CN102245530A - 耐热磷酸盐水泥 - Google Patents

耐热磷酸盐水泥 Download PDF

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CN102245530A
CN102245530A CN2009801491031A CN200980149103A CN102245530A CN 102245530 A CN102245530 A CN 102245530A CN 2009801491031 A CN2009801491031 A CN 2009801491031A CN 200980149103 A CN200980149103 A CN 200980149103A CN 102245530 A CN102245530 A CN 102245530A
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phosphate cement
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J·L·塞尔夫
J·W·小保罗
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Grancrete Inc
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Abstract

提供一种磷酸盐水泥组合物。本水泥组合物包括约10至40重量％的氧化钙或氧化镁，约10至40重量％的酸式磷酸盐和约10至50重量％的蛭石或珍珠岩或其混合物。

Description

耐热磷酸盐水泥
交叉引用相关申请
本申请要求2008年10月7日提交的U.S.临时申请系列号61/103,263的优先权，该申请全文引入以供参考。
技术领域
本发明一般地涉及一种磷酸盐水泥组合物，尤其涉及一种固化快速、耐热耐火的磷酸盐水泥组合物。
背景技术
胶凝材料广泛地在建筑工业中使用，例如道路、桥、池、墙、隧道及其他暴露于自然中并需要维持强度的结构中。波特兰水泥是传统选择的水泥。它一般地是一种水、生石灰和二氧化硅的混合物。它生产便宜、易于处理。然而波特兰水泥存在几个缺点。原料经常品质不一致。波特兰水泥虽然适于倾注和涂抹，然而其经常是高粘度的，如果期望泵送或喷雾的话这是一个主要的缺点。波特兰水泥的固化速度也很缓慢。
由于许多应用要求快速固化且没有对强度或其他物理性能有不利的影响，需要快速固化的水泥组合物。之前的努力提供这样的快速固化水泥的例子是U.S.专利No.3,879,209、3,960,580、5,002,610和6,136,088。然而，仍然需要一种可快速固化和不会对如化学稳定性、强度、腐蚀等物理性能产生不利影响的水泥组合物。
可以代替波特兰水泥的是磷酸盐水泥。磷酸盐水泥典型地包括例如磷酸或碱土金属磷酸盐(例如磷酸镁)等酸性组分、例如氧化镁等碱性组分。磷酸盐水泥趋向于快速固化，并且具有优秀的化学稳定性和抗压强度。
发明内容
本申请提供了一种具有优秀的耐火耐热性的磷酸盐水泥组合物。该磷酸盐水泥组合物包括约10至40重量％的氧化钙或氧化镁、约10至40重量％的酸式磷酸盐和约10至50重量％的粒状材料，其加热膨胀，例如蛭石或珍珠岩。在另一实施方案中，包括15至45重量％的硅灰石。
具体实施方式
根据其他所述的实施方案，现在将更详细地描述本发明的上述及其他方面。其应当被认为是本发明可以以不同的形式实施而且不应该被看作是限制于在此阐明的实施方案。相反，提供这些实施方案是为了彻底的和完全的公开，并且向本领域技术人员完全地传达本发明的范围。
用于此处的发明简要说明中的术语是仅仅出于描述特别的实施方案的目的，不是意于限制本发明。在本发明的实施方案的描述和所附的权利要求中使用的单数形式的“一个”、“一种”和“该”也意指复数形式，除非上下文清楚地指出。还有，此处使用的“和/或”意指和包括任何和所有可能的一个或多个相关的列出项目的综合。此外，当在此使用的术语“约”涉及一种例如化合物量、剂量、时间、温度等可测值时，意味着包括20％、10％、5％、1％、0.5％乃至0.1％的规定量的变化。除非另有定义，本说明书中使用的全部术语，包括技术和科学名词，具有和本发明所属领域的本领域技术人员的通常理解相同的意思。
本发明的磷酸盐水泥组合物具有短的固化时间，是可喷雾的和可倾注的，是水气阻挡物，同波特兰水泥相比具有高抗压强度和抗弯强度，抗盐类腐蚀和可承受超过2000℉的温度而对例如抗压强度等物理性能没有不利影响。
该组合物包括氧化钙或氧化镁、酸式磷酸盐和受热膨胀的粒状材料，如蛭石或珍珠岩。在一实施方案中，该组合物包括约10至40重量％的氧化钙或氧化镁，约10至40重量％的酸式磷酸盐和约10至50重量％的蛭石或珍珠岩。取决于期望的流动性，以每100磅干混料使用20至50磅的组合物(水)将上述物质的混合物制成浆料。可选地可在组合物中加入硅灰石。如果使用硅灰石、蛭石和/或珍珠岩按重量计以2∶1至5∶1的范围加入。
可任选加入多种粒状组成成分。粒状组成成分的例子包括砂、SiO2、TiO2、Al2O3、ZrO2、Cr2O3、滑石、云母、高岭土、粉煤灰(fly ash)、偏高岭土、白云石、铬矿砂(chromium ore)、渣块(clinker)、纤维素、硅石(silica)和废渣。可使用这些物质的混合物或掺合物。粒度一般是0.5至300μm。一般地该组合物具有0至25重量％的一种或多种的这些组成成分。也可包括例如聚丙烯、聚酯、聚芳酰胺、聚酰胺、聚乙烯醇、玻璃纤维、钢和碳的增强纤维，以提供一种制备的增强制品。
