U.S. patent application number 13/807528 was filed with the patent office on 2013-06-20 for coating systems.
This patent application is currently assigned to WACKER CHEMIE AG. The applicant listed for this patent is Jurgen Bezler, Hermann Lutz, Mohammed Sanaobar. Invention is credited to Jurgen Bezler, Hermann Lutz, Mohammed Sanaobar.
Application Number | 20130157025 13/807528 |
Document ID | / |
Family ID | 44628212 |
Filed Date | 2013-06-20 |
United States Patent
Application |
20130157025 |
Kind Code |
A1 |
Sanaobar; Mohammed ; et
al. |
June 20, 2013 |
Coating Systems
Abstract
The invention provides coating systems comprising a) a base
layer, b) middle layer and c) top layer, whereby each of the layers
a), b) and c) is based on mineral binder, filler, polymers from one
or more ethylenically unsaturated monomers and optional further
additives, and whereby the middle layer contains additionally light
weight aggregates.
Inventors: |
Sanaobar; Mohammed; (Dubai,
AE) ; Bezler; Jurgen; (Burghausen, DE) ; Lutz;
Hermann; (Emmerting, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Sanaobar; Mohammed
Bezler; Jurgen
Lutz; Hermann |
Dubai
Burghausen
Emmerting |
|
AE
DE
DE |
|
|
Assignee: |
WACKER CHEMIE AG
Munich
DE
|
Family ID: |
44628212 |
Appl. No.: |
13/807528 |
Filed: |
June 28, 2011 |
PCT Filed: |
June 28, 2011 |
PCT NO: |
PCT/EP2011/060806 |
371 Date: |
March 7, 2013 |
Current U.S.
Class: |
428/215 ;
427/403; 427/407.1; 428/313.9; 428/325; 428/331; 428/447; 428/448;
428/492; 428/515; 428/519; 428/520 |
Current CPC
Class: |
Y10T 428/31826 20150401;
C04B 28/02 20130101; Y10T 428/31663 20150401; C04B 2111/00586
20130101; Y10T 428/31928 20150401; C04B 28/06 20130101; C09D
123/0869 20130101; C08L 2205/02 20130101; B05D 7/586 20130101; C04B
2111/00612 20130101; B05D 7/584 20130101; Y10T 428/31924 20150401;
Y02W 30/94 20150501; Y02W 30/91 20150501; E04D 7/00 20130101; C04B
2111/00482 20130101; Y10T 428/249974 20150401; C09D 1/00 20130101;
C08L 23/0869 20130101; C09D 7/61 20180101; C08K 3/26 20130101; E04D
11/02 20130101; C08K 3/36 20130101; Y10T 428/31909 20150401; Y10T
428/252 20150115; Y10T 428/24967 20150115; Y10T 428/259 20150115;
C08K 3/013 20180101; C09D 7/69 20180101; C09D 123/0869 20130101;
C08L 2666/06 20130101; C04B 28/02 20130101; C04B 14/06 20130101;
C04B 14/28 20130101; C04B 18/146 20130101; C04B 24/2623 20130101;
C04B 2103/50 20130101; C04B 28/06 20130101; C04B 7/02 20130101;
C04B 14/06 20130101; C04B 14/185 20130101; C04B 18/146 20130101;
C04B 24/06 20130101; C04B 24/2623 20130101; C04B 2103/32 20130101;
C04B 28/02 20130101; C04B 14/06 20130101; C04B 24/2623 20130101;
C04B 24/383 20130101; C04B 28/06 20130101; C04B 7/02 20130101; C04B
14/06 20130101; C04B 14/24 20130101; C04B 18/146 20130101; C04B
24/06 20130101; C04B 24/2641 20130101; C04B 2103/32 20130101 |
Class at
Publication: |
428/215 ;
427/407.1; 427/403; 428/448; 428/313.9; 428/492; 428/519; 428/520;
428/515; 428/447; 428/331; 428/325 |
International
Class: |
E04D 11/02 20060101
E04D011/02 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 30, 2010 |
AE |
2010/724-P |
Claims
1. Coating systems comprising a) a base layer, b) a middle layer
and c) a top layer, whereby each of the layers a), b) and c) is
based on mineral binder, filler, polymers from one or more
ethylenically unsaturated monomers and optional further additives,
and whereby the middle layer contains additionally light weight
aggregates.
2. Coating systems according to claim 1, characterized in that one
or more light weight aggregates are selected from the group
comprising vermiculite, perlite, poraver glass beads, hollow glass
spheres, natural lightweight aggregate, expanded clays, shales and
sintered pulverised fuel ash.
3. Coating systems according to claim 1 or 2, characterized in that
the polymers are applied in form of polymer compositions containing
one or more polymers from ethylenically unsaturated monomers and
one or more hydrophobicizing additives H) from the group comprising
H1) fatty acids or fatty acid derivatives and H2) organosilicon
compounds.
