Resin mixture and method of application

Abstract

Disclosed is a product comprising an aggregate mixture including a particulate material and a binding resin. The product can be suitable for forming an aggregate mixture on an inclined or vertical surface. A method of preparing the product is also disclosed, along with method of forming an aggregate mixture on a surface.

Description

[0001] Resin Mixture and Method of Application

[0002] The invention to which this application relates is the provision of an aggregate mixture including a particulate material and a binding resin to be applied to a surface to enhance the visual and / or physical quality of the same and in particular, although not necessarily exclusively, the particulate material including relatively small stone or gravel particles commonly referred to as chippings, gravel or the like and hereby referred to in a non-limiting manner as particulate material. The aggregate mixture can be provided, for example, as an area of hard-standing for use as part of a driveway, path, play area or the like or may in another example be provided as a coating to a vertical surface, such as rendering on the exterior walls of a building.

[0003] It is known to provide a layer of aggregate to a surface to enhance the physical and / or visual quality of the same. The aggregate typically includes a gravel material to form a hardwearing surface when applied to, for example, a surface of grass, soil or the like. Loose gravel is susceptible to movement due to, for example, rainwater flowing across the same or movement of people or vehicles over the same, which can result in the gravel destabilising and being removed from the surface or fail to provide the necessary physical benefits to the surface.

[0004] In the applicant’s granted patent GB2591174 there is disclosed a system, method and resin for stabilising a layer of particulate material for an area or hard standing in which a resin is provided that, once cured, binds particulates of the particulate material to form a unitary body. This provides the advantage that the particulate material is retained with the surface on which the same is applied, and particulates will not be removed by rainwater flow, or pedestrian and / or vehicle traffic.

[0005] The resin known in the art requires correct timing of the curing of the same when applying the resin to the particulate material to be bound. If the resin begins curing before the particulate material is substantially coated, the particulates will not be

[0006] 69993023-1sufficiently bound, which will affect the integrity of the particulate material. If the resin takes too long to cure, the particulate material can begin to lose its shape after it has been applied to the supporting surface before it is sufficiently bound. This problem is exacerbated if the support surface is on an incline.

[0007] It is known to provide the resin in two parts, wherein mixing the parts together begins the curing of the resin. This enables a user to more accurately control the timing of the curing of the resin to ensure the particulate material is adequately bound. The two parts are typically not equal ratios by weight, and as such instructions must be followed by the user to ensure that the correct curing properties are achieved by the mixing of the parts. This can be difficult for an untrained user, and particularly if the volume of resin to be provided is not a controlled amount, and is to be selected by the user for a corresponding volume of particulate. Furthermore, the mixing of the two parts typically requires specialist mixing equipment to ensure that the entire volume of resin experiences uniform curing that is likely not available to an individual user of the resin.

[0008] A further problem in the art is that particulate materials cannot be applied to a vertical surface as, for example, render on the exterior of a building, before the resin cures whilst retaining its structure.

[0009] An aim of the present invention is to address the above mentioned problems, particularly to provide an aggregate mixture including a resin that begins curing without the need for separate components to be combined in a manner that is convenient to an untrained user. A further aim of the invention is to provide an aggregate mixture that can be applied to an inclined or vertical surface that substantially retains its structure during the curing of the resin.

[0010] In a first aspect of the invention, there is provided an aggregate mixture to be applied to a surface to enhance the visual and / or physical quality of the same, said mixture

[0011] 69993023-1including a particulate material comprising a plurality of particulates, and a resin substantially coating the plurality of particulates, wherein the resin and particulates mixture is provided in a first condition in which the same is substantially fluid and is then changed to a second condition such that at least one component of the resin commences curing when exposed to a predetermined amount of moisture so as to bind the said particulates and resin and and / or bind the said mixture with a support surface and harden

[0012] In one embodiment, in the first condition the said mixture is located within a substantially air and / or moisture tight container and the mixture is moved to the second condition by opening the container to expose the mixture to air and / or moisture in the external environment.

