Method for infiltrating a ceramic, artificial or natural stone surface
11667582 · 2023-06-06
Assignee
Inventors
Cpc classification
C04B41/4966
CHEMISTRY; METALLURGY
C04B41/4554
CHEMISTRY; METALLURGY
C04B41/4556
CHEMISTRY; METALLURGY
Y10T428/4935
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
C04B41/53
CHEMISTRY; METALLURGY
International classification
C04B41/45
CHEMISTRY; METALLURGY
Abstract
The object of the invention is a method for infiltrating a ceramic, artificial or natural stone surface, wherein a material forming a bond with valences on the surface is applied and mechanically rubbed onto the surface, whereby frictional heat is generated, wherein the material is used as a solution or suspension, and which comprises applying a hydrophobizing infiltration composition onto the surface to be coated, followed by rubbing it in until a homogeneous distribution and filling of the pores in the surface is achieved for improving the surface properties.
Claims
1. Method for infiltrating a ceramic, artificial or natural stone surface, wherein a material forming a bond with valences on the surface is applied and rubbed onto the surface, whereby frictional heat is generated, wherein the material is a self-repelling hydrophobizing infiltration composition and is used as a suspension, and the method comprises the following steps: (a) applying a self-repelling hydrophobizing infiltration composition onto the surface of a ceramic, artificial or natural stone, (b) rubbing in the self-repelling hydrophobizing infiltration composition until a homogeneous distribution and filling of the pores in the surface is achieved, whereby an excess of material of self-repelling hydrophobizing infiltration composition remains on the surface, (c) drying the surface, and (d) abrading or polishing off excess of material of self-repelling hydrophobizing infiltration composition remaining on the surface, whereby when the self-repelling hydrophobizing infiltration composition reacts in the cavities present in the thus treated ceramic, artificial or natural stone, tridimensional grid or scaffold structures are formed, which increase the material density and increase the mechanical stability along the penetration depth of the infiltration composition, wherein the self-repelling hydrophobizing infiltration composition comprises from 0.1 to 25% weight C.sub.1-4alkanol, and the self-repelling hydrophobizing infiltration composition is used as an aqueous suspension, and wherein the ceramic, artificial or natural stone surface is the surface of a plate or slab of a size greater than 30×30 cm.
2. Method according to claim 1, wherein step (c) further comprises blowing the surface.
3. Method according to claim 1, wherein the step sequence (a) and (b) is repeated once or several times.
4. Method according to claim 1, wherein the self-repelling hydrophobizing infiltration composition further comprises one, or more from the group consisting of poly-di-C.sub.1-6-alkylsiloxanes, C.sub.8-18-Alkyl-tri-C.sub.1-4-alkoxysilanes, polysiloxane, aminofunctional polysiloxanes, and C.sub.1-4-carboxylic acids.
5. Method according to claim 1, wherein the self-repelling hydrophobizing infiltration composition further comprises a C.sub.1-4-carboxylic acid and one, two or more selected from the group consisting of poly-di-C.sub.1-6-alkylsiloxanes, C.sub.8-18-Alkyl-tri-C.sub.1-4-alkoxysilanes, and aminofunctional polysiloxanes.
6. Method according to claim 4, wherein the C.sub.8-18-Alkyl-tri-C.sub.1-4-alkoxysilane is hexadecyltrimethoxysilane, and/or the poly-di-C.sub.1-6-alkylsiloxane is polydimethylsiloxane.
7. Method according to claim 1, wherein the water content in the self-repelling hydrophobizing infiltration composition ranges between 50% and 90% of the total weight of the composition.
8. Method according to claim 1, wherein the self-repelling hydrophobizing infiltration composition further comprises one or more compounds from the group consisting of SiO.sub.2, Al.sub.2O.sub.3, BN, B.sub.2O.sub.3, SiC, SiN, TiO.sub.2 and Zr.sub.2O.sub.3.
9. Method according to claim 1, furthermore comprising before step (a): i. applying a colloidal silica sol or a water glass composition, followed by rubbing in until a homogeneous distribution and filling of the pores in the surface is achieved, ii. drying the surface and polishing off an excess of material, and iii. optionally repeating once or several times step sequence i. and ii.