4. Coating systems according to claims 1 to 3, characterized in
that the polymers from ethylenically unsaturated monomers are based
on one or more monomers from the group comprising vinyl esters of
carboxylic acids having from 1 to 15 carbon atoms, methacrylic
esters or acrylic esters of carboxylic acids with unbranched or
branched alcohols having from 1 to 15 carbon atoms, olefins and
dienes, vinylaromatics and vinyl halides.
5. Coating systems according to claims 1 to 4, characterized in
that the fillers have average diameters of from 0.01 to 4 mm.
6. Coating systems according to claims 1 to 5, characterized in
that the formulation for the preparation of the base layer a)
contains 5% to 25% by weight of one or more mineral binders, 10% to
30% by weight of one or more polymers, and 50% to 85% by weight of
one or more fillers, and optionally 0.01% to 5% by weight of one or
more additives, the amounts in % by weight in the formulation
adding up to 100% by weight.
7. Coating systems according to claims 1 to 6, characterized in
that the formulation for the preparation of the middle layer b)
contains 30% to 70% by weight of one or more mineral binders, 0.1%
to 10% by weight of one or more polymers, and 10% to 50% by weight
of one or more light weight aggregates, 10% to 30% by weight of one
or more fillers other than light weight aggregate, and optionally
0% to 5% one or more additives, the amounts in % by weight in the
formulation adding up to 100% by weight.
8. Coating systems according to claims 1 to 7, characterized in
that the formulation for the preparation of the middle layer b)
contains additionally one or more superfine fillers selected from
the group comprising micro silica, silica flour and calcium
carbonate.
9. Coating systems according to claims 1 to 8, characterized in
that the formulation for the preparation of the top layer c)
contains 35% to 50% by weight of one or more mineral binders, 1% to
5% by weight of one or more polymers and/or polymer compositions
containing one or more hydrophobicizing additives H), and 40% to
60% by weight of one or more fillers, and optionally 0% to 5% by
weight of one or more additives, the amounts in % by weight in the
formulation adding up to 100% by weight.
10. Coating systems according to claims 1 to 9, characterized in
that at least one polymer of the top layer c) contains one or more
monomer units selected from the group comprising vinyl chloride,
vinyl ester and ethylene.
11. Coating systems according to claims 1 to 10, characterized in
that the thickness of the base layer a) is 0.1 to 1 cm, the
thickness of the middle layer b) is 1 to 5 cm, the thickness of the
top layer c) is 0.1 to 1 cm.
12. Coating systems according to claims 1 to 11, characterized in
that the coating systems are roofing systems.
13. Processes for the preparation of the coating systems according
to claims 1 to 12, characterized in that an underground is coated
with one or more layers of coating agent a), upon which one or more
layers of coating agent b) are applied, upon which one or more
layers of coating agent c) are applied.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the national phase filing of
international patent application No. PCT/EP2011/060806, filed 28
Jun. 2011, and claims priority of United Arab Emirates application
number 2010/724-P, filed 30 Jun. 2010, the entireties of which
applications are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to coating systems, particularly
roofing systems, comprising three layers on the basis of mineral
binders, fillers, polymers as well as processes for the preparation
of such coating systems.
BACKGROUND OF THE INVENTION
[0003] In construction engineering it is very common to prepare
coating systems comprising a number of different layers in order to
fulfill the requirements for heat and sound insulation as well as
protection against rain or snow. Due to the long-term use of
buildings and the high costs for their renovation it is of high
importance that each constructional unit of buildings satisfies
high demands. This is particularly true for coating systems exposed
to extreme temperatures and water, such as roofing systems. Thus,
the durability of coating systems is of particular interest.
[0004] Therefore a number of coating systems have been developed up
to now. Five or more layered coating systems are very common. Such
systems comprise for instance a primer prepared from a dissolved
bitumen, secondly a bitumen membrane or a synthetic membrane,
thirdly insulations boards, such as extruded polystyrene, fourthly
geo textile fabric, mainly of polyester or polypropylene in form of
woven, and finally a gravel top layer. The preparation of such
multilayered coating systems is very labor-, cost- and
time-intensive. Furthermore, many different components have to be
applied resulting in a complex logistic at the building site. Such
or related systems are described for example in FR-A 2554151, U.S.
Pat. No. 4,272,936, KR 20040025261, CN 1417432, CN 101413326, CN
201195921 or CN 1777893.
SUMMARY OF THE INVENTION
[0005] It was therefore an object to provide coating systems,
particularly roofing systems, which show high technical
performance, such as a very high durability and very good
insulation properties, and which is based on fewer or more
similarly processable constituents, and which may be prepared in a
more time and cost effective manner.
[0006] These and further objects were achieved with coating systems
comprising a) a base layer, b) a middle layer and c) a top layer,
whereby each of the layers a), b) and c) is based on mineral
binder, filler, polymers from one or more ethylenically unsaturated
monomers and optional further additives, and whereby the middle
layer contains additionally light weight aggregates.
DETAILED DESCRIPTION OF THE INVENTION
[0007] Light weight aggregate are generally known as low density
aggregates, such as vermiculite, perlite, poraver glass beads,
hollow glass spheres, natural lightweight aggregate, like pumice,
expanded clays or shales, like ridgelite or utelite, sintered
pulverised fuel ash.
