Liquid carborundum and construction method thereof

Abstract

The invention provides liquid carborundum and a construction method thereof. The liquid carborundum is prepared by mixing 20 wt% of a waterborne epoxy curing agent and 80 wt% of an emulsion base material. A waterborne epoxy system is adopted as a main binding phase, and high-proportion inorganic aggregate is combined to construct an emulsion base material, so that the concept of liquid carborundum in a real sense is realized, high hardness and excellent wear resistance of a traditional carborundum floor are reserved, and the problems of dust pollution, uneven spreading, weak binding force and the like caused by dry spreading construction are solved; and the construction environment is greatly improved, and the consistency of the operation safety and the construction quality is improved.

Description

Technical Field

[0001] This invention belongs to the field of building construction materials technology, and more specifically, relates to a liquid corundum and its construction method. Background Technology

[0002] In the field of building decoration materials, especially in industrial and commercial flooring systems, the demand for flooring materials with high wear resistance, high strength, and excellent durability is increasing. Traditional corundum wear-resistant flooring has long been widely used in heavy-duty environments such as factories, warehouses, and parking lots. It primarily achieves surface strengthening by dry-spreading high-hardness mineral aggregates (such as quartz sand and corundum powder) during the initial setting stage of freshly poured concrete, followed by mechanical troweling. However, this dry-spreading construction process has significant limitations: it generates a large amount of dust during construction, affecting the working environment, harming the health of construction workers, and failing to meet the requirements of modern green building and environmentally friendly construction; simultaneously, the uniformity of aggregate spreading is greatly affected by manual operation, easily leading to local accumulation or omissions, resulting in unstable floor surface quality and inconsistent wear resistance; furthermore, dry-spreading materials mainly rely on physical embedding and bonding with the substrate, resulting in limited bond strength, making them prone to sanding, delamination, and even peeling during long-term use, indicating insufficient durability. More notably, this process has extremely strict requirements on the concrete pouring time window, which must be precisely controlled during the initial setting stage. It has a low tolerance for construction errors and is difficult to adapt to complex and ever-changing site conditions.

[0003] To overcome the drawbacks of dry-spreading processes, liquid or semi-liquid flooring materials have gained increasing attention in recent years, with epoxy resins being a prime example. Epoxy self-leveling or thin-coat flooring utilizes a liquid application method, offering advantages such as seamless molding, a smooth surface, and diverse colors, while also providing a clean and highly controllable construction process. However, conventional epoxy flooring typically uses organic resins as the continuous phase. While possessing good adhesion and decorative properties, its surface hardness and abrasion resistance are relatively low, making it prone to scratches, wear, and even coating damage, especially under heavy-load wheel pressure or high-frequency friction environments. Furthermore, many epoxy systems still rely on solvent-based formulations to adjust application viscosity, resulting in high emissions of volatile organic compounds (VOCs), flammability, and irritating odors, which contradict current environmental regulations and sustainable development trends. Although attempts have been made to add inorganic aggregates to epoxy coatings to improve abrasion resistance, most solutions only use them as auxiliary fillers with low aggregate content, failing to achieve truly "emery-grade" abrasion resistance. Moreover, the high solids content leads to difficulties in sedimentation and rheological control, limiting its practical application. Summary of the Invention

[0004] To address the aforementioned technical problems, this invention provides a liquid corundum and its construction method, thereby solving the problems of settlement and rheological control difficulties caused by the high solids content in existing corundum flooring.

[0005] A liquid corundum is made by mixing 20 wt% water-based epoxy curing agent with 80 wt% emulsion base material.

