阅读说明：本技术 流平和降噪砂浆组合物 (Leveling and noise reducing mortar composition ) 是由 L·佩里诺 T·拉体格埃尔 A·博吉 C·凯洛 D·海塞尔巴特 L·格拉尼佐 于 2020-03-23 设计创作，主要内容包括：砂浆组合物,特别是流平砂浆组合物,其包含以下或由以下组成：a)3–45wt％的水硬性粘合剂,b)15–80wt％的轻质集料,c)5–50wt％的聚合物。(Mortar composition, in particular a leveling mortar composition, comprising or consisting of: a) 3-45 wt% of a hydraulic binder, b) 15-80 wt% of a lightweight aggregate, c) 5-50 wt% of a polymer.)

1. Mortar composition, in particular a leveling mortar composition, comprising or consisting of:

a) 3-45% by weight of a hydraulic binder,

b) 15-80 wt% of a lightweight aggregate,

c) 5-50 wt% of a polymer.

2. A mortar composition according to claim 1, wherein the hydraulic binder comprises:

3-18% by weight, in particular 4-15% by weight, especially 5-10% by weight, of aluminate cement and/or sulphoaluminate cement;

-optionally from 3 to 18% by weight, in particular from 4 to 15% by weight, especially from 5 to 10% by weight, of portland cement;

-optionally 3-18 wt%, in particular 4-15 wt%, especially 5-10 wt% of a latent hydraulic and/or pozzolanic binder material, in particular slag and/or fly ash;

optionally 1-8 wt%, in particular 2-6 wt%, especially 2-4 wt% of calcium sulphate hemihydrate and/or anhydrite;

-optionally from 0.1 to 5% by weight, in particular from 0.2 to 3% by weight, especially from 0.5 to 1.5% by weight, of hydrated lime;

wherein all amounts are relative to the total weight of the mortar composition in the dry state.

3. A mortar composition according to any one of the preceding claims wherein the hydraulic binder comprises an aluminate cement and/or a sulphoaluminate cement and a latent hydraulic and/or pozzolanic binder material, wherein the weight ratio of aluminate cement and/or sulphoaluminate cement to latent hydraulic and/or pozzolanic binder material is from 0.5 to 3, especially from 0.7 to 2.5, especially from 1 to 2.

4. A mortar composition according to any one of the preceding claims wherein the lightweight aggregate has a particle density of from 100 to 2'000kg/m³In particular 400-1' 900kg/m³Preferably 700-1' 500kg/m³Or 800-1' 300kg/m³。

5. A mortar composition according to any preceding claim wherein the lightweight aggregate comprises or consists of rubber particles.

6. A mortar composition according to any one of the preceding claims wherein the lightweight aggregate comprises two different types of particles, wherein the first type of particles has a particle size in the range 0.01 to 0.5mm, especially 0.1 to 0.4mm, and the second type of particles has a particle size in the range 0.6 to 2mm, especially 0.6 to 1.5mm, wherein preferably both types of particles are rubber particles.

7. A mortar composition according to claim 6, wherein the weight ratio of the first type of particles having a smaller particle size to the second type of particles having a larger particle size is from 1:2 to 8:1, in particular from 1:1 to 5:1, especially from 2:1 to 4:1 or from 2.5:1 to 3.5: 1.

8. A mortar composition according to any preceding claim wherein the lightweight aggregate or particles, especially rubber particles, have a non-spherical or irregular shape.

9. A mortar composition according to any preceding claim, wherein the polymer is a water-soluble or water-redispersible polymer, especially a copolymer based on vinyl acetate and ethylene, and/or wherein the polymer has a glass transition temperature in the range-45 to 10 ℃, especially-35 to 5 ℃, preferably-25 to 0 ℃, especially-20 to 0 ℃, particularly preferably-20 to-10 ℃.

10. A mortar composition according to any preceding claim comprising or consisting of:

-3-18% by weight of calcium aluminate cement and/or calcium sulphoaluminate cement;

-optionally from 3 to 18% by weight, in particular from 4 to 15% by weight, especially from 5 to 10% by weight, of portland cement;

-optionally 4-8 wt% of latent hydraulic and/or pozzolanic binder material, especially slag and/or fly ash;

-30-80 wt.%, in particular 50-75 wt.%, of rubber particles, in particular comprising two types of rubber particles having different particle sizes, wherein, in particular, the weight ratio of the first type of particles having a smaller particle size to the second type of particles having a larger particle size is 2: 1-4: 1 or 2.5: 1-3.5: 1;

-1-15 wt% of porous inorganic particles, especially porous inorganic particles having a particle size of 0.1-0.6 mm;

5-20% by weight, in particular 7-15% by weight, of a water-soluble or water-redispersible polymer, in particular a copolymer based on vinyl acetate and ethylene;

-0-10, especially 1-5 wt% of one or more additives, especially additives comprising layered silicates;

wherein all amounts are relative to the total weight of the mortar composition in the dry state.

11. A kit of parts comprising or consisting of: (i) mortar composition according to any of claims 1 to 10, in particular in the dry state, and (ii) an adhesive composition, in particular a patch adhesive, in particular in the dry state, wherein the adhesive composition comprises or consists of:

a) 10-50% by weight of a hydraulic binder,

b) 20-60 wt% of a lightweight aggregate,

c) 10-25 wt% of a polymer;

and wherein the mortar composition is chemically different from the binder composition.

12. Structure, in particular floor, wall or ceiling, comprising:

-a substrate, in particular a floor, in particular made of concrete;

-a first layer comprising or consisting of a mortar composition according to any of claims 1 to 10, in particular in the hardened state;

-a second layer comprising or consisting of the adhesive composition as defined in claim 11, in particular in a hardened state;

a covering element, in particular a patch, wherein the covering element is fixed to the first layer using the adhesive composition of the second layer.

13. The structure according to claim 12, wherein the thickness of the first layer is greater than the thickness of the second layer, wherein the ratio of the thickness of the first layer to the thickness of the second layer is between 1.1 and 10, in particular between 1.2 and 5, especially between 1.3 and 3.

14. A mortar composition according to any one of claims 1 to 10, optionally in combination with an adhesive composition as defined in claim 11, or a kit of parts according to claim 11, for use in fixing a tile on a substrate, in particular a floor, wall or ceiling of a building or facility.

15. Use of a mortar composition according to any one of claims 1 to 10, optionally in combination with a binder composition as defined in claim 11, or a kit of parts according to claim 11, in particular for acoustic damping, noise reduction and/or vibration reduction on floors, walls or ceilings of buildings and/or installations.

Technical Field

The present invention relates to mortar compositions, in particular to levelling mortar compositions and to a kit of parts comprising a mortar composition and a binder composition. A further object of the invention is a structure, in particular a floor, wall or ceiling, comprising a substrate, a first layer, a second layer and a covering element, in particular a patch. In addition, the invention relates to the use of a mortar composition or kit of parts for fixing a tile on a substrate, for acoustic damping, noise reduction and/or vibration damping.

Background

Substrates, such as flooring substrates, are made of green concrete and are typically rough and uneven. This makes it difficult to secure coverings, such as tiles, carpets, plastic floors, veneers, etc. in a satisfactory manner. It is therefore important to prepare a smooth substrate surface before fixing or laying the cover.

For floor substrates, this can be achieved by applying a leveling mortar on the raw floor substrate to obtain a flat and smooth bedding. Leveling mortars have high flow characteristics and a rather thin consistency, so that once the product is mixed with water, it can simply be poured onto an uneven substrate of a floor and thereby level the surface. Likewise, they may have a higher consistency and may be smoothed out after application.

EP1721876 a1(Sika) for example describes a method for preparing leveling mortars. Whereby a solid component comprising an alkali activated cementitious material comprising 10-20% silica and alumina, 1-10% calcium aluminate cement or white cement and fine aggregate is mixed together with a liquid component comprising a solution of 30-50% sodium hydroxide and sodium silicate, and stirred, wherein the SiO is₂Less than 30% and Na₂The O content is less than 20%, and the ratio between the liquid component and the solid component is in the range of 0.10 to 0.30 by weight.

