1-Title of Invention: Mica Paint Coating

2- The Technical Field of the Invention

The use of Colored Micas (Coated Mica) with the help of water-based resins as a granite wall covers for the facade of the building, or to use the Colored Mica with the help of the epoxy and polyurethane resins as granite floor for the surfaces of the structures in private, public, and industrial structures etc. is very practical.

3- The technical problem and the purpose of the invention

The granite rocks in the market, especially in large dimensions, are very expensive, which also cause heavyweight and impose dead load to the building. Over a period of time they will be separated from the facade of the building due to the heavy weight and the lack of good adhesion, and after a while, they must be screwed in the facade of the building. Even in rocks that used for floor, the presence of seams and joints between the rocks will lead to water penetration under the rocks. These rocks also damaged due to the use of strong detergents and acids. In the other hand, the low thickness of the available colored facade of the building and the use of organic powder will lead whether to the faded of the colors or drops from the facade of the building and in most cases, the cracks are moved over time to the building's facade.

Pulpex granite coatings are kind of coatings which are made of mineral mints (It is similar to the fish loaf coated with resistant colors like Polyurethane) and acrylic resins, which the result of splashing them on the surfaces leads to soft cement level, a beautiful view and low-density granite look, high resistance to acrylic colors, washable and integrated surface without any kind of seam. Using epoxy and polyurethane varnishes and colors in the Pulpex granite flooring covers, and by applying Mica in the middle layers, in addition to the beauty and variety of colors and the similarity of expensive stones, it results in the integrated and seamless work surface and insulates the surface for 100%. It also provides the ability to be washable with all detergents, and it is perfectly hygienic. Due to the use of the coated Mica with the resistant colors, the surface is more resistant, beautiful and fireproof in comparison with the Epoxy floor coatings in the market.

Except the glossy appearance of the epoxy colors and varnishes, they have also a higher adhesion and friction than the stone.

4- Task description of prior technical knowledge

Over the past years, epoxy and polyurethane coating have been used in all industrial and household places in Europe and the United States. This industry has recently entered Iran, and used in industrial structures as an epoxy industrial coating while used in personal and residential structures as decorative coating (three-dimensional, marbled and a simple color, etc.)· Since people are more interested in the designs and colors of natural stones, and given the fact that these colored coating covers the floors seamlessly, and it does not have the beauty and resistance of the stone, and considering that these stones are very expensive in large dimensions, then these colorful coating replace stones, tiles and ceramics. In addition to the beautiful view of these Pulpex coating, the resistance of them is multiplied due to the use of mineral Mica, which is coated with polyurethane colors, and Also, the inflammation of the coating will be very low, because Mica is the most resistant stone to fire and heat, for this reason, to control large fire, there is a lot of use of this flooring in oil companies. In Iran, the facade of buildings has always been made of stones. The rocks are very heavy and dangerous due to their weight, and impose dead loads to the building which are very dangerous in natural disasters such as earthquakes, but, Pulpex granite coatings, in addition to their beauty which is similar to the expensive stones, impose a very little weight on the building, and by using the acrylic resins which are the strongest water- based resins, the adhesion of the Mica grains is further enhanced, where Mica grains placed together in different colors, like beautiful, eye-catching granite and eliminate the technical problems of the stones as well as acrylic colors, which they are light but very weak with no resistance.

5- Problem solving and detailed description of the invention

Pulpex coating application instruction:

A- The best foundation for applying various types of polymer flooring is butterfly cement, but in case of applying Pulpex with grinding, it could be applied to all kind of surfaces (tile, stone, ceramics, concrete, iron, etc.). By grinding, the glaze layer of the tile will remove and the body of the tile will appear, which will applied off the surface, by using a roller and a king of primer which is available in market.

B- Middle layer

After applying the primer and after about 24 hours, the special color of the epoxy coating will apply on the surface by a spatula and all seams will be sealed. After each step, 24 hours is needed for drying. If, after the first step of the middle layer, the seams are still visible, this step should be repeated between 2 and 3 times till the surface get integrated and seamless.

