Salt Accelerators in Epoxy Resin Mortar for Fast Curing
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Solution Overview
Problem
Conventional epoxy-amine based mortars for chemical fastening have slow curing kinetics, extended pot life, low heat resistance, and high creep resistance, making them unsuitable for outdoor construction sites where quick curing and high load-bearing capacity are required, especially in varying temperatures and moist conditions.
Innovation Solution
Incorporating specific salts such as nitrates, iodides, and triflates into the epoxy resin composition as accelerators to significantly shorten the curing time without compromising pull-out strength, allowing the mortar to achieve 90% of its reference load within 7 hours, preferably in less than 4 hours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional epoxy-amine based mortars are used with high proportion of low-viscosity components and low-reactivity components to achieve good handling and extended pot life, then ease of operation is improved, but curing time is extended and heat resistance is reduced
Solution Approach 1:
The patent changes the chemical parameters of the mortar composition by introducing specific salt accelerators (nitrate, nitrite, halogen salts, or trifluoromethanesulfonic acid salts) into the epoxy resin composition. These salts catalyze the curing reaction between epoxy and amine components, significantly reducing curing time from extended pot life to within 7 hours (preferably less than 4 hours) while maintaining good handling properties through controlled addition amounts of 0.1-5 wt%.
2Ease of operation
If conventional epoxy-amine based mortars are used with high proportion of low-viscosity components to achieve good handling, then ease of operation is improved, but creep resistance at elevated temperatures deteriorates
Solution Approach 1:
The patent creates a composite mortar system combining epoxy resin, amine hardener, and specific salt accelerators in controlled proportions. This composite formulation achieves a balance where the salt catalyst enables faster curing that develops higher strength and creep resistance at elevated temperatures, while the base composition maintains adequate viscosity for handling. The cured mortar achieves 90% of reference load within 7 hours and exhibits excellent pull-out strength.
3Ease of operation
If conventional epoxy-amine based mortars are used to achieve extended pot life, then ease of operation is improved, but heat resistance and load bearing capacity deteriorate
Solution Approach 1:
The patent modifies the reaction kinetics parameters by introducing salt accelerators that catalyze the curing reaction. This changes the time-temperature profile from extended slow curing to accelerated curing within 7 hours (preferably less than 4 hours), while the salt concentration is controlled at 0.1-5 wt% to maintain reliability and heat resistance of the cured mortar structure.
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 use of these salts accelerates the curing reaction, enabling the mortar to achieve excellent pull-out strength and load-bearing capacity quickly, even in challenging environmental conditions, while maintaining the application-relevant properties of the epoxy resin composition.
Implementation Method 1
the addition of at least one salt (S) to an epoxy resin compound for chemical bonding leads to a significant acceleration of the curing reaction
Data Source
AI summary
The invention relates to the use of at least one salt (S) selected from the group consisting of salts of nitric acid, salts of nitrous acid, salts of halogens and salts of trifluoromethane sulphonic acid as an accelerator in an epoxy resin composition for chemical fixing. The present invention further relates to a method for the chemical fixing of construction elements and anchoring means, such as anchor rods, anchor bolts, (threads) rods, (threads) sleeves, concrete iron, screws and the like in boreholes in different substrates.