Additionally, from decorative tile surfaces to highly functional tile wall and floor finishes, tiles are the most popular surface finishing techniques used to enhance the appearance and function of all types of buildings and facilities.

Tiled structures typically comprise (i) a substrate, such as a support structure, (ii) optionally a bedding layer, such as a leveling mortar, (iii) an adhesive, (iv) tiles, such as in the form of tiles, stone and/or veneer, and (v) grouted and moved joints between tiles. Thus, the patch is fixed to the substrate or the cushion layer with an adhesive. Depending on their composition, patch adhesives fall into 3 main types according to standard EN12004: 2017: a cement-based binder (C), a dispersion binder (D) and a reaction resin binder (R). Cement-based binders usually contain, inter alia, hydraulic cement, sand and fillers.

WO 2015/179738 a1(Laticrete International, Inc.) describes ready-to-use grout and/or adhesive formulations suitable for use, for example, as tile adhesives or tile grout, filling the spaces between tiles. The formulation is based on a premixed cement slurry and activating ingredients, and is used to destabilize the slurry by increasing its pH.

Furthermore, in buildings or facilities, the transmission of unwanted sound or vibrations through structural elements, floors, walls or ceilings is a challenging problem. Thus, surfaces, especially those of a tiled patch, are not only desired to be visually appealing and functional, but also to help dampen noise or vibration. This is particularly true for floors, as foot noise is a major source of building noise.

Although mortar compositions are very beneficial in terms of smoothing and levelling of the surface, they do not contribute sufficiently to noise or vibration suppression, or they have other disadvantages.

There is therefore a need to provide an improved solution that overcomes the above-mentioned disadvantages.

Disclosure of Invention

It is an object of the present invention to provide advantageous mortar compositions which are particularly advantageous for use as underlayment or facing, especially in tile construction. In particular, the mortar composition should be usable as a leveling mortar composition for floors. Preferably, the mortar composition should be easy to process and have good flow characteristics. At the same time, the mortar composition should help reduce noise or vibration, especially in tile constructions.

Surprisingly, it has been found that this object is achieved by the features of claim 1. The core of the present invention is therefore a mortar composition, in particular a leveling mortar composition, comprising or consisting of:

a) 3-45% by weight of a hydraulic binder,

b) 15-80 wt% of a lightweight aggregate,

c) 5-50 wt% of a polymer.

The preparation of the mortar composition is very simple and safe: the mortar composition, in particular in the dry state, is mixed with an appropriate amount of water. Thereafter, the mortar composition is ready for application. Furthermore, the mortar composition itself may be a one-component mixture. This eliminates the risk of the user confusing or mis-metering the individual components.

After mixing with water, the mortar composition of the invention is easy to process. Thereby, a rather long pot life of about 30 minutes can be achieved. In particular, the mixed composition may have a consistency that allows leveling on a horizontal surface. For example, it is possible to produce a flat and smooth surface on rough and uneven floor substrates made of green concrete.

As can be shown, mortar compositions are furthermore characterized by good adhesion to different kinds of materials, in particular concrete, mortar and adhesives, especially tile adhesives.

Thus, the mortar composition is very useful as a bedding layer for coverings such as tiles, carpets, plastic flooring, veneers, and the like. However, mortar compositions are also suitable as a surface layer, for example as a warehouse floor. The surface layer serves as the actual finished surface, in particular the floor, without further covering.

At the same time, the mortar composition helps to suppress noise and/or vibration, especially in tiled structures. For example, noise on the floor caused by walking can be significantly reduced. In particular, a reduction of the impact noise by 6-20dB (according to ISO 10140-3:2010 and ISO 717-2) can be observed.

Further aspects of the invention are subject matter of further independent claims. Particularly preferred embodiments are outlined throughout the description and the dependent claims.

Modes for carrying out the invention

A first aspect of the present invention relates to a mortar composition, in particular a levelling mortar composition, comprising or consisting of:

a) 3-45% by weight of a hydraulic binder,

b) 15-80 wt% of a lightweight aggregate,

c) 5-50 wt% of a polymer.

In particular, all amounts relate to the total weight of the mortar composition in the dry state.

In the present context, the expression "hydraulic binder" denotes in particular a substance which hardens as a result of the formation of hydrates by chemical reaction with water. Preferably, the hydrate produced is not water soluble. In particular, the chemical reaction of hydration of the hydraulic binder takes place substantially independently of the water content. This means that hydraulic binders harden and retain their strength even when exposed to water (e.g. under water or under high humidity conditions).

The term "lightweight aggregate" denotes in particular a particle density ≦ 2'000kg/m³Preferably ≦ 1'500kg/m³In particular < 1' < 250kg/m³The aggregate of (2). The particle density of the aggregate is the ratio of the mass of the particulate material to the volume occupied by the individual particles. The volume includes pores within the particles but does not include voids between the particles. In particular, the particles of the aggregate may have any spherical and/or non-spherical geometry, uniform or non-uniform. For example, the particles may be spherical, pyramidal, polygonal, cubic, pentagonal, hexagonal, octagonal, prismatic, and/or polyhedral in shape. The inhomogeneous particles may have, for example, a circular, elliptical, oval, square, rectangular, triangular or polygonal cross-section, at least partially present therein. "non-uniform" and "irregularly" shaped particles refer to three-dimensional particle shapes whereinAt least two different cross-sections taken from the particle have different shapes.

In particular, the mortar composition is a dry mortar composition. This means that the mortar composition is substantially free of water or that the amount of water is below 1 wt%, in particular below 0.5 wt% or below 0.1 wt%, relative to the total weight of the mortar composition.

According to a preferred embodiment, the mortar composition is a one-component mixture. This means that all the individual materials and/or substances are mixed. One-component compositions are particularly easy to handle and exclude the risk of the user confusing or mis-metering the individual components.

However, in principle a two-component mortar composition or even a multi-component mortar composition may be provided. The first component may, for example, be present in a first container comprising a hydraulic binder and a polymer. The second component present in the second container may comprise aggregate. Other distributions are also possible. Two-component or multi-component mortar compositions allow, for example, the mortar composition to be tailored to the specific application.

The amount of hydraulic binder is preferably from 3 to 35% by weight, in particular from 4 to 20% by weight, especially from 5 to 15% by weight, relative to the total weight of the mortar composition in the dry state.

Preferably, the hydraulic binder comprises or consists of: portland cement, aluminate cement, sulphoaluminate cement, latent hydraulic and/or pozzolanic binder materials, calcium sulphate hemihydrate, anhydrite and/or hydrated lime.

The preferred portland cements are according to standard EN 197, in particular CEM type I. The term "aluminous cement" denotes in particular Al₂O₃Measured as a cement with an aluminium content of at least 30 wt%, especially at least 35 wt%, especially 35-58 wt%. Preferably, the aluminous cement is an aluminous cement according to standard EN 14647. Preferably, the sulphoaluminate cement is a calcium sulphoaluminate cement.

The term "latent hydraulic and/or pozzolanic binder material" denotes in particular a type II concrete additive having latent hydraulic and/or pozzolanic properties according to EN 206-1. In particular, the latent hydraulic or pozzolanic binder material comprises or consists of: slag, fly ash, silica fume, metakaolin and/or natural pozzolan. Thus, slag and/or fly ash, especially boiler slag, is especially preferred.

Calcium sulfate hemihydrate or CaSO₄·0.5H₂O may be present in the form of alpha-hemihydrate or beta-hemihydrate. Anhydrite is in particular anhydrite II and/or anhydrite III, whereas slaked lime stands for calcium hydroxide.

It is particularly preferred that the hydraulic binder comprises aluminate cement and/or sulphoaluminate cement, preferably in a proportion of from 3 to 18% by weight, in particular from 4 to 15% by weight, especially from 5 to 10% by weight, relative to the total weight of the mortar composition in the dry state.

In particular, the hydraulic binder comprises portland cement, preferably in a proportion of 3 to 18% by weight, in particular 4 to 15% by weight, especially 5 to 10% by weight, relative to the total weight of the mortar composition in the dry state.

In particular, the hydraulic binder comprises portland cement and aluminate cement and/or sulphoaluminate cement in a weight ratio of portland cement to aluminate cement and/or sulphoaluminate cement of between 0.2 and 4, in particular between 0.5 and 3, and especially between 0.7 and 1.5.

