FR2738851A1 - Bi-component composition for making outdoor floor coatings - Google Patents

Abstract

Bi-component composition for floor coatings contains two components which are stored separately and applied successively at the moment of forming the floor coatings. The first component comprises: (i) at least one (meth)acrylic polymer solution in at least one mono-unsaturated (meth)acrylic monomer; (ii) at least one poly-unsaturated (meth)acrylic monomer; (iii) at least one mineral agent having grains of at most 150 theta m; (iv) additives to prevent the inhibition of polymerisation by atmospheric oxygen; (v) optional additive(s) to speed up the polymerisation reaction; (vi) dispersing agent(s); and (vii) polymerisation catalyst(s) which are added to the first component just before use. The second component comprises granules having a diameter equal to at least the thickness of the floor coating. Also claimed is an outdoor floor coating made using the claimed composition.

Description

TWO-COMPONENT COMPOSITION FOR THE PREPARATION
OF AN EXTERIOR FLOOR COVERING
The present invention relates to a two-component composition for the preparation of a decorative and non-slip floor covering.

The two-component composition according to the invention is useful in particular for the production of exterior floor coverings by direct application of this composition to its final location or by laying and fixing of prefabricated elements based on this composition.

By two-component compositions is meant here floor covering compositions in which aggregates having a particle size of the order of a millimeter or greater are applied just after application of a binder matrix formed with the other compounds of these compositions.

It is known, in the state of the art, to manufacture non-slip wear layers (or opposing sliding) for exterior floors, but, to the knowledge of the applicant, their aesthetic qualities are very limited.

Thus, in European patent No. 344382, a bituminous and fiber-reinforced composition has been proposed for cold-cast mixes for producing coatings for large surfaces (roads and motorways) whose thickness is substantially equal to the diameter of the largest aggregates.

As an external, decorative and non-slip floor covering, the so-called "washed concrete" technique is also known, the facing of which reveals surface aggregates, stripped of their surface binder by washing with a fine water jet, at the start hold.

However, the latter technique has many disadvantages
- the installation of a washed concrete involves a long
closure of the site to traffic, which is generally
around 21 days or more
- the thickness of a washed concrete reaching a few
centimeters, it is necessary to make a
disbursement in the support which must receive a
washed concrete
- the aesthetic appearance of the washed concrete is not durable
because it tends to crack over time,
especially under the action of external constraints
such as thermal variations. That is why
withdrawal joints must be provided.

An objective of the present invention is therefore products making it possible to produce exterior floor coverings, without the above-mentioned drawbacks. More specifically, the invention relates to products making it possible to produce exterior floor coverings which simultaneously exhibit all of the following properties
- a good non-slip character
- good aesthetic character
- good durability
- a limited noise level, especially when passing
pedestrians or vehicles.

A second objective of the invention relates to the constraints of application of such exterior floor coverings which must be limited or even non-existent. Thus, the production of an exterior floor covering in accordance with the invention should not involve the elimination of part of the covering support, as in the case of the so-called "washed concrete" technique.

The present invention therefore relates to a two-component composition for the preparation of a decorative and non-slip floor covering comprising two components which are kept separately and applied successively during the production of said covering, this two-component composition being characterized in that it comprises
- a first component consisting of
at least one solution of polymers (meth)
acrylics in solution in at least one monomer
(meth) acrylic monounsaturated ;;
at least one poly (meth) acrylic monomer
unsaturated
at least one finely divided mineral filler of which
grain size does not exceed 150
microns
adjuvants to adjust the rheology of
first component and prevent inhibition of the
air oxygen polymerization
possibly one or more adjuvants, per
avoiding sedimentation phenomena
possibly one or more adjuvants
to accelerate the polymerization.

possibly one or more adjuvants dis
persistent
- one (or more) polymerization catalyst (s) that
we add in said first component shortly before its
use
- and a second component consisting of aggregates,
diameter of the large aggregates being substantially equal to
the thickness of the decorative and non-slip coating or
superior.

In the context of the invention, the terms (meth) acrylic polymers and (meth) acrylic monomers denote, respectively, acrylic polymers and / or methacrylic polymers; acrylic monomers and / or methacrylic monomers.

