URBAN FLOOR COVERINGS BASED ON NATURAL STONE

Abstract

The present disclosure relates to modules (9) for the production of urban floor coverings, each module is made up of two blocks forming a unitary assembly: an upper block (11) of natural stone of thickness H1; and a lower block (10) of thickness H2 made up of a mixture of plastic waste aggregates, mineral fillers, cement, a resin and optionally one or more additives; in which the thickness H1 represents from 30 to 60% of the sum of the thicknesses H1 and H2. Figure to be published with the abstract: Figure 2

Description

Title of the invention: URBAN FLOOR COVERINGS BASED ON NATURAL STONE FIELD OF THE INVENTION

[0001] The present invention relates to urban floor coverings in modular form combining aesthetics and durability, particularly intended for the paving of sidewalks, squares, cycle paths, esplanades, parking for light vehicles, etc. TECHNOLOGICAL BACKGROUND

[0002] Natural stone coverings (paving stones, slabs, borders, etc.) are high-quality coverings, popular with designers of public spaces wishing to combine aesthetics and durability.

[0003] However, the use of natural stones for the preparation of this type of coating is not without impact on the environment. Indeed, this use involves the extraction of exhaustible and non-renewable raw materials and their transport to the installation site, very often far from the extraction site. Furthermore, the installation of this type of coating can be tedious for humans. In order to withstand the constraints of traffic after installation, the paving stones or slabs must be relatively thick. Humans are therefore required to handle relatively heavy materials which, moreover, require manual installation.

[0004] A need therefore exists for the provision of new urban floor coverings that combine aesthetics and respect for the environment, which incorporate a significant proportion of materials from recycling while offering sufficient mechanical performance to meet the intended areas of use. BRIEF DESCRIPTION OF THE INVENTION

[0005] The present invention relates to modules for the production of urban floor coverings, each module being made up of two blocks forming a unitary assembly: - an upper block of natural stone of thickness H1; and - a lower block of thickness H2 made up of a mixture of aggregates, plastic waste, mineral fillers, cement, a resin and optionally one or more additives;

[0006] in which the thickness H1 represents from 30 to 60% of the sum of the thicknesses H1 and H2.

[0007] The present invention also relates to a method for preparing such modules. The method comprises the following steps:

[0008] - supply of a natural stone block;

[0009] - preparation of a mixture of plastic waste aggregates, mineral fillers, cement, a resin, water and optionally one or more additives;

[0010] - formation of a block from the mixture prepared on one of the faces of the block in natural stone in order to form the module;

[0011] - drying of the module to obtain a unitary assembly.

[0012] Finally, the present invention relates to an urban floor covering comprising a plurality of modules according to the invention assembled by joints and to the use of the modules according to the invention for the production of urban floor coverings, in particular for the production of paving of sidewalks, squares, cycle paths, esplanades and parking for light vehicles.

[0013] Other aspects of the invention are as described in the claims and hereinafter. FIGURES

[0014] [Fig.l] illustrates in perspective a mold consisting of two matrices for the preparation of the modules of the invention.

[0015] [Fig.2] illustrates in perspective the modules obtained after removal from the mold.

[0016] [Fig.3] illustrates in perspective an example of installation of the modules of the invention. DETAILED DESCRIPTION OF THE INVENTION

[0017] In order to meet the needs expressed, the inventors have developed urban floor coverings in modular form.

[0018] Each module consists of two blocks forming a unitary assembly: - an upper block of natural stone of thickness H1; and - a lower block of thickness H2 made up of a mixture of plastic waste aggregates, mineral fillers, cement, a resin and optionally one or more additives;

[0019] in which the thickness H1 represents from 30 to 60% of the sum of the thicknesses H1 and H2.

[0020] The top block is the block directly in contact with the air. It forms the surface layer of the coating. Thus, once the coating is laid, the lower layer (lower block) of the modules is not visible. Only the top layer of natural stone of the modules is visible, preserving the qualitative appearance of the coating.

[0021] The proposed coating is presented in a modular form. Each module is independent of the others. Only the installation of the modules makes the assembly solid.

