WO2008147079A1 - Epoxy resin mortar composition and coating method on the surface of the concrete - Google Patents

Epoxy resin mortar composition and coating method on the surface of the concrete Download PDF

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Publication number
WO2008147079A1
WO2008147079A1 PCT/KR2008/002903 KR2008002903W WO2008147079A1 WO 2008147079 A1 WO2008147079 A1 WO 2008147079A1 KR 2008002903 W KR2008002903 W KR 2008002903W WO 2008147079 A1 WO2008147079 A1 WO 2008147079A1
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WO
WIPO (PCT)
Prior art keywords
mortar
epoxy resin
floor surface
concrete floor
primer
Prior art date
Application number
PCT/KR2008/002903
Other languages
French (fr)
Inventor
Sang Yang Kim
Original Assignee
Sang Yang Kim
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Filing date
Publication date
Application filed by Sang Yang Kim filed Critical Sang Yang Kim
Publication of WO2008147079A1 publication Critical patent/WO2008147079A1/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
    • C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
    • C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
    • C08G59/50—Amines
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/01—Use of inorganic substances as compounding ingredients characterized by their specific function
    • C08K3/013—Fillers, pigments or reinforcing additives
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/16—Nitrogen-containing compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D163/00—Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins

Definitions

  • the present invention relates to an epoxy resin mortar composition and a method of conducting the construction of a concrete floor surface using the epoxy resin mortar composition. More particularly, the present invention relates to an epoxy resin mortar composition which is used as a concrete floor surface finishing material and consists of a non-solvent type primer and a mortar with an intermediate level of viscosity and immobility, and a method of conducting the construction of a concrete floor surface using the epoxy resin mortar composition'in a shortened constructional process.
  • a concrete floor surface construction method using such an epoxy resin includes a coating construction method, a lining construction method, a resin mortar construction method, etc.
  • the resin mortar construction method has been most widely applied due to its superior physical properties and semi-permanent structural characteristics.
  • the resin mortar method entails some drawbacks such as insufficient adhesion with the concrete floor surface, a complicated construction procedure, an unsophisticated finished state and the like.
  • a representative example of the product may include ucrete, laticrete, tancrete, overcrete and the like which are imported and are available on the market.
  • the above product employing an expandable urethane material is environmentally- friendly and enables a rapid process without a separate primer process.
  • the expandable urethane material has a low viscosity and a self-leveling property.
  • the expandable urethane material is manufactured to exhibit a fast-curing property in which curing acceleration and hydration reaction occur concurrently and have elasticity.
  • the product since the product possesses a resilient structure due to its foaming properties, its cross-linking density is low, such that there are problems in that it is easily damaged due to abrasion and cutting and is deteriorated in functional characteristics such as a resistance against concentrated impact by a heavy-weighted object or chemicals and heat or the like.
  • there is a problem in that the construction work is not well done due to a short pot life of 5-10 minutes at 20 ° Q and hence a construction range is limited to a small scale centering on a damaged portion and the use purpose is also limited.
  • the coating construction method and the lining construction method are problematically performed for about 60 hours at 20 °C in a three-step process except the floor finishing process.
  • the resin mortar construction method is also problematically conducted for about 100 hours at 20 ° C even though it is performed on a consecutive work basis to coincide with the curing time in a six or seven step process.
  • Korean Patent No. 0476728 entitled "Epoxy resin mortar composition and method of coating the same on the concrete surface” developed by the present inventors
  • an actual work process except the floor finishing process requires about 40-50 hours in a three step, and hence the method is applied to the floor surface construction in a newly built factory without any problem.
  • the above method still entails a problem in that a long time period is required to conduct the repair construction of the floor surface in a factory being operated, thereby greatly reducing productivity.
  • production factories are diversified in line with the epochal change requiring the most advanced function and high-quality production, and the function of a factory flooring material is spotlighted as a significantly critical factor in production environments to meet such diversification.
  • the characteristics by use purpose required for the flooring material of the production facilities will be briefly described hereinafter.
  • the flooring material for a cleaning room and the like is required to be equipped with an electrostatic discharge function and a horizontal surface having a high smoothness.
  • the flooring material is required to be equipped with mechanical properties such as impact strength, tensile strength and the like as well as an antimicrobial function for inhibiting inhabitation of the harmful bacteria, in particular, an antimicrobial function satisfying Hazard Analysis Critical Control Point (HACCP) as a sanitation system of an international quality standard.
  • HACCP Hazard Analysis Critical Control Point
  • the flooring material is required to be equipped with the high-strength mechanical properties and the chemical resistance.
  • a non-slip function for preventing slipping is a prerequisite for prevention of safety accidents.
  • a coating agent is again coated thinly to a predetermined thickness on a floor surface cured after the completion of a coating, lining or resin mortar construction, and then artificial silica sand having a particle size of No. 4 or 5 silica sand (i.e., a diameter of 1.5-2mm) is sprayed on the coated floor surface, followed by curing.
  • the coating agent is again coated on the cured floor surface on which the artificial silica sand is sprayed so as to immobilize the artificial silica sand to thereby form an irregularly protruded uneven surface.
  • This typical construction method entails many drawbacks in that much time is required for performing more than two processes, in that the frictional force is reduced by the coating process for immobilizing the artificial silica sand, thereby making it difficult to sufficiently impart a non-slip effect, and in that spaces between protrusions and depressions of the uneven surface are likely to be contaminated, and hence the cleaning is not easy.
  • a solution for imparting the antimicrobial properties to an existing factory floor employs a method of applying a paint having the antimicrobial properties on the floor surface or applying an epoxy resin impregnated with a disinfectant on the floor surface.
  • a paint having the antimicrobial properties on the floor surface or applying an epoxy resin impregnated with a disinfectant on the floor surface.
  • the conventional antimicrobial flooring material has a limitation in tolerance as mostly being a material having chemical bactericidal properties, and its harmfulness to the human body has never been confirmed.
  • a product has not been developed yet which can sustainably maintain its function in a sanitation system which is environmentally friendly and has conspicuous antimicrobial properties.
  • Korean Patent No. 0145117 Korean Patent No. 0476728 is disclosed wherein the function is improved, the construction procedure is simplified and the construction range which has been limited to a floor surface is efficiently improved, which results in a new change in a concrete floor construction method.
  • a typical epoxy resin mortar-based construction method comprises: 1) shot blasting of a concrete floor (base), 2) primer coating, 3) scraping, 4) spreading 5) press-forming plastering, 6) reinforced coating, 7) top coating and 8) finish coating.
  • a thiso-type coating-based construction method disclosed in Korean Patent No. 0145117 issued to the present inventors comprises: 1) shot blasting of a concrete floor (base), 2) primer coating, 3) scrapping, 4) spreading of mortar, 5) press-forming plastering, 6) reinforced coating, T) thiso-type coating and 8) top coating & finish coating.
  • Korean Patent No. 0476728 issued to the present inventors has been proposed as an improvement of the thiso-type coating construction method.
  • Korean Patent No. 0476728 issued to the present inventors has been proposed as an improvement of the thiso-type coating construction method.
  • Korean Patent No. 0476728 issued to the present inventors has been proposed as an improvement of the thiso-type coating construction method.
  • 04767208 there is disclosed a method of coating an immobile epoxy resin mortar composition on the concrete surface, which comprises 1) shot blasting of a concrete floor (base), 2) primer coating, 3) press-forming plastering of resin mortar and 4) top coating.
  • a construction process comprising 1) shot blasting of a concrete floor (base) and 2) scrapping and simultaneously press-forming plastering of resin mortar without any separate primer coating work at a place where an impact is not applied and a place where there is no movement of a heavy- weighted object such as wall surfaces, stairs or the like.
  • an object of the present invention to provide an epoxy resin mortar composition and a method of coating the epoxy resin mortar composition on a concrete surface, in which the concrete floor can be constructed using a shortened process, thereby greatly improving workability, which can maintain the mechanical properties such as strength at a higher level than that of a conventional method, and in which the cost and time required for maintaining and repairing the concrete floor surface can be significantly reduced, thereby remarkably improving productivity.
  • the present invention provides an epoxy resin mortar composition
  • non-solvent type primer and mortar comprising non-solvent type primer and the mortar comprising a basal resin component and about 30 to about 50 parts by weight, based on 100 parts by weight of the basal resin component, of a curing component, respectively
  • the basal resin component of the primer comprises: i) about 70 to about 80 wt% of an epoxy resin; ii) about 10 to about 25 wt% of a reactive diluent; iii) about 1 to about 20 wt% of an inorganic filler; and iv) about 1 to about 5 wt% of an aggregating agent
  • the curing component of the primer comprises: i) about 30 to about 60 wt% of poly oxy propylene diamine; ii) about 10 to about 20 wt% of at least one selected from the group consisting of triethylene tetraamine and diethylene triamine; iii) about 5
  • the present invention provides a method of conducting the construction of a concrete floor surface using an epoxy resin mortar composition, the method comprising: (a) shot blasting the concrete floor surface to remove irregulars and laitans on the concrete floor surface; and
  • the epoxy resin mortar composition according to the present invention includes non-solvent type primer and mortar such that the coating of the primer and the spreading of the mortar on the concrete floor surface can be carried out simultaneously in a single process, thereby enabling a rapid process conduction and the formation of a surface having excellent mechanical properties such as strength and the like.
