Three component composition for the manufacture of polyurethane cementitious hybrid flooring or coating with improved surface gloss

Patent metadata

Field	Value
Publication number	US-10759700-B2
Application number	US-201515311770-A
Country	US
Kind code	B2
Filing date	May 12, 2015
Priority date	May 16, 2014
Publication date	Sep 1, 2020
Grant date	Sep 1, 2020

Abstract

The present invention relates to a three component composition consisting of a polyol component (A) comprising at least two polyols, one with high and one with low molecular weight, and water, a polyisocyanate component (B) comprising a methylene diphenyl diisocyanate (MDI) product with an average NCO functionality of at least 2.5, or a methylene diphenyl diisocyanate (MDI) product with an average NCO functionality of at least 2 and at least one further polyol with an amount of between 1% and 30% based on the weight of said polyisocyanate component (B), wherein said MDI product and said polyol have reacted at least partially, and a powder component (C) comprising at least one hydraulic binder, preferably cement and/or calcined paper sludge, preferably a calcium compound selected from calcium hydroxide and/or calcium oxide, and optionally one or more aggregates. Polyurethane cementitious hybrid flooring or coating systems having glossy/semiglossy surfaces, good workability and outstanding mechanical properties can be achieved. Blister formation can be avoided.

First claim

The invention claimed is:

1. Three component composition consisting of
a) a polyol component (A) comprising:
at least one polyol P1a with an average molecular weight of 800 g/mol to 30,000 g/mol, and
at least one polyol P1b with an average molecular weight of 48 g/mol to 800 g/mol, and
water, and

b) a polyisocyanate component (B) comprising:
a monomeric or polymeric methylene diphenyl diisocyanate (MDI) with an average NCO functionality of at least 2.5; or
a monomeric or polymeric methylene diphenyl diisocyanate (MDI) with an average NCO functionality of at least 2 and less than 2.5 and further comprising at least one polyol P2 in an amount of between 1% and 30% by weight, based on the total weight of said polyisocyanate component (B), wherein said MDI having an average NCO functionality of at least 2 and less than 2.5 and said polyol P2 have reacted at least partially, and

c) a powder component (C) comprising at least one hydraulic binder,

wherein component (A) comprises said polyol P1a in an amount of 20% to 75% by weight, based on the total weight of component (A), and said polyol P1b in an amount of 2% to 15% by weight, based on the total weight of component (A).

2. Three component composition according to claim 1 , wherein the at least one polyol P1a of component (A) is a polyhydroxy-functional natural oil or fat.

3. Three component composition according to claim 1 , wherein at least one polyol P1b of component (A) has an average OH functionality of 1.6 to 6, and/or is selected from C2 to C12 alkyl diols, glycerol, sugars, or oligomers thereof.

4. Three component composition according to claim 1 , wherein component (A) comprises water in an amount of 20% to 40%, based on the total weight of component (A), and/or wherein the weight ratio of water to polyol P1b is in the range of 0.8 to 40, and/or wherein the weight ratio of water in component (A) to hydraulic binder in component (C) is in the range of 0.1 to 0.7.

5. Three component composition according to claim 1 , wherein the polyisocyanate component (B) consists essentially of monomeric or polymeric methylene diphenyl diisocyanate (MDI) with an average NCO functionality of at least 2.5.

6. Three component composition according to claim 1 , wherein the polyisocyanate component (B) comprises at least one polyol P2 selected from polyhydroxy-functional polyoxyalkylene, polyhydroxy-functional polyester, polyhydroxy-functional polyoxyalkylated alcohol, or polyhydroxy-functional polyoxyalkylated natural oil.

7. Three component composition according to claim 1 , wherein the weight ratio of component (A) to component (B) is in the range of 0.7 to 1.4, and/or wherein the weight ratio of components (A+B) to component (C) is in the range of 0.4 to 2.1, wherein components (A+B) represents the combined weight of component (A) and component (B).

8. Three component composition according to claim 1 , wherein the molar ratio of polyol hydroxyl groups in component (A) to MDI isocyanate groups in component (B) is in the range of 0.1 to 0.4.

9. Three component composition according to claim 1 , wherein component (C) comprises
a) 70% to 97% by weight of at least one hydraulic binder, and
b) 3% to 30% by weight of a calcium compound selected from calcium hydroxide and/or calcium oxide,

based on the total weight of component (C).

10. Three component composition according to claim 1 , wherein component (C) comprises
a) 20% to 30% by weight of at least one hydraulic binder,
b) 1% to 6% by weight of a calcium compound selected from calcium hydroxide and/or calcium oxide, and
c) 65% to 80% by weight of aggregates

based on the total weight of component (C).

11. A method of manufacturing a polyurethane cementitious hybrid flooring or coating with a three component composition according to claim 1 , wherein the method comprises
a) mixing polyol component (A) and polyisocyanate component (B),
b) adding the powder component (C) to the mixture of polyol component (A) and polyisocyanate component (B) and mixing, to obtain a mixed material,
c) applying the mixed material to a substrate,
d) optionally, smoothing the applied mixed material, and
e) curing the applied mixed material, to obtain the polyurethane cementitious hybrid flooring or coating.

12. Polyurethane cementitious hybrid flooring or coating obtained by mixing and curing a composition according to claim 1 , wherein said flooring or coating exhibits a surface gloss of more than 30 GU, based on the gloss measurement method according to EN ISO 2813.

13. The component composition according to claim 1 , wherein at least one polyol P1a of component (A) is castor oil.

14. The component composition according to claim 1 , wherein the powder component (C) comprises cement and/or calcined paper sludge.

Assignees

• Sika Tech Ag

Inventors

• Gimeno Patricia
• Kaddatz Carola
• Grötzinger Jochen
• Gantner Hans

Classifications

• Y02W30/91

  Use of waste materials as fillers for mortars or concrete · CPC title

• C04B28/02 Primary

  containing hydraulic cements other than calcium sulfates · CPC title

• C04B28/04 Primary

  Portland cements · CPC title

• C04B41/50

  with inorganic materials · CPC title

• C04B41/48

  Macromolecular compounds · CPC title