[0022] In the proposed modules, the upper block has a thickness H1 which represents from 30 to 60% of the total thickness of the module, i.e. from 30 to 60% of the sum of the thicknesses H1 and H2. In certain embodiments, the upper block has a thickness H1 which represents from 40 to 55% of the total thickness of the module. In certain embodiments, the upper block has a thickness substantially equal to half of the total thickness of the module. The proposed coatings therefore make it possible to limit the consumption of natural stone since the thickness of the natural stone in the module is reduced while offering aesthetic equivalence as well as a similarity of behavior (structural similarity).

[0023] In some embodiments, each module has: - an upper block of length Ll, width 11 and thickness H1; - a lower block of length L2, width 12 and thickness H2;

[0024] in which the thickness H1 represents from 30 to 60%, or from 40 to 55%, of the sum of the thicknesses H1 and H2, or even in which the thicknesses H1 and H2 are substantially equal.

[0025] For the construction of light roads (soft mobility: pedestrian zones, cycle paths, etc.) in natural stone, paving stones 8 cm thick are generally used. Thus, in certain embodiments of the invention, the thicknesses H1 and H2 are respectively substantially equal to 4 cm.

[0026] In some embodiments, the length L1 is greater than the length L2 and the width 11 is greater than the width 12 (L1>L2 and 11>12). The length L2 may correspond to 70 to 95% of the length L1 or 80 to 90% of the length L1. The width 12 may correspond to 70 to 95% of the width 11 or 80 to 90% of the width 11. In such embodiments, the lower block will preferably be centered relative to the upper block.

[0027] In certain embodiments (A to F), the modules have the following dimensions:

[0028] [Tables 1] Methods of realization ABCDEF Ll (cm) 10 14 20 30 40 60 L2 (cm) 8.5 12 17 28 37 57 11 (cm) 10 14 20 30 40 60 12 (cm) 8.5 12 17 28 37 57

[0029] In these embodiments, the thicknesses H1 and H2 are preferably respectively equal to 4 cm.

[0030] The upper block is preferably made of granite. Other stones meeting the mechanical properties expected for the use may also be used.

[0031] The properties of the module according to the invention make it possible to meet all of the surface properties of the NF EN 1302 standard: dimension, resistance to wear and frost, skid resistance, appearance, etc.

[0032] The lower block consists of a mixture of plastic waste aggregates, mineral fillers, cement, a resin and possibly one or more additives, such as agents for regulating the setting of cohesion and drying.

[0033] Plastic waste aggregates are materials resulting from the recycling of plastics. Such aggregates are currently typically buried or incinerated, as no recovery method is available for them. Thus, by giving pride of place to the use of waste from recycling, the proposed coatings are economically attractive.

[0034] Plastic waste aggregates may be plastic waste aggregates from the recycling of plastics from the automotive industry, electrical and electronic equipment (WEEE), end-of-life vehicles (ELVs), cables, packaging, construction (BTP).

[0035] Plastic waste aggregates typically contain mainly polymers of the type polypropylene, polyethylene, acrylonitrile butadiene styrene, polystyrene, styrene acrylonitrile, polyoxymethylene, polycarbonate, polyvinyl chloride, polymethyl methacrylate, polyethylene terephthalate, etc. potentially polluted by metallic fractions, wood or composites.

[0036] The plastic waste aggregates preferably have a size ranging from 1 to 10 mm, preferably from 2 to 5 mm.

[0037] Examples of plastic waste aggregates useful in the context of the invention include the “FI5” material supplied by the company Galloo Plastics.

[0038] Mineral fillers make it possible to increase the mechanical capacity of the mixture constituting the lower block, they provide rigidity. Examples of mineral fillers include mineral powders such as calcium carbonates or sands. The sands can be of different petrographic natures, be natural or recycled.

[0039] The elements of the mineral filler typically have a size ranging from 0 to 6 mm. The size of the elements of the mineral filler is measured by the tests described in standard NF EN 933-1 (May 2012 version).

[0040] The resin makes it possible both to agglomerate the components of the lower block, that is to say to bind the plastic waste aggregates and the mineral fillers, and to bind the lower block to the upper block. Thus, the module does not include a mechanical attachment system making it possible to join the two blocks together to form a unitary assembly.

