Copolymer Accelerator Composition for Cement Hardening
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Solution Overview
Problem
Existing compositions for accelerating the hardening of hydraulic binders, such as cement, often require excessive mixing water, leading to impaired mechanical strengths and resistance properties due to excess water in concrete elements, and current hardening accelerators are not effective in enhancing early strength development.
Innovation Solution
Compositions comprising calcium silicate hydrate, ettringite, or AFm phases combined with a copolymer containing polyether macromonomers and anionic monomers, where the weight ratio of copolymer to calcium ranges from 1/20 to 20/1, are used to accelerate hardening by reacting an aqueous calcium salt solution with silicate or aluminium salts in the presence of a copolymer, followed by a drying step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If excess mixing water is used to achieve processing consistency, then the mixture becomes more fluid and easier to process, but the mechanical strengths and resistance properties of the concrete element are significantly impaired
Solution Approach 1:
The invention changes the chemical composition parameters by introducing specific inorganic compounds (calcium silicate hydrate, ettringite, AFm phases) and a copolymer with defined weight ratios (1/20 to 20/1), transforming the physical and chemical properties of the mixture to achieve both processability and strength without excess water
Solution Approach 2:
The invention uses a composite accelerator composition combining multiple inorganic compounds (calcium silicate hydrate, ettringite, or AFm phases) with a specifically designed copolymer, creating a synergistic material system that simultaneously improves processing properties and mechanical strength
2Loss of time
If commercially available calcium silicate hydrate is used as hardening accelerator, then the solidification time is shortened, but the effectiveness in enhancing early strength development is relatively low
Solution Approach 1:
The patent combines calcium silicate hydrate with a specifically designed copolymer containing polyether macromonomers and anionic monomers in defined weight ratios, creating a composite accelerator that synergistically enhances both setting acceleration and early strength development, overcoming the limitations of pure calcium silicate hydrate
Solution Approach 2:
The invention modifies the accelerator composition by introducing a copolymer with specific molecular characteristics (polyether macromonomers and anionic monomers in 1/20 to 20/1 weight ratio), changing the chemical and physical parameters to improve both setting time and early strength properties
3Ease of operation
If dispersants are used to improve processing properties, then the fluidity and spreadability are enhanced, but the excess water fraction increases leading to cavity formation
Solution Approach 1:
The invention changes the chemical composition by using a copolymer accelerator with specific molecular structure (polyether macromonomers and anionic monomers) that provides dispersing and fluidizing effects through chemical interaction rather than water addition, maintaining low water fraction while improving processing properties
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 proposed solution effectively reduces excess water in concrete, enhancing the mechanical strengths and resistance properties of hydraulic binders by accelerating the hardening process and improving early strength development, particularly in cement-based compositions.
Implementation Method 1
copolymer CP comprising i) at least one polyether macromonomer of the general formula (I) in copolymerized form and ii) at least one anionic monomer in copolymerized form
Implementation Method 2
weight ratio of copolymer CP to calcium in the composition being from 1/20 to 20/1
Implementation Method 3
an aqueous solution of a calcium salt is reacted in the presence of a copolymer CP in case a) with a silicate salt, in case b) with an aluminium salt and optionally sulphate salt, or in case c) with a silicate salt, aluminium salt and optionally sulphate salt
Implementation Method 4
followed optionally by a drying step
Data Source
Figure 1
AI summary
The invention relates to compositions comprising inorganic compounds selected from calcium silicate hydrate (C-S-H), ettringite or AFm phases and a copolymer comprising thiovinyl ether polyether macromonomers and anionic monomers, the weight ratio of copolymer to calcium being from 1/20 to 20/1. In addition it relates to methods for producing the compositions and construction material mixtures comprising the compositions.