Methods and apparatus for stabilization of surfaces

• US 9,982,143 B2
• Filed: 07/25/2016
• Issued: 05/29/2018
• Est. Priority Date: 06/10/2010
• Status: Active Grant

• Current Assignee: Polylast Systems, LLC
• Original Assignee: Polylast Systems, LLC
• Inventors: Laurence, Peter J.
• Primary Examiner(s): Risic, Abigail A
• Application Number:
  US15/219,070
• Publication Number:
  US 20160333192A1
• Time in Patent Office: 673 Days
• CPC Class Codes: B05D 3/007 After-treatment
• CPC Class Codes: C08G 18/307 Atmospheric humidity
• CPC Class Codes: C08L 95/00 Compositions of bituminous materials, e.g. asphalt, tar, pitch
• CPC Class Codes: C09D 163/00 Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins
• CPC Class Codes: C09D 175/04 Polyurethanes
• CPC Class Codes: C09D 5/14 Paints containing biocides, e.g. fungicides, insecticides or pesticides C09D5/16 takes precedence
• CPC Class Codes: C09J 175/04 Polyurethanes
• CPC Class Codes: E01C 11/005 Methods or materials for repairing pavings E01C7/35 takes precedence; for concrete coverings E01C7/147; for bituminous coverings E01C7/187; devices for repair works E01C23/06; repairing bridge floorings E01D22/00
• CPC Class Codes: E01C 23/06 Devices or arrangements for working the finished surface working freshly laid paving E01C19/42 - E01C19/44, E01C23/02; mining picks E21C35/18; Devices for repairing or reconditioning the surface of damaged paving; Recycling in place or on the road
• CPC Class Codes: E01C 7/35 Toppings or surface dressings; Methods of mixing, impregnating, or spreading them devices therefor E01C19/00; mortar-macadam pavings E01C7/12; bituminous penetration coverings E01C7/18
• CPC Class Codes: E02D 29/14 Covers for manholes or the like; Frames for covers gully gratings E03F5/06
• CPC Class Codes: E02D 29/1409 adjustable in height or inclination
• CPC Class Codes: E04F 15/02183 for outdoor use, e.g. in decks, patios, terraces, verandas or the like
• CPC Class Codes: E04F 15/02188 for use in wet rooms
• CPC Class Codes: E04F 15/12 Flooring or floor layers made of masses in situ, e.g. seamless magnesite floors, terrazzo gypsum floorsinorganic or bituminous masses C04B; organic plastic masses C08L

Abstract

Various embodiments provide surface compositions and methods for durable and/or load-bearing surfaces in a variety of industrial, animal, and marine applications. Compositions and methods may comprise utilizing a liquid binder, catalyst, primer, and/or antimicrobial composition to provide durable, waterproof, and/or long-lasting surface compositions to dispose within the roadway voids and/or to create a durable, sanitary surface. The surface compositions may cure rapidly through an internal exothermic reaction process to form the repair and/or the safety flooring. The surface composition may be substantially impermeable to animal waste and resistant to harboring agents of disease. In some embodiments, a filler materials may be disposed within the liquid binders to provide elasticity, compression, slip resistance, heat transfer, reduced cure time, and/or a desired surface texture to the surface composition.

Claims

1. A sanitary surface composition for a flooring for human and animal traffic that reduces the presence of microbes, the surface composition comprising:

a liquid binder comprising a polyurethane adapted to cure through an exothermic reaction process, wherein the cured liquid binder has an increased viscosity relative to the liquid binder prior to curing; and

a primer adapted to adhere to the cured liquid binder and the at least one of the roadway void and the flooring; and

an effective amount of an antimicrobial composition adapted to retain antimicrobial activity through the exothermic reaction process,

wherein the surface composition applied to the roadway void and the flooring is adapted to withstand wear from the traffic over the roadway void and the flooring.

2. The surface composition of claim 1, further comprising a filler material, wherein the filler material is mixed with the liquid binder.

