Integral waterborne epoxy asphalt waterproofing coating and preparation method thereof

Abstract

This disclosure discloses an integrated waterborne epoxy asphalt waterproof coating, comprising: a blend of anionic emulsified asphalt, a waterborne phenolic resin epoxy emulsion, and an epoxy curing agent. The anionic emulsified asphalt is a waterborne emulsified asphalt obtained by emulsifying with an anionic emulsifier soap solution, which is obtained by saponifying an aqueous solution of anionic emulsifier with sodium hydroxide. The waterborne phenolic resin epoxy emulsion is an emulsion of phenolic epoxy resin grafted with polyetheramine, and the epoxy curing agent is butylated phenyl melamine-formaldehyde resin.

Description

Technical Field

[0001] This disclosure relates to the field of waterproof materials technology, specifically to an integrated water-based epoxy asphalt waterproof coating and its preparation method. Background Technology

[0002] Water-based asphalt waterproof coating is a new type of environmentally friendly coating made primarily from water-based asphalt, with the addition of various additives and fillers. It does not harden after prolonged contact with air, maintaining its gel-like properties and exhibiting strong self-healing ability and good adhesion. Therefore, it is widely used in waterproofing applications in construction, bridges, tunnels, and underground engineering.

[0003] With increasing environmental awareness, the market demand for water-based asphalt-based waterproof coatings is gradually increasing. Currently, water-based asphalt-based waterproof coatings have developed into an environmentally friendly, safe, and efficient waterproofing material. However, compared to traditional asphalt waterproof coatings, the waterproofing effect and durability of water-based asphalt-based waterproof coatings may be slightly inferior. Specifically, as a water-based waterproof coating, its film-forming substance molecular structure contains a large number of hydrophilic groups, resulting in high water absorption. This makes it prone to swelling and wrinkling under long-term immersion in water, affecting its waterproofing effect.

[0004] Oil-based reactive waterproof coatings are based on oil-based substances (such as solvent-based resins and oils) and cure through a chemical reaction to form a waterproof layer. These coatings typically contain two or more components that react chemically after mixing to create a waterproof coating. Due to their excellent waterproof performance and weather resistance, they can be used in waterproofing and repair projects in environments with long-term immersion, such as reservoirs, basements, and roofs, and are widely used in waterproofing applications for buildings, bridges, and tunnels. However, from the perspective of a two-component system, oil-based reactive waterproof coatings have drawbacks such as higher application difficulty, longer curing time, release of harmful substances, and higher cost.

[0005] Therefore, optimizing coating formulations and construction processes to improve the waterproof performance of coatings is the future development direction. Summary of the Invention

[0006] In view of this, to solve at least one technical problem in related technologies and other aspects, this disclosure proposes an integrated waterborne epoxy asphalt waterproof coating, comprising: a blend of anionic emulsified asphalt, a waterborne phenolic resin epoxy emulsion, and an epoxy curing agent. The anionic emulsified asphalt is a waterborne emulsified asphalt obtained by emulsifying with anionic emulsifier soap solution, the anionic emulsifier soap solution is obtained by saponifying an aqueous solution of anionic emulsifier with sodium hydroxide, the waterborne phenolic resin epoxy emulsion is an emulsion of phenolic epoxy resin grafted with polyetheramine, and the epoxy curing agent is butyl ether phenyl melamine-formaldehyde resin.

[0007] According to embodiments of this disclosure, the aforementioned waterborne epoxy asphalt waterproof coating further includes a curing catalyst and a dispersant. The curing catalyst is divinylbenzene crosslinked sulfonated polystyrene, and the dispersant is sodium acrylate dispersant.

[0008] According to embodiments of this disclosure, the aforementioned waterborne epoxy asphalt waterproof coating further includes: toughening latex, diluent, and other additives. These other additives include stabilizers, thickeners, defoamers, film-forming aids, wetting agents, pH adjusters, and inorganic pigments.

