Epoxy mortar material and preparation method thereof

Abstract

The invention discloses an epoxy mortar material and a preparation method thereof, relates to the technical field of building materials, and solves the technical problem that an existing epoxy mortar material cannot meet the requirement for high performance. The epoxy mortar material comprises 20-40 parts of epoxy resin, 5-10 parts of a curing agent, 2-5 parts of a viscosity modifier, 20-40 parts of a special filler, 10-20 parts of reinforced fibers and 5-10 parts of an additive, and during preparation, the raw materials are accurately weighed in proportion and uniformly stirred to obtain the epoxy mortar material; the material with high wear resistance, durability and compressive strength is obtained, the high-performance requirement can be met, the application field of the material is expanded, and the using effect of the material is improved.

Description

Technical Field

[0001] The invention relates to the technical field of building materials, and in particular to an epoxy mortar material and a preparation method thereof. Background Art

[0002] The water conservancy and hydropower industry is a pillar industry of the national economy, and is extremely important for ensuring the normal operation, safety and stability of hydropower facilities. In daily construction, maintenance and overhaul work, the use of materials with strong adaptability and stable and reliable performance plays an irreplaceable and important role.

[0003] Epoxy mortar is a commonly used maintenance material and is widely used in water conservancy and hydropower projects. It has excellent chemical resistance, good bonding properties, high strength and durability, good wear resistance, anti-permeability and sealing properties. In water conservancy and hydropower projects, epoxy mortar is often used for the repair and reinforcement of hydropower station spillway dam surfaces, spillway gate seats, plant floors, lock chamber wall panels and other parts.

[0004] With the continuous development of cement products and the expansion of their application scope, epoxy mortar has been widely used as a repair material and coating material. However, with the advancement of technology and the improvement of processes, the requirements for epoxy mortar materials have become increasingly stringent. Although the current epoxy mortar materials can meet general compression and wear resistance needs, in some extreme environments (such as continuous high temperature environments, extremely cold environments, environments that need to withstand extremely high loads, and environments with high-intensity impact and vibration), epoxy mortar materials are not sufficient to achieve compression and wear resistance. In addition, the raw materials used in the current epoxy mortar materials are not environmentally friendly and pollute the environment. Summary of the invention

[0005] The present invention aims to solve the technical problem that existing epoxy mortar materials cannot meet high performance requirements. The purpose is to provide an epoxy mortar material and a preparation method thereof, so as to obtain a material with high wear resistance, durability and compressive strength, which can meet high performance requirements, expand its application field and improve its use effect.

[0006] The present invention is achieved through the following technical solutions:

[0007] The first object of the present invention is to provide an epoxy mortar material, which comprises, by weight, 20 to 40 parts of epoxy resin, 5 to 10 parts of curing agent, 2 to 5 parts of viscosity regulator, 20 to 40 parts of special filler, 10 to 20 parts of reinforcing fiber, and 5 to 10 parts of additives.

[0008] Furthermore, the special filler is a mixture of at least two of quartz sand, silica sand, and rubber particles.

[0009] Furthermore, the viscosity modifier is a diluent or a thickener.

[0010] Furthermore, the special filler is a mixture of quartz sand and rubber particles, wherein the mass ratio of quartz sand to rubber particles is 6:1, the particle size range of quartz sand is between 0.6 mm and 1.2 mm, and the particle size range of rubber particles is between 0.5 mm and 1.0 mm.

[0011] Furthermore, the special filler is a mixture of silica sand and rubber particles, wherein the mass ratio of silica sand to rubber particles is 4:1, the particle size range of the silica sand is between 1.8 mm and 2.2 mm, and the particle size range of the rubber particles is between 0.5 mm and 1.0 mm.

[0012] Furthermore, the special filler is a mixture of quartz sand and silica sand, wherein the mass ratio of quartz sand to silica sand is 3:1, the particle size range of quartz sand is between 0.8 mm and 1.0 mm, and the particle size range of silica sand is between 1.6 mm and 2.0 mm.

