ES2279720B1 - COLORED GRANULES FOR COATING AND PAVING, METHOD AND FORMULATION. - Google Patents

Abstract

Colored granules for coating and paving, method and formulation. Regular or irregular mineral granules of marble, granite, quartz, basalt and dolomite are used and when colored the natural appearance of the mineral is not altered, providing it with exceptional qualities for use both indoors and outdoors. The mineral granulate is colored by a process of chemical silicification reaction between the formulation, the mineral and atmospheric carbon dioxide. The potassium or sodium silicate is transformed into polymeric silica and potassium or sodium carbonate respectively. The formulation involves inorganic binders (silicate dissolution, etc.), organic binders (polyacrylates etc.), fillers (dolomite, etc.), pigments (titanium dioxide, etc.), dispersant additives (polyphosphates, etc.), humectants (anionic sulfactants, etc.), antifoams (silicone emulsions, etc.), stabilizers (cationic polyfunctional compounds), coalescing (stable alkaline esters, etc.), rheological additives (cellulose derivatives, etc.), water repellents (alkaline siliconates, etc.) and biocides (algicides or fungicides).

Description

Colored granules for coating and paving, method and formulation.

Object of the invention

The present invention, as expressed by the set forth in this specification, refers to obtaining  colored granules for coating and paving, method and formulation, of special application in decoration of facades in building on monolayer mortars, offering a finish architectural completely new for its natural appearance and using material totally respectful also with the environment environment, due to its low or zero emission of organic compounds volatile

It can also be used in decorating interiors, as decorative load in terrazzo type paving continuous, tiles, cementitious base, resin for interior and outside, etc., and outdoors for decoration in gardening, traffic roundabout decoration, furniture manufacturing garden and terraces, etc.

Background of the invention

Currently aggregates or product are used in grain to apply by the projected stone technique, the which have a defined pigmentation or decoration preferably by the type of material used, so that chromatic and decorative possibilities that are obtained are very reduced

In the invention patent No. 9902088 and Certificate of Addition to it No. 9902744, of which they are Two of the applicants of the present invention co-owners, unveiled a colored product for coating and paving, as well as the method of elaboration, of application of projected stone, in the form of granules that undergoes a process of total or partial pigmentation. Solvent resins are used and water emulsion resins, pigments, and after the process of corresponding mixing you get a decorated granulated body chromatically or in a single color according to tastes or needs.

The possibility of adding to the coalescing formulation (butyl glycol acetate, texanol, or any other coalescent), or hardeners (amines or any other hardener), aromatic solvents and / or ketones, etc.

These techniques are compromised to comply  certain present and future regulations on emissions from volatile organic compounds

Description of the invention

In general, the invention consists in the  coloring of regular or irregular mineral granules of marble, granite, quartz, basalt and dolomite, etc., in different colors and in certain granulometries, of the order of 0.5 mm - 50 mm, with the particularity of not altering the natural appearance of the mineral and providing it with exceptional qualities for use both indoors and outdoors, as well as being a product Totally respectful with the environment. For this they have developed a series of specific formulations that allows to be able to give a color treatment on the chosen mineral, obtaining a uniform or disuniform finish, semi-transparent or opaque, preserving the natural and non-synthetic look and feel (such as it happened in the previous coloring methods), like the Mineral before coloring.

This series of formulations may be color pigmented (both powder and pastes water or universal pigment concentrates) from the beginning as at the end of the formulation, being able to use a base formula standard prepared to reproduce a series of colors, then pigmenting on it with different concentrated pastes depending on the desired color.

These specific formulations will vary in function of commercial and production needs, but all they will be based on the choice of at least one of these Raw materials as an essential principle:

-

Silicate solution potassium

-

Potassium silicate solution pre-stabilized

-

Potassium silicate hydrated in powder.

-

Sodium silicate hydrated in powder.

-

Sodium silicate solution.

-

Sodium silicate solution pre-stabilized

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Within all these types of silicates alkaline, we will preferably use the molar ratio SiO_ {2}: M2 {O} higher, covering the range of 1 to 4 between silica and alkali metal (M = Na, K). After the choice of one of them, the formulation will be complemented with a series of suitable fillers and pigments and that these will vary in function of the desired finish, such as: color, transparency, opacity, etc. There is also the possibility of incorporation of a dispersion of a polymer or several polymers organic and additivation with a series of auxiliary products, but also important, which will improve behavior and Product qualities in some particular aspect. In the major of the cases, this additivation will depend on two factors:

-

The formulation selection.