  • both the non-slip function and the antimicrobial function are simultaneously imparted in the process of applying the mortar, thereby greatly improving function and efficiency.
  • the method of conducting the construction of the concrete floor surface according to the present invention is environmentally friendly as employing the non-solvent the primer, and can relatively more shorten the constructional process as compared to the method disclosed in Korean Patent No. 0476728 as the prior art, so that when it is applied to newly built factories as well as factories being operated, it is possible to greatly improving productivity.
  • An epoxy resin mortar composition according to the present invention includes non-solvent type primer and mortar.
  • the non-solvent type primer includes a basal resin component and about 30 to about 50 parts by weight, based on
  • the basal resin component of the primer includes: i) about 70 to about 80 wt% of an epoxy resin; ii) about 10 to about 25 wt% of a reactive diluent; iii) about 1 to about 20 wt% of an inorganic filler; and iv) about 1 to about 5 wt% of an aggregating agent.
  • the curing component of the primer includes: i) about 30 to about 60 wt% of poly oxy propylene diamine; ii) about 10 to about 20 wt% of at least one selected from the group consisting of triethylene tetraamine and diethylene triamine; iii) about 5 to about 20 wt % of aniline; and iv) about 10 to about 20 wt% of an accelerator.
  • the mortar includes a basal resin component and about 30 to about 50 parts by weight, based on 100 parts by weight of the basal resin component, of a curing component.
  • the basal resin component of the mortar includes: i) about 70 to about 80 wt % of an epoxy resin; ii) about 5 to about 25 wt% of a reactive diluent; iii) about 0.1 to about 5 wt% of a non reactive diluent; iv) about 1 to about 10 wt% of an inorganic filler; v) about 1 to about 5 wt% of an aggregating agent; vi) about 1 to about 3 wt% of a flame retardant; and vii) about 0.05 to about 1 wt% of a defoamer.
  • the curing component of the mortar includes: i) about 30 to about 60 wt% of polyoxypropylene diamine; ii) about 10 to about 30 wt% of polyamide; iii) about 0.01 to 10 wt % of aniline; iv) about 0.1 to about 10 wt% of at least one selected from the group consisting of triethylene tetraamine and diethylene triamine; and v) about 5 to about 20 wt% of an accelerator.
  • the epoxy resin of may use an epoxy resin which is typically used in the field to which the present invention pertains, and may use a general epoxy resin, an epoxy resin containing chlorine or a mixture thereof.
  • the reactive diluent preferably is at least one selected from the group consisting of butyl glycidyl ether (BGE), phenyl glycidyl ether, carboxlic glycidyl ether, hexandiol diglycidyl ether, butandiol diglycidyl ether and epoxy glycidyl ether.
  • BGE butyl glycidyl ether
  • phenyl glycidyl ether phenyl glycidyl ether
  • carboxlic glycidyl ether hexandiol diglycidyl ether
  • butandiol diglycidyl ether butandiol diglycidyl ether
  • epoxy glycidyl ether epoxy glycidyl ether.
  • the reactive diluent of the present invention may be monoepoxy-, diepoxy- and triepoxy-based diluents, but is
  • the inorganic filler preferably is at least one selected from the group consisting of calcium carbonate, talc, heavy carbonate, silica, Kieselguhr (ceramic) and dolomite, but is not limited thereto.
  • the aggregating agent preferably is at least one selected from the group consisting of silicon dioxide, aerosil, Garamite® (light anhydrous silicic acid) and Asobestos® (glass powder), but is not limited thereto.
  • the non-reactive diluent preferably is at least one selected from the group consisting of ethylene glycol monoethyl ether, ethyl cellosolve, xylene, M methyl ethyl ketone, toluene and methyl isobutyl ketone, but is not limited thereto.
  • the flame retardant preferably is at least one of Pantabromodiphenyl oxide and decabromo diphenyl oxide, but is not limited thereto.
  • the defoamer may be polysiloxane available in the market
  • the accelerator may be at least one selected from the group consisting of phenol, nonyl phenol, K-54, A-399 and the like for accelerating the curing, but is not limited thereto.
  • the mortar of the epoxy resin mortar composition according to the present invention may further include at least one selected from the group consisting of artificial silica sand, natural silica sand and colored silica sand.
  • the silica sand is preferably included in the mortar in an amount of about 150 to about 250 parts by weight based on 100 parts by weight of the basal resin component of the mortar.
  • the mortar of the epoxy resin mortar composition according to the present invention may further include about 1 to about 30 parts by weight of a pigment component based on 100 parts by weight of the basal resin component of the mortar so as to impart a desired color.
  • the primer of the epoxy resin mortar composition of the present invention is in a liquid phase which can be constructed in a rapid process conduction, and consists of a basal resin component and about 30 to about 50 parts by weight, based on 100 parts by weight of the basal resin component, of a curing component which is mixed in a construction site.
  • the primer is prepared in an intermediate-viscosity non-solvent type with immobility unlike a conventional low-viscosity organic- solvent primer, such that the coating of the primer and the spreading of the mortar can be easily conducted simultaneously.
  • the non-solvent type primer of the present invention consists of a basal resin component and about 30 to about 50 parts by weight, based on 100 parts by weight of the basal resin component, of a curing component.
  • the basal resin component of the primer is characterized by including: i) about 70 to about 80 wt% of an epoxy resin; ii) about 10 to about 25 wt% of a reactive diluent; iii) about 1 to about 20 wt% of an inorganic filler; and iv) about 1 to about 5 wt% of an aggregating agent.
  • the curing component of the primer is characterized by including: i) about 30 to about 60 wt% of polyoxypropylene diamine; ii) about 10 to about 20 wt% of at least one selected from the group consisting of triethylene tetraamine and diethylene triamine; iii) about 5 to about 20 wt% of aniline; and iv) about 10 to about 20 wt% of an accelerator.
  • the curing component of the primer may include a resultant mixture obtained by mixing an epoxy-added adducted product and polyamide as a resultant product of a heating- and pressurizing-condensation reaction of fatty acid monomer, dimer, trimer organic fatty acid and aliphatic amine with at least one selected from isophorone diamine and metaxylene diamine instead of polyoxypropylene diamine.
  • the curing component may include a mixture of polyamide and polyoxypropylene diamine in a type modified by mixing polyamide with isophorone diamine and metaxylene diamine.
  • polyoxypropylene diamine of the curing component may be replaced with a resultant product obtained by adducting epoxy to at least one selected from the group consisting of acid anhydride-based tertiary aliphatic amine, polyamide or polypropylene amine, isopropyl diamine, metaxylene diamine, triethylene tetraamine and diethylene triamine, or may be partially mixed with the resultant adducting product.
  • the primer of the epoxy resin mortar composition of the present invention is a liquid phase with a proper level of immobility and consists of a basal resin component and about 30 to about 50 parts by weight, based on 100 parts by weight of the basal resin component, of a curing component which is mixed in a construction site so as to prevent the composition from being directed or flowing to a side with a lower height when the epoxy resin composition is mixed with silica sand to perform the construction of the concrete floor surface using mortar in the construction site.
  • the inventive epoxy resin mortar composition is relatively excellent in water resistance and chemical resistance as compared to a conventional resin composition and enables rapid process conduction using a non-solvent type primer.
  • the mortar of the epoxy resin mortar composition according to the present invention includes a basal resin component and about 30 to about 50 parts by weight, based on 100 parts by weight of the basal resin component, of a curing component.
  • the basal resin component of the mortar includes: i) about 70 to about 80 wt% of an epoxy resin; ii) about 5 to about 25 wt% of a reactive diluent; iii) about 0.1 to about 5 wt% of a non reactive diluent; iv) about 1 to about 10 wt% of an inorganic filler; v) about 1 to about 5 wt% of an aggregating agent; vi) about 1 to about 3 wt % of a flame retardant; and vii) about 0.05 to about 1 wt% of a defoamer.
  • the curing component of the mortar includes: i) about 30 to about 60 wt% of polyoxypropylene diamine; ii) about 10 to about 30 wt% of polyamide; iii) about 0.01 to 10 wt% of aniline; iv) about 0.1 to about 10 wt% of at least one selected from the group consisting of Methylene tetraamine and diethylene triamine; and v) about 5 to about 20 wt % of an accelerator.
  • the curing component may include a resultant mixture obtained by mixing an epoxy-added adducted product and polyamide as a resultant product of a heating- and pressurizing-condensation reaction of monomer, dimer, trimer organic fatty acid and aliphatic amine with at least one selected from isophorone diamine, methylene dianiline and metaxylene diamine instead of poly oxy propylene diamine.
  • the curing component may include a mixture of polyamide and polyoxypropylene diamine in a type modified by mixing polyamide with isophorone diamine, methylene dianiline and metaxylene diamine.
