Method and composition for waterproofing

Static structures (e.g. – buildings) – Specified terranean relationship – With waterproofing means; e.g. – covering – coating – or lamina

Reexamination Certificate

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C106S033000, C427S407100, C427S393600, C523S130000, C523S177000

Reexamination Certificate

active

06230452

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to a method and a polymeric composition for waterproofing. More particularly, the present invention relates to a method and composition using a hydrocarbon resin and a polymer having either one styrene-containing polymer or one olefin-containing polymer or a mixture of these polymers to waterproof.
BACKGROUND OF THE INVENTION
Structures used in construction, such as foundations and walls, include materials, such as masonry, cement, wood, plaster, stone, clay or brick that may be porous. Such porous materials can be degraded by water and/or loss of water from the porous materials. Below grade structures are often subjected to hydrostatic pressure from ground water. Above grade structures are subject to precipitation and water from other sources. A variety of methods and products for waterproofing and/or sealing these structures against outside water have been developed.
One type of waterproofing and/or sealing system includes polyvinyl or polyethylene sheeting adhered or fastened to the surface of the structure. If an adhesive is used to adhere the sheeting to the structure, the adhesive may not stick well due to dust (e.g., cement or stone dust) produced during construction and other activities and lose its adhesion over time. On the other hand, if fasteners, such as nails or staples, are used to attach the sheeting to the structure, the fasteners typically puncture the sheeting and the structure beneath, providing a channel through which water can flow. Moreover, there are seams between the sheets that require the use of a fastener or adhesive to close. The adhesive may be attacked by microorganisms and/or oxidation and degraded or may dissolve in water over time, allowing water to flow through the seam. Fasteners puncture the sheeting and allow water through the resulting holes. In addition, the waterproofing sheets are often difficult to form around non-uniform structures and adverse weather conditions may hinder the placement of the sheets on the structure. For example, wind may cause wrinkles in the sheet as it is positioned on the structure and, on very cold days, the sheets may tear or even shatter during installation.
Another type of waterproofing and/or sealing system includes the application of a coating composition on the structure. One common type of coating composition for waterproofing and sealing is tar- or asphalt-based. Although these compositions are relatively inexpensive and can be applied year-round, the materials in the composition often leach away from the wall. This often contaminates the soil and reduces the amount of protection afforded by the coating. Moreover, these compositions typically contain a large amount of organic material which may be attacked by soil- or water-borne microorganisms, thereby reducing the effectiveness of the coating.
Other types of coating compositions have been developed. Many of these coating compositions, however, do not produce a durable film over porous substrates (e.g., cement, masonry blocks, wood, etc.). Often, the film that is formed using these coating compositions is easily punctured and/or includes components that are degradable or leach away from the film thus losing its adhesion to substrates. These coating compositions need to be applied with a significant amount of volatile organic compounds as solvents. These emitted volatile organic compounds (VOCs) are limited by current environmental regulations. Moreover, a number of the coating compositions are difficult to apply and/or relatively expensive.
There is a need for alternative waterproofing and/or sealing compositions which emit less volatile organic compounds upon application, are durable, flexible, and stable in below grade and above grade applications. Such compositions may also be useful for coating other substrates, as well.
SUMMARY OF THE INVENTION
The present invention relates to methods and compositions for waterproofing and sealing a surface of a substrate. One embodiment is a method of coating a surface of a substrate. The method includes applying a coating composition to the surface of the substrate. The coating composition includes a) an organic solvent, b) a hydrocarbon resin and c) a copolymer having styrene and diene monomer units with a styrene-content of less than 60 wt. %, a polymer having olefin monomer units, a copolymer having styrene and olefin monomer units with a styrene content of less than 60%.wt, or mixtures thereof.
A further embodiment is a method of coating a surface of a substrate. This method includes applying a coating composition to the surface of the substrate. The coating composition includes: a) an organic solvent, b) about 25 to 85 phr of a coumarone-indene polymer and c) about 15 to 75 phr of a copolymer having styrene and diene monomer units with a styrene-content of more than 5 wt. % and less than 60 wt. %, a copolymer having olefin and styrene monomer units with a styrene-content of about 60 wt. % or less, or mixtures thereof.
Another embodiment is a method of applying a waterproofing coating to a structural unit. A coating composition is applied to a surface of the structural unit. The coating composition includes; a) about 20 to 400 phr of an organic solvent, b) about 1 to 66 phr of a coumarone-indene polymer, c) about 34 to 99 phr of a styrene-diene block copolymer having a styrene-content of about 10 to 35 wt. %, a polyolefin homopolymer, a styrene-olefin block copolymer with a styrene-content of about 10 to 60 wt. % or mixtures thereof and d) about 20 to 600 phr of a filler. The coating composition is then dried to form a film.
A further embodiment of the invention is a waterproofing composition. The waterproofing composition includes; a) about 33 phr to about 250 phr of an organic solvent, b) about 10 to 50 phr of a coumarone-indene polymer; c) about 50 to 90 phr of a copolymer having styrene and diene monomer units with a styrene-content greater than 5 wt. % and less than 60 wt. %, a polymer having olefin monomer units, a copolymer having styrene and olefin monomer units with a styrene content of about 10 to 60 wt. % or mixtures thereof.
Yet another embodiment of the invention is a waterproofing composition. The waterproofing composition includes; a) about 50 to about 150 phr of an organic solvent, b) about 10 to 30 phr of a coumarone-indene polymer, c) about 45 to 80 phr of a polymer having styrene and diene monomer units with a styrene-content of about 10 to 35 wt. %, and d) about 10 to 25 phr of a polymer having olefin monomer units and a styrene-content of about 10 to 60 wt. %.
The above summary of the present invention is not intended to describe each disclosed embodiment or every implementation of the present invention. The detailed description which follows more particularly exemplify these embodiments, but do not limit the scope of the invention, as defined by the claims.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is believed to be applicable to methods and coating compositions for waterproofing and/or sealing a surface of a substrate. In particular, the present invention is directed to methods and coating compositions using a combination of a) a hydrocarbon resin and b) one or more polymers having styrene and usually, but not necessarily, diene monomer units or one or more polymers having olefin monomer units or mixtures of these polymers. While the present invention may not be so limited, an appreciation of various aspects of the invention will be gained through a discussion of the examples provided below.
The term “polymer” includes homopolymers and copolymers, unless otherwise indicated.
The term “hydrocarbon resin” is a term that is used to describe a low molecular weight thermoplastic polymer synthesized via the thermal or catalytic polymerization of coal-tar fractions, cracked petroleum distillates, terpenes, or pure olefinic monomers.
The term “monomer unit” indicates a unit of a polymer which is derived from or has the same chemical structure as a unit derived from a particular monomer.
The term “phr”, as used herein, is

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