还可将适当的添加剂同磷酸盐水泥组合物相混合，一般的加入量可从约0.1至约30重量％。添加剂的例子包括阻燃剂、乳化剂、抗絮凝剂、螯合剂、加速剂(例如可以从The Euclid Chemical Company，Cleveland，Ohio获得的Accelguard)、着色剂和颜料、填料、混凝料(aggregate、硼砂、硅土材料、铁氧化物、粘合剂(例如可以从The Euclid Chemical Company，Cleveland，Ohio获得的Eucopoxy树脂和Eucoweld)、增塑剂、硬化剂(如从The Euclid ChemicalCompany，Cleveland，Ohio获得的Euco Diamond Hard)、修补聚合物(patchingpolymer)(例如可以从The Euclid Chemical Company，Cleveland，Ohio获得的Eucorapid修补剂)、微硅粉(micro silica fume)(例如可以从The Euclid ChemicalCompany，Cleveland，Ohio获得的Eucoshot)、缓凝剂、表面软化剂、固化剂(例如褐砂石CS)、减水剂(例如Accelguard、Eucon AC)和起泡剂(air entrainer)(例如AEA和Air Mix)。
产生的磷酸盐水泥组合物是可喷雾的和可泵送的。它具有10至50分钟的短的固化时间，取决于周围温度、所用水量和水温，其固化时间经常是20至40分钟。本发明的磷酸盐水泥组合物粘附大多数其他材料。因此适当的基质包括其他水泥(波特兰和磷酸盐)、砖、岩石、金属、木材、绝缘泡沫材料、沥青、棚顶材料、布/纺织品(包括地毯、粗麻布、帆布)、稻草材料、干式墙/石膏。该材料还可和本身相结合。这允许增加厚度以及修补已有的材料而没有接缝或结合点。
磷酸盐水泥组合物可通过喷雾或泵送水平地或垂直地施加。本组合物可被用于多种基质上和可被使用于例如涂墙、地板、道路、道路翻修、柱、池、顶、大堤、桥、天井、公路、家具、飞机场、护堤壁等。本组合物可以以结构形式应用以制造风景/硬景观项目、走道、家具、管、柜台面、雕像及其他有用的项目。
在一实施方案中，本发明的磷酸盐水泥组合物可用于喷涂结构钢筋增强混凝土梁。该组合物在有火的情况下同未处理的结构混凝土梁相比可提高梁的负荷。在另一实施方案中，本发明的磷酸盐水泥组合物可用于涂覆碳纤维加强梁。碳纤维增强材料可以是碳纤维嵌入环氧树脂的形式，例如在转让给Lawrence技术大学的U.S.专利No.6,790,518中描述的，该申请全文引入以供参考。本发明的组合物可通过保护碳纤维不受热来用于维持碳纤维的强度。另作说明，磷酸盐水泥组合物可作为一种使碳纤维与热绝缘的手段。虽然发明人不希望拘束于任何一种理论，但应相信蛭石或珍珠岩使用由其吸收的水气以维持温度在大多数时间内都低于约212℉。
下面的例子仅仅是说明本发明而不是限制于此。
实施例
实施例1
制造一种磷酸盐水泥组合物，包括24重量％的氧化镁、27重量％的磷酸二氢钾、29重量％的硅灰石和20重量％的蛭石。样品置于14″×14″×1/8″的厚钢板上，平均干燥厚度是1068密耳。通过使用修正的ASTM E119规程测量耐热性。暴露的侧面的温度逐渐地增加到约2,000℉。在2小时和38分钟时，在未暴露侧的热电偶超过平均1,000℉。
实施例2
制造一种磷酸盐水泥组合物，包括27重量％的氧化镁、27重量％的磷酸二氢钾、14重量％的粉煤灰、12重量％的高岭土和20重量％的蛭石。样品置于14″×14″×1/8″的厚钢板上，平均干燥厚度是1.5英寸。通过使用修正的ASTM E119规程测量耐热性。暴露的侧面的温度逐渐地增加到约2,000℉。在190分钟时，因为未满足任何一项损坏标准而关闭炉子。
实施例3
实施例1的磷酸盐水泥组合物喷雾涂覆在钢筋增强混凝土梁上至约2英寸的厚度。涂覆的混凝土梁允许固化约60天。根据ASTM-E119执行燃烧测试。成型的混凝土梁以三点负载结构承载。在中跨截面的集中载荷设为6500磅(梁的极限负载承载能力的50％)。在梁上放置或植入一排热电偶：外部、绝缘层下和在梁内部在钢筋上。在同样的负荷/火的情况下测试相似的没有绝缘层的梁。没有绝缘层的梁在2小时之后由于钢条的温度到达1100℉导致底部钢筋断裂而失败。对于涂有实施例1的梁，燃烧测试持续6小时。在燃烧测试期间内，梁能够支持6500磅的载荷而没有任何断裂征兆。到6小时结束时，钢的温度到达平均950℉。因此该测试展示了梁在有火的情况下负荷的显著提高。
实施例4
实施例1的磷酸盐水泥组合物喷雾涂覆在碳纤维钢筋混凝土梁上作为绝缘层。碳纤维增强材料是一种在U.S.专利No.6,790,518中描述的专有的构造。
使用ASTM-E119测试组合物的绝缘效力。人们发现有可能在有火的情况下通过本发明的组合物保护构造来维持强化构造、碳纤维的强度长达2小时40分钟。耐火绝缘涂层在有火的情况下有效地保护该构造很长一段时间。研究还表明在碳纤维/环氧基体中的环氧可以在212℉的温度下保持超过其极限负载承载能力的75％较长时间。
尽管在此描述了本发明的某些实施方案，应理解本发明由所附的权利要求来限定，而不是通过在上述说明书中描述的特定细节来限定，因为其许多显著的变化在不脱离后附权利要求的精神或范围的情况下也是可能的。