In particular, the hydraulic binder comprises latent hydraulic and/or pozzolanic binder materials, in particular slag and/or fly ash, preferably in a proportion of 3 to 18 wt.%, in particular 4 to 15 wt.%, in particular 5 to 10 wt.%, relative to the total weight of the mortar composition in the dry state.

In particular, the hydraulic binder comprises an aluminate cement and/or a sulphoaluminate cement and a latent hydraulic and/or pozzolanic binder material, wherein the weight ratio of aluminate cement and/or sulphoaluminate cement to latent hydraulic and/or pozzolanic binder material is from 0.5 to 3, in particular from 0.7 to 2.5, in particular from 1 to 2.

Preferably, the mortar composition comprises:

3-18% by weight, in particular 4-15% by weight, especially 5-10% by weight, of aluminate cement and/or sulphoaluminate cement;

-optionally from 3 to 18% by weight, in particular from 4 to 15% by weight, especially from 5 to 10% by weight, of portland cement;

-optionally 3-18 wt%, in particular 4-15 wt%, especially 5-10 wt% of a latent hydraulic and/or pozzolanic binder material, especially slag and/or fly ash;

optionally 1-8 wt%, in particular 2-6 wt%, especially 2-4 wt% of calcium sulphate hemihydrate and/or anhydrite;

-optionally from 0.1 to 5% by weight, in particular from 0.2 to 3% by weight, especially from 0.5 to 1.5% by weight, of hydrated lime;

wherein all amounts are relative to the total weight of the mortar composition in the dry state.

As for the lightweight aggregate, the particle density of the lightweight aggregate is preferably 100 to 2'000kg/m³In particular 400-1' 900kg/m³Preferably 700-1' 500kg/m³Or 800-1' 300kg/m³。

In particular, the proportion of lightweight aggregate is from 30 to 80% by weight, in particular from 50 to 75% by weight, in particular from 55 to 70% by weight, relative to the total weight of the mortar composition in the dry state.

Preferred lightweight aggregates comprise or consist of: wood particles, rubber particles, lamellar particles, plastic particles and/or porous particles, in particular porous inorganic particles. More preferred particles are rubber particles and/or porous particles. The most preferred particles are rubber particles.

Even more preferably, the lightweight aggregate comprises or consists of rubber particles, lamellar particles and/or porous particles. Most preferably, the lightweight aggregate comprises or consists of: rubber particles, optionally in combination with porous particles.

In particular, the lightweight aggregate has a particle size of from 0.01 to 4mm, especially from 0.05 to 3mm, preferably from 0.1 to 2mm, especially from 0.1 to 1.5 mm.

The particle size may be determined, for example, by laser diffraction as described in ISO 13320: 2009. Preferably, the particle size of the non-spherical or irregular particles is expressed in terms of the equivalent sphere diameter of the equivalent volume sphere. In particular, the lower value of the range is given by the particle size, representing the value of D1, and the upper value of the range is given by the particle size, representing the value of D99. In other words, in this case, 1% of the particles have a size below the lower limit of the range, while 1% of the particles have a size above the upper limit of the range.

In particular, the lightweight aggregate comprises two different types of particles, in particular having two different particle sizes. Preferably, the first type of particles has a particle size of 0.01 to 0.5mm, especially 0.1 to 0.4mm, and the second type of particles has a particle size of 0.6 to 2mm, especially 0.6 to 1.5 mm. Of these, preferably, both types of particles are rubber particles.

In particular, the weight ratio of the particles of the first type having the smaller particle size to the particles of the second type having the larger particle size is from 1:2 to 8:1, in particular from 1:1 to 5:1, especially from 2:1 to 4:1 or from 2.5:1 to 3.5: 1.

Preferably, the particles have a non-spherical and/or irregular shape, in particular a prismatic shape.

In the present context, the term "rubber" especially denotes elastomers, especially thermoset. The rubber particles may be composed of natural and/or synthetic rubber. Rubber is chemically different from the above polymers.

In particular, the rubber particles comprise or consist of: natural polyisoprene; synthesizing polyisoprene; polybutadiene; neoprene, such as polychloroprene, neoprene, baypren; butyl rubber, in particular copolymers of isobutylene and isoprene; halogenated butyl rubbers, such as chlorinated butyl rubber, brominated butyl rubber; styrene-butadiene rubbers, in particular copolymers of styrene and butadiene, nitrile rubbers, in particular copolymers of butadiene and acrylonitrile and/or hydrogenated nitrile rubbers.

For example, the rubber particles are reclaimed rubber particles, which are obtained in particular from worn shoes and/or tires.

For example, rubber particles are derived from rubber products, such as used tires, by cryogenic grinding.

In particular, the lightweight aggregate comprises two different types of rubber particles, in particular having two different particle sizes. Preferably, the particle size of the rubber particles of the first type is from 0.01 to 0.5mm, in particular from 0.1 to 0.4mm, and the particle size of the rubber particles of the second type is from 0.6 to 2mm, in particular from 0.6 to 1.5 mm.

In particular, the weight ratio of the rubber particles of the first type having the smaller particle size to the rubber particles of the second type having the larger particle size is from 1:2 to 8:1, in particular from 1:1 to 5:1, especially from 2:1 to 4:1 or from 2.5:1 to 3.5: 1.

Preferably, the rubber has a non-spherical or irregular shape.

In other preferred embodiments, the lightweight aggregate comprises or consists of porous particles. In particular, the porous particle has a porosity of at least 25 vol%, in particular at least 50 vol%, in particular at least 75 vol%, relative to the total volume of the porous particle.

In particular, the porous particles are selected from expanded polystyrene pellets, expanded silica, volcanic rock, such as pumice and/or perlite. Expanded silica is highly preferred.

However, the lightweight aggregate may also comprise or consist of: layered materials, cork and/or plastics, in particular recycled plastics. For example, lightweight aggregate comprises or consists of: polyethylene terephthalate (PET), mica and/or vermiculite.

In particular, the composition comprises, as lightweight aggregate, from 30 to 80% by weight, in particular from 50 to 75% by weight, of rubber particles and optionally from 1 to 15% by weight, in particular from 2 to 10% by weight, of porous particles, preferably expanded glass.

Most preferably, the lightweight aggregate comprises or consists of:

30 to 80 wt.%, in particular 50 to 75 wt.%, of rubber particles,

-wherein the rubber particles comprise a first type of rubber particles having a particle size of 0.01-0.5 mm, especially 0.1-0.4 mm and a second type of rubber particles having a particle size of 0.6-2 mm, especially 0.6-1.5 mm; and

-wherein the weight ratio of the rubber particles of the first type having the smaller particle size to the rubber particles of the second type having the larger particle size is from 1:2 to 8:1, in particular from 1:1 to 5:1, especially from 2:1 to 4:1 or from 2.5:1 to 3.5: 1; and

-wherein the rubber has a non-spherical or irregular shape; and

optionally 1 to 15 wt.%, in particular 2 to 10 wt.%, of porous particles, in particular having a particle size of 0.1 to 0.6mm, wherein preferably the porous particles comprise or consist of expanded glass,

wherein all proportions are relative to the total weight of the mortar composition in the dry state.

According to other embodiments, the mortar composition additionally comprises 0-10 wt%, in particular 0.5-10 wt%, especially 1-7 wt% of other aggregates, relative to the dry weight of the mortar composition, which have a particle density higher than the particle density of the lightweight aggregates. In particular, the particle density of the particles of the other aggregate>2'000kg/m³In particular>2'100kg/m³Or>2'200kg/m³。

The particle size of the other aggregates is preferably in the range from 0.05 to 1mm, in particular from 0.1 to 0.3 mm.

In particular, the other aggregates comprise sand, quartz, calcium carbonate, natural river sand, gravel, basalt and/or metal aggregates, in particular sand and/or calcium carbonate.

However, it is also possible to provide mortar compositions in which the other aggregates have, relative to the dry weight of the mortar composition, a structure which is a function of the aggregate<5% by weight, especially<1 wt% ratio. In particular, a mortar composition may be provided which does not comprise any other aggregate and/or any particle density>2'000kg/m³In particular>2'100kg/m³Or>2'200kg/m³The aggregate of (2).