10. Method according to claim 1, wherein, during step (b) and/or step (d) and/or the rubbing of step i. and/or the polishing of step ii. the temperature measured at the treated surface is increased by from 5 to 120° C.
11. Method according to claim 1, wherein the ceramic, artificial or natural stone surface is selected from natural stone, ceramics, Lappato and hydraulically, inorganically or resin-bound natural stone, quartz, ceramic, glass and/or artificial stone agglomerate.
12. Method according to claim 1, wherein the self-repelling hydrophobizing infiltration composition comprises from 1 to 10% weight C.sub.1-4-alkanol.
13. Ceramic, artificial or natural stone substrate, in particular a hydraulically, inorganically or resin-bound natural stone, quartz, ceramic, glass, and/or artificial stone agglomerate, obtained by a method for infiltrating a ceramic, artificial or natural stone surface, wherein a material forming a bond with valences on the surface is applied and rubbed onto the surface, whereby frictional heat is generated, wherein the material is a self-repelling hydrophobizing infiltration composition and is used as a suspension, and the method comprises the following steps: (a) applying a self-repelling hydrophobizing infiltration composition onto the surface of a ceramic, artificial or natural stone, (b) rubbing in the self-repelling hydrophobizing infiltration composition until a homogeneous distribution and filling of the pores in the surface is achieved, whereby an excess of material of self-repelling hydrophobizing infiltration composition remains on the surface, (c) drying the surface, and (d) abrading or polishing off excess of material of self-repelling hydrophobizing infiltration composition remaining on the surface, whereby when the self-repelling hydrophobizing infiltration composition reacts in the cavities present in the thus treated ceramic, artificial or natural stone, tridimensional grid or scaffold structures are formed, which increase the material density and increase the mechanical stability along the penetration depth of the infiltration composition, wherein the self-repelling hydrophobizing infiltration composition comprises from 0.1 to 25% weight C.sub.1-4-alkanol, and the self-repelling hydrophobizing infiltration composition is used as an aqueous suspension, and wherein the ceramic, artificial or natural stone surface is the surface of a plate or slab of a size greater than 30×30 cm.
14. Ceramic, artificial or natural stone substrate according to claim 13, wherein step (c) further comprises blowing the surface.
15. Ceramic, artificial or natural stone substrate according to claim 13, wherein the self-repelling hydrophobizing infiltration composition further comprises one, or more from the group consisting of poly-di-C.sub.1-6-alkylsiloxanes, C.sub.8-18-Alkyl-tri-C.sub.1-4-alkoxysilanes, aminofunctional polysiloxanes, and C.sub.1-4-carboxylic acids.
16. Ceramic, artificial or natural stone substrate according to claim 13, wherein the self-repelling hydrophobizing infiltration composition further comprises a C.sub.1-4-carboxylic acid and one, two or more selected from the group consisting of poly-di-C.sub.1-6-alkylsiloxanes, C.sub.8-18-Alkyl-tri-C.sub.1-4-alkoxysilanes, and aminofunctional polysiloxanes.
17. Ceramic, artificial or natural stone substrate according to claim 13, wherein the water content in the self-repelling hydrophobizing infiltration composition ranges between 50% and 90% of the total weight of the composition.
18. Ceramic, artificial or natural stone substrate according to claim 13, wherein the method further comprises before step (a): i. applying a colloidal silica sol or a water glass composition, followed by rubbing in until a homogeneous distribution and filling of the pores in the surface is achieved, ii. drying the surface and polishing off an excess of material, and iii. optionally repeating once or several times step sequence i. and ii.
19. Ceramic, artificial or natural stone substrate according to claim 13, wherein the ceramic, artificial or natural stone surface is selected from natural stone, ceramics, Lappato and hydraulically, inorganically or resin-bound natural stone, quartz, ceramic, glass and/or artificial stone agglomerate.
20. Ceramic, artificial or natural stone substrate according to claim 13, wherein the self-repelling hydrophobizing infiltration composition comprises from 1 to 10% weight C.sub.1-4-alkanol.
Description
(1) Although the invention and advantageous configurations and improvements as well as at least part of the obtained advantages were described in general above, the invention is explained in further detail below by means of embodiments and making reference to the attached drawings, the data in % referring to the percentage by weight of the entire composition, unless otherwise indicated.
