Clear binder comprising recycled plasticized polyvinyl butyral (PVB) particles

Abstract

The present invention relates to the field of road and urban development surfacings, in particular clear or colored surfacings with clear binders. More particularly, the present invention relates to a clear binder comprising recycled plasticized PVB particles and vinyl polymer particles other than PVB. The present invention also relates to asphalt mixes comprising such a binder as well as to road and urban development surfacings comprising the asphalt mixes of the invention.

Description

Title of the invention: Clear binder comprising recycled plasticized polyvinyl butyral (PVB) particles FIELD OF THE INVENTION

[0001] The present invention relates to the field of road and urban development surfacings, in particular clear or colored surfacings with clear binders. More particularly, the present invention relates to a clear binder comprising recycled plasticized PVB particles and vinyl polymer particles other than PVB. The present invention also relates to coatings comprising such a binder as well as to road and urban development surfacings comprising the coatings of the invention. TECHNOLOGICAL BACKGROUND

[0002] Among the various materials used for the construction of roads, pavements and coatings for urban development, we mainly find asphalt mixes, which are used in particular for the manufacture of wearing courses or base layers. The properties of asphalt mixes, such as the mechanical, thermal, acoustic properties, the waterproofing of the resulting coating, are modulated by the nature of the solid particles and the binder.

[0003] By definition, a coating is obtained by mixing solid particles and a binder. They are then applied by spreading and compacted to obtain road surfaces. Bitumen-based hydrocarbon coatings (bituminous coating) are among the most used for these applications and are responsible for the black color of roads.

[0004] The aesthetic value of coatings is generally associated with their clarity. However, bituminous mixes are black in color due to the presence of asphaltenes in the composition of the bitumen. Clear mixes are generally produced using a synthetic binder that has mechanical and rheological characteristics close to a bitumen while being clear and translucent in thin film. Clear binders of the prior art are generally made up of a mixture of petroleum oils, petroleum hydrocarbon resins and polymers. Clear binders known to those skilled in the art that include oils and resins may have an orange / brown color that alters the natural color of the aggregates.

[0005] Known clear binders are generally used in "hot" coating techniques for solid particles, i.e. at temperatures typically ranging from 150°C to 200°C, in particular from 180°C to 200°C. Manufacturing at these temperatures allows good fluidity of the composition and workability suitable for mechanized or manual application on site. However, the coating applied on site is generally at a temperature above 140-150°C, which results in significant fume emissions. By lowering the manufacturing temperature, and therefore the application temperature, of these clear coatings, significant handling problems can be observed.

[0006] The cold production of clear coatings, i.e. at room temperature, typically ranging from 15°C to 40°C, is not very widespread. However, such a cold technique is advantageous in terms of energy, costs and implementation.

[0007] Thus, a need remains for the provision of clear coatings which can be obtained by “cold” techniques, in particular with a lower environmental impact, and having mechanical and rheological characteristics as satisfactory as those of bituminous coatings. Summary of the invention

[0008] The invention relates to a clear binder comprising water, an anionic surfactant, particles based on recycled plasticized polyvinyl butyral (PVB) and particles comprising a vinyl polymer other than PVB.

[0009] The invention also relates to the use of an aqueous dispersion comprising an anionic surfactant and particles based on recycled plasticized polyvinyl butyral, for the preparation of a binder intended for the manufacture of a road or urban development coating.

[0010] Furthermore, the invention relates to clear coatings comprising solid particles and a residual binder derived from the clear binder according to the invention.

[0011] Finally, the invention relates to a road or urban development surface comprising one or more layers of light coatings according to the invention.

[0012] Other aspects of the invention are as described below. DETAILED DESCRIPTION

[0013] Surprisingly, the inventors have discovered that the use of a clear binder comprising water, an anionic surfactant, particles based on recycled plasticized polyvinyl butyral (PVB) and particles comprising a vinyl polymer other than PVB allows the preparation, in particular cold, of clear coatings. Advantageously, the prepared coatings meet the requirements in terms of mechanical properties for wearing courses and urban developments and make it possible to overcome the aforementioned drawbacks.

[0014] The clear binder has a low film-forming temperature. Coatings prepared using such a clear binder have an optimal compromise between rigidity and flexibility as well as water resistance properties suited to the use for which they are intended.

[0015] Furthermore, such a binder has the advantage of being translucent and therefore makes it possible to produce coatings whose color is that of the granular materials that constitute them. Coatings comprising this binder are therefore particularly suitable for pedestrian and cycle areas with little traffic, forest roads, riverbank roads and sidewalks. They can contribute to the safety of these spaces by providing greater readability and visual differentiation of the various developments.

[0016] In addition, the use of recycled plasticized polyvinyl butyral-based particles in the binder makes it possible to reduce the carbon footprint of the resulting coating, due to the use of recycled material.

