Resin mortar for construction and a method of plastering resin mortar TECHNICAL FIELD This invention relates to the resin mortar for construction prepared by mixing globular glass beads, glass powder and glass fiber used as fillers with resin, which has more excellent fluidity and other properties than liquid resin and can be easily and simply plastered only by adding a hardener to the resin mortar, and a method of plastering the resin mortar.

Background Art A conventional method of plastering the resin mortar comprises mixing resin and a hardener in a proper mixing ratio, mixing the resin, mixed with the hardener, and dried silica, laying the mixture of the resin and the dried silica on an surface to be plastered with it, plastering it by means of plaster tools, and hardening and finishing it while repeatedly applying the resin until the plastered surface has been evenly formed.

The conventional method stated above can cover only the limited amount of treatment because resin and filler are mixed together directly at construction sites, and is an inefficient, costly method because plaster works should be carried out manually in small quantities by relatively many workers and tools. In the method, a limited content of filler is often used in the resin to facilitate plastering. If the content is much, it becomes difficult to do plaster works. As a result, the filler stained with a small amount of the resin is exposed to the outside with the lapse of the time, and becomes weak to an impact. Particularly, the silica, which is mostly used as a filler, has the property of absorbing the resin, so it interferes with surface staying of the resin functioning as an bonding agent and eventually may cause damage on the plastered surface by weakening the hardness.

If the silica, which is used as a filler, is exposed to the outside or an upper coating is damaged for any reasons during use, dirty substances stick fast to the surface of the silica, and accordingly the surface becomes dirty. As the property of the silica does not allow cleaning, dirty substances are absorbed into voids of the silica or the inside of the silica, and then a bad smell or bacteria may occur. If the silica is exposed to water or oil, eventually interfacial separation between the resin and the filler may occur.

A method of plastering the self-leveling resin mortar for construction used for a similar purpose was found to have the problem that it is uneconomical and leads to increase in construction costs because the work of plastering expensive resin is performed manually. After the plaster work was completed, the compressive strength and bonding strength are 250kg. f/ cm2 and 20kg. f/cm2, respectively. Accordingly the method has weak bonding power, wear resistance and scratch resistance, and urgently need to be improved because of the property of absorbing water and oil and resistance to contamination.

Disclosure of the Invention Accordingly, the present invention was invented to solve the foregoing problems, and an object of the present invention is to provide the resin mortar with excellent fluidity, excellent storage property and excellent scratch resistance, in which globular beads, glass powder and glass fiber are used as fillers, and a method of plastering the resin mortar which is less expensive in plastering and has a superior property as self-leveling material.

The resin mortar in accordance with the present invention do not require a troublesome process that resin, filler and hardener are mixed directly at construction sites, and provides shorter working time and remarkable decrease in labor costs. The conventional resin mortar had to have a great loss because its residue could not be stored for reuse after being mixed. The resin mortar in accordance with the present invention uses fillers which have high fluidity and is supplied with fillers mixed, so it is possible to reuse the resin mortar in accordance with the present invention by storing it sealed up after using it as much as needed. As the resin mortar in accordance with the present invention can be prepared and applied in the form of a tile, it is expected to bring about a remarkable reform at workshops that use resin mortar for construction or construction sites that perform finishing works with self-leveling materials.

Brief Description of the Drawings Fig. 1 is a cross-sectional view showing a desirable working example. n Explanation of key signs used in the main parts of the drawing- 1 : Resin 2: Filler 2a : Glass bead 2b: Glass powder 2c : Glass fiber Best Mode for Carrying Out the Invention The resin mortar for construction and a method of plastering the resin mortar according to the present invention as shown in Figs 1 which are a cross-sectional view showing a desirable working example and a working flowchart showing a desirable working example, respectively are described in detail hereinafter.

The resin mortar for construction according to the present invention, mostly used as finishing materials for buildings, comprises resin (l) and filler (2).

The resins used in the present invention include: (1) nonsolvent or solvent-diluent epoxy resin with 350~3, OOOMW of molecular weight among diglycidyl types and triglycidyl types ; (2) acryl resin that is solvent-type acrylic urethane and lacquer having methaacrylic acid derivative as essential ingredient or aqueous acryl hydrosol and emulsion nonsolvent type acrylic silane and ultraviolet setting type acryl.