(2)
(3)
(4)
(5)
(6)
(7)
(8) In detail, it can be clearly deduced from
(9) To evaluate the chemical resistance and/or staining resistance of these treated and untreated artificial stone materials, 0.1 mL of different staining or chemical agents were poured onto the surface of the material, and each agent was left for 24 hours. Afterwards, the agents were thoroughly cleaned with water and the effect on the surface was visually evaluated using a scale between 0 (no effect) and 4 (strong effect) (the lower, the better).
(10) Nine different selected agents (including acid and basic substances) were used to evaluate the chemical resistance. The sum of the visual evaluation of all agents scored 5 in the case of the surface treated with silica sol only (without self-repelling hydrophobizing infiltrating composition) and it scored in the case of treatment with silica sol and the self-repelling hydrophobizing infiltration composition of Example 1.
(11) In case of the stain test resistance, the sum of the visual evaluation from treatment with 6 different selected agents (with different particle size and colors), scored 4 in the case of the surface treated with silica sol only (without self-repelling hydrophobizing infiltrating composition) and it scored 1 in the case of treatment with silica sol and the self-repelling hydrophobizing infiltration composition of Example 1.
(12)
(13) Abrasion tests in dry and wet conditions were performed using a scouring pad and a weight equivalent applied force of 1 Kg for 250 back-and-forth cycles. The wetting agent for the wet conditions was tap water. The effect of the abrasion after the 250 cycles was evaluated by measuring the brightness with a PCE-SGM 60 brightness tester before and after the test at 10 different points in the abraded area. The average brightness loss is an indication of the resistance to abrasion of the surface, the lower the loss, the higher the resistance. The average brightness loss in the case of uncoated Silestone® surface was 5.1 (dry conditions) and 2.7 (wet conditions). In comparison, average brightness loss of the Silestone® surface treated according to the invention with silica sol and the self-repelling hydrophobizing infiltration composition of Example 1 was 0.9 (dry conditions) and 0.4 (wet conditions), much lower and therefore more resistant to abrasion than the untreated surface.
(14)
EXAMPLE 1—SELF-REPELLING HYDROPHOBIC INFILTRATION COMPOSITION
(15) TABLE-US-00001 Polydimethylsiloxane ((CH.sub.3).sub.2SiO).sub.n 7.8% H.sub.2O 85% Acetic acid CH.sub.3COOH 0.1% Isopropyl alcohol C.sub.3H.sub.8O .sup. 5% Hexadecyltrimethoxysilane (C.sub.19H.sub.42O.sub.3Si) .sup. 2% Aminofunctional polysiloxane 0.1%
EXAMPLE 2—NON-SELF-REPELLING HYDROPHOBIZING INFILTRATION COMPOSITION
(16) TABLE-US-00002 Isopropyl alcohol C.sub.3H.sub.8O 34.9% Siloxane oligomer 58% Hexadecyltrimethoxysilane (C.sub.19H.sub.42O.sub.3Si) 2% Polyalkylsiloxane 5% Aminofunctional polysiloxane 0.1%.sup.
EXAMPLE 3—SILICA SOL
(17) The silica sols used according to the invention are basically not especially limited and are in general commercially offered in different qualities and with different solid content. The particle size of the silica sols used basically complies with the size of the pores in the surface to be treated. In general, the silica sols used can therefore contain solids with a mean diameter from 0.1 nm to 500 nm.
(18) Silica sols can be used in the usually offered concentrations and they are in general in the range from 1% to 60%. It is preferred to use anionically stabilizing silica sols in the method according to the invention, but it being also possible to use cationically stabilizing and or neutral, acidic, alkaline silica sols.
(19) Depending on the substrate to be treated and the intended result it is also possible to use modified silica sols, such as, for example, silane-modified silica sols. In this respect, the silane percentage can vary strongly with respect to the silica sol and is basically in the range of 1:99 (silane:silica sol) to 5:1.
