Non-explosive anti-static self-leveling mortar and preparation method thereof

Abstract

The application discloses a non-ignition anti-static self-leveling mortar, and relates to the field of building floor materials. The self-leveling mortar comprises 30-40 parts of non-ignition anti-static inorganic cementing material, 0.5-1.5 parts of anti-static organic cementing material, 10-13 parts of anti-static composite material, 48.2-57.7 parts of non-ignition anti-static aggregate, 0.3-0.8 parts of water reducing agent and 1.5-2.5 parts of non-ignition anti-static additive. The anti-static organic cementing material is VAE glue powder particles modified by aluminum ions and acrylic acid. The non-ignition anti-static additive comprises ethoxylated tertiary alkyl amine and modified conductive polymer. By adding the anti-static organic cementing material and the non-ignition anti-static inorganic cementing material, the flexibility and impact resistance of the self-leveling mortar are improved. Meanwhile, the anti-static organic cementing material is obtained by modifying VAE emulsion by aluminum hydroxide and acrylate emulsion, and the non-ignition anti-static additive comprises modified ethoxylated tertiary alkyl amine and modified conductive polymer, so that the anti-static performance and waterproof performance of the self-leveling mortar are significantly improved.

Description

Technical Field

[0001] This invention relates to the field of building flooring materials, and in particular to a non-sparking, anti-static self-leveling mortar and its preparation method. Background Technology

[0002] Self-leveling mortar refers to mortar that exhibits good flowability within a certain timeframe. With manual assistance, self-leveling mortar can quickly spread and automatically level, achieving a high-flatness base surface. It is an important flooring material for modern building construction and has significant market potential.

[0003] Sparking occurs primarily when hard objects collide or rub against each other. Less energy is lost, and the remaining energy instantly accumulates in a localized particle, causing a sudden increase in the particle's energy and resulting in high-temperature luminescence. Electrostatic discharge produces sparks mainly when objects with different electrostatic potentials approach each other. The high voltage breaks down the air, causing ionization of air molecules and creating an electric arc. If the arc's energy reaches a certain level, it produces an electric spark. Electrostatic discharge has caused numerous serious accidents both domestically and internationally, resulting in severe personal injury and property damage. Existing non-sparking antistatic mortar materials can discharge static electricity carried by the human body to the ground, providing antistatic and non-sparking effects. However, their antistatic properties are either unstable or their impact resistance is poor. Therefore, developing a self-leveling mortar with good antistatic and impact resistance properties is of great significance. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a non-sparking antistatic self-leveling mortar and its preparation method. By adding antistatic organic binders and non-sparking antistatic inorganic binders, the flexibility and impact resistance of the self-leveling mortar are improved. The antistatic organic binder is obtained by modifying VAE emulsion with aluminum hydroxide and acrylate emulsions. The non-sparking antistatic additives include modified ethoxylated tert-alkylamines and modified conductive polymers. Their addition significantly enhances the antistatic and waterproof properties of the self-leveling mortar. This is achieved through the following techniques:

[0005] In a first aspect, the present invention provides a non-sparking antistatic self-leveling mortar, comprising, by weight parts: 30-40 parts of non-sparking antistatic inorganic binder, 0.5-1.5 parts of antistatic organic binder, 10-13 parts of antistatic composite material, 48.2-57.7 parts of non-sparking antistatic aggregate, 0.3-0.8 parts of water-reducing agent, and 1.5-2.5 parts of non-sparking antistatic additive;

[0006] The antistatic organic binder material is obtained by modifying VAE emulsion with aluminum hydroxide and acrylate emulsion;

[0007] The non-sparking antistatic additive includes modified ethoxylated tertiary alkylamine and modified conductive polymer; the modified ethoxylated tertiary alkylamine is obtained by mixing sodium methylsilicate, aluminum sulfate, triisopropanolamine, acrylate emulsion, and ethoxylated tertiary alkylamine, and then adding a silane coupling agent and mixing; the preparation method of the modified conductive polymer includes the following steps: soaking polypyrrole and polyaniline in a 20% sodium hydroxide solution for 30 min, adding methyltriethoxysilane to the solution system, stirring and reacting for 2-2.5 h, and drying at 50-55 °C.

