Epoxy-Cement Ternary Binder for Rapid Strength and Low Shrinkage
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Solution Overview
Problem
Existing epoxy-cement-concrete systems do not develop compressive strength quickly enough and exhibit high shrinkage, which is problematic for applications requiring rapid setting and minimal delay in construction or repair processes, especially in flooring and anchoring of reinforcing steel bars.
Innovation Solution
A multicomponent composition comprising an epoxy resin, a hardener, and a ternary hydraulic binder with a higher content of calcium aluminate or sulfoaluminate cement relative to Portland cement, which accelerates the development of compressive strength and reduces shrinkage, achieving high strength within a short curing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional hydraulic binders are used in epoxy-cement-concrete systems, then the system provides basic binding functionality, but the compressive strength development is too slow for rapid construction applications
Solution Approach 1:
The patent changes the chemical composition parameters of the hydraulic binder by incorporating calcium aluminate cement and calcium sulfoaluminate cement in specific proportions (calcium aluminate cement 10-30 wt%, calcium sulfoaluminate cement 5-20 wt%, Portland cement 50-70 wt%). This parameter change accelerates the hydration reactions and compressive strength development, enabling the material to achieve 10 MPa within 3-6 hours and 35 MPa within 6-24 hours, resolving the contradiction between strength development speed and curing time.
Solution Approach 2:
The patent creates a composite binder system combining three types of cement (Portland cement, calcium aluminate cement, and calcium sulfoaluminate cement) with epoxy resin. This composite material leverages the fast-setting properties of calcium aluminate and sulfoaluminate cements while maintaining the bonding strength of Portland cement and epoxy resin, achieving both rapid strength development and adequate curing time.
2Productivity
If ternary hydraulic binders are used to accelerate curing, then workability is improved and curing time is reduced, but shrinkage remains too high for precision applications
Solution Approach 1:
The patent optimizes the compositional parameters of the ternary binder, specifically controlling the ratios of calcium aluminate cement (10-30 wt%), calcium sulfoaluminate cement (5-20 wt%), and Portland cement (50-70 wt%). This precise parameter control balances the fast-curing advantage of calcium aluminate and sulfoaluminate cements with the dimensional stability of Portland cement, reducing shrinkage to below 0.1% while maintaining rapid curing speed.
3Strength
If high content of calcium aluminate cement is used to achieve fast strength development, then compressive strength increases rapidly, but the complexity of binder formulation increases
Solution Approach 1:
The patent establishes specific parameter ranges for the binder composition: calcium aluminate cement (10-30 wt%), calcium sulfoaluminate cement (5-20 wt%), and Portland cement (50-70 wt%). These parameter constraints simplify the formulation process by providing clear guidelines for material proportions, reducing the complexity of binder design while ensuring rapid compressive strength development to 10 MPa within 3-6 hours.
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 composition achieves compressive strength at least 1.5 times higher than comparable systems within 90 minutes and significantly reduces shrinkage, making it suitable for rapid application and minimal downtime in construction and repair operations.
Implementation Method 1
a ternary hydraulic binder with a higher content of calcium aluminate or sulfoaluminate cement relative to Portland cement, which accelerates the development of compressive strength
Implementation Method 2
the curing reactions of the cement and the epoxide component run in parallel, with a thermoset network forming from the epoxy resin in the presence of a hardener
Data Source
AI summary
The invention relates to multicomponent compositions comprising epoxy resin, hardener, and ternary hydraulic binder. Said ternary hydraulic binder consisting of Portland cement, calcium sulfate, and calcium aluminate cement or calcium sulfoaluminate cement, wherein the content of calcium aluminate cement or of calcium sulfoaluminate cement is higher than the content of Portland cement. The multicomponent compositions of the present invention are useful for coating, joining, sealing, injecting, anchoring, or grouting operations in new construction or in refurbishment of existing buildings.