Polyurethane Grout Composition for High Water Pressure Seepage Control
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Solution Overview
Problem
Polyurethane grout materials fail to effectively cure and provide adequate mechanical properties and adhesion under high water pressure environments, which is crucial for applications like core drilling exploration and underground tunnel joints.
Innovation Solution
A polyurethane grout composition comprising an isocyanate prepolymer and auxiliary components such as a silane coupling agent, catalyst, and blowing agent, which reacts with a polyfunctional polyol containing ethylene oxide units and a monofunctional hydroxyl compound, allowing for fast curing and improved bonding strength and impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyurethane grout materials are used under high water pressure environment, then water leakage control is needed, but the materials fail to cure effectively and provide adequate mechanical properties and adhesion
Solution Approach 1:
The patent modifies the chemical composition parameters of the polyurethane grout by incorporating specific ratios of hydrophilic and hydrophobic polyols, silane coupling agents, and catalysts. This compositional parameter change enables the material to cure effectively under high water pressure conditions (up to 20 MPa) while maintaining adequate mechanical properties and adhesion, directly resolving the contradiction between curing effectiveness and water pressure resistance
Solution Approach 2:
The invention creates a composite grout system combining hydrophilic polyol components (for water reactivity and curing), hydrophobic polyol components (for mechanical properties and water resistance), silane coupling agents (for adhesion enhancement), and catalysts. This composite material approach allows the grout to simultaneously achieve effective curing, mechanical strength, and adhesion under high water pressure environments
2Speed
If hydrophilic polyurethane grout is used, then reactivity with water is improved, but mechanical properties and adhesion deteriorate under high water pressure
Solution Approach 1:
The patent merges hydrophilic polyol components (providing rapid water reactivity) with hydrophobic polyol components (providing mechanical strength and adhesion). The specific formulation combines these contrasting components in optimized ratios, allowing the grout to simultaneously achieve fast curing through hydrophilic components while maintaining superior mechanical properties through hydrophobic components, thus resolving the contradiction between reactivity and strength
3Strength
If hydrophobic polyurethane grout is used, then mechanical properties are improved, but curing under water pressure above 1 MPa fails
Solution Approach 1:
The patent introduces silane coupling agents as intermediary components that bridge the hydrophobic polyol matrix with water. These silane agents provide hydrolyzable groups that react with water to initiate curing of the otherwise hydrophobic system, enabling the grout to cure effectively under water pressure while maintaining the mechanical properties provided by the hydrophobic polyol base
4Productivity
If fast curing is achieved under high water pressure, then water leakage stoppage is quick, but formulation complexity increases
Solution Approach 1:
The patent employs catalysts that automatically activate and accelerate the curing reaction under water pressure conditions without requiring external intervention. The silane coupling agents self-hydrolyze upon contact with water, and the catalyst system autonomously promotes polymerization, enabling fast curing (within 30 minutes under 20 MPa) while simplifying the overall formulation approach through self-activating mechanisms rather than complex multi-step processes
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 quick stoppage of water leakage and provides durable sealing with excellent mechanical properties and adhesion under high water pressure, effectively addressing the limitations of prior art by curing into a solid within 30 minutes under pressures up to 20 MPa.
Implementation Method 1
polyurethane grout materials can react with the in-situ water to form a foam or gel
Implementation Method 2
react with the in-situ water to form a foam or gel
Implementation Method 3
auxiliary components selected from a plasticizer, a silane coupling agent, a catalyst
Data Source
Figure 1A~2
AI summary
The present invention typically provides one-component polyurethane grout compositions and more specially to grout composition useful for seepage control and quick stoppage of water leakage under high water pressure environment, wherein the composition comprises a isocyanate prepolymer and auxiliary components selected from a plasticizer, a silane coupling agent, a catalyst, a cell stabilizer, an anionic surfactant, a filler, a blowing agent or a mixture thereof. The invention also provides the isocyanate prepolymer composition, obtained by reacting a polyfunctional isocyanate, with a polyfunctional polyol comprising at least one polyether polyol containing relatively low amount of ethylene oxide units, and optionally other polyfunctional polyols such as polyester polyols, biorenewable polyols or a mixture thereof, and at least a monofunctional hydroxyl containing compound, wherein the NCO content of said prepolymer is 3%~ 18%. The resulting grout composition can cure into a solid under water pressure from 1 MPa to 20 MPa.