[0006] Furthermore, the emulsion base material comprises 12.5% ​​aqueous epoxy emulsion and 87.5% inorganic aggregate powder; the inorganic aggregate powder has a particle size of 40-100 mesh and is selected from one or more of quartz sand, corundum, alumina powder, and iron sand. In this solution, the inorganic aggregates (quartz sand, iron sand, alumina powder, etc.) constitute the main structure of the material, providing high hardness, high wear resistance, and thermal stability. Specifically, quartz sand / corundum / alumina powder, with a Mohs hardness of 6-9, serves as the main wear-resistant component, preferentially bearing the load during friction and protecting the organic matrix; iron sand has high density and good thermal conductivity, which can improve the impact resistance and antistatic ability of the floor (if required); particle size control (40-100 mesh) achieves graded filling, reduces porosity, and increases bulk density; the high content (87.5%) enables the aggregates to form a "point contact" or "surface contact" network, partially undertaking the load transfer function and reducing dependence on the resin matrix.

[0007] Furthermore, the aqueous epoxy emulsion is prepared from the following components: 50 parts E51 epoxy resin, 8 parts R2 emulsifier, 3 parts glacial acetic acid, and 60 parts deionized water. The aqueous epoxy emulsion is obtained through a high-speed shear emulsification process, with a particle size ≤1μm and a storage stability ≥6 months. In this solution, the aqueous epoxy emulsion and curing agent act as a binder, forming a continuous organic cross-linked network that encapsulates and anchors the inorganic aggregate, imparting integrity, impact resistance, and chemical resistance to the material. Specifically, E51 epoxy resin contains a large number of epoxy groups (—CH—CH2—O), which undergo ring-opening polymerization under the action of the curing agent to form a three-dimensional network with high cross-linking density; it adopts an aqueous emulsion form, avoiding VOC emissions and shrinkage cracking problems caused by solvent evaporation; the synergistic effect of R2 emulsifier and glacial acetic acid enables the epoxy resin to be stably dispersed in water, forming a microemulsion with a particle size ≤1μm, improving storage stability and film uniformity; the proportion of aqueous epoxy curing agent is as high as 20%, ensuring that it can still fully react in high solids content systems and avoiding performance degradation caused by "uncured residue".

[0008] Furthermore, the emulsion base material is a dry-mix premix, composed of inorganic bone powder and powdered epoxy resin. Before use, water is added and stirred to form a workable slurry, achieving simultaneous on-site emulsification and curing reactions. Specifically, the powdered epoxy resin, during the water-addition and stirring process, works in conjunction with the water-based curing agent to achieve "on-site emulsification + in-situ curing." Specifically, fine powder (≤80μm) partially dissolves or forms micelles under high-speed shearing in water, reacting with the water-based curing agent to generate low-molecular-weight prepolymers, playing a "self-emulsifying" role. As the reaction proceeds, the molecular weight increases, gradually forming a continuous organic phase. This process occurs simultaneously with cement hydration, achieving a "dual curing mechanism" (chemical crosslinking + hydration gel). The dry-mix form avoids the long-term storage stability problem of high-solids-content slurries. Innovation: Separating "material storage" from the "emulsification process" improves product transportation convenience.

[0009] Furthermore, the emulsion-based dry-mix premix comprises the following parts by weight: 30 parts iron sand, 30 parts cement, 30 parts quartz sand, 2 parts additives, and 8 parts powdered epoxy resin; the additives include 0.5 parts defoamer, 0.5 parts leveling agent, 0.3 parts retarder, and 0.7 parts silane coupling agent. The silane coupling agent (such as KH-560) is used to improve the interfacial bonding strength between the epoxy resin and the inorganic aggregate. Specifically, the silane coupling agent has a molecular structure of Y–(CH2). n –Si(OR)3, wherein: Y groups (such as epoxy groups) are compatible with epoxy resin and participate in cross-linking; Si(OR)3 hydrolyzes to generate Si–OH, which forms hydrogen bonds or covalent bonds (Si–O–Si) with –OH on the aggregate surface; a “chemical bonding layer” is formed at the interface, which transforms the original physical adsorption into chemical anchoring; reduces interface defects and improves stress transfer efficiency.

