Basalt fiber reinforced thermosetting resin repairing material and preparation method thereof, coating, preparation method and application

Abstract

The invention provides a basalt fiber reinforced thermosetting resin repairing material which is a double-component system and comprises a component A and a component B. The component A comprises, by weight, 30-70 parts of epoxy resin, 5-15 parts of a first diluent, 3-10 parts of amine silane coupling agent modified chopped basalt fiber, 10-50 parts of pigment and filler, 1-10 parts of a rheological agent and 1-3 parts of other auxiliaries. And the component B comprises the following components in parts by weight: 60-90 parts of an amine epoxy resin curing agent, 5-20 parts of a second diluent, 1-10 parts of glycidyl ether silane coupling agent modified chopped basalt fiber and 1-10 parts of a rheological additive. According to the invention, the problems of poor dispersibility, easy agglomeration, weak interface bonding and the like of the basalt fiber in a two-component system are solved, so that the basalt fiber reinforced epoxy resin repairing material with high strength, high toughness and low shrinkage is obtained.

Description

Technical Field

[0001] This invention belongs to the field of repair materials technology, and relates to basalt fiber reinforced thermosetting resin repair materials and their preparation methods, coatings, preparation methods and applications. Background Technology

[0002] Most organic or inorganic materials are susceptible to deformation, dents, or damage during production, storage, transportation, and use due to external forces. Surface repair using thermosetting resins is a common method; for example, using putty to repair dents on steel surfaces, using thermosetting resin mortar to repair defects in resin substrates, or using epoxy putty to fill cracks in concrete surfaces. Since the repaired surface usually requires subsequent treatment such as painting, the performance of the repair material directly determines the service life and final appearance of the overall structure.

[0003] Traditional repair materials are typically composed of thermosetting resins and solid fillers, with rheology modifiers added to form a paste. This paste is applied to the defective area and then smoothed. However, common thermosetting resins generally exhibit volume shrinkage during curing. While adding solid fillers can reduce the overall shrinkage rate to some extent, the introduction of fillers often leads to a decrease in material strength and toughness, and affects its adhesion to the substrate. Therefore, in some high-performance applications, traditional thermosetting resin repair materials are insufficient to meet practical requirements.

[0004] Basalt fiber is a high-performance fiber made from basalt ore through melt drawing. Its strength is comparable to carbon fiber, while its density is only one-third that of carbon steel. Combining basalt fiber with epoxy resin can significantly improve the material's flexibility and effectively inhibit resin curing shrinkage. Introducing basalt fiber into epoxy resin repair materials can simultaneously enhance the material's toughness and strength, reduce shrinkage, and, when used with a specialized primer, further strengthen the adhesion between the repair material and the substrate.

[0005] However, the existing technology of directly adding basalt fibers to the repair material system still has the following problems: poor fiber dispersibility in the resin, easy agglomeration; weak interfacial bonding between fibers and the resin matrix, affecting the reinforcement effect; especially in two-component systems, problems such as fiber re-agglomeration during storage, complicated curing reaction system, and uneven final network structure affect the overall performance of the repair material. Therefore, how to obtain high-strength, high-toughness, and low-shrinkage epoxy resin repair materials, especially high-performance basalt fiber-reinforced epoxy resin repair materials, has become an urgent technical problem to be solved in this field. Summary of the Invention

[0006] This invention provides a basalt fiber reinforced thermosetting resin repair material and its preparation method, coating, preparation method and application, aiming to solve the problems of poor dispersibility, easy agglomeration and weak interfacial bonding of basalt fibers in two-component systems, thereby obtaining a basalt fiber reinforced epoxy resin repair material with high strength, high toughness and low shrinkage.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: In a first aspect, the present invention provides a basalt fiber reinforced thermosetting resin repair material, wherein the repair material is a two-component system comprising component A and component B, wherein: Component A comprises, by weight: 30-70 parts epoxy resin, 5-15 parts first diluent, 3-10 parts chopped basalt fiber modified with amine silane coupling agent, 10-50 parts pigments and fillers, 1-10 parts rheology modifier, and 1-3 parts other additives. The B component comprises, by weight, 60-90 parts of amine epoxy resin curing agent, 5-20 parts of second diluent, 1-10 parts of short-cut basalt fiber modified with glycidyl ether silane coupling agent, and 1-10 parts of rheology modifier.

[0008] In this invention, the epoxy resin in component A is rich in epoxy groups. An amine silane coupling agent is used to modify the fibers, allowing the amine groups (-NH2) to undergo a ring-opening reaction with the epoxy groups of the epoxy resin during the mixing stage, forming strong covalent bonds. The amine curing agent in component B is rich in active hydrogen (-NH-), and a glycidyl ether silane coupling agent (containing epoxy groups) is used to modify the fibers. The epoxy groups react with the amine groups of the curing agent molecules during the mixing stage. This targeted modification strategy ensures that the basalt fibers are firmly anchored to the matrix within their respective components through chemical reactions before being mixed with the other component, greatly enhancing the interfacial bonding between the fibers and the matrix.

[0009] This invention grafts organic functional groups onto the fiber surface using a silane coupling agent. This reduces the fiber's surface energy, and the long organic chains create a steric hindrance effect, acting like an "organic protective layer" that physically prevents the fibers from approaching each other. This treatment ensures that the fibers achieve initial uniform dispersion within their respective components and maintains this dispersion during storage, preventing re-aggregation.

[0010] Furthermore, the epoxy resin is a liquid solvent-free epoxy resin.

[0011] Furthermore, the epoxy resin is a bisphenol A type epoxy resin or a phenolic type epoxy resin.

[0012] Furthermore, the amine-based epoxy resin curing agent is a liquid, solvent-free curing agent.

[0013] Furthermore, the amine epoxy resin curing agent is a polyether amine, aliphatic amine, or alicyclic amine curing agent.

[0014] Furthermore, the amine silane coupling agent is selected from 3-aminopropylmethyldimethoxysilane, 3-aminopropylmethyldiethoxysilane, 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, or 3-diethylenetriaminopropyltrimethoxysilane.

[0015] Furthermore, the glycidyl ether silane coupling agent is selected from 3-glycidyl etheroxypropyltriethoxysilane, 3-glycidyl etheroxypropyltrimethoxysilane, 3-glycidyl etheroxypropylmethyldiethoxysilane, 3-glycidyl etheroxypropylmethyldimethoxysilane, 2-(3,4-epoxycyclohexyl)ethyltriethoxysilane or 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane.

[0016] Furthermore, the first diluent is an active diluent and / or an inert diluent.