[0013] Furthermore, the reinforcing fiber is polypropylene fiber.

[0014] Furthermore, the epoxy resin is a water-based epoxy resin.

[0015] Furthermore, the additives are a defoamer and a preservative, wherein the mass ratio of the defoamer to the preservative is 1:5.

[0016] A second object of the present invention is to provide a method for preparing an epoxy mortar material, comprising the following steps:

[0017] Accurately weigh the raw materials according to the proportion and stir them evenly to obtain the epoxy mortar material.

[0018] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0019] 1. The present invention can improve the wear resistance, durability and compressive strength of the mortar material by adding special fillers to the epoxy mortar material, and can improve the overall strength and durability of the material by adding reinforcing fibers. Through the selection and compounding of materials, and controlling the ratio between the components within a suitable range, the final mortar material can meet high performance requirements, expand its application field, and improve its use effect.

[0020] 2. The present invention adds rubber particles to the special filler. The rubber particles are made of recycled rubber, which not only has an environmental protection effect, but also can improve the toughness of the mortar material. When subjected to external force, the epoxy mortar can better absorb energy and reduce the risk of brittle fracture, thereby improving the durability of the overall structure.

[0021] 3. The present invention can improve the overall strength and durability of the material by adding polypropylene fibers into the material. DETAILED DESCRIPTION

[0022] In order to make the objectives, technical solutions and advantages of the present invention more clearly understood, the technical solutions in the embodiments of the present invention are clearly and completely described below in conjunction with the embodiments. Obviously, the schematic implementation modes of the present invention and their description are only used to explain the present invention and are not intended to limit the present invention.

[0023] The following is a detailed description of an embodiment of an epoxy mortar material and a preparation method thereof of the present invention. However, there may be cases where unnecessary detailed descriptions are omitted. For example, there may be cases where detailed descriptions of well-known matters and repeated descriptions are omitted. This is to avoid the following description from becoming unnecessarily lengthy and facilitate the understanding of those skilled in the art.

[0024] The "range" disclosed in this application is defined in the form of a lower limit and an upper limit, and a given range is defined by selecting a lower limit and an upper limit, and the selected lower limit and upper limit define the boundaries of the particular range. The range defined in this way can be inclusive or exclusive of the end values, and can be arbitrarily combined, that is, any lower limit can be combined with any upper limit to form a range.

[0025] Unless otherwise specified, all embodiments and optional embodiments of the present application can be combined with each other to form a new technical solution.

[0026] Unless otherwise specified, all technical features and optional technical features of this application can be combined with each other to form a new technical solution.

[0027] Unless otherwise specified, the terms "include" and "comprising" mentioned in this application may be open-ended or closed-ended. For example, the terms "include" and "comprising" may mean that other substances not listed may also be included or only the listed substances may be included.

[0028] If there is no special explanation, all the steps of the present application can be performed sequentially or randomly, preferably sequentially.

[0029] The present invention provides an epoxy mortar material, which comprises, by weight, 20 to 40 parts of epoxy resin, 5 to 10 parts of curing agent, 2 to 5 parts of viscosity regulator, 20 to 40 parts of special filler, 10 to 20 parts of reinforcing fiber, and 5 to 10 parts of additives.

[0030] The present invention can improve the wear resistance, durability and compressive strength of the mortar material by adding special fillers to the epoxy mortar material, and can improve the overall strength and durability of the material by adding reinforcing fibers. Through the selection and compounding of materials, and controlling the ratio between the components within a suitable range, the mortar material finally obtained can meet high performance requirements, expand its application field, and improve its use effect.

[0031] The viscosity regulator is a diluent or a thickener. In actual use, the viscosity of the mortar is selectively adjusted using a diluent or a thickener according to the needs of the use environment.

[0032] As a preferred embodiment, the special filler is a mixture of at least two of quartz sand, silica sand and rubber particles. The rubber particles are obtained by crushing recycled rubber. The present invention not only has an environmental protection effect, but also can improve the toughness of the mortar material. When subjected to external force, the epoxy mortar can better absorb energy and reduce the risk of brittle fracture, thereby improving the durability of the overall structure.