[0013] In one embodiment when moved to the second condition, the rate of curing is such so as to maintain the mixture in a sufficiently fluid condition so as to be selectively poured from the container and worked with respect to said surface, for a predetermined time range.

[0014] In one embodiment the predetermined amount of moisture is at least the moisture content of the ambient air at the location at which the aggregate mixture is to be applied.

[0015] In one embodiment the component that allows the resin to cure when exposed to a predetermined amount of moisture is a polyurethane binder. Typically, the binder is a 1k polyurethane binder.

[0016] Thus, there is provided an aggregate mixture that can be provided in a sealed condition with an environment devoid of moisture or with a moisture level substantially below the moisture content of ambient air, such that unsealing the aggregate mixture begins the curing process. As such, the resin may be prepared in a controlled environment at a location separate from location at which the mixture

[0017] 69993023-1is to be supplied, such as for example by a supplier or manufacturer of the mixture, and does not require any further treatment or actions by the user at the location at which the mixture is to be applied other than unsealing the container and applying the aggregate mixture to the surface.

[0018] In one embodiment the resin, once cured, bonds the particulate material to adjacent surfaces and forms the particulate material and resin as a substantially integral part of the surface on which the mixture is applied.

[0019] In one embodiment the particulate material has been dehydrated before the particulate material has been coated with the resin. Typically, the particulate material is dehydrated by heating the same. Preferably, the mixture includes a moisture scavenger component.

[0020] In one embodiment the particulate material is formed of gravel.

[0021] In one embodiment the resin includes a thickening agent to ensure that the aggregate mixture substantially retains its shape when the mixture has been applied to a surface and before the resin has cured. In one embodiment the thickening agent is a thixotropic component.

[0022] Thus, there is provided the benefit that the aggregate mixture may be applied to an inclined surface, or a vertical surface, and substantially retain its shape to allow time for the resin to cure to form a unitary body with the surface on which the aggregate mixture has been applied. This is particularly useful when, for example, applying render to the exterior walls of a building, although it will be appreciated that the scope of application of the invention is not limited to this purpose.

[0023] In a further aspect of the invention, there is provided a system for forming an aggregate surface on a support surface to enhance the visual and / or physical quality

[0024] 69993023-1of the same, said system including a sealed container including therein an aggregate mixture as previously described.

[0025] In one embodiment, the container is under a vacuum or near vacuum condition when the aggregate mixture has been located therein. This provides the advantage that moisture in the air is less likely to contact the aggregate mixture when it is sealed in the container.

[0026] In one embodiment the container is a bag.

[0027] In a yet further aspect of the invention, there is provided a method for forming an aggregate mixture on a support surface to enhance the visual and / or physical quality of the same, said method including the steps of: coating a plurality of particulates of a particulate material in a resin, wherein the resin includes a component that allows the resin to cure when exposed to a predetermined amount of moisture, and applying the particulate material and resin to a support surface in an environment with at least the predetermined amount of moisture present.

[0028] As a result of the invention, the resin of the aggregate mixture formed by the particulate material and the resin will begin to cure when the aggregate mixture is applied to a support surface without the need for any additional preparation by the user of the mixture.

[0029] In one embodiment, the particulate material is coated in a sealing material before it is coated in the said resin. In this embodiment, the sealing material prevents any moisture present on the particulates of the particulate material from contacting the resin and inducing curing of the same before the aggregate mixture has been formed on the support surface.

[0030] In one embodiment, the particulate material is dehydrated prior to being coated in the resin. This provides the advantage that moisture present on the particulate

[0031] 69993023-1material is removed or substantially removed before coming into contact with the resin, and prevents curing of the same before the particulate material has been formed on the said support surface. Typically, the particulate material is dehydrated by heating the same immediately prior to the coating of the resin. Preferably, the particulate material is dehydrated prior to the material being coated in the sealing material.

[0032] In one embodiment, the resin includes a thickening agent such that the aggregate mixture can be applied to an inclined surface. In one embodiment the thickening agent includes a thixotropic component.

