Sprayable Phosphate Cement Composition
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Solution Overview
Problem
Portland cement is unsuitable for spraying and pumping due to its high viscosity and slow cure rate, and phosphate cement's rapid cure characteristic makes it undesirable for these applications despite its advantages in chemical stability and compressive strength.
Innovation Solution
A phosphate cement composition comprising 30-40% calcium silicate, 20-35% magnesium oxide, and 25-45% monopotassium phosphate, which is sprayable, pumpable, and cures rapidly, offering high compressive strength and heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If phosphate cement is used, then rapid curing is achieved, but sprayability and pumpability are compromised
Solution Approach 1:
The patent changes the chemical parameters of the phosphate cement by incorporating calcium silicate (30-40%), magnesium oxide (20-35%), and monopotassium phosphate (25-45%) in specific proportions. This parameter modification allows the cement to maintain rapid curing characteristics while achieving suitable viscosity and flow properties for spraying and pumping operations.
Solution Approach 2:
The invention creates a composite phosphate cement material combining multiple components (calcium silicate, magnesium oxide, monopotassium phosphate) to achieve a balance between rapid curing and workability. The composite formulation allows the material to exhibit both fast setting properties and adequate flowability for application methods like spraying and pumping.
2Ease of operation
If Portland cement is used, then ease of handling is achieved, but cure rate is slow
Solution Approach 1:
The patent modifies the chemical composition parameters by replacing traditional Portland cement with a phosphate-based system containing magnesium oxide and monopotassium phosphate. This parameter change transforms the curing kinetics from slow (Portland cement) to rapid (phosphate cement) while maintaining handling characteristics suitable for construction applications.
3Ease of manufacture
If Portland cement is used, then cost-effectiveness is achieved, but viscosity is too high for spraying
Solution Approach 1:
The patent changes the rheological parameters of the cement slurry by using phosphate cement chemistry. The resulting composition achieves lower viscosity suitable for spraying applications while incorporating cost-effective materials like calcium silicate and monopotassium phosphate, balancing both manufacturability and applicability.
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 allows for rapid curing, high compressive strength, and heat resistance, enabling its use in various applications such as coatings, repairs, and hazardous material encapsulation while maintaining flowability and bonding capabilities.
Implementation Method 1
phosphate cement typically comprises an acid component such as phosphoric acid or an alkaline earth phosphate salt (e.g., magnesium phosphate), and a base component such as magnesium oxide
Implementation Method 2
cures rapidly
Data Source
AI summary
A sprayable and pourable cement composition is provided. The cement composition comprises about 30 to 40 percent by weight calcium silicate, about 20 to 35 percent by weight magnesium oxide and about 25 to 45 percent by weight monopotassium phosphate.