Combination of ternary binders with aqueous epoxy resin system

Abstract

A multi-component composition is described that includes: A) a binder component (A) including at least one epoxy resin, B) a hardener component (B) including at least one amine compound as an amine hardener, and C) a solid component (C) including a hydraulic inorganic binder, wherein the hydraulic inorganic binder is a ternary binder composed of aluminous cement, calcium sulfate, and optionally Portland cement, wherein the solid component (C) includes 2 to 30 wt % aluminous cement, 1 to 16 wt % calcium sulfate, and 0 to 20 wt % Portland cement. The multi-component composition is suitable in particular as a self-leveling floor-leveling compound for a floor covering or as a mortar.

Claims

1. A multicomponent composition comprising: A) a binder component (A) comprising at least one epoxy resin of formula (I), wherein R and R independently of one another are each a hydrogen atom or a methyl group, and s is an average value of from 0 to less than 2, ##STR00002## B) a hardener component (B) comprising at least one amine compound as an amine hardener, and C) a solid component (C) comprising a hydraulic inorganic binder, wherein the hydraulic inorganic binder is a ternary binder comprised of high-alumina cement, calcium sulfate, and optionally Portland cement, and wherein the solid component (C) comprises 2 to 30 wt % of high-alumina cement, 1 to 16 wt % of calcium sulfate, and 0 to 20 wt % of Portland cement.

2. The multicomponent composition as claimed in claim 1, wherein the total amount of epoxy resin and amine hardener in the multicomponent composition, based on the total weight of the multicomponent composition, is not more than 4 wt %.

3. The multicomponent composition as claimed in claim 1, wherein the ternary binder comprises Portland cement, and the solid component (C) comprises 5 to 20 wt % of high-alumina cement, 3 to 13 wt % of calcium sulfate, and 3 to 10 wt % of Portland cement.

4. The multicomponent composition as claimed in claim 1, wherein the calcium sulfate is selected from the group consisting of anhydrite, dihydrate, hemihydrate, or a mixture thereof.

5. The multicomponent composition as claimed in claim 1, wherein the binder component (A) and/or the hardener component (B) comprise water.

6. The multicomponent composition as claimed in claim 1, wherein the solid component (C) comprises one or more fillers, and optionally one or more additives.

7. The multicomponent composition as claimed in claim 1, wherein the total amount of epoxy resin and amine hardener in the multicomponent composition, based on the total weight of the multicomponent composition, is not less than 0.1 wt %.

8. The multicomponent composition as claimed in claim 1, wherein the fraction of the ternary binder in the solid component (C) is in the range of 3 to 40 wt %.

9. The multicomponent composition as claimed in claim 1, wherein the at least one epoxy resin comprises at least one epoxy resin and a reactive diluent.

10. The multicomponent composition as claimed in claim 1, wherein the at least one amine compound is a polyamine, a polyaminoamide, a polyamine-polyepoxide adduct, a polyaminoamide-polyepoxide adduct, or a mixture of at least two of these compounds.

11. The multicomponent composition as claimed in claim 1, wherein the multicomponent composition comprises a polymeric binder which is solid at 23 C.

12. A method for coating, joining, sealing, or grouting components with a multicomponent composition as claimed in claim 1, the method comprising the following method steps: a) mixing the binder component (A) and the hardener component (B), b) adding the solid component (C) to the mixture obtained in step a), with stirring, to give a binder mixture, c) processing the resulting binder mixture by c1) applying the binder mixture to the surface of one or more components for coating, c2) applying the binder mixture to the surface of one or more components and placing one or more further components onto the applied binder mixture in order to join the components, or c3) introducing the binder mixture into the space between two or more components for sealing or grouting, d) optionally smoothing and/or deaerating the applied or introduced binder mixture, and e) curing the binder mixture, wherein water is present in the binder component (A) and/or in the hardener component (B) and/or is added as a separate component before or during the addition of the solid component (C).

13. The method as claimed in claim 12, wherein in step a) one or more additional liquid components are admixed and/or in step b) one or more additional solid components are admixed.

14. A product comprising one or more components coated, joined, sealed, or grouted with a cured binder mixture, obtained by a method as claimed in claim 12.

15. A coating composition comprising the multicomponent composition as claimed in claim 1.

16. The multicomponent composition as claimed in claim 2, wherein total amount of epoxy resin and amine hardener is not more than 3 wt %.

17. The multicomponent composition as claimed in claim 2, wherein total amount of epoxy resin and amine hardener is not more than 2 wt %.

18. The multicomponent composition as claimed in claim 4, wherein the calcium sulfate is the hemihydrate.

19. The multicomponent composition as claimed in claim 5, wherein the amount of water present in compounds (A) and/or (B) is sufficient to cure the hydraulic inorganic binder.

20. The multicomponent composition as claimed in claim 6, wherein at least one of the one or more fillers is sand.

21. The multicomponent composition as claimed in claim 6, wherein the filler content in component (C) is at least 36 wt %.

22. The multicomponent composition as claimed in claim 6, wherein the filler content in component (C) is at least 57 wt %.

23. The multicomponent composition as claimed in claim 11, wherein the polymeric binder is an ethylene-vinyl acetate copolymer optionally comprising one or further comonomers.

24. A self-leveling flooring compound for a floor covering, the compound comprising the multicomponent composition as claimed in claim 1.