An essential characteristic of the present invention lies in the presence in the first component of a solution of (meth) acrylic polymers in at least one monounsaturated (meth) acrylic monomer and at least one polyunsaturated (meth) acrylic monomer.

The solution of (meth) acrylic polymers in at least one monounsaturated (meth) acrylic monomer and the polyunsatyrated (meth) acrylic monomer (s) are judiciously selected to achieve maximum mechanical strength (in compression and in bending) in maximum 45 minutes and thus allow reopening of traffic in less than an hour after the end of the work.

Also, the solutions of (meth) acrylic polymers in one or more monounsaturated (meth) acrylic monomers and the polyunsaturated (meth) acrylic monomers suitable for the invention are those which make it possible, after polymerization and hardening, to obtain a binder matrix which is flexible enough to support the deformations of the support and follow the microcracks of the support.

To this end, solutions of (meth) acrylic polymers are preferably used in one or more monounsaturated (meth) acrylic monomers and polyunsaturated (meth) acrylic monomers making it possible to reach, after polymerization and hardening, a binder matrix having a temperature glass transition less than about 300C. Indeed, when the glass transition temperature of the cured binder matrix is greater than or equal to about 300C, the presence of a plasticizing agent in the first component is then necessary.

Advantageously, solutions of (meth) acrylic polymers in methyl methacrylate and one or more other acrylic monomers are used, preferably 2-ethylhexyl acrylate or n-butyl acrylate or a mixture of these two comonomers .

Preferably, these solutions of (meth) acrylic polymers and (meth) acrylic monomers are obtained from (partly by weight)
- methyl methacrylate, at a rate of approximately
25 games to about 50 games
- 2-ethylhexyl acrylate and / or n-acrylate
butyl, at a rate of approximately 10 parts to approximately
25 games
- one or more (meth) acrylic monomer (s)
polyunsaturated and, optionally, one or more
other (meth) acrylic monomers monounsaturated with
about 2.5 parts.

The presence of at least one polyunsaturated (meth) acrylic monomer allows the crosslinking of the matrix necessary for obtaining good mechanical properties and thus promotes good resistance over time of the coating. By way of example of a polyunsaturated (meth) acrylic monomer, mention may be made of 2,2′-ethylenedioxydiethyl dimethacrylate.

The total quantity of the solution of (meth) acrylic polymers and of monounsaturated (meth) acrylic monomers and of polyunsaturated (meth) acrylic monomers is adjusted to obtain, after hardening, of the order of 4.5 kg to approximately 9 kg of 2 (meth) acrylic polymers hardened per m of coated support, depending on the state of the surface of the support. Thus, on the supports having a smooth surface state, this quantity can reach the low values of the above-mentioned range of values. On the other hand, the rougher the surface condition of the support, the more this quantity must be increased. Preferably, this quantity corresponds to approximately 5 to 6 kg of (meth) acrylic polymers hardened per 2 m of coated support. To this end, the total quantity of (meth) acrylic polymers and (meth) acrylic monomers is advantageously between 15% and 40% by weight of the first component.

The first component of the composition according to the invention also contains at least one finely divided mineral filler, the grain dimensions of which do not exceed 150 microns because, beyond this value, sedimentation phenomena are likely to occur in the first component and difficulties in applying the bicomponent composition may appear. Preferably, the grain dimensions of the finely divided filler vary between a few microns and about 50 microns.

The mineral fillers that can be used are products well known to those skilled in the art. As examples of mineral fillers, mention may be made of siliceous fillers such as quartz and cristobalite or other types of fillers such as calcium carbonate.

The content of mineral fillers can vary within wide limits; it is preferably less than or equal to 75% by weight, relative to the total weight of the first component.

In order to guarantee short curing times of the binder matrix, to avoid problems of adhesion of this matrix with the support and to achieve sufficient mechanical properties, the first component contains almost no water, preferably in is completely free.

Also, the first component according to the invention does not contain an organic solvent, chemically inert and volatile at room temperature (that is to say at a temperature of the order of 200C to 300C), this in order to respect the environment and achieve sufficient mechanical properties.

