Mortar Composition for Shaped Clinker Bricks
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Solution Overview
Problem
Existing mortars for shaped clinker bricks are prone to efflorescence and fungal attacks due to migration of dissolved salts from ingredients or atmospheric influences, and existing solutions for reducing efflorescence are not durable, leading to recurring issues with salt washing out and porosity.
Innovation Solution
A mortar composition comprising cement, quartz sand, limestone flour, modified cellulose ether, redispersible powder, aerating additive, organic and non-organic pigments, nanometric silicate additives, hydrophobic agents, and biocides, which provides enhanced resistance to salt migration, water absorption, and fungal growth, with a formulation that retains physical and chemical properties and includes pozzolanic additives for improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pozzolanic additives and hydrophobic additives are used to prevent efflorescence, then efflorescence resistance is improved, but salt migration and porosity remain problematic over time
Solution Approach 1:
The patent employs a composite material system combining multiple additives (pozzolanic additives, hydrophobic additives, starch ethers, and nanometric silicate additives) working synergistically. The pozzolanic additives bind calcium hydroxide, hydrophobic additives reduce water absorption, starch ethers control rheology, and nanometric silicates provide durable surface protection, creating a multi-functional composite mortar that addresses both immediate efflorescence prevention and long-term durability
Solution Approach 2:
The patent changes the physical and chemical parameters of the mortar system by incorporating additives at specific dosage ranges (e.g., 0.01-5% pozzolanic additives, 0.05-2% hydrophobic additives, 0.01-0.5% nanometric silicate additives). These parameter changes transform the mortar's properties to achieve both efflorescence resistance and durable salt migration prevention without excessive porosity
2Quantity of substance
If hydrophobic efflorescence control agents are used, then initial water absorption is reduced, but protection is not durable as compounds are washed out over time
Solution Approach 1:
The patent introduces nanometric silicate additives as an intermediary substance that forms a durable protective layer within the mortar matrix. This intermediary acts as a long-term barrier that prevents salt migration and efflorescence without being washed out, complementing the hydrophobic additives that provide initial water absorption reduction. The nanometric silicates serve as a permanent structural modifier rather than a temporary surface coating
Solution Approach 2:
The patent utilizes the porous structure created by aerating additives to incorporate nanometric silicate particles throughout the mortar matrix. These porous structures allow the nanometric additives to be distributed effectively while maintaining the mortar's overall integrity. The porous material approach enables the hydrophobic and nanometric additives to work together synergistically, with the porous structure providing pathways for additive distribution while maintaining durability
3Quantity of substance
If super absorbents and thickeners are used, then water absorption is reduced, but porosity cannot be reduced and salts can still penetrate
Solution Approach 1:
The patent creates a composite material system where super absorbents/thickeners (starch ethers) work in combination with nanometric silicate additives and hydrophobic agents. The starch ethers control water absorption and rheology, while the nanometric silicates and hydrophobic additives specifically address salt penetration by forming a durable barrier within the mortar matrix. This composite approach ensures that reducing water absorption does not compromise salt migration resistance
Solution Approach 2:
The patent applies local quality by concentrating nanometric silicate additives and hydrophobic agents at strategic locations within the mortar system - particularly at the surface and within capillary structures where salt migration occurs. This localized concentration of protective additives ensures that salt penetration is blocked at critical points without requiring uniform distribution throughout the entire mortar volume, maintaining effectiveness while optimizing performance
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 mortar demonstrates significantly reduced water absorption, higher compression strength, and improved resistance to salt migration and algae growth, as confirmed by testing, maintaining performance over time and outperforming similar products in the market.
Implementation Method 1
from 0.05 to 0.3% of modified cellulose ether by weight
Implementation Method 2
from 0.2 to 0.5% of hydrophobic agent in the form of silicone
Implementation Method 3
from 0.01 to 0.02% of aerating additive by weight
Implementation Method 4
from 0.05 to 0.5% of additive of nanometric size favourably belonging to the group of silicates by weight
Implementation Method 5
from 0.03 to 0.3% of biocide by weight
Data Source
AI summary
Mortar designed especially for shaped clinker bricks comprised of the dry mixture of cement, fillers, chemical additives and requiring addition of water only, is characterised in that it contains from 15 to 28% of cement by weight, from 50 to 68% of quartz sand of grain size from 0.1 to 1.25 mm by weight, from 2 to 10% of quartz sand of grain size from 0.1 to 0.2 mm by weight, from 4 to 10% of limestone flour of grain size of up to 0.5 mm by weight, from 1 to 5% of quartz flour of grain size of up to 0.25 mm by weight, modified cellulose ether from 0.05 to 0.3% by weight, redispersible powder from 0.5 to 1.0% by weight, aerating additive in the amount from 0.01 to 0.02% by weight, favourably organic and non-organic pigments in the amount from 0.1 to 4% by weight, additive of nanometric size favourably belonging to the group of silicates in the amount from 0.05 to 0.5% by weight, water-proofing agent in the form of silicone, powder of nanometric size in capsules in wax envelopes in the amount from 0.2 to 0.5% by weight, and biocide favourably in the amount from 0.03 to 0.3% by weight