[0017] Furthermore, the second diluent is an inert diluent.

[0018] Furthermore, the pigments and fillers include titanium dioxide, talc, or heavy calcium carbonate.

[0019] Furthermore, the active diluent is selected from dodecyl to tetradecyl glycidyl ether, butyl glycidyl ether, or octyl glycidyl ether; the inert diluent is selected from benzyl alcohol or phthalate esters.

[0020] Furthermore, the rheology modifier is hydrophobic fumed silica.

[0021] Furthermore, the other additives include at least one of defoamers or dispersants.

[0022] In a second aspect, the present invention provides a method for preparing a basalt fiber reinforced thermosetting resin repair material as described in the first aspect, comprising the following steps: (a) Modification treatment of chopped basalt fibers: The chopped basalt fibers are soaked in dilute acid, washed until neutral, dried and then soaked in organic solvent, and then reacted with silane coupling agents. The fibers used for component A are modified with amine silane coupling agents, and the fibers used for component B are modified with glycidyl ether silane coupling agents. (b) Preparation of component A: Short basalt fibers modified with amine silane coupling agent are mixed evenly with epoxy resin, and after curing, the first diluent, other additives, pigments and fillers and rheology modifiers are added in sequence and stirred until a paste is formed; (c) Preparation of component B: Short basalt fibers modified with glycidyl ether silane coupling agent are mixed evenly with amine epoxy resin curing agent, and after curing, the second diluent and rheology modifier are added in sequence and stirred until a paste is formed.

[0023] Further, in step (a), the dilute acid is sulfuric acid, hydrochloric acid, or acetic acid, with a mass concentration of 5% to 20%; the organic solvent is toluene, xylene, ethyl acetate, or ethanol; the weight ratio of the basalt fiber, the organic solvent, and the silane coupling agent is 2:(1 to 5):(0.5 to 2); the acid soaking time is 2 to 6 hours, and the organic solvent soaking time is 1 to 5 hours; the reaction temperature of the coupling reaction is 50 to 80°C, and the reaction time is 0.5 to 2 hours.

[0024] Furthermore, in steps (b) and (c), the curing is carried out at room temperature for 2 to 3 hours.

[0025] Thirdly, the present invention provides a basalt fiber reinforced thermosetting resin coating, comprising a repair material and a primer, wherein the repair material is a basalt fiber reinforced thermosetting resin repair material as described in the first aspect or a basalt fiber reinforced thermosetting resin repair material prepared by the preparation method described in the second aspect; the primer is a solvent-free epoxy primer, which is a two-component system comprising component a and component b, wherein: Component a comprises, by weight, 70-95 parts solvent-free epoxy resin and 5-30 parts diluent; Component b comprises, by weight: 70-95 parts solvent-free epoxy resin curing agent and 5-30 parts diluent.

[0026] Furthermore, the primer and the repair material use the same epoxy resin and curing agent.

[0027] Furthermore, the diluent in component a is an active diluent and / or an inert diluent, and the diluent in component b is an inert diluent.

[0028] Furthermore, the active diluent is selected from dodecyl to tetradecyl glycidyl ether, butyl glycidyl ether, or octyl glycidyl ether; the inert diluent is selected from benzyl alcohol or phthalate esters.

[0029] Fourthly, the present invention provides a method for preparing a basalt fiber reinforced thermosetting resin coating as described in the third aspect, comprising: preparation of a primer (S1): mixing raw material component a and component b uniformly; wherein component a and component b are mixed uniformly by mechanical stirring; and preparation of a repair material (S2): using the preparation method described in the second aspect.

[0030] Fifthly, the present invention provides a method of using a basalt fiber reinforced thermosetting resin coating as described in the third aspect or a basalt fiber reinforced thermosetting resin coating prepared by the preparation method described in the fourth aspect, for repairing surface defects of carbon steel, concrete, or thermosetting materials, comprising the following steps: (1) Surface treatment: Remove oil, rust, stains and dust from the area to be repaired, and sand the substrate until a fresh surface is exposed; (2) Apply primer: Apply primer to the prepared surface, apply two coats, and apply the second coat after the first coat is surface dry; (3) Apply the repair material: After the primer is surface dry, mix the A and B components of the repair material evenly, apply it to the repair area, and smooth it out; (4) Curing: Allow to dry to the surface. If coating is required, grind and clean the surface. Otherwise, let stand for more than 3 days until fully cured.

[0031] Furthermore, in step (1), for carbon steel substrates, the surface is polished until a metallic luster is exposed; for concrete substrates, the surface is polished until the underlying capillaries are exposed; and for resin substrates, the surface is treated until it is matte.

[0032] Furthermore, in step (2), raw material component a and component b are mixed in a mass ratio of 2:1 to 4:1 before application.

[0033] Furthermore, in step (3), the mass ratio of component A to component B of the repair material is 3:1 to 4:1.

[0034] Furthermore, the complete curing time is 7 days.

[0035] Compared with the prior art, the beneficial effects of the present invention include at least one of the following: 1) Significantly improved mechanical properties and bonding strength: The epoxy resin in component A is rich in epoxy groups. Amine silane coupling agents are used to modify the fibers, allowing the amine groups (-NH2) to undergo ring-opening reactions with the epoxy groups of the epoxy resin during the mixing stage, forming strong covalent bonds. The amine curing agent in component B is rich in active hydrogen (-NH-). Glycidyl ether silane coupling agents (containing epoxy groups) are used to modify the fibers, allowing the epoxy groups to react with the amine groups of the curing agent molecules during the mixing stage. This targeted modification strategy ensures that the basalt fibers are firmly "anchored" to the matrix in their respective components through chemical reactions before being mixed with the other component, greatly enhancing the interfacial bonding between the fibers and the matrix. Repair materials prepared using components A and B can be further used to prepare coatings, exhibiting tensile shear strength (10.4-12.4 MPa), tensile strength (19-23 MPa), and dry bond strength (5.0-5.4 MPa). 2) Effectively improves fiber dispersibility and storage stability: This invention grafts organic functional groups onto the fiber surface using a silane coupling agent. On the one hand, this reduces the surface energy of the fiber; on the other hand, these long organic chains create a steric hindrance effect, acting like an "organic protective layer" on the fiber surface, physically preventing the fibers from approaching each other. This treatment ensures that the fibers achieve initial uniform dispersion in their respective components and maintains this dispersion during storage, preventing re-aggregation. 3) Optimizing the cured network structure to improve material uniformity and performance consistency: In traditional two-component systems, after components A and B are mixed, the curing reaction occurs simultaneously and competitively among the epoxy groups of the resin, the amine groups of the curing agent, and the functional groups (epoxy and amine groups) on the surfaces of the two fibers. This "multiple reaction" leads to uneven crosslinking density distribution, forming local stress concentrations, resulting in a chaotic, disordered, and fragile final three-dimensional network structure. This invention simplifies the complex reaction back to a standard, controllable two-component curing reaction between resin and curing agent by pre-reacting and "consuming" the functional groups of basalt fibers with their respective components. This makes the curing process more stable and orderly, resulting in a more regular and uniform crosslinked network structure. A uniform network structure means consistent mechanical properties throughout, lower internal stress, and thus exhibits lower shrinkage, better mechanical properties, and superior bond strength. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions in the embodiments of this invention will be clearly and completely described below in conjunction with the embodiments of this invention. Those skilled in the art should understand that the embodiments described are merely illustrative of the invention and should not be considered as specific limitations thereof. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention. Process parameters not specifically specified in the following embodiments are generally performed under conventional conditions.