(20) In addition, it is possible to increase the reactivity of the silica sols used by shifting the pH value by means of the suitable addition of acids and bases. Also in this case, variation in a wide range is possible, in general by adding from 10% to 80% of 3% KOH to the silica sol. The addition of 5% to 60% of a 5% KOH has proven to be especially advantageous, since the reaction of the silica sol in this range takes place quickly and especially uniform in a corresponding manner.
(21) Examples of the surface functionality of silica sol particles, also in modified form, are exemplarily depicted and explained in the following formulae 1 to 3:
(22) ##STR00001##
(23) The silica sol depicted in Formula 1 is a usually used silica sol, which is conventionally anionically stabilized with ammonia, KOH and/or NaOH.
(24) ##STR00002##
(25) Formula 2 depicts a silica sol modified with aluminum, which is also conventionally anionically stabilized with ammonia, KOH and/or NaOH.
(26) ##STR00003##
(27) The silane-modified silica sol according to formula 3 is usually also basically stabilized with ammonia, KOH and/or NaOH.
(28) However, the silica sols used are not limited to the above described silica sols. Other modifications are also easily possible and the person skilled in the art is familiar with them. In general a plurality of metal oxides can be used in the context of the present invention for such a modification. For example, titanium, zirconium and boron oxides.
(29) The following examples are compositions of cationically and neutrally stabilized silica sols, which have proven to be especially advantageous in the context of the present invention. Köstrosol K 1530 is a trade name for colloid-disperse solutions of SiO.sub.2 in water with an average particle size of 5-80 nm and a concentration of 30%, which are cationically stabilized, whereas Levasil CC 301 and Levasil CC 401 are neutral silica sols in a concentration of 30 or 40%:
EXAMPLE 3.1A CATIONICALLY STABILIZED SILICA SOL
(30) TABLE-US-00003 Octamethylcyclotetrasiloxane 0.04% AminoalkyIfunctional polysiloxane 2% Methoxyterminated poly[3-((2- 1% aminoethyl)amino)propyl]methyl(dimethyl)siloxane Branched tridecanol ethoxylate 1% H.sub.2O 16% Köstrosol K1530 80%
EXAMPLE 3.1B CATIONICALLY STABILIZED SILICA SOL
(31) TABLE-US-00004 Octamethylcyclotetrasiloxane 0.02% AminoalkyIfunctional polysiloxane 1% Methoxyterminated poly[3-((2- 0.5% aminoethyl)amino)propyl]methyl(dimethyl)siloxane Branched tridecanol ethoxylate 0.5% Kostrosol K1530 .sup. 80% Hexadecyltrimethylammonium chloride 0.1% 3-Aminopropyltriethoxysilane 0.05% 2-Bromo-2-nitropropane-1,3-diol 0.01% H.sub.2O 17.82%
EXAMPLE 3.2 CATIONICALLY STABILIZED SILICA SOL
(32) TABLE-US-00005 Hexadecyltrimethylammonium chloride 0.2% 3-Aminopropyltriethoxysilane 0.1% 2-Bromo-2-nitropropane-1,3-diol 0.02% H.sub.2O 19.68% Köstrosol K1530 80%
