Method for sealing natural stone

• US 20080280061A1
• Filed: 05/07/2008
• Published: 11/13/2008
• Est. Priority Date: 05/07/2007
• Status: Abandoned Application

• Current Assignee: Questech Corporation
• Original Assignee: Questech Corporation
• Inventors: Pelletier, David, Questel, Roger, Wasowski, Larry, Marmer, Gary
• Application Number:
  US12/151,515
• Publication Number:
  US 20080280061A1
• Time in Patent Office: Days
• US Class Current: 427/508
• CPC Class Codes: C04B 14/00 Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone expanding or defibrillating materials C04B20/00
• CPC Class Codes: C04B 14/285 Marble
• CPC Class Codes: C04B 2103/67 Biocides
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/463 Organic solvents
• CPC Class Codes: C04B 41/4826 Polyesters
• CPC Class Codes: C04B 41/483 Polyacrylates
• CPC Class Codes: C04B 41/4884 Polyurethanes; Polyisocyanates
• CPC Class Codes: C04B 41/502 Water
• CPC Class Codes: C04B 41/5089 Silica sols, alkyl, ammonium or alkali metal silicate cements
• CPC Class Codes: C04B 41/52 Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
• CPC Class Codes: C04B 41/522 Multiple coatings, for one of the coatings of which at least one alternative is described
• CPC Class Codes: C09D 175/16 having terminal carbon-to-carbon unsaturated bonds
• CPC Class Codes: E04F 13/144 with an outer layer of marble or other natural stone

Abstract

Provided is a novel method for sealing natural stone. The method comprises applying a base coat comprising a synthetic polymer, drying the base coat, applying a UV-cure topcoat, volatizing organic solvents from the topcoat, and curing the UV-cure topcoat by exposure to UV light. The UV-cure topcoat used in the method comprises an acrylate oligomer, photoinitiators, and flow and wetting additives. Methods are also provided wherein the topcoat further comprises a fungal inhibitor. The described methods provide a coating with excellent adhesion, and a smoother, more uniform topcoat. Moreover, this coating system allows moisture to migrate from the back side of tile through the coatings to evaporate to the surface, a feature critical to preventing deterioration of the stone over time.

Claims

1. ) A method for sealing natural stone, the method comprising:

a) providing a base coat comprising an aqueous dispersion of a synthetic polymer having a percentage of dispersed synthetic polymer ranging from 20% to 40% by weight;

b) applying the base coat to natural stone to a wet film thickness ranging from 0.5 to 2.5 mil;

c) drying the base coat;

d) providing a UV-cure topcoat comprising a 20%-40% by weight dispersion of acrylate oligomer in a volatile organic solvent or mixtures thereof, the UV-cure topcoat further comprising photoinitiators, and flow and wetting additives;

e) applying the UV-cure topcoat to natural stone over the dried base coat of step c) to a wet film thickness of 0.5 to 2.5 mil;

f) volatizing the volatile organic solvent or mixtures thereof; and

g) exposing the product of step f) to UV light thereby curing the UV-cure topcoat by promoting the cross-linking of the acrylate oligomer.

2. ) The method of claim 1 wherein the base coat comprises an aqueous dispersion of synthetic polymer having a percentage of dispersed synthetic polymer ranging from 25% to 35% by weight.

3. ) The method of claim 1 wherein the synthetic polymer is selected from the group consisting of urethane, polyester, acrylic and hybrids thereof.

4. ) The method of claim 1 wherein the UV-cure topcoat further comprises amorphous silica.

5. ) The method of claim 1 wherein the UV-cure topcoat further comprises a mold and mildew inhibitor.

6. ) The method of claim 1 wherein the volatile organic solvent is selected from the group consisting of methyl propyl ketone, methyl isobutyl ketone, and ethyl alcohol.

7. ) The method of claim 1 wherein the photoinitiators are selected from the group consisting of methanone, - (1-hydroxycyclohexyl) phenyl, [947-19-3];

and phosphine oxide, phenylbis (2,4,6-trimethyl benzoyl).

8. ) The method of claim 1 wherein the UV-cure topcoat comprises a 27%-37% by weight dispersion of acrylate oligomer in a volatile organic solvent or mixtures thereof.

9. ) The method of claim 1 wherein the base coat further comprises 10% to 15% by weight 2-butoxy ethanol [111-76-2].

10. ) The method of claim 1 wherein the base coat further comprises dinonyl phthalate plasticizer.

11. ) The method of claim 1 wherein the base coat is applied to a wet film thickness of 1.5 to 2.0 mil.

12. ) The method of claim 1 wherein the UV-cure topcoat is applied to a wet film thickness of 1.5 to 2.0 mil.

13. ) The method of claim 1 wherein natural stone is selected from the group consisting of marble, granite, travertine, limestone, slate, and sandstone.