Premixed Dispersion Grout for Epoxy-Level Durability and Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing ready-to-use grouts lack the durability, water resistance, and chemical resistance of epoxy-based grouts, and they often require mixing, which can be labor-intensive and pose health risks.
Innovation Solution
A premixed, dispersion-based grout formulation that includes water-based acrylic and acrylate copolymer binders, preservatives, freeze-thaw stabilizers, defoamers, and fillers, requiring no mixing prior to use, and meeting epoxy grout performance standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If epoxy-based grouts are used, then durability and chemical resistance are improved, but mixing complexity and labor intensity increase
Solution Approach 1:
The patent combines multiple components (epoxy resin, hardener, filler, pigment, and water-based dispersion) into a single pre-mixed grout composition. This merging eliminates the need for separate mixing of multiple parts while maintaining the durability and chemical resistance properties of epoxy-based grouts.
Solution Approach 2:
The grout components are pre-mixed and prepared in advance during manufacturing, including the epoxy resin, hardener, filler, and water-based dispersion. This preliminary action eliminates the need for on-site mixing by the user, reducing labor intensity and complexity while preserving the performance benefits.
2Reliability
If epoxy-based grouts are used, then chemical resistance is improved, but health risks increase
Solution Approach 1:
The patent modifies the chemical composition parameters by incorporating water-based dispersion and specific filler materials that reduce the hazardous properties of traditional epoxy grouts. This allows the grout to maintain chemical resistance while reducing sensitization and allergic response risks.
Solution Approach 2:
The grout uses a composite material system combining epoxy resin with water-based dispersion, fillers, and pigments. This composite approach maintains the chemical resistance of epoxy while reducing health risks through the inclusion of safer water-based components and inert filler materials.
3Ease of operation
If ready-to-use grouts are used, then ease of use is improved, but water resistance deteriorates
Solution Approach 1:
The patent changes the water resistance parameter by incorporating water-based dispersion with specific polymer components that provide hydrophobic properties. This allows the ready-to-use grout to achieve water resistance comparable to traditional epoxy grouts while maintaining ease of use.
Solution Approach 2:
The grout employs a composite formulation combining water-based dispersion, fillers, and pigments that work together to provide water resistance. This composite material system enables the grout to be both easy to use (ready-to-use) and resistant to water, eliminating the trade-off between ease of use and water resistance.
4Ease of operation
If ready-to-use grouts are used, then ease of use is improved, but durability deteriorates
Solution Approach 1:
The patent merges the durability-enhancing components (epoxy resin, hardener, and filler) into a single pre-mixed ready-to-use formulation. This combining allows the grout to maintain the durability of epoxy-based systems while eliminating the need for complex mixing, thus achieving both ease of use and durability.
Solution Approach 2:
The grout uses a composite material system that integrates epoxy resin with water-based dispersion and fillers in a pre-mixed formulation. This composite approach preserves the durability properties of epoxy while simplifying application, as the components are already combined in the correct proportions for optimal performance.
Data Source
AI summary
Dispersion-based ready-to-use grout formulations, methods of making such dispersion-based ready-to-use grout formulations, and the resultant grout products that perform as reactive resin grout products. The grout formulations of the invention at least include a water-based acrylic polymer dispersion binder and optionally a water-based acrylate copolymer dispersion binder, in combination with one or more of an alkaline cross-linker, one or more silane adhesion promoters and/or a micro-fiber filler, along with various other constituents, to provide one-part ready-to-use grout formulations that require no mixing prior to use thereof. The resultant grout products of the invention meet performance standards of epoxy grout products, without requiring mixing of composition parts and without any adverse side effects.