[0041] The resin may be a resin based on polymers obtained by polymerization of monomers chosen from the group consisting of vinyl and / or diene monomers, esters comprising at least one polymerizable olefinic unification, ethylenically unsaturated monomers carrying at least one carboxylic acid and / or anhydride function and combinations thereof. In particular, the monomers are chosen from styrene and its derivatives, including for example vinyltoluenes (ortho, meta, para), a-methylstyrene, isopropylstyrene, tert-butylstyrene, para-butylstyrene, para-decylstyrene, para-chloro-styrene and also from butadiene, isoprene, (meth)acrylic esters, nitriles such as (meth)acrylonitrile, vinyl esters such as vinyl acetate, vinyl butyrate, vinyl caprolate, and vinyl pivalate, (meth)acrylic acid, itaconic acid, fumaric acid, maleic acid, crotonic acid, isocrotonic acid, vinyl-benzoic acid and combinations thereof. The wording (meth)acryl* refers to acryl* and methacryl*, * denoting the suffix -ate or -ique.

[0042] The (meth)acrylic esters are preferentially selected from linear C1-10 alkyl (meth)acrylates, such as methyl (meth)acrylate, ethyl (meth)acrylate or butyl (meth)acrylate, branched C3-10 alkyl (meth)acrylates, 2-ethylhexyl acrylate and combinations thereof. The monomers may be chosen from styrene and (meth)acrylic esters such as linear C1-10 alkyl (meth)acrylates, branched C3-10 alkyl (meth)acrylates.

[0043] Preferably, the resin is an acrylic resin or a styrene-acrylic resin. An example of a resin useful in the context of the invention is the resin marketed by the company Everad under the reference ADL5107.

[0044] The cement may be a cement of type CEM I, CEM II, CEM III, CEM IV or CEM V. Preferably, the cement is a Portland cement (CEM I or CEM II).

[0045] The additives are typically agents for regulating cohesion setting and drying. Examples of additives useful in the context of the present invention include additives ADL5113 and 5114 from Everad.

[0046] The lower block is typically made up of (% expressed relative to the total weight of the lower block): - from 15 to 40%, preferably from 20 to 25%, by weight of plastic waste aggregates; - from 20 to 50%, preferably from 30 to 40%, typically 35%, by weight of mineral fillers; - from 5 to 15%, preferably from 8 to 12%, by weight of resin; - from 10 to 25%, preferably from 15 to 20%, by weight of cement; and - from 0 to 2% by weight of additives to regulate the setting of cohesion and drying. Module preparation process

[0047] The urban paving modules of the present invention can be prepared by a process as described in detail below.

[0048] The method comprises the following steps:

[0049] - supply of a natural stone block;

[0050] - preparation of a mixture of aggregates, plastic waste, mineral fillers, cement, a resin, water and optionally one or more additives;

[0051] - formation of a block from the mixture prepared on one of the faces of the block in natural stone in order to form the module;

[0052] - drying of the module to obtain a unitary assembly.

[0053] The method of preparing the modules can be implemented by means of a mold consisting of two matrices 1, 2 as illustrated in [Fig.l]. Matrix 1

[0054] A first matrix 1 is used to predispose the natural stone forming the upper layer of the module. The first matrix 1 is generally placed on a production table (not shown).

[0055] The first matrix 1 has through voids between the upper face 3 and the lower face (not visible), the voids being separated by walls 4 of the matrix, delimiting compartments 5. In this example, the first matrix 1 has a generally rectangular shape, and the compartments 5 are square. Other shapes are possible for the compartments or for the matrix, for example with sections according to geometric shapes such as rectangles, other preferably regular polygons, ellipses or circles, or even more complex shapes. Preferably, the first matrix 1 is metallic, and generally made of galvanized steel.

[0056] The first die 1 is generally placed on a vibrating production table (not shown). The natural part is typically placed flamed side towards the production table. Matrix 2

[0057] The second matrix 2 is intended to be placed on the first matrix 1 after predisposition of the blocks of natural stones in the compartments 5 of this first matrix 1.