[0010] Furthermore, the cement is rapid-hardening sulfoaluminate cement or high-alumina cement; the powdered epoxy resin has a softening point of 85–95℃, a particle size ≤80μm, and is reactive with water-based curing agents. In this scheme, the cement (rapid-hardening sulfoaluminate or high-alumina cement) undergoes a hydration reaction in the presence of water, generating CSH gel and ettringite crystals to form an inorganic microstructure network, providing early strength and volume stability. Specifically, the cement hydration products coexist and interpenetrate with the epoxy crosslinking network, forming an "organic-inorganic interpenetrating network (IPN)"; ​​the hydration process releases heat, promoting the curing reaction of the epoxy resin at low temperatures; the hydration products fill the micropores in the epoxy network, increasing density; and react with the subsequently sprayed lithium-based curing agent to generate a denser, low-alkalinity CSH gel, avoiding alkali-aggregate reaction. Innovation: Cement is not only a filler but also an "active inorganic component," participating in structural construction and synergistic reactions.

[0011] Furthermore, the emulsion base material also contains 0.5–2% nano-silica or nano-calcium carbonate. In this scheme, nanofillers (nano-SiO2 or CaCO3) are used to improve rheological properties, inhibit sedimentation, and enhance density and impermeability. Specifically, nanoparticles have a high specific surface area and can be adsorbed on the surface of aggregates or between resin molecular chains to form a "network structure," improving the thixotropy of the slurry and preventing sedimentation before construction; during film formation, nanoparticles fill the micropores (<100nm) between the epoxy network and the aggregate, reducing defects; surface hydroxyl groups (—OH) can react with epoxy groups or silane coupling agents to participate in interfacial bonding; the coefficient of thermal expansion is close to that of inorganic aggregates, reducing temperature stress. Innovation: Full-scale structural optimization from "macroscopic uniformity" to "microscopic density."

[0012] A method for applying liquid corundum includes the following steps:

[0013] S1: The construction surface is ground and dust is removed to achieve a surface cleanliness level of Sa2.0 according to CNS or ISO standards.

[0014] S2: Take two portions of emulsion base:

[0015] Add 10-15% water to the first batch and stir well. Apply the mixture to the ground to form a penetrating base layer.

[0016] The second part contains 20% water-based epoxy curing agent and 5-10% water. After stirring, it is slowly applied to the base surface to form a wear-resistant surface layer.

[0017] S3: After the surface layer has initially set, spray with lithium-based concrete sealant and hardener at a dosage of 0.2 kg / m². 2 In this step, a lithium-based sealing and curing agent is used to penetrate and react after the initial setting of the surface layer, forming an "organic-inorganic hybrid reinforcement layer." Specifically, the Li₂SiO₃ solution penetrates into the surface micropores and reacts with the cement hydration product Ca(OH)₂ to generate a low-alkalinity CSH gel.

[0018] Li2SiO3+Ca(OH)2+H2O→CaO·SiO2·nH2O+2LiOHLi2

[0019] SiO3+Ca(OH)2+H2O→CaO·SiO2·nH2O+2LiOH

[0020] The generated CSH gel fills the surface pores, improving hardness and impermeability; at the same time, Li+ ions can weakly coordinate with polar groups (such as –OH) in the epoxy network, promoting the fusion of organic-inorganic interfaces; during the grinding process, this dense layer is polished to a high-gloss surface, forming a "mirror-finish wear-resistant layer".

[0021] S4: Curing at room temperature for 24–48 hours;

[0022] S5: Use a refurbishing grinder to perform dry grinding in sequence with 50#, 150# and 300# resin grinding discs, and polish until the surface gloss is ≥70GU;

[0023] S6: Optionally, after grinding, apply a water-based topcoat varnish to enhance stain resistance and decorative effect.

[0024] Furthermore, the "slow coating" described in step S2 is applied using a toothed scraper or a spiral roller, controlling the wet film thickness to 1.5–2.5 mm to ensure uniform distribution of aggregate.

[0025] Furthermore, the sealing and curing agent sprayed in S3 is a lithium silicate solution with a modulus of 2.0–3.0, which promotes the interfacial fusion of cement hydration products and epoxy crosslinking network to form an "organic-inorganic hybrid reinforcement layer".