-

The Production process selection.

Once the specific formulation is selected, the mineral granulate is colored by the process of chosen production, always looking for and achieving chemical reaction between said formulation, the mineral and the dioxide atmospheric carbon, called silicification. Thus, potassium silicate is transformed into polymeric silica and carbonate potassium or sodium (if the silicate were sodium). The silica obtained it combines with the elements of the mineral, dragging in turn to the pigments into the granule.

The correct silicification reaction will guarantee a strong union of character physicochemical between said color formulation and the chosen mineral, forming a joint structure of nature inorganic, finally obtaining a product completely ecological.

The production process can be divided into Two phases:

1st.- Phase

Color treatment on the chosen mineral

From the selection of the formulation, proceed to give the color treatment on the chosen mineral following the following steps:

- The amount of ore is weighed and introduced in a concrete mixer.

- The selected formula is entered previously weighed with the amount that corresponds to the mineral and the type of granulometry.

- Then the mixer is left in movement for a time ranging from 30 seconds to 20 minutes according to the type and granulometry of the mineral.

- After the corresponding time, the mineral and is introduced into a hopper in which through a drag system (such as through a conveyor belt) It goes to the drying process.

2nd Phase

Mineral Drying Process

The drying process consists of introducing the mineral in a dryer where air circulates at a temperature which can range between 15ºC to 100ºC.

This drying machine consists of an enclosure closed inside which there is a tube that can rotate select the desired speed based on the chosen mineral and which in turn has some shovels inside that make flip the mineral so that it does not stick together.

Once the mineral is dry, it comes out from the other end from the tube to another conveyor belt that takes it to hoppers with weighing cells where it is finally packaged in the type of desired container This container can be: plastic bags, bags, plastic or metal boats, drums, Big-Bag, etc.

As alternatives of the production process and specifically as alternatives to the first phase, we can cite the following:

- In a plastic bag or sack: Put the components, the mouth is closed and shaken manually.

- On the ground: The mineral is put in a pile, the formula is added and with a shovel, rake, etc. it goes mixing

- Sprayed by gun: On a surface static or moving spray the formula on the  mineral.

- By immersion: The formulation is introduced selected in some deposit or container and then introduce the mineral until the deposit is total or partially complete It is also possible on the contrary, first introduce the mineral and then the formulation until the mineral It is totally submerged. Then the mineral is extracted.

- Mixing: With a mixer, the mineral in the mixing tank, the formulation is added and leaves giving the color treatment by stirring the Pallas.

As alternatives to the second phase of the process of production, we can cite the following:

- The mineral is spread on the ground so that it dry at room temperature. If drying is desired to be more fast, the ore must be moved from time to time.

- On a static surface, the mineral and with the help of some device either manual or electric (bellows, fan, heat gun, etc.) project normal air or hot on him.

- A drying tunnel whose interior was crossed by one or several conveyor belts and projected  natural or hot air over it.

- In the same mixer or in another tank apart from having a system by which it was projected natural or hot air. Also being on the move would give Place to dry.

- On a conveyor belt with or without vibration and coupling a series of fans, turbines or any utensil that will project air in all its route.

- Drying by fluid bed: Drying system that  it consists of an enclosure or chamber that has an entrance mouth, another exit and inside an air projection system hot or cold at high pressure that pushes the ore from a bed metallic perforated in the upward direction and also in the direction towards the exit mouth getting dry and ready for packing.

All the alternatives of the 1st phase are compatible with any of the alternatives of the 2nd phase, what which means that combining them together results in Multiple production process options, allowing great flexibility when choosing the most optimal depending on the eventual needs

The components or raw materials used in the formulas developed for the color treatment on the chosen mineral, we can detail them in the following groups and types:

Types of binders A) Inorganic

quad

From 1% -90%

-

Silicate solution potassium

-

Potassium silicate solution pre-stabilized

-

Potassium silicate hydrated in powder.

-

Sodium silicate hydrated in powder.

-

Sodium silicate solution.

-

Sodium silicate solution pre-stabilized

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B) Organic

quad

0% -80%

-

Polyacrylates

-

Styrene Acrylates.

-

Terpolymers

Types of fillers and pigments - Loads

quad

0% -90%

-

Dolomite

-

Calcium Carbonate

-

Quartz.

-

Kaolin.

-

Talcum powder.