As indicated above, in the case where the glass transition temperature of the cured binder matrix of (meth) acrylic polymers is of the order of 300C or higher, the first component of the composition according to the invention must also contain an agent plasticizer whose main function is to increase the flexibility of the exterior floor covering, allowing it to withstand thermal expansion or mechanical deformation. Thus, the presence of a plasticizing agent may be necessary when the (meth) acrylic monomer of the first component according to the invention consists solely of methyl methacrylate. In practice, it is preferred to use solutions of (meth) acrylic polymers not requiring the presence of a plasticizing agent, due to the long-term volatility of this agent and consequently, the gradual loss of flexibility of the non-slip floor covering.

The plasticizing agent is generally used at a rate of 2.5% to 3.5% by weight, this percentage being related to the total weight of the first component.

As an example of a plasticizing agent suitable for the invention, mention may be made of dioctylphthalate.

The first component of the composition according to the invention also contains
one or more adjuvants to adjust the
rheology of the first component such as an agent
wetting agent and / or thickening agent
and one or more agents to prevent
inhibition of oxygen polymerization.

As examples of thickening agents, well known to those skilled in the art, mention may be made of swelling clays, such as bentonite or ultra-fine powders such as, for example, ultra-fine silicas such as the products sold under the Aérosil brand by DEGUSSA.

By way of example of wetting agents, well known to those skilled in the art, mention may be made of polymeric polyelectrolytes such as phosphoric salts.

By way of example of agents making it possible to prevent the inhibition of polymerization by oxygen, there may be mentioned waxes and paraffins.

It is preferable that the total amount of these various adjuvants does not exceed 5% by weight, a percentage relative to the weight of the first component.

If necessary, provision may also be made in the first component according to the invention
one or more adjuvants to avoid
sedimentation phenomena such as one of the agents
aforementioned thickeners
one or more polymerization accelerators
one or more dispersing agents, generally
tension-active agents.

The first component of the composition according to the invention may optionally contain fibers, in particular glass fibers or polyester fibers, the latter being preferred.

Advantageously, the length of these fibers is of the order of 2 mm or more. Advantageously also, this length does not exceed 15 mm.

When the composition according to the invention is intended for the preparation of prefabricated floor covering elements, fibers of short length are preferably chosen, preferably of the order of 2 to 5 mm so that the rheological characteristics of the composition are compatible with an industrial installation.

Also, it is preferred to use polyester fibers or glass fibers, having a tensile strength of between 200 and 600 MPa.

The color of the fibers must also be taken into consideration, in relation to the desired aesthetic effect. Due to the rather translucent nature of (meth) acrylic polymers, it is generally desirable to use only polyester fibers or glass fibers of colorless, white, gray or pale color.

The amount of polyester fibers or glass fibers can vary from 2 g to 10 g per kg of total (meth) acrylic resin obtained after completion of the polymerization of the solution of (meth) acrylic polymers, in at least one monomer ( meth) acrylic, and polyunsaturated (meth) acrylic monomer (s).

As indicated above, the preparation of a composition according to the invention, ready for use, involves the addition, in the first component, of at least one polymerization catalyst. As examples of such catalysts well known to those skilled in the art, there may be mentioned organic peroxides such as dibenzoyl peroxide.

The polymerization catalyst (s) are generally used in small quantities, of the order of 0.5% to 4.0% by weight, this percentage being related to the total weight of the first component. Preferably, the amount of polymerization catalysts is of the order of 2% by weight, relative to the total weight of the first component.

The second component used to prepare the two-component composition according to the invention contains, as an essential constituent, aggregates, the diameter of the large aggregates being substantially equal to or less than the thickness of the decorative and non-slip coating.

Since the bicomponent composition according to the invention essentially serves to prepare exterior floor coverings having a thickness generally between approximately 2 mm and approximately 10 mm, aggregates are preferably chosen whose minimum and maximum dimensions vary respectively between approximately 1 mm and approximately 10 mm, more preferably between about 1 mm and about 6 mm. Indeed, such a particle size allows sufficient embedding of the aggregates in the matrix formed with the first component and, consequently, contributes to giving the exterior floor covering a good rolling resistance, in accordance with French legislation. particle sizes, which involve the elimination of coarse aggregates and fines, a homogeneous binder matrix is obtained leading to exterior floor coverings which are very satisfactory with regard to their aesthetic appearance as well as their non-slip nature.