[0026] The construction process in this method has a synergistic effect, specifically the S2 layered construction: First layer (emulsion base material + water only): The low-viscosity slurry penetrates into the capillary pores of the concrete, forming an "anchoring layer" and improving overall adhesion; Second layer (with hardener): Forms a dense surface layer, undertaking the main wear-resistant function; S3 spraying hardener: Spraying before the surface layer is fully hardened, ensuring that Li2SiO3 fully penetrates and reacts with unhydrated cement; S5 grinding: Mechanical action removes surface laitance and uneven layers; exposes the internal dense structure and aggregate particles; polishing forms a smooth mirror surface, improving light reflectivity and decorative effect; the grinding process generates local temperature rise, promoting the completion of residual reactions.

[0027] Compared with the prior art, the present invention has the following beneficial effects:

[0028] (1) By using a water-based epoxy system as the main binder and combining it with a high proportion of inorganic aggregates to construct an emulsion base, the concept of "liquid corundum" is realized in a true sense. It retains the high hardness and excellent wear resistance of traditional corundum flooring, while overcoming the problems of dust pollution, uneven spreading and weak bonding caused by dry spreading construction. It greatly improves the construction environment and enhances the safety of operation and the consistency of construction quality.

[0029] (2) By optimizing the materials, this invention innovatively proposes two implementation paths: one is a liquid system of pre-emulsified waterborne epoxy emulsion mixed with inorganic aggregates, which has good fluidity and storage stability; the other is a powder form of pre-dry mixed powdered epoxy resin and inorganic aggregates, which can be mixed with water before use to form a workable slurry. This solution greatly improves the storage period and transportation convenience of the materials, solves the technical problems of high solids content slurries being prone to settling and difficult to store, and expands the application scenarios and market adaptability of the products. At the same time, by introducing micron-level fillers such as nano-silica or nano-calcium carbonate, the thixotropic properties of the slurry are effectively improved, aggregate settling is inhibited, and the density and impermeability after film formation are enhanced, further improving the chemical corrosion resistance and long-term durability of the floor.

[0030] (3) The present invention adopts a step-by-step coating strategy: first, the base layer is coated with diluted emulsion base material to achieve good penetration and interface anchoring; then, a surface slurry containing curing agent is applied to ensure full cross-linking and film formation; then, the curing agent is sprayed for deep strengthening, and combined with a multi-stage dry grinding process, to finally obtain a high-gloss, seamless mirror-like floor surface, which combines the practicality of industrial flooring with the decorativeness of commercial space. Attached Figure Description

[0031] Figure 1 This is a comparison chart of experimental data in this embodiment. Detailed Implementation

[0032] The embodiments of the present invention will be described in further detail below with reference to examples. These examples are for illustrative purposes only and should not be construed as limiting the scope of the invention.

[0033] Example 1: Water-based emulsion type liquid corundum

[0034] 1. Preparation of waterborne epoxy emulsion:

[0035] Take 50 kg of E51 epoxy resin and 8 kg of R2 nonionic emulsifier, mix them evenly in a stirring tank, slowly add 3 kg of glacial acetic acid to adjust the pH to 6.0, and then gradually add 60 kg of deionized water in a high-speed shear emulsifier with a speed of 3000 rpm. Continue emulsifying for 30 minutes to obtain a stable waterborne epoxy emulsion with a particle size ≤1 μm. It does not show any stratification or demulsification after being stored at room temperature for 6 months.

[0036] 2. Preparation of emulsion base material:

[0037] 12.5 kg of the above-mentioned aqueous epoxy emulsion was mixed with 87.5 kg of inorganic bone powder, wherein the bone powder consisted of 40 kg of quartz sand, 30 kg of corundum, and 17.5 kg of iron sand, with a particle size controlled at 60–80 mesh. 1.5 kg of nano-silica (accounting for 1.5% of the total base material) was added, and the mixture was stirred in a planetary mixer at 500 rpm for 20 minutes to form a uniform and stable emulsion base material.

[0038] 3. Composition of liquid diamond:

[0039] Take 80 kg of the above emulsion base material, add 20 kg of water-based epoxy curing agent (polyamide modified amine), stir evenly to obtain the liquid carborundum finished product, which is a flowable slurry with a viscosity of about 800–1200 mPa·s, and is suitable for roller coating or toothed scraper application.

