PROCESS FOR ADHERING PREFORMED RESINOUS COVERINGS TO ARCHITECTURAL SURFACES

• US 3,765,972 A
• Filed: 01/21/1971
• Issued: 10/16/1973
• Est. Priority Date: 07/14/1969
• Status: Expired due to Term

• Current Assignee: George L. Wesp
• Original Assignee: George L. Wesp
• Inventors: Wesp, George L.
• Primary Examiner(s): Ansher, Harold
• Application Number:
  US05/108,637
• Time in Patent Office: 999 Days
• Field of Search: 156/78,330,71 161/184,161,252 260/2.5L,2.5EP,2.5AG
• US Class Current: 156/71
• CPC Class Codes: C08L 2666/34 Oxygen-containing compounds, including ammonium and metal salts
• CPC Class Codes: C08L 63/00 Compositions of epoxy resins; Compositions of derivatives of epoxy resins
• CPC Class Codes: C09J 133/12 Homopolymers or copolymers of methyl methacrylate
• CPC Class Codes: Y10T 428/249984 Adhesive or bonding component contains voids
• CPC Class Codes: Y10T 428/31515 As intermediate layer
• CPC Class Codes: Y10T 428/31909 Next to second addition polymer from unsaturated monomers

Abstract

A process for applying preformed resinous coverings to architectural surfaces such as floors, walls and the like comprises adhering a covering to a surface with a pressuresensitive adhesive which, upon contact after drying, develops an immediate bond of high cohesive strength between the surface and the covering that becomes a permanent moisture-resistant bond. The adhesive compositions comprise a latex and a transient tackifier which comprises an epoxy resin and a curing agent. Some adhesive compositions may be foamed to provide a conformable smooth supporting surface for a high modulus preformed resinous covering. The architectural surface, preformed resinous covering and pressure-sensitive adhesive containing a transient tackifier comprise a useful architectural surface composite for residential and commercial installations.

Claims

2. The process of claim 1 wherein the preformed resinous covering is a preformed high modulus resinous covering having a flexural modulus of at least 1,000,000 pounds per square inch.

3. The process of claim 2 wherein a foam layer is interposed between said covering and said architectural surface to provide a conformable supporting surface for said covering.

4. The process of claim 3 wherein said foam layer is in sheet form and is adhered to said covering and said architectural surface.

5. The process of claim 4 wherein said foam layer is a polymeric foam selected from the group which consists of foams of polyvinyl chloride, polystyrene, polyurethane, polypropylene and phenol-formaldehyde resin.

6. The process of claim 3 wherein said foam layer is a pressure sensitive adhesive composition comprising a latex, a water-soluble colloid, said water-soluble colloid being a high polymer having a molecular weight in excess of 20,000 and being soluble in media selected from the group which consists of water and aqueous alkaline media and a transient tackifier, which transient tackifier comprises an epoxy resin and a curing agent for the epoxy resin.

7. The process of claim 6 wherein the foamed adhesive composition, when applied, occupies from about 1.2 to about four times its pre-foamed volume.

8. The process of claim 6 wherein said foamed adhesive composition comprises a latex, the solids of which latex comprise from about 40 percent by weight to about 95 percent by weight of the total solids content of said composition, an epoxy resin and a curing agent for the epoxy resin, which resin and curing agent together are present as a combination in the amount of from about five to about 50 parts by weight per 100 parts by weight of latex solids, and in which combination of epoxy resin and curing agent said curing agent is present in the amount of from about 25 percent by weight of the stoichiometric amount of the curing agent to fully react with the epoxy resin to about 200 percent by weight of said stoichiometric amount, a surfactant selected from the group which consists of an anionic surfactant and a nonionic surfactant in the amount of from 0 to about 3 parts by weight per 100 parts by weight of latex solids and a water-soluble colloid in the amount of from about 0.01 to about 2.0 parts by weight per 100 parts by weight of latex solids.