[0008] Suitable polymers from ethylenically unsaturated monomers
are for example those based on one or more monomers from the group
comprising vinyl esters of carboxylic acids having from 1 to 15
carbon atoms, methacrylic esters or acrylic esters of carboxylic
acids with unbranched or branched alcohols having from 1 to 15
carbon atoms, olefins and dienes, vinylaromatics and vinyl
halides.
[0009] Preferred vinyl esters are vinyl acetate, vinyl propionate,
vinyl butyrate, vinyl-2-ethylhexanoate, vinyl laurate,
1-methylvinyl acetate, vinyl pivalate and vinyl esters of
.alpha.-branched monocarboxylic acids having from 9 to 13 carbon
atoms, for example VeoVa9R or VeoVa10R (trade names of Shell).
Particular preference is given to vinyl acetate.
[0010] Preferred methacrylic esters or acrylic esters are methyl
acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate,
propyl acrylate, propyl methacrylate, n-butyl acrylate, n-butyl
methacrylate, 2-ethylhexyl acrylate, norbornyl acrylate. Preference
is given to methyl acrylate, methyl methacrylate, n-butyl acrylate
and 2-ethylhexyl acrylate.
[0011] Preferred olefins and dienes are ethylene, propylene and
1,3-butadiene. Preferred vinylaromatics are styrene and
vinyltoluene. A suitable vinyl halide is vinyl chloride.
[0012] If appropriate, from 0.05 to 20% by weight, preferably from
1 to 10% by weight, based on the total weight of the base polymer,
of auxiliary monomers can be copolymerized in. Examples of
auxiliary monomers are ethylenically unsaturated monocarboxylic and
dicarboxylic acids, preferably acrylic acid, methacrylic acid,
fumaric acid and maleic acid; ethylenically unsaturated
carboxamides and carboxylic nitriles, preferably acrylamide and
acrylonitrile; monoesters and diesters of fumaric acid and maleic
acid, e.g. the diethyl and diisopropyl esters, and also maleic
anhydride, ethylenically unsaturated sulfonic acids or their salts,
preferably vinylsulfonic acid, 2-acrylamido-2-methylpropanesulfonic
acid. Further examples are precrosslinking comonomers such as
multiply ethylenically unsaturated comonomers, for example divinyl
adipate, diallyl maleate, allyl methacrylate or triallyl cyanurate,
or postcrosslinking comonomers, for example acrylamidoglycolic acid
(AGA), methyl methylacrylamidoglycolate (MAGME),
N-methylolacrylamide (NMA), N-methylolmethacrylamide (NMMA),
N-methylol allyl carbamate, alkyl ethers such as isobutoxy ether or
the ester of N-methylolacrylamide, of N-methylolmethacrylamide and
of N-methylol allyl carbamate. Also suitable are epoxy-functional
comonomers such as glycidyl methacrylate and glycidyl acrylate.
Further examples are silicon-functional comonomers such as
acryloxypropyltri(alkoxy)silanes and
methacryloxypropyltri(alkoxy)silanes, vinyltrialkoxysilanes and
vinylmethyldialkoxysilanes, in which, for example, methoxy, ethoxy
and ethoxypropylene glycol ether radicals can be present as alkoxy
groups. Mention may also be made of monomers having hydroxy or CO
groups, for example hydroxyalkyl methacrylates and acrylates, e.g.
hydroxyethyl, hydroxypropyl or hydroxybutyl acrylate or
methacrylate and also compounds such as diacetoneacrylamide and
acetylacetoxyethyl acrylate or methacrylate. Further examples are
vinyl ethers such as methyl, ethyl or isobutyl vinyl ether.
[0013] Examples of suitable homopolymers and copolymers are vinyl
ester homopolymers, copolymers of one or more vinyl esters with
ethylene, copolymers of vinyl acetate with ethylene and one or more
further vinyl esters, copolymers of one or more vinyl esters with
ethylene and acrylic esters, styrene-acrylic ester copolymers,
styrene-1,3-butadiene copolymers.