[0033] As a preferred embodiment, the special filler is a mixture of quartz sand and rubber particles, wherein the mass ratio of quartz sand to rubber particles is 6:1, the particle size range of quartz sand is between 0.6 mm and 1.2 mm, and the particle size range of rubber particles is between 0.5 mm and 1.0 mm.

[0034] As a preferred embodiment, the special filler is a mixture of silica sand and rubber particles, wherein the mass ratio of silica sand to rubber particles is 4:1, the particle size range of the silica sand is between 1.8 mm and 2.2 mm, and the particle size range of the rubber particles is between 0.5 mm and 1.0 mm.

[0035] As a preferred embodiment, the special filler is a mixture of quartz sand and silica sand, wherein the mass ratio of quartz sand to silica sand is 3:1, the particle size range of quartz sand is between 0.8 mm and 1.0 mm, and the particle size range of silica sand is between 1.6 mm and 2.0 mm.

[0036] As a preferred embodiment, the reinforcing fiber is polypropylene fiber. By adding polypropylene fiber to the material, the overall strength and durability of the material can be improved.

[0037] As a preferred embodiment, the epoxy resin is a water-based epoxy resin. The water-based epoxy resin is a green and environmentally friendly material that can reduce the emission of harmful substances and reduce the pollution of the material of the present invention to the environment.

[0038] Furthermore, the additives are defoamers and preservatives, wherein the mass ratio of the defoamer to the preservative is 1: 5. The defoamer reduces the surface tension of the liquid, destroys the gas-liquid interface, reduces the ability of bubble generation and stability, and thus reduces the number and size of bubbles in the mortar. The main function of the preservative in the epoxy mortar is to further enhance its resistance to chemical corrosion and electrochemical corrosion.

[0039] The present invention also provides a method for preparing an epoxy mortar material, comprising the following steps:

[0040] Accurately weigh the raw materials according to the proportion and stir them evenly to obtain the epoxy mortar material. In practical applications, diluents or thickeners can be added according to the needs of the materials. Diluents and thickeners are used to adjust the fluidity of the materials to make construction more convenient.

[0041] The technical solution of the present invention is further described in detail below in conjunction with embodiments.

[0042] It should be noted that the experimental methods used in the examples are conventional methods unless otherwise specified. The materials, reagents, methods and instruments used are conventional materials, reagents, methods and instruments in the art unless otherwise specified, and can be obtained by those skilled in the art through commercial channels.

[0043] Example 1

[0044] An epoxy mortar material comprises, calculated by weight, 35 parts of epoxy resin, 6 parts of curing agent, 2 parts of viscosity regulator, 35 parts of special filler, 15 parts of reinforcing fiber and 5 parts of additive.

[0045] Among them, the special filler is a mixture of quartz sand and rubber particles, wherein the ratio of quartz sand to rubber particles is 6:1, the particle size range of quartz sand is between 0.6㎜ and 1.2㎜, and the particle size range of rubber particles is between 0.5 and 1.0㎜.

[0046] Wherein, the reinforcing fiber is polypropylene fiber.

[0047] Among them, the additives are defoaming agent and preservative in a mass ratio of 1:5.

[0048] It should be noted that the epoxy resin used is the CYD128 model of Baling Petrochemical, the curing agent used is the CYDHD-220 model of Baling Petrochemical, the diluent used is the LG-692 model of Hubei Linggu, the thickener used is the LS1036 model of Kunshan Loris Polymer Materials Co., Ltd., and among the additives, the defoaming agent used is the SPA-202 model of Delong Jingcheng, and the preservative used is the PCA-Ⅰ model of Jiangsu Subote New Materials.

[0049] The preparation method of the above-mentioned epoxy mortar material is:

[0050] Accurately weigh 35 parts of epoxy resin, 6 parts of curing agent, 2 parts of viscosity modifier, 35 parts of special filler, 15 parts of reinforcing fiber, and 5 parts of additive according to proportion, put them together in a mixer and stir, and after stirring evenly, the epoxy mortar material is obtained.

