welding, clipping or any other practicable means. The caddy 28 is attached upward of the crosspiece 26 to avoid interference with the tops of cylinder 12 and container 14. In this example, the tool caddy 28 is located at about 90cm-100cm from the base 16.

The crosspiece 26 and tool caddy 28 each have a hose reel 30, 32

respectively attached to the rear of the crosspiece 26 and tool caddy 28. Figure 3 shows a rear view of a trolley of the invention, including hose reels 30, 32. The hose reels 30, 32 enable winding of the hoses (not shown) attached to the cylinder 12 and container 14, which are thereby safely stored and transported at the rear of the trolley 18. The hose reels can be manufactured from any material, such as for example plastic, aluminium, stainless steel, galvanised steel, but is preferably manufactured from lightweight aluminium.

Figure 4 is a top view of a trolley of the invention, which particularly illustrates the shape of the base 16. Figure 6 shows details of the base 16 in isolation, viewed from a top rear perspective.

The planar base 16 includes a rim 60 extending operably upward around at least part of the periphery of the base 16. In this example, the rim 60 encloses the rear face 62 and two side faces 64, 66 of the base 16. The front face 68 includes an aperture 70 which can function as a handle for safely lifting the trolley 18.

The irregular trapezoidal configuration of the planar base 16 defines an outwardly curved front corner of radius of curvature from about 1 to about 3. This configuration substantially increases the stability of the trolley of the invention, particularly when the cylinder 12 and container 14 are in place. Generally the cylinder 12 and container 14 are of different sizes and weights, and this could lead to instability of the trolley during transport or lifting. The configuration of the base 16 as described above, on its own or in combination with the other features of the trolley including the rim 60, the curved member 36, and the crosspiece 26, provide stable and safe storage and transport of the cylinder 12 and container 14.

The base 16 and rim 60 can be manufactured from any practicable material, such as plastic, aluminium, stainless steel, galvanised steel, but is preferably manufactured from lightweight aluminium. The base can generally be manufactured from the same material as the frame 22, caddy 28 and crosspiece 26.

An example of method of the invention using the assembly and sealing system of the invention, is provided below.

The first composition of non-cross linked water soluble acrylic polymer is diluted with water to a solids content of 20%, and is placed in the container 14. The container 14 and a cylinder 12 of C0₂ are loaded onto the trolley 18 such that the larger and heavier container 14 is accommodated by the curved corner 72 of the base 16. The container 14 and cylinder 12 are also accommodated by the curvature of the front face of the crosspiece 26 and the curved member 36. The container 14 and cylinder 12 are connected via a hose.

The concrete surface to be sealed is sprayed with water at 3500psi at 15lt of water per minute for a period sufficiently long to remove surface debris without damaging the concrete surface. While not bound by theory, a thin layer of clean water on the surface acts to break the surface tension of the surface and lower the surface temperature. This breaking of the surface tension is required in order to prevent the negative/positive (wet to dry) disturbance of the composition. The aqueous barrier also catalyses curing of the composition within a more controlled neutral pH environment.

Before the surface dries, the first composition is applied to the wet surface using the C0₂ to deliver the composition.

The composition is further evenly spread and distributed using a wide broom, and allowed to dry for 1-2 hours, or up to 10 hours depending on the application. Further layers of the first composition can be applied if desired or required.

The dried first composition is then sprayed with water and allowed to dry. The first composition is considered the‘soft’ component of the system of the invention. This composition, when cured, stabilises the colour of the concrete and provides UV resistance to the surface.

The container 14 is then filled with the second composition: cross-linked water-soluble acrylic polymer, which has been diluted with water to a solids content of 20%. The second composition is applied to the cured first composition using the C0₂ to deliver the second composition. The composition is further evenly spread and distributed using a wide broom, and allowed to dry for 1-2 hours, or up to 10 hours depending on the application and weather/environmental conditions. The second composition is considered the‘hard’ component of the system of the invention: it provides a clear coat that resists staining, including from motor oil, tree tannins, bird stains and the most common water- and oil-based stains. The second composition also has UV protective properties.

Further layers of the second composition can be applied if desired or required.

The first and second compositions of the invention do not require

preservatives or solvents other than water. This substantially reduces the toxicity of system.

