CN102471154B - 用于混凝土和水泥配制剂的固化组合物或密封组合物及其使用方法 - Google Patents
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Abstract
本发明公开了用于固化或密封混凝土和水泥配制剂的蜡乳液组合物、其制备方法以及使用方法。改性剂适用于在道路、公路、停车场和其他新铺置或浇注的混凝土表面中使用的固化或密封膜以保持水分并获得高压缩强度。本发明还涉及用于在常规波特兰水泥混凝土混合料设计或其他以形成的结构形状施用的混凝土混合料以及运输道路混合料设计上涂布、喷射、刷涂、辊涂等的材料，所述材料提供有效层，该有效层控制并最小化混合料的水分损失从而能够进行合适的固化并获得期望的压缩强度。本发明的组合物进一步提供具有较低水溶性氯化物含量的混凝土和水泥配制剂。
Description
技术领域
本发明涉及用于混凝土和水泥配制剂的固化或密封组合物，所述组合物包括烷烃蜡、可皂化蜡、皂化剂和任选的分散剂，本发明还涉及所述组合物的制备方法和使用方法。本发明的组合物适用于在道路、公路、停车场和其他新铺置(placed)或浇注的表面中使用的固化或密封混凝土以保持湿度并获得高压缩强度。本发明还涉及用于在常规波特兰水泥混凝土混合料设计或其他以形成的结构形状施用的混凝土混合料以及运输道路混合料设计中涂布、喷射、刷涂、辊涂等的组合物。本发明的组合物提供有效层，所述有效层控制并最小化混合料的水分损失以能够进行合适的固化并获得高的压缩强度。本发明的组合物进一步提供具有较低水溶性氯化物含量的混凝土和水泥配制剂。
背景技术
固化和密封配混料通常用于混凝土工业以促进新浇注的混凝土混合料的物理性能发展。期望的材料为结合了如下性能的那些材料：易于应用、有效的成膜特性、渗入并密封混凝土中的孔或缺陷的能力、低危害特性、最少的VOC排放或无VOC排放、以及以有竞争力成本的可利用性。然而，现今提供的很多材料不能提供具有混凝土工业所要求的这些属性的有利混合料。
混凝土固化配混料通常用作新浇注的混凝土表面的涂层，从而提供水不渗透性层以保持混凝土混合料中的水分不过快蒸发，由此保持合适的水合水平用于恰当固化和压缩强度发展。长期使用混凝土密封配混料以保护混凝土混合料免受碱金属盐等物质(其会浸入并导致裂开、过早降解或破坏)的影响。
目前可获得的用于固化或密封目的的材料包括以丙烯酸为基础的树脂、乳液聚合物、蜡乳液、以脲为基础的聚合物、天然衍生的材料及其他。一些材料用于密封或固化的单独目的，其他材料用于双重目的作为密封和固化配混料。这些材料通常与颜料如二氧化钛(TiO2)一起配制以用作对日光的反射表面，最小化热吸收，由此降低固化混凝土的温度从而允许合适的固化、强度发展并降低内应力。
用于密封和固化应用的水基材料是高度期望的，因为易于处理和清除、除去挥发性有机配混料和除去与溶剂相关的可燃性危害。尽管溶剂基材料已经证实能够满足用于固化的标准性能要求，但是它们优选用于密封应用。
现有技术提供蜡乳液组合物，用表面活性剂改进在稳定化的水性乳液中的水泥聚集体产品的初期强度的方法，所述表面活性剂如脂肪酸的碱金属盐、硫酸化脂肪酸的碱金属盐、碱金属烷基硫酸酯盐、碱金属烷基磺酸盐、碱金属芳基磺酸盐、碱金属烷基十二烷基磺酸盐、烷基化萘的碱金属盐、木素磺酸的碱金属盐、环氧乙烷与聚亚烷基二醇的缩合产物、脂肪酸甘油酯、脂肪酸酰胺、脂肪酸的聚乙烯山梨醇酯、季铵卤化物、脱水山梨糖醇酯、磺化或硫酸化脂肪酸酯或酰胺以及磺酸。
现有技术还指出引入蜡乳液组合物特别地针对混凝土产品的固化应用而不是固化和密封功能的双重目的。蜡乳液已被确定为良好的成膜材料，但是缺乏总体保水能力，除非与其他树脂或组分例如烃类树脂组合。
发明内容
在一个实施方案中，本发明提供一种水性乳液，其可用作水泥质混合料的固化配混料，以获得根据ASTM-309测得的在150ft2/gal应用速率下在72小时内小于0.55kg/m2的失水水平，所述乳液包含烷烃蜡、可皂化蜡、皂化剂和任选的分散剂。