[0009] According to embodiments of this disclosure, based on a total weight of 100 parts by weight of all components, the composition includes: 10-30 parts by weight of asphalt, 10-20 parts by weight of water, 0.1-0.5 parts by weight of sodium hydroxide, 0.5-2.5 parts by weight of anionic emulsifier, 20-30 parts by weight of aqueous phenolic resin epoxy emulsion, 5-20 parts by weight of epoxy curing agent, 2.5-10 parts by weight of curing catalyst, 5-10 parts by weight of toughening latex, 1-10 parts by weight of diluent, 0.1-0.5 parts by weight of dispersant, and 2-15.5 parts by weight of other additives. Other additives include 0.1-0.5 parts by weight of stabilizer, 0.5-2 parts by weight of thickener, 0.1-0.5 parts by weight of defoamer, 0.1-1 parts by weight of film-forming aid, 0.1-0.5 parts by weight of wetting agent, 0.1-1 parts by weight of pH adjuster, and 1-10 parts by weight of inorganic pigment.

[0010] According to embodiments of this disclosure, the asphalt is 70# Grade A petroleum asphalt; the anionic emulsifier includes at least one of sodium dodecyl sulfonate, sodium dodecyl sulfate, sodium dodecylbenzene sulfonate, and sodium dodecyl polyoxyethylene ether sulfate; the defoamer is an organosilicon defoamer based on polydimethylsiloxane; the stabilizer is hydroxyethyl cellulose; the diluent includes one of butyl acetate, acetone, and isopropanol; the toughening latex is styrene-butadiene latex; the thickener is a hydrophobically modified alkali-soluble emulsion type thickener; the pH adjuster is a pH adjuster amine neutralizer; the film-forming aid is 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate; the wetting agent is a polyether wetting agent; and the inorganic pigment is one of carbon black or titanium dioxide.

[0011] According to embodiments of this disclosure, the divinylbenzene crosslinked sulfonated polystyrene is 400 mesh.

[0012] According to embodiments of this disclosure, the water-based asphalt epoxy waterproof coating has a water absorption rate of less than 2% after curing.

[0013] In another aspect of this disclosure, a method for preparing a signed waterborne bitumen epoxy waterproof coating is also provided, comprising:

[0014] Anionic emulsifier and stabilizer are dispersed in water, and then sodium hydroxide is added to adjust the pH to obtain soap solution;

[0015] Asphalt is heated and melted, and then soap solution is added for emulsification and dispersion to obtain anionic emulsified asphalt;

[0016] The aforementioned integrated waterborne asphalt epoxy waterproof coating is obtained by uniformly dispersing anionic emulsified asphalt, dispersant, film-forming aid, wetting agent, pH adjuster, waterborne phenolic epoxy resin emulsion, curing catalyst, curing agent, toughening latex, inorganic pigments and fillers, defoamer, and thickener.

[0017] According to embodiments of this disclosure, the pH of the soap solution is 10-12.

[0018] According to embodiments of this disclosure, the curing agent is obtained by diluting butylated phenyl melamine formaldehyde resin with a diluent at a ratio of 2:1.

[0019] According to embodiments of this disclosure, a waterborne epoxy asphalt waterproof coating with integrated storage of all components is proposed. Phenolic epoxy resin is used to modify the waterborne asphalt-based coating. After curing, the numerous benzene rings in the phenolic resin and the epoxy groups in the epoxy resin form a dual hydrophobic group. Simultaneously, the highly cross-linked structure formed during curing solves the problem of poor water resistance in traditional waterborne asphalt-based waterproof coatings. Unlike traditional two-component oil-based epoxy resin waterproof coatings, the waterborne epoxy asphalt waterproof coating proposed in this disclosure uses butylated ether phenyl melamine-formaldehyde resin, which requires specific conditions to undergo a curing reaction, as the epoxy curing agent, forming an integrated waterborne coating system. This waterborne epoxy asphalt waterproof coating can be stably stored as a single unit, is easy to apply, safe, and environmentally friendly. It can be applied to waterproofing and repair projects in long-term immersion environments, such as reservoirs, basements, and roofs. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this disclosure clearer, the following detailed description is provided in conjunction with specific embodiments.

[0021] The endpoints and any values ​​of the ranges disclosed in this disclosure are not limited to the precise ranges or values, and such ranges or values ​​should be understood to include values ​​close to such ranges or values. For numerical ranges, the endpoint values ​​of the various ranges, the endpoint values ​​of the various ranges and individual point values, and individual point values ​​can be combined with each other to obtain one or more new numerical ranges, which should be regarded as specifically disclosed in this disclosure.

[0022] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit this disclosure. The terms “comprising,” “including,” etc., as used herein indicate the presence of the stated features, steps, operations, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, or components.