[0017] The expression "comprises one" means "comprises at least one" or "comprises one or more". For example, when it is indicated that the binder comprises an anionic surfactant, it is understood that the binder comprises one or more anionic surfactants.

[0018] The term “clear binder” refers to a binder that is generally colorless or light in color (e.g., white or beige).

[0019] The term "residual binder" refers to the binder included in the coatings after coating and removal of water (and / or solvents where applicable). In other words, the residual binder is anhydrous.

[0020] The term "anionic surfactant" designates a surfactant product, i.e. capable of modifying the surface tension between two surfaces, ionizing in aqueous solutions to provide anions and responsible for surface activity.

[0021] The term "glass transition temperature" (denoted Tg) refers to the temperature below which the physical properties of amorphous materials change from a rubbery state to a glassy state. Thus, the Tg is also the temperature below which molecules have little relative mobility. The glass transition temperature is typically measured using the following tests:

[0022] - DSC (Differential Scanning Calorimetry)

[0023] - DMA (Dynamic Mechanical Analysis)

[0024] - TMA (ThermoMechanical Analysis) Clear binder

[0025] The clear binder according to the invention comprises: - water, - an anionic surfactant, - particles based on recycled plasticized polyvinyl butyral (PVB), and - particles comprising a vinyl polymer other than PVB.

[0026] In some embodiments, the clear binder comprises one or more, or all, of the following features:

[0027] - from 5% to 50% by weight of particles based on recycled plasticized PVB, and / or

[0028] - from 5% to 50% by weight of particles comprising a vinyl polymer other than PVB; and / or

[0029] - from 0.2 to 5% by weight of one or more anionic surfactants, relative to the weight total binder.

[0030] The clear binder comprises in particular from 30% to 70%, in particular from 40% to 60%, more particularly from 45% to 55%, by weight of dry matter relative to the total weight of the binder.

[0031] The clear binder according to the invention is in particular free of bitumen.

[0032] The clear binder may also include additives.

[0033] In the clear binder, the particles based on recycled plasticized PVB have a character rubbery and particles comprising a vinyl polymer other than PVB have a more rigid character. The use of such a binder thus makes it possible to obtain a residual binder providing a good rigidity / flexibility compromise to the layer of asphalt comprising such a binder.

[0034] The clear binder may in particular be obtained by a process comprising mixing an aqueous dispersion of PVB-based particles with an aqueous dispersion of particles comprising a vinyl polymer other than PVB. Additives conventionally used in the preparation of binders may be added. The mixing of the two aqueous dispersions may be carried out upstream of or simultaneously with the step of mixing the binder with the solid particles during the preparation of the clear coatings.

[0035] The components of the clear binder are as defined below. The aqueous dispersion of PVB-based particles

[0036] The aqueous dispersion of PVB particles useful for the preparation of the clear binder comprises particles based on recycled plasticized PVB, an anionic surfactant and water.

[0037] The aqueous dispersion of PVB particles typically comprises from 20 to 60% by dry weight of recycled plasticized PVB-based particles relative to the total weight of the dispersion, preferably from 40 to 55%, more preferably from 45 to 50%.

[0038] Typically, the aqueous dispersion of PVB-based particles comprises at least 0.2%, preferably from 0.2% to 5%, by weight of one or more anionic surfactant(s) relative to the total weight of said dispersion.

[0039] The binder prepared from the aqueous dispersion of PVB-based particles therefore comprises the particles based on recycled plasticized PVB and one or more anionic surfactants, as described below.

[0040] An example of an aqueous dispersion of PVB particles useful in the context of the present invention includes the Shark Dispersion SX2™ dispersion marketed by the company Shark Solutions.

[0041] Polyvinyl butyral (PVB) based particles

[0042] The particles based on recycled plasticized PVB are mainly made up of PVB and one or more plasticizers.

[0043] Polyvinyl butyral (PVB) is mainly used as a raw material (rolling sheet) in the preparation of laminated safety glass for car windshields and buildings. In these applications, PVB generally contains one or more plasticizers.

[0044] The use of particles based on recycled plasticized PVB makes it possible to reduce the cost and carbon footprint of the binder, and therefore of the coatings prepared from this binder. Nevertheless, it will be understood that the present invention can be implemented from particles of native (non-recycled), preferably plasticized, PVB, but will be of lesser interest in terms of cost and carbon footprint.

[0045] The recycled plasticized PVB useful in the context of the invention is preferably obtained by isolating the PVB contained in laminated glass waste from windshields and building glazing. The method of isolating the PVB may be as described in applications US 2009 / 230224 and US 2018 / 371202.

[0046] Recycled plasticized PVB therefore contains PVB and one or more plasticizers. The plasticizers contained in the PVB particles would make it possible to stabilize the aqueous dispersion of PVB-based particles. Typically, this is a plasticizer commonly present in the PVB used for the manufacture of laminated safety glass and known to those skilled in the art, such as diesters of carboxylic acids of tri- or tetraethylene glycol, butylricinoleate, castor oil, mixed alkyl and alkylaryl adipates (e.g. benzyl or octyl adipate), or a mixture thereof.

