HYBRID POLYMER COATING FOR PETROUS OR CERAMIC SUBSTRATES, PETROUS OR CERAMIC SUBSTRATE, AND OBTAINING METHOD

• US 20170066690A1
• Filed: 11/21/2016
• Published: 03/09/2017
• Est. Priority Date: 07/18/2011
• Status: Active Grant

• Current Assignee: Silicalia Sl
• Original Assignee: Silicalia Sl
• Inventors: Ortola, Alberto, Schoneveld, Erik, Sanchis Brines, Francisco, Sanchez Sevilla, Bernardo
• Granted Patent: US 10,640,675 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/22 Glass ; Devitrified glass
• CPC Class Codes: C04B 14/26 Carbonates
• CPC Class Codes: C04B 14/303 Alumina
• CPC Class Codes: C04B 20/0076 characterised by the grain distribution
• CPC Class Codes: C04B 20/008 Micro- or nanosized fillers, e.g. micronised fillers with particle size smaller than that of the hydraulic binder colloidal silica C04B14/062 ; silica fume C04B18/146
• CPC Class Codes: C04B 2103/54 Pigments; Dyes
• CPC Class Codes: C04B 2111/00129 Extrudable mixtures
• CPC Class Codes: C04B 2111/00405 Materials with a gradually increasing or decreasing concentration of ingredients or property from one layer to another
• CPC Class Codes: C04B 2111/00482 Coating or impregnation materials
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/54 Substitutes for natural stone, artistic materials or the like
• CPC Class Codes: C04B 26/02 Macromolecular compounds
• CPC Class Codes: C04B 40/0028 Aspects relating to the mixing step of the mortar preparation
• CPC Class Codes: C04B 40/0064 Processes of the Magnini or Hatscheck type
• CPC Class Codes: C04B 40/0263 Hardening promoted by a rise in temperature C04B40/024 takes precedence
• CPC Class Codes: C04B 41/5323 to make grain visible, e.g. for obtaining exposed aggregate concrete
• CPC Class Codes: C09D 167/00 Coating compositions based on polyesters obtained by reactions forming a carboxylic ester link in the main chain based on polyester-amides C09D177/12; based on polyester-imides C09D179/08; Coating compositions based on derivatives of such polymers

Abstract

A coating having a thickness between 0.1 and 2 mm is obtained from a mixture with the following composition: 10-25% by weight of micronized powder; 40-60% by weight of inorganic gravels of petrographic origin of sizes comprised between 0.063-2 mm; 10-40% by weight of a polymerisable base resin selected from polyurethane, polyester, epoxy or acrylic, with additives, and optionally pigments. The proportion of the mentioned gravel and micronized powder of the coating being up to 90% in an inner most area of interphase between coating and surface of the petrous substrate, covering one third of the thickness of the coating. The method comprises depositing the mentioned mixture on the substrate and vibrating the assembly, and subsequently proceeding to a step of curing and subsequent mechanical finishing of the surface.

Claims

1. A hybrid polymer coating for petrous or ceramic substrates providing a surface layer adhered firmly to the substrate, wherein said coating is prepared from a mixture with the following composition:

10-25% by weight of micronized powder with inorganic loads of petrographic origin;

40-60% by weight of inorganic gravels of petrographic origin comprising at least one of quartz, silica or silica sand, glass, recycled mirrors, or silicon, of sizes comprised between 0.063-2 mm;

10-40% by weight of a polymerisable base resin selected from polyurethane, polyester, epoxy or acrylic comprising up to 3% of additives for said resin;

said inorganic gravels and micronized powder form a concentration gradient in the coating, and

the proportion of the mentioned gravel and micronized powder of the coating being up to 90% in one lower third of the thickness of the coating corresponding to the inner most area of the coating at the interphase between coating and surface of the petrous or ceramic substrate,

whereby an upper part of the coating is removed to provide a thickness of the coating between 0.1 and 2 mm.

2. The coating according to claim 1, wherein, when said coating is divided in three layers having the same thickness, the concentration of the mentioned gravel and micronized powder in each of said layers is the following:

lower third of the coating corresponding to the first inner most area at the interphase between the coating and surface of the petrous or ceramic substrate;

between 55%-90%;

middle third of the coating;

between 16%-60%; and

upper third of the coating close to the visible surface of the coating ;

between 1%-15%.

3. The coating according to claim 1, further comprising 0.1 to 5% by weight of pigments.

4. The coating according to claim 1, wherein the thickness of said surface layer is comprised between 0.1 and 1 mm or between 0.1 and 0.7 mm.

5. The coating according to claim 1, wherein said micronized powder is of siliceous materials comprising quartz, silicon, cristobalite and/or glass, of aluminium oxides or of calcareous materials.

6. The coating according to claim 1, wherein the mentioned gravels comprise gravels selected by their sizes comprised between 0.1 and 0.5 mm.

7. The coating according to claim 1, wherein the mentioned mixture comprises gravels of different nature and grading.

8. The coating according to claim 2, further comprising a polished surface having a hardness greater than 5 Mohs.

9. A petrous or ceramic substrate incorporating a coating on a visible surface according to claim 1.

10. A method for obtaining a hybrid polymer coating for petrous or ceramic substrates, said coating having a thickness between 0.1 and 2 mm and comprising a mixture of micronized powder, gravels, base resin selected from polyurethane, polyester, epoxy or acrylic and in general pigments and additives for said resin, comprising:

preparing a base mixture comprising at least one first gravel of quartz, silica or silica sand of sizes comprised between 0.1-2 mm and micronized powder with inorganic loads in a mixer;

stirring the mentioned mixture;

preparing a base resin selected from polyurethane, polyester, epoxy or acrylic;

adding said resin to the mentioned mixture with a catalyst, additives for said resin and optionally pigments, and subsequent stirring in said mixer;

creating a vacuum inside said mixer affecting the mentioned mixture;

applying a layer of the semi-fluid mixture obtained on the substrate and retaining on the same;

vibrating the substrate to displace the larger gravels towards the bottom;

accelerating the curing of the mixture by providing or generating heat, said mixture being consolidated on the substrate; and

finishing by a mechanical treatment selected from polishing with abrasives, polishing with brushes or sand blasting and/or by a chemical treatment of acid etching of the coating polymer.

11. The method according to claim 10, wherein in said first step for forming the mixture several gravels which are of different sizes and of the same or different materials and which are introduced in the mixture subjected to a stirring are used.

12. The method according to claim 10, wherein said mixture is prepared according to a process of continuously mixing in a screw extruding machine in which all the gravels and powder are loaded, injecting the liquid materials comprising resin, catalyst, and additives in a subsequent section of the path of the screw.

13. The method according to claim 10, wherein the step of applying the mixture on the substrate is performed with an applicator retaining a layer of mixture on said substrate and which is maintained during the step of curing.

14. The method according to claim 10, wherein the Brookfield viscosity at room temperature of the mentioned mixture obtained from the mixer is comprised between 4,350 and 4,440 mPas corresponding to a shearing speed of 30-20 rpm.

15. The method according to claim 10, wherein the coating has a hardness greater than 5 Mohs.