CN104263227B - 高铁混凝土表面强防水薄涂型聚氨酯涂料及其涂装方法 - Google Patents
高铁混凝土表面强防水薄涂型聚氨酯涂料及其涂装方法 Download PDFInfo
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- CN104263227B CN104263227B CN201410474706.1A CN201410474706A CN104263227B CN 104263227 B CN104263227 B CN 104263227B CN 201410474706 A CN201410474706 A CN 201410474706A CN 104263227 B CN104263227 B CN 104263227B
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- C08L2205/20—Hollow spheres
Abstract
本发明公开高铁混凝土表面强防水薄涂型聚氨酯涂料及其涂装方法，由封闭漆、底面漆和表面漆组成，每种漆均由树脂组份和固化组份组成，树脂组份以聚醚多元醇、扩链剂、催化剂、成膜助剂为主，固化组份由异氰酸酯和溶剂组成，在进行制备时，分别制备三种漆中的树脂组份和固化组份。在进行施工时，首先将三种漆的树脂组份和固化组份进行混合均匀后进行涂装使用，所述封闭漆设置在混凝土表面上并形成封闭漆层，所述底面漆设置在封闭漆层的上表面上并形成底面漆层，所述表面漆设置在底面漆层的上表面上并形成底面漆层。本发明的防水漆具有较强的附着性，能够在高铁项目的混凝土表面形成强防水层，且整体涂覆厚度降低，使用方便安全。
Description
技术领域
本发明属于高分子涂料技术领域，更加具体的说，涉及薄涂型聚氨酯涂料及其涂装方法，主要用作高铁项目的混凝土表面防水漆。
背景技术
我国高铁混凝土路面、桥面防水层材料和结构目前还是普遍采用的以前普通铁路混凝土路面桥面防水层标准TB/T2965-2011《铁路混凝土桥面防水层技术条件》中的三种防水层结构，分别是：卷材加粘贴涂料(或胶粘剂)型、高聚物改性沥青卷材型及无卷材的涂料型。目前，我国高铁轨道混凝土路面、桥面通常使用喷涂聚脲作为防水材料，这种喷涂聚脲属于第一代聚脲产品，需要使用专门的喷涂设备进行涂覆作业，并且涂层厚度通常在2mm以上。
高铁轨道混凝土路面、桥面上防水层结构使用的这种喷涂型第一代聚脲产品，虽然能够裸露在室外使用，有一定的耐候性，但与混凝土路面、桥面的附着性较差，易出现龟裂和大面积剥落等防水层失效的病态，对高铁的安全运行产生严重影响。而且，这种第一代聚脲产品必须使用专门的喷涂设备进行涂覆施工，在一些地形条件特殊地段施工困难。另外，这种产品经过验证，涂层必须达到较厚的厚度，通常要达到2mm以上才能起到防水效果，耗材较大，使用成本较高。
发明内容
本发明的目的在于克服现有技术的不足，提供一种基于聚氨酯的薄膜型防水漆及其涂装方法，该防水漆具有较强的附着性，能够在高铁项目的混凝土表面形成强防水层，且整体涂覆厚度降低，使用方便安全。
本发明的技术目的通过下述技术方案予以实现：
高铁混凝土表面强防水薄涂型聚氨酯涂料，由封闭漆、底面漆和表面漆组成。