[0047] Typically, the PVB useful in the context of the invention can be any PVB used for the preparation of laminated safety glass, that is to say whatever its molar mass and its content of hydroxyl groups and butyral groups and the sequence of these groups within the polymer.

[0048] The particles based on recycled plasticized PVB have a total content of plasticizer(s) typically ranging from 5% to 50%, preferably from 15% to 30%, by weight relative to the total weight of the particles.

[0049] The particles based on recycled plasticized PVB have a PVB content typically ranging from 50% to 95%, preferably from 70% to 85%, more preferably from 75% to 80%, by weight relative to the total weight of the particles.

[0050] In certain embodiments, the size of the particles based on recycled plasticized PVB is in a range from 50 nm to 1000 nm, preferably from 100 nm to 400 nm.

[0051] PVB-based particles have a glass transition temperature (Tg) typically ranging from -10°C to 80°C. When the particles are based on non-recycled (so-called native) PVB, the Tg is in particular in a range from 60°C to 80°C. When the particles are based on recycled plasticized PVB, the Tg is in particular in a range from -10°C to 40°C, in particular from 0°C to 30°C.

[0052] The presence of particles based on recycled plasticized PVB makes it possible to reduce the film-forming temperature of the binder. A low film-forming temperature ensures good cohesion of the resulting coating. The film-forming temperature of the binder according to the invention, obtained from the aqueous dispersion described above, is in particular within a range from 0°C to 10°C, preferably from 0°C to 5°C, even more preferably lower than 0°C to 1°C. In particular, this film-forming temperature is equal to 0°C. Anionic surfactant

[0053] The anionic surfactant can effectively disperse PVB-based particles and improve the stability of the aqueous dispersion of PVB-based particles.

[0054] The anionic surfactant is typically selected from the group consisting of fatty acid carboxylates such as potassium oleate, sulfates such as sodium dodecyl sulfate, sulfonates such as sodium alkylbenzene sulfonates and alpha-olefin sulfonates, phosphates, sulfosuccinates, phospholipids and mixtures thereof.

[0055] The aqueous dispersion of particles comprising a vinyl polymer other than PVB

[0056] The aqueous dispersion of particles of vinyl polymer other than PVB useful for the preparation of the clear binder comprises particles comprising a vinyl polymer other than PVB, water and an anionic surfactant.

[0057] The aqueous dispersion of particles comprising a vinyl polymer other than PVB typically comprises from 30 to 70% by dry weight of particles comprising one or more vinyl polymers other than PVB relative to the total weight of the dispersion, preferably from 40 to 60%, more preferably from 45 to 55%.

[0058] Typically, the aqueous dispersion of particles comprising a vinyl polymer other than PVB comprises at least 0.2%, preferably from 0.2% to 5%, by weight of one or more anionic surfactant(s) relative to the total weight of said dispersion.

[0059] The binder prepared from the aqueous dispersion of particles comprising a vinyl polymer other than PVB therefore comprises the particles comprising a vinyl polymer other than PVB and an anionic surfactant, as described below.

[0060] Particles comprising a vinyl polymer other than PVB

[0061] It is understood that the particles comprising a vinyl polymer other than PVB may consist of a single vinyl polymer or a mixture of several vinyl polymers. Vinyl polymers denote, in the context of the present invention, the polymers obtained by polymerization of vinyl and / or diene monomers, other than polyvinyl butyral. These vinyl and / or diene monomers may in particular be esters comprising at least one polymerizable olefinic unrestation, ethylenically unsaturated monomers carrying at least one carboxylic acid and / or anhydride function and combinations thereof.

[0062] In particular, these vinyl and / or diene monomers are chosen from styrene and its derivatives (such as vinyltoluenes (ortho, meta, para), a-methylstyrene, isopropylstyrene, tert-butylstyrene, para-butylstyrene, para-decylstyrene, para-chloro-styrene), 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, vinylbenzoic acid and combinations thereof. The wording (meth)acryl* refers to acryl* and methacryl*, * denoting the suffix -ate or -ique.

[0063] 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.

[0064] Preferably, the monomers are chosen from styrene and (meth)acrylic esters such as linear C1-10 alkyl (meth)acrylates, branched C3-10 alkyl (meth)acrylates.

[0065] In certain embodiments, the size of the particles comprising a vinyl polymer other than PVB is in a range from 50 nm to 1000 nm, preferably from 1000 nm to 400 nm.

[0066] Particles comprising a vinyl polymer other than PVB have one or more glass transition temperatures (Tg), each typically ranging from -100°C to 100°C.