[0014] copolymers of one or more vinyl halogenides with
.alpha.-olefins, such as ethylene or propylene, and/or vinyl
esters, such as vinyl acetate, and/or (meth)acrylic esters of
unbranched or branched alcohols having from 1 to 15 carbon atoms,
such as methyl(meth) acrylate, ethyl (meth)acrylate, propyl
(meth)acrylate, n-butyl (meth)acrylate, t-butyl (meth)acrylate, or
2-ethylhexyl (meth) acrylate,
[0015] Preference is given to vinyl acetate homopolymers;
copolymers of vinyl acetate with from 1 to 40% by weight of
ethylene; copolymers of vinyl acetate with from 1 to 40% by weight
of ethylene and from 1 to 50% by weight of one or more further
comonomers from the group comprising vinyl esters having from 1 to
12 carbon atoms in the carboxylic acid radical, e.g. vinyl
propionate, vinyl laurate, vinyl esters of alpha-branched
carboxylic acids having from 9 to 13 carbon atoms, e.g. VeoVa9R,
VeoVa10R, VeoVa11R; copolymers of vinyl acetate, from 1 to 40% by
weight of ethylene and preferably from 1 to 60% by weight of
acrylic esters of unbranched or branched alcohols having from 1 to
15 carbon atoms, in particular n-butyl acrylate or 2-ethylhexyl
acrylate; and copolymers comprising from 30 to 75% by weight of
vinyl acetate, from 1 to 30% by weight of vinyl laurate or vinyl
esters of an alpha-branched carboxylic acid having from 9 to 11
carbon atoms, and also from 1 to 30% by weight of acrylic esters of
unbranched or branched alcohols having from 1 to 15 carbon atoms,
in particular n-butyl acrylate or 2-ethylhexyl acrylate, which may
additionally contain from 1 to 40% by weight of ethylene;
copolymers comprising vinyl acetate, from 1 to 40% by weight of
ethylene and from 1 to 60% by weight of vinyl chloride; copolymers
comprising from 30 to 75% by weight of vinyl chloride, from 1 to
30% by weight of vinyl laurate or vinyl esters of an alpha-branched
carboxylic acid having from 9 to 11 carbon atoms, and also from 1
to 40% by weight of ethylene; where the polymers can additionally
contain the above-mentioned auxiliary monomers in the amounts
indicated and the figures in % by weight in each case add up to
100% by weight.
[0016] Preference is also given to (meth)acrylic ester polymers
such as copolymers of n-butyl acrylate or 2-ethylhexyl acrylate or
copolymers of methyl methacrylate with n-butyl acrylate and/or
2-ethylhexyl acrylate and, if appropriate, ethylene;
styrene-acrylic ester copolymers comprising one or more monomers
from the group consisting of methyl acrylate, ethyl acrylate,
propyl acrylate, n-butyl acrylate, 2-ethylhexyl acrylate; vinyl
acetate-acrylic ester copolymers comprising one or more monomers
from the group consisting of methyl acrylate, ethyl acrylate,
propyl acrylate, n-butyl acrylate, 2-ethylhexyl acrylate and, if
appropriate, ethylene; styrene-1,3-butadiene copolymers; vinyl
halogenide polymers such as copolymers of vinyl chloride and
ethylene; where the polymers can additionally contain the
abovementioned auxiliary monomers in the amounts indicated and the
figures in % by weight in each case add up to 100% by weight.
[0017] The monomers and the proportions by weight of the comonomers
are chosen so that, in general, a glass transition temperature Tg
of from -50.degree. C. to +50.degree. C., preferably from
-30.degree. C. to +40.degree. C., results. The glass transition
temperature Tg of the polymers can be determined in a known way by
means of differential scanning calorimetry (DSC). The Tg can also
be calculated approximately beforehand by means of the Fox
equation. According to Fox T. G., Bull. Am. Physics Soc. 1, 3, page
123 (1956): 1/Tg=x1/Tg1+x2/Tg2+ . . . +xn/Tgn, where xn is the mass
fraction (% by weight/100) of the monomer n and Tgn is the glass
transition temperature in Kelvin of the homopolymer of the monomer
n. Tg values for homopolymers are given in Polymer Handbook 2nd
Edition, J. Wiley & Sons, New York (1975).
[0018] The polymers are prepared in a manner known per se,
preferably in aqueous medium, for usually by the emulsion
polymerization process, as described in DE-A 102006007282 for
example. Use may be made either of emulsifier-stabilized
dispersions or of dispersions stabilized with protective colloid.
The dispersions contain preferably protective colloids in amounts
of 1 to 20 weight percent, based on the total weight of the
monomers. The protective colloids may be anionic or preferably
non-ionic or cationic or combinations of non-ionic and cationic
protective colloids. Preferred non-ionic protective colloids are
polyvinyl alcohols. Suitable cationic protective colloids are
polymers having a cationic charge. Such polymers are described, for
example, in E. W. Flick, Water-Soluble Resins--an Industrial Guide,
Noyes Publications, Park Ridge, N.J., 1991. To prepare polymers in
form of water-redispersible polymer powders, the resultant polymers
in form of aqueous dispersions are dried, preferably after addition
of drying assistants, such as polyvinyl alcohol. The method of
drying may be spray drying, freeze drying, or coagulation of the
dispersion followed by fluidized-bed drying. Spray drying is
preferred. The polymers in form of water-redispersible powders
contain protective colloids in amounts of preferably 3 to 30 weight
percent, based on the total weight of the polymer components.
[0019] The polymers are applied preferably in form of
water-redispersible powders stabilized by one or more protective
colloids.
[0020] The polymers from ethylenically unsaturated monomers may
also be applied in form of polymer compositions containing one or
more polymers from ethylenically unsaturated monomers, preferably
stabilized by one or more protective colloids, and one or more
further additives, such as hydrophobicizing additives H). Examples
of such hydrophobicizing additives H) are additives H1), i.e. fatty
acids or fatty acid derivatives and/or additives H2), i.e.
organosilicon compounds. In general, additives H) are used in
amounts of 1% to 20% by weight, preferably 1% to 10% by weight,
based in each case on the total weight of the polymer
composition.