[0051] Example 2

[0052] An epoxy mortar material comprises, calculated by weight, 35 parts of epoxy resin, 6 parts of curing agent, 2 parts of viscosity regulator, 35 parts of special filler, 15 parts of reinforcing fiber and 5 parts of additive.

[0053] Among them, the special filler is a mixture of silica sand and rubber particles, wherein the ratio of silica sand to rubber particles is 4:1, the particle size range of silica sand is between 1.8㎜ and 2.2㎜, and the particle size range of rubber particles is between 0.5 and 1.0㎜.

[0054] Wherein, the reinforcing fiber is polypropylene fiber.

[0055] Among them, the additives are defoaming agent and preservative in a mass ratio of 1:5.

[0056] It should be noted that the epoxy resin used is the CYD128 model of Baling Petrochemical, the curing agent used is the CYDHD-220 model of Baling Petrochemical, the diluent used is the LG-692 model of Hubei Linggu, and the thickener used is the LS1036 model of Kunshan Loris Polymer Materials Co., Ltd.

[0057] The preparation method of the above-mentioned epoxy mortar material is:

[0058] Accurately weigh 35 parts of epoxy resin, 6 parts of curing agent, 2 parts of viscosity modifier, 35 parts of special filler, 15 parts of reinforcing fiber, and 5 parts of additive according to proportion, put them together in a mixer and stir, and after stirring evenly, the epoxy mortar material is obtained.

[0059] Example 3

[0060] An epoxy mortar material comprises, calculated by weight, 35 parts of epoxy resin, 6 parts of curing agent, 2 parts of viscosity regulator, 35 parts of special filler, 15 parts of reinforcing fiber and 5 parts of additive.

[0061] Among them, the special filler is a mixture of quartz sand and silica sand, wherein the ratio of quartz sand to silica sand is 3:1, the particle size range of quartz sand is between 0.8㎜ and 1.0㎜, and the particle size range of silica sand is between 1.6㎜ and 2.0㎜.

[0062] Wherein, the reinforcing fiber is polypropylene fiber.

[0063] Among them, the additives are defoaming agent and preservative in a mass ratio of 1:5.

[0064] It should be noted that the epoxy resin uses the CYD128 model of Baling Petrochemical, the curing agent uses the CYDHD-220 model of Baling Petrochemical, the diluent uses the LG-692 model of Hubei Linggu, the thickener uses the LS1036 model of Kunshan Loris Polymer Materials Co., Ltd., and among the additives, the defoaming agent and preservative are manufactured by manufacturer’s model.

[0065] The preparation method of the above-mentioned epoxy mortar material is:

[0066] Accurately weigh 35 parts of epoxy resin, 6 parts of curing agent, 2 parts of viscosity modifier, 35 parts of special filler, 15 parts of reinforcing fiber, and 5 parts of additive according to proportion, put them together in a mixer and stir, and after stirring evenly, the epoxy mortar material is obtained.

[0067] Example 4

[0068] The difference between this embodiment and embodiment 1 is that the raw material composition content is different, specifically:

[0069] An epoxy mortar material comprises, calculated by weight, 20 parts of epoxy resin, 5 parts of curing agent, 2 parts of viscosity regulator, 20 parts of special filler, 10 parts of reinforcing fiber and 5 parts of additive.

[0070] Example 5

[0071] The difference between this embodiment and embodiment 1 is that the raw material composition content is different, specifically:

[0072] The invention discloses an epoxy mortar material, which comprises, by weight, 40 parts of epoxy resin, 10 parts of curing agent, 5 parts of viscosity regulator, 20 parts of special filler, 10 parts of reinforcing fiber and 5 parts of additive.

[0073] Example 6

[0074] The difference between this embodiment and embodiment 1 is that the raw material composition content is different, specifically:

[0075] The invention discloses an epoxy mortar material, which comprises, by weight, 40 parts of epoxy resin, 10 parts of curing agent, 5 parts of viscosity regulator, 30 parts of special filler, 15 parts of reinforcing fiber and 8 parts of additive.