[0067] In some embodiments, at least a portion, e.g., half or all, of the particles comprising a vinyl polymer other than PVB are comprised of two or more vinyl polymers other than PVB, each polymer having a distinct Tg. In one example of this embodiment, the Tg of each polymer increases from the surface to the center of the particle, such that that a positive gradient of Tg is observed from the surface of the particles towards the center of the particles.

[0068] In a preferred embodiment, the particles consisting of two or more vinyl polymers other than PVB correspond to ir 1 particles as described in application FR 3 095 665, on page 3, lines 15-21, from page 4, line 19 to page 5, line 10 and from page 5, line 10 to page 7, line 13. These jt 1 particles are structured so that a positive gradient of Tg is observed from the surface of the particles towards the center of the particles. The polymer having the highest glass transition temperature Tgi, greater than or equal to 10°C, is located at the center of the ir particle and the polymer having the lowest glass transition temperature Tg2, less than or equal to 0°C, is located at the surface of the ir 1 particle.

[0069] Tgi is in particular included in a range from 10°C to 100°C, in particular from 30°C to 100°C, and preferably from 50°C to 100°C. Tg2 is in particular included in a range from 0°C to -100°C, in particular from 0°C to -50°C, and preferably from 0°C to -20°C.

[0070] In particular, the particles jt ​​1 with a Tg gradient may comprise a polymer PI having a Tgi in the center of the particle surrounded by one or more intermediate polymer layers comprised between the polymer PI and a layer of polymer P2 having a Tg2 at the surface of the particle, the intermediate layers having Tgs comprised between Tgl and Tg2, such that the value of the Tg of each polymer layer increases when going from the layer of P2 to the layer of PI. Preferably, the particles ir 1 are structured in the form of core / shell particles, comprising a polymer PI in their center, having a Tgi as defined above, surrounded by a shell consisting of a polymer P2 having a Tg2 as defined above. The polymer PI is in particular a methacrylic ester and the polymer P2 is in particular styrene or one of its derivatives, in particular styrene.

[0071] The clear binder may comprise particles comprising a vinyl polymer other than PVB which are all identical or of different natures. This means that the binder may comprise particles consisting of a single vinyl polymer other than PVB, a mixture of particles consisting of a single vinyl polymer other than PVB, particles consisting of a mixture of vinyl polymers other than PVB, a mixture of particles consisting of a mixture of vinyl polymers other than PVB or a mixture of particles consisting of a single vinyl polymer other than PVB and particles consisting of a mixture of vinyl polymers other than PVB. For example, the binder may comprise jtl particles in a mixture with other particles consisting of a single vinyl polymer other than PVB having a single Tg.

[0072] In a preferred embodiment, in the binder, the particles comprising a vinyl polymer other than PVB are all identical. These include ir 1 particles as described above, in particular ir 1 particles in the form of core / shell particles, comprising a polymer P1 in their center, surrounded by a shell consisting of a polymer P2, as described above.

[0073] The presence of vinyl polymer particles other than PVB, in particular jt 1 particles, improves the hardness of the binder film. The residual binder thus has high modulus values, being less susceptible to fracture, while remaining rigid and suitable for the urban or road surfaces envisaged. These modulus values ​​vary little as a function of the outside temperature, the latter typically ranging from -40°C to 60°C. In other words, the mechanical properties of the coatings comprising the binder obtained from the aqueous dispersion as described above remain stable over a wide range of outside temperatures to which the coatings may be exposed during the year, in winter as well as in summer. Light coatings

[0074] The invention also relates to coatings obtained by mixing solid particles and a clear binder as described above. Solid particles

[0075] The term "solid particles" designates all solid particles which can be used for the production of road and development products according to the invention, in particular for road construction and urban development in light coatings.Examples of solid particles include mineral solid particles such as natural mineral aggregates (gravel, sand, fines), for example from quarries or gravel pits, clear surface recycling products such as clear asphalt aggregates, for example resulting from the recycling of materials recovered during the repair of clear surfaces or from surplus from clear asphalt plants, manufacturing waste, aggregates from the recycling of road materials including concrete, slag, in particular slag, schists, in particular bauxite or corundum, rubber crumb, for example from tire recycling, artificial aggregates of any origin and aggregates from, for example, household waste incineration bottom ash (MIOM), as well as their mixtures in all proportions.

[0076] Solid particles, in particular mineral solid particles, for example natural mineral aggregates, typically comprise elements less than 0.063 mm (filler or fines), sand whose elements are between 0.063 mm and 2 mm and gravel or aggregates, whose elements have dimensions between 2 mm and 6 mm and greater than 6 mm.

[0077] The size of solid particles, in particular mineral solid particles, for example mineral aggregates, is measured by the tests described in standard NF EN 933-2 (07 / 2020).

