GEOPOLYMER AND EPOXY SIMULTANEOUS INTERPENETRATING POLYMER NETWORK COMPOSITION, AND METHODS FOR THE SAME

• US 20140005302A1
• Filed: 09/05/2013
• Published: 01/02/2014
• Est. Priority Date: 10/14/2010
• Status: Abandoned Application

• Current Assignee: Tnemec Company, Inc.
• Original Assignee: Tnemec Company, Inc.
• Inventors: BRIAND, Remi, BETZEN, Laura J., ETHINGTON, Jeremy M., McKENZIE, Erin, SMITH, Peter A.
• Application Number:
  US14/019,361
• Publication Number:
  US 20140005302A1
• Time in Patent Office: Days
• US Class Current: 523/402
• CPC Class Codes: C04B 14/024 Graphite
• CPC Class Codes: C04B 14/08 Diatomaceous earth
• CPC Class Codes: C04B 14/22 Glass ; Devitrified glass
• CPC Class Codes: C04B 14/30 Oxides other than silica ferrites C04B14/363
• CPC Class Codes: C04B 14/368 Baryte
• CPC Class Codes: C04B 18/146 Silica fume
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 24/281 Polyepoxides
• CPC Class Codes: C04B 28/006 containing mineral polymers, e.g. geopolymers of the Davidovits type
• CPC Class Codes: C04B 40/065 Two or more component mortars
• CPC Class Codes: C08G 59/40 characterised by the curing agents used
• CPC Class Codes: C08K 3/34 Silicon-containing compounds
• CPC Class Codes: C08L 63/00 Compositions of epoxy resins; Compositions of derivatives of epoxy resins
• CPC Class Codes: C09J 11/08 Macromolecular additives
• CPC Class Codes: Y02P 40/10 Production of cement, e.g. improving or optimising the production methods; Cement grinding
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

A simultaneous interpenetrating polymer network—geopolymer epoxy composition includes a first component comprised of a waterborne epoxy curing agent and an alkaline silicate solution, and a second component comprised of an epoxy resin and an aluminosilicate. The two components are mixed to produce a SIN-GE composition that cures at ambient temperatures. The SIN-GE composition may be a low-viscosity, sprayable composition, or may be a higher-viscosity composition. The compositions may be used as coatings, adhesives, mortars, casting materials, and the like.

Claims

1. A geopolymer-epoxy composition comprising:

a) a first component comprising a waterborne epoxy curing agent, at least one surfactant and an alkaline silicate solution; and

b) a second component comprising an epoxy resin and an aluminosilicate source,

wherein, when mixed together, said first and second components form a simultaneous interpenetrating polymer network—

geopolymer and epoxy (SIN-GE) composition that cures at ambient temperature.

2. The composition according to claim 1, wherein the at least one surfactant comprises at least one anionic surfactant or at least one nonionic surfactant.

3. The composition according to claim 1, wherein the first component alkaline silicate solution is sodium silicate solution or potassium silicate solution.

4. The composition according to claim 1, wherein the second component aluminosilicate source is metakaolin.

5. The composition according to claim 1, wherein the SIN-GE composition further comprises a material selected from the group consisting of fillers, defoamers, pigments, toughening agents, hydrophobic agents, dispersants, thickeners, plasticizers, catalysts, solvents, and combinations thereof.

6. The composition according to claim 1, wherein the first component waterborne epoxy curing agent is present in the SIN-GE composition at a percent by weight from about 0.3% to about 45%;

the first component water is present in the SIN-GE composition at a percent by weight from about 5.2% to about 48%;

the first component surfactant is present in the SIN-GE composition at a percent by weight of from about 0.07% to about 13%;

the first component alkaline silicate solution is present in the SIN-GE composition at a percent by weight of from about 3.3% to about 31%;

the second component epoxy resin is present in the SIN-GE composition at a percent by weight from about 1.2% to about 80%; and

the second component aluminosilicate source is present in the SIN-GE composition at a percent by weight from about 1.5% to about 27%.

