DESC:PHOTOLUMINESCENT EPOXY TILE GROUT

Technical Field
[0001] The present disclosure relates generally to an epoxy composition and, in particular, to a photo luminescent epoxy grout used as a tile grout.

Background
[0002] Background description includes information that may be useful in understanding the present disclosure. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed disclosure, or that any publication specifically or implicitly referenced is prior art.
[0003] The tiles are assembled in an edge-to-edge pattern. The tiles assembled have spaces between them and it is necessary to fill the areas or joints between adjacent tiles with a bonding material. The material used to fill the joints is referred commonly as a tile grout. Further, the tile grout is often used to secure tile to its base. There are a variety of tile grout compounds including acrylic grout, epoxy grout and Portland and regular cement based grout known in the art. The tile grout composition is used in construction, concrete restoration, surface decorations, wall and pool plasters, and tile settings.
[0004] Tile grouts, regardless of the type, are expected to provide certain properties. These properties include workability, chemical resistance, water absorption, compressive strength, stain resistance, forming a full grout in the spaces, uniform look and color and easy cleanup or maintenance with a minimum amount of water. In addition, to above properties the tiling grout is applied for either aesthetic or safety reasons also. Dyes and pigments are added to the above mentioned types of grouts which also have wide application. Such materials can be selected to provide a daytime coloration which will demarcate and emphasize areas to be marked, such as: edges of steps, corners of walls, highway edges/lanes/directional markings, median traffic divider stripes, airport runway markings, or buildings outlines. However, once there is no light source the color is not visible at all.
[0005] Fluorescence, phosphorescence, and photoluminescence occur when a sample is excited by a source of light, produce an emission of light. Once they have been excited, remain luminous with a soft, slowly decaying emission or radiation. After an initial exposure to a light source, luminescence can be renewed by once again exposing the materials to either a natural or an artificial light. Photoluminescent pigment into grout material can be used for aesthetic or safety reasons when there is no light source. Currently, photoluminescent pigment is added externally to the grout at the application site. An experienced and skilled person is required for mixing the components in correct proportion to provide the photoluminescent grout composition. Hence, there is a need to provide the tile grout with premixed photoluminescent pigment, which has capability to utilize natural and household light and create illumination in the darkness for longer duration of time when exposed to light for short duration of time. Further, the photoluminescent tile grout composition can enhance applicability for both aesthetic and safety reasons.

Summary of the Disclosure
[0006] One aspect of the present disclosure provides a tile grout composition comprising of at least one epoxy resin; a photoluminescent pigment; glass beads and at least one hardener. The photoluminescent pigment is preferentially distributed around the glass beads.
[0007] The object of the present disclosure is to provide a premixed photoluminescent tile grout that creates illumination in the darkness.
[0008] Another object is to provide methods for using the tile grout in the installation of tiles.
[0009] Another object is to provide a photoluminescent tile grout composition which is stain and chemical resistant, forms a full joint in the spaces and is highly workable and easy to clean up.
[0010] Another object is to provide a transparent photoluminescent tile grout composition with a very long lasting glowing effect even for very short light exposure.
[0011] Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.