[0023] All terms used herein (including technical and scientific terms) have the meanings commonly understood by those skilled in the art, unless otherwise defined. It should be noted that the terms used herein are to be interpreted in a manner consistent with the context of this specification, and not in an idealized or overly rigid way.

[0024] Similarly, to simplify this disclosure and aid in understanding one or more of the various aspects of the disclosure, in the above description of exemplary embodiments of the present disclosure, various features of the present disclosure are sometimes grouped together into a single embodiment or its description. The use of terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refers to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of the present disclosure. In this specification, illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0025] Furthermore, the technical solutions of the various embodiments can be combined with each other, but only if they are based on the ability of a person skilled in the art to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed in this disclosure.

[0026] The term "monolithic" as used in this disclosure means that the components are stored together, and may also be referred to as "single-component".

[0027] The term "waterborne phenolic epoxy resin emulsion" as used in this disclosure means that phenolic epoxy resin is prepared by adding epichlorohydrin to phenolic resin under certain temperature and catalytic conditions, then grafting the phenolic epoxy resin with polyetheramine to introduce hydrophilic groups (e.g., hydroxyl groups) to achieve dispersion in aqueous solution, and finally adding a certain proportion of water and stirring at high speed to obtain waterborne phenolic epoxy emulsion.

[0028] The terms "latent curing agent" and "latent curing catalyst" as used in this disclosure mean that the addition of the agent will not immediately trigger a cross-linking curing reaction, but will only cause a curing reaction under specific conditions.

[0029] Traditional water-based asphalt-based waterproof coatings often use acrylate emulsions for modification. The monomers of acrylates introduce hydrophilic groups such as hydroxyl and carboxyl groups into the emulsion molecule structure, resulting in high water absorption and poor water resistance after film formation. Traditional oil-based waterproof coatings use epoxy resin curing agents such as amines, acid anhydrides, and polyamides. The curing agent and epoxy base cannot be mixed and stored, requiring two-component use, which increases the burden of storage and use.

[0030] In the process of this implementation, it was discovered that using waterborne phenolic resin epoxy emulsion to modify waterborne asphalt-based waterproof coatings improves water resistance. Butyl-etherified benzoyl melamine-formaldehyde resin can be used as a curing agent, utilizing its alkoxymethyl groups to undergo ether exchange and crosslinking reactions with the hydroxyl groups in the waterborne phenolic resin epoxy emulsion, thereby curing the waterborne epoxy asphalt coating. Simultaneously, due to the low reactivity of the alkoxymethyl groups, an acidic environment is required to provide hydrogen ions for curing, allowing the waterborne phenolic resin epoxy emulsion to be mixed and stored as a single unit.

[0031] This disclosure discloses an integrated waterborne epoxy asphalt waterproof coating, comprising: a blend of anionic emulsified asphalt, a waterborne phenolic resin epoxy emulsion, and an epoxy curing agent. The anionic emulsified asphalt is a waterborne emulsified asphalt obtained by emulsifying with an anionic emulsifier soap solution, which is obtained by saponifying an aqueous solution of anionic emulsifier with sodium hydroxide. The waterborne phenolic resin epoxy emulsion is an emulsion of phenolic epoxy resin grafted with polyetheramine, and the epoxy curing agent is butylated phenyl melamine-formaldehyde resin.

[0032] According to embodiments of this disclosure, a waterborne epoxy asphalt waterproof coating with integrated storage of all components is proposed. Phenolic epoxy resin is used to modify the waterborne asphalt-based coating. After curing, the numerous benzene rings in the phenolic resin and the epoxy groups in the epoxy resin form a dual hydrophobic group. Simultaneously, the highly cross-linked structure formed during curing solves the problem of poor water resistance in traditional waterborne asphalt-based waterproof coatings. Unlike traditional two-component oil-based epoxy resin waterproof coatings, the waterborne epoxy asphalt waterproof coating proposed in this disclosure uses butylated ether phenyl melamine-formaldehyde resin, which requires specific conditions to undergo a curing reaction, as the epoxy curing agent, forming an integrated waterborne coating system. This waterborne epoxy asphalt waterproof coating can be stably stored as a single unit, is easy to apply, safe, and environmentally friendly. It can be applied to waterproofing and repair projects in long-term immersion environments, such as reservoirs, basements, and roofs.