[0040] 4. Construction method:

[0041] S1: Grind the concrete substrate to remove dust and oil stains, achieving a cleanliness level of Sa2.0 according to ISO 8501-1 standard;

[0042] S2: Take two portions of emulsion base:

[0043] The first batch is mixed with 12% water until smooth, then applied to the ground using a short-nap roller to form a penetrating base layer. The dosage is approximately 0.8 kg / m². 2 The second part contains 20% water-based epoxy curing agent and 8% water. It is then slowly applied to the substrate surface using a 1.5mm toothed scraper, with the wet film thickness controlled at 2.0mm, to form a wear-resistant surface layer.

[0044] S3: Approximately 2 hours after the surface layer application, evenly spray a lithium-based concrete sealant and hardener. The lithium-based concrete sealant and hardener used in this solution is a lithium silicate solution with a modulus of 2.5 and a dosage of 0.2 kg / m². 2 ;

[0045] S4: Curing at room temperature (25℃) for 36 hours;

[0046] S5: Dry grinding was performed using a refurbishing grinder with 50#, 150#, and 300# resin grinding discs in sequence. Dust was cleaned after each grinding, and the final surface gloss reached 72GU.

[0047] S6: Apply a layer of water-based acrylic topcoat varnish to enhance stain resistance and decorative effect.

[0048] Example 2: Dry-mixed powder type liquid diamond

[0049] 1. Preparation of dry premix: Weigh the raw materials according to the following parts by weight: iron sand: 30 parts (particle size 70-100 mesh), rapid hardening sulfoaluminate cement: 30 parts, quartz sand: 30 parts (particle size 40-60 mesh), additives: 2 parts (including defoamer 0.5 parts, leveling agent 0.5 parts, retarder 0.3 parts, silane coupling agent KH-560 0.7 parts); powdered epoxy resin: 8 parts (softening point 90℃, particle size ≤75μm).

[0050] Mix the above components in a double cone mixer for 30 minutes to obtain a uniform dry premix. Store in sealed packaging with a shelf life of up to 12 months.

[0051] 2. On-site preparation of liquid diamond:

[0052] During construction, take 80 parts of dry mix and add 35 parts of water and stir for 5 minutes to form a workable slurry; add another 20 parts of water-based epoxy curing agent to the slurry and continue stirring for 3 minutes to obtain liquid diamond with a viscosity of about 1000 mPa·s.

[0053] 3. Construction method:

[0054] S1: Same as Example 1; S2: Dilute the first batch of slurry (without curing agent) with 15% water and apply it by roller as a base layer; after adding the curing agent to the second batch, apply it as a top layer with a thickness of 2.2mm; S3: Spray lithium silicate curing agent (0.2kg / m²). 2 S4–S5: After curing for 48 hours, grind to a gloss level of 75 GU; S6: No topcoat.

[0055] Example 3: Low Nanoparticle Additive Type

[0056] Based on Example 1, the amount of nano silica was adjusted to 0.5% (i.e., 0.5% of the emulsion base), while the rest of the formulation and process remained unchanged.

[0057] Example 4: High Quartz Sand Content Liquid Carborundum

[0058] Formula and process: Emulsion base composition: 12.5kg waterborne epoxy emulsion + 87.5kg inorganic bone powder, including: 60kg quartz sand (particle size 80-100 mesh), 20kg corundum powder (Mohs hardness 9), 7.5kg iron sand, and 1.0kg nano calcium carbonate (accounting for 1.1% of the base material).

[0059] Liquid carbide formulation: 80kg emulsion base + 20kg water-based epoxy curing agent

[0060] The construction method is the same as in Example 1, but the surface layer in S2 is coated with a spiral roller, and the wet film thickness is controlled to be 1.8mm; after spraying lithium silicate curing agent in S3, grinding begins after 24 hours of curing.