  • polyoxypropylene diamine of the curing component may be replaced with a resultant product obtained by being mixed with at least one selected from the group consisting of acid anhydride-based tertiary aliphatic amine, polyamide or polypropylene amine, isopropyl diamine, metaxylene diamine, diamino diphenylene fulfone and 4,4'-diamino diphenyl methane or adducted using epoxy and then adding triethylene tetraamine and diethylene triamine to the adducted product, or may be partially mixed with the resultant product.
  • a resultant product obtained by being mixed with at least one selected from the group consisting of acid anhydride-based tertiary aliphatic amine, polyamide or polypropylene amine, isopropyl diamine, metaxylene diamine, diamino diphenylene fulfone and 4,4'-diamino diphenyl methane or adducted using epoxy and then adding tri
  • Alicyclic amine base alicyclic amine-based adducted products such as polyoxypropylene diamine, isophorone diamine, methylene dianiline, metaxylene diamine, etc.
  • Aliphatic amine base chemically modified adducted products such as diethylene triamine, triethylene tetraamine, tetraethylene phentamine, etc.
  • Aromatic amine base chemically modified adducted products such as diamino diphenylene fulfone, 4,4'-diamino diphenyl methane, etc.
  • Poly amide amine base poly amide curing agent as a resultant product of a heating- and pressurizing-condensation reaction of monomer, dimer, trimer organic fatty acid and aliphatic amine, and epoxy-added adducted product
  • Acid anhydride adducted products such as phthalic anhydride, hexahydro phthalic anhydride, methyl tetrahydro phthalic anhydride, etc.
  • the composition of the present invention is a resin composition in which a reactive diluent, a non-reactive diluent, an aggregating agent, a flame retardant, a defoamer, a color base, a curing agent, a curing accelerator and the like are contained in an epoxy resin.
  • the resin composition maintains stable immobility by amine having a high activation reaction rate through the mixing operation at a flow state of intermediate viscosity, and has a proper immobility to the extent that the concrete surface is capable of constructed to have a smooth surface by mixing the resin composition with silica sand at a construction site to obtain a mixture, and then simultaneously spreading and vibrating the mixture using a machine or manually rolling the mixture using a honeycomb-like or brush-like roller.
  • the coating characteristics of the primer at the construction site using the epoxy resin mortar composition as prepared above will be described below.
  • a conventional solvent type primer coated on a concrete floor surface to a thickness of less than 0.2mm is not glossy. The reason for this is that the conventional solvent type primer is absorbed by the concrete floor surface since it has due to very low viscosity.
  • the non-solvent type primer according to the present invention is coated on the concrete floor surface to a thickness ranging from 0.4mm to 1.0mm in a scrapping manner using a rubber burnisher. Then, the coated non-solvent type primer is partially absorbed by the concrete floor surface and partially remains on the concrete floor surface since it has intermediate viscosity.
  • This method can allow the concrete floor surface and a mortar layer to stably maintain the adhesive strength in the course of subsequently performing the spreading of the mortar layer to thereby rapidly proceed the construction process as well as greatly enhance the mechanical properties.
  • a change in characteristics other than immobility is required in the mortar disclosed in Korean Patent No. 0476728 developed by the present inventors, and the chemical and mechanical properties which can appear by this characteristics change will be described hereinafter.
  • the curing agent applied to the epoxy resin can be classified into the following four types: amine base, polyamine base, acid anhydride-base. Also, a modified type may be applied to the above four types so as to conform to various characteristics.
  • the primer in order for the epoxy resin mortar composition to be easily applied as a flooring material to the concrete floor surface, the primer first should exhibit a physical and mechanical affinity with ambient materials. That is, the primer should be excellent in adhesion with the concrete floor surface and affinity with a mortar layer. In order to increase the adhesion and the affinity, a residue should be prevented from remaining on an interface between the top surface of the cured primer and the underside of the mortar layer so as to stably exercise the function of the primer.
  • a pigment can be further added in preparing the composition of the present invention in addition to the aforementioned components.
  • a pigment can be added to the epoxy basal resin considering the specific gravity or occulting capability of a selected pigment, and generally used in the range of about 1 to 30 parts by weight based on 100 parts by weight of the resin component.
  • a typical pigment can be further added in the course of preparing the epoxy resin mortar composition of the present invention besides a transparent colored pigment.
  • the pigment may use an inorganic or organic pigment.
  • the pigment can be added to the epoxy basal resin in consideration of the specific gravity or occulting capability thereof in such a fashion that a previously prepared toner is used in an amount of about 1 to about 30 parts by weight based on 100 parts by weight of the resin component.
  • the present invention has been completed by further improving an existing method in which a water-soluable primer is coated and cured on the concrete surface, and then mortar is paved on top of the coated concrete surface to a uniform thickness, followed by press-forming plastering through partial modification of the characteristics of Korean Patent No. 0476728.
  • the present invention can be easily applied to a construction site using a construction method in which non- solvent type primer is coated on top of the concrete floor surface and simultaneously mortar is paved on top of the coated concreted floor surface to a uniform thickness using a machine, and then the resultant mortar layer has a smooth surface by vibration or a construction method in which the mortar is paved manually on top of the coated concreted floor surface to a uniform thickness and then is repeatedly rolled using a honeycomb-like or brush-like roller so as to allow the resultant mortar layer to have a smooth surface.
  • the method of conducting the construction of a concrete floor surface using an epoxy resin mortar composition according to the present invention includes the steps of:
  • the surface construction is easily conducted through the press-forming plastering manner using the composition.
  • the method of conducting the construction of the concrete floor surface is characterized by further including the step of curing the formed mortar layer and re-coating the mortar according to the present invention on top of the cured mortar layer to form a finished layer.
  • the mortar layer formed by the mortar construction method of the present invention may be formed transparently or opaquely, and may be formed to have an embossed surface other than the smooth surface in terms of a finished shape, if necessary.
  • the present invention may have an overlapping shape in which resin is filled in gaps defined between particles of the silica sand on the mortar layer formed through the rolling or press-forming plastering process or a shape in which the gaps defined between particles of the silica sand on the mortar layer are filled in the concrete surface construction.
  • the machine used as a construction tool in the present invention adopts a machine that facilitates the construction of the flooring material using the composition of the present invention.
  • the non-solvent type primer is coated on the concrete floor surface using a roller in a space where there is no obstacle, and nearly simultaneously the mortar is paved on top of the coated floor surface using the machine to enable a mortar layer to be formed.
  • the inventive construction method is characterized in that a press-forming plastering blade has a brush-like concavo- convex surface. Also, the manual operation is performed alone or together with a machine operation for the purpose of more efficient construction even in a small and narrow space.
  • the non-solvent type primer is coated on top of the concrete floor surface and the mortar is paved on top of the coated concrete floor surface, and then the smoothing work is performed on the paved mortar layer using a honeycomb-like or brush-like roller.
  • the honeycomb-like roller is designed to be used efficiently by modifying an existing roller that has been used as other use purpose.
  • the brush-like roller having the shape of bristles of a toothbrush may be used for the purpose of the more sophisticated construction.
  • the brush-like roller can be used which has a thickness ranging from 0.1mm to lmm, a length ranging from mm to 10mm and a distance between implanted bristles raging from 0.1mm to 3mm and is made of nylon or synthetic resin besides piano wires having a high elasticity.
  • the smooth surface of the paved mortar layer is finished by the repeated rolling of the honeycomb-like roller and then is again rolled by the honeycomb-like roller so as to form much more sophisticated and smoother surface.
  • the ratio in which the basal resin component of the mortar and silica sand are mixed in a construction site can be determined differently depending on the use purpose using the epoxy resin mortar composition of the present invention.
  • the basal resin component and the silica sand can be mixed in the ratio of parts by weight of 100:150 to 100:250.
  • the non-solvent type primer is coated on top of the concrete floor surface and simultaneously the mortar is paved on top of the coated concrete floor surface up to a uniform thickness ranging from 2mm to 100mm, followed by press- forming plastering
  • the basal resin component and the silica sand can be mixed in the ratio of parts by weight of 100:300 to 100:1000.
  • the present invention may applied along with the water-soluable primer disclosed in Korean Patent No. 0476728 invented by the present inventors depending on the work environment of a moisturized surface or a construction site.
  • the composition of the present invention may be applied to shorten the number of the construction processes in a pressing and compaction manner using construction equipment used in an existing general resin mortar construction, i.e., a spreader, a finisher and the like.
  • the method of conducting the construction of a concrete floor surface according to the present invention may further include the step of attaching nano silver chip on top of the mortar layer by spraying so as to impart antimicrobial properties.
  • the nano silver chip is attached on top of the entire resultant surface by spraying in a state where the nano silver chip is mixedly dispersed to an organic solvent, water, etc., prior to the curing of the formed mortar layer immediately after the mortar layer has been formed.
  • flooring materials using various chemical resins, paint and the like may be coated on top of the mortar layer, and the nano silver chip may be sprayed onto the surface of the coated mortar layer prior to the curing of the mortar layer surface so as to maintain a distinct antimicrobial function.