[0008] In the above-mentioned modified ethoxylated tertiary alkylamine, the addition of triisopropanolamine can reduce the surface tension of the liquid phase and enhance the permeability of the ethoxylated tertiary alkylamine; the added aluminum sulfate can release aluminum ions after dissolving, and undergo complexation and cation exchange reactions with the acrylate emulsion to form a cationic complex acrylate emulsion. Then, a silane coupling agent is added to crosslink sodium methylsilicate, the cationic complex acrylate emulsion, and the ethoxylated tertiary alkylamine. The resulting modified ethoxylated tertiary alkylamine has high hydrophobic and waterproof properties as well as electrical conductivity.

[0009] In the above-mentioned modified conductive polymers, sodium hydroxide is used to cover polypyrrole and polyaniline, which facilitates the formation of a hydrophobic silica-based polymer film on the surface of polypyrrole and polyaniline by methyltriethoxysilane. This not only improves the conductivity but also enhances the waterproof performance of concrete through the hydrophobic effect.

[0010] Furthermore, by mass fraction, the above-mentioned modified ethoxylated tertiary alkylamine is prepared by mixing 15-18% sodium methylsilicate, 5-7% aluminum sulfate, 3-4% triisopropanolamine, 30-32% acrylate emulsion, and 42-45% ethoxylated tertiary alkylamine, and then adding 1-2% silane coupling agent and mixing.

[0011] Furthermore, the preparation method of the above-mentioned antistatic organic binder material includes the following steps: by mass fraction, 3-5% aluminum hydroxide, 30-32% acrylate emulsion, and 64-66% VAE emulsion are stirred and dispersed at 2000 r / min, and then vacuum spray granulated.

[0012] In the aforementioned antistatic organic adhesive materials, VAE emulsion and acrylate emulsion exhibit weak acidity. Upon addition of aluminum hydroxide, they rapidly dissolve and dissociate to release aluminum ions. VAE emulsion and acrylate emulsion are polymerized into VAE acrylate polymer emulsion. The VAE acrylate polymer emulsion copolymerizes and complexes with aluminum ions, giving the polymer emulsion a metallic cation charge, thereby significantly enhancing the conductivity of the antistatic organic adhesive material.

[0013] Furthermore, in the above-mentioned non-sparking antistatic additives, the mass ratio of modified ethoxylated tertiary alkylamine to modified conductive polymer is (5-6):4.

[0014] Furthermore, in the above modified conductive polymer, the mass ratio of polypyrrole to polyaniline is 1:(2-3).

[0015] Furthermore, in the above-mentioned modified conductive polymer, methyltriethoxysilane accounts for 10-15% of the mass fraction of the solution system.

[0016] Furthermore, by mass fraction, the aforementioned non-sparking, antistatic inorganic binder is prepared by ball milling and mixing 40–43% cement, 5–6% high-alumina cement, 20–22% magnesium oxide, 25–30% silica fume, 2–5% metakaolin, and 0.05–0.07% triisopropanolamine. Adding high-alumina cement and magnesium oxide to cement can significantly improve the non-sparking properties of cement as an inorganic binder.

[0017] Furthermore, by mass fraction, the aforementioned antistatic composite material comprises: 44–48% basalt fiber, 10–12% carbon fiber, 4–8% graphite powder, and 35–40% nano-graphite flakes. Among these, basalt fiber possesses extremely high elastic modulus, while carbon fiber and graphite powder exhibit excellent electrical conductivity. The simultaneous use of basalt fiber, carbon fiber, and graphite powder fibers provides good physical crack resistance and toughening effects.

[0018] Furthermore, by mass fraction, the aforementioned water-reducing agent comprises: 60–62% polycarboxylate high-performance water-reducing mother liquor, 38–40% polycarboxylate high-performance slump-retaining mother liquor, and 0.08% air-entraining agent. Using this water-reducing agent enables self-leveling mortar to possess high fluidity and excellent workability, with virtually no loss of fluidity after 40 minutes.

[0019] Furthermore, the aforementioned non-sparking antistatic aggregate is made by mixing dolomite sand and calcium carbonate in a mass ratio of (4-5):1.

