Silicate-Modified Polymer Grouting Material for Small-Crack Leakage Plugging
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Solution Overview
Problem
Existing grouting materials face issues such as high viscosity, difficulty penetrating small cracks, slow curing times, incompatibility with wet conditions, and safety hazards, particularly in coal mine applications.
Innovation Solution
A silicate-modified polymer material comprising prepolymerized isocyanate and silicate aqueous solution, which combines the advantages of inorganic and polymer grouting materials, allowing for rapid penetration, expansion, and improved safety and adhesion in wet conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cement polymer mortar mixed with aggregate is sprayed, then the material provides structural support, but the viscosity is high and it is difficult to penetrate into tiny cracks
Solution Approach 1:
The material is divided into two separate components (liquid polymer solution and dry aggregate) that are mixed just before application. This allows the liquid component to penetrate cracks first, followed by the aggregate providing structural strength, resolving the contradiction between penetration ability and structural support.
Solution Approach 2:
The viscosity of the material is dynamically adjusted by controlling the water content and polymer concentration in the liquid solution. By optimizing these parameters, the material achieves low viscosity for crack penetration while maintaining sufficient strength after aggregation.
2Ease of manufacture
If cement polymer mortar is sprayed, then the material can be applied, but the solidification time is long and quick use cannot be achieved
Solution Approach 1:
The liquid polymer solution is prepared in advance with optimized composition and pH value to ensure rapid setting. The dry aggregate is also pre-screened and prepared, so that when mixed together, the chemical reaction proceeds quickly with reduced solidification time while maintaining application capability.
3Ease of operation
If polyurethane foam is used, then the material has low viscosity and good penetration, but it is not suitable for damp or water-bearing conditions and cannot bond
Solution Approach 1:
The invention creates a composite material system combining liquid polymer (providing penetration and bonding) with dry aggregate (providing structural strength). The liquid component contains water-soluble polymers that maintain bonding capability in wet conditions while the aggregate provides mechanical strength, resolving the contradiction between penetration and wet-condition reliability.
Solution Approach 2:
The liquid polymer solution acts as an intermediary between the wet environment and the aggregate material. It provides a bonding bridge that works effectively in damp conditions, allowing the aggregate to bond reliably to surfaces even in the presence of moisture.
4Strength
If polyurethane foam is used, then the material provides good adhesion, but the surface resistance is insufficient and insulation performance is relatively good
Solution Approach 1:
The composite of liquid polymer and aggregate creates a material with both strong adhesion (from the polymer) and sufficient surface resistance (from the aggregate structure). The aggregate particles provide a rougher surface texture and higher electrical resistance while the polymer ensures bonding, resolving the contradiction between adhesion and surface resistance.
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 material effectively fills small cracks, cures quickly, reduces dust hazards, and enhances adhesion and toughness, providing improved safety and performance in coal mine environments.
Implementation Method 1
the foaming ratio being adjustable, 5-10 times, 20-50 times, and being adjustable according to customer requirements; Once solidified after foaming, the broken matrix being quickly reinforced
Implementation Method 2
A silicate-modified polymer material comprising prepolymerized isocyanate and silicate aqueous solution, which combines the advantages of inorganic and polymer grouting materials
Data Source
AI summary
A silicate-modified polymer grouting material for leakage plugging is provided, which belongs to the technical field of silicate modification, includes 60% by weight of silicate-modified aqueous solution component, and about 40% of structural flame-retardant isocyanate. According to the proportion of the main total amount, the main components are classified into inorganic components, so the silicate-modified polymer grouting material for leakage plugging has excellent flame retardant performance, oxygen index ≥35%, adhesion ≥1.5 mPa, maximum reaction temperature ≤95° C., odor level (80° C.) ≤3.5, fog test ≤5 mg (without physical additive flame retardants diffusion to the environment). In particular, a main component of the silicate-modified aqueous solution, endows it with good surface resistance.