EXAMPLE 3.3 CATIONICALLY STABILIZED SILICA SOL
(33) TABLE-US-00006 Oxirane, phenyl-polymer with 2.0% oxirane-mono(3,5,5-trimethylhexyl)ether Alkyldimethylbenzylammonium chloride 0.2% H.sub.2O 17.8% Köstrosol K1530 80%
EXAMPLE 3.4 CATIONICALLY STABILIZED SILICA SOL
(34) TABLE-US-00007 Triethoxy(2,4,4-trimethylpentyl)silane 6.0% α-iso-Tridecyl-omega-hydroxy-polyglycol ether 0.15% H.sub.2O 13.85% Köstrosol K1530 .sup. 80%
EXAMPLE 3.5 CATIONICALLY STABILIZED SILICA SOL
(35) TABLE-US-00008 3,3,4,4,5,5,6,6,7,7,8,8,8- 0.2% Tridecafluorooctyltriethoxysilane Octadecyltriethoxysilane 1.5% Triethoxy(2,4,4-trimethylpentyl)silane 3.0% α-iso-Tridecyl-omega-hydroxy-polyglycol ether 0.55% H.sub.2O 14.75% Köstrosol K1530 80%
EXAMPLE 3.6 NEUTRAL SILICA SOL
(36) TABLE-US-00009 Octamethylcyclotetrasiloxane 0.04% AminoalkyIfunctional polysiloxane 2% Methoxyterminated poly[3-((2- 1% aminoethyl)amino)propyl]methyl(dimethyl)siloxane
EXAMPLE 3.11 NEUTRAL STABILIZED SILICA SOL
(37) TABLE-US-00010 Octamethylcyclotetrasiloxane 0.02%.sup. AminoalkyIfunctional polysiloxane 1% Methoxyterminated poly[3-((2- 0.5% aminoethyl)amino)propyl]methyl(dimethyl)siloxane Branched tridecanol ethoxylate 0.5% Levasil CC 301 40% Levasil CC 401 40% Hexadecyltrimethylammonium chloride 0.1% 3-Aminopropyltriethoxysilane 0.05%.sup. 2-Bromo-2-nitropropan-l, 3-diol 0.01%.sup. H.sub.2O 17.82% Branched tridecanol ethoxylate 1% H.sub.2O 16% Levasil CC 301 40% Levasil CC 401 40%
EXAMPLE 3.7 NEUTRAL SILICA SOL
(38) TABLE-US-00011 Hexadecyltrimethylammonium chloride 0.2% 3-Aminopropyltriethoxysilane 0.1% 2-Bromo-2-nitropropan-1,3-diol 0.02% H.sub.2O 19.68% Levasil CC 301 40% Levasil CC 401 40%
EXAMPLE 3.8 NEUTRAL SILICA SOL
(39) TABLE-US-00012 Oxirane, phenyl-polymer with oxirane-mono(3,5,5- 2.0% trimethylhexyl)ether Alkyldimethylbenzylammonium chloride 0.2% H.sub.2O 17.8% Levasil CC 301 40% Levasil CC 401 40%
EXAMPLE 3.9 NEUTRAL SILICA SOL
(40) TABLE-US-00013 Triethoxy(2,4,4-trimethylpentyl)silane 6.0% α-iso-Tridecyl-omega-hydroxy-polyglycol ether 0.15%.sup. H.sub.2O 13.85% Levasil CC 301 40% Levasil CC 401 40%
EXAMPLE 3.10 NEUTRAL SILICA SOL
(41) TABLE-US-00014 3,3,4,4,5,5,6,6,6-Nonafluorohexyltrimethoxysilane 0.1% Hexadecyltrimethoxysilane 1.2% α-iso-Tridecyl-omega-hydroxy-polyglycol ether 0.25% H.sub.2O 18.45% Levasil CC 301 40% Levasil CC 401 40%
EXAMPLE 4—FUNCTIONALIZATION
(42) Compounds for the admixture thereof to the infiltration composition or to the colloidal silica sol or water glass and the functionalization resulting thereof are set forth in this example. The percentage values are understood as percentage by weight and relate in each case to the total weight of the infiltration composition or of the colloidal silica sol or water glass. Individual compounds or also mixtures and/or combinations can be used.