9. A process which comprises adhering a preformed resinous covering to an architectural surface by a pressure-sensitive composition comprising a copolymer latex selected from the group which consists of an acrylic ester-unsaturated acid copolymer and an acrylic ester-hydroxyl functional monomer copolymer in combination with a terpolymer selected from the group which consists of acrylonitrile-butadiene unsaturated acid and acrylonitrile-isoprene-unsaturated acid in which combination said terpolymer solids comprise from 0 to 60 percent by weight of the total latex solids of the combination;

an epoxy resin selected frOm the group which consists of a glycidyl ether of an aliphatic polyol, a glycidyl ether of a phenol containing more than one phenolic group and a mixture of a glycidyl ether of an aliphatic polyol and a glycidyl ether of a phenol containing more than one phenolic group and which has an epoxy equivalent weight from about 150 to about 1000;

a curing agent selected from the group which consists of an aliphatic amine and an aliphatic polyamine modified by partial reaction of amine functionality with a reactant selected from the group which consists of ethylene oxide, propylene oxide, and a glycidyl ether;

a surfactant selected from the group which consists of an alkyl phenol having from eight to 13 carbon atoms reacted with 10 to 50 equivalents of ethylene oxide, a condensed phosphate ester salt, an alkyl aryl ethylene oxide sulfonate and an alkyl phenol-ethylene oxide adduct; and

a water soluble colloid selected from the group which consists of polyacrylamide and carboxymethyl cellulose.

10. The process of claim 1 wherein the preformed resinous covering is a composition comprising a. from about 10 to about 95 percent by volume based on the total composition of an inorganic filler having a Mohs'"'"''"'"' hardness of at least about 4, and b. from about 90 to about 5 percent by volume based on the total composition of a polyalkylmethacrylate.

11. The process of claim 10 wherein said polyalkylmethacrylate is polymethylmethacrylate.

12. The process of claim 10 wherein the preformed resinous covering has a flexural modulus of at least 1,000,000 pounds per square inch.

13. The process of claim 1 wherein said architectural surface is a floor.

14. The process of claim 1 wherein said architectural surface is a floor located below ground level.

15. The process of claim 1 wherein said architectural surface is a wall.

16. The process of claim 1 wherein said pressure sensitive adhesive composition comprises a latex, the solids of which latex comprise from about 40 to about 95 percent by weight of the total solids content of said composition, an epoxy resin and a curing agent for the epoxy resin, which resin and curing agent together are present as a combination in the amount of from about 5 to about 50 parts by weight per 100 parts by weight of latex solids, and in which combination of resin and curing agent said curing agent is present in the amount of from about 25 percent by weight of the stoichiometric amount of the curing agent to fully react with the epoxy resin to about 200 percent by weight of said stoichiometric amount.

17. The process of claim 1 wherein said latex is selected from the group which consists of an acrylic ester-hydroxyl functional monomer terpolymer, an acrylic ester-vinyl ester-hydroxyl functional monomer terpolymer, an acrylic ester-vinyl ester-carboxyl functional monomer terpolymer, an acrylic ester-vinyl ester-glycidyl functional monomer terpolymer, an acrylic ester-butadiene-hydroxyl functional monomer terpolymer, an acrylic ester-butadiene-carboxyl functional monomer terpolymer, an acrylic ester-butadiene-glycidyl functional monomer terpolymer, an acrylic ester-isoprene-hydroxyl functional monomer terpolymer, an acrylic esterisoprene carboxyl functional monomer terpolymer, an acrylic ester-isoprene-glycidyl functional monomer terpolymer, an acrylic ester-vinyl ether-hydroxyl functional monomer terpolymer, an acrylic ester-vinyl ether-carboxyl functional monomer terpolymer and an acrylic ester-vinyl ether-glycidyl functional monomer terpolymer.

18. The process of claim 17 wherein said latex is used in combination with a latex selected from the group which consists of an acrylonitrile-butadiene-unsaturated acid terpolymer and an acrylonitrile-isoprene-unsaturated acid terpolymer which latter latex is present in the amount of from 0 to about 70 percent by weight of total latex solids of the combination.

19. The proCess of claim 1 wherein said epoxy resin is selected from the group which consists of a glycidyl ether of an aliphatic polyol, a glycidyl ether of a phenol containing more than one phenolic group and a mixture of a glycidyl ether of an aliphatic polyol and a glycidyl ether of a phenol containing more than one phenolic group.

20. The process of claim 1 wherein said epoxy resin is dissolved in an organic solvent.

21. The process of claim 1 wherein said curing agent is selected from the group which consists of an aliphatic polyamine and an aliphatic polyamine modified by partial reaction of amine functionality with a reactant selected from the group which consists of ethylene oxide, propylene oxide and a glycidyl ether.

22. The process of claim 1 wherein a primer is applied to said covering before said covering is adhered to said architectural surface.

