High-performance cement epoxy self-leveling material and preparation method thereof

Abstract

The invention discloses a high-performance cement epoxy self-leveling material and a preparation method thereof. The high-performance cement epoxy self-leveling material comprises the following raw materials in parts by weight: 30-50 parts of cement; 10 to 20 parts of epoxy resin; 5-10 parts of a reactive diluent; 8-15 parts of a curing agent; 2-5 parts of nano silicon dioxide; 5 to 10 parts of metakaolin; 3-8 parts of redispersible latex powder; 0.5-2 parts of a water reducing agent; 0.1 to 0.5 part of a defoaming agent; 0-3 parts of a pigment; and 20-40 parts of water. According to the self-leveling material, due to the addition of the epoxy resin and the filling effect of the nano silicon dioxide, the material forms a compact three-dimensional network structure after being cured, the mechanical property is excellent, and due to a benzene ring structure in the epoxy resin, the water resistance and the chemical corrosion resistance of the material are effectively improved.

Description

Technical Field

[0001] The present invention relates to the technical field of building materials, and in particular to a high-performance cement epoxy self-leveling material and a preparation method thereof. Background Art

[0002] As a new type of floor finishing material, cement-epoxy self-leveling materials offer advantages such as smoothness, wear resistance, corrosion resistance, and ease of construction. They are widely used for flooring in industrial plants, commercial spaces, homes, and more. However, existing cement-epoxy self-leveling materials still face some challenges in practical application. For example, their early strength development is slow, impacting construction progress; their water resistance and chemical resistance need improvement, making them susceptible to damage in humid environments or when exposed to chemicals; and their insufficient bond strength with the base layer makes them prone to hollowing and delamination. Furthermore, the preparation process of traditional cement-epoxy self-leveling materials may use additives that are harmful to the environment and human health, making them incompatible with environmentally friendly practices. Summary of the Invention

[0003] In order to solve the problems existing in existing self-leveling materials, the present invention provides a high-performance cement epoxy self-leveling material, which has high early strength, good water resistance and chemical corrosion resistance, high bonding strength with the base layer, and meets green environmental protection requirements.

[0004] To achieve the purpose of the present invention, the high-performance cement epoxy self-leveling material provided comprises the following raw materials in parts by weight:

[0005] 30-50 parts of cement; 10-20 parts of epoxy resin; 5-10 parts of reactive diluent; 8-15 parts of curing agent; 2-5 parts of nano-silicon dioxide; 5-10 parts of metakaolin; 3-8 parts of redispersible latex powder; 0.5-2 parts of water reducer; 0.1-0.5 parts of defoaming agent; 0-3 parts of pigment; 20-40 parts of water.

[0006] The present application also provides a method for preparing a high-performance cement epoxy self-leveling material. The high-performance cement epoxy self-leveling material prepared by the method comprises the following raw materials in parts by weight:

[0007] 30-50 parts cement; 10-20 parts epoxy resin; 5-10 parts reactive diluent; 8-15 parts curing agent; 2-5 parts nano-silica; 5-10 parts metakaolin; 3-8 parts redispersible latex powder; 0.5-2 parts water reducer; 0.1-0.5 parts defoamer; 0-3 parts pigment; 20-40 parts water;

[0008] The preparation method comprises the following steps:

[0009] S1: Add cement, nano-silica, metakaolin, redispersible latex powder, water reducer, and defoamer according to the above weight parts into a mixer and stir evenly to obtain a dry mix;

[0010] S2: adding the epoxy resin and reactive diluent according to the above weight parts into another container and stirring evenly to obtain an epoxy resin mixture;

[0011] S3: While stirring, slowly add the epoxy resin mixture to the dry mix and continue stirring for 3-5 minutes to obtain a mixture;

[0012] S4: Add the curing agent and water according to the above weight parts to the mixture obtained in step S3, and stir for 2-4 minutes to obtain the high-performance cement epoxy self-leveling material.

[0013] The present invention has the following beneficial effects:

[0014] (1) High early strength: The present invention can significantly improve the early strength of the material to meet the requirements of rapid construction by reasonably selecting cement varieties (such as sulphoaluminate cement) and adding active materials such as nano-silica and metakaolin. The disadvantage of traditional ternary system self-leveling is that it is easy to crack. The present invention adds nano-silica, which can play a filling role. In combination with active materials such as sulphoaluminate cement and metakaolin, the self-leveling can quickly build strength and avoid cracking caused by shrinkage.