[0021] Suitable for use as additives H1) are, generally, fatty acid
compounds from the group consisting of fatty acids having 8 to 22
carbon atoms, their metal soaps, their amides, and their esters
with monohydric alcohols having 1 to 14 carbon atoms, with glycol,
with polyglycol, with polyalkylene glycol, with glycerol, with
mono-, di- or triethanolamine, or with monosaccharides.
[0022] Examples for fatty acids are n-dodecanoic acid,
n-tetradecanoic acid, n-hexadecanoic acid, n-octadecanoic acid and
9-dodecenoic acid. Suitable metal soaps are those of the
aforementioned fatty acids with metals from main group lithium,
sodium, potassium, magnesium, calcium, aluminium and zinc and with
the ammonium compounds. Suitable fatty acid amides are those
obtainable with mono- or diethanolamine and with the abovementioned
C.sub.8 to C.sub.22 fatty acids. Fatty acid esters are for example
the C.sub.1 to C.sub.14 alkyl and alkylaryl esters of the stated
C.sub.8 to C.sub.22 fatty acids, preferably methyl, ethyl, propyl,
butyl and ethylhexyl esters and also the benzyl esters. Suitable
fatty acid esters are also the mono-, di- and polyglycol esters of
the C.sub.8 to C.sub.22 fatty acids. Further suitable fatty acid
esters are the monoesters and diesters of polyglycols and/or
polyalkylene glycols having up to 20 oxyalkylene units, such as
polyethylene glycol and polypropylene glycol. Also suitable are the
mono-, di- and tri-fatty acid esters of glycerol with the stated
C.sub.8 to C.sub.22 fatty acids, and also the mono-, di- and
tri-fatty acid esters of mono-, di- and triethanolamine with the
stated C.sub.8 to C.sub.22 fatty acids. Also suitable are the fatty
acid esters of sorbitol and mannitol.
[0023] Particularly preferred are the C.sub.1 to C.sub.14 alkyl and
alkylaryl esters of lauric acid and oleic acid, mono- and diglycol
esters of lauric acid and oleic acid, and the mono-, di- and
tri-fatty acid esters of glycerol with lauric acid and oleic
acid.
[0024] Suitable additives H2) are silicic esters Si(OR').sub.4,
silanes such as tetraorganosilanes SiR.sub.4 and
organoorganoxysilanes SiR.sub.n(OR').sub.4-n with n=1 to 3,
polysilanes with preferably the general formula
R.sub.3Si(SiR.sub.2).sub.nSiR.sub.3 with n=0 to 500, organosilanols
SiR.sub.n(OH).sub.4-n, di-, oligo- and polysiloxanes composed of
units of the general formula
R.sub.cH.sub.DSi(OR').sub.e(OH).sub.fO.sub.(4-c-d-e-f)/2 with c=0
to 3, d=0 to 1, e=0 to 3, f=0 to 3 and the sum c+d+e+f not more
than 3.5 per unit, R in each case being identical or different and
denoting branched or unbranched alkyl radicals having 1 to 22
carbon atoms, cycloalkyl radicals having 3 to 10 carbon atoms,
alkylene radicals having 2 to 4 carbon atoms, and aryl, aralkyl and
alkylaryl radicals having 6 to 18 carbon atoms, and R' denoting
identical or different alkyl radicals and alkoxyalkylene radicals
having in each case 1 to 4 carbon atoms, preferably methyl and
ethyl, it also being possible for the radicals R and R' to be
substituted by halogens such as Cl or by ether, thioether, ester,
amide, nitrile, hydroxyl, amine, carboxyl, sulphonic acid,
carboxylic anhydride and carbonyl groups, and in the case of the
polysilanes it also being possible for R to have the definition
OR'. Also suitable are carbosilanes, polycarbosilanes,
carbosiloxanes, polycarbosiloxanes and polysilylenedisiloxanes.
[0025] Preferred additives H2) are tetramethoxysilane,
tetraethoxysilane, methyltripropoxysilane,
methyltri(ethoxyethoxy)silane, vinyltri(methoxyethoxy)silane,
(meth)acryloyloxypropyltrimethoxysilane,
(meth)acryloyloxypropyltriethoxysilane,
.gamma.-chloropropyltriethoxysilane,
.beta.-nitriloethyltriethoxysilane,
.gamma.-mercaptopropyltrimethoxysilane,
.gamma.-mercaptopropyltriethoxysilane, phenyltriethoxysilane,
isooctyltriethoxysilane, n-octyltriethoxysilane,
hexadecyltriethoxysilane, dipropyldiethoxysilane,
methylphenyldiethoxysilane, diphenyldimethoxysilane,
methylvinyltri(ethoxyethoxy)silane, tetramethyldiethoxydisilane,
trimethyltrimethoxydisilane, trimethyltriethoxydisilane,
dimethyltetramethoxydisilane, dimethyltetraethoxydisilane,
methylhydropolysiloxanes terminally blocked with trimethylsiloxy
groups, copolymers of dimethylsiloxane and methylhydrosiloxane
units that are terminally blocked with trimethylsiloxy groups,
dimethylpolysiloxanes, and also dimethylpolysiloxanes having Si--OH
groups in the terminal units. Maximum preference is given to the
organoorganoxysilanes SiR.sub.n(OR').sub.4-n with n=1 to 3,
especially isooctyltriethoxysilane, n-octyltriethoxysilane and
hexadecyltriethoxysilane.