[0037] The endpoints and any values ​​of the ranges disclosed in this invention are not limited to the precise ranges or values, and these ranges or values ​​should be understood to include values ​​close to these ranges or values. For numerical ranges, the endpoint values ​​of the various ranges, the endpoint values ​​of the various ranges and individual point values, and individual point values ​​can be combined with each other to obtain one or more new numerical ranges, which should be considered as specifically disclosed in this invention.

[0038] In a first aspect, the present invention provides a basalt fiber reinforced thermosetting resin repair material, wherein the repair material is a two-component system comprising component A and component B, wherein: Component A comprises, by weight: 30-70 parts epoxy resin, 5-15 parts first diluent, 3-10 parts chopped basalt fiber modified with amine silane coupling agent, 10-50 parts pigments and fillers, 1-10 parts rheology modifier, and 1-3 parts other additives. The B component comprises, by weight, 60-90 parts of amine epoxy resin curing agent, 5-20 parts of second diluent, 1-10 parts of short-cut basalt fiber modified with glycidyl ether silane coupling agent, and 1-10 parts of rheology modifier.

[0039] Before being mixed with another component, the basalt fiber of this invention is firmly "anchored" to the matrix through a chemical reaction within its respective component, greatly enhancing the interfacial bonding force between the fiber and the matrix. The repair material prepared using components A and B is further used to prepare a coating with tensile shear strength (10.4-12.4 MPa), tensile strength (19-23 MPa), and dry bond strength (5.0-5.4 MPa). By grafting organic functional groups onto the fiber surface using a silane coupling agent, the surface energy of the fiber is reduced. Furthermore, these long organic chains create a steric hindrance effect, acting like an "organic protective layer" on the fiber surface, physically preventing the fibers from approaching each other. This treatment ensures that the fibers achieve initial uniform dispersion within their respective components and maintains this dispersion during storage, preventing re-aggregation. By pre-reacting and "consuming" the functional groups of the basalt fiber with its respective component, the complex reaction is simplified back to a standard, controllable two-component curing reaction between resin and curing agent. This makes the curing process more stable and orderly, resulting in a more regular and uniform cross-linked network structure. A uniform network structure means that mechanical properties remain consistent throughout the entire process, with lower internal stress, thus exhibiting better mechanical properties and superior bond strength.

[0040] As an optional implementation, the epoxy resin in component A can be 30 parts, 40 parts, 50 parts, 60 parts, 65 parts, 66 parts, or 70 parts.

[0041] As an optional implementation, in component A, the first diluent may be 5 parts, 6 parts, 9 parts, 10 parts, 11 parts, or 15 parts.

[0042] As an optional implementation, in component A, the amine silane coupling agent modified short-cut basalt fibers can be 3 parts, 5 parts, 6 parts, 7 parts, or 10 parts.

[0043] As an optional implementation, the pigment and filler in component A can be 10 parts, 12 parts, 20 parts, 22 parts, 30 parts, 40 parts, or 50 parts.

[0044] As an optional implementation, the rheology modifier in component A can be 1 part, 4 parts, 5 parts, 6 parts or 10 parts.

[0045] As an optional implementation, the other additives in component A may be 1 part, 2 parts, or 3 parts.

[0046] As an optional implementation, the amine epoxy resin curing agent in component B can be 60 parts, 70 parts, 75 parts, 80 parts, 83 parts, or 90 parts.

[0047] As an optional implementation, in component B, the second diluent can be 5 parts, 7 parts, 10 parts, 11 parts, 15 parts, or 20 parts.

[0048] As an optional implementation, in component B, the short-cut basalt fibers modified by the glycidyl ether silane coupling agent can be 1 part, 5 parts, 8 parts, or 10 parts.

[0049] As an optional implementation, the rheology modifier in component B can be 1 part, 4 parts, 5 parts, 6 parts, or 10 parts.

[0050] As an optional embodiment, the epoxy resin is a liquid solvent-free epoxy resin.

[0051] As an optional embodiment, the epoxy resin is a bisphenol A type epoxy resin or a phenolic type epoxy resin.

[0052] As an optional implementation, the amine epoxy resin curing agent is a liquid solvent-free curing agent.

[0053] As an optional embodiment, the amine epoxy resin curing agent is a polyether amine, aliphatic amine, or alicyclic amine curing agent.

[0054] As an optional implementation, the amine silane coupling agent is selected from 3-aminopropylmethyldimethoxysilane, 3-aminopropylmethyldiethoxysilane, 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, or 3-diethylenetriaminopropyltrimethoxysilane.

[0055] As an optional embodiment, the glycidyl ether silane coupling agent is selected from 3-glycidyl etheroxypropyltriethoxysilane, 3-glycidyl etheroxypropyltrimethoxysilane, 3-glycidyl etheroxypropylmethyldiethoxysilane, 3-glycidyl etheroxypropylmethyldimethoxysilane, 2-(3,4-epoxycyclohexyl)ethyltriethoxysilane or 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane.

[0056] As an optional implementation, the first diluent is an active diluent and / or an inert diluent.

[0057] As an optional implementation, the second diluent is an inert diluent.

[0058] As an alternative embodiment, the pigment and filler include titanium dioxide, talc, or heavy calcium carbonate.

[0059] As an alternative embodiment, the pigment is titanium dioxide; the filler is talc or heavy calcium carbonate.

[0060] This invention uses liquid solvent-free epoxy resin and curing agent, and combines them with specific pigments and fillers (such as titanium dioxide, talc, and heavy calcium carbonate) to further reduce the curing shrinkage rate of the system and ensure its workability, making the repair material easy to mix and smooth, forming a paste.