[0015] (2) Good water resistance and chemical corrosion resistance: The addition of epoxy resin and the filling effect of nano-silica form a dense three-dimensional network structure of the material after curing, which has excellent mechanical properties. In addition, the benzene ring structure in the epoxy resin effectively improves the water resistance and chemical corrosion resistance of the material.

[0016] (3) High bonding strength with the base layer: When using redispersible latex powder alone, its bonding strength is relatively low. Epoxy resin has cyclic hydroxyl groups at both ends, which gives it a strong bonding effect. When redispersible latex powder and epoxy resin are used together, the bonding strength between the material and the base layer is enhanced, avoiding the occurrence of hollowing, delamination and other phenomena.

[0017] (4) Green and environmentally friendly: The raw materials used in the present invention are all environmentally friendly materials, do not contain harmful substances, and meet the requirements of green and environmental protection.

[0018] (5) Greatly improved mechanical properties: Traditional self-leveling is a single component with a strength of C25-C30. It has good fluidity, but its performance cannot reach C60. In addition, its water resistance and wear resistance are poor, which greatly reduces the scope of application of cement-based self-leveling. In the present invention, by optimizing the raw materials and formula, epoxy resin, diluent and curing agent are introduced. The self-leveling obtained is a two-component one, which has high requirements for formula and production. In addition, nano-silica and metakaolin active materials are added. The strength of the epoxy resin self-leveling obtained can reach above C60, and the water resistance, wear resistance and corrosion resistance are better, which greatly expands the application range of self-leveling. DETAILED DESCRIPTION

[0019] The present invention may also be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

[0020] Unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant art and will not be interpreted according to an idealized or very formal meaning unless specifically defined herein.

[0021] The self-leveling material provided by the present invention is composed of the following raw materials in parts by weight:

[0022] 30-50 parts of cement;

[0023] 10-20 parts of epoxy resin;

[0024] 5-10 parts of active diluent;

[0025] 8-15 parts of curing agent;

[0026] 2-5 parts of nano silicon dioxide;

[0027] 5-10 parts of metakaolin;

[0028] 3-8 parts of redispersible latex powder;

[0029] 0.5-2 parts of water reducing agent;

[0030] Defoaming agent 0.1-0.5 parts;

[0031] Pigment 0-3 parts;

[0032] 20-40 parts water.

[0033] Among them, the cement is ordinary Portland cement or sulphoaluminate cement with a strength grade of not less than 42.5: ordinary Portland cement has good comprehensive properties, and sulphoaluminate cement develops fast early strength. The choice of the two can be adjusted according to specific construction requirements and performance requirements.

[0034] The epoxy resin is bisphenol A epoxy resin, and its epoxy value is 0.4-0.5: bisphenol A epoxy resin has good adhesion and mechanical properties, and the appropriate epoxy value ensures the reaction effect with the curing agent, that is, ensures the self-leveling strength after curing.

[0035] The active diluent is a glycidyl ether active diluent: the glycidyl ether active diluent can reduce the viscosity of the epoxy resin, improve its fluidity, and participate in the curing reaction without affecting the performance of the material.

[0036] The curing agent is an amine curing agent or an acid anhydride curing agent: the amine curing agent has a fast curing speed, and the acid anhydride curing agent has better performance after curing. The appropriate curing agent can be selected according to specific needs.

[0037] The average particle size of nano-silica is 20-50nm: the addition of nano-silica can significantly improve the strength, hardness and chemical corrosion resistance of the material.

[0038] The specific surface area of metakaolin is not less than 800m2 / kg: metakaolin has volcanic ash activity and can react with cement hydration products to improve the later strength and durability of the material.

[0039] The redispersible latex powder is ethylene-vinyl acetate copolymer latex powder: the redispersible latex powder can improve the flexibility, adhesion and water resistance of the material.

[0040] The water reducer is a polycarboxylic acid water reducer: the polycarboxylic acid water reducer has a high efficiency in water reduction, can reduce the water-cement ratio of the material, and improve the strength and durability.

[0041] The defoaming agent is a silicone defoaming agent: the silicone defoaming agent can effectively eliminate bubbles generated during material preparation and construction, and ensure the surface quality of the material.