[0033] In one embodiment, the predetermined amount of moisture is the moisture levels in ambient air at the location at which the aggregate mixture is to be applied. In this embodiment, the aggregate mixture will therefore begin curing when exposed to the atmosphere.

[0034] In one embodiment, the resin is mixed with the particulate material in a controlled environment with a reduced moisture level present and then sealed in a sealed container. In this embodiment, the aggregate mixture can be prepared at a first location, such as a supplier or manufacturer, and provided in a controlled amount to a user. The user may then unseal the container and begin the curing of the resin without any further preparation steps.

[0035] In one embodiment, the resin and particulate material is mixed with a moisture scavenger component, such that the resin and particulate material mixture is dehydrated by the moisture scavenger component. Typically, the weight of the moisture scavenger component is 2-15% of the mixture.

[0036] In one embodiment, the container is sealed under a vacuum or near vacuum condition. This provides the advantage that air containing moisture cannot contact

[0037] 69993023-1the resin within the sealed bag and begin to cure the same before the aggregate mixture has been applied to the support surface.

[0038] In a further aspect of the invention there is provided a product suitable for forming an aggregate mixture on an inclined or vertical surface, the product including an aggregate mixture in a sealed container; wherein the aggregate mixture comprises a particulate material comprising a plurality of particulates; and a resin substantially coating the plurality of particulates, wherein the resin includes at least one component which upon opening the container to expose the aggregate mixture to moisture commences curing allowing the binding of said particulates to the inclined or vertical surface; and wherein the resin further includes a thickening agent.

[0039] In a further aspect, there is provided a method of preparing a product suitable for forming an aggregate mixture on an inclined or vertical surface (e.g. the product as described immediately above), said method including the steps of: mixing a resin with a particulate material (i.e. a particulate material comprising a plurality of particulates) to provide an aggregate mixture; and sealing the aggregate mixture in a sealed container, wherein the resin includes at least one component that allows the resin to cure when exposed to moisture, and wherein the resin further includes a thickening agent.

[0040] In the products and methods above and herein, the thickening agent may include a thixotropic component. The term “thixotropic component” is known in the art and is intended to be given it conventional meaning. For example, it includes solid or fluids that change their viscosity when loaded by stress to become less viscous. Advantageously, the use of the thixotropic component in the resin can allow for the aggregate mixture to be sufficiently thick and viscous at rest that it resists being misshapen or detached due to gravity when applied to an inclined or vertical surface, while still allowing the aggregate mixture to be deliberately shaped by the user when applying physical force via an implement such as a trowel. Thixotropic properties

[0041] 69993023-1can be present in gels, however, other suitable thixotropic components will also be readily apparent to the skilled person, and may for instance be selected from conventional thixotropic additives used in inks, pharmaceuticals or personal hygiene products (e.g. lotions).

[0042] In the products and methods above, the at least one component of the resin may be a polyurethane binder. For example, the at least one component may be a 1k polyurethane binder. This is also known as a one component polyurethane binder.

[0043] In the products and methods above, the particulate material may be formed of gravel, stones, wood chippings and / or sand. Preferably, the particulate material is formed of gravel.

[0044] In the products and methods above, the sealed container may be a bag.

[0045] In the products above, the aggregate mixture may further comprise a moisture scavenger component. Analogously, methods of preparing the product may comprise mixing the resin and particulate material with a moisture scavenger component. The moisture scavenger component may be present in an amount from 2 to 15% by weight of the aggregate mixture. Suitable moisture scavengers for use in the invention will be readily apparent to the skilled person.

[0046] In the products above, the particulate material may be dehydrated before the particulate material has been coated with the resin. Analogously, methods of preparing the product may comprise dehydrating the particulate material prior to mixing the resin with the particulate material. Dehydrating the particulate material may comprise heating the particulate material.

[0047] In the methods above, the resin may be mixed with the particulate material in a environment with a reduced moisture level compared to ambient air, preferably in

[0048] 69993023-1an environment with substantially no moisture. The environment may for example have no moisture.