所述底面漆由第一树脂组份和第一固化组份组成，其中所述第一树脂组份由50—55质量份的聚醚多元醇、15—25质量份的钛白粉、填料、5—20质量份的扩链剂、1—3质量份的催化剂、成膜助剂和溶剂组成，所述第一固化组份由70—80质量份的异氰酸酯和溶剂组成，其中：在所述第一树脂组份中，所述聚醚多元醇为端羟基聚丁二烯或者聚四氢呋喃醚二醇，所述钛白粉为锐钛型钛白粉，所述填料由3—5质量份硫酸钡、4—8质量份的中色素和5—8质量份的膨润土组成，所述扩链剂为1,4-丁二醇、乙二醇、丙二醇或者丙三醇的一种，所述催化剂为N,N-二甲基苄胺、正丁基锂或者二月桂酸二正丁基锡的一种，所述成膜助剂由1—3质量份的消泡剂和1—2质量份的流平剂组成，所述溶剂由10—20质量份的二甲苯和15—20质量份的醋酸丁酯组成；在所述第一固化组份中，所述异氰酸酯为氨基甲酸酯改性MDI，NCO质量含量为10～30％，优选10～28％，上述异氰酸酯可进行市购，也可自行制备如下：氨基甲酸酯改性MDI中，按照质量份计，多元醇组分占5～50份，优选5～25份，4,4'-MDI含量占20～80份，优选30～70份，2,4'-MDI占0～60份，优选0～40份。改性用多元醇为PTMEG或PPG，PTMEG数均分子量为100～3000，优选100～1000；PPG数均分子量为100～4000，优选100～2000。所述溶剂由10—20质量份的二甲苯和15—20质量份的醋酸丁酯组成。
所述表面漆由第二树脂组份和第二固化组份组成，其中所述第二树脂组份由45—55质量份的聚醚多元醇、25—30质量份的钛白粉、填料、10—20质量份的扩链剂、1—3质量份的催化剂、10—15质量份的空心微球、成膜助剂和溶剂组成，所述第二固化组份由60—75质量份的异氰酸酯和溶剂组成，其中：在所述第二树脂组份中，所述聚醚多元醇为端羟基聚丁二烯或者聚四氢呋喃醚二醇，所述钛白粉为金红石型钛白粉，所述填料由3—5质量份硫酸钡、4—8质量份的中色素和5—8质量份的膨润土组成，所述扩链剂为1,4-丁二醇、乙二醇、丙二醇或者丙三醇的一种，所述催化剂为N,N-二甲基苄胺、正丁基锂或者二月桂酸二正丁基锡的一种；所述空心微球的粒径范围为0.1～100μm优选10～50微米。空心微球包括聚合物空心微球、陶瓷空心微球或者玻璃空心微球，内含惰性气体，密度低于0.25g/cc，空心微球的质量填充比为1％～50％，优选10～30％；所述成膜助剂由1—3质量份的消泡剂和1—2质量份的流平剂组成，所述溶剂由10—20质量份的二甲苯和15—20质量份的醋酸丁酯组成；在所述第二固化组份中，所述异氰酸酯为氨基甲酸酯改性MDI，NCO质量含量为10～30％，优选10～28％，上述异氰酸酯可进行市购，也可自行制备如下：氨基甲酸酯改性MDI中，按照质量份计，多元醇组分占5～50份，优选5～25份，4,4'-MDI含量占20～80份，优选30～70份，2,4'-MDI占0～60份，优选0～40份。改性用多元醇为PTMEG或PPG，PTMEG数均分子量为100～3000，优选100～1000；PPG数均分子量为100～4000，优选100～2000。所述溶剂由10—20质量份的二甲苯和15—20质量份的醋酸丁酯组成。
所述封闭漆由第三树脂组份和第三固化组份组成，其中所述第三树脂组份由45—50质量份的聚醚多元醇、填料、10—15质量份的扩链剂、1—3质量份的催化剂、20—40质量份的环氧树脂、成膜助剂和溶剂组成，所述第二固化组份由70—75质量份的异氰酸酯和溶剂组成，其中：在所述第三树脂组份中，所述聚醚多元醇为端羟基聚丁二烯或者聚四氢呋喃醚二醇，所述填料由3—5质量份硫酸钡、4—8质量份的中色素和5—8质量份的膨润土组成，所述扩链剂为1,4-丁二醇、乙二醇、丙二醇或者丙三醇的一种，所述催化剂为N,N-二甲基苄胺、正丁基锂或者二月桂酸二正丁基锡的一种；所述环氧树脂是指环氧官能度为1或2以上的脂肪族或芳香族环氧树脂，如饱和或不饱和脂肪族，脂环族，芳香族或杂环环氧化合物。