(43) TABLE-US-00015 antibacterial/ Cu salts 0.005-2% antiviral/ Sn salts 0.005-2% antimoss: Zn salts 0.005-2% Rhozone 0.5-2% (Dichlorooctylisothiazolinone) silver nitrate 0.005-1% antistatic: metal oxides 0.5-5% CuO slip inhibition: Zr.sub.2O.sub.3 0.1-50% Al.sub.2O.sub.3 surface hardness: Zr.sub.2O.sub.3 0.1-50% Al.sub.2O.sub.3 BN chemical Hexadecylsilane 0.05-10% resistance: Zr.sub.2O.sub.3 0.1-50%
(44) The present invention is further defined in the embodiments that follow. 1. Method for infiltrating a ceramic, artificial or natural stone surface, wherein a material forming a bond with valences on the surface is applied and rubbed onto the surface, whereby frictional heat is generated, wherein the material is used as a solution or suspension, and comprising the following steps: (a) applying a hydrophobizing infiltration composition onto the surface to be treated, (b) rubbing in until a homogeneous distribution and filling of the pores in the surface is achieved (c) drying and blowing the surface and (d) abrading or polishing off excess of material, whereby when the infiltration composition reacts in the cavities present in the thus treated substrate tridimensional grid or scaffold structures are formed, which increase the material density and increase the mechanical stability along the penetration depth of the infiltration composition. 2. Method according to embodiment 1, characterized in that steps (a) and (b) are repeated once or several times, preferably once, twice or three times. 3. Method according to any of embodiments 1 to 2, characterized in that the hydrophobizing infiltration composition contains two or more from the group consisting of hybrid polymer, alkyl silanes, aryl silanes, aminofunctional silanes, esters of silicic acids, chlorosilanes, organofunctional silanes, fluoroalkylsilanes, silazanes, epoxy- and glycolfunctional silanes, mercaptofunctional silanes, vinylfunctional silanes, isocyanatosilanes, silicone resin, poly-di-C.sub.1-6-alkylsiloxan, C.sub.8-18-Alkyl-tri-C.sub.1-4-alkoxysilan, wherein the alkyl groups of both preceding compounds are optionally substituted with one or more fluorine atoms, siloxane oligomer, polysiloxane, aminofunctional polysiloxane, silicone oil, C.sub.1-4-alkanol, C.sub.1-4-carboxylic acid and water. 4. Method according to any of embodiments 1 to 3, characterized in that the infiltration composition further comprises one or more compounds from the group consisting of SiO.sub.2, Al.sub.2O.sub.3, BN, B.sub.2O.sub.3, SiC, SiN, TiO.sub.2 and Zr.sub.2O.sub.3. 5. Method according to any of embodiments 1 to 4, furthermore comprising before step (a): i. applying a colloidal silica sol or a water glass composition, followed by rubbing in until a homogeneous distribution and filling of the pores in the surface is achieved, ii. drying the surface and polishing off an excess of material, and iii. optionally repeating once or several times steps i. and ii., preferably repeating once. 6. Method according to embodiment 5, characterized in that the colloidal silica sol used contains amorphous SiO.sub.2 with a particle size of 0.1 to 500 nm, preferably 0.1 to 150 nm, more preferably with a mean particle size D.sub.50 from 15 to 30 nm, in particular 20 nm, is configured in a neutral, acidic, alkaline manner, and/or is anionically or cationically stabilized and the colloidal silica sol is optionally modified with acids, bases, catalysts, polysiloxane, organopolysiloxane, siloxane, silane, silicone oil and/or epoxysilane. 7. Method according to embodiment 5 or 6, characterized in that the silica sol further comprises one or more compounds from the group consisting of SiO.sub.2, Al.sub.2O.sub.3, TiO.sub.2, and Zr.sub.2O.sub.3. 8. Method according to any of embodiments 1-7, characterized in that step (b) and/or step ii. is carried out under a temperature increase from 5 to 120° C., in the event of a lower warming preferably under a temperature increase from 0 to 30° C., more preferably under a temperature increase from 0 to 10° C., and in the event of a higher warming preferably under a temperature increase from 30 to 120° C., more preferably under a temperature increase from 50 to 80° C. 9. Method according to any of embodiments 1 to 8, characterized in that the surface is selected from natural stone, ceramics, Lappato and hydraulically, inorganically or resin-bound natural stone, quartz, ceramic, glass and/or artificial stone agglomerate. 10. Method according to any of embodiments 1 to 9, characterized in that the ceramic, artificial or natural stone surface is the surface of a plate, of a slab or of a tile, in particular the surface of artificial stones made of hydraulically or resin-bound natural stone, ceramic, glass, and/or quartz agglomerates. 11. Ceramic, artificial or natural stone substrate, in particular a hydraulically, inorganically or resin-bound natural stone, quartz, ceramic, glass, and/or artificial stone agglomerate, processed with a method according to any of embodiments 1 to 10. 12. Ceramic, artificial or natural stone substrate according to embodiment 11, characterized in that it is highly glossy, matt, satined, antibacterial, anti-moss, scratch-resistant, scratch-proof, abrasion-proof, slip-resistant, stain-resistant, resistant to chemicals, footprint-resistant, photocatalytic, antistatic, electrically conductive, heat-reflecting and/or heat-absorbing.