[0061] As an optional implementation, the active diluent is selected from dodecyl to tetradecyl glycidyl ether (AGE), butyl glycidyl ether (BGE), or octyl glycidyl ether (EHGE).

[0062] As an optional implementation, the inert diluent is selected from benzyl alcohol or phthalate esters.

[0063] As an optional implementation, the rheology modifier is hydrophobic fumed silica.

[0064] As an alternative implementation, the other additives include at least one of defoamers or dispersants.

[0065] As an optional implementation, the defoamer is selected from one of BYK-A515, BYK-051, TEGO Ariex 910, and Defom 6500.

[0066] As an alternative implementation, the dispersant is selected from one of BYK-9010, BYK-2015, TEGO 760W, TEGO673 and BYK-2152.

[0067] This invention further specifies the types of diluents. Component A can use reactive diluents (such as AGE, BGE), whose terminal epoxy groups can participate in the final curing crosslinking network, avoiding the decrease in crosslinking density and performance loss caused by adding diluents. This operation, while ensuring workability, maximizes the maintenance of the system's final performance. Component B uses an inert diluent (such as benzyl alcohol), which does not participate in the curing reaction and acts purely as a physical diluent, thus perfectly ensuring the stability of component B during storage. The use of hydrophobic fumed silica can form a strong three-dimensional network structure in the system, giving the product excellent thixotropy, enabling it to stably encapsulate fillers and fibers, preventing sagging during application and preventing dripping even with thick coatings on vertical surfaces. Hydrophobic fumed silica has better compatibility with organic resin systems and is less likely to absorb moisture from the environment, further ensuring the storage stability of the system (especially component B, which is sensitive to moisture). Defoamers effectively reduce the surface tension of the system, causing existing bubbles to escape and break down rapidly, resulting in a dense, defect-free cured body and ensuring the material's mechanical properties (especially tensile strength and bond strength). Dispersants adsorb onto the surface of pigment and filler particles, forming charge repulsion or steric hindrance, preventing particle re-aggregation and ensuring uniform and stable dispersion in the resin. This not only guarantees uniformity in appearance but also ensures uniformity and reliability of mechanical properties.

[0068] In a second aspect, the present invention provides a method for preparing a basalt fiber reinforced thermosetting resin repair material as described in the first aspect, comprising the following steps: (a) Modification treatment of chopped basalt fibers: The chopped basalt fibers are soaked in dilute acid, washed until neutral, dried and then soaked in organic solvent, and then reacted with silane coupling agents. The fibers used for component A are modified with amine silane coupling agents, and the fibers used for component B are modified with glycidyl ether silane coupling agents. (b) Preparation of component A: Short basalt fibers modified with amine silane coupling agent are mixed evenly with epoxy resin, and after curing, the first diluent, other additives, pigments and fillers and rheology modifiers are added in sequence and stirred until a paste is formed; (c) Preparation of component B: Short basalt fibers modified with glycidyl ether silane coupling agent are mixed evenly with amine epoxy resin curing agent, and after curing, the second diluent and rheology modifier are added in sequence and stirred until a paste is formed.

[0069] This invention employs a series of steps—"dilute acid soaking, cleaning, organic solvent soaking, and silane coupling agent reaction"—to ensure the fiber surface is fully activated and grafted, laying the foundation for a strong bond with the resin / curing agent. The modified fibers are first mixed with their respective components (component A: fiber and epoxy resin; component B: fiber and curing agent) and then cured, achieving "pre-anchoring" of the fibers before mixing. This is crucial for solving dispersion and interface problems. A clearly defined order of addition and mixing method ensures uniform mixing of all components, ultimately yielding a high-performance paste-like repair material.

[0070] As an optional implementation, in step (a), the dilute acid is sulfuric acid, hydrochloric acid, or acetic acid, with a mass concentration of 5% to 20%, for example, 5%, 10%, 15%, or 20%; the organic solvent is toluene, xylene, ethyl acetate, or ethanol; the weight ratio of the basalt fiber, the organic solvent, and the silane coupling agent is 2:(1-5):(0.5-2); the acid soaking time is 2-6 hours, for example, 2 hours, 3 hours, 4 hours, 5 hours, or 6 hours; the organic solvent soaking time is 1-5 hours, for example, 1 hour, 2 hours, 3 hours, 4 hours, or 5 hours; the coupling reaction temperature is 50-80°C, for example, 50°C, 60°C, 70°C, or 80°C; and the reaction time is 0.5-2 hours, for example, 0.5 hours, 1 hour, 1.5 hours, or 2 hours.

[0071] As an optional implementation, in steps (b) and (c), the curing is carried out at room temperature for 2 to 3 hours, for example, 2 hours, 2.5 hours or 3 hours.

[0072] This invention ensures that amine silane coupling agents and glycidyl ether silane coupling agents can be efficiently and stably grafted onto the surface of basalt fibers by specifying parameters such as dilute acid concentration, type of organic solvent, reaction temperature and time of coupling reaction.

[0073] Thirdly, the present invention provides a basalt fiber reinforced thermosetting resin coating, comprising a repair material and a primer, wherein the repair material is a basalt fiber reinforced thermosetting resin repair material as described in the first aspect or a basalt fiber reinforced thermosetting resin repair material prepared by the preparation method described in the second aspect; the primer is a solvent-free epoxy primer, which is a two-component system comprising component a and component b, wherein: Component a comprises, by weight, 70-95 parts solvent-free epoxy resin and 5-30 parts diluent; Component b comprises, by weight: 70-95 parts solvent-free epoxy resin curing agent and 5-30 parts diluent.

[0074] This invention, by using an epoxy primer, forms a high-strength transition layer between the substrate and the repair material, greatly enhancing the adhesion between the entire repair system and the substrate. This solves the problem of insufficient adhesion between a single repair material and the substrate (especially concrete and carbon steel), which easily leads to delamination at the interface.

[0075] As an optional implementation, in component a, the solvent-free epoxy resin can be 70 parts, 75 parts, 80 parts, 85 parts, 90 parts, or 95 parts.

[0076] As an optional implementation, in component a, the diluent may be 5 parts, 10 parts, 15 parts, 20 parts, 25 parts, or 30 parts.

[0077] As an optional implementation, the solvent-free epoxy resin in component b can be 70 parts, 75 parts, 80 parts, 85 parts, 90 parts, or 95 parts.

[0078] As an optional implementation, the diluent in component b can be 5 parts, 10 parts, 15 parts, 20 parts, 25 parts, or 30 parts.

[0079] As an alternative implementation, the primer and the repair material use the same epoxy resin and curing agent.