-

Baryta.

-

Plastorita

-

Fibrous Matters

-

Aluminum and Sodium Silicate.

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- Pigments

quad

0.01% -90%

-

Titanium dioxide.

-

®Lithopone. (Barium Sufalt + Oxide zinc).

-

Non-reactive inorganic pigments how:

-

Oxides of iron.

-

Oxides Chrome

-

Blues Overseas

-

Blues Cobalt

-

Bismuth Vanadato.

-

Etc.

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Additives A) Dispersants

quad

0% -2%

-

Polyphosphates

-

Polyacrylates

-

Phosphonates

-

Naphthalene sulfonates and lignin

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B) Moisturizers

quad

0% -2%

-

Anionic surfactants.

-

Cationic

-

Amphoteric and non-ionic.

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C) Defoamers

quad

From 0% -1%

-

Silicone emulsions.

-

Long chain alcohols.

-

Hydrocarbons

-

Etc.

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D) Stabilizers

quad

0% -2%

-

Polyfunctional compounds, mainly cationic.

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E) Coalescers

quad

From 0% -4%

-

Stable alkaline esters.

-

Glycols

-

Hydrocarbons (white spirit).

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F) Rheological additives

quad

0% -3%

-

Cellulose derivatives (CMC, HEC).

-

Rubber bands of xanthan.

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Polyurethane.

-

Polyacrylate

-

Modified starch.

-

Bentonites and other silicates laminar

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G) Water repellents

quad

From 0% -4%

-

Alkaline Silicates

-

Siloxanes

-

Wax emulsions

-

You go out Lithium fatty acid.

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H) Biocides

quad

0% -1.5%

-

Though they don't need the addition of a biocide due to its alkalinity, sometimes algaecides or fungicides are added to preserve the movie.

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Description of a preferred embodiment

Citing an example of realization of the formulation, would be of the following composition and proportions:

\dotl

10%- Water

 \ dotl 

10%

\dotl

0.1%- CMC

 \ dotl 

0.1%

\dotl

0.5%- Sodium polyacrylate

 \ dotl 

0.5%

\dotl

5%- Cobalt Oxide

 \ dotl 

5%

\dotl

0.5%- Silicone emulsion

 \ dotl 

0.5%

\dotl

35%- Dolomite

 \ dotl 

35%

\dotl

2%- Talcum powder

 \ dotl 

2%

\dotl

10%- Acrylic emulsion

 \ dotl 

10%

\dotl

1%- Butyldiglycol

 \ dotl 

one%

\dotl

0.5%- White spirit

 \ dotl 

0.5%

\dotl

35%- Sodium silicate solution

 \ dotl 

35%

\dotl

0.4%- Water-emulsion wax emulsion

 \ dotl 

0.4%

\dotl

100%Total

 \ dotl 

100%

For 1 kg of formulation, 10 kg of Marble granule to be colored, 3 to 5 mm in diameter mixed in mixer for 2 minutes and then dried scattered to room temperature for 24 hours.

The advantages of the invention with respect to known existing in the market are numerous and can be observed  in the following comparative table:

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(Table goes to page next)

one

As you can see, the product of the invention behaves better than the known existing in the market, in the different properties shown in the table, since its final use will be destined in most cases to a outdoor use, where they will intervene and act on it different weather elements, such as temperature, humidity, different types of rainfall such as rain, snow, hail and others.

In addition, the product of the invention has three great particular characteristics and which in turn are the ones that they represent the great novelty regarding the products known in the market they are: the penetration of color in the mineral, the conservation of the natural appearance of it as before Color it and its ecological character.

Products that are known to exist in the market, they are colored products with some type of coating based on water or solvent systems, and offering finishes synthetic and artificial. In addition the color is fixed in surface through a film adhered to the substrate and does not reach penetrate the ore, as we had previously indicated in the background section of the invention.

You also have to keep in mind that using this type of technologies today represents major problem by the handling and use of more toxic raw materials, such as use of resins that require aromatic solvents or resins less polluting water, but also in its formulations require the use of a large amount of organic compounds volatile, with the consequent aggravating impact on the environment ambient.