Preferably, the polymer used in the mortar composition is a water-soluble or water-redispersible polymer, in particular a redispersible polymer. Such polymers have proven beneficial in the present mortar compositions. However, other polymers may also be suitable, for example for specific purposes.

Preferably, the polymer is present in the solid state, especially as a powder.

In particular, polymers are used as binders to control the strength of the mortar composition.

Preferably, the glass transition temperature of the polymer is from-45 to 10 ℃, especially from-35 to 5 ℃, preferably from-25 to 0 ℃, especially from-20 to 0 ℃, particularly preferably from-20 to-10 ℃. Such polymers may further improve the strength and noise suppression properties of the mortar composition. Most preferred are redispersible polymers having these glass transition temperatures.

Glass transition temperatures are measured by differential scanning calorimetry according to the standard ASTM E1356-08 (2014).

In particular, the polymer is a homopolymer or a copolymer based on one or more monomers selected from: vinyl esters, vinyl acetate, vinyl alcohol, vinyl chloride, vinyl laurate, acrylic acid esters, methacrylic acid esters, methyl methacrylate, acrylonitrile, styrene, butadiene, ethylene, or mixtures thereof.

Very preferred are copolymers based on vinyl esters and ethylene.

Preferably, the polymer is selected from poly (vinyl acetate-ethylene), poly (vinyl acetate-ethylene-methyl methacrylate), poly (vinyl acetate-ethylene-vinyl ester), poly (vinyl acetate-ethylene-acrylate), poly (vinyl acetate-ethylene-vinyl laurate), poly (vinyl acetate-vinyl versatate), poly (acrylate-acrylonitrile), poly (acrylate-styrene butadiene), or mixtures thereof. A highly preferred polymer is poly (vinyl ester-ethylene).

However, other polymers may also be suitable.

The preferred amount of polymer is from 3 to 30% by weight, in particular from 5 to 20% by weight, especially from 7 to 15% by weight, relative to the total weight of the adhesive composition.

Preferably, the weight ratio of polymer to hydraulic binder in the mortar composition is from 0.1 to 17, in particular from 0.2 to 7, especially from 0.3 to 5, in particular from 0.4 to 2 or from 0.7 to 1.5. Preferably, the weight ratio of lightweight aggregate to polymer is from 1 to 20, in particular from 2 to 15, especially from 3 to 10. This is particularly true if the lightweight aggregate comprises or consists of rubber and the polymer is a redispersed polymer.

Furthermore, it may be advantageous for the mortar composition to comprise at least one additive selected from the group consisting of: curing time regulators, plasticizers, defoamers, rheology modifiers, thixotropic agents, gassing and/or blowing agents, anti-shrinkage agents, corrosion inhibitors, flame retardants, fibers, and chromium reducing agents.

Preferably, the total proportion of additives is from 0 to 10% by weight, in particular from 1 to 10% by weight, relative to the weight of the mortar composition in the dry state.

Preferably, the mortar composition comprises a phyllosilicate, in particular a phyllosilicate, as an additive. Preferably, the phyllosilicate is bentonite or an aluminum phyllosilicate. In particular, a layered silicate is used in combination with the above rubber particles. It has been shown that the layered silicate helps to stabilize the rubber particles in the mortar composition.

The proportion of the layer silicate is preferably from 0.01 to 10% by weight, in particular from 0.1 to 7% by weight, in particular from 0.2 to 3% by weight, based on the weight of the mortar composition in the dry state.

In particular, the mortar composition comprises a thixotropic agent, in particular silica, silica fume, cellulose, and/or a saccharide. The proportion of thixotropic agent is preferably from 0.001 to 1% by weight, in particular from 0.1 to 0.5% by weight, relative to the weight of the mortar composition in the dry state.

According to another preferred embodiment, the mortar composition comprises a plasticizer, wherein the plasticizer is selected in particular from the group consisting of lignosulfonates, gluconates, naphthalene sulfonates, melamine sulfonates, vinyl copolymers and/or polycarboxylate ethers. Polycarboxylate ethers are preferred.

In particular, plasticizers are chemically different from the above polymers and rubbers. The proportion of polycarboxylate ether is preferably from 0.001 to 1% by weight, in particular from 0.1 to 0.5% by weight, based on the weight of the mortar composition in the dry state.

Preferably, the mortar composition comprises fibers, in particular glass, plastic and/or cellulose fibers. Glass fibers are highly preferred. The proportion of fibres is preferably from 0.001 to 3% by weight, in particular from 0.01 to 2.0% by weight, especially from 0.1 to 1% by weight, relative to the weight of the mortar composition in the dry state. The preferred length of the fibres is from 0.5 to 12mm, especially from 2 to 5 mm. The diameter of the fibers is, for example, from 0.5 to 1000. mu.m, in particular from 1 to 100. mu.m, in particular from 5 to 40 μm.

Preferred mortar compositions comprise or consist of:

3-18% by weight, in particular 4-15% by weight, especially 5-10% by weight, of aluminate cement and/or sulphoaluminate cement;

-optionally from 3 to 18% by weight, in particular from 4 to 15% by weight, especially from 5 to 10% by weight, of portland cement;

-optionally 4-8 wt% of latent hydraulic and/or pozzolanic binder material, especially slag and/or fly ash;

30-80 wt.%, in particular 50-75 wt.%, of rubber particles, in particular comprising two different types of rubber particles having two different particle sizes, wherein, in particular, the weight ratio of particles of the first type having a smaller particle size to particles of the second type having a larger particle size is 2: 1-4: 1 or 2.5: 1-3.5: 1;

1-15 wt% of porous particles, especially having a particle size of 0.1-0.6mm, wherein preferably the porous particles comprise or consist of expanded glass, 1-15 wt% of porous inorganic particles, especially having a particle size of 0.1-0.6 mm;

5-20% by weight, in particular 7-15% by weight, of a water-soluble or water-redispersible polymer, in particular a copolymer based on vinyl acetate and ethylene;

-0-10, especially 1-5 wt% of one or more additives, especially additives comprising layered silicates;

wherein the proportions are relative to the weight of the mortar composition in the dry state.

Highly preferred mortar compositions comprise or consist of:

-4-15 wt% of calcium aluminate cement;

-4-15% by weight of portland cement;

-optionally 4-8 wt% of latent hydraulic and/or pozzolanic binder material, especially slag and/or fly ash;

-50-75 wt% of rubber particles comprising two different types of rubber particles having two different particle sizes, wherein the weight ratio of particles of the first type having a smaller particle size to particles of the second type having a larger particle size is 2: 1-4: 1 or 2.5: 1-3.5: 1;

-2-20 wt% of porous inorganic particles having a particle size of 0.1-0.6mm, wherein preferably the porous particles comprise or consist of expanded glass;

7-15% by weight of a water-soluble or water-redispersible polymer, in particular a copolymer based on vinyl acetate and ethylene;

-1-10 wt% of one or more additives, in particular an additive comprising a layered silicate;

-wherein, preferably, the particle density>2'000kg/m³In a proportion of aggregate of<5 wt% or<1wt％；

Wherein the proportions are relative to the weight of the mortar composition in the dry state.

Without being bound by theory, it is believed that compositions of the invention having a higher polymer content of at least 3 wt%, in particular at least 5 wt%, can be formulated with less hydraulic binder (e.g. cement) and still have improved properties compared to compositions comprising a rather low proportion of polymer (e.g. less than 3 wt%). For example, the compositions of the present invention are characterized by greater flexibility and better acoustic damping without significantly affecting other mechanical properties. If a smaller amount of polymer is used, the content of hydraulic binder needs to be increased to achieve similar mechanical properties. However, this in turn leads to poorer acoustic damping. If the amount of the polymer used is too large, the retardation is strong. However, the retardation of a higher proportion of polymer can be compensated for by the use of high alumina cement. The proportion of the polymer according to the invention and the ratio of the polymer according to the invention to the hydraulic binder (optionally in combination with aluminate cement and/or sulphoaluminate cement) are therefore very advantageous.