The aggregates suitable for the invention can be rounded or angular in shape. Preferably, angular aggregates are chosen, most often the result of a crushing operation because it is under these conditions that the best performance in terms of resistance to fouling has been obtained.

The aggregates suitable for the invention have an accelerated polishing coefficient greater than 0.30 (according to standard NF Pl8572 or the calculation of a microdeval).

However, in the case where the two-component composition is intended for producing pavements circulated in an urban environment, the aggregates likely to enter into the composition of the composition according to the invention preferably has a LOS ANGELES coefficient of the order 40, even better, around 50 (according to standard NF Pl8573).

Also, an important selection criterion for aggregates lies in their color which must be stable over time, in particular with respect to ultraviolet rays, rain and wear. This is why it is recommended to use natural aggregates rather than superficially colored aggregates. As examples of natural aggregates which are well suited to the invention, there may be mentioned
- black, gray, speckled, pink, greenish granites
or red,
- milky or yellowish white quartz,
- white, beige, blue, black, gray marbles,
yellow, pink, red, green or purple;
- red, brown, green or pink porphyries.

 - rolled or crushed rollers.

Within the framework of the invention, the production of an exterior floor covering generally follows the steps
v successive below (a) the support must be dry and must first be
free of all stains (in particular, stains
fatty substance) or dust (b) in the case where the support is hardened concrete, we
preferably apply a bonding varnish to the
hardened concrete, the essential function of this varnish
being to strengthen the adhesion of the coating with its
support (c) optionally, a base layer is made
colored with a base paint composition
a (meth) acrylic resin and / or compatible with it
type of resin, to form colored joints
different or nuanced relative to that of
floor covering (d) afterwards, a layer of binder matrix is formed
depositing, on the support or on the varnish
hanging, an appropriate amount of the first
component according to the invention, in which there is
previously added one or more catalysts
polymerization, the viscosity of the first component
catalyzed being such that during operations
following, the binder matrix substantially retains its
form (e) immediately afterwards, the binder matrix is sprinkled with
aggregates which are introduced into the matrix,
preferably by tamping, the quantity of aggregates
deposited being such that we can saturate the matrix
aggregate binder (f) aggregates not embedded in the matrix, or
only weakly, are eliminated, generally by
suction and / or sweeping operations; (g) optionally, a thin layer of a
transparent product such as a decorative varnish in order to
give the exterior flooring an appearance
gloss and / or varnish to increase its
resistance to fouling.

Quickly after the end of the above steps (a) - (g), the exterior floor covering produced with the two-component composition according to the invention can be opened to traffic, pedestrian or road, generally in less than an hour after the end of the works. So
- when the outside temperature is around 20 to
25 "C, the construction site for a coating of
exterior floor may be subject to traffic again
about 20 minutes after the end of the work
- while at lower temperatures, around
of 50C, the opening of a site can be carried out
approximately 45 minutes after the end of the work.

The nature of the support on which the two-component composition according to the invention can be applied is not critical. Thus, the support can also be made of hardened concrete, hydraulic mortar, bituminous mixes or asphalt. On the other hand, the bicomponent composition according to the invention does not adhere correctly to a fresh concrete when rebounds of laitance going against the adhesion of coating can occur.

Also, the support may have been more or less well compacted and, consequently, have a good chance of cracking. this constitutes an advantage of the invention since the exterior floor covering according to the invention has sufficient flexibility to be able to withstand the normal deformations of the insufficiently compacted support and, therefore, to follow its micro-cracks.

This is why the present invention is particularly well suited for coating areas where it is difficult, if not impossible, to compact the materials forming the support well, such as for example on the edge of sidewalks or around a bench, d 'a tree or pole.

The decorative character of the exterior floor covering according to the invention results mainly from the use of a mixture or not of aggregates of various colors, with which it is possible to produce coverings having one or more colors, the (meth) acrylic polymers being, in effect, rather translucent.