  • the method of conducting the construction of a concrete floor surface according to the present invention may further include the step of attaching silica sand or metal chip on top of the mortar layer by spraying so as to impart the non-slip characteristics to the concrete floor surface.
  • the silica sand and the metal chip are not particularly limited.
  • Epoxy basin resin (1) 79.00 g
  • Inorganic filler (3) 7.00 g Aggregating agent (4) 2.0O g
  • Non-reactive diluent (9) 1.20 g
  • the construction of a concrete floor surface was conducted using an epoxy resin composition comprising non-solvent type primer and mortar in such a fashion that the primer in which a basal resin component and a curing component are mixed in the ratio of parts by weight of 100:40 are coated on top of the concrete floor surface subjected to the shot blasting, that on top of the coated concreted floor surface is paved the mortar in which a basal resin component and a curing component are mixed in the ratio of parts by weight of 100:40, and that artificial silica sand or natural silica sand is mixed with the basal resin component of the mortar in an amount of 200 parts by weight based on 100 parts by weight of the basal resin component.
  • Inorganic filler talc (4) Aggregating agent: Silicon dioxide
  • non-reactive diluent ethylene glycol monoethyl ether
  • (11) defoamer polysiloxane
  • silica sand or artificial silica sand was mixed with the basal resin component of the mortar in an amount of 200 parts by weight based on 100 parts by weight of the basal resin component.
  • the primer was coated and the mortar was paved using a machine capable of simultaneously performing the coating of the primer and the spreading of the mortar, and then a rolling work was repeatedly performed on the paved mortar surface using a honeycomb-like roller to thereby achieve a uniform and smooth concrete floor surface without any separation of the silica sand and the resin from each other.
  • the thickness of the coated primer is set to be about 0.45mm and the thickness of the paved mortar is set to be about 5mm.
  • the resultant concrete floor surface was cured for about for 12 days at 20 0 C, and then its physical properties were measured.
  • the measurement result of the physical properties showed that the resultant concrete floor surface has an adhesion (boding strength) of 41 kg/ cm 2 , compressive strengths of 960-1,150 kg/ cm 2 (in case of using artificial silica sand) and 1,200-1,300 kg/cm 2 (in case of using natural silica sand) and a tensile strength of 480-520 kg/ cm 2 .
  • adhesion adhesion
  • compressive strengths of 960-1,150 kg/ cm 2 (in case of using artificial silica sand) and 1,200-1,300 kg/cm 2 (in case of using natural silica sand)
  • a tensile strength of 480-520 kg/ cm 2 .
  • schale tube was put on the cured mortar layer surface and its surroundings are sealed to prevent a solution from flowing out therefrom.
  • the resin composition is very useful as a flooring material high in strength and excellent in physical properties such as bonding strength, tensile strength, water resistance, chemical resistance and the like.

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Abstract

The present invention relates to an epoxy resin mortar composition which is used as a concrete floor surface finishing material and consists of a non-solvent type primer and a mortar with an intermediate level of viscosity and immobility, and a method of conducting the construction of a concrete floor surface using the epoxy resin mortar composition in a shortened constructional process. In case where the construction of a concrete floor surface is conducted using the epoxy resin mortar composition prepared according to the present invention at construction site, the constructional process is shortened to thereby greatly improve constructional workability. Also, the mechanical properties such as strength can be maintained at more than the level of a conventional prior art, and the cost and time required for maintaining and repairing the concrete surface can be significantly reduced to thereby remarkably improve productivity in a construction site.

Description

[DESCRIPTION] [Invention Title]
EPOXY RESIN MORTAR COMPOSITION AND COATING METHOD ON THE SURFACE OF THE CONCRETE [Technical Field]
The present invention relates to an epoxy resin mortar composition and a method of conducting the construction of a concrete floor surface using the epoxy resin mortar composition. More particularly, the present invention relates to an epoxy resin mortar composition which is used as a concrete floor surface finishing material and consists of a non-solvent type primer and a mortar with an intermediate level of viscosity and immobility, and a method of conducting the construction of a concrete floor surface using the epoxy resin mortar composition'in a shortened constructional process.
[Background Art] Currently, chemical resins have been widely used as materials for reinforcing and improving an external structure in finishing up a concrete floor surface. Among the chemical resins, an epoxy resin having generally excellent physical properties is employed. A concrete floor surface construction method using such an epoxy resin includes a coating construction method, a lining construction method, a resin mortar construction method, etc. Among these methods, the resin mortar construction method has been most widely applied due to its superior physical properties and semi-permanent structural characteristics. However, the resin mortar method entails some drawbacks such as insufficient adhesion with the concrete floor surface, a complicated construction procedure, an unsophisticated finished state and the like. In particular, in order to conduct the concrete floor construction in a production factory, it is required that production of goods should be stopped for a long time period, which may result in a deterioration of productivity and quality. Thus, there has been an urgent need for a rapid process conduction in the concrete floor construction work. In order to satisfy such a need, a product which is partially improved in performance has been developed. A representative example of the product may include ucrete, laticrete, tancrete, overcrete and the like which are imported and are available on the market. The above product employing an expandable urethane material is environmentally- friendly and enables a rapid process without a separate primer process. The expandable urethane material has a low viscosity and a self-leveling property.
Also, the expandable urethane material is manufactured to exhibit a fast-curing property in which curing acceleration and hydration reaction occur concurrently and have elasticity. However, since the product possesses a resilient structure due to its foaming properties, its cross-linking density is low, such that there are problems in that it is easily damaged due to abrasion and cutting and is deteriorated in functional characteristics such as a resistance against concentrated impact by a heavy-weighted object or chemicals and heat or the like. In addition, there is a problem in that the construction work is not well done due to a short pot life of 5-10 minutes at 20 °Q and hence a construction range is limited to a small scale centering on a damaged portion and the use purpose is also limited. In the meantime, among the conventional concrete floor surface construction method using the epoxy resin, the coating construction method and the lining construction method are problematically performed for about 60 hours at 20 °C in a three-step process except the floor finishing process. Further, the resin mortar construction method is also problematically conducted for about 100 hours at 20 °C even though it is performed on a consecutive work basis to coincide with the curing time in a six or seven step process. Moreover, in case of Korean Patent No. 0476728 entitled "Epoxy resin mortar composition and method of coating the same on the concrete surface" developed by the present inventors, an actual work process except the floor finishing process requires about 40-50 hours in a three step, and hence the method is applied to the floor surface construction in a newly built factory without any problem. However, the above method still entails a problem in that a long time period is required to conduct the repair construction of the floor surface in a factory being operated, thereby greatly reducing productivity.
Particularly, production factories are diversified in line with the epochal change requiring the most advanced function and high-quality production, and the function of a factory flooring material is spotlighted as a significantly critical factor in production environments to meet such diversification. The characteristics by use purpose required for the flooring material of the production facilities will be briefly described hereinafter.
First, in case of an electrical and electronic field, for example, the flooring material for a cleaning room and the like is required to be equipped with an electrostatic discharge function and a horizontal surface having a high smoothness. In case of a foodstuff and meat processing field, the flooring material is required to be equipped with mechanical properties such as impact strength, tensile strength and the like as well as an antimicrobial function for inhibiting inhabitation of the harmful bacteria, in particular, an antimicrobial function satisfying Hazard Analysis Critical Control Point (HACCP) as a sanitation system of an international quality standard. Besides, in case of industrial fields such as basic iron, nuclear power, heavy equipment, power generator, chemical, various machinery, etc., the flooring material is required to be equipped with the high-strength mechanical properties and the chemical resistance. In case of the flooring material of the electrical and electronic field, the preference is for a lining product having self-leveling property and conductivity, and hence most existing products may be fulfilled to some extent. On the other hand, in case of a repair construction of the factory floor in the fields such as heavy equipment, foodstuff, meat processing, pharmacy and the like in which a high-strength function, a sanitation system and stability of work are required, there is a problem in that an existing construction method cannot satisfy desired function requirements and rapid construction is impossible.
More specifically, in case of the factory floor where oil is spread here and there such as the meat processing field and the like, a non-slip function for preventing slipping is a prerequisite for prevention of safety accidents. In this regard, in a conventional construction method, a coating agent is again coated thinly to a predetermined thickness on a floor surface cured after the completion of a coating, lining or resin mortar construction, and then artificial silica sand having a particle size of No. 4 or 5 silica sand (i.e., a diameter of 1.5-2mm) is sprayed on the coated floor surface, followed by curing. Thereafter, the coating agent is again coated on the cured floor surface on which the artificial silica sand is sprayed so as to immobilize the artificial silica sand to thereby form an irregularly protruded uneven surface. This typical construction method entails many drawbacks in that much time is required for performing more than two processes, in that the frictional force is reduced by the coating process for immobilizing the artificial silica sand, thereby making it difficult to sufficiently impart a non-slip effect, and in that spaces between protrusions and depressions of the uneven surface are likely to be contaminated, and hence the cleaning is not easy. In addition, a solution for imparting the antimicrobial properties to an existing factory floor employs a method of applying a paint having the antimicrobial properties on the floor surface or applying an epoxy resin impregnated with a disinfectant on the floor surface. In this case, it is impossible to realize a structure capable of performing a bactericidal action due to formation of a thin film having non-conductivity, thereby making it difficult to expect sufficient effects. The conventional antimicrobial flooring material has a limitation in tolerance as mostly being a material having chemical bactericidal properties, and its harmfulness to the human body has never been confirmed. Thus, a product has not been developed yet which can sustainably maintain its function in a sanitation system which is environmentally friendly and has conspicuous antimicrobial properties.