[0042] This self-leveling material is used for floor paving. The specific construction steps are as follows:

[0043] Step 1: Base treatment: Clean the surface of the base, remove oil, dust, loose objects, etc., and then polish it to make the surface of the base smooth and rough;

[0044] Step 2: Apply primer: Apply a layer of epoxy resin primer on the surface of the base, and proceed to the next step of construction after the primer is dry;

[0045] Step 3: Prepare self-leveling material: prepare high-performance cement epoxy self-leveling material according to the preparation method described in this disclosure;

[0046] Step 4: Laying self-leveling material: Pour the prepared self-leveling material on the base layer, scrape it flat with a scraper, and then roll it with a defoaming roller to eliminate bubbles;

[0047] Step 5: Maintenance: After the self-leveling material is laid, maintenance should be carried out for no less than 7 days.

[0048] Example 1

[0049] A high-performance cement epoxy self-leveling material is composed of the following raw materials in parts by weight: 30 parts of ordinary Portland cement; 10 parts of epoxy resin; 5 parts of glycidyl ether active diluent; 8 parts of amine curing agent; 2 parts of nano-silicon dioxide; 5 parts of metakaolin; 3 parts of ethylene-vinyl acetate copolymer latex powder; 0.5 parts of polycarboxylic acid water reducer; 0.1 parts of silicone defoaming agent; and 20 parts of water.

[0050] Preparation method:

[0051] S1: Add ordinary Portland cement, nano-silica, metakaolin, ethylene-vinyl acetate copolymer latex powder, polycarboxylic acid water reducer, and silicone defoamer into a mixer and mix well to obtain a dry mix;

[0052] S2: adding epoxy resin and glycidyl ether active diluent into another container and stirring evenly to obtain epoxy resin mixed solution;

[0053] S3: While stirring, slowly add the epoxy resin mixture to the dry mix and continue stirring for 3 minutes;

[0054] S4: adding an amine curing agent and water, and stirring for 2 minutes to obtain the high-performance cement epoxy self-leveling material.

[0055] Application: Following the above construction steps, the self-leveling material was applied to the floor. After seven days of curing, its performance was tested. The results showed that the material achieved an early strength (compressive strength at day 1) of 15 MPa and a compressive strength of 60 MPa at day 28. It also exhibited excellent water resistance and a bond strength of 2.5 MPa to the base layer.

[0056] Example 2

[0057] A high-performance cement epoxy self-leveling material is composed of the following raw materials in parts by weight: 50 parts of sulphoaluminate cement; 20 parts of epoxy resin; 10 parts of glycidyl ether reactive diluent; 15 parts of acid anhydride curing agent; 5 parts of nano-silica; 10 parts of metakaolin; 8 parts of ethylene-vinyl acetate copolymer latex powder; 2 parts of polycarboxylic acid water reducer; 0.5 parts of organosilicon defoaming agent; 3 parts of pigment; and 40 parts of water.

[0058] Preparation method:

[0059] S1: adding sulphoaluminate cement, nano-silica, metakaolin, ethylene-vinyl acetate copolymer latex powder, polycarboxylic acid water reducer, organosilicon defoamer and pigment into a mixer and stirring uniformly to obtain a dry mix;

[0060] S2: adding epoxy resin and glycidyl ether active diluent into another container and stirring evenly to obtain epoxy resin mixed solution;

[0061] S3: While stirring, slowly add the epoxy resin mixture to the dry mix and continue stirring for 5 minutes;

[0062] S4: adding an anhydride curing agent and water, stirring for 4 minutes to obtain the high-performance cement epoxy self-leveling material.

[0063] Application: Following the above construction steps, the self-leveling material was applied to the floor. After seven days of curing, its performance was tested. The results showed that the material achieved an early strength (compressive strength at day 1) of 20 MPa and a compressive strength of 70 MPa at day 28. It also exhibited excellent water and chemical resistance, and a bond strength of 3.0 MPa with the base layer.

[0064] Example 3

[0065] A high-performance cement epoxy self-leveling material is composed of the following raw materials in parts by weight: 40 parts of ordinary Portland cement; 15 parts of epoxy resin; 8 parts of glycidyl ether reactive diluent; 12 parts of amine curing agent; 3 parts of nano-silicon dioxide; 8 parts of metakaolin; 6 parts of ethylene-vinyl acetate copolymer latex powder; 1.5 parts of polycarboxylic acid water reducer; 0.3 part of organosilicon defoamer; 1 part of pigment; and 30 parts of water.