The pressurised CO2 used in the method of the invention both propels the compositions from the container and ensures thorough mixing of each composition with its diluent water. Carbon dioxide also stabilises each composition as acrylic solutions or dispersions can separate, with solids accumulating at the bottom of a storage vessel. The latter can lead to uneven and uncontrolled application of a composition, resulting in inferior sealing of a surface. The carbon dioxide used with an assembly according to the invention is an environmentally preferred propellant, which also assists in the curing of each applied layer of sealing composition.

Carbonation of the compositions on application results in streak-free sealed surfaces.

The assembly according to an aspect of the invention delivers the

compositions in a fine spray under pressure, which ensures even, effective, predictable and reproducible coverage of the surface.

The concrete surface sealing system, method of sealing, and assembly of the invention provide a safe and effective way of transporting, storing, and applying effective sealants to concrete surfaces.

The appended claims are to be considered as incorporated into the above description.

It is to be understood that the terminology employed above is for the purpose of description and should not be regarded as limiting. The described embodiments are intended to be illustrative of the invention, without limiting the scope thereof. The invention is capable of being practised with various modifications and additions as will readily occur to those skilled in the art.

When any number or range is described herein, unless clearly stated otherwise, that number or range is approximate. Recitation of ranges of values herein are intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value and each separate subrange defined by such separate values is incorporated into the specification as if it were individually recited herein.

Words indicating direction or orientation, such as“front”,“rear”,“back”, etc, are used for convenience. The inventor(s) envisages that various embodiments can be used in a non-operative configuration, such as when presented for sale. Thus, such words are to be regarded as illustrative in nature, and not as restrictive.

Claims

1. A concrete surface sealing system including:

a first sealant composition for application to cover a concrete surface, including a preservative-free non-crosslinked water-soluble acrylic polymer;

a spray assembly, the spray assembly including a trolley configured to support a gas canister containing the carbon dioxide and a container of one of the first or second sealant composition, the trolley including a planar base of irregular quadrilateral configuration in which a rim extends operably upward around at least part of the periphery of the base, the irregular quadrilateral configuration optimised to stabilise the canister and the container when in place.

2. The concrete surface sealing system of claim 1 , in which the planar base is of trapezoidal configuration.

3. The sealing system as claimed in claim 2, in which at least one corner of the trapezoid is outwardly curved.

4. The sealing system as claimed in any one of claims 1-3, in which the rim includes an aperture defining a base handle in a front face of the rim.

5. The sealing system as claimed in any one of claims 1-4, including a cross-member positioned above a rear portion of the base, configured to accommodate each of the gas canister and the container of the first or second sealant composition.

6. The sealing system as claimed in any one of claims 1-5, including a bar attached to the base at each of two rear corners of the base, each bar extending operably upward from the base, and forming a trolley handle at a position above the base.

7. The sealing system as claimed in claim 6, including a crosspiece attached to the frame at a position between the trolley handle and the base, the crosspiece configured for further accommodation of at least one of the gas canister and the container of the first or second sealant composition.

8. The sealing system as claimed in claim 7, including a hose reel attached at a rear face of the crosspiece.

9. The sealing system as claimed in claim 5, including two wheels operably attached to either side of the cross-member.

10. The sealing system as claimed in any one of claims 6-9, including a tool caddy attached to the frame at a position between the trolley handle and the base.

11. The sealing system as claimed in claim 10, including a hose reel attached at a rear face of the tool caddy.

12. The sealing system as claimed in any one of claims 7-11 , including the cylinder of pressurised carbon dioxide and the container of first or second sealant composition fitted to the base and crosspiece of the trolley, a first hose connecting the cylinder to the container, and a second hose connected to the container, the second hose configured for application of the first or second sealant composition to a concrete surface.

13. A method of sealing a concrete surface using the sealing system as claimed in any one of claims 1-12, the method including:

14. The method as claimed in claim 13, which includes applying a layer of water to the concrete surface before application of the first sealant composition.

15. The method as claimed in claim 13, which includes diluting the first sealant composition with water before application to concrete surface.

16. The method as claimed in claim 15, in which the first sealant composition is diluted to 20% solids.

17. The method as claimed in claim 15, which includes applying a layer of water to the concrete surface covered by the first sealant composition before application of the second composition.

18. The method as claimed in claim 13, which includes diluting the second sealant composition with water before application to the concrete surface covered by the first composition.

19. The method of any one of claims 13-18, in which the first sealant composition is an aqueous solution of poly(methyl methacrylate) and the second sealant composition is an aqueous solution of a mixture of poly(methyl methacrylate) and 2- (2-butoxyethoxy)ethyl acetate.