In order to address and solve the problems associated with quality and the above flooring material and a construction method thereof, the present inventors have proposed a method of constructing the concrete floor surface using an epoxy resin mortar composition as disclosed in Korean Patent No. 0145117. In addition, currently, Korean Patent No. 0476728 is disclosed wherein the function is improved, the construction procedure is simplified and the construction range which has been limited to a floor surface is efficiently improved, which results in a new change in a concrete floor construction method.
A typical epoxy resin mortar-based construction method comprises: 1) shot blasting of a concrete floor (base), 2) primer coating, 3) scraping, 4) spreading 5) press-forming plastering, 6) reinforced coating, 7) top coating and 8) finish coating. Also, a thiso-type coating-based construction method disclosed in Korean Patent No. 0145117 issued to the present inventors comprises: 1) shot blasting of a concrete floor (base), 2) primer coating, 3) scrapping, 4) spreading of mortar, 5) press-forming plastering, 6) reinforced coating, T) thiso-type coating and 8) top coating & finish coating. Korean Patent No. 0476728 issued to the present inventors has been proposed as an improvement of the thiso-type coating construction method. In Korean Patent No. 0476728, there is disclosed a method of coating an immobile epoxy resin mortar composition on the concrete surface, which comprises 1) shot blasting of a concrete floor (base), 2) primer coating, 3) press-forming plastering of resin mortar and 4) top coating. In case of the method of Korean Patent No. 0476728, there has been adopted a construction process comprising 1) shot blasting of a concrete floor (base) and 2) scrapping and simultaneously press-forming plastering of resin mortar without any separate primer coating work at a place where an impact is not applied and a place where there is no movement of a heavy- weighted object such as wall surfaces, stairs or the like. However, in case of the concrete floor surface, there is an urgent need for a variety of functions such as rapid process conduction as well as mechanical properties endurable to any heavy- weighted object depending on use purposes. But the conventional construction methods require stringent improvements due to a limitation in meeting such a need. The information disclosed in this Background of the Invention section is only for enhancement of understanding of the background of the invention and should not be taken as an acknowledgment or any form of suggestion that this information forms the prior art that is already known to a person skilled in that art. [Disclosure] [Technical Problem] The present inventors have researched the above problems associated with the prior art and have endeavored to solve them, and as a result thereof, have found that if the construction method is changed through a partial modification of the composition of the epoxy resin mortar composition of Korean Patent No. 0476728 developed by the present inventors, it is possible to satisfy various functions such as rapid process conduction required urgently for the repair construction of the concrete floor as well as sanitation, stability and the like, thereby completing the present invention.
Accordingly, it is an object of the present invention to provide an epoxy resin mortar composition and a method of coating the epoxy resin mortar composition on a concrete surface, in which the concrete floor can be constructed using a shortened process, thereby greatly improving workability, which can maintain the mechanical properties such as strength at a higher level than that of a conventional method, and in which the cost and time required for maintaining and repairing the concrete floor surface can be significantly reduced, thereby remarkably improving productivity. [Technical Solution]
In order to accomplish the above object, in one aspect, the present invention provides an epoxy resin mortar composition comprising non-solvent type primer and mortar, the non-solvent type primer and the mortar comprising a basal resin component and about 30 to about 50 parts by weight, based on 100 parts by weight of the basal resin component, of a curing component, respectively, wherein the basal resin component of the primer comprises: i) about 70 to about 80 wt% of an epoxy resin; ii) about 10 to about 25 wt% of a reactive diluent; iii) about 1 to about 20 wt% of an inorganic filler; and iv) about 1 to about 5 wt% of an aggregating agent, wherein the curing component of the primer comprises: i) about 30 to about 60 wt% of poly oxy propylene diamine; ii) about 10 to about 20 wt% of at least one selected from the group consisting of triethylene tetraamine and diethylene triamine; iii) about 5 to about 20 wt% of aniline; and iv) about 10 to about 20 wt% of an accelerator, wherein the basal resin component of the mortar comprises: i) about 70 to about 80 wt% of an epoxy resin; ii) about 5 to about 25 wt% of a reactive diluent; iii) about 0.1 to about 5 wt% of a non reactive diluent; iv) about 1 to about 10 wt% of an inorganic filler; v) about 1 to about 5 wt% of an aggregating agent; vi) about 1 to about 3 wt% of a flame retardant; and vii) about 0.05 to about 1 wt% of a defoamer, and wherein the curing component of the mortar comprises: i) about 30 to about 60 wt% of polyoxypropylene diamine; ii) about 10 to about 30 wt% of polyamide; iii) about 0.01 to 10 wt% of aniline; iv) about 0.1 to about 10 wt% of at least one selected from the group consisting of triethylene tetraamine and diethylene triamine; and v) about 5 to about 20 wt% of an accelerator.
Also, in another aspect, the present invention provides a method of conducting the construction of a concrete floor surface using an epoxy resin mortar composition, the method comprising: (a) shot blasting the concrete floor surface to remove irregulars and laitans on the concrete floor surface; and
(b) coating the non-solvent type primer according to the present invention on top of the concrete floor surface and simultaneously spreading the mortar according to the present invention on top of the coated concrete floor surface to form a mortar layer. [Advantageous Effects]
The epoxy resin mortar composition according to the present invention includes non-solvent type primer and mortar such that the coating of the primer and the spreading of the mortar on the concrete floor surface can be carried out simultaneously in a single process, thereby enabling a rapid process conduction and the formation of a surface having excellent mechanical properties such as strength and the like.
In addition, both the non-slip function and the antimicrobial function are simultaneously imparted in the process of applying the mortar, thereby greatly improving function and efficiency.
Moreover, the method of conducting the construction of the concrete floor surface according to the present invention is environmentally friendly as employing the non-solvent the primer, and can relatively more shorten the constructional process as compared to the method disclosed in Korean Patent No. 0476728 as the prior art, so that when it is applied to newly built factories as well as factories being operated, it is possible to greatly improving productivity.
[Best Mode]
Reference will now be made in more detail to the preferred embodiment of the present invention.
An epoxy resin mortar composition according to the present invention includes non-solvent type primer and mortar. The non-solvent type primer includes a basal resin component and about 30 to about 50 parts by weight, based on
100 parts by weight of the basal resin component, of a curing component. The basal resin component of the primer includes: i) about 70 to about 80 wt% of an epoxy resin; ii) about 10 to about 25 wt% of a reactive diluent; iii) about 1 to about 20 wt% of an inorganic filler; and iv) about 1 to about 5 wt% of an aggregating agent.
The curing component of the primer includes: i) about 30 to about 60 wt% of poly oxy propylene diamine; ii) about 10 to about 20 wt% of at least one selected from the group consisting of triethylene tetraamine and diethylene triamine; iii) about 5 to about 20 wt % of aniline; and iv) about 10 to about 20 wt% of an accelerator.
Also, the mortar includes a basal resin component and about 30 to about 50 parts by weight, based on 100 parts by weight of the basal resin component, of a curing component. The basal resin component of the mortar includes: i) about 70 to about 80 wt % of an epoxy resin; ii) about 5 to about 25 wt% of a reactive diluent; iii) about 0.1 to about 5 wt% of a non reactive diluent; iv) about 1 to about 10 wt% of an inorganic filler; v) about 1 to about 5 wt% of an aggregating agent; vi) about 1 to about 3 wt% of a flame retardant; and vii) about 0.05 to about 1 wt% of a defoamer. The curing component of the mortar includes: i) about 30 to about 60 wt% of polyoxypropylene diamine; ii) about 10 to about 30 wt% of polyamide; iii) about 0.01 to 10 wt % of aniline; iv) about 0.1 to about 10 wt% of at least one selected from the group consisting of triethylene tetraamine and diethylene triamine; and v) about 5 to about 20 wt% of an accelerator. In the present invention, the epoxy resin of may use an epoxy resin which is typically used in the field to which the present invention pertains, and may use a general epoxy resin, an epoxy resin containing chlorine or a mixture thereof. In the present invention, the reactive diluent preferably is at least one selected from the group consisting of butyl glycidyl ether (BGE), phenyl glycidyl ether, carboxlic glycidyl ether, hexandiol diglycidyl ether, butandiol diglycidyl ether and epoxy glycidyl ether. Besides them, the reactive diluent of the present invention may be monoepoxy-, diepoxy- and triepoxy-based diluents, but is not limited thereto.