[0049] The methods may also further comprise the step of removing air from the container using a vacuum prior to sealing the aggregate mixture in the sealed container.

[0050] The method may also comprise coating the particulate material in a sealing material before mixing the resin with the particulate material.

[0051] In a further aspect of the invention there is provided a method of applying an aggregate mixture to an inclined or vertical surface using the product described, or prepared, in the previous two aspects (i.e. a product including an aggregate mixture in a sealed container; wherein the aggregate mixture comprises a particulate material comprising a plurality of particulates; and a resin substantially coating the plurality of particulates, wherein the resin includes at least one component which upon opening the container to expose the aggregate mixture to moisture commences curing allowing the binding of said particulates to the inclined or vertical surface; and wherein the resin further includes a thickening agent). The method includes the steps of unsealing the container; and applying the aggregate mixture to the inclined or vertical surface.

[0052] The aggregate mixture may be applied, for example, as a render to the inclined or vertical surface. The inclined or vertical surface may be an exterior wall of a building.

[0053] For the avoidance of doubt, it will be appreciated, where appropriate, that any embodiments as described herein in relation to one aspect of the present invention are intended to apply to all the other aspects of the present invention.

[0054] Specific embodiments of the invention are now described with reference to the accompanying drawings; wherein:

[0055] 69993023-1Figure 1 illustrates an aggregate mixture in accordance with one embodiment.

[0056] Figure 2 illustrates the preparation of an aggregate mixture in accordance with one embodiment.

[0057] Figure 3 illustrates the process of applying an aggregate mixture to a surface in accordance with one embodiment.

[0058] Figure 4 illustrates the process of applying an aggregate mixture to a vertical surface in accordance with one embodiment.

[0059] Referring firstly to Figure 1, there is illustrated an aggregate mixture 2 in accordance with the invention. The aggregate mixture 2 is to be applied to a support surface 4 to enhance the physical and / or visual qualities of the same. The support surface 4 may be a surface subject to vehicle or foot traffic, as in the embodiments illustrated in Figure 3, and as such would benefit from increased stability, particularly if the support surface is a foundation layer formed of soil, loose stones, grass or the like. The aggregate mixture 2 may be applied to form an area of hard standing. In an alternative preferred embodiment, as illustrated in Figure 4, the support surface 4 may be an inclined or vertical surface, and the aggregate mixture 2 may be applied as a render to a building exterior, providing aesthetic benefits to the same. It is to be understood by the skilled reader that the application of the aggregate mixture of the invention is not limited to these demonstrative purposes.

[0060] The aggregate mixture 2 is formed by a particulate material 6 and a resin 8. The particulate material 6 is formed by a plurality of particulates 10, which in this example is gravel but may be in alternate examples any of stones, wood chippings, sand or any other particulate suitable for use as an aggregate. The resin 8 substantially coats the particulates 10 and, once cured, binds them to each other, forming a unitary body. The resin 8 may also act to bind the particulate material 6 to a support surface 4. The bound particulate material forms an exterior surface 12 with increased

[0061] 69993023-1stability to act as a suitable area of hardstanding, that may act to withstand the forces of pedestrian or vehicle traffic applied to the supporting surface 4. In desirable embodiments, the amount of resin 8 used to coat the particulates 10 is suitable such that gaps are formed sufficient to allow the permeability of the unitary body, allowing rain water to sufficiently pass through the same and drain through the support surface 4.

[0062] It is to be appreciated that the binding quality of the resin 8 is essential to the function of the aggregate mixture, to ensure stability of the particulate material 10. The binding of the particulates is achieved when the resin 8 cures. This can provide a means to allow a user, who may not be a trained applicator of the aggregate mixture, to ensure an adequate binding of the particulate material of the aggregate mixture. The resin 8 includes a component that allows the resin to begin curing when the resin is exposed to a predetermined amount of moisture. In this example, the component is a Ik polyurethane binder.