[0076] Comparative Example 1

[0077] The difference between this comparative example and Example 1 is that the special filler is not a mixture but only quartz sand. Specifically:

[0078] An epoxy mortar material comprises, by weight, 35 parts of epoxy resin, 6 parts of curing agent, 2 parts of viscosity regulator, 35 parts of quartz sand, 15 parts of reinforcing fiber and 5 parts of additives.

[0079] Among them, the particle size range of quartz sand is between 0.6mm and 1.2mm, the reinforcing fiber is polypropylene fiber, and the additives are defoaming agent and preservative with a mass ratio of 1:5.

[0080] Comparative Example 2

[0081] The difference between this comparative example and Example 1 is that no reinforcing fiber is added. Specifically:

[0082] An epoxy mortar material comprises, calculated by weight, 35 parts of epoxy resin, 6 parts of curing agent, 2 parts of viscosity regulator, 35 parts of special filler and 5 parts of additive.

[0083] Among them, the special filler is a mixture of quartz sand and rubber particles, wherein the ratio of quartz sand to rubber particles is 6:1, the particle size range of quartz sand is between 0.6㎜ and 1.2㎜, and the particle size range of rubber particles is between 0.5 and 1.0㎜; the additives are defoaming agent and preservative in a mass ratio of 1:5.

[0084] Comparative Example 3

[0085] The difference between this embodiment and embodiment 1 is that the content of the special filler is different. Specifically:

[0086] An epoxy mortar material comprises, calculated by weight, 35 parts of epoxy resin, 6 parts of curing agent, 2 parts of viscosity regulator, 43 parts of special filler, 15 parts of reinforcing fiber and 5 parts of additive.

[0087] Among them, the special filler is a mixture of quartz sand and rubber particles, wherein the ratio of quartz sand to rubber particles is 6:1, the particle size range of quartz sand is between 0.6㎜ and 1.2㎜, and the particle size range of rubber particles is between 0.5 and 1.0㎜.

[0088] Wherein, the reinforcing fiber is polypropylene fiber.

[0089] Among them, the additives are defoaming agent and preservative in a mass ratio of 1:5.

[0090] Comparative Example 4

[0091] The difference between this embodiment and embodiment 1 is that the content of the special filler is different. Specifically:

[0092] The invention discloses an epoxy mortar material, which comprises, calculated by weight, 35 parts of epoxy resin, 6 parts of curing agent, 2 parts of viscosity regulator, 17 parts of special filler, 15 parts of reinforcing fiber and 5 parts of additive.

[0093] Among them, the special filler is a mixture of quartz sand and rubber particles, wherein the ratio of quartz sand to rubber particles is 6:1, the particle size range of quartz sand is between 0.6㎜ and 1.2㎜, and the particle size range of rubber particles is between 0.5 and 1.0㎜.

[0094] Wherein, the reinforcing fiber is polypropylene fiber.

[0095] Comparative Example 5

[0096] The difference between this embodiment and embodiment 1 is that the content of reinforcing fibers is different. Specifically:

[0097] An epoxy mortar material comprises, calculated by weight, 35 parts of epoxy resin, 6 parts of curing agent, 2 parts of viscosity regulator, 35 parts of special filler, 23 parts of reinforcing fiber and 5 parts of additive.

[0098] Among them, the special filler is a mixture of quartz sand and rubber particles, wherein the ratio of quartz sand to rubber particles is 6:1, the particle size range of quartz sand is between 0.6㎜ and 1.2㎜, and the particle size range of rubber particles is between 0.5 and 1.0㎜.

[0099] Wherein, the reinforcing fiber is polypropylene fiber.

[0100] Comparative Example 6

[0101] The difference between this embodiment and embodiment 1 is that the content of reinforcing fibers is different. Specifically:

[0102] An epoxy mortar material comprises, calculated by weight, 35 parts of epoxy resin, 6 parts of curing agent, 2 parts of viscosity regulator, 35 parts of special filler, 7 parts of reinforcing fiber and 5 parts of additive.