在另一实施方案中，本发明提供一种水性乳液，其可用作水泥质混合料的固化配混料，以获得根据ASTM-309测得的在150ft2/gal应用速率下在72小时内小于0.55kg/m2的失水水平，所述乳液基本上只包含烷烃蜡、可皂化蜡、皂化剂和任选的分散剂。
在又一实施方案中，本发明提供用于制备水性乳液的方法，所述水性乳液可用作水泥质混合料的固化配混料，以获得根据ASTM-309测得的在150ft2/gal应用速率下在72小时内小于0.55kg/m2的失水水平，该方法包括如下步骤：将水、烷烃蜡、可皂化蜡和皂化剂组合，将组合料加热至约185°F(85℃)至约205°F(96.1℃)的温度，然后均化该混合料。
在一个实施方案中，本发明提供一种水性乳液，其可用作水泥质混合料的固化和密封配混料，以获得根据ASTM-309测得的在150ft2/gal应用速率下在72小时内小于0.55kg/m2的失水水平，并有效地进行盐水渗透测试，例如ASTM-C 1218，所述乳液包含烷烃蜡、可皂化蜡、皂化剂和任选的分散剂。
在另一实施方案中，本发明提供一种水性乳液，其可用作水泥质混合料的固化配混料，以获得根据ASTM-309测得的在150ft2/gal应用速率下在72小时内小于0.55kg/m2的失水水平，并有效地进行盐水渗透测试例如ASTM-C 1218，所述乳液基本上只包含烷烃蜡、可皂化蜡、皂化剂和任选的分散剂。
在又一实施方案中，本发明提供用于制备水性乳液的方法，所述水性乳液可用作水泥质混合料的固化配混料，以获得根据ASTM-309测得的在150ft2/gal应用速率下在72小时内小于0.55kg/m2的失水水平，并有效地进行盐水渗透测试例如ASTM-C 1218，该方法包括如下步骤：将水、烷烃蜡、可皂化蜡和皂化剂组合，将组合料加热至约185°F(85℃)至约205°F(96.1℃)的温度，然后均化该混合料。
在又一实施方案中，本发明提供用本文中所述的乳液涂布或密封的混凝土和水泥配制剂。
具体实施方式
已经发现，本发明的包含烷烃蜡、可皂化蜡、皂化剂和任选的分散剂的水性乳液组合物，当施用于新浇注或铺置的混凝土表面，提供优异的保水性能以满足例如ASTM-309的测试的初期强度标准要求。此外，已经发现，这些独特的乳液渗入混凝土基质以用作有效的密封配混料，如在例如ASTM-C 1218的测试中所证实的。
在一个实施方案中，烷烃蜡的熔点范围为约50℃至约70℃。在另一实施方案中，烷烃蜡包含一种或多种CnH2n+2烃，其中n为18至42的整数。烷烃蜡可包含约10至约40重量％的乳液。在另一实施方案中，烷烃蜡可包含约15至约35重量％的乳液。在另一实施方案中，烷烃蜡可包含约15至约25重量％的乳液。
在一个实施方案中，第二蜡为熔点为约70℃至约100℃、酸值大于25且皂化值大于85的蒙旦蜡，又称为褐煤蜡。第二蜡还可以来自其特征在于具有酸值和皂化值两者的一类蜡，例如巴西棕榈蜡、小烛树蜡、蜡杨梅-桃金娘蜡、日本蜡等。第二蜡也可以为这样的可皂化蜡的组合或者任何子集。在一个实施方案中，第二蜡在乳液中的存在量为每100重量份烷烃蜡约0.01重量份至约20重量份。在另一实施方案中，第二蜡的存在量为每100重量份烷烃蜡约0.01重量份至约10重量份。在另一实施方案中，第二蜡的存在量为每100重量份烷烃蜡约0.5重量份至约7重量份。在另一实施方案中，第二蜡的存在量为每100重量份烷烃蜡约0.02重量份至约5重量份。
如本领域已知的，这样的蜡的皂化可通过将蜡与强碱性物质如氢氧化铵或碱金属氢氧化物(例如氢氧化钾、氢氧化钠或氢氧化锂)组合来实现。所需皂化剂的量可以基于蜡的皂化值计算。例如，皂化值除以1000等于每克蜡要加入的氢氧化钾的克数。对于蒙旦蜡(Montanwax)，每份蒙旦蜡需要至少0.1重量份氢氧化钾或者小于1重量份氢氧化钠或者多于0.1重量份氢氧化铵。所需碱金属氢氧化物或氢氧化铵的实际量可由本领域技术人员容易地确定。