Brief Description of the Drawings
[0012] Embodiments are illustrated by way of example and are not limited in the accompanying figures.
[0013] FIG. 1 is a graph illustrating luminance during attenuation after 5 min exposure at 1000 lux of the tile grout composition, in accordance with the concept of the present disclosure;
[0014] Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the disclosure.
Detailed Description
[0015] The present disclosure is now discussed in more detail referring to the drawings that accompany the present application. The present disclosure is to provide a tile grout composition exhibiting optical effects such as luminescence or phosphorescence or photoluminescence. The present disclosure further provides a tile grout composition which is highly effective for filling a joint (grouting) between tiles. Further, the present work relates to grout composition which is resistant to water, chemicals (acid and solvent), forms a full grout in the spaces which is uniform and smooth, stain resistant and has excellent wetting and physical property characteristics. Moreover, the grout composition is workable and easy to apply and easy to clean from the tile surface.
[0016] The present disclosure provides tile grout composition comprising of at least one epoxy resin; a photoluminescent pigment; glass beads and at least one hardener. The photoluminescent pigment is preferentially distributed around the glass beads.
[0017] The particular grout used in the present disclosure is an epoxy resin grout which is very well known in the art. Any epoxy resin can be used herein and the epoxy resins are characterized by containing one or more 1,2-epoxide groups, preferably more than one, and the epoxy resin is preferably a liquid at room temperature. The epoxy resin generally has an epoxide equivalent weight (EEW) based on solids of from about 150 to about 1150.
[0018] The epoxy resin may be saturated or unsaturated, cycloaliphatic, allylcyclic, or heterocyclic and may be substituted with constituents such as halogen atoms, hydroxyl groups, ether radicals, and the like. The epoxy resin is preferably difunctional and may also be trifunctional or polyfunctional.
[0019] The epoxy resin may be used as is, may be dissolved in an appropriate solvent, or may be employed as an already formed emulsion in water or water/cosolvent blend. It will be recognized to those skilled in the art that the use of solvent or a water/solvent blend may be required with solid epoxy resins or extremely viscous epoxy resins. The ratio of epoxy groups in the epoxy resins to amine hydrogen in the hardener may vary widely and will depend on the nature of the epoxy resin employed and the properties necessary to meet the grout requirement.
[0020] A particularly preferred epoxy resin is cyclo aliphatic epoxy resin. The epoxy resin is selected from the group consisting of bisphenol-A diglycidyl ether epoxy resin, aliphatic epoxy resin and combination thereof. The aliphatic epoxy resin is preferably 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexane carboxylate. The epoxy resin is in an amount from 10 to 50% by weight based on the weight of the tile grout.
[0021] The epoxy resin is used as such, or in the form of a solution in a solvent or diluent, or of an aqueous emulsion, optionally in the presence of a co-solvent. The diluent is oxirane and/or mono ((C12-14-alkyloxy)methyl) derivative.
[0022] The tile grout, preferably the epoxy grouts described, can be made highly reflective by admixture with glass beads. These glass beads are in combination with a photoluminescent pigment in a grouting material. The maximum diameter of the glass beads should not exceed 150 µm. The glass beads are translucent or substantially translucent. The glass beads are highly rounded. The glass beads are preferentially distributed with photoluminescent pigment in a solvent. The glass beads are preferentially distributed with photoluminescent pigment in an amount from 50-80% by weight based on the weight of the tile grout.
[0023] The hardener of the present disclosure is an amine based hardener and, in particular, selected from the group consisting of poly amino amide, cyclo aliphatic amine, polyether amine and combination thereof. Such amine based hardeners are well known in the art. The hardener generally has an amine hydrogen equivalent weight (AHEW) based on solids of from about 75 to about 105.
[0024] In a preferred embodiment, the tile grout composition of the present disclosure include other components such as rheology modifiers, light stabilisers, non-ionic surfactants, anti-foam additives, adhesion promoters, dye and/ or ultra violet stabilisers. The rheology modifiers preferably are selected from the group consisting of hydrogenated castor oil based, silica based nano-micro particles, grinded quartz, precipitated silica, pygrogenous silica, silica fume and combination thereof. The light stabilizers are preferably selected from the group consisting of bis(1,2,2,6,6-pentamethyl-4-piperidyl) sebacate, methyl 1,2,2,6,6-pentamethyl-4-piperidyl sebacate and combination thereof. The non-ionic surfactants preferably are 2-ethyl hexanol. The adhesion promoters preferably are silane – containing adhesion promoters. The dye is preferably an organic white dye. The ultra violet stabilisers preferably are Poly(oxy-1,2-ethanediyl), alpha.-[3-[3-(2H-benzotriazol- 2-yl)-5-(1,1-dimethylethyl)- 4-hydroxyphenyl]-1-oxopropyl]-. omega.-[3-[3-(2H-benzotriazol- 2-yl)-5-(1,1-dimethylethyl)- 4-hydroxyphenyl]-1-oxopropoxy]- (104810-47-1), Poly(oxy-1,2-ethanediyl), .alpha.-[3-[3-(2H-benzotriazol- 2-yl)-5-(1,1-dimethylethyl)- 4-hydroxyphenyl]-1-oxopropyl]-. omega.-hydroxy-(104810-48-2) and combination thereof. The ultra violet stabilisers preferably are tinuvin-1130.
[0025] The grout composition of the present disclosure can be mixed from the components thereof using conventional methods and equipment. Preferably, two components are separately prepared. The two components are mixed together in proportion to provide the grout composition and subsequently packaged and stored and then transported to the application site where the grout composition is used as it is. In one product, a first component termed A contains the epoxy resin, the photoluminescent pigment, the glass beads and optionally additives such as the rheology modifiers, the light stabilisers, the non-ionic surfactants, the anti-foam additives, the adhesion promoters, the dye and/ or the ultra violet stabilisers. The photoluminescent pigment is preferentially distributed around said glass beads. A second component termed B is the hardener.
[0026] Preferably, when mixed, the glass beads and photoluminescent pigment are first mixed. The preferentially distributed glass beads with photoluminescent pigment are added to epoxy resin and additives to form component A. Then components A and B are mixed and made into a workable mass. The grout product is then ready to be applied to the spaces between the set ceramic tiles.
[0027] In a preferred embodiment, the tile grout composition provided is translucent. The epoxy resin, photoluminescent pigment and all additives are translucent. The composition is translucent so that it allows the light to enter deep inside the material and excite the photoluminescent pigment. When the composition is translucent or translucent, the light absorption levels are very fast and even at lower level light energy it will absorbs the light and emits light in darkness. Another advantage of composition to be translucent is aesthetic during day time. Moreover, translucent grout composition of the present disclosure will give color diffusion effect so the tile surface looks aesthetic and uniform.
[0028] In general, the proportions of components in the grout composition in weight % is as follows:
Component % Wt
Epoxy Resin 10 to 50%
Glass beads with preferentially distributed Photoluminescent Pigment 50-80%
Hardener 5-30%