[0033] In some specific embodiments, asphalt is used as a base material for coatings, serving as a raw material for producing emulsified asphalt. Anionic emulsifiers are used to generate anionic emulsified asphalt, and sodium hydroxide is added to adjust the pH value of the emulsified asphalt, ensuring its stability and preventing stratification or segregation during use. Waterborne phenolic epoxy resin emulsion serves as the main film-forming substance in waterborne epoxy asphalt waterproof coatings, imparting high strength and water resistance. Butyl etherified melamine-formaldehyde resin, as an epoxy curing agent (latent curing agent), is pre-mixed into the coating. After dehydration and film formation, it undergoes a cross-linking curing reaction with phenolic epoxy resin under the action of a curing catalyst (latent curing catalyst), giving the coating a three-dimensional cross-linked structure, significantly increasing material strength and water resistance.

[0034] According to embodiments of this disclosure, the aforementioned waterborne epoxy asphalt waterproof coating further includes a curing catalyst (latent curing catalyst) and a dispersant. The curing catalyst is divinylbenzene crosslinked sulfonated polystyrene, and the dispersant is a sodium acrylate dispersant, such as SN5040 type dispersant.

[0035] According to embodiments of this disclosure, divinylbenzene crosslinked sulfonated polystyrene can adsorb metal cations such as calcium and magnesium ions in the solution during coating mixing, and release its own hydrogen ions to undergo a cation exchange reaction. The released hydrogen ions can catalyze the ether exchange and crosslinking reaction between the hydroxyl groups and alkoxymethyl groups in the waterborne epoxy asphalt coating, thereby causing the coating to undergo a crosslinking and curing reaction.

[0036] In some specific embodiments, this disclosure pre-incorporates divinylbenzene crosslinked sulfonated polystyrene into waterborne epoxy asphalt coatings, and adds a dispersant to make it uniformly suspended in the coating. When the coating is applied to the target substrate, calcium ions in the target substrate enter the coating solution and undergo an ion exchange reaction with the divinylbenzene crosslinked sulfonated polystyrene. The calcium ions are adsorbed and release hydrogen ions, which on the one hand accelerate the dehydration and demulsification of the coating to form a film, and on the other hand, the released hydrogen ions begin to catalyze the curing reaction of butyl ether benzoyl melamine formaldehyde resin and phenolic epoxy resin, thereby realizing the curing reaction and film formation of waterborne epoxy asphalt waterproof coating.

[0037] In some specific embodiments, divinylbenzene crosslinked sulfonated polystyrene is used as a latent curing catalyst, pre-mixed into the coating components. During the film formation process in contact with the target substrate, an ion exchange reaction occurs, providing hydrogen ions to enable the catalytic curing reaction. The dispersant ensures that the divinylbenzene crosslinked sulfonated polystyrene is fully wetted and uniformly dispersed by the liquid phase, and minimizes the separation and aggregation of the system, reducing the settling velocity of solid particles to maintain the maximum kinetic stability of the coating.

[0038] According to embodiments of this disclosure, the aforementioned waterborne epoxy asphalt waterproof coating further includes: toughening latex, diluent, and other additives. These other additives include stabilizers, thickeners, defoamers, film-forming aids, wetting agents, pH adjusters, and inorganic pigments.

[0039] In some specific embodiments, toughening latex is used to improve the low-temperature flexibility and elongation at break of the coating after film formation; diluents can dilute butyl ether benzoyl melamine formaldehyde resin for better dispersion in waterborne epoxy asphalt coatings. Among other additives, stabilizers can improve the storage stability of the anionic emulsified asphalt base material; thickeners are used to increase the viscosity of the coating system and increase the storage stability of the coating; defoamers can reduce the surface tension of the emulsion and prevent foam formation; film-forming aids can dissolve and swell polymer particles in the emulsion, allowing the particles to undergo plastic flow and elastic deformation to aggregate into a film at lower temperatures, but they can evaporate and escape within a short time after film formation without affecting the glass transition temperature of the coating, and the coating does not become tacky during the coating process at high temperatures. Wetting agents can be used to improve the surface tension and permeability of the coating to better wet the substrate and improve the adhesion of the coating to the target substrate; pH adjusters are used to adjust the pH value of the coating; inorganic pigments are used to fill the coating thickness, increase the coating's hiding power and weather resistance, and reduce costs.