C- Coated layer

In this step, a suitable roller will use for applying Mica color on the surface, and at the same time, the coated Micas will splash on the surface of the color. After splashing the proper amount of Micas on the surface of the color, a heavy metal roller will be pulled up on the Micas until all Micas stick completely to the color.

D- Final Layer

After 24 hours of waiting for the color to dry, the extra Mica of the surface is swept away. In this step, a suitable roller or a spatula used to apply Epoxy varnish for coatings in covers and dark areas and for the open places which are exposed to the sunlight, due to its highly resistant to UV ray of the Sun. In this step the surface is rough and is suitable to be used in crowded parking and public places. A 2 or 3 mm layer could apply by customer's request, which turned the surface of the coating to a glassy, clear and polished surface.

The production of colored Mica coating.

a- Mica is composed of silicate minerals\. The process for separation Silica from Mica perform by using wind turbines or by Mica grinding.

b- Mica (like the fish loaf) after separation of Silica will be in different sizes of crushed small rocks (1 to 2 mm and 3 to 5 mm) c- A similar mixer to the concrete mixer will use for Micas. The mixer will charge with material, with the ration of 20 kg of Mica, 4 kg of polyurethane color, 2 liters of thinner must be added to the Micas which are mixing inside the mixer, then the color must be added to this material and after 1 hour of mixing at 25 C, the Mica will completely color.

d- The colored Mica will place in a Furnace at 80 C for 4 hours e- To separate the sticky dried Micas, we will sieve them in sieve lacing of 5 mm, therefore, Micas in various colors will be ready to be used in different coatings or building facade.

- A clear and precise expression of the benefits of the invention

A- Coated Micas with polyurethane color in Pulpex coatings

1- The surface is completely integrated, seamless, and fully-insulated and water proof.

2- Its beauty is similar to the expensive stones with high variety.

3- Compared with ordinary epoxy floorings in the market, it has a very high mechanical strength due to the presence of Mica grains.

4- Antibacterial

5- Easy to clean with all detergents.

6- The capability of being applied with anti UV coatings, for structures exposed to the sunlight which increase the color and flooring resistance.

7- Easy restoration.

8- Very low weight.

9- Suitable price.

10- They can be applied at high speed, with no degradation and environmental pollution.

B- Pulpex coatings

1- High speed of application.

2- It is similar to the granite stones with much high variety.

3- Anti-UV and color resistance due to the use of polyurethane colors for coating the Mica.

4- Washable and waterproof (only 5% water absorption)

5- High elasticity and prevent cracking by covering the cracks which are under the surface.

6- Low weight (about one-fifteenth of the weight of a stone per square meter)

C- Coated Micas with polyurethane color in building facade covers

1- Great similarity to the expensive stones with a variety beyond the colors of the stones.

2- The low weight of the Mica (per meter with resin is about one and a half kg).

3- High speed of application (one hundred meters per day).

4- Washable and waterproof.

5- In addition to the high resistance, using Mica covers the imperfections .

6- Resistance to sunlight due to the use of polyurethane color for coating the Mica. -Description of one Execution Methods: An execution method for applying the Pulpex coatings has been described in section 5 of the invention described in three parts a, b, and c.

Using a pistol with 6 to 8 mm holes is the best option for Mica grading in Pulpex wall covering. Kenitex splash pistol is very popular in the market, which splashes the Mica on the cement or fine cement after being diluted by the wind compressor. Removing the spots will be the second step.

8. The industrial application of the invention

Using coated Micas with resins is applicable for all kind of structures. The application variety depends on the changes of the resins, which means that Mica is the fixed product which will be created with different percentages and hundred variety of colors. The changes in the resins depend on the application of the Mica. Acrylic resins are used for Micas which applied on the wall, which is cheaper and easy to splash. Polyurethane resins and colors are used to make more adhesion in Micas which use in metal, polycarbonates, and polyester structures, which create a very beautiful glassy surface stone by using Polyurethane or epoxy varnish, and it will be applicable to use in metal structures such as ships, air crafts, and trains and so on. Using this product also is very applicable in urban structures (Parking, parks, houses, niches, etc...), which in addition to the beauty and variety of colors and the similarity of expensive stones, the resistance of the color and the coating is multiplied due to the use of mineral Mica.