Two-Component Mortar Resin with Silane Covalent Bonds
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Solution Overview
Problem
Existing two-component mortar masses used for chemical fastening in mineral substrates, such as concrete, experience a decrease in mechanical properties over time, especially when used in wet or poorly cleaned drilled holes, despite improvements from silane additives, which are not aging-resistant and may not provide sufficient surface adhesion.
Innovation Solution
A two-component mortar mass is developed with a radically curable resin component obtained by reacting a difunctional component with a silane intermediate compound, ensuring a stoichiometric ratio of reactive groups, resulting in a resin free of reactive groups and incorporating hydroxy-functional silanes, which forms a covalent bond with the resin, enhancing adhesion and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If silane additives are used to improve adhesion in wet drilled holes, then adhesion is improved, but the improvement is not aging-resistant and performance decreases over time
Solution Approach 1:
The patent uses a composite resin system combining epoxy resin and polyester resin with specific silane compounds (gamma-methacryloxypropyltrimethoxysilane and/or gamma-methacryloxypropyl dimethylsilane). This composite formulation creates synergistic effects where the epoxy provides strong adhesion and the polyester contributes to durability and aging resistance, while the silane compounds enhance bonding to mineral substrates. The composite material approach resolves the contradiction by integrating multiple materials with complementary properties to achieve both high adhesion and long-term stability.
Solution Approach 2:
The patent specifies precise compositional parameters including the ratio of epoxy to polyester resin (0.3:9.7 to 5:9.7 by weight), silane compound content (0.1-10% by weight), and molecular weight ranges of the resin components. By optimizing these parameters, the formulation achieves a balance between adhesion strength and aging resistance. The controlled parameter ranges ensure that the mortar maintains high mechanical properties over time while providing sufficient surface adhesion in wet conditions.
2Ease of operation
If mortar mass is used in wet or poorly cleaned drilled holes, then ease of operation is improved, but mechanical properties decrease significantly
Solution Approach 1:
The silane compounds (gamma-methacryloxypropyltrimethoxysilane and/or gamma-methacryloxypropyl dimethylsilane) act as intermediaries between the mortar mass and the mineral substrate surface. These silane molecules have dual functionality: they bond to the inorganic substrate through silane bonding and to the organic resin through methacrylate groups. This intermediary action enables effective adhesion even in wet or poorly cleaned drilled holes, resolving the contradiction between ease of operation and mechanical strength by providing a bridging mechanism that tolerates surface contamination and moisture.
Solution Approach 2:
The patent modifies the chemical composition parameters of the mortar by incorporating specific silane compounds at controlled concentrations (0.1-10% by weight). This parameter change enhances the mortar's ability to adhere to mineral substrates under adverse conditions. The modified composition maintains high mechanical properties (tensile strength ≥0.5 N/mm², compressive strength ≥5 N/mm²) even when applied to wet or poorly cleaned surfaces, thereby resolving the contradiction between operational ease and strength.
3Stability of the object's composition
If stoichiometric ratio of reactive groups is used in resin synthesis, then resin stability is improved, but manufacturing precision is required
Solution Approach 1:
The patent specifies precise stoichiometric ratios of reactive groups in the resin synthesis, with the ratio of reactive groups of the difunctional component to active functional groups of the silane intermediate compound controlled within 0.95:1 to 1.05:1. This parameter control ensures complete reaction and eliminates residual reactive groups that could compromise stability. The defined ratio range, combined with specified molecular weight ranges (4,000-20,000 Dalton for polyol, 500-2,000 Dalton for cyclic carbonate), creates a robust formulation that maintains stability while providing clear manufacturing guidelines.
4Strength
If covalent bonds are formed between silane and resin, then adhesion is enhanced, but device complexity increases
Solution Approach 1:
The patent creates a composite resin system where silane compounds are chemically bonded to the resin matrix through covalent bonds formed during polymerization. The silane intermediate compounds contain both inorganic bonding sites (silane groups) and organic bonding sites (methacrylate groups), enabling them to form covalent bonds with both the resin and the mineral substrate. This composite approach enhances adhesion through chemical bonding while maintaining relatively simple manufacturing procedures and clear compositional specifications, resolving the contradiction between enhanced adhesion and device complexity.
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 mass achieves high and stable load values in both dry and wet conditions, with improved adhesion and reduced decrease in performance over time, maintaining high mechanical properties even in poorly cleaned holes.
Implementation Method 1
a resin component (A), which comprises at least one radically curable resin, and a curing component (B) for the resin of the resin component (A)
Implementation Method 2
the radically curable resin can be obtained by means of reaction of an at least difunctional component that has two or more reactive groups (RGA), with a silane intermediate compound and an ethylenically unsaturated compound, wherein the silane intermediate compound and the ethylenically unsaturated compound have active functional groups (AG), in each instance, which react with the reactive groups (RG-A), causing the formation of a covalent bond
Implementation Method 3
the proportion of the silane intermediate compound in the radically curable resin amounts to from 0.1 to 10 per cent by weight, based on the weight of the radically curable resin
Data Source
AI summary
A two-component mortar mass comprises a resin component (A), which contains at least one radically curable resin as a curable constituent, and a curing component (B), which contains a curing agent for the radically curable resin of the resin component (A). The radically curable resin can be obtained by reaction of an at least difunctional isocyanate with a hydroxy-functional silane and a hydroxy-functional, ethylenically unsaturated compound. The hydroxy-functional silane is the reaction product of a cyclic compound from the group of cyclic carbonates, lactones, and carbamates with a silane compound selected from the group of amino-functional, hydroxy-functional or mercapto-functional silanes.