[0040] According to embodiments of this disclosure, based on a total weight of 100 parts by weight of all components, the composition includes: 10-30 parts by weight of asphalt, 10-20 parts by weight of water, 0.1-0.5 parts by weight of sodium hydroxide, 0.5-2.5 parts by weight of anionic emulsifier, 20-30 parts by weight of aqueous phenolic resin epoxy emulsion, 5-20 parts by weight of epoxy curing agent, 2.5-10 parts by weight of curing catalyst, 5-10 parts by weight of toughening latex, 1-10 parts by weight of diluent, 0.1-0.5 parts by weight of dispersant, and 2-15.5 parts by weight of other additives. Other additives include 0.1-0.5 parts by weight of stabilizer, 0.5-2 parts by weight of thickener, 0.1-0.5 parts by weight of defoamer, 0.1-1 parts by weight of film-forming aid, 0.1-0.5 parts by weight of wetting agent, 0.1-1 parts by weight of pH adjuster, and 1-10 parts by weight of inorganic pigment.

[0041] According to embodiments of this disclosure, the asphalt is 70# Grade A petroleum asphalt; the anionic emulsifier includes at least one of sodium dodecyl sulfonate, sodium dodecyl sulfate, sodium dodecylbenzene sulfonate, and sodium dodecyl polyoxyethylene ether sulfate; the defoamer is an organosilicon defoamer based on polydimethylsiloxane; the stabilizer is hydroxyethyl cellulose; the diluent includes one of butyl acetate, acetone, and isopropanol; the toughening latex is styrene-butadiene latex; the thickener is a hydrophobically modified alkali-soluble emulsion type thickener; the pH adjuster is a pH adjuster amine neutralizer, such as AMP-95 type pH adjuster; the film-forming aid is 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate (alcohol ester dodecyl); the wetting agent is a polyether wetting agent, such as HW-1000 wetting agent; and the inorganic pigment is one of carbon black or titanium dioxide.

[0042] According to embodiments of this disclosure, the divinylbenzene crosslinked sulfonated polystyrene is 400 mesh.

[0043] According to embodiments of this disclosure, the water-based asphalt epoxy waterproof coating has a water absorption rate of less than 2% after curing.

[0044] According to the embodiments of this disclosure, after the water-based asphalt epoxy waterproof coating loses water and forms a film, the large number of benzene rings in the phenolic resin and the epoxy groups in the epoxy resin form a double hydrophobic structure network to resist the intrusion of water molecules. At the same time, after the coating is applied, a curing and cross-linking reaction will occur under the action of the epoxy curing agent to form a cross-linked network structure, making it difficult for water molecules to penetrate and further reducing the water absorption rate. Meanwhile, the hydrophilic hydroxyl groups disappear through a condensation reaction and generate polymers, thereby achieving high water resistance of the coating.

[0045] In another aspect of this disclosure, a method for preparing the aforementioned waterborne asphalt epoxy waterproof coating is also provided, comprising:

[0046] Anionic emulsifier and stabilizer are dispersed in water, and then sodium hydroxide is added to adjust the pH to obtain soap solution;

[0047] Asphalt is heated and melted, and then soap solution is added for emulsification and dispersion to obtain anionic emulsified asphalt;

[0048] The aforementioned integrated waterborne asphalt epoxy waterproof coating is obtained by uniformly dispersing anionic emulsified asphalt, dispersant, film-forming aid, wetting agent, pH adjuster, waterborne phenolic epoxy resin emulsion, curing catalyst, curing agent, toughening latex, inorganic pigments and fillers, defoamer, and thickener.

[0049] In some specific embodiments, the method for applying water-based asphalt epoxy waterproof coatings includes the following steps 1-3:

[0050] Step 1: Add sodium dodecyl sulfonate and Dow QP100 hydroxyethyl cellulose to water, heat to 55-65℃, stir for 10 minutes, then add sodium hydroxide to adjust the pH to 10-12, obtaining a soap solution, and store it at 45-55℃. Melt Sinopec Maoming Petrochemical 70#A asphalt to a fluid state at 125-160℃, and store the liquid asphalt at 130-160℃. Add the soap solution and liquid asphalt to an emulsifier for dispersion and emulsification. After emulsification, cool to room temperature to obtain anionic emulsified asphalt.