[0080] As an optional implementation, the diluent in component a is an active diluent and / or an inert diluent, and the diluent in component b is an inert diluent.

[0081] As an optional embodiment, the active diluent is selected from dodecyl to tetradecyl glycidyl ether, butyl glycidyl ether, or octyl glycidyl ether; the inert diluent is selected from benzyl alcohol or phthalate esters.

[0082] In this invention, the primer and repair material use the same epoxy resin and curing agent system, enabling a strong chemical bond to form between the two layers, blurring the interface, and facilitating more efficient stress transfer. These limitations allow the primer and repair material to work synergistically as a whole, achieving optimal peel resistance and durability for the overall coating system.

[0083] Fourthly, the present invention provides a method for preparing a basalt fiber reinforced thermosetting resin coating as described in the third aspect, comprising: preparation of a primer (S1): mixing raw material component a and component b uniformly; wherein component a and component b are mixed uniformly by mechanical stirring; and preparation of a repair material (S2): using the preparation method described in the second aspect.

[0084] Fifthly, the present invention provides a method of using a basalt fiber reinforced thermosetting resin coating as described in the third aspect or a basalt fiber reinforced thermosetting resin coating prepared by the preparation method described in the fourth aspect, for repairing surface defects of carbon steel, concrete, or thermosetting materials, comprising the following steps: (1) Surface treatment: Remove oil, rust, stains and dust from the area to be repaired, and sand the substrate until a fresh surface is exposed; (2) Apply primer: Apply primer to the prepared surface, apply two coats, and apply the second coat after the first coat is surface dry; (3) Apply the repair material: After the primer is surface dry, mix the A and B components of the repair material evenly, apply it to the repair area, and smooth it out; (4) Curing: Allow to dry to the surface. If coating is required, grind and clean the surface. Otherwise, let stand for more than 3 days until fully cured.

[0085] As an optional implementation, in step (1), for carbon steel substrates, the surface is polished until a metallic luster is exposed; for concrete substrates, the surface is polished until the underlying capillaries are exposed; and for resin substrates, the surface is treated until it is matte.

[0086] As an optional implementation, in step (2), raw material component a and component b are mixed in a mass ratio of 2:1 to 4:1 before application, for example, 2:1, 2.5:1, 3:1 or 4:1.

[0087] As an optional implementation, in step (3), the mass ratio of component A to component B of the repair material is 3:1 to 4:1, for example, it can be 3:1, 3.5:1 or 4:1.

[0088] As an optional implementation, the complete curing time is 7 days.

[0089] The present invention will now be described in further detail with reference to specific embodiments and comparative examples.

[0090] In the following embodiments and comparative examples: All reagents used in the examples and comparative examples are commercially available.

[0091] All reagents used in the examples and comparative examples are in parts by weight.

[0092] Example 1 Step 1: Primer preparation Component a: Mix 70 parts of liquid solvent-free bisphenol A type epoxy resin (E51), 10 parts of dodecyl to tetradecyl glycidyl ether (AGE, reactive diluent) and 20 parts of benzyl alcohol (inert diluent) until homogeneous.

[0093] Component b: Mix 85 parts of polyetheramine solvent-free epoxy resin curing agent (Hunsman D230) and 15 parts of dioctyl phthalate (inert diluent) until homogeneous.

[0094] Step 2: Modification treatment of chopped basalt fibers Short-cut basalt fibers with a diameter of 10–15 μm and a length of 3–6 mm were soaked in a 20% acetic acid solution at a mass ratio of 1:3 for 3 hours. After filtration, the fibers were washed with water until the pH of the filtrate was approximately 6.8, and then dried.

[0095] Soak in toluene for 2 hours, filter, and divide into two portions: One batch for component A: Basalt fiber, toluene, and 3-aminopropyltrimethoxysilane coupling agent are mixed in a weight ratio of 2:3:1 (stirred at 500 rpm, 3-aminopropyltrimethoxysilane is added dropwise), stirred and reacted at 50°C for 0.5 h, cooled and discharged, the fiber is washed with toluene and dried at 60°C.

[0096] One batch for component B: Basalt fiber, toluene, and 3-glycidoxypropyltrimethoxysilane coupling agent are mixed in a weight ratio of 2:3:1 (stirred at 500 rpm, 3-glycidoxypropyltrimethoxysilane is added dropwise), stirred and reacted at 50°C for 0.5 h, cooled and discharged, the fiber is washed with toluene and dried at 60°C.

[0097] Step 3: Preparation of Repair Material Component A Add 66 parts of liquid solvent-free bisphenol A type epoxy resin (E51) to 5 parts of aminopropyltrimethoxysilane modified short-cut basalt fiber, stir quickly until uniform, and then cure at room temperature for 2 hours.

[0098] After curing, add 7 parts benzyl alcohol (first diluent, inert diluent), 4 parts dodecyl glycidyl ether (AGE, first diluent, reactive diluent), 0.5 parts defoamer (Defom 6500, other additives), and 1.5 parts dispersant (BYK-2152, other additives) in sequence. After stirring evenly, add 5 parts titanium dioxide (DuPont R706), 10 parts 800-mesh talc powder, and 7 parts 800-mesh heavy calcium carbonate (pigment and filler). Stir evenly. Finally, add 4 parts hydrophobic fumed silica (TS620, rheology modifier) ​​and stir until a paste is formed.

[0099] Step 4: Preparation of Component B of the Repair Material Add 70 parts of polyetheramine solvent-free epoxy resin curing agent (Hunsman D230) to 10 parts of 3-glycidyl etheroxypropyltrimethoxysilane modified short-cut basalt fibers, stir quickly and evenly, and then cure at room temperature for 2 hours.

[0100] After maturation, add 10 parts of dioctyl phthalate (second diluent, inert diluent) and 5 parts of hydrophobic fumed silica (TS620, rheology modifier) ​​in sequence, and stir until a paste is formed.

[0101] Step 5: Surface treatment and primer application Repairing cracks on concrete surfaces: Use an angle grinder to grind the area to be repaired, removing oil, stains and dust, and grind until the underlying pores are exposed.

[0102] Mix the primer components A and B at a mass ratio of 4:1, and apply them in two coats to the surface to be repaired: after the first coat is dry to the touch, apply the second coat.

[0103] Step 6: Apply and cure the repair material After the primer has dried to the touch, mix components A and B of the repair material at a mass ratio of 4:1. Apply the repair material to the primer on the area to be repaired using a scraper or trowel sprayed with alcohol, smooth it out, and remove any excess material.