As mentioned above, it is of course necessary to saturate the binder matrix with aggregates in order to prepare an exterior floor covering which is both decorative and non-slip. To this end, we are generally led to
2 sprinkle on the order of 8 to 15 kg of aggregates per m of coating to embed on the order of 3 to 7 kg of 2 aggregates in the binder matrix per m of coating.

The two-component compositions according to the invention are preferably prepared and put in place as follows in a conventional mixer, the solution of (meth) acrylic polymers and (meth) acrylic monomers, at least one (meth) monomer, is introduced with stirring. polyunsaturated acrylic, at least one finely divided mineral filler, various additives making it possible to adjust the rheology of the first component and to prevent the inhibition of polymerization by oxygen in the air and, only at the end, the possible rest of the (meth) acrylic monomers, as well as the catalyst. As soon as the mixture is sufficiently homogeneous, it can be applied to the surface to be coated, for example using a spatula, preferably surfaces of variable dimensions depending on the nature of the (meth) acrylic resin, generally of the order of a few m or less, and immediately afterwards, the aggregates are deposited which are made to penetrate into the resin (met h) acrylic during polymerization.

The bicomponent composition according to the present invention is suitable for the production of exterior floor coverings, such as for example pedestrian zones, public squares, roads circulated in urban areas such as road crossings, covered and non-closed areas such as yards or covered markets, etc.

The exterior floor coverings obtained with the two-component composition according to the invention have numerous advantages. In addition to their aesthetic qualities, they also fulfill all of the following properties
- good rolling resistance such as when
are subjected to the simulated traffic of the fatigue merry-go-round
road structures (with no braking), we
finds
good adhesion of the coating on the support;
after the immediate departure refusal, almost not
aggregate heaving
good conservation over time of
mechanical characteristics.

Therefore, it is believed that these coatings can
bear the equivalent without problems, if we limit ourselves
only heavy goods vehicles, around ten years old
of traffic considered to be medium or strong (i.e.
2.3 million 65 kN twinning passes simulating
130 kN axles, with no apparent damage).

- good resistance to outside temperatures of
- 300C to + 500C and good inertness to the salts of
de-icing.

- good hardness of the coating and good resistance
abrasion, according to the standards in force in France.

- sufficient flexibility to support
the deformations of the support and follow the micro
cracks.

- good roughness of the coating surface,
associated with good slip resistance which,
when evaluated under the conditions of the
NF P 18-578 standard of December 1979, using a
friction pendulum, normally decreases in the
time under the effect of simulated traffic of the carousel
fatigue of the road structures mentioned above.

In fact, under these conditions, the values obtained
locate the coatings according to the invention above
traditional bituminous mixes.

 - a long service life.

- the ease of maintenance of the coating according to
the invention, using, for example, water under
pressure, without disturbing its characteristics
mechanical and aesthetic.

Because of the simplicity with which the two-component composition according to the invention can be applied, generally manually, without any deterioration of the support and without the need for sawing and disbursement, it is particularly suitable for the repair of exterior floor coverings damaged in the following, for example, work or abnormal use or normal aging of the coating.

Another advantageous potential application of the two-component composition according to the present invention resides in the production of exterior floor coverings by bonding prefabricated elements, preferably in the form of flexible tiles made of a rigid or flexible support, such as a woven or non-woven plate, to which this two-component composition has been applied while conforming at least to the steps (a) - (g) above. Such prefabricated elements can also be produced without rigid or flexible supports.

Claims (22)