Claims (10)

1. Colored granules for coating and paving, especially granules of marble, granite, quartz, basalt, dolomite, etc., in different colors and granulometries between 0.5 mm and 50 mm, characterized in that the mineral granulate is colored by a production process that achieves a chemical silicification reaction between the formulation, the mineral and atmospheric carbon dioxide, transforming the potassium or sodium silicate used in polymeric silica and potassium or sodium carbonate; combining the silica obtained with the elements of the mineral, in turn dragging the pigments into the granule, this silicification reaction achieving a strong physical-chemical bond, forming a joint structure of inorganic nature. 2. Method of coloring granules for coating and paving, characterized in that it includes a first phase of color treatment on ore in granules, consisting of:

-

to weigh the amount of ore and introduce it in a mixer type concrete mixer,

-

enter the coloring formula desired and previously weighed depending on the mineral and the type of granulometry,

-

mix for a selected time between 30 seconds to 20 minutes depending on the type and particle size of the material,

-

take the ore and introduce it into a hopper with a drag system for go to a drying process.

3. Method of coloring granules for coating and paving, according to claim 2, characterized in that the drying process includes the introduction of the mineral in a dryer with air circulation at a temperature between 15 ° C and 100 ° C. 4. Method of coloring granules for cladding and paving, according to claim 3, characterized in that the dryer is a closed enclosure in which there is an adjustable speed rotating tube and provided with blades that turn the ore, leaving it once dry, by the other end to a conveyor belt that leads to hoppers with weighing cells where it is packaged. 5. Formulation for coloring granules for coating and paving, characterized in that it includes at least one of the following types of inorganic binders between 1% -90%:

?

silicate solution potassium

?

potassium silicate solution pre-stabilized

?

potassium silicate hydrated in powder

?

sodium silicate hydrated in powder

?

silicate solution sodium

?

sodium silicate solution pre-stabilized

and optionally at least one of the following Types of 0% -80% organic binders:

?

Polyacrylates

?

Styrene Acrylates

?

Terpolymers

6. Formulation for coloring granules for coating and paving, according to claim 5, characterized in that it includes at least one of the following types of fillers and pigments:

-

Loads from 0% -90% composed of:

?

Dolomite

?

Calcium carbonate

?

Quartz

?

Kaolin

?

talcum powder

?

Baryta

?

Plastorita

?

Fibrous Matters

?

Aluminum Silicate and Sodium

-

0.01% -90% pigments composed of at minus one of the following types:

?

Titanium dioxide

?

®Lithopone (sulfate barium and zinc oxide)

?

Inorganic pigments no Reagents such as: iron oxides, chromium oxides, ultramarine blue, cobalt blues, bismuth vanadate, etc.

7. Formulation for coloring granules for coating and paving, according to claim 5, characterized in that it optionally includes the following additives:

-

Dispersants of 0% -2% composed of at minus one of the following types:

?

Polyphosphates

?

Polyacrylates

?

Phosphonates

?

Naphthalene sulfonates and lignin

-

0% -2% humectants composed of at minus one of the following types:

?

Anionic surfactants

?

Caitonic

?

Amphoteric and non-ionic

-

Defoamers of 0% -1% composed of At least one of the following types:

?

Silicone emulsions

?

Chain alcohols long

?

Hydrocarbons

-

Stabilizers of 0% -2% composed of At least one of the following types:

?

Polyfunctional compounds, mainly cationic.

-

Coalescents of 0% -4% composed of at minus one of the following types:

?

Alkaline esters stable

?

Glycols

?

Hydrocarbons

-

Rheological additives of 0% -3% compounds for at least one of the following types:

?

Cellulose derivatives (CMC, HEC)

?

Xanthan gums

?

Polyurethane

?

Polyacrylate

?

Modified starch

?

Bentonites and other silicates laminar

-

Water repellents of 0% -4% compounds for at least one of the following types:

?

Alkaline silicates

?

Siloxanes

?

Wax emulsions

?

Acid lithium salts fatty

-

Biocides of 0% -1.5% composed at least by an algaecide or fungicide to preserve the film.

8. Formulation for coloring granules for coating and paving, according to claim 5 to 7, characterized in that it defines a standard base composition prepared to be able to produce a series of colors, then pigmenting on it with different pastes concentrated according to the desired color. 9. Formulation for coloring granules for coating and paving, according to claim 5, characterized in that the alkali silicates used as inorganic binders preferably have a SiO2: M2 or molar ratio as high as possible, covering the range of 1 to 4 between silica and alkali metal (M = Na, K). 10. Formulation for coloring granules for coating and paving, according to claim 7, characterized in that the addition of the additives is based on two factors: the selection of the formulation and that of the production process.