[0104] After the surface is allowed to dry, if the next coating step is required, clean the surface with solvent and sand it; if using directly, let it stand for 7 days until the strength reaches its maximum.

[0105] Example 2 Step 1: Primer preparation Component A: Mix 85 parts of liquid solvent-free bisphenol A type epoxy resin (Nanya 128), 10 parts of dodecyl to tetradecyl glycidyl ether (AGE, reactive diluent) and 5 parts of butyl glycidyl ether (BGE, reactive diluent) until homogeneous.

[0106] Component b: Mix 95 parts of alicyclic amine solvent-free epoxy resin curing agent (BASF EC210) and 5 parts of benzyl alcohol (inert diluent) evenly.

[0107] Step 2: Modification treatment of chopped basalt fibers Short-cut basalt fibers with a diameter of 6–10 μm and a length of 4–8 mm were soaked in a 10% hydrochloric acid solution at a mass ratio of 1:5 for 2 hours. After filtration, the fibers were washed with water until the pH of the filtrate was approximately 6.8, and then dried.

[0108] Soak in xylene for 2 hours, then filter and divide into two portions: One batch for component A: Basalt fiber, toluene, and 3-aminopropyltriethoxysilane coupling agent are mixed in a weight ratio of 2:4:0.5 (stirred at 500 rpm, 3-aminopropyltriethoxysilane is added dropwise), stirred and reacted at 50°C for 1 hour, cooled and discharged, the fiber is washed with p-xylene and dried at 60°C.

[0109] One batch for component B: Basalt fiber, toluene, and 3-glycidyl etheroxypropylmethyldiethoxysilane coupling agent are mixed in a weight ratio of 2:4:1 (stirred at 500 rpm, 3-glycidyl etheroxypropylmethyldiethoxysilane is added dropwise), stirred and reacted at 50°C for 0.5 h, cooled and discharged, the fiber is washed with toluene and dried at 60°C.

[0110] Step 3: Preparation of Repair Material Component A 65 parts of liquid solvent-free bisphenol A type epoxy resin (Nanya 128) were added to 7 parts of aminopropyltriethoxysilane modified short-cut basalt fibers and stirred evenly. The mixture was then cured at room temperature for 2 hours.

[0111] After curing, add 6 parts of dodecyl glycidyl ether (AGE, first diluent, reactive diluent), 3 parts of butyl glycidyl ether (BGE, first diluent, reactive diluent), 0.5 parts of defoamer (Defom 6500, other additives), and 1.5 parts of dispersant (BYK-2152, other additives) in sequence. After stirring evenly, add 2 parts of titanium dioxide (DuPont R706) and 10 parts of 800-mesh talc powder (pigment and filler), and stir evenly. Finally, add 5 parts of hydrophobic fumed silica (TS620, rheology modifier) ​​and stir until a paste is formed.

[0112] Step 4: Preparation of Component B of the Repair Material Add 75 parts of alicyclic amine solvent-free epoxy resin curing agent (BASF EC210) to 8 parts of 3-glycidyl etheroxypropylmethyl diethoxysilane modified short-cut basalt fibers, stir quickly and evenly, and then cure at room temperature for 2 hours.

[0113] After aging, add 11 parts benzyl alcohol (second diluent, inert diluent) and 6 parts hydrophobic fumed silica (TS620, rheology modifier) ​​in sequence, and stir until a paste is formed.

[0114] Step 5: Surface treatment and primer application Repairing dents on carbon steel surfaces: Use an angle grinder to grind the area to be repaired, removing oil, rust, dirt, and dust, until the surface shows a metallic luster.

[0115] Clean the surface with dilute acid and organic solvent in sequence, and then let it air dry.

[0116] Mix the primer components A and B at a mass ratio of 2:1, and apply them in two coats to the surface to be repaired: after the first coat is dry to the touch, apply the second coat.

[0117] Step 6: Apply and cure the repair material After the primer has dried to the touch, mix the A and B components of the repair material evenly at a mass ratio of 3:1.

[0118] Apply the repair material to the base coat of the area to be repaired using a scraper or trowel sprayed with alcohol, smooth it out, and remove any excess material.

[0119] After the surface is allowed to dry, if the next coating step is required, clean the surface with solvent and sand it; if using directly, let it stand for 7 days until the strength reaches its maximum.

[0120] Example 3 Step 1: Primer preparation Component a: Mix 90 parts of liquid solvent-free bisphenol A type epoxy resin (Nanya 128), 5 parts of dodecyl to tetradecyl glycidyl ether (AGE, reactive diluent) and 5 parts of butyl glycidyl ether (BGE, reactive diluent) until homogeneous.

[0121] Component b: Mix 90 parts of alicyclic amine solvent-free epoxy resin curing agent (curing agent 1327) and 10 parts of dioctyl phthalate (inert diluent) evenly.

[0122] Step 2: Modification treatment of chopped basalt fibers Short-cut basalt fibers with a diameter of 6–12 μm and a length of 5–10 mm were soaked in a 10% sulfuric acid solution at a mass ratio of 1:4 for 3 hours. After filtration, the fibers were washed with water until the pH of the filtrate was approximately 6.8, and then dried.

[0123] Soak in toluene for 1 hour, filter, and divide into two portions: One batch for component A: Basalt fiber, butyl acetate, and 3-aminopropylmethyldiethoxysilane coupling agent are mixed in a weight ratio of 2:3:2 (stirred at 600 rpm, 3-aminopropylmethyldiethoxysilane is added dropwise), stirred and reacted at 60°C for 1 hour, cooled and discharged, the fiber is washed with toluene and dried at 70°C.

[0124] One batch for component B: Basalt fiber, toluene, and 3-glycidyl etheroxypropyltriethoxysilane coupling agent are mixed in a weight ratio of 2:3:2 (stirred at 600 rpm, 3-glycidyl etheroxypropyltriethoxysilane is added dropwise), stirred and reacted at 60°C for 1 hour, cooled and discharged, the fiber is washed with toluene and dried at 70°C.

[0125] Step 3: Preparation of Repair Material Component A 70 parts of liquid solvent-free bisphenol A type epoxy resin (Nanya 128) were added to 6 parts of aminopropylmethyldiethoxysilane modified short-cut basalt fibers and stirred evenly. The mixture was then cured at room temperature for 2 hours.

[0126] After curing, add 3 parts of dodecyl glycidyl ether (AGE, first diluent, reactive diluent), 3 parts of butyl glycidyl ether (BGE, first diluent, reactive diluent), 0.5 parts of defoamer (Defom 6500, other additives), and 1.5 parts of dispersant (BYK-2152, other additives) in sequence. After stirring evenly, add 4 parts of titanium dioxide (DuPont R706) and 6 parts of 800-mesh heavy calcium carbonate (pigment and filler). Stir evenly and finally add 6 parts of hydrophobic fumed silica (TS620, rheology modifier) ​​and stir until a paste is formed.