常用环氧树脂为端缩水甘油醚类环氧化合物，优选双酚A环氧树脂；所述成膜助剂由1—3质量份的消泡剂和1—2质量份的流平剂组成，所述溶剂由10—20质量份的二甲苯和15—20质量份的醋酸丁酯组成；在所述第二固化组份中，所述异氰酸酯为氨基甲酸酯改性MDI，NCO质量含量为10～30％，优选10～28％，上述异氰酸酯可进行市购，也可自行制备如下：氨基甲酸酯改性MDI中，按照质量份计，多元醇组分占5～50份，优选5～25份，4,4'-MDI含量占20～80份，优选30～70份，2,4'-MDI占0～60份，优选0～40份。改性用多元醇为PTMEG或PPG，PTMEG数均分子量为100～3000，优选100～1000；PPG数均分子量为100～4000，优选100～2000。所述溶剂由10—20质量份的二甲苯和15—20质量份的醋酸丁酯组成。
在进行制备时，分别制备封闭漆、底面漆和表面漆即可，分别制备三种漆中的树脂组份和固化组份，具体来说：
底面漆中第一树脂组份的制备：依次将钛白粉、硫酸钡、中色素、膨润土、二甲苯、醋酸丁酯、扩链剂、催化剂、消泡剂和流平剂在持续搅拌的条件下加入到聚醚多元醇中，搅拌均匀后进入研磨机，经研磨后过滤即得到第一树脂组份；
底面漆中第一固化组份的制备：依次将异氰酸酯、二甲苯和醋酸丁酯加入到搅拌釜中，持续搅拌均匀后过滤即得到第一固化组份；
表面漆中第二树脂组份的制备：依次将钛白粉、硫酸钡、中色素、膨润土、二甲苯、醋酸丁酯、扩链剂、催化剂、空心微球、消泡剂和流平剂在持续搅拌的条件下加入到聚醚多元醇中，搅拌均匀后进入研磨机，经研磨后过滤即得到第二树脂组份；
表面漆中第二固化组份的制备：依次将异氰酸酯、二甲苯和醋酸丁酯加入到搅拌釜中，持续搅拌均匀后过滤即得到第二固化组份；
封闭漆中第三树脂组份的制备：依次将钛白粉、硫酸钡、中色素、膨润土、二甲苯、醋酸丁酯、扩链剂、催化剂、环氧树脂、消泡剂和流平剂在持续搅拌的条件下加入到聚醚多元醇中，搅拌均匀后进入研磨机，经研磨后过滤即得到第三树脂组份；
封闭漆中第三固化组份的制备：依次将异氰酸酯、二甲苯和醋酸丁酯加入到搅拌釜中，持续搅拌均匀后过滤即得到第三固化组份。
在上述技术方案中，所述消泡剂、流平剂分别选择本领域中常用的消泡剂、流平剂，例如消泡剂为聚硅氧烷消泡剂、流平剂为丙烯酸树脂流平剂。
在上述技术方案中，在制备过程中，搅拌速度为1200—1500r/min，搅拌时间为15—20min。
在进行施工时，首先将三种漆的树脂组份和固化组份进行混合均匀后进行涂装使用，所述封闭漆设置在混凝土表面上并形成封闭漆层，所述底面漆设置在封闭漆层的上表面上并形成底面漆层，所述表面漆设置在底面漆层的上表面上并形成底面漆层，由上述三层漆层组成的整体聚氨酯涂料层的厚度大于600μm且小于1000μm，其中所述底面漆层的干膜厚度大于等于400μm，表面漆层的干膜厚度大于等于200μm，其余为封闭漆层的干膜厚度。
此外，若混凝土基材表面存在不平整或者潮湿时，在混凝土表面设置找平层，在找平层的上表面上设置封闭漆层，继续进行防水层施工。
本发明薄涂型聚氨酯作为一种高铁轨道混凝土基面防水层材料，相对如以前使用的喷涂型聚脲(第一代聚脲产品)，不断克服了喷涂聚脲受限于涂装方法和施工操作时间短的缺陷，而且防水性能得到进一步提升，拥有很好的抗拉伸性能和耐温变性能，且具备了一定的防腐性能。其最大的有点是，产品独特的配方造就了优异的性能，并且实现了涂装方法、操作工艺的简化和涂层的薄涂性，一般只需要600～800μm，而以往使用的喷涂聚脲则需要喷涂至少2mm厚度才可达到与之匹配的防水效果。