[0020] A second aspect of the present invention provides a method for preparing the above-mentioned non-sparking antistatic self-leveling mortar, comprising the steps of: mixing non-sparking antistatic inorganic binder, antistatic organic binder, antistatic composite material, non-sparking antistatic aggregate, water-reducing agent, and non-sparking antistatic additive according to the mass proportions of each raw material to obtain a mixture, and adding water to the mixture and mixing.

[0021] Furthermore, the water constitutes 28-30% of the mass fraction of the mixture.

[0022] Compared with the prior art, the advantages of the present invention are:

[0023] 1. The non-sparking antistatic self-leveling mortar provided by the present invention significantly improves the impact resistance of the self-leveling mortar by simultaneously using non-sparking antistatic inorganic binder and antistatic organic binder. At the same time, the antistatic organic binder is aluminum ion acrylic acid modified VAE adhesive powder particles, which significantly improves the conductivity of the self-leveling mortar after being added.

[0024] 2. By modifying the non-sparking antistatic additives, such as ethoxylated tertiary alkylamines, polyaniline, and polypyrrole, the electrical conductivity and waterproofing properties of self-leveling mortar can be significantly improved. Detailed Implementation

[0025] The technical solution of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] In the following examples and comparative examples, unless otherwise specified, the non-sparking antistatic self-leveling mortar provided by the present invention is prepared by ball milling and mixing 40-43% cement, 5-6% high-alumina cement, 20-22% magnesium oxide, 25-30% silica fume, 2-5% metakaolin, and 0.05-0.07% triisopropanolamine.

[0027] The method for preparing the antistatic organic binder material is as follows: by mass fraction, 3-5% aluminum hydroxide, 30-32% acrylate emulsion, and 64-66% VAE emulsion are stirred and dispersed at 2000 r / min for 50-60 min, and then vacuum spray granulated.

[0028] The modified ethoxylated tertiary alkylamine is prepared by stirring and mixing 15-18% sodium silicate, 5-7% aluminum sulfate, 3-4% triisopropanolamine, 30-32% acrylate emulsion, and 42-5% ethoxylated tertiary alkylamine for 20-25 minutes, and then adding 1-2% silane coupling agent and mixing thoroughly.

[0029] The modified conductive polymer is prepared by soaking polypyrrole and polyaniline in a 20% sodium hydroxide solution for 30 minutes, adding methyltriethoxysilane to the solution system (methyltriethoxysilane accounting for 10-15% of the solution system by mass), stirring the reaction for 2-2.5 hours, and drying at 50-55°C. The mass ratio of polypyrrole to polyaniline is 1:(2-3).

[0030] Example 1

[0031] This embodiment provides a non-sparking antistatic self-leveling mortar, specifically comprising the following raw materials in parts by weight: 32 parts non-sparking antistatic inorganic binder, 1.0 part antistatic organic binder, 12 parts toughening and reinforcing fiber composite material, 52 parts non-sparking antistatic aggregate, 0.5 parts high-performance water-reducing agent, and 2.0 parts non-sparking antistatic additive.

[0032] The preparation method of the non-sparking antistatic inorganic cementitious material is as follows: by mass fraction, 43% PO425 cement, 5% high alumina cement, 20% lightly calcined magnesium oxide, 29.95% silica fume, 2% metakaolin, and 0.05% triisopropanolamine are ball-milled and stirred in a ball mill for 45 minutes.

[0033] The antistatic organic binder material is prepared by vacuum spray granulation after stirring and dispersing 5% 200-mesh aluminum hydroxide, 30% acrylate emulsion, and 65% VAE emulsion at 2000 r / min for 50 min.

[0034] The toughened and reinforced antistatic composite material is composed of 44% basalt fiber, 10% carbon fiber, 6% graphite powder, and 40% nano-graphite sheets.

[0035] The non-sparking, antistatic aggregate is composed of 10-120 mesh continuously graded dolomite sand and 200 mesh heavy calcium carbonate mixed in a mass ratio of 4:1.