[0063] Referring now to Figure 2, there is illustrated a mixing apparatus 20 for coating the particulate material 6 with the resin 8 including the curing component. Prior to the mixing of the particulate material with the resin, the particulate material is dehydrated. In this example, the particulate material 6 is heated to a temperature in a heating apparatus such as an oven (not shown) to a temperature sufficient to cause evaporation of any or substantially all of the moisture in and on the particulate material. In alternate embodiments, the particulate material may be dehydrated in other known ways common in the art, such as by the introduction of desiccants. This provides the advantage that the resin will not begin to occur when it is mixed with the particulate material, decreasing the effectiveness of the same.

[0064] The mixing apparatus 20 is a forced-action mixer and includes a drum 21 in which is located a rotatable vane 22. The mixing speed is controlled by a controller 24. Initially, a sealing material (not shown) can be introduced to the drum 21 and mixed

[0065] 69993023-1with the dehydrated particulate material. This sealing material can be useful to prevent the transfer of any moisture remaining on the particulate material from transferring to the resin and inducing curing of the same when it contacts the particulate material.

[0066] When the particulate material is substantially uniformly coated in the sealing material, the resin 8 is introduced from a container 26 in a liquid form to the drum, as illustrated by arrow 28. The rotation of the vane 22 ensures that substantially all of the particulates 10 of the particulate material 6 are coated with the required amount of resin 8. The mixing of the particulate material 6 with the resin 8 occurs in a controlled environment, with no or a reduced atmospheric moisture level. This ensures that the resin including the curing component does not begin curing within the controlled environment. The controlled environment can be a location separate from the location at which the aggregate mixture is to be applied, such as a manufacturer’s or supplier’s facility, and can be controlled by trained operators to ensure that an adequate amount of resin is applied to the particulate material and coats substantially all of the particulates. The skilled person may adjust the ratio of binder to aggregate according to the intended functional and aesthetic properties of the final mixture. Desirable ratios will allow the aggregates to be adequately bound while also providing adequate moisture permeability.

[0067] A moisture scavenger component (not shown) can also be introduced to the mixing apparatus 20. This ensures that any moisture present in the mixture is absorbed by the scavenger component and does not induce curing of the resin. In this example, the weight of scavenger component is 2-15% of the mixture.

[0068] Following the mixing of the particulate material 6 with the resin 8, the aggregate mixture 2 is sealed within a sealed container and transported to a location at which the mixture 2 is to be applied. When the mixture 2 is located within the sealed container, a vacuum may typically be induced to draw out the air from the container

[0069] 69993023-1such that the condition within the sealed container is that of a vacuum or nearvacuum. Drawing out the air from the container reduces the moisture content that would be present in the air within the container, and which would otherwise begin curing the resin within the container. It has been found that this extends the storage life of the container and the materials held within the same. Alternative ways to minimise premature curing during storage in the container include sealing the contents of the container under an inert atmosphere such as CO2or nitrogen.

[0070] When the mixture 2 is unsealed (e.g. by opening the container at the point of use), the moisture in the ambient atmosphere is sufficient to begin the curing of the resin, due to the presence of the polyurethane binder component. Additional water may optionally be added by the user if necessary (e.g. by spraying, pouring, spreading or the like) to assist the curing. As illustrated in Figure 3, a user uses a hand trowel 30 to form the aggregate mixture 2 on the surface 4 to form the area of hardstanding. The aggregate mixture 2 can be shaped by the user during the curing of the resin, which causes the mixture to bind with the support surface 4 and boundary surfaces 4a. When the mixture 2 has been shaped and flattened, the mixture is left until the resin has fully cured to form the unitary body. This provides the advantage that the user is only required to unseal the container in which the mixture is provided in the desired ratio, apply the same to the surface 4 and shape the same. The user is not required to mix the resin with the particulates, and there are no further preparatory steps to be taken by the user to begin the curing of the resin. It has been found that the time taken for the resin to fully cure when unsealed in ambient conditions is up to one hour.