23. The process of claim 22 wherein said primer is a polyester urethane composition.

24. The process of claim 1 wherein said adhesive composition additionally includes a tackifier, said tackifier being a low molecular weight polymer which is insoluble in water but soluble in alkaline aqueous media and organic solvents and is present in the amount of from 10 to about 40 parts by weight per 100 parts by weight of latex solids.

25. The process of claim 1 wherein said latex, said epoxy resin and said curing agent are mixed together after being maintained separate from each other until about four hours before said adhesive composition is applied.

26. The process of claim 1 wherein said covering is placed in contact with said applied adhesive composition during the time period extending from about when the adhesive composition is dry to about 3 days after the adhesive composition is dry.

27. The process of claim 1 wherein initial tack of the pressure-sensitive adhesive composition is temporarily destroyed by application of a temporary lubricant solution, said temporary lubricant solution being a dilute aqueous solution of polyvinyl methyl ether in a concentration from about 0.1 weight percent to about 3 weight percent, to a surface without diminishing the dry and wet strength of the adhesive bond.

28. The process of claim 27 wherein the temporary lubricant solution is applied to an adhesive surface.

29. A process for adhering a preformed high modulus polymethyl-methacrylate covering having a flexural modulus of at least 1, 000,000 pounds per square inch to a floor by a pressure-sensitive adhesive composition comprising a latex which comprises an acrylate ester/methylol acrylamide copolymer, the solids of which latex are present in the amount of from about 55 to about 92 percent by weight of the total adhesive composition solids, a transient tackifier in the amount of from about 10 to about 40 parts by weight per 100 parts by weight of latex solids, which transient tackifier comprises an epoxy resin comprising a mixture of a partially resinified condensate of epichlorohydrin and an aliphatic polyol having an epoxy equivalent weight of approximately 70 and a bisphenol A/epichlorohydrin condensate with an epoxy equivalent weight of approximately 190 in an organic solvent and an ethylene oxide/polyamine adduct curing agent, which curing agent is present in the amount of from about 80 percent by weight of the stoichiometric amount of the curing agent to fully react with the epoxy resin to about 120 percent by weight of said stoichiometric amount, and a sodium carboxymethyl cellulose water-soluble colloid in the amount of from about 0.05 to about 1 part by weight per 100 parts by weight of latex solids in which process said pressure-sensitive adhesive composition is mixed and foamed to the extent that, when applied, said foamed composition occupies from about 1.8 to about 2.5 times its pre-foamed volume and is applied to said floor within about 4 hours after said composition is mixed togEther and said covering is placed with firm finger pressure in contact with said applied adhesive composition during a period extending from about as soon as said adhesive composition is dry to the end of the next day.

30. The process of claim 29 wherein said latex comprises an acrylate ester/unsaturated acid copolymer.

31. A process for adhering a preformed high modulus polymethyl-methacrylate covering having a flexural modulus of at least 1, 000,000 pounds per square inch to a floor by a pressure-sensitive adhesive composition comprising a latex which comprises a vinyl acetate/acrylic ester copolymer, the solids of which copolymer are present in the amount of from about 55 to about 92 percent by weight of the total adhesive composition solids, and a transient tackifier in the amount of from about 10 to about 40 parts by weight per 100 parts by weight of latex solids, which transient tackifier comprises an epoxy resin comprising a glycidated phenol-formaldehyde novolac with an epoxy equivalent weight of approximately 175 and a curing agent which comprises a 42 percent solids solution in organic solvent of an epichlorohydrinbisphenol A condensate having an epoxy equivalent weight of approximately 490 reacted with diethylenetriamine to give an adduct with an amine-epoxy equivalent weight of approximately 34, which curing agent is present in the amount of from about 80 percent by weight of the stoichiometric amount of the curing agent to fully react with the epoxy resin to about 120 percent by weight of said stoichiometric amount, in which process a plasticized polyvinyl chloride foam is interposed between said covering and said floor, which foam provides a conformable smooth supporting surface for said covering, said foam is laminated to said covering, a polyester urethane primer is applied to an exposed surface of said foam, said adhesive composition is applied to said floor within four hours after said composition is mixed together and the primed foam surface of the covering foam laminate is placed with firm finger pressure is contact with said applied adhesive composition during a period extending from about as soon as said adhesive composition is dry to the end of the next day.

32. The process of claim 31 wherein said latex comprises an acrylic ester/methylol acrylamide copolymer.

33. The process of claim 31 wherein said latex comprises an acrylic ester/unsaturated acid copolymer.