7. The composition according to claim 1, wherein the composition has a geopolymer:

epoxy weight ratio from about 10;

90 to about 90;

10 and the composition has a M₂O;

Al₂O₃;

SiO₂ molar ratio from about 0.4;

0.5;

0.7 to about 1.5;

1.5;

40.

8. The composition according to claim 1, further comprising fibers selected from the group consisting of polyolefin fibers, cellulose fibers, carbon fibers, wollastonite, fiberglass, and combinations thereof.

9. The composition according to claim 1, further comprising fibers, wherein said fibers are added to the composition from about 0.5% to about 10% by weight to produce an adhesive composition.

10. The composition according to claim 1, further comprising sand and/or fibers, wherein the combination of sand and fibers is added at a total weight percent from about 100% to about 250% to produce a mortar composition.

11. A method of making a geopolymer-epoxy composition, the method comprising:

a) preparing a first component by combining a waterborne epoxy curing agent, at least one surfactant and an alkaline silicate solution;

b) preparing a second component by combining an epoxy resin and an aluminosilicate source; and

c) mixing together the first and second components,

wherein, when mixed together, said first and second components form a simultaneous interpenetrating polymer network—

geopolymer and epoxy (SIN-GE) composition that cures at ambient temperature.

12. The method according to claim 11, wherein the method further comprises adding to the SIN-GE composition and/or adding to either the first component or second component a material selected from the group consisting of fillers, defoamers, pigments, toughening agents, hydrophobic agents, dispersants, thickeners, plasticizers, catalysts, solvents, and combinations thereof.

13. The method according to claim 11, wherein the first component waterborne epoxy curing agent is present in the SIN-GE composition at a percent by weight from about 0.3% to about 45%;

the first component water is present in the SIN-GE composition at a percent by weight from about 5.2% to about 48%;

the first component surfactant is present in the SIN-GE composition at a percent by weight of from about 0.07% to about 13%;

the first component alkaline silicate solution is present in the SIN-GE composition at a percent by weight of from about 3.3% to about 31%;

the second component epoxy resin is present in the SIN-GE composition at a percent by weight from about 1.2% to about 80%; and

the second component aluminosilicate source is present in the SIN-GE composition at a percent by weight from about 1.5% to about 27%.

14. The method according to claim 11, wherein the composition has a geopolymer:

epoxy weight ratio from about 10;

90 to about 90;

10 and the composition has a M₂O;

Al₂O₃;

SiO₂ molar ratio from about 0.4;

0.5;

0.7 to about 1.5;

1.5;

40.

15. The method according to claim 11, further comprising adding to the composition fibers selected from the group consisting of polyolefin fibers, cellulose fibers, carbon fibers, wollastonite, fiberglass, and combinations thereof.

16. The method according to claim 11, further comprising adding fibers to the composition from about 0.5% to about 10% by weight to produce an adhesive composition.

17. The method according to claim 11, further comprising adding sand and/or fibers to the SIN-GE composition wherein the combination of sand and/or fibers is added at a total weight percent from about 100% to about 250% to produce a mortar composition.

18. A geopolymer-epoxy composition comprising:

a) a first component comprising about 7.1% by weight of a waterborne epoxy curing agent, about 17.9% by weight of water, about 2.3% by weight of surfactant and about 11.6% by weight of an alkaline silicate solution; and

b) a second component comprising about 54.9% by weight of an epoxy resin and about 6.2% by weight of an aluminosilicate,

wherein, when mixed together, said first and second components form a SIN-GE composition that cures at ambient temperature.

19. The composition according to claim 18, wherein the composition has a geopolymer:

epoxy weight ratio of about 25;

75.

20. The composition according to claim 18, wherein the composition has a M₂O:

Al₂O₃;

SiO₂ molar ratio of about 1;

1;

3.77.