US3801347A - Covering - Google Patents

Covering Download PDF

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Publication number
US3801347A
US3801347A US00208900A US3801347DA US3801347A US 3801347 A US3801347 A US 3801347A US 00208900 A US00208900 A US 00208900A US 3801347D A US3801347D A US 3801347DA US 3801347 A US3801347 A US 3801347A
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US
United States
Prior art keywords
floor
coating
fibers
layer
hardener
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US00208900A
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English (en)
Inventor
P Keller
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Glasurit Werke M Winkelmann GmbH
Original Assignee
Glasurit Werke M Winkelmann GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Glasurit Werke M Winkelmann GmbH filed Critical Glasurit Werke M Winkelmann GmbH
Application granted granted Critical
Publication of US3801347A publication Critical patent/US3801347A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/16—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of fibres or chips, e.g. bonded with synthetic resins, or with an outer layer of fibres or chips
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44F—SPECIAL DESIGNS OR PICTURES
    • B44F11/00—Designs imitating artistic work
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
    • C08L67/06—Unsaturated polyesters

Definitions

  • ABSTRACT A method of preparing a seamless carpetlike floor covering comprising applying a layer of a solvent-free liquid two component plastic system of resin and hardener to an inside floor or wall of a building, electrostatically spraying fiber flocking material onto the plastic system before it hardens, and hardening the plastic system with the flock material imbedded therein.
  • 949,261 may be used where the adjoining edges are coated with selfhardening synthetic resins such as polyester resins, preferably mixed with fillers, casting resin or styrene resin, and are then smoothed and polished.
  • selfhardening synthetic resins such as polyester resins, preferably mixed with fillers, casting resin or styrene resin, and are then smoothed and polished.
  • the polyester resins can also be used in combination with diisocyanates.
  • the adhesive film Since the carrier substances are usually good electrical insulators, the adhesive film has to be grounded during flocculation. If the electricity is not conducted away quickly enough, then there will be formed over the flocculated surface an opposing electric field which will disturb further flocculation and will lead to undesired difficulties. Another difficulty with the usual process is that after the flock has been deposited, the excess has to be removed. This is usually done by brushing it away after the drying operation. If synthetic resins are used, and especially with polystyrene sheets, such removal is rendered difficult by the tendency of the synthetic resin to acquire a strong electrostatic charge resulting from friction, which will tend to retain the excess flock that is to be removed.
  • Still another disadvantage is the usual necessity of leveling the floor, as by troweling, in preparation for laying the carpet.
  • Floor coverings are also disclosed in Swiss Pat. No. 361,1 14 which consist of a coating of duroplastic under polyadditions of hardened synthetic resins, one component of which is an unsaturated polyester resin. To increase its tearaway resistance, the freshly applied coating has dispersed in it some silicon carbide, marble, basalt or polyester in the form of thin broken pieces. Any of such particles which remain partly on the surface of such a floor covering are imbedded by polishing.
  • a seamless tightly adhering duroplastic coating on a plaster, concrete, artificial stone, ornamental or wooden base and having a carpet-like surface effect is obtained by the hardening of coatings of possibly colored, pigmented or fillercontaining synthetic resins on a bottom layer of twocomponent materials.
  • the hardened surface layer is produced by mixing a two-component system comprising liquid solvent-free synthetic resins with hardeners and before the hardening, imbedding flocked-in shortly cut fibers therein.
  • the process is advantageously performed by first applying upon a base of plaster, concrete, artificial stone or wood, a mixture of liquid solvent-free twocomponent synthetic resin of a viscosity between 500 and 20,000 centipoises and a hardener by painting, rolling, spraying pouring or troweling, and then, before the commencement of any hardening by the hardener, electrostatically depositing shortly cut fibers upon the coated surface and allowing the latter to harden.
  • plaster coatings and cementitious coatings are used, but also those containing other hydraulic binders such as lime or gypsum, as well as bituminous or asphaltic paving materials.
  • suitable materials are concrete, terrazzo, ornamental material and especially wooden floors.
  • solvent-free liquid twocomponent synthetic resin materials are to be understood all two-component materials which after being mixed with the hardener will harden. They do not contain any volatile organic solvents which do not participate in the hardening process. There can, however, be present certain solvents which do take part in the hardening process and which will become permanent components of the hardened layer, as for example styrene, vinyl toluene, acrylic acid ester, methacrylic acid ester and other monomers.
  • Especially suitable solvent-free liquid duroplastics belong to the following groups:
  • hydroxyl group containing compounds which are hardened by polyisocyanates, such as polyethcrs, polyesters, alkyd resins, acrylate resins and epoxide resins;
  • acrylic polymers and unsaturated polylesters which are hardened by peroxides in mixtures with copolymerizable monomers, such as styrene, vinyl toluene, acrylic acid ester, methacrylic acid ester and the like; and
  • the hardener can be mixed with the two-component materials before the processing. It is also possible, however, for the hardener of the two-component material to be deposited separately upon a base by means of a two-component spraying gun, whereupon a reaction occurs. Finally, the hardener can also be first applied to the base and then a layer of the two-component material deposited thereon. In each case, the hardening of the two-component material commences as soon as the hardener and the two-component material come into intimate contact with each other.
  • the two-component materials are applied as clear lacquers to the base. They can, however, also be pigmented with the usual inorganic and organic pigments, and/or mixed with fillers such as talcum, barium sulfate, mica, asbestos, quartz, sand, etc. They can also contain the usual hardening accelerators.