在本发明的某些实施方案中，分散助剂或流动性改性剂可能是有用的。这种分散剂为强亲脂体，因此为良好的消泡剂。一种这样的分散剂为聚(氧-1，2-亚乙基)、α-苯基-ω-羟基苯乙烯。多萘磺酸的盐也可用作分散剂/表面活性剂。所述盐可通过多萘磺酸与皂化剂的反应制得。一种商购可得的多萘磺酸为DISAL GPS，其可获自HandyChemical，Montreal，Quebec，Canada。DURASAR多萘磺酸钙盐(也可获自Handy Chemical，Montreal，Quebec，Canada)也可用作分散剂。在一个实施方案中，分散剂/表面活性剂可包含约0.1至约5重量％的乳液。在另一实施方案中，分散剂/表面活性剂可包含约0.25至约5重量％的乳液。
已经发现，本发明的水性乳液组合物与颜料如二氧化钛高度相容，所述水性乳液组合物包含烷烃蜡、可皂化蜡、皂化剂和任选的分散剂。此外，在高百分比固体下的浓缩乳液可容易地稀释至较低的浓度同时保持稳定的乳液。
在一个实施方案中，本发明的水性乳液组合物用作固化或密封配混料，且在制备水泥混合料时引入或掺入乳液的组分，例如作为部分水性组分，据信这提供了另外的相容性，使得具有所需的强度要求和所需的保水性能。这样的水泥混合料可不含高范围的减水剂、粘度或流变改性剂或混合阻滞剂。
在一个实施方案中，本发明的水性乳液有利地用于获得根据ASTM-309测得的在150ft2/gal应用速率下在72小时内小于0.55kg/m2的失水水平。在另一实施方案中，本发明的水性乳液有效地用作渗透密封剂以通过盐水渗透测试，例如ASTM-C 1218。在另一实施方案中，本发明的水性乳液作为表面涂层施用，其进一步渗入水泥质混合料的表面至少3/4英寸的深度。
在一个实施方案中，当成膜合成聚合物在新鲜混凝土或灰泥的钙离子存在下时，本发明的水性乳液不含使得成膜合成聚合物絮凝的絮凝剂。在另一实施方案中，本发明的乳液不含合成聚合物。
在一个实施方案中，本发明的水性乳液不含烯烃-马来酸酐衍生物。
在一个实施方案中，本发明的水性乳液在制备水泥质产品时用作表面涂层而不用作水性成分。
在一个实施方案中，在均化器中制备水性蜡乳液。通过均化，优选的是获得的胶束直径的分布范围为约0.6微米至约1.8微米。但是，胶束直径的分布范围可以为约0.5微米至约2.5微米。例如，通过使用在约2,000至约4,000psig下操作的双口均化器可以获得该均化的水平。
实施例
实施例1：表1列出了在实施例中使用的组合物的配制剂。在通常的制备中，将水和水溶性组分组合，然后加热至约185°F(85℃)至约205°F(96.1℃)的温度。引入蜡配混料，并加热至约185°F(85℃)至约205°F(96.1℃)的温度。将水性混合料和蜡混合料组合，然后将所得混合料置入均化器中。通过均化，优选的是获得的胶束的直径分布范围为约0.6微米至约1.8微米。但是，胶束直径的分布范围可以为约0.5微米至约2.5微米。例如，通过使用在约2,000至约4,000psig下操作的双口均化器可以获得该均化的水平。向该基础组合物中加入7.5重量％的TiO2以获得ASTM C 309类型1的成膜配混料，并加入8.5体积％的TiO2以获得ASTM C309类型2成膜配混料。
表1组合物配制剂
| 组分 | 重量百分比(重量％) |
| 烷烃蜡 | 20 |
| 蒙旦蜡 | 1.0 |
| DISAL1分散剂 | 1.0 |
| 45％KOH水溶液 | 0.25 |
| 水 | 77.75 |
1DISAL为可获自Handy Chemical，Montreal，Quebec，Canada的多萘磺酸分散剂。
实施例2：根据ASTM 309测试本发明的实施例1的组合物作为用于固化混凝土的成膜配混料的稳定性。结果汇总于表2。
表2
| ASTM C-309要求 | 实施例1 | |
