Gypsum-based self-leveling interface agent for mortar tiling as well as preparation method and coating process thereof

Abstract

The invention discloses an interface agent for gypsum-based self-leveling mortar tiling, a preparation method and a coating process thereof, and belongs to the technical field of building materials. The interface agent for the gypsum-based self-leveling mortar tiling comprises mesoporous particles, a polyurethane acrylic emulsion, an epoxy modified acrylic emulsion, an acrylic emulsion, modified potassium silicate or modified sodium silicate, a silane coupling agent, a wetting agent, a dispersing agent and other auxiliaries. According to the interface agent for the gypsum-based self-leveling mortar tiling, the preparation method and the coating process of the interface agent, the problem of insufficient bonding strength after tiling caused by pulverization or surface compactness and difficulty in permeation due to bleeding of the surface of the self-leveling gypsum is solved.

Description

Technical Field

[0001] The present invention belongs to the technical field of building materials, and particularly relates to an interface agent for sticking tiles with gypsum-based self-leveling mortar, a preparation method thereof, and a coating process thereof. Background Art

[0002] There are generally two ways for gypsum-based self-leveling mortar to achieve a leveling effect during construction:

[0003] a. Increasing the water addition amount to reduce the viscosity;

[0004] b. Adjusting the formula thickening system: such as reducing cellulose and increasing water reducing agent, etc.

[0005] Both of these two ways will exacerbate the surface water bleeding and dew condensation phenomena of gypsum to varying degrees during the hardening process, resulting in surface powdering of gypsum or the formation of a smooth and dense film. When used in combination with tile adhesive for sticking tiles, the interfacial bonding strength is poor and the tiles are prone to falling off;

[0006] The invention patent CN113802794A discloses a treatment process for sticking wall and floor tiles on a gypsum base, which uses a two-component epoxy as an interface agent for the reinforcement and treatment of the base before tiling. This solution has a complex construction process. The two-component epoxy is an oily material with a strong smell and is not environmentally friendly. At the same time, its wetting effect is poor, it is difficult to penetrate the surface of the gypsum-based self-leveling mortar, and the effect is limited. It also cannot fundamentally solve the abnormalities such as powdering caused by surface water bleeding of the gypsum-based self-leveling mortar.

[0007] The invention patent CN115820053A discloses a penetrating and reinforcing concrete interface agent, a preparation method thereof, and its uses, which uses acrylate polymer emulsion, water, wetting agent, and other auxiliaries as the main components. This solution is essentially a traditional interface agent, and its applicable range is loose concrete substrates, not applicable to dense gypsum-based self-leveling mortar layers. It is difficult to wet its smooth and dense surface, so it cannot improve the bonding strength of the subsequent supporting tile adhesive for sticking tiles. Moreover, the air permeability of the organic emulsion film is poor. If it is applied when the moisture content of the gypsum-based self-leveling mortar is relatively high, it is easy to hinder the evaporation of water, and abnormalities such as film bubbling will occur.

[0008] In view of this, the present invention is specifically proposed. Summary of the Invention

[0009] The technical problem to be solved by the present invention is to provide an interface agent for sticking tiles with gypsum-based self-leveling mortar, a preparation method thereof, and a coating process thereof, so as to improve the problem of insufficient bonding strength after tiling caused by reasons such as water bleeding, powdering, and difficult penetration of the dense surface of the gypsum-based self-leveling mortar.

[0010] To solve the above problems, the present invention is achieved through the following technical solutions:

[0011] The first object of the present invention is:

[0012] Provide an interface agent for sticking tiles with gypsum-based self-leveling mortar, which comprises the following components in percentage by weight:

[0013] Mesoporous particles 10-25%, polyurethane acrylate emulsion 5-20%, epoxy-modified acrylate emulsion 5-20%, acrylate emulsion 5-30%, modified potassium silicate or modified sodium silicate 5-15%, silane coupling agent 0.2-0.8%, wetting agent 0.2-1%, dispersant 0.2-1%, other auxiliaries 0-3%, and the rest is made up with water; the sum of all components is 100%.