[0061] Example 5: Low-temperature rapid-setting type

[0062] Formula adjustments: Modified fatty amine-based fast-setting waterborne epoxy curing agent (applicable temperature 5–15℃) is used; powdered epoxy resin is replaced with ultrafine powder with a softening point of 85℃ and a particle size ≤60μm; high-alumina cement (CA-70) is used for the cement component, which has rapid early hydration heat release; the retarder in the additives is reduced to 0.1 parts, and the early strength agent (sodium sulfate) is increased by 0.2 parts;

[0063] Construction conditions: ambient temperature 8℃, relative humidity 70%; construction method: same as in Example 2, but the curing time is shortened to 18 hours before grinding begins.

[0064] Comparative Example 1: Conventional water-based epoxy self-leveling flooring (organic system only, no high aggregate content)

[0065] Materials: 100 parts of commercially available water-based epoxy self-leveling compound A (resin + filler) and 30 parts of component B (curing agent). Application: Apply in one coat with a thickness of 2.0 mm. After curing for 7 days, grind to 300#.

[0066] Comparative Example 2: Traditional dry-spreading emery flooring (representing the current mainstream process)

[0067] Materials and Processes: 2-3 hours after the concrete base layer is poured (initial setting stage), apply 3-5 kg / m² of dry-state corundum hardener (quartz sand + metal powder). 2 Apply two passes of mechanical polishing.

[0068] Comparative Example 3: Ordinary cement-based self-leveling compound + sealing and curing agent (without epoxy)

[0069] Materials: Cement-based self-leveling mortar + commercially available sodium-based sealant and hardener

[0070] Application: Spray the hardener 7 days after the self-leveling compound is applied, and grind to 300#.

[0071] The following performance indicators were tested on Examples 1-5 and Comparative Examples 1-3 as described above:

[0072] Abrasion resistance (grinding wheel method), test standard: GB / T 22374-2008 "Floor Coating Materials" Article 6.8; Note: The smaller the value, the better the abrasion resistance.

[0073] Compressive strength, test standard: GB / T 17671-1999 "Test method for strength of cement mortar (ISO method)".

[0074] Adhesion pull-off test, test standard: GB / T 5210-2006 "Adhesion test of paints and varnishes by pull-off test".

[0075] Surface gloss, test standard: GB / T 9754-2007 "Determination of specular gloss of paint and varnish film without metallic pigments".

[0076] VOC content, test standard: GB / T 23986-2009 "Determination of VOC content in paints and varnishes by gas chromatography", limit reference: GB 38468-2019 specifies that the VOC limit for floor coatings is ≤120g / L (water-based).

[0077] Construction dust concentration, testing standard: GBZ / T 192.1-2007 "Determination of dust in workplace air - Part 1: Total dust concentration", occupational exposure limit: GBZ 2.1-2019 specifies total dust (TWA) as 4 mg / m³. 3

[0078] Pencil hardness, test standard: GB / T 6739-2006 "Determination of Hardness of Paints and Varnishes by Pencil Method"

[0079] Chemical resistance, reference standard: ASTM D1308-02 "Standard Test Method for Effect of Household Chemicals on Clear and Pigmented Organic Finishes"; judgment: no visible change is "pass".

[0080] Impact resistance, test standard: GB / T 1732-1993 "Determination of impact resistance of paint film".

[0081] Early strength performance testing was conducted in accordance with GB / T 17671-1999, but the curing time was adjusted to 24 hours.

[0082] Test results as follows Figure 1 As shown, through Figure 1 The analysis is as follows:

[0083] Examples 1-5 all employed liquid or on-site liquefaction construction, with aggregate content as high as 87.5%. In contrast, Comparative Example 1 had a low aggregate content (<60%), and Comparative Example 2, although high in aggregate, was dry-spread, resulting in severe construction pollution. This invention successfully resolves the contradiction between fluidity and storage stability in high-solids-content systems through two approaches: aqueous emulsion stable dispersion technology and dry premixing + on-site emulsification. The dry-mixing scheme in Example 2 particularly highlights its engineering adaptability, avoiding the problems of easy sedimentation and difficult transportation inherent in traditional liquid high-filler systems. It achieves a flexible "dry storage, liquid construction" model, significantly superior to the dust pollution process of Comparative Example 2.

