Solid Organosilane Powder for Cement-Free Mortar Hydrophobisation
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Solution Overview
Problem
Existing gypsum-based mortars without cement are sensitive to water, limiting their use in exterior applications and rooms with high moisture, and existing hydrophobizing solutions often require on-site mixing of powders with liquids, leading to quality issues and safety concerns.
Innovation Solution
A dry mortar formulation containing an organosilane and a water-soluble carrier material, where the organosilane has specific alkyl and alkoxy groups, and the carrier material is solid at room temperature, allowing for easy mixing with water to create a hydrophobic and storage-stable product with reduced water absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid silicon-based compounds are used as hydrophobising components, then water resistance is improved, but on-site mixing with liquids is required which leads to quality problems and safety concerns
Solution Approach 1:
The invention changes the physical state of the hydrophobising agent from liquid to solid form. The organosilane is provided as a solid powder that can be directly incorporated into dry mortar formulations, eliminating the need for on-site liquid mixing while maintaining the hydrophobising effect. This parameter change resolves the contradiction by improving ease of operation without sacrificing water resistance.
Solution Approach 2:
The invention creates a composite material by combining the solid organosilane with a carrier material. The carrier material serves as a support structure that allows the organosilane to be handled as a stable solid powder. This composite approach enables direct incorporation into dry mortars, eliminating liquid mixing requirements while preserving the hydrophobising functionality.
2Reliability
If powdery gypsum components are mixed with liquid silane-based compounds on site, then hydrophobicity is achieved, but additional expenses and quality problems arise
Solution Approach 1:
The invention merges the organosilane with a carrier material to create a unified solid powder formulation. This combined solid powder can be directly mixed with dry gypsum components in a single dry mixing process, eliminating the need for separate liquid addition and mixing steps. This reduces process complexity and manufacturing expenses while maintaining hydrophobicity.
Solution Approach 2:
The organosilane is pre-combined with the carrier material to form a stable solid powder before use. This preliminary preparation eliminates the need for on-site liquid mixing operations, as the hydrophobising agent is already in the correct form for direct incorporation into dry mortar formulations, simplifying the manufacturing process.
3Adaptability or versatility
If gypsum products are made hydrophobic, then exterior application capability is improved, but water sensitivity of gypsum materials must be overcome
Solution Approach 1:
The solid organosilane acts as an intermediary substance that modifies the surface properties of gypsum materials. When incorporated into the mortar, it forms a hydrophobic barrier that mediates between the inherently water-sensitive gypsum and the external water environment, enabling exterior application capability while protecting against water sensitivity.
Solution Approach 2:
The invention changes the surface energy parameters of the gypsum material by incorporating the organosilane. This parameter change transforms the hydrophilic surface of gypsum into a hydrophobic surface, allowing the material to resist water penetration and enabling application in exterior and high-moisture environments.
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 solution provides excellent hydrophobicity and reduced water absorption in gypsum-based and cement-free mortars, ensuring superior wettability and safety while eliminating the need for on-site liquid mixing, thus enhancing handling and logistics.
Implementation Method 1
contacting the mineral and/or filler in powder form with a hydrolysable organosilane, water, and a catalyst for hydrolysis and condensation of the organosilane under conditions such that the organosilane is hydrolysed in the presence of the mineral and/or filler
Implementation Method 2
the organosilane hydrolysis product condenses to form polyorganosiloxane in the presence of the mineral or filler
Implementation Method 3
GB 2 433 497 A describes a method of preparing a hydrophobic mineral and/or filler, which comprises contacting the mineral and/or filler in powder form with a hydrolysable organosilane
Data Source
AI summary
The present invention relates to the use of a solid comprising at least one organosilane and a carrier material to hydrophobise mortars, wherein the organosilane has the formula R1Si(OR')3 or R1R2Si(OR')2 wherein R1 and R2 are the same or different and are a linear or branched C1- to C4- alkyl and/or alkenyl group, OR' is an acetoxy, a C1- to C4- alkoxy and/or a C2- to C6- methoxyalkoxy and/or ethoxyalkoxy group, and the carrier material is a solid at room temperature. The amount of cement in the final formulation is zero or less than 5 wt.-%, based on the total weight of the final formulation in the dry and uncured form. Claimed are also a powder comprising the silane and a carrier with the carrier being a water-soluble polymer, dry mortar formulations containing no or less than 5 wt.-% cement, based on the dry weight of the uncured mortar formulation, as well as processes to manufacture the formulations and/or compounds.