[0014] The further optimization of the interface agent for sticking tiles with gypsum-based self-leveling mortar of the present invention is as follows:

[0015] The mesoporous particles are modified, with hydrophilicity inside the pores, can be used as carriers, the average particle size is 5-50 microns; the shape is mainly spherical; the pores are through mesopores, and the average pore diameter is 2-50 nm.

[0016] The further optimization of the interface agent for sticking tiles with gypsum-based self-leveling mortar of the present invention is as follows:

[0017] The acrylate emulsion includes one or more of styrene-acrylate emulsion, pure acrylate emulsion, silicone-acrylate emulsion, and functional monomer-modified acrylate emulsion, the solid content is 40-60%, the glass transition temperature Tg≤15°C, and it can pass the 10% calcium ion stability test.

[0018] The further optimization of the interface agent for sticking tiles with gypsum-based self-leveling mortar of the present invention is as follows:

[0019] The modified potassium silicate is organically modified and stabilized potassium silicate, and the modulus is 2.5-3.5.

[0020] The further optimization of the interface agent for sticking tiles with gypsum-based self-leveling mortar of the present invention is as follows:

[0021] The silane coupling agent is a combination of one or several of epoxy-based polysiloxane, amino-based polysilane, isocyanate-based polysilane, and urea-based polysilane.

[0022] The further optimization of the interface agent for sticking tiles with gypsum-based self-leveling mortar of the present invention is as follows:

[0023] It includes one or several of the following technical features:

[0024] The wetting agent is one or a combination of quaternary ammonium salt-type cationic surfactants and heterocyclic-type cationic surfactants;

[0025] The dispersant includes one or a combination of polyphosphates, polyacrylates, polymethacrylates, polycarboxylates, and polyphosphate esters;

[0026] The other auxiliaries described above include one or a combination of several of a film-forming auxiliary, a thickener, an antifoaming agent, a bactericidal and preservative agent, and a mildew-proof agent.

[0027] The second object of the present invention is:

[0028] To provide a preparation method of an interface agent for pasting tiles with gypsum-based self-leveling mortar described above (including the optimized scheme), which comprises the following preparation steps:

[0029] S1. At normal temperature, water, a wetting agent, a dispersing agent, mesoporous particles, and a silane coupling agent are sequentially added into a container according to a ratio and subjected to high-speed dispersion for 30 minutes to be pre-mixed evenly;

[0030] S2. Stir and add a modified potassium silicate or a modified sodium silicate, a polyurethane acrylate emulsion, an epoxy-modified acrylate emulsion, an acrylate emulsion, and other auxiliaries, and disperse until it is uniform to obtain the product.

[0031] The third object of the present invention is:

[0032] To provide a coating process of the interface agent for pasting tiles with gypsum-based self-leveling mortar described above (including the optimized scheme) in a self-leveling system, wherein the coating structure of the self-leveling system from bottom to top includes:

[0033] A base layer, an interface agent layer, a gypsum-based self-leveling mortar layer, the interface agent for pasting tiles described above (including the optimized scheme), a tile adhesive layer, and tiles;

[0034] The coating process includes the following steps:

[0035] s1. Clean the floating ash on the surface of the base layer;

[0036] s2. Uniformly spray or brush a layer of interface agent on the surface of the base layer, and dry and cure for 2 to 24 hours until it is completely film-formed;

[0037] s3. Pour the gypsum-based self-leveling mortar, cure until the final setting is completed, and the surface moisture content is 40% to 95%;

[0038] s4. Spray or brush the interface agent for pasting tiles with gypsum-based self-leveling mortar described above (including the optimized scheme), and the dosage is 60 to 180 g / m 2 , and cure until the surface moisture content ≤ 20%;

[0039] s5. Lay tiles with a supporting tile adhesive.

[0040] The interface agent for tile pasting in the present invention uses water as the main dispersion medium, and adds wetting agent, dispersant, mesoporous particles, modified potassium silicate or modified sodium silicate, polyurethane acrylate emulsion, and epoxy modified acrylate emulsion as the main raw materials, and adds auxiliaries such as silane coupling agent, film-forming aid, thickener, defoaming agent, etc. to prepare the interface agent for tile pasting of gypsum-based self-leveling mortar. Through the synergistic effect of several raw materials and the optimization of the coating process, problems such as powdering caused by water bleeding on the surface of self-leveling are solved, and the problems of low strength and easy shelling after tile pasting of gypsum self-leveling mortar are improved.