[0084] The wear resistance, compressive strength, and adhesion of Examples 1-5 are comprehensively superior to Comparative Example 1 (pure organic) and Comparative Example 3 (pure inorganic), especially in adhesion, where Examples generally have an adhesion of ≥3.0 MPa, while Comparative Example 3 only has 2.0 MPa, and Comparative Example 2 is even lower at 1.8 MPa. This invention utilizes a triple reaction mechanism of epoxy crosslinking + cement hydration + lithium-based penetration curing to form an "organic-inorganic interpenetrating network," significantly improving interfacial bonding and overall performance. Comparative Example 1, lacking an inorganic skeleton, exhibits poor wear resistance; Comparative Example 3, lacking epoxy network support, suffers from insufficient toughness and is prone to pulverization. Example 4 maintains high adhesion even with high-hardness aggregates, indicating that the hybrid structure effectively transfers stress, avoiding a "rigid yet brittle" structure.

[0085] The gloss levels (70–78 GU) of Examples 1, 4, and 5 were significantly higher than those of Comparative Example 2 (<20 GU) and Comparative Example 3 (<30 GU), and their wear resistance was also superior. Nano-SiO2 / CaCO3 filled the micropores, increasing density; the silane coupling agent strengthened the interface, resulting in a smoother surface and stronger reflectivity after polishing. Comparative Example 2, due to uneven aggregate distribution and weak interfacial bonding, could not achieve a high-gloss polishing effect.

[0086] Example 4 still achieved 78 GU with a high quartz / corundum ratio, verifying the decisive role of nano-control on surface quality.

[0087] From a construction process perspective, all embodiments employ a step-by-step brushing, curing agent spraying, and grinding process, while Comparative Examples 1 and 3 only involve simple coating, and Comparative Example 2 lacks grinding. The gloss and decorative effect of the embodiments far surpass those of the comparative examples. This demonstrates that the process chain of this invention is optimized through a complete process of "penetration anchoring → dense film formation → deep reinforcement → surface polishing." S2 layered application ensures the adhesion to the substrate; S3 spraying of lithium-based curing agent promotes the formation of CSH gel on the surface; S5 grinding exposes the dense structure and polishes to achieve a mirror-like effect. The comparative examples cannot achieve this type of systematic reinforcement, especially Comparative Example 2, whose surface is rough and does not meet the decorative requirements of modern commercial flooring.

[0088] All examples showed VOC levels < 50 g / L and no dust during construction, while Comparative Example 2 had excessive dust concentration (12.5 mg / m³). 3 Comparative Example 1 showed a VOC concentration of 60 g / L. This invention employs an all-aqueous system or a dry-mix solvent-free approach, ensuring high performance while meeting green building standards. Comparative Example 2, although VOC-free, suffers from severe dust pollution, failing to meet occupational health requirements; Comparative Example 1, on the other hand, has solvent evaporation issues. This solution truly achieves "environmentally friendly without performance degradation."

[0089] Example 5 can still achieve rapid curing in 18 hours at a low temperature of 8℃, with a strength of 40MPa after 24 hours, while Comparative Example 1 cures slowly at low temperatures and is prone to defects. By selecting a fast-curing curing agent, high-alumina cement, and an early-strength agent, this invention can adapt to low-temperature construction scenarios, breaking through the temperature limitations of traditional epoxy flooring. The dry-mix form of Example 2 also facilitates long-distance transportation and long-term storage, making it suitable for remote areas or seasonal construction projects, with far greater engineering flexibility than the Comparative Example.

[0090] By comparing Example 3 with Examples 1 / 2 / 4 / 5, it can be seen that the amount of nano-silica used in Example 3 is only 0.5%, which is lower than the lower limit of "0.5-2%" in this scheme; the test results (gloss 65GU, abrasion resistance 0.068g / cm) are as follows. 2 The performance was slightly lower than that of Example 1 (gloss 72 GU, abrasion resistance 0.058 g / cm). 2 This indicates that when the nanofiller content is <0.5%, the thixotropy and densification effects decrease significantly, thus highlighting the necessity of "appropriate amount of nanofiller addition" in this invention.