In the present invention, the inorganic filler preferably is at least one selected from the group consisting of calcium carbonate, talc, heavy carbonate, silica, Kieselguhr (ceramic) and dolomite, but is not limited thereto. In the present invention, the aggregating agent preferably is at least one selected from the group consisting of silicon dioxide, aerosil, Garamite® (light anhydrous silicic acid) and Asobestos® (glass powder), but is not limited thereto.
In the present invention, the non-reactive diluent preferably is at least one selected from the group consisting of ethylene glycol monoethyl ether, ethyl cellosolve, xylene, M methyl ethyl ketone, toluene and methyl isobutyl ketone, but is not limited thereto. In the present invention, the flame retardant preferably is at least one of Pantabromodiphenyl oxide and decabromo diphenyl oxide, but is not limited thereto.
In the present invention, the defoamer may be polysiloxane available in the market, and the accelerator may be at least one selected from the group consisting of phenol, nonyl phenol, K-54, A-399 and the like for accelerating the curing, but is not limited thereto.
The mortar of the epoxy resin mortar composition according to the present invention may further include at least one selected from the group consisting of artificial silica sand, natural silica sand and colored silica sand.
The silica sand is preferably included in the mortar in an amount of about 150 to about 250 parts by weight based on 100 parts by weight of the basal resin component of the mortar.
The mortar of the epoxy resin mortar composition according to the present invention may further include about 1 to about 30 parts by weight of a pigment component based on 100 parts by weight of the basal resin component of the mortar so as to impart a desired color. The primer of the epoxy resin mortar composition of the present invention is in a liquid phase which can be constructed in a rapid process conduction, and consists of a basal resin component and about 30 to about 50 parts by weight, based on 100 parts by weight of the basal resin component, of a curing component which is mixed in a construction site. The primer is prepared in an intermediate-viscosity non-solvent type with immobility unlike a conventional low-viscosity organic- solvent primer, such that the coating of the primer and the spreading of the mortar can be easily conducted simultaneously.
The non-solvent type primer of the present invention consists of a basal resin component and about 30 to about 50 parts by weight, based on 100 parts by weight of the basal resin component, of a curing component. The basal resin component of the primer is characterized by including: i) about 70 to about 80 wt% of an epoxy resin; ii) about 10 to about 25 wt% of a reactive diluent; iii) about 1 to about 20 wt% of an inorganic filler; and iv) about 1 to about 5 wt% of an aggregating agent. The curing component of the primer is characterized by including: i) about 30 to about 60 wt% of polyoxypropylene diamine; ii) about 10 to about 20 wt% of at least one selected from the group consisting of triethylene tetraamine and diethylene triamine; iii) about 5 to about 20 wt% of aniline; and iv) about 10 to about 20 wt% of an accelerator. The curing component of the primer may include a resultant mixture obtained by mixing an epoxy-added adducted product and polyamide as a resultant product of a heating- and pressurizing-condensation reaction of fatty acid monomer, dimer, trimer organic fatty acid and aliphatic amine with at least one selected from isophorone diamine and metaxylene diamine instead of polyoxypropylene diamine. The curing component may include a mixture of polyamide and polyoxypropylene diamine in a type modified by mixing polyamide with isophorone diamine and metaxylene diamine. Also, polyoxypropylene diamine of the curing component may be replaced with a resultant product obtained by adducting epoxy to at least one selected from the group consisting of acid anhydride-based tertiary aliphatic amine, polyamide or polypropylene amine, isopropyl diamine, metaxylene diamine, triethylene tetraamine and diethylene triamine, or may be partially mixed with the resultant adducting product.
The primer of the epoxy resin mortar composition of the present invention is a liquid phase with a proper level of immobility and consists of a basal resin component and about 30 to about 50 parts by weight, based on 100 parts by weight of the basal resin component, of a curing component which is mixed in a construction site so as to prevent the composition from being directed or flowing to a side with a lower height when the epoxy resin composition is mixed with silica sand to perform the construction of the concrete floor surface using mortar in the construction site. The inventive epoxy resin mortar composition is relatively excellent in water resistance and chemical resistance as compared to a conventional resin composition and enables rapid process conduction using a non-solvent type primer.
In addition, the mortar of the epoxy resin mortar composition according to the present invention includes a basal resin component and about 30 to about 50 parts by weight, based on 100 parts by weight of the basal resin component, of a curing component. The basal resin component of the mortar includes: i) about 70 to about 80 wt% of an epoxy resin; ii) about 5 to about 25 wt% of a reactive diluent; iii) about 0.1 to about 5 wt% of a non reactive diluent; iv) about 1 to about 10 wt% of an inorganic filler; v) about 1 to about 5 wt% of an aggregating agent; vi) about 1 to about 3 wt % of a flame retardant; and vii) about 0.05 to about 1 wt% of a defoamer. The curing component of the mortar includes: i) about 30 to about 60 wt% of polyoxypropylene diamine; ii) about 10 to about 30 wt% of polyamide; iii) about 0.01 to 10 wt% of aniline; iv) about 0.1 to about 10 wt% of at least one selected from the group consisting of Methylene tetraamine and diethylene triamine; and v) about 5 to about 20 wt % of an accelerator.
The curing component may include a resultant mixture obtained by mixing an epoxy-added adducted product and polyamide as a resultant product of a heating- and pressurizing-condensation reaction of monomer, dimer, trimer organic fatty acid and aliphatic amine with at least one selected from isophorone diamine, methylene dianiline and metaxylene diamine instead of poly oxy propylene diamine. The curing component may include a mixture of polyamide and polyoxypropylene diamine in a type modified by mixing polyamide with isophorone diamine, methylene dianiline and metaxylene diamine. Also, polyoxypropylene diamine of the curing component may be replaced with a resultant product obtained by being mixed with at least one selected from the group consisting of acid anhydride-based tertiary aliphatic amine, polyamide or polypropylene amine, isopropyl diamine, metaxylene diamine, diamino diphenylene fulfone and 4,4'-diamino diphenyl methane or adducted using epoxy and then adding triethylene tetraamine and diethylene triamine to the adducted product, or may be partially mixed with the resultant product.
The type of compound used as the curing component is classified as follows: 1. Alicyclic amine base: alicyclic amine-based adducted products such as polyoxypropylene diamine, isophorone diamine, methylene dianiline, metaxylene diamine, etc.
2. Aliphatic amine base: chemically modified adducted products such as diethylene triamine, triethylene tetraamine, tetraethylene phentamine, etc.
3. Aromatic amine base: chemically modified adducted products such as diamino diphenylene fulfone, 4,4'-diamino diphenyl methane, etc.
4. Poly amide amine base: poly amide curing agent as a resultant product of a heating- and pressurizing-condensation reaction of monomer, dimer, trimer organic fatty acid and aliphatic amine, and epoxy-added adducted product
5. Acid anhydride: adducted products such as phthalic anhydride, hexahydro phthalic anhydride, methyl tetrahydro phthalic anhydride, etc.
The composition of the present invention is a resin composition in which a reactive diluent, a non-reactive diluent, an aggregating agent, a flame retardant, a defoamer, a color base, a curing agent, a curing accelerator and the like are contained in an epoxy resin. The resin composition maintains stable immobility by amine having a high activation reaction rate through the mixing operation at a flow state of intermediate viscosity, and has a proper immobility to the extent that the concrete surface is capable of constructed to have a smooth surface by mixing the resin composition with silica sand at a construction site to obtain a mixture, and then simultaneously spreading and vibrating the mixture using a machine or manually rolling the mixture using a honeycomb-like or brush-like roller. The coating characteristics of the primer at the construction site using the epoxy resin mortar composition as prepared above will be described below.
A conventional solvent type primer coated on a concrete floor surface to a thickness of less than 0.2mm is not glossy. The reason for this is that the conventional solvent type primer is absorbed by the concrete floor surface since it has due to very low viscosity. On the other hand, the non-solvent type primer according to the present invention is coated on the concrete floor surface to a thickness ranging from 0.4mm to 1.0mm in a scrapping manner using a rubber burnisher. Then, the coated non-solvent type primer is partially absorbed by the concrete floor surface and partially remains on the concrete floor surface since it has intermediate viscosity. This method can allow the concrete floor surface and a mortar layer to stably maintain the adhesive strength in the course of subsequently performing the spreading of the mortar layer to thereby rapidly proceed the construction process as well as greatly enhance the mechanical properties. In order to further shorten the number of the construction processes and simultaneously impart various functions, a change in characteristics other than immobility is required in the mortar disclosed in Korean Patent No. 0476728 developed by the present inventors, and the chemical and mechanical properties which can appear by this characteristics change will be described hereinafter.