  • the viscosity of the two-component material is between about 500 and 20,000 centipoises, and it is applied to the base by the usual methods such as painting, roller application, spraying, casting or troweling.
  • the textile fibers are shortly cut fibers of different lengths and thicknesses which are applied as flocks. Suitable for this purpose are natural fibers such as cotton, wool, preferably goat wool, but also synthetic fibers such as viscose flocks, triacetate flocks and polyamide flocks. The fibers are cut into lengths ranging from about 0.3 to 12 mm.
  • the textile fibers are flocked upon the coated surface of the base by electrostatic methods with the help of screen radiators (ball screens) in a high voltage field or by means of electrostatic spraying devices or installations.
  • the use of the suggested two-component materials has the advantage of permitting a layer of sufficient thickness to be applied by a single coating operation, the layer being then ready to imbed the flocked textile fibers deposited thereon and firmly hold them so that a floor covering of this kind can be subjected to the roughest use after the resin has hardened, without loss of its carpet-like appearance. It also eliminates the usual troweling and smoothing of the floor which must usually be done whenever a carpet is to be laid.
  • the coating of this invention is to a large extent resistant to thermal, chemical and mechanical treatment. It is surprising that such a coating with its fibrous surface can be cleaned with alkaline cleaning agents. In a similar manner fat-dissolving solvents such as gasoline are used for cleaning the coating without damage to either the textile fibers or the resin. A more important advantage is, however, that a seamless coating is obtained in contrast to the polyvinyl chloride coverings which must be welded and the other carpet coverings which must be fastened by adhesives.
  • the solvent-free liquid duroplast is coated upon the base in layers of at least 0.5 to several mm thick.
  • the preferred thickness is between about 0.5 and 5 mm.
  • the solvent-free liquid duroplast is mixed with a hardener, or the latter is sprayed separately upon the base by means of a two-component spraying nozzle, but simultaneously with the application of the liquid duroplast. The mixing of the hardener with the duroplast then occurs during the spraying.
  • gelling of the solvent-free liquid duroplast coating commences.
  • the flock is applied.
  • not more than about 600 g, preferably to 400 g of flock are applied, the exact amount depending on the length and thickness of the fibers.
  • Different kinds of surface effects are produced by flocking upon the adhesive surface either cut fibers of uniform length or of different lengths. It is also possible to deposit upon the same surface fibers of different lengths in successive operations. By the use of differently colored fibers, a variety of color effects is produced.
  • the flock covered surface hardens under the influence of hardeners with the possible help of accelerators, even at room temperature, to produce a carpetlike surface structure which is useful for covering not only floors but also walls and ceilings.
  • a floor covering it is extremely durable and wear-resistant and differs from the usual floor coverings in that it can be applied in a single combined operation.
  • a mixture is spread containing a liquid epoxide resin, a colored pigment such as yellow iron oxide, powdered quartz of particle size smaller than 150 microns, and a cyclo-aliphatic polyamine as a hardener.
  • the liquid epoxide resin is a known article of commerce which is produced by reacting bisphenol-A with epichlorhydrin.
  • Resins of this type are sold by the Shell group under the name Epikote.
  • the ratio of the epoxide resin to the powdered quartz is 1:13
  • the ratio of the epoxide resin to the amine is 5: 1.
  • a coating 1 mm thick is produced by spreading 2 kg of the mixture over each square meter of floor surface. At a room temperature of 18C, the coating will have a gelling time of two hours. Before gelling of the layer commences, polyamide fibers cut to 2 mm lengths and of 20 denier thickness are flocked upon the epoxide resin surface through an electrostatic ball screen. For this purpose 196 g fibers/m are used. The resulting coating has a carpet-like surface. After 6 hours it will be hard throughout and can then be walked upon, and after one week the fiber covered surface can be brushed with water and soft soap without damage thereto.
  • a layer of hardener which besides an acrylic styrene polymer, also contains benzoyl peroxide in dibutyl phthalate.
  • a material is sprayed, two-thirds of which consists of monomeric acrylic compounds and one-third of which consists of powdered quartz of 10,000 mesh size. A layer 500 microns thick is formed.
  • 200 g hardener and 1.5 kg coating material are used per m of floor surface.
  • the coating gels after 30 minutes at 18C. Within 15 minutes 200 g polyamide fibers of 20 denier thickness and 2 mm length are flocked upon the coating per in of floor surface. After 2 hours the carpet-like surface can be walked upon and clings tenaciously to the floor.
  • An inlaid floor is coated by means of a twocomponent spray gun with a material of the following composition in parts by weight:
  • Example 1 With a layer thickness of 1.2 mm, 2 kg per m of floor surface were used. The coating gels after one hour. Upon the still liquid layer, 200 g cotton flock of 2-3 mm length are deposited per m as in Example 1. After 3 hours, the coating has hardened and can be walked upon. A carpet-like coating has been produced.
  • a two-component material is painted which contains liquid polysulfides with which a paste of lead peroxide in dibutyl phthalate has been mixed.
  • a layer thickness of 0.8 mm 1 kg of the material was used per m of floor surface.
  • the coating gels at room temperature in 30 minutes. Within this time 196 g polyamide fibers of 1.5 to 2 mm length and 15 to 20 denier thickness are flocked electrostatically upon the still wet coating per m of floor surface. After 2 hours, the coating which then firmly adheres to the floor and has the appearance of a carpet, can be walked upon.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Medicinal Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • Structural Engineering (AREA)
  • Floor Finish (AREA)
  • Finishing Walls (AREA)
  • Adhesives Or Adhesive Processes (AREA)
  • Paints Or Removers (AREA)
  • Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
US00208900A 1968-03-08 1971-12-16 Covering Expired - Lifetime US3801347A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
AT231668A AT278326B (de) 1968-03-08 1968-03-08 Verfahren zur Herstellung von fugenlosen Fußbodenbelägen, Wand- oder Deckenverkleidungen