| 保水 | 在72小时内＜0.55kg/m2 | 0.16 |
| 日光反射 | ＞60％ | 61.8％ |
| 干燥时间 | ＜4小时 | ＜4小时 |
实施例3：混凝土粉末试样的水溶性氯化物的含量根据ASTM 1218进行测量。结果汇总在表3A、3B、3C和3D中，其中实施例1-4使用本发明实施例1的蜡乳液。比较实施例A1-A4引入现有技术的蜡乳液而不是可皂化蜡。比较实施例B和D为未暴露于氯化物盐的基准对照混凝土样品。比较实施例C1-C4为暴露于氯化物盐的混凝土对照样品，比较实施例X1-X4使用可从Xurex，Inc购得的XUREX纳米涂层。
表3A
(1)基于620lb/yd3的总水泥质含量
(2)基于3915lb/yd3的混凝土重量
表3B
(3)基于846lb/yd3的总水泥质含量
(4)基于3697lb/yd3的混凝土重量
表3C
(1)基于620lb/yd3的总水泥质含量
(2)基于3915lb/yd3的混凝土重量
表3D
(5)基于643lb/yd3的总水泥质含量
(6)基于3859lb/yd3的混凝土重量
尽管已经参照特定实施方案和实施例描述并阐述了本发明，但是本领域技术人员应该理解本发明适用于不一定在本文中阐述的变体。由于这个原因，仅参照所附权利要求书来确定本发明的真实范围。
Claims (13)
1.一种用于固化或密封混凝土和水泥质混合料的方法，该方法包括：
将包括以下的组分组合成水性乳液以形成水性乳液：
以乳液重量计10重量％至40重量％的烷烃蜡，每100重量份烷烃蜡0.01重量份至20重量份的可皂化蜡，皂化剂，和以乳液重量计0.1重量％至5重量％的分散剂；
将所述水性乳液加热至85℃至96.1℃的温度；
均化该乳液；
将所述水性乳液施用于所述混凝土或水泥质混合料的表面；以及
c)将所述混凝土或水泥质混合料固化、密封、或固化和密封。
2.根据权利要求1所述的方法，其中所述水性乳液渗入混凝土或者水泥质混合料的表面达至少3/4英寸的深度。
3.根据权利要求1所述的方法，其中当成膜合成聚合物在新鲜混凝土或灰泥的钙离子存在下时，所述水性乳液不含使得成膜合成聚合物絮凝的絮凝剂。
4.根据权利要求1所述的方法，其中所述水性乳液不含合成聚合物。
5.根据权利要求1所述的方法，其中所述水性乳液不含烯烃-马来酸酐衍生物。
6.根据权利要求1所述的方法，其中所述水性乳液基本由以乳液的重量计10重量％至40重量％的烷烃蜡、每100重量份烷烃蜡0.01重量份至20重量份的可皂化蜡，皂化剂和以乳液重量计0.1重量％至5重量％的分散剂组成。
7.根据权利要求1所述的方法，其中所述混凝土或水泥质混合料通过将作为水性组分的包含烷烃蜡、可皂化蜡、皂化剂和分散剂的组合物混合制得。
8.根据权利要求1所述的方法，其中所述烷烃蜡的熔点为50℃至70℃，可皂化蜡为熔点范围为70℃至100℃、酸值大于25且皂化值大于85的蒙旦蜡，皂化剂为氢氧化氨或碱金属氢氧化物，分散剂为多萘磺酸。
9.一种固化或密封组合物，其施用于水泥质组合物的表面以获得根据ASTM-309测得的在150ft2/gal应用速率下在72小时内小于0.55kg/m2的失水水平，并有效地进行盐水渗透测试ASTM-C1218，所述固化或密封组合物包含水性乳液，所述乳液包含以乳液重量计10重量％至40重量％的烷烃蜡，每100重量份烷烃蜡0.01重量份至20重量份的可皂化蜡，皂化剂和以乳液重量计0.1重量％至5重量％的分散剂。
10.根据权利要求9所述的固化或密封组合物，其中当成膜合成聚合物在新鲜混凝土或灰泥的钙离子存在下时，所述水性乳液不含使得成膜合成聚合物絮凝的絮凝剂。
11.根据权利要求9所述的固化或密封组合物，其中所述水性乳液不含合成聚合物。
12.根据权利要求9所述的固化或密封组合物，其中所述水性乳液不含烯烃-马来酸酐衍生物。