[0078] “Mineral solid particles” are also referred to as “0 / D mineral fraction”. This 0 / D mineral fraction can be separated into two particle sizes: the 0 / d mineral fraction and the d / D mineral fraction. The finest elements (the 0 / d mineral fraction) are those in the range between 0 and a maximum diameter that can be set between 2 and 6 mm (from 0 / 2 to 0 / 6), advantageously between 2 and 4 mm. The other elements (minimum diameter greater than 2, 3, 4, 5 or 6 mm; and approximately up to 31.5 mm) constitute the d / D mineral fraction.

[0079] Advantageously, the coatings of the invention are light in color. Thus, the aggregates used in the coatings of the invention preferably have a high L* luminescence, typically greater than 50. This property gives the coatings improved visibility by day and night as well as great clarity. The luminescence is typically calculated according to standards NF EN 11664-1, NF EN 11664-2 and NF 11664-4, dated 07-01-2011. Additives

[0080] The coatings according to the invention may comprise an additive, either added to the solid particles before mixing with the binder, or present in the binder or added to the binder before mixing with the solid particles, or during the mixing of the solid particles and the binder. This additive may be used for mechanical purposes, for rheological purposes, for adhesion purposes, for aesthetic purposes, in particular for a change in color of the final road products.

[0081] When the additive is present in the binder, it may be present in the aqueous dispersion of PVB-based particles, in the aqueous dispersion of particles comprising a vinyl polymer other than PVB and / or be added to the binder, typically after mixing the two aqueous dispersions or simultaneously with it.

[0082] For example, the additive may be selected from plasticizers, non-ionic surfactants, adhesion dopes, coloring agents, antifoaming agents, viscosifying agents, antimicrobial agents, calcium carbonate dispersions, fibers and a combination thereof.

[0083] The clear binder may in particular comprise one or more additives commonly used in the preparation of binders for road surfacing.

[0084] Plasticizers

[0085] When the particles are native PVB particles, a plasticizer is preferably added to the clear binder. This plasticizer is notably chosen from diesters of carboxylic acids of tri- or tetraethylene glycol, butylricinoleate, castor oil, mixed alkyl and alkylaryl adipates (benzyl or octyl adipate) or a mixture thereof.

[0086] When the particles are based on recycled plasticized PVB, which therefore includes plasticizer, typically no additional plasticizer is added to the clear binder.

[0087] The clear binder preferably comprises from 1% to 25% by weight of one or more plasticizers (included in the PVB particles and / or added in the dispersion or the binder) relative to the total weight of the binder, preferably from 5% to 12%.

[0088] Non-ionic surfactant

[0089] The binder may optionally comprise a non-ionic surfactant, which does not ionize in water, in combination with one or more anionic surfactants as defined above. In this case, the binder may comprise from 0.2 to 5%, and preferably from 0.2 to 0.5% by weight of one or more anionic surfactant(s) relative to the total weight of the binder. This non-ionic surfactant is for example selected from glycol esters such as ethylene glycol stearate, glycerol esters, sorbitan esters (Tween®), polyoxyethylene glycol esters, fatty alcohol ethers, alkanolamides and mixtures thereof.

[0090] Antimicrobial agents

[0091] Antimicrobial agents include antibacterial and antifungal agents and agents combining these properties.

[0092] Such agents prevent the proliferation of pathogenic agents (bacteria, fungi, etc.) within the aqueous dispersion during storage. They mainly serve as preservatives.

[0093] The antimicrobial agent may be any antimicrobial agent known to those skilled in the art. It is for example selected from benzoisothiazolinone (BIT), methylisothiazolinone (MIT), their derivatives and mixtures thereof.

[0094] Adhesion Dopes

[0095] The adhesion dopes make it possible to improve the reciprocal affinity between the binder composition and the aggregates and ensure their durability.

[0096] Examples of dopes useful in the context of the present invention include, but are not limited to, nitrogenous surfactant compounds derived from fatty acids (amines, amidoamines, imidazolines), fatty acids or polymerized fatty acids, phosphate esters, organosilanes, etc.

[0097] Coloring agents

[0098] The coloring agents can be mineral pigments or organic dyes. The pigments are selected according to the shade, the color desired for the coating. For example, metal oxides such as iron oxides, chromium oxides, cobalt oxides, titanium oxides can be used to obtain the colors red, yellow, gray, green, blue or white.

[0099] The coloring agents can be added, indifferently in the binder composition or during the manufacture of the coating in a mixture with the solid mineral particles (fillers, sands and aggregates).

[0100] Viscosifying Agents

[0101] The viscosifying agents are chosen from inorganic viscosifiers and organic viscosifiers, such as clays, fumed silicas, cellulosic viscosifiers and synthetic viscosifiers of associative type (such as HEUR (Hydrophobically modified Ethylene oxide URethane according to the appropriate English acronym), HMPE (High Modulus PolyEthylene according to the English acronym) or HASE) or non-associative (ASE).