[0051] Step 2: Dilute the butylated phenyl melamine formaldehyde resin and diluent at a ratio of 2:1 to obtain a butylated phenyl melamine formaldehyde resin diluent.

[0052] Anionic emulsified asphalt was stirred at room temperature, and dispersant, film-forming aid, wetting agent, and pH adjuster were added. The stirring speed was controlled at 400-600 r / min, and the mixture was stirred for 5 min. Then, waterborne phenolic epoxy resin emulsion and divinylbenzene crosslinked sulfonated polystyrene were added, and the stirring speed was controlled at 400-600 r / min, and the mixture was stirred for 15 min. Butyl etherified benzoyl melamine formaldehyde resin dilution was slowly added, and the stirring speed was controlled at 300-500 r / min, and the mixture was stirred for 15 min. Then, toughening latex was added, and the stirring speed was controlled at 300-500 r / min, and the mixture was stirred for 5 min. Then, inorganic pigments were added, and the stirring speed was controlled at 400-600 r / min, and the mixture was stirred for 5 min. Then, defoamer was added, and the stirring speed was controlled at 400-600 r / min, and the mixture was stirred for 5 min. Finally, thickener was added, and the stirring speed was controlled at 800-1000 r / min, and the mixture was stirred for 15 min to obtain waterborne asphalt epoxy waterproof coating.

[0053] According to embodiments of this disclosure, the pH of the soap solution is 10-12.

[0054] According to embodiments of this disclosure, the curing agent is obtained by diluting butylated phenyl melamine formaldehyde resin with a diluent at a ratio of 2:1.

[0055] It should be noted that the described embodiments are merely some, not all, of the embodiments disclosed herein. Other embodiments obtained by those skilled in the art based on the embodiments of this disclosure without inventive effort are all within the scope of protection of this disclosure.

[0056] Example 1

[0057] In this embodiment, the formulation components and proportions of the single-component waterborne epoxy asphalt coating are as follows:

[0058] 27 parts by weight of Sinopec Maoming Petrochemical 70#A asphalt, 17 parts by weight of deionized water, 0.3 parts by weight of sodium hydroxide, 2 parts by weight of sodium dodecyl sulfonate, 22 parts by weight of BS-2155F emulsion, 9 parts by weight of BG5142 resin, 3 parts by weight of AMBERLYST-15 resin powder, 0.2 parts by weight of Dow AFE-1410, 0.4 parts by weight of Dow QP100 hydroxyethyl cellulose, 4.5 parts by weight of butyl acetate, 5 parts by weight of Haifang SBR1502 latex, 0.3 parts by weight of SN5040, 0.2 parts by weight of dodecyl alcohol ester, 0.1 parts by weight of AMP-95, 0.8 parts by weight of TT935, 0.2 parts by weight of HW-1000, and 8 parts by weight of carbon black.

[0059] Sodium dodecyl sulfonate and Dow QP100 hydroxyethyl cellulose were added to water, heated to 60°C, and stirred for 10 minutes. Sodium hydroxide was then added to adjust the pH to 10-12, yielding a soap solution, which was stored at 50°C. Sinopec Maoming Petrochemical 70#A asphalt was heated and melted to a fluid state, and the liquid asphalt was stored at 150°C. The soap solution and liquid asphalt were then fed into an emulsifier for dispersion and emulsification. After emulsification, the mixture was cooled to room temperature to obtain anionic emulsified asphalt.

[0060] The butylated phenyl melamine formaldehyde resin and diluent were diluted at a ratio of 2:1 to obtain a butylated phenyl melamine formaldehyde resin diluent.

[0061] Anionic emulsified asphalt was stirred at room temperature, and then dispersant, film-forming aid, wetting agent, and pH adjuster were added sequentially, with the stirring speed controlled at 500 r / min for 5 min. Next, waterborne phenolic epoxy resin emulsion and divinylbenzene crosslinked sulfonated polystyrene were added, with the stirring speed controlled at 500 r / min for 15 min. Then, butylated phenyl melamine-formaldehyde resin dilution was slowly added, with the stirring speed controlled at 400 r / min for 15 min. Next, toughening latex was added, with the stirring speed controlled at 400 r / min for 5 min. Next, inorganic pigments and fillers were added, with the stirring speed controlled at 500 r / min for 5 min. Next, defoamer was added, with the stirring speed controlled at 500 r / min for 5 min. Finally, thickener was added, with the stirring speed controlled at 900 r / min for 15 min, to obtain a one-component waterborne epoxy asphalt coating.