[0041] The technical solution of the present invention involves the following improvements:

[0042] (I) Formula improvement:

[0043] Traditional interface agents use materials such as acrylic emulsion, vinyl acetate-ethylene copolymer emulsion or polyvinyl alcohol as the main materials, and have good sealing properties. Due to problems such as powdering and dense and difficult-to-penetrate surfaces on the surface of gypsum-based self-leveling mortar, traditional interface agents are not suitable for use in supporting tile pasting on gypsum self-leveling mortar. The present invention is improved through the following technical routes

[0044] a. Improve the water conductivity of the interface agent for tile pasting: Mesoporous particles are added to the formula. The mesoporous particles play a role in water conduction and water storage, and export the excess water in the lower layer of self-leveling mortar, which can effectively prevent problems such as powdering or formation of a smooth and dense surface caused by water bleeding on the surface of self-leveling mortar; at the same time, the water stored in the pores of the mesoporous particles can provide the required humidity for the curing of tile adhesive, which is beneficial to the improvement of the strength of tile adhesive; in addition, the mesoporous particles are evenly distributed in the coating film and float to the surface of the coating film, increasing the roughness and specific surface area of the interface agent layer, and playing an anchoring role for the upper layer of tile adhesive, which is beneficial to increasing the interlayer adhesion.

[0045] b. Improve the bonding force of the interface agent for tile pasting with the upper and lower layers: Modified potassium silicate or modified sodium silicate is added to the formula, which can react with polyvalent ions or silica sand in the incompletely dried gypsum, tile adhesive;

[0046] c. Endow the interface agent for tile pasting with strength and toughness: Different types of emulsions are compounded to form the framework structure of the coating film, which not only makes the interlayer bonding force better, but also enables the system to achieve a combination of rigidity and flexibility.

[0047] d. Synergistic effect between various materials: The silane group of the silane coupling agent reacts with inorganic components such as modified potassium silicate / sodium, substrate and tile adhesive; the organic group forms chemical bonds on the surface of acrylic emulsion, epoxy modified acrylate emulsion, and polyurethane acrylate emulsion to form an interpenetrating network structure, thereby further enhancing the strength and toughness of the interface agent layer for tile pasting itself, and effectively improving the bonding force between the interface agent for tile pasting and the upper and lower layers.

[0048] (2) Improvement of painting process / construction method:

[0049] Water in the self-leveling mortar plays a role in leveling and participating in the hydration reaction of hemihydrate gypsum. Excess water after coagulation will affect the gypsum crystal structure and strength. Therefore, in the traditional painting process, before tiling, the gypsum self-leveling mortar needs to be cured until the moisture content ≤ 20%, then the interface agent for tiling is brushed or sprayed, and finally the next tiling step is carried out. However, it is often affected by factors such as water addition amount, environment, and formula. Water bleeding will occur on the gypsum surface, resulting in powdering problems, or a smooth and dense surface will be formed, which will affect the subsequent tiling.

[0050] In the present invention, when the gypsum-based self-leveling mortar is not completely dry, the interface agent for gypsum-based self-leveling mortar in the present invention is brushed or sprayed. Through the mesoporous particles in the interface agent, water is conducted to prevent the gypsum surface from being powdered due to water bleeding or generating a smooth and dense surface, and finally the bonding strength after tiling of the gypsum-based self-leveling mortar is improved.

[0051] Therefore, through the synergistic effect of each component and combined with the improvement of the painting process, the present invention improves the surface effect of the gypsum-based self-leveling and meets the strength requirements at the interface of the gypsum-based self-leveling mortar supporting tiling.

[0052] After adopting the above technical solutions, the present invention has the following beneficial effects compared with the prior art:

[0053] 1. The interface agent for tiling of the self-leveling mortar provided by the present invention is a water-based system, which is environmentally friendly and pollution-free.

[0054] 2. The optimization of the painting process of the interface agent for tiling of the self-leveling mortar provided by the present invention improves the application construction tolerance, and also solves the problems of powdering or forming a smooth and dense surface caused by water bleeding on the gypsum surface due to environmental temperature and humidity, gypsum water addition amount, etc.