Another aspect of the invention relates to a method for preparing a processable mortar composition, comprising the step of adding water to the mortar composition as described above.

Thus, preferably, the weight ratio of water to mortar composition in the dry state is between 0.30 and 0.70, in particular between 0.32 and 0.50, especially between 0.34 and 0.44.

A further aspect of the invention is a hardened mortar composition obtainable or obtainable by the method as described above by adding water to the mortar composition as described above. Preferably, the mortar composition is placed on a substrate, in particular on a floor, in particular made of concrete.

Preferably, the hardened mortar composition is present in the form of a layer, coating and/or sheet, in particular placed on a substrate. Preferably, the hardened mortar composition has a thickness of 4 to 10mm, especially 5 to 9 mm.

Another aspect of the invention relates to a kit of parts comprising or consisting of: (i) a mortar composition as described above, in particular in the dry state, and (ii) an adhesive composition, in particular a patch adhesive, in particular in the dry state, wherein the adhesive composition comprises or consists of:

a) 10-50% by weight of a hydraulic binder,

b) 20-60 wt% of a lightweight aggregate,

c) 10-25 wt% of a polymer;

and wherein the binder composition is chemically different from the mortar composition. In particular, all the proportions given for the adhesive composition are relative to the total weight of the adhesive composition in the dry state.

"chemically different" means in particular compositions which differ at least in terms of chemical composition, percentage of components, chemical structure of components and/or particle size of components.

Preferably, the kit of parts is provided as a two-component product. Thus, preferably, a first component of the product is present in a first container comprising the mortar composition and a second component of the product is present in a second container comprising the binder composition.

However, multicomponent products having more than two components may also be provided. In this case, for example, the mortar composition and/or the binder composition may be provided in two separate containers. The multi-component product allows, for example, the binder composition and/or mortar composition to be adjusted for a particular application.

In the following, the adhesive composition is described in more detail. Thus, the terms "hydraulic binder", "lightweight aggregate", "high alumina cement", "latent hydraulic and/or pozzolanic binder material" and "rubber" have the same general meaning as described above for the mortar composition, if not otherwise stated.

In particular, the adhesive composition is a dry adhesive composition. This means that the adhesive composition is substantially free of water or that the amount of water is below 1 wt. -%, in particular below 0.5 wt. -% or below 0.1 wt. -%, relative to the total weight of the adhesive composition.

According to a preferred embodiment, the adhesive composition is a one-component mixture. This means that all the individual materials and/or substances are mixed. One-component compositions are particularly easy to handle and exclude the risk of the user confusing or mis-metering the individual components.

However, in principle two-component adhesive compositions or even multi-component adhesive compositions can be provided. The first component may, for example, be present in a first container comprising a hydraulic binder and a polymer. The second component present in the second container may comprise aggregate. Other distributions are also possible. Two-or multi-component adhesive compositions allow, for example, the adhesive composition to be tailored to a particular application.

The hydraulic binder of the binder composition is preferably present in an amount of 21 to 50 wt.%, in particular 25 to 45 wt.%, especially 30 to 40 wt.%, relative to the total weight of the binder composition in the dry state.

Preferably, the weight ratio of polymer to hydraulic binder in the binder composition is from 0.1 to 5, in particular from 0.2 to 2.5, especially from 0.2 to 1, in particular from 0.3 to 0.8 or from 0.3 to 0.6.

Preferably, the hydraulic binder of the binder composition comprises or consists of cement. Preferably, the cement is portland cement and/or high alumina cement and/or sulphoaluminate cement.

The preferred portland cements are according to standard EN 197, in particular CEM type I. Preferably, the aluminous cement is an aluminous cement according to standard EN 14647. Preferably, the sulphoaluminate cement is a calcium sulphoaluminate cement.

The preferred amount of portland cement in the binder composition is 10 to 40 wt%, in particular 20 to 35 wt%, especially 25 to 30 wt%, relative to the total weight of the binder composition in the dry state.

In particular, the hydraulic binder of the binder composition comprises two different types of portland cement, in particular two types of portland cement of different strength grades. In particular, a strength grade of 42.5N portland cement is combined with a strength grade of 52.5N portland cement. The intensity rating is according to EN 197-1: 2011.

Preferably, the proportion of lower strength grade cement is higher than the proportion of higher strength grade cement in the binder composition. In particular, the proportion of lower strength grade cement is 1.5 to 5 times the proportion of lower strength grade cement.

Such a mixture of different portland cements has been found to be very beneficial in terms of noise suppression, adhesion and strength development of the hardened binder composition.

Preferably, the binder composition comprises an aluminous cement and/or a sulphoaluminate cement, preferably a sulphoaluminate cement. In particular, the proportion of these cements in the binder composition is from 1 to 15% by weight, in particular from 3 to 10% by weight, and especially from 4 to 7% by weight, relative to the total weight of the binder composition in the dry state.

According to other preferred embodiments, the hydraulic binder of the binder composition comprises portland cement and sulphoaluminate cement, in particular calcium sulphoaluminate cement.

Even more preferably, the hydraulic binder of the binder composition comprises two different types of portland cement, in particular two types of portland cement of different strength grades, in combination with a sulphoaluminate cement, in particular a calcium sulphoaluminate cement. The two types of portland cement of different strength grades are chosen in particular as described above.

Sulphoaluminate cements, especially in combination with portland cement, have proven to be particularly advantageous for binder compositions.

The weight ratio of portland cement to sulphoaluminate cement in the binder composition is preferably from 2 to 10, especially from 3 to 8, especially from 4 to 7 or from 5 to 6.

According to a preferred embodiment, the binder composition comprises as hydraulic binder 10 to 40% by weight, in particular 20 to 35% by weight, especially 25 to 30% by weight, of portland cement and 1 to 15% by weight, in particular 3 to 10% by weight, especially 4 to 7% by weight, of sulphoaluminate cement, each relative to the total weight of the binder composition in the dry state. Also in this case, it is preferable to select two types of portland cements of different strength grades as described above.

Furthermore, the hydraulic binder of the binder composition may optionally comprise or consist of a latent hydraulic and/or pozzolanic binder material. In particular, the latent hydraulic or pozzolanic binder material comprises or consists of: slag, fly ash, silica fume, metakaolin and/or natural pozzolan. Thus, slag, in particular boiler slag, is particularly preferred.

Preferably, the proportion of latent hydraulic and/or pozzolanic binder material in the binder composition is from 0.5 to 20% by weight, in particular from 2 to 10% by weight, especially from 3 to 7% by weight, relative to the total weight of the binder composition in the dry state.

According to a preferred embodiment, the hydraulic binder of the binder composition comprises, in combination:

10-40% by weight, in particular 20-35% by weight, especially 25-30% by weight, of portland cement, relative to the total weight of the binder composition in the dry state; and

1-15% by weight, in particular 3-10% by weight, especially 4-7% by weight, of sulphoaluminate cement relative to the total weight of the binder composition in the dry state. Also in this case, two types of portland cement of different strength grades are selected as described above; and

0.5-20 wt.%, in particular 2-10 wt.%, in particular 4-8 wt.% of latent hydraulic and/or pozzolanic binder material, in particular slag and/or fly ash, relative to the total weight of the binder composition in the dry state.

With respect to the lightweight aggregate of the binder composition, the particle density of the lightweight aggregate is preferably 100 to 2'000kg/m³In particular 400-1' 900kg/m³Preferably 700-1' 500kg/m³Or 800-1' 300kg/m³。

In particular, the proportion of lightweight aggregate of the binder composition is from 20 to 50% by weight, in particular from 25 to 55% by weight, in particular from 35 to 45% by weight, relative to the total weight of the binder composition in the dry state.

Preferred lightweight aggregates of the binder composition comprise or consist of: wood particles, rubber particles, plastic particles and/or porous particles, in particular porous inorganic particles. More preferred particles are rubber particles and/or porous particles. The most preferred particles are rubber particles.

The rubber particles may be composed of natural and/or synthetic rubber. The rubber is chemically different from the above-mentioned polymers of the adhesive composition.