[0029] The grouting composition of the present disclosure may be applied by any method known in the art including a trowel, rubber float, squeegee, or cartridge dispenser. The present disclosure provides a method for grouting tiles with a grout. Firstly assembling a plurality of tiles in spaced relationship having spaces there between. Secondly applying a tile grout composition to the spaces between the tiles the tile grout composition. Thirdly, cleaning the excess tile grout composition from the tile surfaces with water. Lastly, allowing the tile grout composition to cure resulting in a grouted tile installation.
[0030] The grout composition of the present disclosure may be used to grout a large variety of ceramic surfaces including non-skid surfaces, smooth surfaces, and the like. The tiles will normally be ceramic tiles but may also be travertine, porcelain, wood, slate, marble, limestone, mason block, granite, pebbles, stones, onyx, quartzite, glass and combination thereof. The tile grout is used for filing spaces between the tile as well as an adhesive to fix the tiles. In general, any ceramic surface requiring a grout can be used with the grout composition of the present disclosure.
[0031] The tile grout composition provided is easy to mix manually, requires less cleaning time, easy in gap filing for even small joints, better luminance and longer glow time.
[0032] Various embodiments of the present disclosure will now be illustrated by reference to the following specific examples. It is to be understood, however, that such examples are represented for purposes of illustration only, and the present disclosure is in no way to be deemed as limited thereby.
Example 1
[0033] The following components were mixed together in weight % forming a trowelable mass. The mass was floated into spaces between sets of ceramic tiles and evaluated for a number of properties as indicated below.
Component % Wt
Epoxy Resin 12%
Glass beads with preferentially distributed Photoluminescent Pigment 80%
Hardener 8%
Table 1: The above grout had the following properties:
Test Parameters Units Observed Results Standard requirement Test Method
Water Clean Ability Min 88 >80 ANSI 118.3
Initial Setting Time Min 192 150 -200 ANSI 118.3
Service Setting Days 6 <7 ANSI 118.3
Linear Shrinkage % 0.06 <0.25% ANSI 118.3
Sag In Vertical Joints No Sag No change in shape of the joint observed. No Change ANSI 118.3
Tensile Strength N/mm2 12.5 >7 Mpa ANSI 118.3
Thermal Shock N/mm2 11.2 >4 Mpa ANSI 118.3
Abrasion Resistance Mm3 190 < 250 ISO:13007-4
Compressive Strength N/mm2 60 > 45 ISO:13007-4
Flexural Strength N/mm2 35 >30 ISO:13007-4
Shrinkage Mm/m 0.25 <0.3 ISO:13007-4
Water Absorption,
(At R.T. for 240 minute) gm 0.05 0.03 -0.08 ISO:13007-4