[0066] Preparation method:

[0067] S1: adding ordinary Portland cement, nano-silica, metakaolin, ethylene-vinyl acetate copolymer latex powder, polycarboxylic acid water reducer, organosilicon defoamer and pigment into a blender and stirring evenly to obtain a dry mix;

[0068] S2: adding epoxy resin and glycidyl ether active diluent into another container and stirring evenly to obtain epoxy resin mixed solution;

[0069] S3: While stirring, slowly add the epoxy resin mixture to the dry mix and continue stirring for 4 minutes;

[0070] S4: adding an amine curing agent and water, and stirring for 3 minutes to obtain the high-performance cement epoxy self-leveling material.

[0071] Application: Following the above construction steps, the self-leveling material was applied to the floor. After seven days of curing, its performance was tested. The results showed that the material achieved an early strength (compressive strength at day 1) of 18 MPa and a compressive strength of 65 MPa at day 28. It also exhibited excellent water and chemical resistance, and a bond strength of 2.8 MPa with the base layer.

[0072] The present disclosure has been described using the aforementioned embodiments. However, the aforementioned embodiments are merely exemplary embodiments of the present disclosure. It should be noted that the disclosed embodiments do not limit the scope of the present disclosure. On the contrary, modifications and alterations made without departing from the spirit and scope of the present disclosure are within the scope of patent protection of the present disclosure.

Claims

1. A high performance cement epoxy self-leveling material, characterized in that: The invention comprises the following raw materials in parts by weight: 30-50 parts of cement; 10-20 parts of epoxy resin; 5-10 parts of reactive diluent; 8-15 parts of curing agent; 2-5 parts of nano-silicon dioxide; 5-10 parts of metakaolin; 3-8 parts of redispersible latex powder; 0.5-2 parts of water reducing agent; 0.1-0.5 parts of defoaming agent; Pigment 0-3 parts; Water 20-40 parts.

2. The high performance cement epoxy self-leveling material according to claim 1, characterized in that: The cement is ordinary Portland cement or sulphoaluminate cement with a strength grade of not less than 42.

5.

3. The high performance cement epoxy self-leveling material according to claim 1, characterized in that: The epoxy resin is bisphenol A type epoxy resin, and its epoxy value is 0.4-0.

5.

4. The high performance cement epoxy self-leveling material according to claim 1, characterized in that: The active diluent is a glycidyl ether active diluent.

5. The high performance cement epoxy self-leveling material according to claim 1, characterized in that: The curing agent is an amine curing agent or an acid anhydride curing agent.

6. The high performance cement epoxy self-leveling material according to claim 1, characterized in that: The average particle size of the nano-silicon dioxide is 20-50 nm.

7. The high performance cement epoxy self-leveling material according to claim 1, characterized in that: The specific surface area of the metakaolin is not less than 800m 2 / kg.

8. The high performance cement epoxy self-leveling material according to claim 1, characterized in that: The redispersible latex powder is ethylene-vinyl acetate copolymer latex powder.

9. The high performance cement epoxy self-leveling material according to claim 1, characterized in that: The water reducer is a polycarboxylic acid water reducer.

10. A method for preparing a high-performance cement epoxy self-leveling material, characterized in that: The high-performance cement epoxy self-leveling material prepared by the method comprises the following raw materials in parts by weight: 30-50 parts of cement; 10-20 parts of epoxy resin; 5-10 parts of reactive diluent; 8-15 parts of curing agent; 2-5 parts of nano-silicon dioxide; 5-10 parts of metakaolin; 3-8 parts of redispersible latex powder; 0.5-2 parts of water reducing agent; 0.1-0.5 parts of defoaming agent; Pigment 0-3 parts; 20-40 parts water; The preparation method comprises the following steps: S1: Add cement, nano-silica, metakaolin, redispersible latex powder, water reducer, and defoamer according to the above weight parts into a mixer and stir evenly to obtain a dry mix; S2: adding the epoxy resin and reactive diluent according to the above weight parts into another container and stirring evenly to obtain an epoxy resin mixture; S3: While stirring, slowly add the epoxy resin mixture to the dry mix and continue stirring for 3-5 minutes to obtain a mixture; S4: Add the curing agent and water according to the above weight parts to the mixture obtained in step S3, and stir for 2-4 minutes to obtain the high-performance cement epoxy self-leveling material.