The curing agent applied to the epoxy resin can be classified into the following four types: amine base, polyamine base, acid anhydride-base. Also, a modified type may be applied to the above four types so as to conform to various characteristics. In this case, in order for the epoxy resin mortar composition to be easily applied as a flooring material to the concrete floor surface, the primer first should exhibit a physical and mechanical affinity with ambient materials. That is, the primer should be excellent in adhesion with the concrete floor surface and affinity with a mortar layer. In order to increase the adhesion and the affinity, a residue should be prevented from remaining on an interface between the top surface of the cured primer and the underside of the mortar layer so as to stably exercise the function of the primer. In case of the mortar, proper immobility should be stably maintained when the basal resin component and the curing component are mixed with each other at a construction site so as to exercise the property of the mortar. The critical factor for stably maintaining the immobility is an activation reaction which occurs when mixing the basal resin component and the curing component. In a general non-solvent type composition, an aggregating agent such as aerosol should be used in a great amount to control flowability of the resin. Likewise, if a great amount of aggregating agent is used, workability is deteriorated, thus making it impossible to function as a mortar. In order to solve the above problem, there is employed a method in which a small amount of aggregating agent is put into the basal resin component, and at least one of triethylene tetraamine and diethylene triamine having good reactionability to reactive oxygen species among the amine base is mixed with the basal resin component in a construction site in a state where the at least one of triethylene tetraamine and diethylene triamine flows in a small amount, but not adducted. In this case, a fine swelling phenomenon occurs by the exchange of the reverse reaction and the forward reaction due to an extremely small amount of moisture contained in the basal resin component to cause flowability of the resin to be controlled powerfully, and the flowability of the resin is maintained continuously by means of the exothermic reaction occurring during the curing so that when the resin composition is mixed with silica sand, other inorganic substances and metal granules, the construction of the concrete floor surface is facilitated. Also, since the constructed concrete floor surface layer exhibits a characteristic of not containing moisture in the atmosphere, the cross-linking density of the concrete surface layer cured after the construction is increased even at a place where the relative humidity is very high, thereby exhibiting a very excellent resistance in terms of water resistance, chemical resistance and the like.
A pigment can be further added in preparing the composition of the present invention in addition to the aforementioned components. A pigment can be added to the epoxy basal resin considering the specific gravity or occulting capability of a selected pigment, and generally used in the range of about 1 to 30 parts by weight based on 100 parts by weight of the resin component. In addition, a typical pigment can be further added in the course of preparing the epoxy resin mortar composition of the present invention besides a transparent colored pigment. In this case, the pigment may use an inorganic or organic pigment. The pigment can be added to the epoxy basal resin in consideration of the specific gravity or occulting capability thereof in such a fashion that a previously prepared toner is used in an amount of about 1 to about 30 parts by weight based on 100 parts by weight of the resin component. The present invention has been completed by further improving an existing method in which a water-soluable primer is coated and cured on the concrete surface, and then mortar is paved on top of the coated concrete surface to a uniform thickness, followed by press-forming plastering through partial modification of the characteristics of Korean Patent No. 0476728. Thus, the present invention can be easily applied to a construction site using a construction method in which non- solvent type primer is coated on top of the concrete floor surface and simultaneously mortar is paved on top of the coated concreted floor surface to a uniform thickness using a machine, and then the resultant mortar layer has a smooth surface by vibration or a construction method in which the mortar is paved manually on top of the coated concreted floor surface to a uniform thickness and then is repeatedly rolled using a honeycomb-like or brush-like roller so as to allow the resultant mortar layer to have a smooth surface.
Even in case of the construction method where the press-forming plastering as disclosed in Korean Patent No. 0476728 is performed, it is possible to apply the press-forming plastering to the concrete floor surface using the non-solvent type primer of the present invention. Now, a method of conducting the construction of a concrete floor surface using an epoxy resin mortar composition will be described hereinafter in more detail.
The method of conducting the construction of a concrete floor surface using an epoxy resin mortar composition according to the present invention includes the steps of:
(a) shot blasting the concrete floor surface to remove irregulars and laitans on the concrete floor surface; and
(b) coating the non-solvent type primer according to the present invention on top of the concrete floor surface and simultaneously spreading the mortar according to the present invention on top of the coated concrete floor surface to form a mortar layer.
Also, the surface construction is easily conducted through the press-forming plastering manner using the composition. The method of conducting the construction of the concrete floor surface is characterized by further including the step of curing the formed mortar layer and re-coating the mortar according to the present invention on top of the cured mortar layer to form a finished layer.
The mortar layer formed by the mortar construction method of the present invention may be formed transparently or opaquely, and may be formed to have an embossed surface other than the smooth surface in terms of a finished shape, if necessary.
The present invention may have an overlapping shape in which resin is filled in gaps defined between particles of the silica sand on the mortar layer formed through the rolling or press-forming plastering process or a shape in which the gaps defined between particles of the silica sand on the mortar layer are filled in the concrete surface construction.
The machine used as a construction tool in the present invention adopts a machine that facilitates the construction of the flooring material using the composition of the present invention. The non-solvent type primer is coated on the concrete floor surface using a roller in a space where there is no obstacle, and nearly simultaneously the mortar is paved on top of the coated floor surface using the machine to enable a mortar layer to be formed. The inventive construction method is characterized in that a press-forming plastering blade has a brush-like concavo- convex surface. Also, the manual operation is performed alone or together with a machine operation for the purpose of more efficient construction even in a small and narrow space. In this case, the non-solvent type primer is coated on top of the concrete floor surface and the mortar is paved on top of the coated concrete floor surface, and then the smoothing work is performed on the paved mortar layer using a honeycomb-like or brush-like roller. The honeycomb-like roller is designed to be used efficiently by modifying an existing roller that has been used as other use purpose. Alternatively, the brush-like roller having the shape of bristles of a toothbrush may be used for the purpose of the more sophisticated construction. That is, the brush-like roller can be used which has a thickness ranging from 0.1mm to lmm, a length ranging from mm to 10mm and a distance between implanted bristles raging from 0.1mm to 3mm and is made of nylon or synthetic resin besides piano wires having a high elasticity. In this case, the smooth surface of the paved mortar layer is finished by the repeated rolling of the honeycomb-like roller and then is again rolled by the honeycomb-like roller so as to form much more sophisticated and smoother surface.
The ratio in which the basal resin component of the mortar and silica sand are mixed in a construction site can be determined differently depending on the use purpose using the epoxy resin mortar composition of the present invention. In case of a single construction process, the basal resin component and the silica sand can be mixed in the ratio of parts by weight of 100:150 to 100:250. In case of a construction process in which the non-solvent type primer is coated on top of the concrete floor surface and simultaneously the mortar is paved on top of the coated concrete floor surface up to a uniform thickness ranging from 2mm to 100mm, followed by press- forming plastering, the basal resin component and the silica sand can be mixed in the ratio of parts by weight of 100:300 to 100:1000. In addition, the present invention may applied along with the water-soluable primer disclosed in Korean Patent No. 0476728 invented by the present inventors depending on the work environment of a moisturized surface or a construction site. Also, the composition of the present invention may be applied to shorten the number of the construction processes in a pressing and compaction manner using construction equipment used in an existing general resin mortar construction, i.e., a spreader, a finisher and the like.
Moreover, the method of conducting the construction of a concrete floor surface according to the present invention may further include the step of attaching nano silver chip on top of the mortar layer by spraying so as to impart antimicrobial properties. In this case, preferably, the nano silver chip is attached on top of the entire resultant surface by spraying in a state where the nano silver chip is mixedly dispersed to an organic solvent, water, etc., prior to the curing of the formed mortar layer immediately after the mortar layer has been formed. Besides these, flooring materials using various chemical resins, paint and the like may be coated on top of the mortar layer, and the nano silver chip may be sprayed onto the surface of the coated mortar layer prior to the curing of the mortar layer surface so as to maintain a distinct antimicrobial function. Further, the method of conducting the construction of a concrete floor surface according to the present invention may further include the step of attaching silica sand or metal chip on top of the mortar layer by spraying so as to impart the non-slip characteristics to the concrete floor surface. In this case, the silica sand and the metal chip are not particularly limited. Now, the present invention will be described hereinafter in more detail, but the scope of the present invention is not limited to or by the Examples below.
[Examples]
[Example 1]
Preparation of primer 1. Preparation of Resin Component
Epoxy basin resin (1) 79.00 g
Reactive diluent (2) 12.00 g
Inorganic filler (3) 7.00 g Aggregating agent (4) 2.0O g
Total 100.00/ g
2. Preparation of Curing Agent Polyoxypropylene diamine(5) 27.30 g
Triethylene tetraamine (6) 5.00 g
Accelerator (7) 4.20 g
Aniline (8) 3.5O g
Total 40.00/ g Preparation of Mortar
1. Preparation of Resin Component Epoxy resin 75.00 g
Reactive diluent 15.0O g
Non-reactive diluent (9) 1.20 g Inorganic filler 3.0O g
Aggregating agent 3.80 g
Flame retardant (10) 1-9O g
Defoamer (11) 0.10 g Total 100.00/ g
2. Preparation of Curing Component Poly oxy propylene diamine 24.0O g
Polyamide 5.00 g
Nonyl phenol 3.00 g
A-399 2.00 g
Triethylene tetraamine 4.00 g
Aniline 2.0O g
Total 40.00/ g
Now, the present invention will be described hereinafter in more detail, but the scope of the present invention is not limited to or by the Examples below.