[0091] The embodiments of the present invention are given for illustrative and descriptive purposes only, and are not intended to be exhaustive or to limit the invention to the forms disclosed. Many modifications and variations will be apparent to those skilled in the art. The embodiments were chosen and described in order to better illustrate the principles and practical application of the invention, and to enable those skilled in the art to understand the invention and to design various embodiments with various modifications suitable for a particular purpose.

Claims

1. A liquid corundum, characterized in that: It is made by mixing 20wt% water-based epoxy curing agent with 80wt% emulsion base.

2. The liquid diamond according to claim 1, characterized in that: The emulsion base material comprises 12.5% ​​aqueous epoxy emulsion and 87.5% inorganic bone powder; the inorganic bone powder has a particle size of 40-100 mesh and is selected from one or more of quartz sand, corundum, corundum powder, and iron sand.

3. The liquid diamond according to claim 2, characterized in that: The aqueous epoxy emulsion is prepared from the following components: 50 parts of E51 epoxy resin, 8 parts of R2 emulsifier, 3 parts of glacial acetic acid, and 60 parts of deionized water. The aqueous epoxy emulsion is prepared by high-speed shear emulsification process, with a particle size ≤1μm and a storage stability ≥6 months.

4. The liquid corundum according to claim 1, characterized in that: The emulsion base material is a dry premix, composed of inorganic bone powder and powdered epoxy resin; water is added and stirred before use to form a workable slurry, so that on-site emulsification and curing reactions can be carried out simultaneously.

5. The liquid diamond according to claim 4, characterized in that: The emulsion-based dry-mix premix consists of the following parts by weight: 30 parts iron sand, 30 parts cement, 30 parts quartz sand, 2 parts additives, and 8 parts powdered epoxy resin; the additives include 0.5 parts defoamer, 0.5 parts leveling agent, 0.3 parts retarder, and 0.7 parts silane coupling agent.

6. The liquid diamond according to claim 5, characterized in that: The cement is rapid-hardening sulfoaluminate cement or high-alumina cement; the powdered epoxy resin has a softening point of 85–95℃, a particle size ≤80μm, and is reactive with water-based curing agents.

7. A liquid diamond powder according to any one of claims 1 to 6, characterized in that: The emulsion base also contains 0.5–2% nano-silica or nano-calcium carbonate.

8. A method for constructing with liquid corundum, characterized in that: Includes the following steps: S1: The construction surface is ground and dust is removed to achieve a surface cleanliness level of Sa2.0 according to CNS or ISO standards. S2: Take two portions of emulsion base: Add 10-15% water to the first batch and stir well. Apply the mixture to the ground to form a penetrating base layer. The second part contains 20% water-based epoxy curing agent and 5-10% water. After stirring, it is slowly applied to the base surface to form a wear-resistant surface layer. S3: After the surface layer has initially set, spray with lithium-based concrete sealant and hardener at a dosage of 0.2 kg / m². 2 ; S4: Curing at room temperature for 24–48 hours; S5: Use a refurbishing grinder to perform dry grinding in sequence with 50#, 150# and 300# resin grinding discs, and polish until the surface gloss is ≥70GU; S6: Optionally, after grinding, apply a water-based topcoat varnish to enhance stain resistance and decorative effect.

9. The construction method according to claim 8, characterized in that: The "slow coating" process described in step S2 is carried out using a toothed scraper or a spiral roller, with the wet film thickness controlled at 1.5–2.5 mm to ensure uniform distribution of aggregate.

10. The construction method according to claim 8, characterized in that: The sealing and curing agent sprayed in S3 is a lithium silicate solution with a modulus of 2.0–3.0, which promotes the interfacial fusion of cement hydration products and epoxy crosslinking network to form an "organic-inorganic hybrid reinforcement layer".

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