[0127] Step 4: Preparation of Component B of the Repair Material Add 83 parts of alicyclic amine solvent-free epoxy resin curing agent (curing agent 1327) to 5 parts of 3-glycidyl etheroxypropyltriethoxysilane modified short-cut basalt fibers, stir quickly and evenly, and then cure at room temperature for 2 hours.

[0128] After aging, add 7 parts benzyl alcohol (second diluent, inert diluent) and 5 parts hydrophobic fumed silica (TS620, rheology modifier) ​​in sequence, and stir until a paste is formed.

[0129] Step 5: Surface treatment and primer application Repairing damaged areas on epoxy resin fiberglass surfaces: Use an angle grinder to grind the area to be repaired, removing oil, stains, and dust, and grind until the surface is matte.

[0130] Use an angle grinder to cut and round the damaged area, then clean the surface with toluene and let it dry.

[0131] Mix the primer components A and B at a mass ratio of 2.5:1 until homogeneous, and apply in two coats to the surface to be repaired: after the first coat is surface dry, apply the second coat.

[0132] Step 6: Apply and cure the repair material After the primer has dried to the touch, mix the A and B components of the repair material evenly at a mass ratio of 3:1.

[0133] Apply the repair material to the base coat of the area to be repaired using a scraper or trowel sprayed with alcohol, smooth it out, and remove any excess material.

[0134] After the surface is allowed to dry, if the next coating step is required, clean the surface with solvent and sand it; if using directly, let it stand for 7 days until the strength reaches its maximum.

[0135] Comparative Example 1 Comparative Example 1 is basically the same as Example 1, except that the short-cut basalt fibers are only acid-washed and solvent-cleaned, and are not modified with silane coupling agent in step 2.

[0136] Comparative Example 2 Comparative Example 2 is basically the same as Example 1, except that the chopped basalt fibers in step 2 are modified only with 3-glycidyl etheroxypropyltrimethoxysilane, and all of them are added to component A of the repair material in step 3; the modified chopped basalt fibers are not added to component B of the repair material in step 4.

[0137] Comparative Example 3 Comparative Example 3 is basically the same as Example 1, except that 3-glycidoxypropyltrimethoxysilane modified short-cut basalt fibers are added to component A of the repair material in step 3, and aminopropyltrimethoxysilane modified short-cut basalt fibers are added to component B of the repair material in step 4.

[0138] Comparative Example 4 Comparative Example 4 is basically the same as Example 1, except that the AGE (active diluent) in component A is completely replaced with an equal amount of benzyl alcohol (inert diluent), while the rest remains unchanged.

[0139] Comparative Example 5 Comparative Example 5 is basically the same as Example 1, except that the acid washing and solvent cleaning in step 2 are omitted, and the silane coupling agent treatment is performed directly, while the rest remains unchanged.

[0140] Performance testing To verify the comprehensive performance of the basalt fiber reinforced thermosetting resin coatings provided by this invention, the basalt fiber reinforced thermosetting resin coatings prepared in Examples 1-3 and Comparative Examples 1-5 were systematically tested according to the test methods for key performance indicators such as tensile shear strength, tensile strength, and dry bond strength in industry standard JC / T 1041-2007. The test results are shown in Table 1. All tests were conducted under standard conditions of (23±2)℃ and (50±5)% relative humidity.

[0141] Table 1 In Examples 1-3, Component A was modified with an amine silane coupling agent to pre-react with epoxy resin; Component B was modified with a glycidyl ether silane coupling agent to pre-react with an amine curing agent; the basalt fibers were subjected to acid washing, solvent cleaning, and grafting treatment with different types of coupling agents to improve interfacial bonding and dispersibility. The repair materials obtained in Examples 1-3 exhibited high strength, high adhesion, and excellent toughness. The coatings further prepared from these repair materials had a tensile shear strength of 10.4-12.4 MPa, far exceeding the standard requirement (≥8.0 MPa); a tensile strength of 19-23 MPa, both higher than the standard (≥15 MPa); and a dry bond strength of 5.0-5.4 MPa, better than the standard (≥4.0 MPa).

[0142] The basalt fibers in Comparative Example 1 underwent only acid washing and solvent cleaning without silane coupling agent modification. Their tensile shear strength was 6.2 MPa, tensile strength was 10 MPa, and dry bond strength was 3.1 MPa. Compared to Example 1, all properties were significantly reduced. Comparative Example 1 demonstrates that the unmodified basalt fibers lack chemical bonding with the resin / curing agent, resulting in weak interfacial adhesion and easy fiber agglomeration, leading to a substantial decrease in mechanical and bonding properties.

[0143] In Comparative Example 2, all basalt fibers were modified with epoxy silanes, with only component A added. Components A and B were not modified separately. The tensile shear strength was 8.1 MPa, the tensile strength was 12 MPa, and the dry bond strength was 4.2 MPa. Compared to Example 1, all properties decreased. Comparative Example 2 demonstrates that component B lacks fiber reinforcement, resulting in insufficient overall fiber content and failing to enhance performance. While the epoxy groups on the fiber surface in component A have good compatibility with the resin, they cannot form an ordered network after mixing with the curing agent, leading to a chaotic reaction system and limited performance improvement.

[0144] In Comparative Example 3, the coupling agents of components A and B were interchanged. Component A used basalt fiber modified with epoxy silane, and component B used basalt fiber modified with amino silane. The tensile shear strength was 8.2 MPa, the tensile strength was 12 MPa, and the dry bond strength was 4.1 MPa, similar to Comparative Example 2. Compared with Example 1, all properties decreased. Comparative Example 3 shows that the functional groups of basalt fiber cannot pre-react with the components they belong to, thus failing to achieve "pre-anchoring"; after mixing, a "quaternary competitive reaction" is formed, resulting in a chaotic cross-linking network, poor interfacial bonding, and inability to further improve performance.

[0145] Comparative Example 4 did not use an active diluent, but instead used an inert diluent, benzyl alcohol. This resulted in a softer overall system after curing. Therefore, the tensile shear strength (8.8 MPa), tensile strength (17 MPa), and dry bond strength (4.4 MPa) were all lower than those of Example 1. However, since the modification method of the basalt fiber was the same as that of Example 1, the fiber and the system had good interfacial compatibility and could be effectively dispersed in the system. Therefore, all strengths still met the requirements of JC / T 1041-2007.