[0036] The preparation method of the high-performance water-reducing agent is as follows: 60% polycarboxylate high-performance water-reducing mother liquor, 39.92% polycarboxylate high-performance slump-preserving mother liquor, and 0.08% AE80 air-entraining agent are stirred evenly according to the mass fraction.

[0037] The non-sparking antistatic additive, by mass fraction, consists of 58% modified ethoxylated tertiary alkylamine and 42% modified conductive polymer. The modified ethoxylated tertiary alkylamine is prepared as follows: 15% sodium methylsilicate, 5% aluminum sulfate, 3% triisopropanolamine, 32% acrylate emulsion, and 44% ethoxylated tertiary alkylamine are stirred thoroughly for 20 minutes, then 1% silane coupling agent is added, and stirring continues for 40 minutes to obtain the modified ethoxylated tertiary alkylamine. The modified conductive polymer is prepared as follows: polypyrrole and polyaniline (mass ratio of polypyrrole to polyaniline is 1:2.3) are soaked in a 20% sodium hydroxide solution for 30 minutes. Methyltriethoxysilane, accounting for 10% of the mass fraction of the solution, is added to the solution system, and the mixture is stirred thoroughly for 2 hours. The mixture is then dried at 50°C to obtain modified polypyrrole and polyaniline particles.

[0038] Example 2

[0039] The non-sparking antistatic self-leveling mortar provided in this embodiment specifically includes the following raw materials in parts by weight: 30 parts of non-sparking antistatic inorganic binder, 0.5 parts of antistatic organic binder, 10 parts of toughening and reinforcing fiber composite material, 57.7 parts of non-sparking antistatic aggregate, 0.3 parts of high-performance water-reducing agent, and 1.5 parts of non-sparking antistatic additive.

[0040] The preparation methods for each raw material of the non-sparking anti-static self-leveling mortar are the same as in Example 1.

[0041] Example 3

[0042] The non-sparking antistatic self-leveling mortar provided in this embodiment specifically includes the following raw materials in parts by weight: 34 parts of non-sparking antistatic inorganic binder, 1.5 parts of antistatic organic binder, 13 parts of toughening and reinforcing fiber composite material, 48.2 parts of non-sparking antistatic aggregate, 0.8 parts of high-performance water-reducing agent, and 2.5 parts of non-sparking antistatic additive.

[0043] The preparation methods for each raw material of the non-sparking anti-static self-leveling mortar are the same as in Example 1.

[0044] Comparative Example 1

[0045] The non-sparking antistatic self-leveling mortar provided in this comparative example has the same raw materials and preparation method as that in Example 1, except that the antistatic organic binder is replaced by an equal amount of unmodified VAE emulsion.

[0046] Comparative Example 2

[0047] This comparative example provides a non-sparking antistatic self-leveling mortar, whose raw materials and preparation method are basically the same as those in Example 1, except that the non-sparking antistatic additives are replaced with equal amounts of unmodified ethoxylated tertiary alkylamine, polypyrrole and polyaniline particles.

[0048] Comparative Example 3

[0049] This comparative example provides a non-sparking, anti-static self-leveling mortar, whose raw materials and preparation method are basically the same as those in Example 1. The difference is that the high-alumina cement and lightly calcined magnesium oxide in the non-sparking, anti-static inorganic binder are replaced by an equal amount of ordinary silicate PO425 cement.

[0050] Comparative Example 4

[0051] This comparative example provides a non-sparking, anti-static self-leveling mortar, whose raw materials and preparation method are basically the same as those in Example 1, except that the anti-static organic binder is replaced by an equal amount of styrene-acrylic emulsion.

[0052] The non-sparking anti-static self-leveling mortars prepared in Examples 1-3 and Comparative Examples 1-4 were subjected to performance tests according to relevant standards. The test results are shown in Table 1 below.