[0102] The acronym *HASE”, denotes a hydrophobically modified alkali-soluble emulsion, comprising a carboxylated copolymer based on: - (al) at least one anionic monomer comprising at least one polymerizable olefinic unsaturation, preferably an anionic monomer comprising at least one polymerizable olefinic unsaturation and at least one carboxylic acid function, - (a2) of at least one ester of a compound derived from a carboxylic acid comprising at least one polymerizable olefinic unsaturation, and - (a3) ​​of at least one associative hydrophobic monomer.

[0103] The acronym “ASE” denotes an alkali-soluble emulsion comprising a carboxylated copolymer based on: - (al) at least one anionic monomer comprising at least one polymerizable olefinic unsaturation, preferably an anionic monomer comprising at least one polymerizable olefinic unsaturation and at least one carboxylic acid function, - and (a2) at least one ester of a compound derived from a carboxylic acid comprising at least one polymerizable olefinic unsaturation.

[0104] Anti-foaming agents

[0105] Anti-foaming agents make it possible to limit the formation of foam during the process of coating the granular fractions with the binder. The anti-foaming agents can be compounds of the PDMS (PolyDimethylSiloxane) type, organopolysiloxane, POA (polyoxyalkylene), a vegetable oil or polyamide particles.

[0106] Dispersion of calcium carbonate

[0107] A dispersion of calcium carbonate may be added to the binder in order to confer rigidity and reinforcement properties to the binder. Such a dispersion of calcium carbonate has in particular a dry extract of between 50 and 80%.

[0108] Fibers

[0109] The fibers are for example chosen from cellulosic fibers, polyacrylonitrile fibers and / or glass fibers. The addition of fibers makes it possible to limit the dripping of the binder based on the aqueous dispersion and to improve the abrasion resistance at the early age of the resulting coating.

[0110] According to a particular embodiment of the invention, the coating may also comprise a minor quantity of hydraulic binder in combination with the clear binder according to the invention. By "minor quantity", it is meant that the residual hydraulic binder content is less than or equal to 2% relative to the total weight of the coating, preferably less than 1%. Advantageously, said hydraulic binder is chosen from Portland cement, lime, milk of lime, magnesia, synthetic or natural calco-magnesian compounds such as dolomites, magnesium limes or dolomitic limes, calcium and / or magnesium silicate or aluminate cements or any other hydraulic binder well known to those skilled in the art.

[0111] The addition of hydraulic binder makes it possible to increase the rigidity of the final residual binder, and therefore of the resulting asphalt coating, depending on the intended uses. The addition of hydraulic binder can also reduce the setting time of the asphalt, i.e. the time required for the water and possibly the solvents to evaporate from the binder and for the asphalt to be sufficiently consolidated and stable for traffic.

[0112] The hydraulic binder may be introduced either when mixing the various components of the coating, or beforehand to the solid particles or to the emulsion binder before coating, subject to the compatibility and stability of the hydraulic binder in the aqueous dispersion as defined above. Preferably, the hydraulic binder is added to the solid particles before mixing with the binder.

[0113] Depending on the climatic conditions, the dryness of the solid mineral fraction, water, called filler water, can be added to the solid particles before mixing with the binder. The total water content by weight of the solid particles consisting of the filler water and the water naturally present in the solid particles, ranges for example from 1% to 6% by weight relative to the total weight of the solid particles, typically the water content is 4%.

[0114] Optional drying of the solid particles may be carried out if they contain a water content greater than 6% by weight relative to the total weight of the solid particles, in order to achieve a water content ranging from 1 to 6%, typically 4%.

[0115] Process for preparing coatings and characteristics

[0116] The process for preparing the coatings comprises mixing the solid particles and the clear binder as defined above, followed by a drying step allowing the evaporation of the water initially present in the binder and the solid particles.

[0117] In the present invention, the mixing of the solid particles and the clear binder, as well as the drying step, is preferably carried out cold, i.e. at a temperature ranging from 15°C to 40°C. In such cold coating, the solid particles are not previously dried and are mixed with their natural moisture (plus an adjustment of the water content if necessary).

[0118] The clear coatings according to the invention are laid by spreading, for example with a finisher or a grader, then compacted. These coatings allow a return to traffic in less than 72 hours, more advantageously within 24 hours after spreading. Typically, the spreading of the coatings is also carried out in this temperature range at a temperature ranging from 15°C to 40°C.

[0119] Preferably, the coatings according to the present invention have a void content of less than 35%, preferably in a range from 5 to 30%, even more preferably from 20 to 30%.

[0120] The coated materials therefore comprise solid particles as described above and the residual binder derived from the clear binder as defined above. In other words, the coated materials comprise solid particles, PVB-based particles, particles comprising a vinyl polymer other than PVB, a surfactant and optionally additives, as defined above. The residual binder content of the coated materials is typically in a range from 1 to 20% by weight relative to the total weight of the coated material, preferably from 1.5 to 10% by weight, more preferably from 2.5 to 3.5% by weight. The quantity of binder within the coated material may be adjusted depending on the intended use of the coated materials. Road surfacing or urban development

[0121] The present invention also relates to a road or urban development surface, comprising one or more layers of coatings according to the present invention.