1. Two-component composition for the preparation of a  decorative and non-slip flooring including  two components kept separately and applied  successively during the realization of said  coating, this two-component composition being  characterized in that it includes  - a first component consisting of  at least one solution of polymers  (meth) acrylics in at least one monomer  (meth) acrylic monounsaturated  at least one polyunsaturated (meth) acrylic monomer;  at least one finely divided mineral filler of which  the grain dimensions do not exceed 150 microns  adjuvants to adjust the rheology of  first component and prevent inhibition of the  air oxygen polymerization  . possibly one or more adjuvants  to avoid the phenomena of  sedimentation  . possibly one or more adjuvants  allowing to accelerate the polymerization ;;  . possibly one or more agents dis  persistent  - one (or more) polymerization catalyst (s)  that we add in said first component little  before use  - and a second component consisting of aggregates,  the diameter of the large aggregates being substantially  equal to the thickness of the decorative coating and  non-slip or superior. 2. Two-component composition according to claim 1,  characterized in that the polymer solution  (meth) acrylics in at least one (meth) monomer  monounsaturated acrylic and the monomer (s)  (meth) polyunsaturated acrylics are judiciously  choose to have the (meth) acrylic resin hardened  obtained can reach its mechanical strength (in  compression and flexion) maximum in 45 minutes  maximum. 3. Two-component composition according to claim 1 or  2, characterized in that solutions are used  of (meth) acrylic polymers in methacrylate  methyl and one or more other monomers  acrylics, preferably 2-ethylhexyl acrylate  or n-butyl acrylate or a mixture of these two  comonomers. 4. Two-component composition according to claim 3,  characterized in that these polymer solutions  (meth) acrylic and (meth) acrylic monomers are  obtained from (partly by weight)  - methyl methacrylate, at a rate of approximately  25 games to about 50 games  - 2-ethylhexyl acrylate and / or n acrylate  butyl, at a rate of approximately 10 parts to approximately  25 games  - one or more (meth) acrylic monomers  polyunsaturated and possibly one or more  other monounsaturated (meth) acrylic monomers, to  about 2.5 parts. 5. Two-component composition according to any one of  previous claims, characterized in that the  total amount of (meth) acrylic polymers and  (meth) acrylic monomers is adjusted to obtain,  after hardening, around 4.5 kg to approximately  2  9 kg of (meth) acrylic resin per m of support  coated, depending on the state of the surface of the support. 6. Two-component composition according to claim 5,  characterized in that this quantity corresponds to  about 5 to 6 kg of (meth) acrylic resin hardened by  2  m of coated support. 7. Two-component composition according to any one of  previous claims, characterized in that the  total amount of (meth) acrylic polymers and  (meth) acrylic monomers is between 15% and  40% by weight of the first component. 8. Two-component composition according to any one of  previous claims, characterized in that the  first component also contains fibers. 9. Two-component composition according to any one of  previous claims, characterized in that the  content of mineral fillers is less than or equal to  75% by weight based on the total weight of the first  component. 10. Two-component composition according to any one of  previous claims, characterized in that the  grain dimensions of finely divided filler  vary between a few microns and about 50 microns. 11. Two-component composition according to any one of  previous claims, characterized in  the adjuvant allowing the rheology of the  first component is a wetting agent or an agent  thickener or a combination of these two types  agents. 12. Two-component composition according to claim 1,  characterized in that the first component contains  a plasticizer when the temperature of  glass transition of the cured binder matrix  (meth) acrylic polymers and monomers  (meth) acrylics is around 30 "C or higher. 13. Two-component composition according to any one of  previous claims, characterized in that the  first component contains one or more adjuvants  allowing to avoid the phenomena of sedimentation. 14. Two-component composition according to any one of  previous claims, characterized in that the  first component contains one or more  polymerization accelerators. 15. Two-component composition according to any one of  previous claims, characterized in that the  first component contains one or more agents  dispersants, generally surfactants. 16. Two-component composition according to claim 1,  characterized in that the aggregates are shaped  angular. 17. Two-component composition according to claim 1 or  16, characterized in that the dimensions of the  aggregates vary between approximately 1 mm and approximately 10 mm. 18. A two-component composition according to claim 17,  characterized in that the dimensions of the aggregates  vary between about 1 mm and about 6 mm. 19. Two-component composition according to claim 1 and  claims 16 to 18, characterized in that the  aggregates have a polishing coefficient  accelerated greater than 0.30 (according to standard NF P18572). 20. Covering of exterior floors using  bicomponent composition defined in any one  of claims 1 to 19. 21. Exterior floor covering according to claim  20, characterized in that it is obtained by application  direct of the two-component composition on its  final location. 22. External floor covering according to claim  20, characterized in that it is obtained by laying and  fixing of prefabricated elements based on the  two-component composition.