In particular, the rubber particles of the adhesive composition comprise or consist of: natural polyisoprene; synthesizing polyisoprene; polybutadiene; neoprene, such as polychloroprene, neoprene, baypren; butyl rubber, in particular copolymers of isobutylene and isoprene; halogenated butyl rubbers, such as chlorinated butyl rubber, brominated butyl rubber; styrene-butadiene rubbers, in particular copolymers of styrene and butadiene, nitrile rubbers, in particular copolymers of butadiene and acrylonitrile and/or hydrogenated nitrile rubbers.

For example, the rubber particles are reclaimed rubber particles, particularly obtained from worn shoes and/or tires. For example, rubber particles are derived from rubber products, such as used tires, by cryogenic grinding.

In other preferred embodiments, the lightweight aggregate of the binder composition comprises or consists of porous particles. In particular, the porous particle has a porosity of at least 25 vol%, in particular at least 50 vol%, in particular at least 75 vol%, relative to the total volume of the porous particle.

In particular, the porous particles of the binder composition are selected from expanded polystyrene pellets, expanded silica, volcanic rock, such as pumice and/or perlite. Expanded silica is highly preferred.

However, the lightweight aggregate of the binder composition may also comprise or consist of: cork and/or plastic, in particular recycled plastic. For example, the light weight aggregate comprises or consists of polyethylene terephthalate (PET).

Preferably, the lightweight aggregate of the binder composition has a particle size of from 0.01 to 2mm, especially from 0.05 to 1.5mm, preferably from 0.1 to 1.0mm, especially from 0.1 to 0.6 mm. This is particularly independent of the type of lightweight aggregate used in the binder composition.

Also in this case, the particle size can be determined, for example, by laser diffraction as described in ISO 13320: 2009. Preferably, the particle size of the non-spherical or irregular particles is expressed in terms of the equivalent spherical diameter of a sphere of equivalent volume. In particular, the lower value of the range is given by the particle size, representing the value of D1, and the upper value of the range is given by the particle size, representing the value of D99. In other words, in this case, 1% of the particles have a size below the lower limit of the range, while 1% of the particles have a size above the upper limit of the range.

In particular, the adhesive composition comprises 30 to 60 wt%, especially 35 to 55 wt% of rubber particles and 1 to 15 wt%, especially 3 to 10 wt% of porous particles, preferably porous inorganic particles, as lightweight aggregate. Therefore, expanded silica or glass is most preferable as the inorganic particle.

According to a very preferred embodiment, the particle density in the binder composition>2'000kg/m³In particular>2'100kg/m³Or>2'200kg/m³In proportion of aggregate<25% by weight, in particular<10% by weight, preferably<5 wt% or<1 wt%. In particular, the adhesive composition is not encapsulatedContaining any particle density>2'000kg/m³In particular>2'100kg/m³Or>2'200kg/m³The aggregate of (2).

In particular, the proportion of sand, quartz, calcium carbonate, natural river sand, gravel, basalt and/or metal aggregate in the binder composition is <25 wt.%, in particular <10 wt.%, preferably <5 wt.% or <1 wt.%. In particular, the binder composition does not contain any such aggregate.

Preferably, the polymer used in the adhesive composition is a water-soluble or water-redispersible polymer, in particular a redispersible polymer. Such polymers have proven beneficial in the present adhesive compositions. However, other polymers may also be suitable, for example for specific purposes.

Preferably, the polymer is present in the solid state, especially as a powder.

In particular, the polymer of the adhesive composition acts as an adhesive to control the strength of the adhesive composition.

Preferably, the glass transition temperature of the polymer of the adhesive composition is from-45 to 10 ℃, especially from-35 to 5 ℃, preferably from-25 to 0 ℃, especially from-20 to-10 ℃. Such polymers may further improve the strength and noise suppression properties of the adhesive composition. Most preferred are redispersible polymers having these glass transition temperatures.

In particular, the polymer of the adhesive composition is a homopolymer or a copolymer based on one or more monomers selected from: vinyl esters, vinyl acetate, vinyl alcohol, vinyl chloride, vinyl laurate, acrylic acid esters, methacrylic acid esters, methyl methacrylate, acrylonitrile, styrene, butadiene, ethylene, or mixtures thereof.

A highly preferred polymer of the adhesive composition is a copolymer based on vinyl esters, ethylene and acrylic esters.

Preferably, the polymer of the adhesive composition is selected from poly (vinyl acetate-ethylene), poly (vinyl acetate-ethylene-methyl methacrylate), poly (vinyl acetate-ethylene-vinyl ester), poly (vinyl acetate-ethylene-acrylate), poly (vinyl acetate-ethylene-vinyl laurate), poly (vinyl acetate-vinyl versatate), poly (acrylate-acrylonitrile), poly (acrylate-styrene butadiene), or mixtures thereof. A highly preferred polymer is poly (vinyl ester-ethylene-acrylate).

However, other polymers may also be suitable for the adhesive composition.

The preferred amount of polymer in the adhesive composition is from 10 to 20% by weight, in particular from 12 to 18% by weight, especially from 13 to 17% by weight, relative to the total weight of the adhesive composition.

Preferably, the weight ratio of lightweight aggregate to polymer in the binder composition is from 1 to 10, especially from 1.5 to 7, especially from 2 to 5. This is particularly true if the lightweight aggregate comprises or consists of rubber and the polymer is a redispersed polymer.

Furthermore, it may be advantageous for the adhesive composition to comprise additives selected from the group consisting of curing time regulators, plasticizers, defoamers, rheology modifiers, thixotropic agents, gassing and/or blowing agents, anti-shrinkage agents, corrosion inhibitors, flame retardants, fibers and chromium reducing agents.

Preferably, the total proportion of additives of the adhesive composition is from 0 to 5% by weight, in particular from 1 to 5% by weight, relative to the weight of the adhesive composition in the dry state.

Preferably, the adhesive composition comprises a phyllosilicate, in particular a phyllosilicate, as an additive. Preferably, the phyllosilicate is bentonite or an aluminum phyllosilicate. In particular, a layered silicate is used in combination with the above rubber particles. It has been demonstrated that the layered silicate helps to stabilize the rubber particles in the adhesive composition.

The proportion of the layer silicate of the adhesive composition is preferably from 0.01 to 2% by weight, in particular from 0.1 to 1% by weight, in particular from 0.2 to 0.7% by weight, based on the weight of the adhesive composition in the dry state.

In particular, the adhesive composition comprises a thixotropic agent, in particular silica, silica fume, cellulose, and/or sugars. The proportion of thixotropic agent of the adhesive composition is preferably from 0.001 to 1% by weight, in particular from 0.1 to 0.5% by weight, relative to the weight of the adhesive composition in the dry state.

According to another preferred embodiment, the adhesive composition comprises a plasticizer, wherein the plasticizer is in particular selected from the group consisting of lignosulfonates, gluconates, naphthalene sulfonates, melamine sulfonates, vinyl copolymers and/or polycarboxylate ethers. Polycarboxylate ethers are preferred.

In particular, the plasticizer is chemically different from the above-mentioned polymers and rubbers of the adhesive composition. The proportion of polycarboxylate ether in the adhesive composition is preferably from 0.001 to 1% by weight, in particular from 0.1 to 0.5% by weight, relative to the weight of the adhesive composition in the dry state.

Preferably, the binder composition comprises fibers, in particular glass, plastic and/or cellulose fibers. Glass fibers are highly preferred. The proportion of fibres of the binder composition is preferably from 0.001 to 3% by weight, in particular from 0.01 to 2.0% by weight, especially from 0.1 to 1% by weight, relative to the weight of the binder composition in the dry state. The preferred length of the fibres of the adhesive composition is from 0.5 to 12mm, especially from 2 to 5 mm. The diameter of the fibres of the adhesive composition is, for example, from 0.5 to 1' 000. mu.m, in particular from 1 to 100. mu.m, in particular from 5 to 40 μm.

Preferred adhesive compositions comprise or consist of:

25-45% by weight of a hydraulic binder, in particular comprising portland cement, and sulphoaluminate cement and optionally fly ash;

35-55% by weight of rubber aggregate, in particular having a particle size of 0.1-1.0 mm, preferably 0.1-0.6 mm;

10-25% by weight of a water-redispersible polymer, in particular having a glass transition temperature of-20 to 0 ℃;

-0-5 wt%, especially 1-5 wt% of one or more additives; and

-wherein, preferably, the particle density>2'000kg/m³In a proportion of aggregate of<5 wt% or<1wt％，

Wherein the proportions are relative to the weight of the adhesive composition in the dry state.