具体实施方式
下面结合具体实施例进一步说明本发明的技术方案。本发明的实施例采用的原料均从现有市场供给商处予以购买，分析纯的纯度原料，下面以表格说明各个漆层的组份和含量，
单位为g，均采用发明内容中的加料顺序和搅拌方式予以制备。
底面漆的第一树脂组份的制备
| 实施例1 | 实施例2 | 实施例3 | 实施例4 | |
| 端羟基聚丁二烯 | 50 | 55 | 0 | 0 |
| 聚四氢呋喃醚二醇 | 0 | 0 | 55 | 50 |
| 锐钛型钛白粉 | 25 | 15 | 20 | 18 |
| 硫酸钡 | 5 | 4 | 5 | 3 |
| 中色素 | 8 | 4 | 6 | 6 |
| 膨润土 | 8 | 5 | 7 | 6 |
| 1,4-丁二醇 | 15 | 0 | 0 | 0 |
| 乙二醇 | 0 | 20 | 0 | 0 |
| 丙二醇 | 0 | 0 | 5 | 0 |
| 丙三醇 | 0 | 0 | 0 | 8 |
| N,N-二甲基苄胺 | 3 | 0 | 0 | 0 |
| 正丁基锂 | 0 | 2 | 0 | 0 |
| 二月桂酸二正丁基锡 | 0 | 0 | 1 | 1 |
| 聚硅氧烷消泡剂 | 3 | 2 | 1 | 2.5 |
| 丙烯酸树脂流平剂 | 2 | 1.5 | 1 | 1 |
| 二甲苯 | 20 | 15 | 12 | 10 |
| 醋酸丁酯 | 15 | 20 | 18 | 16 |
底面漆的第一固化组份的制备
表面漆的第二树脂组份的制备
表面漆的第二固化组份的制备
封闭漆的第三树脂组份的制备
| 实施例1 | 实施例2 | 实施例3 | 实施例4 | |
| 端羟基聚丁二烯 | 50 | 45 | 0 | 0 |
| 聚四氢呋喃醚二醇 | 0 | 0 | 45 | 50 |
| 硫酸钡 | 5 | 4 | 5 | 3 |
| 中色素 | 8 | 4 | 6 | 6 |
| 膨润土 | 8 | 5 | 7 | 6 |
| 1,4-丁二醇 | 15 | 0 | 0 | 0 |
| 乙二醇 | 0 | 10 | 0 | 0 |
| 丙二醇 | 0 | 0 | 12 | 0 |
| 丙三醇 | 0 | 0 | 0 | 14 |
| N,N-二甲基苄胺 | 3 | 0 | 0 | 0 |
| 正丁基锂 | 0 | 2 | 0 | 0 |
| 二月桂酸二正丁基锡 | 0 | 0 | 1 | 1 |
| 双酚A环氧树脂 | 40 | 30 | 20 | 35 |
| 聚硅氧烷消泡剂 | 3 | 2 | 1 | 2.5 |
| 丙烯酸树脂流平剂 | 2 | 1.5 | 1 | 1 |
| 二甲苯 | 20 | 15 | 12 | 10 |
| 醋酸丁酯 | 15 | 20 | 18 | 16 |
封闭漆的第三固化组份的制备
将各个漆层中树脂组份的实施例和固化组份的实施例按照编号进行匹配，即树脂组份的实施例1和固化组份的实施例1进行配合使用，在混凝土表面进行涂层的设置。涂装作业完全可采用人工涂覆，刷涂、滚涂均可采用。依据混凝土基材表面情况确定前处理步骤：基面若存在不平整(如麻面)或潮湿时，应先施工找平层，再进行防水层施工，若无麻面，可直接进行防护涂层的施工。