[0058] The second matrix 2 also has through voids between the upper face 6 and the lower face (not visible), the voids being separated by walls 7 of the matrix, delimiting compartments 8. In this example, the second matrix 2 has a generally rectangular shape, and the compartments 8 are square. Other shapes are possible for the compartments or for the matrix, for example with sections according to geometric shapes such as rectangles, other preferably regular polygons, ellipses or circles, or even shapes more complex. Preferably, the matrix is ​​metallic, and generally made of galvanized steel.

[0059] In the illustrated example, the matrices 1, 2 respectively have 15 compartments 5, 8, but any number of compartments can be envisaged. However, the matrices preferably have at least 4 compartments, and preferably at least 8 compartments.

[0060] Since the matrices 1, 2 are intended to be removed after the application and solidification of the mixture of plastic waste aggregates, cement, mineral fillers, resin and optionally one or more additives, the walls of the matrices 1, 2 are shaped to allow this removal. The walls of each matrix are preferably straight between the upper face and the lower face, and typically perpendicular to these parallel faces. Thus, in the case of compartments having a square or rectangular section, the compartments form cubes or paving stones, respectively. The walls may however have a positive draft angle.

[0061] Once the second matrix 2 rests on the first matrix 1, a mixture of plastic waste aggregates, mineral fillers, cement, water, a resin and optionally one or more additives is applied into the second matrix 2 until the compartments 8 are filled. The mixture is typically prepared and applied at room temperature (no melting of the plastic waste aggregates).

[0062] The filling is carried out to refusal, then leveled. Thus, preferably, the upper face 6 of the second matrix 2 is flat, and the application of the mixture of non-recyclable plastic aggregates, mineral fillers, cement, a resin, water and optionally one or more additives comprises a leveling of the mixture to level with the upper face of the second matrix 2. Typically, it is sufficient to level the mixture by passing over the upper face of the second matrix 2, for example with a hand tool such as a scraper or a simple ruler.

[0063] Using a vibrating table, the compactness of the mixture is optimized.

[0064] After solidification of the mixture, it reaches a consistency allowing the removal of the matrices 1, 2 while retaining the shape of the compartments. The duration of solidification can range from 8 hours to 30 hours.

[0065] The matrices are then removed, typically by an upward translation. After removal of the matrices 1, 2, several modules 9 are obtained. [Fig.2] illustrates the modules 9 obtained after removal of the matrices 1, 2. The modules 9 rest on a production table 12. Each module 9 comprises an upper block 11 made of natural stone with a thickness H1 and a lower block 10 with a thickness H2 made of a mixture of plastic waste aggregates, mineral fillers, cement, a resin and optionally one or more additives. Each module 9 obtained forms a single-piece part. Installation of the modules

[0066] An example of installation is illustrated in [Fig.3]. The modules 9 are typically placed on a laying bed 13 then joined 15.

[0067] The laying bed can be made of sand or gravel.

[0068] Preferably, the laying bed is made of crushed porphyry 2 / 4.

[0069] The laying bed is typically arranged on a flexible structure 14, such as for example an untreated granular soil (GNT) 0 / 31.5.

[0070] The structure will be sufficiently load-bearing to withstand traffic, thick to resist frost, and draining to reduce runoff and urban heat islands.

[0071] The modules for urban floor covering can be arranged on a load-bearing and draining road surface.

[0072] After laying the modules on the laying bed, the assembly is rolled. If necessary, the modules are realigned after the cylinder has passed through. The assembly is then joined.

[0073] The seals 15 may be conventional seals.

[0074] The modules are generally firmed with a mallet, then a vibrating plate is placed on the assembly before bonding the joints.

[0075] Preferably, the joints are made of crushed 2 / 4 porphyry bound with a polyurethane binder.

[0076] A one-component polyurethane binder, such as Mapei's Mapestone Joint binder, is typically used.

[0077] The modules can be used for the creation of urban floor coverings, in particular for the creation of paving of sidewalks, squares, cycle paths, esplanades, parking for light vehicles.

[0078] The following examples are given for illustrative purposes, but should in no way be considered as limiting the present invention. Examples

[0079] A 2.5 m2 test board was produced.

