Polymer surfaced composites for floor tiles and other building structures
AssigneeMargrace Enterprises INC
InventorJohn N. Mushovic
Life of this patent
Estimating the term…
Abstract
Composites useful in building structures such as floor tiles, are prepared having a very strong bond between a highly filled polymeric surface layer and a cementitious backing. The composite comprises: a first layer of solid particles intimately mixed with a polymeric binder; a second layer of an organic and/or inorganic solid; and a transitional layer located between the first and second layers comprising both the polymeric binder and the organic and/or inorganic solids wherein the polymeric binder is contained in pockets within the organic and/or inorganic solid and at least some of the pockets of the polymeric binder extend from the first layer.
Claims15
A composite structure suitable for a wide range of building products comprising:
- a first layer of solid particles mixed with a polymeric binder;
- a second layer of an organic and/or inorganic solid;
- an optional transitional layer located between the first and second layers comprising both the polymeric binder and the organic and/or inorganic solid, wherein the polymeric binder is contained in pockets within the organic and/or inorganic solid and at least some of the pockets of the polymeric binder extend from the first layer;
- and
- a third layer of a cured polymer resin in contact with at least one of the first, second, or transitional layers, the third layer having color different from the first layer;
- with the proviso that the transitional layer must be present unless the organic and/or inorganic solid is a cast structure having a smooth surface and the polymeric binder is curable with ultraviolet radiation;
- and
- with the additional proviso that when the organic and/or inorganic solid is a cast structure, then the polymeric binder is curable with ultraviolet radiation.
A composite structure suitable for a wide range of building products comprising:
- a first layer including an ultraviolet radiation curable polymeric binder having mixed therein solid particles comprising at least one of vitrified quartz, aluminum trihydrate, glass frit, fly ash, perlite, or silica plus at least one of colored transparent polyacrylics, colored quartz, colored translucent polyacrylics or unsaturated polyesters containing aluminum trihydrate;
- a second layer of an organic and/or inorganic solid;
- and
- a transitional layer located between the first and second layers and including portions of the polymeric binder and the organic and/or inorganic solid, wherein the polymeric binder is contained in pockets in the organic and/or inorganic solid and at least some of the pockets of polymeric binder extend from the first layer.
A composite structure suitable for a wide range of building products comprising:
- a first layer of solid particles mixed with a polymeric binder;
- a second layer of an organic and/or inorganic solid;
- and
- an optional transitional layer located between the first and second layers comprising both the polymeric binder and the organic and/or inorganic solid, wherein the polymeric binder is contained in pockets within the organic and/or inorganic solid and at least some of the pockets of the polymeric binder extend from the first layer;
- with the proviso that the transitional layer must be present unless the organic and/or inorganic solid is a cast structure having a smooth surface and the polymeric binder is curable with ultraviolet radiation;
- and
- with the additional proviso that when the organic and/or inorganic solid is a cast structure, then the polymeric binder is curable with ultraviolet radiation;
- wherein the solid particles of the first layer comprise:
- at least one of aluminum trihydrate, ground or whole grain silica, calcium carbonate, transitional metal oxides, a mineral granite mixture, clear polymer chips, fly ash, perlite;
- and
- at least one of aluminum trihydrate-based granite mixture, polymer-coated minerals, opaque or transparent colored acrylic, pigmented acrylic modified unsaturated polyester chips and mixtures thereof.
A composite structure suitable for a wide range of building products comprising:
- a first layer including an ultraviolet radiation and thermal curable thermoset polymeric binder containing a mixture of ultraviolet radiation-transmitting solid particles and ultraviolet radiation-absorbing solid particles, at least some of the solid particles having decorative characteristics;
- a second layer providing a cement-based substrate;
- a transition layer located between the first and second layers and including the polymeric binder and interfacial portions of the substrate, wherein the polymeric binder is contained in pockets and pores of the substrate to provide a mechanical bond between the first and second layers.
Dependencies are inferred from the claim text.