[0034] All of this performed testing and results shown in Table 1 evidences that the photoluminescent epoxy tile grout of the present disclosure are superior in performance and meet or exceeds various standards for tile grout composition, such as initial setting time, service setting, linear shrinkage, sag in vertical joints, tensile strength, thermal shock, abrasion resistance, compressive strength, flexural strength, shrinkage and water absorption. The tile group composition of the present disclosure passes the water cleanability test. Further the tile grout is also sag resistant. The compressive strength and thermal shock resistance is 60 N/mm2 and 11.2 N/mm2. The shrinkage of the grout is as low as 0.25 Mm/m. The initial setting time of the grout is 192 minutes. The present tile grout composition meets these standards as shown in Table 1.
Measurement of photoluminescence
[0035] The samples were exposed during a time of 5 minutes at 1000 lux from an unfiltered 150 W xenon lamp. The illuminance at the measuring plane was measured with a luxmeter, Hagner, Model S4. After 5 minutes the xenon lamp was turned off and a luminance meter, Photo Research Model 1980A, connected to a computer, was recording the luminance every minute until the luminance level had dropped to below 2 mcd/m2 (about 15 hours). A measuring spot of about Ø 50 mm was used. The samples were kept under dark conditions for at least 48 h prior to excitation.
[0036] The colour during excitation and attenuation was measured with a spectrometer, Spectrascan PR-735. The excitation was done with the above light source at 1000 lux for 5 minutes and the attenuation colour measurement started about 15 seconds after the lamp was switched off.
[0037] In accordance with section 4.5 in DIN 67510-1, a logarithmic parabolic extrapolation of the results was made in order to determine the time when the luminance is 0,3 mcd/m2, the decay time.
Measurement condition
Room temperature (23 ± 1) °C
Relative humidity (45 ± 5) %
Illumination 1000 lx perpendicular to the sample, Xenon lamp
Table 2: Compilation of the results for luminance and calculated decay time.
Sample ID Luminance (mcd/m2)
2 min 10 min 30 min 60 min 120 min Decay time
(min)
B no. 6 (blue) 739 218 71.2 32.5 14.3 2920

[0038] FIG. 1 illustrates a graphical representation of luminance after 5 min exposure at 1000 lux of the tile grout composition.
[0039] The decay time of the present photoluminescent epoxy grout composition was 2920 minutes when exposed for of 5 minutes at 1000 lux. It can be interpreted from the Table 2 that when the grout is exposed for shorter duration of time the composition could achieve better decay time.
[0040] The sample was exposed during a time of 2 hours at 1000 lux from an unfiltered 150 W xenon lamp. The illuminance at the measuring plane was measured with a luxmeter, Hagner, Model S4. After 5 minutes the xenon lamp was turned off and a luminance meter, Photo Research Model 1980A, connected to a computer, was recording the luminance every minute until the luminance level had dropped to below 2 mcd/m2 (about 15 hours). A measuring spot of about Ø 50 mm was used. The sample was kept under dark conditions for at least 48 h prior to excitation.
[0041] In accordance with section 4.5 in DIN 67510-1, a logarithmic parabolic extrapolation of the results was made in order to determine the time when the luminance is 0,3 mcd/m2, the decay time.
Measurement condition
Room temperature (23 ± 1) °C
Relative humidity (45 ± 5) %
Illumination 1000 lx perpendicular to the sample, Xenon lamp
Table 3: Compilation of the results for luminance and calculated decay time.
Sample ID Luminance (mcd/m2)
2 min 10 min 30 min 60 min 120 min Decay time
(min)
B no. 6 (blue) 1137 374 131.3 62.4 28.6 4470

[0042] The decay time of the present photoluminescent epoxy grout composition was 4470 minutes when exposed for of 2 hours at 1000 lux. It can be interpreted from the Table 3 that when the grout is exposed for longer duration of time the composition could achieve better decay time.
[0043] Note that not all of the activities described above in the general description or the examples are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. Still further, the order in which activities are listed is not necessarily the order in which they are performed.
[0044] Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.
[0045] The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all of the elements and features of apparatus and systems that use the structures or methods described herein. Certain features, that are for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in a sub combination. Further, reference to values stated in ranges includes each and every value within that range. Many other embodiments may be apparent to skilled artisans only after reading this specification. Other embodiments may be used and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Accordingly, the disclosure is to be regarded as illustrative rather than restrictive.
[0046] While the present disclosure has been particularly described, in conjunction with a specific preferred embodiment, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications and variations as falling within the true scope and spirit of the present disclosure.
[0047] The description in combination with the figures is provided to assist in understanding the teachings disclosed herein, is provided to assist in describing the teachings, and should not be interpreted as a limitation on the scope or applicability of the teachings. However, other teachings can certainly be used in this application.
[0048] As used herein, the terms "comprises," "comprising," "includes," "including," "has," "having" or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, "or" refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
[0049] Also, the use of "a" or "an" is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the disclosure. This description should be read to include one or at least one and the singular also includes the plural, or vice versa, unless it is clear that it is meant otherwise. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for that more than one item.
[0050] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. The materials, methods, and examples are illustrative only and not intended to be limiting. To the extent that certain details regarding specific materials and processing acts are not described, such details may include conventional approaches, which may be found in reference books and other sources within the manufacturing arts.
[0051] While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed machines, systems and methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.