Very preferred adhesive compositions comprise or consist of:

-20-30% by weight of portland cement, in particular two different types of portland cement;

-3-10% by weight of calcium sulfoaluminate cement;

-optionally 4-8 wt% of latent hydraulic and/or pozzolanic binder material, especially slag and/or fly ash;

35-55% by weight of rubber aggregate, in particular having a particle size of 0.1-1.0 mm, preferably 0.1-0.6 mm;

-3-10 wt% of porous inorganic particles, especially having a particle size of 0.1-0.6 mm;

10-25% by weight of a water-redispersible polymer, in particular having a glass transition temperature of-20 to 0 ℃;

-0-5 wt%, especially 1-5 wt% of one or more additives; and

-wherein, preferably, the particle density>2'000kg/m³In a proportion of aggregate of<5 wt% or<1wt％，

Wherein the proportions are relative to the weight of the adhesive composition in the dry state.

In the kit of parts, preferably, the proportion of lightweight aggregate, in particular rubber particles, in the mortar composition is higher than the proportion of lightweight aggregate, in particular rubber particles, in the binder composition. In particular, the proportion of lightweight aggregate, in particular rubber particles, in the mortar composition is 1.1 to 5 times, in particular 1.5 to 3 times, the proportion of lightweight aggregate, in particular rubber particles, in the binder composition.

In particular, in the kit of parts, the proportion of hydraulic binder in the binder composition is higher than the proportion of hydraulic binder in the mortar composition.

In particular, in the kit of parts, the proportion of portland cement in the binder composition is higher than the proportion of portland cement in the mortar composition.

Preferably, in the kit of parts, the polymer of the adhesive composition is chemically different from the polymer of the mortar composition. Preferably, the glass transition temperature of the polymer of the binder composition is different from the glass transition temperature of the polymer of the mortar composition.

Preferably, in the kit of parts, the rubber particles of the mortar composition are different in shape from the rubber particles of the adhesive composition. For example, the rubber particles of the mortar composition are non-spherical or irregular in shape, especially prismatic, while the rubber particles of the adhesive composition are round.

Preferred kit of parts compositions comprise or consist of:

(i) a mortar composition comprising:

30-80 wt.%, in particular 50-75 wt.%, of rubber particles comprising two different types of rubber particles having two different particle sizes, wherein, in particular, the weight ratio of the first type of particles having the smaller particle size to the second type of particles having the larger particle size is 2: 1-4: 1 or 2.5: 1-3.5: 1;

wherein the ratio is relative to the weight of the mortar composition in the dry state; and

(ii) an adhesive composition comprising or consisting of:

-a hydraulic binder comprising portland cement and sulphoaluminate cement and optionally fly ash;

35-55% by weight of rubber aggregate, in particular having a particle size of 0.1-1.0 mm, preferably 0.1-0.6 mm;

-wherein, preferably, the particle density>2'000kg/m³In a proportion of aggregate of<5 wt% or<1wt％，

Wherein the ratio is relative to the weight of the adhesive composition in the dry state.

More preferred kit of parts compositions comprise or consist of:

(i) a mortar composition comprising or consisting of:

-3-18% by weight of calcium aluminate cement and/or calcium sulphoaluminate cement;

-optionally 4-8 wt% of latent hydraulic and/or pozzolanic binder material, especially slag and/or fly ash;

30-80 wt.%, in particular 50-75 wt.%, of rubber particles, in particular comprising two different types of rubber particles having two different particle sizes, wherein, in particular, the weight ratio of the particles of the first type having the smaller particle size to the particles of the second type having the larger particle size is 2: 1-4: 1 or 2.5: 1-3.5: 1;

1-15 wt% of porous particles, especially porous particles having a particle size of 0.1-0.6mm, wherein preferably the porous particles comprise or consist of expanded glass, 1-15 wt% of porous inorganic particles, especially having a particle size of 0.1-0.6 mm;

5-20% by weight, in particular 7-15% by weight, of a water-soluble or water-redispersible polymer, in particular a copolymer based on vinyl acetate and ethylene;

-0-10, especially 1-5 wt% of one or more additives, especially comprising a layered silicate;

wherein the ratio is relative to the weight of the mortar composition in the dry state; and

(ii) an adhesive composition comprising or consisting of:

25-45% by weight of a hydraulic binder, in particular comprising portland cement and sulphoaluminate cement and optionally fly ash;

35-55% by weight of rubber aggregate, in particular having a particle size of 0.1-1.0 mm, preferably 0.1-0.6 mm;

10-25% by weight of a water-redispersible polymer, in particular having a glass transition temperature of-20 to 0 ℃;

-0-5, especially 1-5 wt% of one or more additives; and

-wherein, preferably, the particle density>2'000kg/m³In a proportion of aggregate of<5 wt% or<1wt％。

Wherein the ratio is relative to the weight of the adhesive composition in the dry state.

Most preferably, the kit of parts comprises or consists of:

(i) a mortar composition comprising or consisting of:

-4-15 wt% of calcium aluminate cement;

-optionally 4-8 wt% of latent hydraulic and/or pozzolanic binder material, especially slag and/or fly ash;

50-75 wt% of rubber particles comprising two different types of rubber particles having two different particle sizes, wherein the weight ratio of particles of the first type having a smaller particle size to particles of the second type having a larger particle size is 2: 1-4: 1 or 2.5: 1-3.5: 1

-2-20 wt% of porous inorganic particles having a particle size of 0.1-0.6mm, wherein preferably the porous particles comprise or consist of expanded glass;

7-15% by weight of a water-soluble or water-redispersible polymer, in particular a copolymer based on vinyl acetate and ethylene;

-1-10 wt% of one or more additives, in particular comprising a layered silicate;

-wherein, preferably, the particle density>2'000kg/m³In a proportion of aggregate of<5 wt% or<1wt％；

Wherein the ratio is relative to the weight of the mortar composition in the dry state; and

(ii) an adhesive composition comprising or consisting of:

-20-30% by weight of portland cement, in particular two different types of portland cement;

-3-10% by weight of calcium sulfoaluminate cement;

-optionally 4-8 wt% of latent hydraulic and/or pozzolanic binder material, especially slag and/or fly ash;

35-55% by weight of rubber aggregate, in particular having a particle size of 0.1-1.0 mm, preferably 0.1-0.6 mm;

-3-10 wt% of porous inorganic particles, especially having a particle size of 0.1-0.6 mm;

10-25% by weight of a water-redispersible polymer, in particular having a glass transition temperature of-20 to 0 ℃;

-0-5, especially 1-5 wt% of one or more additives; and

-wherein, preferably, the particle density>2'000kg/m³In a proportion of aggregate of<5 wt% or<1wt％；

Wherein the ratio is relative to the weight of the adhesive composition in the dry state.

A further aspect of the invention relates to a structure, in particular a floor, wall or ceiling, comprising:

-substrates, in particular floors, in particular made of concrete;

-a first layer comprising a mortar composition as described above or consisting of an expanded glass, in particular in the hardened state;

-a second layer, in particular comprising or consisting of an adhesive composition as described above, in particular in a hardened state;

a covering element, in particular a patch, wherein the covering element is fixed to the first layer using the adhesive composition of the second layer.

In particular, for the preparation of the structure, an adhesive composition as defined above or a kit of parts as described above may be used. However, in principle different adhesive compositions can be used.

In particular, the thickness of the first layer is greater than the thickness of the second layer. Thus, preferably, the ratio of the thickness of the first layer to the thickness of the second layer is 1.1 to 10, in particular 1.2 to 5, especially 1.3 to 3.

In particular, the thickness of the first layer is 4 to 10mm, in particular 5.0 to 9mm, and the thickness of the second layer is 3 to 5mm, in particular 3.5 to 4.5 mm.