[0103] Among them, the special filler is a mixture of quartz sand and rubber particles, wherein the ratio of quartz sand to rubber particles is 6:1, the particle size range of quartz sand is between 0.6㎜ and 1.2㎜, and the particle size range of rubber particles is between 0.5 and 1.0㎜.

[0104] Wherein, the reinforcing fiber is polypropylene fiber.

[0105] The performance data of the epoxy mortar materials obtained in the examples and comparative examples are shown in Table 1.

[0106] Table 1. Performance data of epoxy mortar materials obtained in Examples and Comparative Examples

[0107]

[0108] From the data comparison in Table 1, it can be seen that only by adopting the epoxy mortar formula of the present invention, the comprehensive performance of the obtained material is more uniform, with higher wear resistance, durability, and compressive and tensile strength. In Comparative Example 1, the filler is only quartz sand, and the tensile strength is significantly reduced. In Comparative Example 2, no reinforcing fiber is added, and the tensile and compressive strengths are significantly reduced. In Comparative Examples 3-6, the content of certain components is not within the set range of the present invention. Although some properties of the material are improved, the tensile strength is greatly reduced, and the comprehensive performance is poor.

[0109] Finally, it should be noted that the above specific embodiments are only used to explain in detail the purpose, technical solutions and beneficial effects of the present invention. It should be understood that the above description is only a specific implementation method of the present invention and is not used to limit the protection scope of the present invention. Although the present invention is described in detail with reference to the above specific embodiments, ordinary technicians in this field should understand that it is still possible to modify the technical solutions recorded in the above embodiments, or to replace or improve some or all of the technical features therein. These modifications, equivalent replacements and improvements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present invention, and they should all be included in the scope of the claims and description of the present invention.

Claims

1. An epoxy mortar material, characterized in that: Calculated by weight, the epoxy mortar material includes: 20 to 40 parts of epoxy resin, 5 to 10 parts of curing agent, 2 to 5 parts of viscosity regulator, 20 to 40 parts of special filler, 10 to 20 parts of reinforcing fiber, and 5 to 10 parts of additives.

2. The epoxy mortar material according to claim 1, characterized in that: The special filler is a mixture of at least two of quartz sand, silica sand and rubber particles.

3. The epoxy mortar material according to claim 1, characterized in that: The viscosity modifier is a diluent or a thickener.

4. The epoxy mortar material according to claim 2, characterized in that: The special filler is a mixture of quartz sand and rubber particles, wherein the mass ratio of quartz sand to rubber particles is 6:1, the particle size range of quartz sand is between 0.6 mm and 1.2 mm, and the particle size range of rubber particles is between 0.5 mm and 1.0 mm.

5. The epoxy mortar material according to claim 2, characterized in that: The special filler is a mixture of silica sand and rubber particles, wherein the mass ratio of silica sand to rubber particles is 4:1, the particle size range of the silica sand is between 1.8 mm and 2.2 mm, and the particle size range of the rubber particles is between 0.5 mm and 1.0 mm.

6. The epoxy mortar material according to claim 2, characterized in that: The special filler is a mixture of quartz sand and silica sand, wherein the mass ratio of quartz sand to silica sand is 3:1, the particle size range of quartz sand is between 0.8 mm and 1.0 mm, and the particle size range of silica sand is between 1.6 mm and 2.0 mm.

7. The epoxy mortar material according to claim 1, characterized in that: The reinforcing fiber is polypropylene fiber.

8. The epoxy mortar material according to claim 1, characterized in that: The epoxy resin is a water-based epoxy resin.

9. The epoxy mortar material according to claim 1, characterized in that: The additives are a defoamer and a preservative, wherein the mass ratio of the defoamer to the preservative is 1:

5.

10. The method for preparing the epoxy mortar material according to any one of claims 1 to 9, characterized in that: The following steps are involved: Accurately weigh the raw materials according to the proportion and stir them evenly to obtain the epoxy mortar material.

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