[0053] Table 1. Performance Test Results of Non-Sparking Antistatic Self-Leveling Mortar

[0054]

[0055]

[0056] As can be seen from the table above, the non-sparking antistatic self-leveling mortar provided in this embodiment not only has excellent crack resistance and mechanical properties, but also good antistatic and waterproof properties, meeting the requirements for static dissipation type antistatic performance. Compared with Example 1, Comparative Example 1 uses ordinary VAE emulsion, Comparative Example 2 uses unmodified non-sparking antistatic additives composed of ethoxylated tert-alkylamine, polypyrrole, and polyaniline particles, and Comparative Example 4 uses styrene-acrylic emulsion, all of which affect the antistatic performance of the non-sparking antistatic self-leveling mortar. The waterproof performance of the self-leveling mortar in Comparative Example 2 is also significantly reduced. The non-sparking antistatic inorganic binder in Comparative Example 3 does not contain high-alumina cement or lightly calcined magnesium oxide, which affects the impact resistance and non-sparking properties of the self-leveling mortar.

[0057] The above detailed embodiments describe the implementation of the present invention; however, the present invention is not limited to the specific details described in the above embodiments. Within the scope of the claims and technical concept of the present invention, various simple modifications and changes can be made to the technical solution of the present invention, and these simple modifications all fall within the protection scope of the present invention.

Claims

1. A non-sparking, anti-static self-leveling mortar, characterized in that, By weight, it includes: 30-40 parts of non-sparking antistatic inorganic binder, 0.5-1.5 parts of antistatic organic binder, 10-13 parts of antistatic composite material, 48.2-57.7 parts of non-sparking antistatic aggregate, 0.3-0.8 parts of water-reducing agent, and 1.5-2.5 parts of non-sparking antistatic additive; The non-sparking, antistatic inorganic binder is prepared by ball milling and stirring 40-43% ordinary silicate cement, 5-6% high-alumina cement, 20-22% magnesium oxide, 25-30% silica fume, 2-5% metakaolin, and 0.05-0.07% triisopropanolamine. The antistatic organic binder material is obtained by modifying VAE emulsion with aluminum hydroxide and acrylate emulsion; The antistatic composite material comprises: 44-48% basalt fiber, 10-12% carbon fiber, 4-8% graphite powder, and 35-40% nano-graphite flakes. The non-sparking antistatic additive includes modified ethoxylated tertiary alkylamine and modified conductive polymer; the modified ethoxylated tertiary alkylamine is obtained by mixing sodium methylsilicate, aluminum sulfate, triisopropanolamine, acrylate emulsion, and ethoxylated tertiary alkylamine, and then adding a silane coupling agent and mixing; the preparation method of the modified conductive polymer includes the following steps: soaking polypyrrole and polyaniline in sodium hydroxide solution, adding methyltriethoxysilane to the solution system, stirring the reaction, and drying.

2. The non-sparking, anti-static self-leveling mortar according to claim 1, characterized in that, The preparation method of the antistatic organic binder material includes the following steps: by mass fraction, 3-5% aluminum hydroxide, 30-32% acrylate emulsion, and 64-66% VAE emulsion are stirred and dispersed, and then granulated by vacuum spraying.

3. The non-sparking, anti-static self-leveling mortar according to claim 1, characterized in that, In the non-sparking antistatic additive, the mass ratio of the modified ethoxylated tertiary alkylamine to the modified conductive polymer is (5~6):

4.

4. The non-sparking, anti-static self-leveling mortar according to claim 1, characterized in that, In the modified conductive polymer, the mass ratio of polypyrrole to polyaniline is 1:(2~3).

5. The non-sparking, anti-static self-leveling mortar according to claim 1, characterized in that, The water-reducing agent comprises, by mass fraction: 60% polycarboxylate high-performance water-reducing mother liquor, 39.92% polycarboxylate high-performance slump-retaining mother liquor, and 0.08% air-entraining agent.

6. The non-sparking, anti-static self-leveling mortar according to claim 1, characterized in that, The non-sparking, antistatic aggregate is made by mixing dolomite and calcium carbonate in a mass ratio of (4~5):

1.

7. The method for preparing the non-sparking, anti-static self-leveling mortar according to any one of claims 1 to 6, characterized in that, The steps include: mixing non-sparking antistatic inorganic binder, antistatic organic binder, antistatic composite material, non-sparking antistatic aggregate, water-reducing agent, and non-sparking antistatic additive according to the mass proportions of each raw material to obtain a mixture; adding water to the mixture and mixing well to obtain the non-sparking antistatic self-leveling mortar.

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