3. The method of claim 2, wherein the filler material is adapted to provide slip resistance to the surface composition.

4. The surface composition of claim 2, wherein the filler material comprises at least one of an aggregate material, rubber particles, asphalt particles, sand, ceramics, glass, marble, rock, and gravel particles.

5. The surface composition of claim 1, wherein the liquid binder comprises a first component comprising a polyol and a second component comprising an isocyanate, wherein the exothermic reaction is initiated upon at least one of:

(1) the mixing of the first component and the second component and (2) the exposure of the liquid binder to air.

6. The surface composition of claim 5, wherein the first component further comprises a catalyst.

7. The surface composition of claim 5, wherein the isocyanate comprises at least one of an aliphatic and an aromatic isocyanate.

8. The surface composition of claim 1, further comprising an additive.

9. The surface composition of claim 8, wherein the additive comprises at least one of a surfactant, and a pigment.

10. The surface composition of claim 8, wherein the additive comprises an edge retention composition.

11. The surface composition of claim 1, wherein the primer comprises an epoxy.

12. The surface composition of claim 1, wherein the antimicrobial composition comprises an antifungal composition.

13. The surface composition of claim 1, wherein the antimicrobial composition comprises an antiviral composition.

14. The surface composition of claim 1, wherein the antimicrobial composition comprises an antiprotozoal composition.

15. The surface composition of claim 1, wherein the antimicrobial composition comprises an antibacterial composition.

16. The surface composition of claim 1, wherein the antimicrobial composition comprises triclosan.

17. The surface composition of claim 1, wherein the antimicrobial composition comprises a metal oxide.

18. The surface composition of claim 1, wherein the antimicrobial composition is present throughout the surface composition to prevent the survival or propagation of the microbes within scratches or cracks in the surface composition.

20. The method of claim 18, wherein the filler material is adapted to provide slip resistance to the safety flooring.

21. The method of claim 18, wherein the filler material is adapted to provide compressibility to the safety flooring.

22. The method of claim 18, wherein the filler material is applied over a top surface of the liquid binder and adsorbs to the liquid binder prior to curing.

23. The method of claim 18, in which the step of curing the liquid binder comprises spraying the surface of the liquid binder with a catalyst.

24. The method of claim 18, wherein the liquid binder comprises a first component comprising a polyol and a second component comprising an isocyanate, wherein the exothermic reaction is initiated upon at least one of:

(1) the mixing of the first component and the second component and (2) the exposure of the liquid binder to air.

25. The method of claim 23, wherein the first component further comprises a catalyst.

26. The method of claim 23, wherein the isocyanate is at least one of an aliphatic and an aromatic isocyanate.

27. The method of claim 18, wherein the antimicrobial composition comprises an antifungal composition.

28. The method of claim 18, wherein the antimicrobial composition comprises an antiviral composition.

29. The method of claim 18, wherein the antimicrobial composition comprises an antiprotozoal composition.

30. The method of claim 18, wherein the antimicrobial composition comprises an antibacterial composition.

31. The method of claim 18, wherein the antimicrobial composition comprises triclosan.

32. The method of claim 18, wherein the antimicrobial composition comprises a metal oxide.

33. The method of claim 18, wherein the antimicrobial composition is present throughout the surface composition to prevent the survival or propagation of the microbes within scratches or cracks in the surface composition.

19. A method for forming a safety flooring over a surface for at least one of human traffic and animal traffic that reduces the presence of microbes, comprising the steps of:

mixing a liquid binder with a filler material and an effective amount of an antimicrobial composition;

applying a mixture of the liquid binder, the filler material, and the antimicrobial composition over the surface, wherein the liquid binder comprises a polyurethane adapted to cure through an exothermic reaction process, and wherein the cured liquid binder has an increased viscosity relative to the liquid binder prior to curing; and

allowing a sufficient amount of time for the liquid binder to cure before resuming the at least one of the human traffic and the animal traffic over the surface.