[0055] 3. The present invention provides good interlayer bonding force for the self-leveling mortar tiling system, is convenient for construction, and extends the service life of material use. BRIEF DESCRIPTION OF THE DRAWINGS

[0056] Figure 1 It is a legend of the painting system related to the present invention.

[0057] Reference numerals:

[0058] 1 - Base layer 2 - Interface agent layer 3 - Gypsum-based self-leveling mortar layer

[0059] 4 - Interface agent for tiling of the present invention 5 - Tile adhesive layer 6 - Tile DETAILED DESCRIPTION OF THE INVENTION

[0060] To make the application, technical solution and advantages of the present invention clearer and more understandable, the content of the present invention will be described in detail in combination with specific embodiments. It should be understood that the embodiments are only used to illustrate the present invention, rather than limiting the protection scope of the present invention. Any simple improvement to the preparation method of the present invention under the premise of the inventive concept belongs to the protection scope of the present invention.

[0061] The raw material information involved in the following examples and comparative examples is as follows:

[0062] The mesoporous particles are SIPERNAT 22S produced by Evonik Specialties (Shanghai) Co., Ltd.; the silane coupling agent is CoatOSil MP 200 produced by Momentive Performance Materials Inc.; the acrylic emulsion is ECO502 produced by BASF Shanghai Co., Ltd.; the polyurethane acrylate emulsion is Lacper 4219 produced by Wanhua Chemical Group Co., Ltd.; the epoxy-modified acrylic emulsion is XG-2217 produced by Hengshui Xinguang New Materials Technology Co., Ltd.; the modified potassium silicate is CROSFECT K99 produced by Shanghai Aorun Chemical Co., Ltd.; the wetting agent is BYK 346 produced by BYK Additives (Shanghai) Co., Ltd.; the wetting agent is BYK 190 produced by BYK Additives (Shanghai) Co., Ltd.; the thickener is BR30000H produced by Silver Eagle Chemical Fiber Co., Ltd.; the defoaming agent is DF 691 produced by Solvay Chemicals (Shanghai) Co., Ltd.; the preservative is Rocima 631 produced by Dow Chemical (China) Investment Co., Ltd.

[0063] Example 1

[0064] First step: At room temperature, 25.3 parts of water, 1 part of wetting agent, 1 part of dispersant, and 25 parts of mesoporous particles are successively added to a container and dispersed at high speed for 30 minutes to be pre-mixed evenly;

[0065] Second step: Stir and add 15 parts of modified potassium silicate, 5 parts of polyurethane acrylate emulsion, 20 parts of epoxy-modified acrylic emulsion, 5 parts of acrylic emulsion, 0.8 part of silane coupling agent, 1.5 parts of thickener, 0.2 part of defoaming agent and 0.2 part of bactericidal preservative and disperse until uniform to obtain.

[0066] Examples 2 to 4 and Comparative Examples A to G are prepared according to the preparation method of Example 1 and configured with reference to the formula in Table 1 to obtain an interfacial agent for sticking tiles in gypsum-based self-leveling mortar.

[0067] Table 1 Raw materials and specific weight parts in examples and comparative examples:

[0068]

[0069] The coating process of the interfacial agent for sticking tiles prepared in Examples 2 to 4 and Comparative Examples A to G in gypsum-based self-leveling mortar is as follows:

[0070] S1. Clean the floating ash on the surface of the base layer;

[0071] S2. Uniformly spray or brush a layer of primer on the surface of the base layer, and dry and cure for 18 h until the film is completely formed;

[0072] S3. Pour the gypsum-based self-leveling mortar, cure until the final setting is completed, and the surface moisture content is 90%;

[0073] S4. Spray or brush the primer for tile pasting prepared in Examples 2-4 or Comparative Examples A-G on the surface of the gypsum-based self-leveling mortar, and the dosage is 100 g / m 2 , cure until the surface moisture content ≤ 20%;

[0074] S5. Lay tiles with the supporting tile adhesive.