[0122] In certain embodiments, the coating according to the present invention is a clear pavement layer particularly suitable for lightly trafficked roads such as, for example, pedestrian paths, cycle paths, squares, forecourts, playgrounds, sports grounds and greenways.

[0123] The coating of the invention may further comprise a sealing layer over the coating layer(s), advantageously applied between 24 and 48 hours after the end of the application of the coatings.

[0124] By "sealing layer" is meant a layer of binder sprayed onto a layer of roadway intended to fix the surface gravel (the rolling). Indeed, the good level of cohesion of the coatings guarantees the absence of tearing of gravel and sand. The binder of the sealing layer can be any light binder suitable for the preparation of road surfacing.

[0125] For example, the sealing layer consists of a residual binder derived from the binder according to the invention, as described above.

[0126] The sealing layer is preferably applied at a dosage of 50 to 400 g / m2 of residual binder. EXAMPLES

[0127] For all the examples below, the total residual anhydrous binder content was set at 3.15% by weight relative to the total weight of the solid particles.

[0128] The granulometric curve of the solid particles is as follows for all the examples below:

[0129] [Tables 1] Sieve (mm) 0.063 0.125 0.250 0.500 1 2 4 6.3 8 Passers (%) 4.0 4.9 6.9 9.3 14.6 25.2 57.6 94.0 100

[0130] The binders tested are aqueous dispersions having the following compositions and properties:

[0131] [Tables2] Product Comment Nature of polymer particles Glass transition temperature (Tg) Particle content in dry weight relative to the weight of the binder) LT1* Control binder Core-shell (Meth)acrylic esters and styrene 4°C / 96°C 50% LT2** Control binder Recycled polyvinyl butyral 22°C 48% read Binder according to the invention Mixture 70% LT1 + 30% LT2 Not measured 50% LI2 Binder according to the invention Mixture 50% LT1 + 50% LT2 Not measured 49%

[0132] * the control binder LT1 used in the examples is a commercial binder from the company Celanese® sold under the trade name Mowilith®7416. It includes an anionic surfactant.

[0133] **the LT2 binder used in the examples is a commercial binder from the company Shark Solutions® sold under the trade name Shark Dispersion SX2. It comprises an anionic surfactant. Production of asphalt mixes

[0134] In each example below, the solid particles were introduced into a mixer, water was added to the mixture and then the aqueous binder was introduced into the formulation. After 20 seconds of mixing, the mix is ​​compacted using a static press in order to achieve a void content of 20% in the test pieces and then curing for 14 days at 35°C / 20% humidity is carried out.

[0135] Mechanical properties in sinusoidal diametrical compression

[0136] The coatings are then characterized by sinusoidal diametrical compressions in order to obtain the phase angle, as well as the complex modulus of the coatings as a function of temperature and frequency. Surface cohesion test

[0137] A surface cohesion test of the Surface Cohesion Test (TCS) type from the NF EN 12274-5 standard can be carried out to estimate the surface tear resistance of the coating. This test is carried out after a curing time of 72 hours at 20°C before immersion in water. The loss of mass of the coating is then evaluated as a percentage in relation to the abrasion surface after an abrasion time of 5 minutes. Example 1#: Control formulation no. 1 (Binder LT1)

[0138] An example of a reference cold mix formulation with solid particles of size 0 / 6 and the control aqueous phase binder LT1 is given in the following table:

[0139] [Tables 3] Materials % by weight 2 / 6 Limestone (%) 55.3 0 / 4 Limestone (%) 36.9 Water supply (%) 1.8 LT1 (%) 6.0

[0140] In order to characterize the mechanical properties of the coatings obtained, curing at 35°C / 20% humidity was carried out following the cold production of the coatings.

[0141] The mechanical properties in sinusoidal diametrical compression of the coatings obtained from this formulation are given in the following table:

[0142] [Tables4] Isochronous 10 Hz Temperature (°C) Phase angle (°) E* (MPa) -20 0.3 22940 0 1.2 20024 20 2.4 15407 40 2.7 12584 60 2.7 9985 Example 2#: Control formulation no. 2 (LT2 binder)

[0143] Another example of a reference cold mix formulation with solid particles of size 0 / 6 and the control aqueous phase binder LT2 is given in the following table:

[0144] [Tables5] Materials % by weight 2 / 6 Limestone (%) 55.3 0 / 4 Limestone (%) 36.9 Water supply (%) 1.8 LT2 (%) 6.0

[0145] The mechanical properties in sinusoidal diametrical compression of the coatings obtained from this formulation are given in the following table:

[0146] [Tableauxô] Isochronous 10 Hz Temperature (°C) Phase angle (°) E* (MPa) -20 5.7 15847 0 4.2 14780 20 9.5 10143 40 22.4 3586 60 12.7 1222

[0147] This example demonstrates that the use of an aqueous dispersion comprising particles based on recycled polyvinyl butyral alone leads to a high thermal susceptibility of the mechanical properties of the coating, in particular from 30-40°C. The very low complex modulus value E* of this coating at 60°C is incompatible with the good mechanical resistance required of the coating up to a temperature range of 40°C to 60°C, temperatures common on coatings in summer periods.