[0146] In Comparative Example 5, no acid washing and solvent cleaning were used, which could not remove impurities from the fiber surface or effectively etch the fiber surface to form reaction points. Therefore, the silane coupling agent could not effectively modify the fiber surface, resulting in poor compatibility between the fiber and the system and a significant reduction in strength performance.

[0147] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A basalt fiber reinforced thermoset resin repair material, characterized in that, The repair material is a two-component system, comprising A component and B component, wherein: The A component comprises by weight: 30-70 parts of epoxy resin, 5-15 parts of first diluent, 3-10 parts of amine silane coupling agent modified short basalt fiber, 10-50 parts of pigment and filler, 1-10 parts of rheological aid, 1-3 parts of other aids; The B component comprises by weight: 60-90 parts of amine epoxy resin curing agent, 5-20 parts of second diluent, 1-10 parts of glycidyl ether silane coupling agent modified short basalt fiber, 1-10 parts of rheological aid.

2. The patch material of claim 1, wherein The epoxy resin is a liquid solvent-free epoxy resin, preferably a bisphenol A type epoxy resin or a phenolic type epoxy resin; and / or, The amine epoxy resin curing agent is a liquid solvent-free curing agent, preferably a polyether amine, aliphatic amine or alicyclic amine curing agent; and / or, The amine silane coupling agent is selected from 3-aminopropyl methyldimethoxysilane, 3-aminopropyl methyldiethoxysilane, 3-aminopropyl trimethoxysilane, 3-aminopropyl triethoxysilane or 3-diethylenetriamine propyl trimethoxysilane; and / or, The glycidyl ether silane coupling agent is selected from 3-glycidyl ether propyl triethoxysilane, 3-glycidyl ether propyl trimethoxysilane, 3-glycidyl ether propyl methyldiethoxysilane, 3-glycidyl ether propyl methyldimethoxysilane, 2- (3, 4-epoxycyclohexyl) ethyl triethoxysilane or 2- (3, 4-epoxycyclohexyl) ethyl trimethoxysilane; and / or, The first diluent is an active diluent and / or an inert diluent; and / or, The second diluent is an inert diluent; and / or, The pigment and filler include titanium white, talc or heavy calcium carbonate.

3. The patch material of claim 2, wherein The active diluent is selected from dodecyl to tetradecyl glycidyl ether, butyl glycidyl ether or octyl glycidyl ether; the inert diluent is selected from benzyl alcohol or phthalic acid diester; and / or, The rheological aid is hydrophobic fumed silica; and / or, The other aids include at least one of defoaming agent or dispersant.

4. A process for the production of a basalt fiber reinforced thermoset resin patching material according to any one of claims 1 to 3, characterized in that, The method comprises the following steps: (a) modification treatment of short basalt fiber: the short basalt fiber is soaked with dilute acid, washed to neutral, dried, then soaked with organic solvent, and then reacted with silane coupling agent, wherein the fiber for A component is modified with amine silane coupling agent, and the fiber for B component is modified with glycidyl ether silane coupling agent; (b) preparation of A component: the amine silane coupling agent modified short basalt fiber is mixed uniformly with epoxy resin, then the first diluent, other aids, pigment and filler and rheological aid are added in sequence after aging, and stirred to paste; (c) preparation of B component: the glycidyl ether silane coupling agent modified short basalt fiber is mixed uniformly with amine epoxy resin curing agent, then the second diluent and rheological aid are added in sequence after aging, and stirred to paste.

5. The preparation method according to claim 4, characterized in that, In step (a), the dilute acid is sulfuric acid, hydrochloric acid or acetic acid, with a mass concentration of 5% to 20%; the organic solvent is toluene, xylene, ethyl acetate or ethanol; the weight ratio of the basalt fiber, the organic solvent and the silane coupling agent is 2: (1-5): (0.5-2); the acid soaking time is 2-6 hours, the organic solvent soaking time is 1-5 hours; the coupling reaction temperature is 50-80°C, and the reaction time is 0.5-2 hours; and / or, In steps (b) and (c), the curing is carried out at room temperature, and the curing time is 2-3 hours.

6. A basalt fiber-reinforced thermoset resin coating, characterized by, The repair material is a basalt fiber reinforced thermosetting resin repair material as claimed in any one of claims 1-3 or prepared by the preparation method as claimed in claims 4-5; and the primer is a solvent-free epoxy primer, which is a two-component system and comprises an a component and a b component. The a component comprises, by weight, 70-95 parts of a solvent-free epoxy resin and 5-30 parts of a diluent; and the b component comprises, by weight, 70-95 parts of a solvent-free epoxy resin curing agent and 5-30 parts of a diluent. The primer and the repair material use the same epoxy resin and curing agent; and / or The diluent in the a component is an active diluent and / or an inert diluent, and the diluent in the b component is an inert diluent.

7. The coating of claim 6, wherein, Preferably, the active diluent is selected from dodecyl to tetradecyl glycidyl ether, butyl glycidyl ether or octyl glycidyl ether; and the inert diluent is selected from benzyl alcohol or phthalic acid diester. The preparation of the S1 primer comprises the following steps: The preparation of the S2 repair material is carried out by the preparation method as claimed in claims 4 or 5.

8. A process for the preparation of basalt fiber reinforced thermoset resin coating as claimed in claim 7, wherein, The method comprises the following steps: (1) surface treatment: removing oil stains, rust marks, stains and dust from the surface to be repaired, and polishing the substrate to expose a fresh surface; (2) brushing the primer: brushing the primer on the treated surface, and brushing two layers, with the second layer brushed after the first layer is dry; 9. A method of using the basalt fiber reinforced thermoset resin coating according to claim 6 or 7 or the basalt fiber reinforced thermoset resin coating prepared according to the method of claim 8 for repairing surface defects of carbon steel, concrete or thermoset materials, characterized in that, (3) applying the repair material: mixing the A component and the B component of the repair material uniformly, and applying them on the repaired part and smoothing them; (4) curing: air drying, and if painting is needed, polishing and cleaning the surface, otherwise, standing still for more than 3 days until complete curing.

10. The use method of claim 9, wherein In step (1), for a carbon steel substrate, polishing to expose a metallic luster on the surface; for a concrete substrate, polishing to expose the underlying capillary pores; and for a resin substrate, treating to expose a matte surface; and / or In step (2), the a component and the b component are mixed in a mass ratio of 2: 1-4: 1 before brushing; In step (3), the mass ratio of the A component to the B component of the repair material is 3: 1-4: 1; and / or In step (4), the complete curing time is 7 days. ​ ​ ​

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