依据基面情况进行前处理，保持干燥洁净，在基面上涂覆一层封闭漆，以形成封闭漆层，待封闭漆表干后，在其表面涂覆底面漆PPU-M1，干膜厚度控制大于400μm，待底面漆PPU-M1表干后，在其表面涂覆表面漆PPU-M2，干膜厚度控制大于200μm。
薄涂型聚氨酯防水漆和封闭漆、防水层的性能测试平均结果见附表1、2、3
附表1封闭漆层
附表2薄涂型聚氨酯防水漆层(PPU-M1、PPU-M2)
附表3薄涂型聚氨酯防水层综合技术性能
附录1：拉伸强度、断裂伸长率测定：防护涂层要求制成自由膜，厚度为200～500μm，自然干燥12～24h后放入105℃的烘箱中，烘1～2h，取出，自然冷却，将自由膜裁成GB/T528-2009规定的哑铃状Ⅰ型试样，在250mm/min±50mm/min移动速度的试验机上进行测定；
附录2：耐温变性测定：在150×75的水泥样板上，按现场施工工艺依次涂装封闭漆、PPU-M1和PPU-M2，干燥7d后做耐温变性试验。60℃热烘2h，室温下水中浸泡6h，-40℃冷冻16h，为一个循环。
以上对本发明做了示例性的描述，应该说明的是，在不脱离本发明的核心的情况下，任何简单的变形、修改或者其他本领域技术人员能够不花费创造性劳动的等同替换均落入本发明的保护范围。
Claims (8)
1.高铁混凝土表面强防水薄涂型聚氨酯涂料，其特征在于，由封闭漆、底面漆和表面漆组成，其中所述底面漆由第一树脂组份和第一固化组份组成，其中所述第一树脂组份由50—55质量份的聚醚多元醇、15—25质量份的钛白粉、3—5质量份硫酸钡、4—8质量份的中色素、5—8质量份的膨润土、5—20质量份的扩链剂、1—3质量份的催化剂、1—3质量份的消泡剂、1—2质量份的流平剂、10—20质量份的二甲苯和15—20质量份的醋酸丁酯组成，所述第一固化组份由70—80质量份的异氰酸酯、10—20质量份的二甲苯和15—20质量份的醋酸丁酯组成，其中：在所述第一树脂组份中，所述聚醚多元醇为聚四氢呋喃醚二醇，所述钛白粉为锐钛型钛白粉，所述扩链剂为1,4-丁二醇、乙二醇、丙二醇或者丙三醇的一种，所述催化剂为N,N-二甲基苄胺、正丁基锂或者二月桂酸二正丁基锡的一种；在所述第一固化组份中，所述异氰酸酯为氨基甲酸酯改性MDI，NCO质量含量为10～30％；
所述表面漆由第二树脂组份和第二固化组份组成，其中所述第二树脂组份由45—55质量份的聚醚多元醇、25—30质量份的钛白粉、3—5质量份硫酸钡、4—8质量份的中色素、5—8质量份的膨润土、10—20质量份的扩链剂、1—3质量份的催化剂、10—15质量份的空心微球、1—3质量份的消泡剂、1—2质量份的流平剂、10—20质量份的二甲苯和15—20质量份的醋酸丁酯组成，所述第二固化组份由60—75质量份的异氰酸酯、10—20质量份的二甲苯和15—20质量份的醋酸丁酯组成，其中：在所述第二树脂组份中，所述聚醚多元醇为聚四氢呋喃醚二醇，所述钛白粉为金红石型钛白粉，所述扩链剂为1,4-丁二醇、乙二醇、丙二醇或者丙三醇的一种，所述催化剂为N,N-二甲基苄胺、正丁基锂或者二月桂酸二正丁基锡的一种；所述空心微球的粒径范围为0.1～100μm，包括聚合物空心微球、陶瓷空心微球或者玻璃空心微球，内含惰性气体，密度低于0.25g/cc，空心微球的质量填充比为1％～50％；在所述第二固化组份中，所述异氰酸酯为氨基甲酸酯改性MDI，NCO质量含量为10～30％；