Optionally, there may be additional primer layers and/or intermediate layers between the substrate and the first layer, between the first layer and the second layer, and/or between the second layer and the cover element. This may further increase the adhesion between the substrate, layer and/or cover element and/or help to achieve even better noise or vibration suppression.

According to a preferred embodiment, the structure comprises an intermediate layer, in particular a mortar layer, between the first and second layers. The thickness of the intermediate layer is, for example, from 1 to 80mm, in particular from 3 to 15 mm. Such an intermediate layer may help stabilize the overall structure by reducing cracks in the cover element. Furthermore, it has been found that the overall acoustic damping effect of the structure can be improved due to the increased mass.

Preferably, the intermediate layer is a cement-based mortar layer, in particular according to DIN EN 13813: 2017. In particular, the mortar layer comprises cement and sand, wherein the ratio of cement to sand is from 1:1 to 1: 5. Preferably, the maximum particle size of the sand is 16mm, more preferably 8 mm. In particular, the cement is a portland cement, in particular according to CEM type I.

Therefore, a very preferred structure, in particular a floor, wall or ceiling, comprises:

-a substrate, in particular a floor, in particular made of concrete;

-a first layer comprising or consisting of a mortar composition as described above, in particular in the hardened state;

-an intermediate layer, in particular a mortar layer as described above, in particular in hardened state;

-a second layer, in particular comprising or consisting of an adhesive composition as described above, in particular in a hardened state;

a covering element, in particular a patch, wherein the covering element is fixed to the first layer using the adhesive composition of the second layer.

However, in another preferred embodiment, the second layer is applied directly onto the first layer.

In particular, the substrate is a floor, wall or ceiling substantially made of mortar, concrete, brick, plaster, metal, plastic and/or wood. Preferably, the covering element is a patch in the form of a tile, stone and/or veneer.

With this type of structure, significant noise reduction can be achieved.

Another aspect of the invention relates to a method for manufacturing a structure, in particular using a kit of parts as described above, wherein:

-mixing the mortar composition as described above with water and applying onto the substrate as a first layer;

-then mixing the adhesive composition as described above with water and applying onto the first layer as a second layer;

subsequently, a covering element, in particular a patch, is placed on the second layer.

Preferably, the mortar composition of the first layer is applied in a thickness of 4 to 10mm, in particular 5.0 to 9mm, and the binder composition is applied in a thickness of 3 to 5mm, in particular 3.5 to 4.5 mm.

Another aspect of the invention relates to a method for manufacturing a structure, in particular using a kit of parts as described above, wherein:

-mixing the mortar composition as described above with water and applying onto the substrate as a first layer;

-then applying an intermediate layer, in particular a mortar layer as described above, onto the first layer;

-then mixing the adhesive composition as described above with water and applying onto the intermediate layer as a second layer;

subsequently, a covering element, in particular a patch, is placed on the second layer.

In this case, it is preferred that the mortar composition of the first layer is applied in a thickness of 4 to 10mm, in particular 5.0 to 9mm, the intermediate layer is applied in a thickness of 1 to 80mm, in particular 3 to 15mm, and the adhesive composition is applied in a thickness of 3 to 5mm, in particular 3.5 to 4.5 mm.

A further aspect of the invention relates to the use of said mortar composition, optionally in combination with an adhesive composition as described above, or a kit of parts as described above, for fixing a tile on a substrate, in particular a floor, wall or ceiling of a building or installation.

According to another preferred embodiment, the mortar composition described herein, optionally in combination with a binder composition as described above, or a kit of parts as described above, is used for acoustic damping, noise reduction and/or vibration damping, in particular on the floor, wall or ceiling of a building and/or installation.

Other advantageous configurations of the invention are apparent from the exemplary embodiments.

Exemplary embodiments

1.Mortar composition

Table 1 shows six mortar compositions M1-M6. Mortar compositions have been prepared by mixing all the components in the dry state. Mortar composition M1-M6 was present as a dry powder.

TABLE 1 mortar compositions

¹⁾Isidac 40, calcium aluminate cement, Cimsa, Turkish

²⁾Alimem, available from Heidelberg Cement, Germany

³⁾Prismatic rubber particles with a particle size of 0-0.4 mm

⁴⁾Prismatic rubber particles with a particle size of 0.6-1.5 mm

⁵⁾Poraver, particle size 0.3-0.5 mm, Dennert Poraver GmbH, Germany

⁶⁾Soft, flexible vinyl acetate-ethylene copolymer (Tg about-14 ℃ C.)

⁷⁾Highly flexible vinyl acetate-ethylene-vinyl ester terpolymer (Tg about-14 ℃ C.)

⁸⁾Sika Viscocrete 225, polycarboxylate ethers, Sika Germany

⁹⁾Bentonil CV15V, Bentonil, Clariant, Germany

¹⁰⁾Defoaming agent, rheology modifier and thixotropic agent

Mortar compositions M1-M6 have been mixed with water (weight ratio of water to total weight of dry mortar composition ═ 0.34-0.64) to obtain processable compositions.

The flow table diffusion value was evaluated according to the standard EN 12350-5: 2009. Values in the range of 250-290mm were obtained immediately after preparation. Thus, the mortar composition exhibits a flow behavior that facilitates processing.

Internal tests similar to ISO 10140-3:2010 and ISO 717-2 show that with an uncovered mortar composition, an impact noise reduction Δ Lw of about up to 20dB can be achieved.

2.Adhesive composition

Table 2 shows six adhesive compositions C1-C7. Adhesive compositions have been prepared by mixing all components in the dry state. The adhesive compositions C1-C7 were present as dry powders.

TABLE 2 adhesive composition

¹⁾Alimem, available from Heidelberg Cement, Germany

²⁾Genan 40 mesh, particle size 180-

³⁾Prismatic rubber particles with a particle size of 0.1-0.4 mm

⁴⁾Poraver, particle size 0.1-0.3 mm, Dennert Poraver GmbH, Germany

⁵⁾Semi-flexible vinyl acetate-ethylene-acrylate terpolymers

⁶⁾Sika Viscocrete 125P, polycarboxylate ethers, Sika, Germany

⁷⁾Cem-Fil, type 70/30, glass fiber, 3mm length, 20 μm diameter, Owens Corning Composite Materials LLC, USA

⁸⁾Calcium formate and aluminum sulfate

⁹⁾Optibent 602, layered silicate, Byk-Chemie GmbH, Germany

^#)1:1 mixtures of Optibent 602 and Optibent NT10, layered silicates, Byk-Chemie GmbH, Germany

¹⁰⁾Defoaming agents, rheology modifiers, thixotropic agents

The binder composition C1-C7 has been mixed with water (weight ratio of water to total weight of dry mortar composition ═ 0.32-0.37) to obtain a processable composition.

Tests of the adhesive composition according to EN 12004-1/2:2017 show that properties according to the standards C1E S2 and C2E S2 can be achieved.

Internal tests similar to ISO 10140-3:2010 and ISO 717-2 show that with covered patches, impact noise reductions Δ Lw of about up to 10dB can be achieved using the adhesive composition (not combined with the mortar composition).

3.Floor structure with paster

The first flooring structure was prepared as follows: a substrate in the form of a concrete slab (according to EN10140-3) was covered with a first layer of mortar composition M1 (as described in table 1 above) to a thickness of 10 mm. Subsequently, the first layer was covered with a second layer of adhesive composition C3 (as described in table 2 above) to a thickness of 4 mm. On top of the second layer, tiles of dimensions 30cm x 60cm were placed.

For comparative reasons, a second floor structure was prepared similar to the first floor structure. However, instead of the first layer mortar composition M1, a conventional asphalt composition was used as the first layer.

Tests according to ISO 10140-3:2010 and ISO 717-2 show a 15dB reduction in impact noise Δ Lw for the first floor structure, while the impact noise reduction for the second structure is Δ Lw 6 dB.

When comparing the noise reduction data of the adhesive and the floor structure, it is clear that the mortar composition of the invention functionally interacts with the adhesive composition such that a high level of noise reduction can be achieved (note that the sound level in decibels is logarithmic and therefore cannot be used for calculation without first being converted back to a linear scale).

Thus, it will be appreciated by those skilled in the art that the invention can be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restrictive.