Publications (1)

Publication Number Publication Date
US3801347A true US3801347A (en) 1974-04-02

Family

ID=3532103

Family Applications (1)

Application Number Title Priority Date Filing Date
US00208900A Expired - Lifetime US3801347A (en) 1968-03-08 1971-12-16 Covering

Country Status (14)

Country Link
US (1) US3801347A (de)
JP (1) JPS5027658B1 (de)
AT (1) AT278326B (de)
BE (1) BE729324A (de)
BR (1) BR6906921D0 (de)
CH (1) CH517131A (de)
DE (1) DE1909865C3 (de)
DK (1) DK126392B (de)
ES (1) ES363878A1 (de)
FR (1) FR2003476A1 (de)
GB (1) GB1262524A (de)
NL (1) NL6902035A (de)
NO (1) NO123279B (de)
SE (1) SE365004B (de)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4162237A (en) * 1976-04-10 1979-07-24 Albert Kauderer Cement for wall and floor coverings and the like
US5431962A (en) * 1993-12-27 1995-07-11 Chemproof Polymers, Inc. Abrasion resistant floor covering
US5494729A (en) * 1992-05-20 1996-02-27 Impact Coatings, Inc. Non-slip, non-abrasive coated surface
US8096892B2 (en) 2002-03-25 2012-01-17 Water Ride Concepts, Inc. Control system for water amusement devices

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102005057793B4 (de) * 2005-12-03 2010-04-22 Flooring Technologies Ltd. Fußboden, Bodenpaneel und Verfahren zur Herstellung eines Bodenpaneels

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4162237A (en) * 1976-04-10 1979-07-24 Albert Kauderer Cement for wall and floor coverings and the like
US5494729A (en) * 1992-05-20 1996-02-27 Impact Coatings, Inc. Non-slip, non-abrasive coated surface
US5431962A (en) * 1993-12-27 1995-07-11 Chemproof Polymers, Inc. Abrasion resistant floor covering
US8096892B2 (en) 2002-03-25 2012-01-17 Water Ride Concepts, Inc. Control system for water amusement devices

Also Published As

Publication number Publication date
NO123279B (de) 1971-10-25
AT278326B (de) 1970-01-26
SE365004B (de) 1974-03-11
DE1909865A1 (de) 1969-09-18
ES363878A1 (es) 1971-01-01
FR2003476A1 (de) 1969-11-07
DE1909865C3 (de) 1974-01-10
BE729324A (de) 1969-08-18
CH517131A (de) 1971-12-31
BR6906921D0 (pt) 1973-02-08
JPS5027658B1 (de) 1975-09-09
GB1262524A (en) 1972-02-02
NL6902035A (de) 1969-09-10
DK126392B (da) 1973-07-09

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