Additive building material mixtures containing solid microparticles

Abstract

The present invention relates to the use of compact polymeric microparticles in hydraulically setting building material mixtures for the purpose of enhancing their frost resistance and cyclical freeze/thaw durability.

1 . A hydraulically setting building material mixture, consisting essentially of:
 a hydraulically setting building material: and   polymeric microparticles which are synthesized in one or more stages from at least one ethylenically unsaturated monomer;   wherein said polymeric microparticles are in the form of spray-dried, coagulated or freeze-dried powder: and   wherein said ethylenically unsaturated monomer is selected from the group consisting of nitriles of (meth)acrylic acid, nitrogen-containing methacrylates, carbonyl-containing methacrylates, glycol dimethacrylates, methacrylates of ether alcohols, oxiranyl methacrylates, phosphorus-containing methacrylates, boron-containing methacrylates, silicon-containing methacrylates, sulfur-containing methacrylates, vinyl esters, styrene, substituted styrenes with an alkyl substituent in the side chain, heterocyclic vinyl compounds, vinyl ethers, isoprenyl ethers, maleic acid compounds, fumaric acid compounds, α-olefins and mixtures thereof.   
   
   
       2 . The hydraulically setting building material mixture according to  claim 1 , wherein the ethylenically unsaturated monomer is selected from the group consisting of styrene, butadiene, vinyltoluene, ethylene, propylene, vinyl acetate, vinyl chloride, vinylidene chloride, acrylonitrile, acrylamide, methacrylamide, C 1 -C 18  alkyl esters of acrylic acid, C 1 -C 18  alkyl esters of methacrylic acid, and mixtures thereof. 
   
   
       3 . The hydraulically setting building material mixture according to  claim 1 , wherein said polymeric microparticles further comprise at least one crosslinker. 
   
   
       4 . The hydraulically setting building material mixture according to  claim 3 , wherein said crosslinker is selected from the group consisting ethylene glycol di(meth)acrylate, propylene glycol di(meth)acrylate, allyl (meth)acrylate, divinylbenzene, diallylmaleate, trimethylolpropane trimethacrylate, glycerol dimethacrylate, glycerol trimethacrylate, pentaerythritol tetramethacrylate, and mixtures thereof. 
   
   
       5 . The hydraulically setting building material mixture according to  claim 1 , wherein the said polymeric microparticles are in the form of a dispersion. 
   
   
       6 . The hydraulically setting building material mixture according to  claim 1  wherein said polymeric microparticles are in the form of spray-dried, coagulated or freeze-dried powder. 
   
   
       7 . The hydraulically setting building material mixture according to  claim 1 , wherein the polymeric microparticles have an average particle size of 10 to 5000 nm. 
   
   
       8 . The hydraulically setting building material mixture according to  claim 1 , wherein the polymeric microparticles are used in an amount of 0.01% to 5% by volume, based on the volume of the building material mixture. 
   
   
       9 . The hydraulically setting building material mixture according to  claim 1 , wherein the polymeric microparticles are used in an amount of 0.1% to 0.5% by volume, based on the volume of the building material mixture. 
   
   
       10 . The hydraulically setting building material mixture according to  claim 1 , further comprising a binder selected from the group consisting of cement, lime, gypsum anhydrite and mixtures thereof. 
   
   
       11 . The hydraulically setting building material mixture according to  claim 1 , which comprises concrete or mortar. 
   
   
       12 . A method of producing a hydraulically setting building material mixture, comprising:
 adding polymeric microparticles to a setting building material,   wherein said polymeric microparticles are synthesized in one or more stages from at least one ethylenically unsaturated monomer;   wherein said polymeric microparticles are in the form of spray-dried, coagulated or freeze-dried powder,   wherein said hydraulically setting building material mixture consists essentially of said polymeric microparticles and said setting building material; and   wherein said ethylenically unsaturated monomer is selected from the group consisting of nitriles of (meth)acrylic acid, nitrogen-containing methacrylates, carbonyl-containing methacrylates, glycol dimethacrylates, methacrylates of ether alcohols, oxiranyl methacrylates, phosphorus-containing methacrylates, boron-containing methacrylates, silicon-containing methacrylates, sulfur-containing methacrylates, vinyl esters, styrene, substituted styrenes with an alkyl substituent in the side chain, heterocyclic vinyl compounds, vinyl ethers, isoprenyl ethers, maleic acid compounds, fumaric acid compounds, α-olefins and mixtures thereof.   
   
   
       13 . The method according to  claim 1 , wherein the ethylenically unsaturated monomer is selected from the group consisting of styrene, butadiene, vinyltoluene, ethylene, propylene, vinyl acetate, vinyl chloride, vinylidene chloride, acrylonitrile, acrylamide, methacrylamide, C 1 -C 18  alkyl esters of acrylic acid, C 1 -C 18  alkyl esters of methacrylic acid, and mixtures thereof. 
   
   
       14 . The method according to  claim 1 , wherein said polymeric microparticles further comprise at least one crosslinker. 
   
   
       15 . The method according to  claim 14 , wherein said crosslinker is selected from the group consisting of ethylene glycol di(meth)acrylate, propylene glycol di (meth)acrylate, allyl (meth)acrylate, divinylbenzene, diallylmaleate, trimethylolpropane trimethacrylate, glycerol dimethacrylate, glycerol trimethacrylate, pentaerythritol tetramethacrylate, and mixtures thereof. 
   
   
       16 . The method according to  claim 1 , wherein said polymeric microparticles are in the form of a dispersion. 
   
   
       17 . The method according to  claim 1 , wherein said polymeric microparticles are in the form of spray-dried, coagulated or freeze-dried powder. 
   
   
       18 . The method according to  claim 1 , wherein the polymeric microparticles have an average particle size of 10 to 5000 nm. 
   
   
       19 . The method according to  claim 1 , wherein the polymeric microparticles are used in an amount of 0.01% to 5% by volume, based on the volume of the building material mixture. 
   
   
       20 . The method according to  claim 1 , wherein the polymeric microparticles are used in an amount of 0.1% to 0.5% by volume, based on the volume of the building material mixture. 
   
   
       21 . The method according to  claim 1 , further comprising a binder selected from the group consisting of cement, lime, gypsum anhydrite and mixtures thereof. 
   
   
       22 . The method according to  claim 1 , which comprises concrete or mortar. 
   
   
       23 . A hydraulically setting building material mixture, comprising:
 a hydraulically setting building material; and   polymeric microparticles which are synthesized in one or more stages from at least one ethylenically unsaturated monomer;   wherein said polymeric microparticles are homogeneously distributed in said mixture; and   wherein capillary-active pores have an average spacing from one another which is smaller than a power spacing factor.