[0148] Example 3: Formulation according to the invention no. 1 (LU binder)

[0149] A binder according to the invention consisting of a mixture of 70% by weight of LT1 + 30% by weight of LT2 was then used for the formulation of cold light coatings according to the following composition:

[0150] [Tables?] Materials % by weight 2 / 6 Limestone (%) 55.3 0 / 4 Limestone (%) 36.9 Water supply (%) 1.8 LU (%) 6.0

[0151] The mechanical properties in sinusoidal diametrical compression of the coatings obtained from this formulation are given in the following table:

[0152] [Tables8] Isochronous 10 Hz Temperature (°C) Phase angle (°) E* (MPa) -20 1.3 22727 0 3.7 18423 20 4.4 15229 40 5.0 12653 60 9.9 7704

[0153] This example demonstrates that the use of an aqueous dispersion comprising particles based on recycled plasticized PVB in combination with particles based on vinyl polymers other than PVB, one of which has a high Tg (=96°C) allows a high complex modulus value E* to be obtained at 40°C and an acceptable modulus value at 60°C.

[0154] Example 4: Formulation according to the invention no. 2 (Binder LI2)

[0155] Another binder according to the invention consisting of a mixture of 50% by weight of LT1 + 50% by weight of LT2 was then used for the formulation of cold light coatings according to the following composition:

[0156] [Tables9] Materials % by weight 2 / 6 Limestone (%) 55.3 0 / 4 Limestone (%) 36.9 Water supply (%) 1.8 LI2 (%) 6.0

[0157] The mechanical properties in sinusoidal diametrical compression of the coatings obtained from this formulation are given in the following table:

[0158] [TableauxlO] Isochronous 10 Hz Temperature (°C) Phase angle (°) E* (MPa) -20 1.8 20551 0 4.1 15430 20 4.3 13442 40 8.0 9930 60 16.9 4084

[0159] This example shows that a balanced mixture of LT1 and LT2 (50% / 50% mixture by weight) still allows a high complex modulus value E* to be obtained at 40°C and an acceptable modulus value at 60°C.

Claims

Claims

1. A clear binder comprising water, an anionic surfactant, recycled plasticized polyvinyl butyral (PVB) based particles and particles comprising a vinyl polymer other than PVB.

2. A clear binder according to claim 1, wherein the recycled plasticized PVB-based particles comprise a plasticizer selected from tri- or tetraethylene glycol carboxylic acid diesters, butylricinoleate, castor oil, mixed alkyl and alkylaryl adipates and a mixture thereof.

3. A clear binder according to claim 1 or 2, wherein the vinyl polymer other than PVB is a polymer obtained by polymerization of monomers selected from styrene and its derivatives, butadiene, isoprene, (meth)acrylic esters, nitriles, vinyl esters, (meth)acrylic acid, itaconic acid, fumaric acid, maleic acid, crotonic acid, isocrotonic acid, vinylbenzoic acid and combinations thereof.

4. A clear binder according to any one of claims 1 to 3, wherein at least a portion of the particles comprising a vinyl polymer other than PVB are comprised of at least two polymers having distinct glass transition temperatures (Tg), such that a positive gradient of Tg is observed from the surface of the particles toward the center of the particles.

5. A clear binder according to any one of claims 1 to 4, comprising from 5% to 50% by weight of particles based on recycled plasticized PVB and / or from 5% to 50% by weight of particles comprising a vinyl polymer other than PVB, relative to the total weight of binder.

6. Use of an aqueous dispersion comprising an anionic surfactant and particles based on recycled plasticized polyvinyl butyral, for the preparation of a binder intended for the manufacture of a road or urban development coating.

7. Clear coatings comprising solid particles and a residual binder derived from the binder defined in any one of claims 1 to 5.

8. Clear coatings according to claim 7, characterized in that the residual binder content is within a range from 1 to 20% by weight relative to the total weight of the coating, preferably from 1.5 to 10% by weight, more preferably from 2.5 to 3.5% by weight.

9. 21 Clear coatings according to claim 7 or 8, further comprising an additive selected from plasticizers, non-ionic surfactants, adhesion dopes, coloring agents, anti-foaming agents, viscosifying agents, antimicrobial agents, calcium carbonate dispersions, fibers and a combination thereof.

10. Road or urban development surface comprising one or more layers of coatings as defined in any one of claims 7 to 9.