Aggregate, manufacturing process thereof, and resin mortar

Details Aggregate, manufacturing process thereof, and resin mortar Aggregate, manufacturing process thereof, and resin mortar

2000-12-22

2002-11-12

Sanders, Kriellion A. (Department: 1714)

Synthetic resins or natural rubbers -- part of the class 520 ser

Synthetic resins

Processes of preparing a desired or intentional composition...

C523S209000, C428S411100, C524S002000, C524S425000, C524S492000

Reexamination Certificate

active

06479570

ABSTRACT:

BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an aggregate mixed for use with a set-hard material.
2. Prior Art
Cement and asphalt are usually called a “set-hard” material which may be filled or applied, during its having fluidity, in a predetermined shape or a plane to be caused to set hard naturally or with a predetermined means.
The set-hard materials are usually mixed with an ordinary aggregate consisting of inorganic particles for obtaining an increased quantity or for making lightweight, reinforcing, or improving troweling (workability). The ordinary aggregate to be mixed in an asphalt mixture may be usually macadam (crushed stones), sands, and stone powder, or, for a special use, silica sand or ceramics aggregate. The ordinary aggregates to be mixed in cement concrete may be similarly macadam and sands, or, for a special use, silica sand or the like. Those to be mixed in resin mixture may be silica sand, ceramics aggregate, or organic aggregates.
These conventional aggregates having rigidity or stiffness make stiff the whole of the set-hard material and cause the same to have no softness. Even in case that the set-hard material itself has softness to some extent, it becomes rigid as a whole when the aggregate has rigidity. Moreover, an actual situation may require a set-hard material having softness to some extent, for example, for pavement or particularly a playground which is to be soft to some extent for absorbing the impact to players feet. An aggregate material usable in such case may be rubber having flexibility or pliability to make soft or pliable the whole of the set-hard material, satisfying the foregoing need.
In recent years, rubber chips are mixed as aggregate in an asphalt mixture to provide the same with elasticity. Furthermore, rubber or plastic materials are used as aggregate for concrete to make it lightweight.
However, the rubber chips aggregate lower in the set-hard material completely or partially. Strength of the whole set-hard material is apparently or definitely influenced by adhesion between the set-hard material and aggregate. In detail, when adhesion between the set-hard material and aggregate is low, crack occurs between the set-hard material and aggregate, causing the aggregate to fall. The aggregate exposed to the outside from the set-hard material falls off (peels off and scatters) under the foregoing condition of low adhesion.
Rubber chips aggregate, which are pliable, when used for pavement has such defect as making impossible or quite difficult to trowel or rolled-fill. Namely, the pliable rubber chips aggregate cannot be smoothly applied by troweling, or, do not go into every corner (predetermined positions) even by pressuring to then deform there and recover after releasing of the pressuring force. This means that rubber chips cannot be tightened and stiffened (compacted) by pressuring and have a quite poor workability.
As a result, any elastic material hitherto cannot be put into practical use as the aggregate material.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a novel aggregate which uses an elastic material as an aggregate material and eliminates the defects shown in the conventional elastic aggregate.
The present invention provides: an aggregate which is mixed for use with a set-hard material and comprises a core made of an elastic material and a surfacing material adhered thereon by use of a resin; a manufacturing process of the novel aggregate comprising such steps as mixing 100 parts by weight of a core made of an elastic material with 0.1 to 20, preferably 0.5 to 10 parts by weight of a resin to cause the resin to stick uniformly on the surface of the core, and thereafter, contacting and mixing the core with 1 or more part by weight of a surfacing material having one-tenth or less average particle diameter of that of the core; and a resin mortar mixing the novel aggregate, a resin and preferably other admixtures.
DETAILED DESCRIPTION OF THE INVENTION
The set-hard material referred to herein may be cement such as concrete, an asphalt mixture, an asphalt emulsion, a resin, or resin mortar, which have plasticity and can be caused to set hard.
The core is a main body of the aggregate according to the present invention and the core part itself is just the aggregate in the conventional art. Materials for the core may be any elastic materials, for example, synthetic organic high polymeric substances such as rubber or plastics, or fibers of plants or animals. Elastic plastic solid called industrial wastes may be usable. Sizes and shapes of the core may be determined depending upon kinds or use of the set-hard material. Usually, average particle diameters of the core may be about 0.2 to 30 mm, preferably 2 to 20 mm. The average particle diameter 0.2 to 2 mm may be most preferable when the aggregate is used as a resin mortar to be filled in gaps among aggregates in a draining (water-permeable) asphalt pavement (described later). Shapes of the core may be spherical, flat, crushed or fiber-like. The core may employ crushed waste tire, whereby reducing cost to produce and having effect of disposing wastes (recycling) and mitigating environmental problems.
Adhesives to be applied on the core may use those which have function of sticking the core to a surfacing material described later. Fixing or sealing does not necessarily need sure adhesive-bonding and may sometimes be merely bonding with some degree of force since a force high enough to peel off the surfacing material from the aggregate surface and scatter the same is inherently not applied in the set-hard material. Hence, adhesive-bonding or sticking will do. To make more effective the elasticity of the core, adhesives which have some recovery property from deformation after setting hard may be usable.
Examples of the adhesives are urethane resin, epoxy resin, ethylene-vinyl acetate resin, vinyl chloride resin, acrylic resin (MMA resin, etc.,), or polyester resin. The adhesives may be mixed with solvent for making solution of solid polymer or modifying viscosity.
Putting the adhesive on the core may be carried out in such ways as spraying, coating, soaking, or agitating inside a container. Thickness of adhesive put on may be in an extent enough to fix the surfacing material and does not necessarily need to be thicker.
Surfacing material may employ particles or powder of silica sand, cement powder, calcium carbonate, silica, ceramics, microballoons, inorganic powder such as crushed concrete powder, organic powder such as crushed plastic products, or industrial wastes powder such as constructional wastes. Shapes of the materials may be powdery, particles-like, or in any odd or distorted shapes, or elongated like fibers or impalpable powdery such as fly ash. It is because chemical quality or reaction is not necessarily required in this case but physical existence and shapes are pursued first, through it is preferable that the material interlocks chemically. Sizes of the surfacing materials may be about 0.01 * to 1 mm, or further larger depending upon the cores sizes, and may be determined in correlation with the cores. Fibers or the like may be usable in length of the same order of the cores diameter (the longest diagonal line). The surfacing material may be used in a single kind or a plural kinds, for example, those in a larger size may be first fixed or sealed on the core, and thereafter, smaller surfacing materials fixed partially or locally, thereby providing the whole of aggregate with a larger uneven surface. Particularly, fiber-like materials may be used for providing a larger surfacing material, enabling high resistance when the aggregates fall.
Fixing the surfacing materials on the cores putting adhesives thereon may be freely carried out by covering the core with the surfacing material, for example, by rolling the cores coated with adhesives over the surfacing material, spraying the surfacing material over the cores, or placing the cores in a container having the surfacing material and agitating the cores.

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