[0071] Figure 4 illustrates a preferred embodiment wherein the aggregate mixture 2 is provided for use as a “vertical” binder and application so as to allow the same to be applied to an inclined surface 4, in this example a vertical surface that is the exterior of a building such that the aggregate mixture 2 acts as render for the same. In this preferred embodiment, the resin 8 includes a thixotropic component that acts as a

[0072] 69993023-1thickening agent, allowing the mixture to be applied to the vertical surface 4 and be shaped by the user using a shaping implement 30, without the mixture becoming substantially misshapen or detached from the wall 4 under the force of gravity 42 before the resin 8, including the curing component, has substantially cured. In this embodiment, the aggregate mixture 2 has been prepared in a manner as illustrated in Figure 2.

[0073] 69993023-1

Claims

CLAIMS:

1. A product suitable for forming an aggregate mixture on an inclined or vertical surface, the product including an aggregate mixture in a sealed container; wherein the aggregate mixture comprises:a particulate material comprising a plurality of particulates, and a resin substantially coating the plurality of particulates, wherein the resin includes at least one component which upon opening the container to expose the aggregate mixture to moisture commences curing allowing the binding of said particulates to the inclined or vertical surface; and wherein the resin further includes a thickening agent.

2. The product according to claim 1, wherein the thickening agent includes a thixotropic component.

3. The product according to claim 1 or 2, wherein the at least one component of the resin is a polyurethane binder.

4. The product according to claim 3, wherein the polyurethane binder is a Ik polyurethane binder.

5. The product according to any preceding claim, wherein the particulate material is formed of gravel, stones, wood chippings and / or sand, preferably wherein the particulate material is formed of gravel.

6. The product according to any preceding claim, wherein the sealed container is a bag.

7. The product according to any preceding claim, wherein the aggregate mixture further comprises a moisture scavenger component.69993023-18. The product according to claim 7, wherein the moisture scavenger component is present in an amount of from 2 to 15% by weight of the aggregate mixture.

9. The product according to any preceding claim, wherein the particulate material has been dehydrated before the particulate material has been coated with the resin.

10. The method preparing the product according to any of claims 1 to 9, said method including the steps of:mixing a resin with a particulate material to provide an aggregate mixture; andsealing the aggregate mixture in a sealed container,wherein the resin includes at least component that allows the resin to cure when exposed to moisture, and wherein the resin further includes a thickening agent.

11. The method according to claim 10, wherein the thickening agent includes a thixotropic component.

12. The method according to claim 10 or 12, wherein the at least one component of the resin is a polyurethane binder.

13. The method according to claim 12, wherein the polyurethane binder is a Ik polyurethane binder.

14. The method according to any of claims 10 to 13, wherein the particulate material is formed of gravel, stones, wood chippings and / or sand, preferably wherein the particulate material is formed of gravel.69993023-115. The method according to any preceding claim, wherein the sealed container is a bag.

16. The method according to any of claims 10 to 15, further comprising dehydrating the particulate material prior to mixing the resin with the particulate material, preferably by heating the particulate material.

17. The method according to any of claims 10 to 16, further comprising mixing the resin and particulate material with a moisture scavenger component.

18. The method according to claim 18, wherein the moisture scavenger component is present in an amount of from 2 to 15% by weight of the aggregate mixture.

19. The method according to any of claims 12 to 19, wherein the resin is mixed with the particulate material in an environment with a reduced moisture level compared to ambient air, preferably in an environment with substantially no moisture, such as an environment with no moisture.

20. The method according to claim 20, further comprising the step of drawing out the air from the container using a vacuum.

21. The method according to any of claims 10 to 20, wherein the particulate material is coated in a sealing material prior to mixing the resin with the particulate material.

22. The method of applying an aggregate mixture to an inclined or vertical surface using the product according to claims 1 to 9, said method including the steps of:unsealing the container; andapplying the aggregate mixture to the inclined or vertical surface.69993023-123. The method according to claim 22, wherein the inclined or vertical surface is an exterior wall of a building.69993023-1

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