[0026] The polymer composition may be present in form of aqueous
dispersions or preferably in form of water-redispersible powders.
The preparation of the polymer compositions is known in the art and
described for example in EP-A 1763553.
[0027] Suitable mineral binders are for example cement, such as
Portland cement or blast funast cement, aluminate cement, silica
dust cement, gypsum, waterglass or lime hydrate. Preferred is
Portland cement, optionally in combination with aluminate
cement.
[0028] Examples of fillers which can be used are carbonates such as
calcium carbonate in the form of dolomite, calcite and chalk.
Further examples are silicates, such as magnesium silicate in the
form of talc, or aluminium silicates such as loam and clays; quartz
flour, quartz sand, highly disperse silica, feldspar, heavy spar
and light spar, fillers having a pozzolanic reaction, such as fly
ash, metakaolin, microsilica or rubber shreds. Also suitable are
fibrous fillers. In practice, mixtures of different fillers are
frequently used. Generally less than 10%, preferably less than 5%
by weight gravel is applied, based on the total amount of filler.
More preferably no gravel is applied.
[0029] The fillers have preferably average diameters of from 0.01
to 4 mm, particularly preferably from 0.05 to 0.5 mm.
[0030] Examples of further additives are pigments, an example being
titanium dioxide as an inorganic pigment, and also the customary
organic pigments. Examples of further additives are wetting agents
in fractions of generally 0.1% to 0.5% by weight, based on the
total weight of the respective formulation. Examples of such are
sodium or potassium polyphosphates, polyacrylic acids and salts
thereof. Other additives which may be mentioned include thickeners,
which are generally used in an amount of 0.01% to 2.0% by weight,
based on the total weight of the respective formulation. Customary
thickeners are cellulose ethers, starches, phyllosilicates, or
bentonite, as an example of an inorganic thickener.
[0031] Further additives are preservatives, defoamers, air-pore
formers, plasticizers, retardants, accelerants and frost
preventatives.
[0032] A typical formulation for the preparation of the base layer
a) contains 5% to 25% by weight, preferably 8% to 20% by weight of
one or more mineral binders, 10% to 30% by weight, preferably 10%
to 25% by weight of one or more polymers, and 50% to 85% by weight,
preferably 60% to 80% by weight of one or more fillers, and
optionally 0.01% to 5% by weight, preferably 0,1% to 2% by weight
of one or more additives, the amounts in % by weight in the
formulation adding up to 100% by weight. Additionally, 20% to 40%
by weight of water is used, based on the total weight of the
formulation.
[0033] Polymers containing units of one or more vinyl esters and
ethylene are preferred for the base layer a). The polymers applied
for the preparation of the base layer a) have a glass transition
temperature Tg of preferably from -20.degree. C. to +20.degree. C.
The amount of the polymers as well as the glass transition
temperature Tg contributes to the flexibility of the base layer a)
and works against the occurrence of cracks in the coating
systems.
[0034] A typical formulation for the preparation of the middle
layer b) contains 30% to 70% by weight, preferably 40% to 60% by
weight of one or more mineral binders, 0.1% to 10% by weight,
preferably 0.5% to 5% by weight of one or more polymers, and 10% to
50% by weight, preferably 20% to 40% by weight of one or more light
weight aggregates, 10% to 30% by weight, preferably 15% to 25% by
weight of one or more fillers other than light weight aggregate, 0%
to 5% by weight, preferably 0.1% to 2% by weight of one or more
additives, preferably plasticizers or retardants, the amounts in %
by weight in the formulation adding up to 100% by weight.
Additionally, 20% to 30% by weight of water is used, based on the
total weight of the formulation.
[0035] The middle layer b) contains as light weight aggregate
preferably vermiculite, perlite, poraver glass beads, hollow glass
spheres, natural lightweight aggregate, like pumice, expanded clays
or shales, like ridgelite or utelite, sintered pulverised fuel ash
or various blends thereof. More preferred light weight aggregate
are perlite, poraver glass beads or vermiculite. The light weight
aggregates have preferably an average diameter of from 1 to 4 mm,
particularly preferably from 2 to 4 mm.
[0036] The middle layer b) contains preferably superfine filler,
such as micro silica, silica flour, calcium carbonate, preferably
in combination with the above mentioned fillers. The amount of
superfine filler is preferably 1% to 5% by weight, more preferably
1.5% to 4% by weight, based on the total amount of fillers. The
application of superfine filler reduces the number of pores or pore
volume of the coating system and improves the density of the
coating system.