[0075] Comparative Example 1

[0076] This comparative example is a traditional water-based primer, and its raw material composition, specific parts and preparation method are as follows:

[0077] Add 0.5 part of wetting agent, 35 parts of acrylic emulsion, 0.5 part of thickener, 0.2 part of defoamer, and 0.2 part of bactericidal and preservative to 63.6 parts of water in sequence and stir well.

[0078] The coating process of this comparative example in the gypsum-based self-leveling mortar is the same as that of Examples 2-4 and Comparative Examples A-G.

[0079] Comparative Example 2

[0080] This comparative example is the tile pasting process of the primer for tile pasting prepared in Example 2 using the traditional process of self-leveling mortar, and the specific steps are as follows:

[0081] S1. Clean the floating ash on the surface of the base layer;

[0082] S2. Uniformly spray or brush a layer of primer on the surface of the base layer, and dry and cure for 18 h until the film is completely formed;

[0083] S3. Pour the gypsum-based self-leveling mortar, cure until the moisture content ≤ 20%;

[0084] S4. Spray or brush the primer for tile pasting prepared in Comparative Example 2 on the surface of the gypsum-based self-leveling mortar, and the dosage is 100 g / m 2 , cure for 24 h.

[0085] Test Example 1

[0086] This Test Example 1 compares the technical indexes of the primer for tile pasting prepared in Examples 1-4 and the traditional primer prepared in Comparative Example 1, and the results are shown in Table 2.

[0087] Table 2 Comparison of Performance Indicators of Examples 1-4 and Comparative Example 1

[0088]

[0089] As can be seen from the above test results, the coating processes used in Examples 1-4 and Comparative Example 1 of the present invention are all the coating processes described in the present invention. The draw strength results of Examples 1-4 are relatively high, the surface state is good, and the curing time is short, less than 14 days. Comparative Example 1 is a traditional water-based interface agent. Although the coating process described in the present invention is adopted, the system dries slowly, and the time for curing to a moisture content ≤ 20% exceeds 30 days. The draw strength is poor. Since the high moisture content will affect the strength of the gypsum itself, the fracture occurs inside the gypsum.

[0090] Test Example 2

[0091] This Test Example 2 is the performance test results of Example 2 and Comparative Examples A-G. The effects of the addition of emulsion type, mesoporous particles, modified potassium silicate, and silane coupling agent on the prepared interface agent in the tile pasting system of gypsum-based self-leveling mortar were investigated. The results are shown in Table 3:

[0092] Table 3 Effects of Different Materials on the Performance of Interface Agents for Tile Pasting of Gypsum-Based Self-Leveling Mortar

[0093]

[0094]

[0095] As can be seen from the above test results, the performance of Example 2 of the present invention meets the requirements, and the performance of Comparative Examples A-G all has defects. It can be shown that the addition of emulsion type, mesoporous particles, modified potassium silicate, and silane coupling agent produces a synergistic effect and affects the comprehensive performance of the interface agent for tile pasting of gypsum-based self-leveling of the present invention.

[0096] Test Example 3

[0097] This test example investigated the effects of the coating process of the present invention and the traditional coating process on the performance of the tile pasting system of gypsum-based self-leveling mortar. The results are shown in Table 4:

[0098] Table 4: Effects of Different Coating Processes on Performance

[0099]

[0100] As can be seen from the above test results, Example 2 and Comparative Example 2 have the same formulation ratio, but the coating processes for tiling the system are different. Example 2 has a better bonding effect and a higher draw strength, far exceeding the standard requirements. Comparative Example 2 uses the traditional coating process and has a poor bonding effect. Therefore, to solve the problem of tiling the gypsum-based self-leveling mortar system, it is necessary to optimize the formulation and coating process simultaneously.

[0101] In summary, the above are only the preferred embodiments of the present invention, and there is no restriction in any form on the present invention; any equivalent changes, modifications and evolutions made by those skilled in the art within the scope of the technical solution of the present invention by using the disclosed technical content are regarded as the equivalent embodiments of the present invention; at the same time, any equivalent changes, modifications and evolutions made to the above embodiments according to the essential technology of the present invention still fall within the protection scope of the technical solution of the present invention.

[0102] The technical features of the above embodiments can be combined arbitrarily. For the sake of concise description, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, it should be considered as the scope recorded in this specification.