13.根据权利要求9所述的固化或密封组合物，其中所述水性乳液由以乳液的重量计10重量％至40重量％的烷烃蜡，每100重量份烷烃蜡0.01重量份至20重量份的可皂化蜡，皂化剂和以乳液重量计0.1重量％至5重量％的分散剂组成。
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2009
- 2009-07-07 US US12/498,481 patent/US8404040B2/en active Active
-
2010
- 2010-06-21 AU AU2010270978A patent/AU2010270978B2/en not_active Ceased
- 2010-06-21 MX MX2011013366A patent/MX2011013366A/es not_active Application Discontinuation
- 2010-06-21 WO PCT/US2010/039349 patent/WO2011005480A1/en active Application Filing
- 2010-06-21 BR BRPI1011887A patent/BRPI1011887A2/pt not_active IP Right Cessation
- 2010-06-21 CN CN201080030397.9A patent/CN102471154B/zh not_active Expired - Fee Related
- 2010-06-21 RU RU2012104014/03A patent/RU2496749C2/ru not_active IP Right Cessation
- 2010-06-21 CA CA2767165A patent/CA2767165C/en not_active Expired - Fee Related
- 2010-06-21 EP EP20100797546 patent/EP2451757A4/en not_active Withdrawn
-
2013
- 2013-03-07 US US13/789,276 patent/US20130183533A1/en not_active Abandoned
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Also Published As
| Publication number | Publication date |
|---|---|
| CA2767165A1 (en) | 2011-01-13 |
| US20130183533A1 (en) | 2013-07-18 |
| CN102471154A (zh) | 2012-05-23 |
| MX2011013366A (es) | 2012-02-21 |
| RU2496749C2 (ru) | 2013-10-27 |
| US8404040B2 (en) | 2013-03-26 |
| US20110005431A1 (en) | 2011-01-13 |
| CA2767165C (en) | 2014-08-12 |
| EP2451757A4 (en) | 2013-10-09 |
| RU2012104014A (ru) | 2013-08-20 |
| EP2451757A1 (en) | 2012-05-16 |
| BRPI1011887A2 (pt) | 2016-04-12 |
| AU2010270978A1 (en) | 2012-02-02 |
| WO2011005480A1 (en) | 2011-01-13 |
| AU2010270978B2 (en) | 2013-08-01 |
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