[0080] The paving stones were prepared according to the method described previously (L1 20.11: 20 cm, L2 = 17 cm, 12 = 17 cm, 8 cm total thickness including 4 cm of granite).

[0081] Composition for the preparation of the lower block (% by weight relative to the total weight of the composition): - 21% of FI5 plastic waste; - 35% CaCO3 (mineral filler); - 9.5% ADL5107, Everad (resin); - 17.5% of ADL 5112, Everad (cement); - 0.5% ADL5113, Everad (additive); - 0.5% ADL 5114, Everad (additive); - Qsp 100% water.

[0082] The paving stones were laid on a bed of 2 / 4 crushed porphyry, with joints of 2 / 4 crushed porphyry bonded with polyurethane glue.

[0083] After laying, the paving stones were firmed with a mallet, then a vibrating plate was passed over the whole thing and then the joints were made.

[0084] After 18 months of heavy traffic in turns, no deterioration of the board is observed. The coating is therefore suitable for paving sidewalks, squares, esplanades, etc., particularly intended for pedestrian use.

Claims

Claims

1. Module (9) for producing urban floor coverings consisting of two blocks (10, 11) forming a unitary assembly: - an upper block (11) made of natural stone with a thickness H1; and - a lower block (10) with a thickness H2; characterized in that the lower block (10) consists of a mixture of plastic waste aggregates, mineral fillers, cement, a resin and optionally one or more additives; and in which the thickness H1 represents from 30 to 60% of the sum of the thicknesses H1 and H2.

2. Module (9) according to claim 1 in which the plastic waste aggregates are plastic waste aggregates from the recycling of plastics from the automotive industry, electrical and electronic equipment (WEEE), end-of-life vehicles (ELV), cables, packaging and construction (BTP).

3. Module (9) according to claim 1 or 2 wherein the resin is a resin based on polymers obtained by polymerization of monomers chosen from the group consisting of vinyl and / or diene monomers, esters comprising at least one polymerizable olefinic unrestation, ethylenically unsaturated monomers carrying at least one carboxylic acid and / or anhydride function and combinations thereof, preferably the monomers are chosen from styrene and its derivatives, butadiene, isoprene, (meth)acrylic esters, nitriles, vinyl esters, (meth)acrylic acid, itaconic acid, fumaric acid, maleic acid, crotonic acid, iso-crotonic acid, vinylbenzoic acid and combinations thereof.

4. Module (9) according to any one of claims 1 to 3 in which the thickness H1 represents from 40 to 55% of the sum of the thicknesses H1 and H2 or in which the thicknesses H1 and H2 are substantially equal.

5. Module (9) according to any one of claims 1 to 4 in which: - the upper block (11) has a length L1 and a width 11; - the lower block (10) has a length L2 and a width 12; with L1>L2 and 11>12.

6. Module (9) according to claim 5 in which the length L2 corresponds to 70 to 95% of the length L1 and the width 12 corresponds to 70 to 95% of the width 11.

7. Module (9) according to any one of claims 1 to 6 wherein the lower block (10) is made up of: - from 15 to 40%, preferably from 20 to 25%, by weight of plastic waste aggregates; - from 20 to 50%, preferably from 30 to 40%, typically 35%, by weight of mineral fillers; - from 5 to 15%, preferably from 8 to 12%, by weight of resin; - from 10 to 25%, preferably from 15 to 20%, by weight of cement; and - from 0 to 2% by weight of additives to regulate the setting of cohesion and drying.

8. A method of preparing a module (9) according to any one of claims 1 to 7 comprising the following steps: - providing a block (11) of natural stone; - preparing a mixture of plastic waste aggregates, mineral fillers, cement, a resin, water and optionally one or more additives; - forming a block (10) from the mixture prepared on one of the faces of the block (11) of natural stone so as to form the module; - drying the module (9) to obtain a unitary assembly.

9. Urban floor covering comprising a plurality of modules (9) according to one of claims 1 to 7 assembled by joints.

10. Use of modules (9) according to one of claims 1 to 7 for the production of urban floor coverings, in particular for the production of paving of sidewalks, squares, cycle paths, esplanades and parking for light vehicles.

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