[0037] The mineral binder applied for the middle layer b) is
preferably a combination of an aluminate cement and one or more
further mineral binders. The ratio of aluminate cement to cement is
preferably 1 to 3 till 3 to 1. These measures accelerate the
manufacturing speed of the coating system.
[0038] Polymers containing units of one or more vinyl esters and
ethylene are preferred for the middle layer b).
[0039] A typical formulation for the preparation of the top layer
c) contains 35% to 50% by weight, preferably 40% to 50% by weight
of one or more mineral binders, 1% to 5% by weight, preferably 1%
to 5% by weight of one or more polymers and/or one or more polymer
compositions containing one or more hydrophobicizing additives H),
and 40% to 60% by weight, preferably 45% to 55% by weight of
filler, 0% to 5% by weight, preferably 0.05% to 2% by weight of one
or more additives, such as thickeners or pigments, the amounts in %
by weight in the formulation adding up to 100% by weight.
Additionally, 20% to 40% by weight, preferably 20% to 30% by weight
of water is used, based on the total weight of the formulation.
[0040] Polymers containing units of vinyl chloride, one or more
vinyl esters, such as vinyl acetate and/or vinyl laurate, and
ethylene are preferred for the top layer c).
[0041] Coating agents a), b) or c) are prepared from the
constituents of the respective formulation for the base layer a),
the middle layer b) or the top layer c). The preparation of the
coating agents is not associated with any specific measure and can
be performed with well-known equipment. Preferably, the dry
components of each formulation are mixed first and water as well as
liquid components are added subsequently.
[0042] Appropriate undergrounds for the base layer a) are cement
bonded undergrounds, such as concrete or screeds, rocks or
boulders, for instance.
[0043] Each of the coating agents a), b) and c) might be applied by
manual methods or mechanical methods, such as spraying machines.
The coating agents are for usually applied at temperatures common
in the construction sector, such as at temperatures from 0 to
50.degree. C. For the preparation of the coating system the
underground is coated with one or more layers of coating agent a),
upon which one or more layers of coating agent b) are applied, upon
which one or more layers of coating agent c) are applied. The
middle layer b) is applied preferably directly onto the base layer
a). The top layer c) is applied preferably directly onto the middle
layer b). In general, the coating agents a), b) and c) have set
before another coating agent is applied onto it.
[0044] Alternatively the underground might be coated with one or
more primers, before the application of the coating agent a).
Alternatively, but less preferred there might be applied a further
coating between the layer a) and b) or between the middle layer b)
and the top layer c). Furthermore, top layer c) might be coated
with a finishing, such as tile.
[0045] In general, the coating agent b) is applied 0.5 to 10 days,
more preferably 1 to 5 after the application of the coating agent
a). The coating agent c) is generally applied 0.5 to 10 days, more
preferably 1 to 5 after the application of the coating agent b).
The whole coating system has set preferably 10 days, more
preferably 7 days after the application of the base coating a).
[0046] The thickness of the base layer a) is preferably 0.1 to 1
cm, more preferably 0.2 to 0.4 cm. The thickness of the middle
layer b) is preferably 1 to 5 cm, more preferably 2 to 3 cm. The
thickness of the top layer c) is preferably 0.1 to 1 cm, more
preferably 0.2 to 0.4 cm. The thickness of the entire coating
systems is preferably 2 to 7 cm, more preferably 2 to 4 cm.
[0047] The most preferred application of the coating systems is for
roofing systems.
[0048] Advantageously, the preparation of the instant coating
system is very effective with respect to the production time as
well as the logistic efforts at the building site. The raw
materials exist in a uniform form and may be furnished to the
construction site as a ready to use premix such that for each of
the coating layers only one coating agent needs to be handled and
the coating agents for the different layers may be applied in the
same way, for example with the same machines. Furthermore, the
instant coating system shows excellent technical performance, such
as high water proofness, flexibility with respect to mechanical
strain, solar irradiation, thermal insulation against heat or cold
as well as sound dampening.
[0049] But the most important aspect of the instant invention is
the synergistic effect of the different layers a), b) and c) which
results in a surprisingly high durability of the system, e.g. a
very high resistance against demands typical for coating systems,
particularly roofing systems, such as for example heat, cold, water
and frost, solar irradiation or corrosive air. This prolongs the
lifetime of the coating system as well as the entire building and
reduces the need for restoration which is very cost intensive.
[0050] The examples which follow serve to illustrate the invention
further.