[0062] Example 2

[0063] In this embodiment, the formulation components and proportions of the single-component waterborne epoxy asphalt coating are as follows:

[0064] 25 parts by weight of Sinopec Maoming Petrochemical 70#A asphalt, 17 parts by weight of deionized water, 0.3 parts by weight of sodium hydroxide, 2.1 parts by weight of sodium dodecyl sulfonate, 24 parts by weight of BS-2155F emulsion, 9 parts by weight of BG5142 resin, 3 parts by weight of AMBERLYST-15 resin powder, 0.4 parts by weight of Dow AFE-1410, 0.2 parts by weight of Dow QP100, 4.5 parts by weight of isopropanol, 8 parts by weight of Haifang SBR1502 latex, 0.3 parts by weight of SN5040, 0.3 parts by weight of dodecyl alcohol ester, 0.1 parts by weight of AMP-95, 0.7 parts by weight of TT935, 0.1 parts by weight of HW-1000, and 5 parts by weight of carbon black.

[0065] In this Example 2, the preparation method is the same as or similar to that in Example 1, and will not be repeated here.

[0066] Example 3

[0067] In this embodiment, the formulation components and proportions of the single-component waterborne epoxy asphalt coating are as follows:

[0068] 28 parts by weight of Sinopec Maoming Petrochemical 70#A asphalt, 15 parts by weight of deionized water, 0.3 parts by weight of sodium hydroxide, 2.1 parts by weight of sodium dodecyl polyoxyethylene ether sulfate, 22 parts by weight of BS-2155F emulsion, 7 parts by weight of BG5142 resin, 5 parts by weight of AMBERLYST-15 resin powder, 0.4 parts by weight of Dow AFE-1410, 0.2 parts by weight of Dow QP100, 3.5 parts by weight of acetone, 9 parts by weight of Haifang SBR1502 latex, 0.3 parts by weight of SN5040, 0.1 parts by weight of dodecyl alcohol ester, 0.1 parts by weight of AMP-95, 0.9 parts by weight of TT935, 0.1 parts by weight of HW-1000, and 6 parts by weight of titanium dioxide.

[0069] In this Example 3, the preparation method is the same as or similar to that in Example 1, and will not be described again here.

[0070] Comparative Example 1

[0071] In this embodiment, the formulation components and proportions of the waterborne epoxy asphalt coating are as follows:

[0072] 27 parts by weight of Sinopec Qilu Petrochemical 70#A asphalt, 19 parts by weight of deionized water, 2.0 parts by weight of sodium dodecyl polyoxyethylene ether sulfate, 0.5 parts by weight of AMP-95, 40 parts by weight of Dow DC-436 styrene-acrylic emulsion, 11 parts by weight of talc, and 0.5 parts by weight of Rohm and Haas thickener RM8W.

[0073] Test case

[0074] According to JC / T864-2023 "Polymer Emulsion Waterproof Coatings for Buildings", the mechanical properties and waterproof performance indicators of the single-component waterborne epoxy bitumen waterproof coatings prepared in Examples 1-3 and the waterborne bitumen-based waterproof coating prepared in Comparative Example 1 were tested. The specific test results are shown in Table 1 below.

[0075] Table 1:

[0076]

[0077] As shown in Table 1, this disclosure presents a high water-resistant single-component waterborne epoxy bitumen waterproof coating. The water resistance of this coating is enhanced by employing phenolic-epoxy dual hydrophobic structural groups and a thermosetting crosslinked structure after film formation. Its water absorption rate is reduced to below 2%, making it suitable for waterproofing repair projects in environments requiring long-term immersion. Furthermore, compared to ordinary waterborne bitumen coatings, both tensile strength and bond strength are increased by more than 2 MPa.

[0078] The specific embodiments described above further illustrate the purpose, technical solutions, and beneficial effects of this disclosure. It should be understood that the above descriptions are merely specific embodiments of this disclosure and are not intended to limit this disclosure. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this disclosure should be included within the protection scope of this disclosure.