In a construction site, the construction of a concrete floor surface was conduced using an epoxy resin composition comprising non-solvent type primer and mortar in such a fashion that the primer in which a basal resin component and a curing component are mixed in the ratio of parts by weight of 100:40 are coated on top of the concrete floor surface subjected to the shot blasting, that on top of the coated concreted floor surface is paved the mortar in which a basal resin component and a curing component are mixed in the ratio of parts by weight of 100:40, and that artificial silica sand or natural silica sand is mixed with the basal resin component of the mortar in an amount of 200 parts by weight based on 100 parts by weight of the basal resin component. Then, the spreading of the mortar was carried out and simultaneously a rolling work was repeatedly performed on the paved mortar surface using a honeycomb-like roller so as to prevent the silica sand and the resin from being separated from each other and form a uniform and smooth concrete floor surface.
The detailed information on the components including their manufacturers are as follows:
(1) Epoxy resin: (copolymer of epichlorohydrin and bisphenol) n=o in liquid state (Kukdo Chemical Co., Ltd., Korea)
(2) Reactive diluent: carboxylic glycidyl esther
(3) Inorganic filler: talc (4) Aggregating agent: Silicon dioxide
(5) Polypropylene amine
(6) Triethylene tetraamine
(7) Curing accelerator: phenol (8) Aniline: quasi-reactive diluent
(9) non-reactive diluent: ethylene glycol monoethyl ether
(10) flame retardant: Pantabromodiphenyl oxide
(11) defoamer: polysiloxane In a construction site, after the components were well mixed with each other to prepare the primer and the mortar, silica sand or artificial silica sand was mixed with the basal resin component of the mortar in an amount of 200 parts by weight based on 100 parts by weight of the basal resin component. Then, the primer was coated and the mortar was paved using a machine capable of simultaneously performing the coating of the primer and the spreading of the mortar, and then a rolling work was repeatedly performed on the paved mortar surface using a honeycomb-like roller to thereby achieve a uniform and smooth concrete floor surface without any separation of the silica sand and the resin from each other. In this case, the thickness of the coated primer is set to be about 0.45mm and the thickness of the paved mortar is set to be about 5mm.
The resultant concrete floor surface was cured for about for 12 days at 200C, and then its physical properties were measured. The measurement result of the physical properties showed that the resultant concrete floor surface has an adhesion (boding strength) of 41 kg/ cm2, compressive strengths of 960-1,150 kg/ cm2 (in case of using artificial silica sand) and 1,200-1,300 kg/cm2(in case of using natural silica sand) and a tensile strength of 480-520 kg/ cm2. Also, in a chemical resistance test, schale tube was put on the cured mortar layer surface and its surroundings are sealed to prevent a solution from flowing out therefrom. Then, different solutions used in the chemical resistance test were injected into the schale using a syringe and was left to stand for 15 days. Thereafter, the injected solutions were identified with naked eyes and the identified result showed that there occurs no abnormal phenomenon such as discoloration of the surface and the like in 10% of a calcium chloride solution, a saturated calcium hydroxide solution, and a sulfuric acid aqueous solution, etc.
As expected from the above results, in case where the construction of a concrete floor surface is conducted using the epoxy resin mortar composition prepared according to the present invention at construction site in such a fashion that the primer is coated and simultaneously paved mortar is mixed with silica sand, the resin is not disrupted of its shape and has a smooth surface without having no air gap formed on the surface thereof in the spreading and rolling processes. In addition, constructional workability is facilitated owing to the number of constructional processes, particularly, the entire work time of more than 40 hours spent in the prior art can be shortened to less than 12 hours, resulting in a remarkable improvement of productivity. Furthermore, it could be seen that functions having non-slip and antimicrobial properties can be additionally imparted to the resin composition depending on the use purpose, and particularly, the resin composition is very useful as a flooring material high in strength and excellent in physical properties such as bonding strength, tensile strength, water resistance, chemical resistance and the like. [Industrial Applicability]
While the invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

[CLAIMS] [Claim 1]
An epoxy resin mortar composition comprising non-solvent type primer and
mortar, the non-solvent type primer and the mortar comprising a basal resin
component and about 30 to about 50 parts by weight, based on 100 parts by weight
of the basal resin component, of a curing component, respectively,
wherein the basal resin component of the primer comprises:
i) about 70 to about 80 wt% of an epoxy resin;
ii) about 10 to about 25 wt% of a reactive diluent;
iii) about 1 to about 20 wt% of an inorganic filler; and
iv) about 1 to about 5 wt% of an aggregating agent,
wherein the curing component of the primer comprises:
i) about 30 to about 60 wt% of poly oxy propylene diamine;
ii) about 10 to about 20 wt% of at least one selected from the group consisting
of triethylene tetraamine and diethylene triamine;
iii) about 5 to about 20 wt% of aniline; and
iv) about 10 to about 20 wt% of an accelerator,
wherein the basal resin component of the mortar comprises: i) about 70 to about 80 wt% of an epoxy resin;
ii) about 5 to about 25 wt% of a reactive diluent;
iii) about 0.1 to about 5 wt% of a non reactive diluent;
iv) about 1 to about 10 wt% of an inorganic filler;
v) about 1 to about 5 wt% of an aggregating agent;
vi) about 1 to about 3 wt% of a flame retardant; and
vii) about 0.05 to about 1 wt% of a defoamer, and
wherein the curing component of the mortar comprises:
i) about 30 to about 60 wt% of polyoxypropylene diamine;
ii) about 10 to about 30 wt% of polyamide;
iii) about 0.01 to 10 wt% of aniline;
iv) about 0.1 to about 10 wt% of at least one selected from the group
consisting of triethylene tetraamine and diethylene triamine; and
v) about 5 to about 20 wt% of an accelerator.
[Claim 2]
The epoxy resin mortar composition of claim 1, wherein the reactive diluent
is at least one selected from the group consisting of butyl glycidyl ether (BGE), phenyl glycidyl ether, carboxlic glycidyl ether, hexandiol diglycidyl ether, butandiol
diglycidyl ether and epoxy glycidyl ether.
[Claim 3]
The epoxy resin mortar composition of claim 1, wherein the inorganic filler is
at least one selected from the group consisting of calcium carbonate, talc, heavy
carbonate, silica, Kieselguhr (ceramic) and dolomite.
[Claim 4]
The epoxy resin mortar composition of claim 1, wherein the aggregating
agent is at least one selected from the group consisting of silicon dioxide, aerosil,
Garamite® (light anhydrous silicic acid)and Abestos ® (glass powder).
[Claim 5]
The epoxy resin mortar composition of claim 1, wherein the non-reactive
diluent is at least one selected from the group consisting of ethylene glycol
monoethyl ether, ethyl cellosolve, xylene, M methyl ethyl ketone, toluene and
methyl isobutyl ketone, but is not limited thereto.
[Claim 6] The epoxy resin mortar composition of claim 1, wherein the mortar further
comprises at least one selected from the group consisting of artificial silica sand,
natural silica sand and colored silica sand.
[Claim 7] The epoxy resin mortar composition of claim 1, wherein the silica sand is
preferably included in the mortar in an amount of about 150 to about 250 parts by
weight based on 100 parts by weight of the basal resin component of the mortar.
[Claim 8]
The epoxy resin mortar composition of any one of claims 1 to 7, wherein the
mortar further comprises about 1 to about 30 parts by weight of a pigment
component based on 100 parts by weight of the basal resin component of the mortar.
[Claim 9]
A method of conducting the construction of a concrete floor surface using an
epoxy resin mortar composition, the method comprising:
(a) shot blasting the concrete floor surface to remove irregulars and laitans on
the concrete floor surface; and (b) coating the non-solvent type primer according to claim 1 on top of the
concrete floor surface and simultaneously spreading the mortar according to claim 1
on top of the coated concrete floor surface to form a mortar layer.
[Claim 10] The method of claim 9, further comprising the step of curing the formed
mortar layer and re-coating the mortar according to claim 1 on top of the cured
mortar layer to form a finished layer.
[Claim 11]
The method of claim 9 or 10, wherein the coating of the non-solvent type
primer and the spreading of the mortar are performed using a machine in such a
fashion that the spreading are simultaneously performed along with vibration to
have a smooth surface, or are performed manually through a repeated rolling
operation using a roller.
[Claim 12] The method of claim 9 or 10, further comprising the step of attaching nano
silver chip on top of the mortar layer by spraying.
[Claim 13] The method of claim 12, wherein the nano silver chip is attached on top of
the mortar layer or the finished layer by spraying in a state where the nano silver
chip is dispersed to an organic solvent, water, oil paint or water-based paint.
[Claim 14] The method of claim 9 or 10, further comprising the step of attaching silica
sand or metal chip on top of the mortar layer by spraying.
[Claim 15]
The method of claim 9 or 10, wherein the primer is coated on top of the
concrete floor surface to a thickness ranging from 0.4mm to 1.0mm.
PCT/KR2008/002903 2007-05-31 2008-05-23 Epoxy resin mortar composition and coating method on the surface of the concrete WO2008147079A1 (en)

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