[0103] The experimental methods without specific conditions noted in the present invention are generally in accordance with conventional conditions or conditions recommended by the manufacturer.

[0104] For the various optimized technical solutions in the present invention, unless otherwise stated, the various optimized technical solutions can be combined with each other.

[0105] Unless otherwise stated, percentages and parts are weight percentages and weight parts.

[0106] The experimental methods without specific conditions noted in the specification and the embodiments are generally in accordance with conventional conditions or conditions recommended by the manufacturer.

[0107] Unless otherwise defined, all professional and scientific terms used herein have the same meaning as those familiar to those skilled in the art. In addition, any methods and materials similar or equivalent to the described content can be applied to the method of the present invention.

Claims

1. An interface agent for gypsum-based self-leveling mortar tile paving, Features: It includes the following components in weight percentage: Mesoporous particles 10-25%, polyurethane acrylic emulsion 5-20%, epoxy modified acrylic emulsion 5-20%, acrylic emulsion 5-30%, modified potassium silicate or modified sodium silicate 5-15%, silane coupling agent 0.2-0.8%, wetting agent 0.2-1%, dispersant 0.2-1%, other additives 0-3%, and the rest is made up of water; the sum of all components is 100%.

2. The interface agent for gypsum-based self-leveling mortar tile according to claim 1, Features: The average particle size of the mesoporous particles is 5 to 50 microns; the shape is mainly spherical; the pores are through mesopores, and the average pore size is 2 to 50 nm.

3. The interface agent for gypsum-based self-leveling mortar tile according to claim 1, Features: The acrylic emulsion includes one or more of styrene acrylic emulsion, pure acrylic emulsion, silicone acrylic emulsion, and functional monomer modified acrylic emulsion, with a solid content of 40-60% and a glass transition temperature Tg≤ 15℃, can pass 10% calcium ion stability test.

4. The interface agent for gypsum-based self-leveling mortar tile according to claim 1, Features: The modified potassium silicate is organically modified and stabilized potassium silicate, and its modulus is 2.5-3.

5.

5. The interface agent for gypsum-based self-leveling mortar tile according to claim 1, Features: The silane coupling agent is one or a combination of epoxy polysiloxane, amino polysilane, isocyanate polysilane and urea polysilane.

6. The interface agent for gypsum-based self-leveling mortar tile according to claim 1, Features: It includes one or more of the following technical features: The wetting agent is one or a combination of quaternary ammonium salt type cationic surfactant, heterocyclic type cationic surfactant, etc.; The dispersant includes one or a combination of polyphosphates, polyacrylates, polymethacrylates, polycarboxylates, and polyphosphate esters; The other auxiliary agents include one or a combination of thickeners, defoamers, bactericides and preservatives, and mildew inhibitors.

7. A method for preparing an interface agent for gypsum-based self-leveling mortar tile tiling according to any one of claims 1 to 6, Features: It comprises the following preparation steps: S1. Add water, wetting agent, dispersant, mesoporous particles and silane coupling agent into a container in proportion at room temperature and disperse at high speed for 30 minutes to pre-mix evenly; S2. Stir and add modified potassium silicate or modified sodium silicate, polyurethane acrylic emulsion, epoxy modified acrylic emulsion, acrylic emulsion and other additives, and disperse them evenly.

8. A coating process of the interface agent for gypsum-based self-leveling mortar tile tiling according to any one of claims 1 to 6 in a self-leveling system, Features: The coating structure of the self-leveling system from bottom to top includes: Base layer, interface agent layer, gypsum-based self-leveling mortar layer, interface agent for tiling according to any one of claims 1 to 6, tile adhesive layer, and tile; The coating process comprises the following steps: s1. Clean the dust on the surface of the base layer; s2. Spray or brush a layer of interface agent evenly on the surface of the base layer, and dry and cure for 2 to 24 hours until the film is completely formed; s3. Pour gypsum-based self-leveling mortar and maintain until final setting. The surface moisture content is 40% to 95%; s4. Spray or brush the gypsum-based self-leveling mortar tile interface agent according to any one of claims 1 to 6, with an amount of 60 to 180 g / m 2 , maintain until the surface moisture content is ≤20%; s5. Use matching tile adhesive to lay ceramic tiles.

Images