,CLAIMS:We claim:
1. A tile grout composition comprising:
at least one epoxy resin;
a photoluminescent pigment;
glass beads and
at least one hardener; wherein the said photoluminescent pigment is preferentially distributed around the said glass beads.
2. The tile grout composition as claimed in claim 1, wherein the epoxy resin is a cyclo aliphatic epoxy resin.
3. The tile grout composition as claimed in claim 1, wherein the epoxy resin is from 10 to 50% by weight based on the weight of the tile grout.
4. The tile grout composition as claimed in claim 1, wherein the epoxy resin is selected from the group consisting of bisphenol-A diglycidyl ether epoxy resin, aliphatic epoxy resin and combination thereof.
5. The tile grout composition as claimed in claim 1, wherein the aliphatic epoxy resin is preferably 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexane carboxylate.
6. The tile grout composition as claimed in claim 1, wherein the epoxy resin is used as such, or in the form of a solution in a solvent or diluent, or of an aqueous emulsion, optionally in the presence of a co-solvent.
7. The tile grout composition as claimed in claim 1, wherein the diluent is oxirane and/or mono ((C12-14-alkyloxy)methyl) derivative.
8. The tile grout composition as claimed in claim 1, wherein the epoxy resin has an Epoxide Equivalent Weight (EEW) ranging from 150 to 1000.
9. The tile grout composition as claimed in claim 1, wherein the glass beads having a maximum diameter which is less than 150 µm.
10. The tile grout composition as claimed in claim 1, wherein the glass beads are translucent or substantially translucent.
11. The tile grout composition as claimed in claim 1, wherein the glass beads are highly rounded.
12. The tile grout composition as claimed in claim 1, wherein the glass beads are preferentially distributed with photoluminescent pigment in a solvent.
13. The tile grout composition as claimed in claim 1, wherein the glass beads which are preferentially distributed with photoluminescent pigment is from 50-80% by weight based on the weight of the tile grout.
14. The tile grout composition as claimed in claim 1, wherein the hardener is an amine-containing hardener.
15. The tile grout composition as claimed in claim 1, wherein the hardener is selected from the group consisting of poly amino amide, cyclo aliphatic amine, polyether amine and combination thereof.
16. The tile grout composition as claimed in claim 1, wherein the hardener has an Amine Hydrogen Equivalent Weight (AHEW) ranging from 75-105.
17. The tile grout composition as claimed in claim 1, optionally comprising rheology modifiers, light stabilisers, non-ionic surfactants, anti-foam additives, adhesion promoters, dye and/ or ultra violet stabilisers.
18. The tile grout composition as claimed in claim 1, wherein the rheology modifiers are selected from the group consisting of hydrogenated castor oil based, silica based nano-micro particles, grinded quartz, precipitated silica, pygrogenous silica, silica fume and combination thereof.
19. The tile grout composition as claimed in claim 1, wherein the light stabilizers are selected from the group consisting of bis(1,2,2,6,6-pentamethyl-4-piperidyl) sebacate, methyl 1,2,2,6,6-pentamethyl-4-piperidyl sebacate and combination thereof.
20. The tile grout composition as claimed in claim 1, wherein the non-ionic surfactants are 2-ethyl hexanol.
21. The tile grout composition as claimed in claim 1, wherein the adhesion promoters are silane – containing adhesion promoters.
22. The tile grout composition as claimed in claim 1, wherein the dye is an organic white dye.
23. The tile grout composition as claimed in claim 1, wherein the ultra violet stabilisers are tinuvin-1130.
24. The tile grout composition as claimed in claim 1, wherein the tile is made of material selected from the group consisting of travertine, ceramic, porcelain, wood, slate, marble, granite, pebbles, stones, onyx, quartzite and combination thereof.
25. A method for grouting tiles with a grout comprising the steps of:
assembling a plurality of tiles in spaced relationship having spaces there between;
applying a tile grout composition to the spaces between the tiles the tile grout composition as claimed in claim 1;
cleaning the excess tile grout composition from the tile surfaces with water; and
allowing the tile grout composition to cure resulting in a grouted tile installation.