Claims (9)

1.一种磷酸盐水泥组合物，包括约10至40重量％氧化钙或氧化镁、约10至40重量％的酸式磷酸盐和约10至50重量％蛭石或珍珠岩或其混合物。
2.如权利要求1的磷酸盐水泥组合物，进一步包括一种粒状组合物，选自由砂、SiO2、TiO2、Al2O3、ZrO2、Cr2O3、滑石、云母、高岭土、粉煤灰、偏高岭土、白云石、铬矿砂、渣块、纤维素、硅石和废渣组成的组中。
3.一种磷酸盐水泥组合物，包括约10至40重量％氧化钙或氧化镁、约10至40重量％的酸式磷酸盐、约10至50重量％的蛭石或珍珠岩或其混合物和约15至45重量％的硅灰石。
4.如权利要求2的磷酸盐水泥组合物，进一步包括一种粒状组合物，选自由砂、SiO2、TiO2、Al2O3、ZrO2、Cr2O3、滑石、云母、高岭土、粉煤灰、偏高岭土、白云石、铬矿砂、渣块、纤维素、硅石和废渣组成的组中。
5.一种制品，包括嵌入在磷酸盐水泥组合物中的增强材料，所述磷酸盐水泥组合物包括约10至40重量％的氧化钙或氧化镁、约10至40重量％的酸式磷酸盐和约10至50重量％的加热膨胀材料。
6.如权利要求5的制品，其中增强材料是钢筋。
7.如权利要求5的制品，其中加热膨胀材料是蛭石或珍珠岩或其混合物。
8.一种制品，包括嵌入在磷酸盐水泥组合物中的增强材料，该磷酸盐水泥组合物包括约10至40重量％的氧化钙或氧化镁、约10至40重量％的酸式磷酸盐、约10至50重量％的选自由蛭石和珍珠岩或其混合物组成的组中的加热膨胀材料，和一种包括约15至45重量％的硅灰石的组合物。
9.如权利要求8的制品，其中增强材料是钢筋。
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