Claims

1. An integrated water-based epoxy asphalt waterproof coating, characterized in that, The water-based epoxy asphalt waterproof coating includes: A blend of anionic emulsified asphalt, waterborne phenolic resin epoxy emulsion, and epoxy curing agent. The anionic emulsified asphalt is an aqueous emulsified asphalt obtained by heating and melting asphalt, then adding anionic emulsifier soap solution for emulsification and dispersion. The anionic emulsifier soap solution is obtained by dispersing anionic emulsifier and stabilizer in water, then adding sodium hydroxide to adjust the pH. The aqueous phenolic resin epoxy emulsion is an emulsion of phenolic epoxy resin grafted with polyetheramine, and the epoxy curing agent is butyl ether phenyl melamine formaldehyde resin.

2. The water-based epoxy asphalt waterproof coating according to claim 1, wherein the water-based epoxy asphalt waterproof coating further comprises: Solidified catalysts and dispersants The curing catalyst is divinylbenzene crosslinked sulfonated polystyrene, and the dispersant is sodium acrylate dispersant.

3. The water-based epoxy asphalt waterproof coating according to claim 2, wherein the water-based epoxy asphalt waterproof coating further comprises: Toughening latex, diluents and other additives, The other additives include stabilizers, thickeners, defoamers, film-forming aids, wetting agents, pH adjusters, and inorganic pigments.

4. The water-based epoxy asphalt waterproof coating according to claim 3, wherein, Based on a total weight of 100 parts by weight, the product includes: 10-30 parts by weight of asphalt, 10-20 parts by weight of water, 0.1-0.5 parts by weight of sodium hydroxide, 0.5-2.5 parts by weight of anionic emulsifier, 20-30 parts by weight of waterborne phenolic resin epoxy emulsion, 5-20 parts by weight of epoxy curing agent, 2.5-10 parts by weight of curing catalyst, 5-10 parts by weight of toughening latex, 1-10 parts by weight of diluent, 0.1-0.5 parts by weight of dispersant, and 2-15.5 parts by weight of other additives. The other additives include 0.1-0.5 parts by weight of stabilizer, 0.5-2 parts by weight of thickener, 0.1-0.5 parts by weight of defoamer, 0.1-1 parts by weight of film-forming aid, 0.1-0.5 parts by weight of wetting agent, 0.1-1 parts by weight of pH adjuster, and 1-10 parts by weight of inorganic pigment.

5. The water-based epoxy asphalt waterproof coating according to claim 4, wherein, The asphalt is 70# Grade A petroleum asphalt; The anionic emulsifier includes at least one of sodium dodecyl sulfonate, sodium dodecyl sulfate, sodium dodecylbenzene sulfonate, and sodium dodecyl polyoxyethylene sulfate. The defoamer is an organosilicon defoamer with polydimethylsiloxane as the main component; The stabilizer is hydroxyethyl cellulose; The diluent includes one of butyl acetate, acetone, and isopropanol; The toughening latex is styrene-butadiene latex; The thickener is a hydrophobically modified alkali-soluble emulsion type thickener; The pH adjuster is an amine neutralizer; The film-forming aid is 2,2,4-trimethyl-1,3-pentanediol monoisobutyrate; The wetting agent is a polyether wetting agent; The inorganic pigment is either carbon black or titanium dioxide.

6. The water-based epoxy asphalt waterproof coating according to claim 2, wherein, The divinylbenzene crosslinked sulfonated polystyrene is 400 mesh.

7. The water-based epoxy asphalt waterproof coating according to claim 1, wherein, The water-based epoxy asphalt waterproof coating has a water absorption rate of less than 2% after curing.

8. A method for preparing the waterborne epoxy bitumen waterproof coating as described in any one of claims 1-7, characterized in that, The method includes: Anionic emulsifier and stabilizer are dispersed in water, and then sodium hydroxide is added to adjust the pH to obtain soap solution; Asphalt is heated and melted, and then soap solution is added for emulsification and dispersion to obtain anionic emulsified asphalt; The anionic emulsified asphalt, dispersant, film-forming aid, wetting agent, pH adjuster, waterborne phenolic epoxy resin emulsion, curing catalyst, curing agent, toughening latex, inorganic pigment, defoamer, and thickener are dispersed evenly to obtain an integrated waterborne epoxy asphalt waterproof coating.

9. The method according to claim 8, wherein, The pH of the soap solution is 10-12.

10. The method according to claim 8, wherein, The curing agent is obtained by diluting butylated phenyl melamine formaldehyde resin and diluent at a ratio of 2:1.

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