25. A mortar compound comprising the multicomponent composition as claimed in claim 1.

Description

EXAMPLES

(1) Components used for producing the compositions were as follows.

(2) Binder Component A

(3) Epoxy resin component as an emulsion composed of about 62 wt % of an epoxy resin mixture of diglycidyl ether of bisphenol A/F and 38 wt % of water.

(4) Hardener Component B1

(5) Mixture of 2.4 wt % of a modified amine hardener based on 1-amino-3-aminomethyl-3,5,5-trimethylcyclohexane, 0.1 wt % of a defoamer, and 97.5 wt % of water.

(6) Hardener component B2

(7) Mixture of 18 wt % of a modified amine hardener based on 1-amino-3-aminomethyl-3,5,5-trimethylcyclohexane, 0.75 wt % of a defoamer, and 81.25 wt % of water. In terms of the constituents, the hardener component B2 corresponds to the hardener component B1, but in respect of the amine compound it is more highly concentrated.

(8) Solid Component C

(9) Two solid components, C1 and C2, were produced, in accordance with the composition indicated in Table 1.

(10) TABLE-US-00001 TABLE 1 C1 C2 Solid component (Parts by weight) (Parts by weight) Portland cement I 42.5R 33 Portland cement I 52.5R 6 Calcium sulfate.sup.1) 8 High-alumina cement.sup.2) 14 Silica sand.sup.3) 62 58 Calcium carbonate 2 10 Shrinkage reducer.sup.4) 1 1 Further additives.sup.5) 2 3 .sup.1)Alpha-hemihydrate .sup.2)Ternal LC from Kerneos .sup.3)Particle sizes in the range of 0.06-0.6 mm .sup.4)Based on calcium sulfoaluminate and neopentyl glycol .sup.5)Fibers, thickener, amorphous silica, chromate reducer, defoamer, accelerator, and retardant

(11) Binder component A and hardener component B were mixed with one another. Then a solid component C was added to give a homogeneous mixture. For comparative example 2 and inventive example 1, the addition of the solid component C was accompanied by addition of Vinnapas 7220N from Wacker AG, a water-redispersible ethylene-vinyl acetate copolymer, in a fraction of about 2.5 wt %, based on the total weight of the mixture. The Vinnapas may equally well be accommodated directly in corresponding amount in component C, in which case no additional component is needed. The compositions thus produced were tested for their workability, shrinkage characteristics, compressive strength, and adhesive strength. For this purpose, coatings on a concrete substrate and test specimens were produced using the mixtures obtained.

(12) The workability was determined by applying the composition to a conventional concrete paving slab and processing it thereon. The workability was specified by the worker as a value on a scale from 1 to 4, on which 1 represents the poorest value and 4 the best value.

(13) The shrinkage characteristics were determined in accordance with standard EN 12617-4 on 4416 cm prisms. The prisms were cured for 28 days prior to measurement.

(14) The compressive strength was determined in accordance with standard EN 12190 on 4416 cm prisms. The prisms were cured for 28 days prior to measurement.

(15) The adhesive strength was determined in accordance with standard EN 1542 on a sandblasted concrete garden slab. Prior to measurement, the composition was cured on the slab for 28 days.

(16) The surface moisture of a coating of the composition applied to concrete was determined using a moisture meter from Tramex, where the moisture content is determined by means of an electronic impedance measurement.

(17) Measurements were carried out on the applied coating at regular intervals. The time from application of the coating until a moisture content of 4% was reached was ascertained.

(18) The components used, mixing ratios, and results are shown in Table 2 below.

(19) TABLE-US-00002 TABLE 2 Comparative Comparative Inventive example 1 example 2 example 1 Component A A A A Component B B2 B1 B1 Component C C1 C1 C2 Mixing ratio A:B:C (weight) 1:2.5:18.5 1:14:84 1:7:60 Epoxy resin + amine about 4 about 1 about 1 hardener, wt %.sup.1) Workability 1 4 2 Compressive strength, in MPa 58 40.9 61.4 Shrinkage, in 0.948 0.637 0.142 Adhesive strength, in MPa 3.9 2.1 2.77 Surface moisture (time to 19 h >45 h 2 h moisture content of 4%) .sup.1)based on the total weight of the mixture

(20) Systems of this kind are typically required to exhibit compressive strength of at least 50 MPa, shrinkage of less than 0.6 mm/m, adhesive strength of at least 2 MPa, and attainment of a moisture content of 4% within 24 hours.

(21) From the table above it is evident that the use of the ternary binder allows substantial improvement to the properties of the multicomponent composition of the invention in respect of shrinkage, compressive strength, and adhesive strength, and also in respect of surface moisture. The surface moisture is reduced to below 4% within a short time, thus allowing recoating to take place rapidly.

(22) The multicomponent composition of the invention features very quick setting times, producing relatively short working times. For numerous applications, however, the working times are sufficient. The setting time can be influenced by varying the proportions of the components of the ternary binder. Overall, however, the workability of inventive example 1 is significantly better by comparison with comparative example 1, which has a customary organic binder content, and the compound is also less tacky and therefore easier to apply. Relative to comparative example 1 there is also a significantly reduced shrinkage.

(23) It is found, accordingly, that through use of a ternary binder as defined it is possible to improve the properties of multicomponent ECC systems in some cases significantly.