[0051] The coating agent a) was prepared by mixing the following
components as described in EN 14891:2006:
TABLE-US-00001 Sand (0-0.3 mm) 55% per weight, Grey Cement 12% per
weight, Calcium Carbonate (filler) 10% per weight, Foamaster
(anti-foaming agent) 0.2% per weight, Bentonil CF (filler) 1.5% per
weight, Micro Silica 0.55% per weight, Arbocel BC 1000 (additive)
0.75% per weight, Vinnapas 5044N* 20% per weight, and 50% by water,
based on the total weight of the dry components of the recipe. *:
Polyvinyl alcohol stabilized vinyl acetate-ethylene copolymer in
the form of a water-redispersible powder;
[0052] Coating agent a) was applied with a straight edge trowel on
a concrete substrate to give the base layer a) having a thickness
of 0.3 cm. After storage for 28 days under standard conditions as
defined in EN 14891:2006 the base layer a) was tested as per EN
14891:2006. The results are summarized in Table 1.
TABLE-US-00002 TABLE 1 Test results obtained with the base layer
a): Tests according to EN14891:2006: Base layer a) Tensile Adhesion
[N/mm.sup.2] 1.74 Hydrostatic Pressure Withstand 1.5 bars for 7
days Crack bridging ability [mm] 0.60
[0053] The coating agent b) was prepared by mixing the following
components as described in EN 196-1:2004:
TABLE-US-00003 Portland Cement CEM 42.5 10.9 per weight, Cement
Fondu (HAC) 21.8 per weight, Hydrated Lime (a mineral binder) 0.87
per weight, Citric Acid (additive) 0.35 per weight,
Anhydrate-selecta (a mineral binder) 11.63 per weight, Super
plasticiser--Melflux PP 100F 0.28 per weight, Silica sand (0-300
mic) 17.24 per weight, VINNAPAS 5044 N* 2.0 per weight, Perlite
(1-4 mm) 32.5 per weight, Micro Silica 2.43 per weight, and 25%- by
water, based on the total weight of the dry components of the
recipe. *: Polyvinyl alcoholstabilized vinyl acetate-ethylene
copolymer in the form of a water-redispersible powder;
[0054] Coating agent b) was applied with a straight edge trowel on
a concrete substrate to give the middle layer b) having a thickness
of 2.5 cm. The middle layer b) was tested as per EN13813:2005 after
storage for a time specified in Table 2 under standard conditions
according to EN 13813:2005. The results are summarized in Table
2.
TABLE-US-00004 TABLE 2 Test results obtained with the middle layer
b): Middle layer b) [N/mm.sup.2] Compressive Strength after 7 days
12.67 Compressive Strength after 28 days 16.06 Compressive Strength
after 28 days 3.37 Flexural Strength after 7 days 2.22
[0055] The coating agent c) was prepared by mixing the following
components as described in EN 196-1: 2004:
TABLE-US-00005 White Cement 45 per weight, Sand (0-0.6 mm) 51.5 per
weight, Walocel MKX 6000 PF01 0.2 per weight, (methyl cellulose;
thickener) Vinnapas 8034 H* 3 per weight, Bentonil CF (filler) 0.3
per weight, and 25% by water, based on the total weight of the dry
components of the recipe. *: Polyvinyl alcohol stabilized polymer
composition in the form of a water-redispersible powder containing
calcium stearate and a terpolymer from vinyl chloride, vinyl
acetate and ethylene;
[0056] Coating agent c) was applied with a straight edge trowel on
a concrete substrate to give the top layer c) having a thickness of
0.3 cm. After storage for 28 days under standard conditions as
defined in EN 14891 the top layer c) tested as per EN 14891. The
results are summarized in Table 3.
TABLE-US-00006 TABLE 3 Test results obtained with the top layer c):
Top layer c) Compressive Strength [N/mm.sup.2] 33.5 Flexural
Strength [N/mm.sup.2] 8.7 Shrinkage [mm/m] 1.71 Water
Impermeability--EN 14891 Withstand 1.5 bar for 7 days
[0057] A coating system was constructed by performing the following
steps in the following order: [0058] the coating agent a) from the
above described experiment was applied with a straight edge trowel
on a concrete substrate to give a layer having a thickness of 0.3
cm; [0059] storage of the thus obtained layer for 3 days under
standard conditions as defined in EN 14891:2006 gave the base layer
a); [0060] the coating agent b) from the above described experiment
was applied with a straight edge trowel on the aforementioned base
layer a); [0061] the thus obtained coating system was stored for 3
days under standard conditions as defined in EN 14891:2006;
afterwards, the coating system based on coating agents a) and b)
had a thickness of 2.8 cm; [0062] the coating agent c) from the
above described experiment was applied with a straight edge trowel
on the aforementioned coating system based on coating agents a) and
b); [0063] the thus obtained coating system was stored for 1 day
under standard conditions as defined in EN 14891:2006; afterwards,
the entire coating system, e.g. the coating system based on coating
agents a), b) and c) had a thickness of 3.1 cm.
[0064] The entire coating system was tested against the following
two standards: [0065] 1) The thermal conductivity as per ASTM C 518
and the results were in average 0.2 W/m.K. The specimen was
conditioned in such a way that change in mass within 24 hours was
less than 1%. The conditioning of the specimen was carried out in
accordance to ASTM C 518-02. Caluse 7.3. [0066] 2) The sound
insulation test as per ASTM E-90: 2004. The improved STC by using
the system was by 4 dB.
* * * * *