所述封闭漆由第三树脂组份和第三固化组份组成，其中所述第三树脂组份由45—50质量份的聚醚多元醇、3—5质量份硫酸钡、4—8质量份的中色素、5—8质量份的膨润土、10—15质量份的扩链剂、1—3质量份的催化剂、20—40质量份的环氧树脂、1—3质量份的消泡剂、1—2质量份的流平剂、10—20质量份的二甲苯和15—20质量份的醋酸丁酯组成，所述第二固化组份由70—75质量份的异氰酸酯、10—20质量份的二甲苯和15—20质量份的醋酸丁酯组成，其中：在所述第三树脂组份中，所述聚醚多元醇为聚四氢呋喃醚二醇，所述扩链剂为1,4-丁二醇、乙二醇、丙二醇或者丙三醇的一种，所述催化剂为N,N-二甲基苄胺、正丁基锂或者二月桂酸二正丁基锡的一种；所述环氧树脂是指环氧官能度为1或环氧官能度为2以上的脂肪族或芳香族环氧树脂；在所述第二固化组份中，所述异氰酸酯为氨基甲酸酯改性MDI，NCO质量含量为10～30％。
2.根据权利要求1所述的高铁混凝土表面强防水薄涂型聚氨酯涂料，其特征在于，在所述底面漆的第一固化组份中，所述异氰酸酯为氨基甲酸酯改性MDI，NCO质量含量为10～28％。
3.根据权利要求1所述的高铁混凝土表面强防水薄涂型聚氨酯涂料，其特征在于，在所述表面漆的第二树脂组份中，所述空心微球的粒径范围为10～50微米，空心微球的质量填充比为10～30％；在所述表面漆的第二固化组份中，所述异氰酸酯为氨基甲酸酯改性MDI，NCO质量含量为10～28％。
4.根据权利要求1所述的高铁混凝土表面强防水薄涂型聚氨酯涂料，其特征在于，在所述封闭漆的第三树脂组份中，所述环氧树脂为双酚A环氧树脂；在所述封闭漆的第三固化组份中，所述异氰酸酯为氨基甲酸酯改性MDI，NCO质量含量为10～28％。
5.根据权利要求1—4之一所述的高铁混凝土表面强防水薄涂型聚氨酯涂料，其特征在于，所述消泡剂、流平剂分别选择本领域中常用的消泡剂、流平剂。
6.根据权利要求1—4之一所述的高铁混凝土表面强防水薄涂型聚氨酯涂料，其特征在于，消泡剂为聚硅氧烷消泡剂、流平剂为丙烯酸树脂流平剂。
7.如权利要求1所述的高铁混凝土表面强防水薄涂型聚氨酯涂料的制备方法，其特征在于，在进行制备时，分别制备封闭漆、底面漆和表面漆即可，分别制备三种漆中的树脂组份和固化组份，具体来说：
底面漆中第一树脂组份的制备：依次将钛白粉、硫酸钡、中色素、膨润土、二甲苯、醋酸丁酯、扩链剂、催化剂、消泡剂和流平剂在持续搅拌的条件下加入到聚醚多元醇中，搅拌均匀后进入研磨机，经研磨后过滤即得到第一树脂组份；
底面漆中第一固化组份的制备：依次将异氰酸酯、二甲苯和醋酸丁酯加入到搅拌釜中，持续搅拌均匀后过滤即得到第一固化组份；
表面漆中第二树脂组份的制备：依次将钛白粉、硫酸钡、中色素、膨润土、二甲苯、醋酸丁酯、扩链剂、催化剂、空心微球、消泡剂和流平剂在持续搅拌的条件下加入到聚醚多元醇中，搅拌均匀后进入研磨机，经研磨后过滤即得到第二树脂组份；
表面漆中第二固化组份的制备：依次将异氰酸酯、二甲苯和醋酸丁酯加入到搅拌釜中，持续搅拌均匀后过滤即得到第二固化组份；
封闭漆中第三树脂组份的制备：依次将钛白粉、硫酸钡、中色素、膨润土、二甲苯、醋酸丁酯、扩链剂、催化剂、环氧树脂、消泡剂和流平剂在持续搅拌的条件下加入到聚醚多元醇中，搅拌均匀后进入研磨机，经研磨后过滤即得到第三树脂组份；
封闭漆中第三固化组份的制备：依次将异氰酸酯、二甲苯和醋酸丁酯加入到搅拌釜中，持续搅拌均匀后过滤即得到第三固化组份。
8.根据权利要求7所述的制备方法，其特征在于，在制备过程中，搅拌速度为1200—1500r/min，搅拌时间为15—20min。
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