Blocked Aluminous Cement Mortar for Fast, Low-Toxicity Anchoring
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Solution Overview
Problem
Existing two-component mortar systems for chemical fastening in mineral substrates are often polluting, expensive, hazardous, and have reduced mechanical performance under thermal exposure, with a reliance on rare and expensive alkali-metal salts that are environmentally and economically unsustainable.
Innovation Solution
A two-component mortar system comprising a curable aqueous-phase aluminous cement component A with a blocking agent and a silicate-based initiator component B, including an accelerator and retarder, which uses sodium silicate, potassium silicate, or lithium silicate as activators, and mineral fillers to achieve rapid setting and hardening while reducing the use of rare alkali-metals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rare alkali-metal salts (lithium salts) are used as activators in aluminous cement systems, then rapid setting and high mechanical performance are achieved, but environmental sustainability and economic cost deteriorate due to mining concerns and expense
Solution Approach 1:
The patent replaces expensive and environmentally concerning lithium salts with more abundant and economical alkali metal salts (such as sodium or potassium salts). This substitution maintains the rapid setting functionality while reducing economic cost and environmental impact associated with rare metal mining and usage
Solution Approach 2:
The patent modifies the chemical composition parameters of the activator system by changing from lithium-based to alternative alkali metal-based compositions. This parameter change allows the system to achieve similar performance characteristics (setting speed, mechanical strength) while improving sustainability and cost-effectiveness
2Productivity
If organic resin systems are used for chemical fastening, then rapid curing is achieved, but environmental safety and mechanical stability under thermal exposure deteriorate
Solution Approach 1:
The patent substitutes organic resin-based chemical systems with inorganic aluminous cement-based systems. This replacement eliminates the environmental hazards, toxicity, and thermal instability associated with organic resins while maintaining rapid setting capabilities through the use of alternative activators and accelerators
Solution Approach 2:
The patent changes the fundamental chemical nature of the binding system from organic polymerization to inorganic cement hydration. This parameter change enables the system to achieve rapid curing through chemical activation while providing superior thermal stability and mechanical reliability inherent to inorganic cement systems
3Object-generated harmful factors
If aluminous cement systems are used instead of organic systems, then environmental safety and thermal resistance are improved, but setting time control and handling characteristics may deteriorate
Solution Approach 1:
The patent introduces blocking agents as intermediary substances that temporarily inhibit the reactive components in the aluminous cement system. These blocking agents allow the mortar to maintain stable, handleable characteristics during storage and application, then release their inhibiting effect to enable rapid setting when activated, thus mediating between environmental safety and ease of operation
Solution Approach 2:
The patent applies blocking agents to the aluminous cement component in advance to prevent premature setting. This preliminary action ensures the mortar remains workable and easy to handle during storage and application, while the setting reaction is delayed until intentional activation occurs, thereby improving ease of operation without compromising environmental safety
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides superior environmental and safety performance, extended storage time, and balanced setting and hardening, maintaining mechanical strength and durability while being cost-effective and less toxic, addressing ecological and economic concerns related to climate change and resource limitations.
Implementation Method 1
an initiator component B in aqueous-phase for initiating the curing process, wherein the initiator comprises a silicate-based activator component and accelerator component
Implementation Method 2
component A further comprising at least one blocking agent selected from the group consisting of boric acid, phosphoric acid, metaphosphoric acid, phosphorous acid, phosphonic acids, salts and mixtures thereof
Data Source
AI summary
The present invention pertains to a two-component mortar system for chemical fastening of anchoring means in mineral substrates, comprising a curable aqueous-phase aluminous cement component A and an initiator component B in aqueous-phase for initiating the curing process, component A further comprising at least one blocking agent selected from the group consisting of boric acid, phosphoric acid, metaphosphoric acid, phosphorous acid, phosphonic acids, salts and mixtures thereof, at least one plasticizer and water, and component B comprising an initiator including an silicate-based activator component and accelerator component, at least one retarder, at least one mineral filler and water. Moreover, the present invention pertains to a two-component system, which is ready-for-use, for chemical fastening of anchoring means, preferably of metal elements, in mineral substrates, such as structures made of brickwork, concrete, pervious concrete or natural stone as well as its use for chemical fastening of anchoring means.