(3) Paint-type alkyd resin denatured with polybasic acid and polyhydric alcohol ester compound ; rosin, phenol, epoxy, vinyl styrene monomer, isocyanate or silicon-denatured alkyd resin that may be used selectively.

Fillers used in the present invention include glass bead (2a), glass powder (2b) and glass fiber (2c) which are mixed with the foregoing resin.

No voids occur because of compound bonding of glass beads (2a) of several sizes within the resin (1) and small-sized fillers filling up voids between the glass beads. Buffer effect is obtained as the pressure is dispersed by globular glass beads when there is an external impact. There is no increase in viscosity due to the fillers, so the fluidity is good and eventually the working efficiency is remarkably improved. Glass bead (2a) with higher hardness than silica used in the present invention provides increased surface hardness, higher scratch resistance and excellent prevention of surface contamination. The use of glass fiber (2c) also allows the tensile strength of resin to increase. Especially, glass fiber (2c) as filler functions to prevent the crack of resin mortar. Glass powder (2b) with 6-7 of hardness functions to raise the scratch resistance by strengthening the surface hardness of the resin mortar. # Comparison of the resin mortar according to the present invention with conventional resin mortar Resin mortar Items Conventional resin mortar according to the present invention . No volds occurs due to compound particles and resin to be applied bonding globular glass beads of several sizes within the resin and small-sized fillers through plaster work and then filling up voids between glass beads. The hardened. So voids occur rigidity of mortar will increase because the between silica as filler and the glass beads are regularly arranged due to bonding between silica particles falling by buoyant force and the resin is are not stable. filled up between them. # When an excessive impact is # When an external impact is given, the Tissue given, irregular silica has a direct pressure is dispersed by beads. of damage. There is a structural defect that the force is not # Glass beads are not absorbent, so no mortar water is absorbed. dispersed. # No increase of viscosity occurs after the # Cohesion between silica filler is mixed, so the fluidity is still good particles is generated and and improved working efficiency is obtained. maintained by bonding power of # As substancs with high hardness are resin. used, the surface hardness increases. # Interfacial separation occurs Accordingly the scratch resistance is because absorbing property of excellent and the contamination of surface is porous silica and infiltration of reduced. contaminants into voids Globular beads are used. Glass fiber is used in the resin to increase tensile strength. The fluidity does not change after long-trime storage. Irregular silica is used.. The shape is maintained after work Bonding power is generated by ristics of the resin. because of the improved shrinkage. # The generation of heat is controlled at the # it is impossible to store after materials time of hardening, so it is possible to supply mixing. a large quantity at a time. # As the material is highly hard and chemically stable, physical properties such as wear resistance are improved and chemical resistance increase. 'if the coating comes off after work, the contamination of surface is aggravated. #A single structure is formed to the bottom, # If water infiltrates into the Characte so it does not allow water or contaminants ristics of bottom of the surface, peeling or to be infiltrated. discoloration of the surface # No discoloration occurs even when it is surface occurs. exposed to water. # As only single membrane is formed, it is slippery and is weak to scratch.

The conventional resin mortar using silica as filler could not be reused after use and storage because the fluidity of silica is insufficient and therefore precipitation and coagulation occur at the time of mixing.

However, the resin mortar for construction according to the present invention as described above can be reused after long-time storage because, although the filler (2) is primarily precipitated by self-load during storage, the fluidity of the filler is so excellent that the precipitates move by changing the direction of the storage container.

A method of plastering the resin mortar according to the present invention comprises step 1. surface cleaning and leveling, step 2. prime coating, step 3. applying and plastering the resin mortar according to the present invention, and step 4. hardening and finishing. These steps can be explained in detail as follows. First, the surface of a site to be plastered with the resin mortar will be cleaned and leveled. After prime coating, the resin mortar according to the present invention wherein the resin and filler are mixed will be mixed with a hardener. Then, the resin mortar will be applied, and the surface will be levelled, using a rake. Lastly, the resin mortar will be hardened.

As described above, conventional, complex processes are simplified so that massive working is possible and the working time is reduced to one fifth. The plastering work with the resin mortar according to the present invention requires only assistant workers who will mix and carry the resin and painters who will lay and plaster the mixed resin, so it is possible to remarkably reduce labor costs. In addition to the method as described above, the resin mortar according to the present invention can be supplied to construction sites in the form of a tile for easy construction. ffiComparison of the resin mortar according to the present invention with conventional resin mortar in terms of work Resin mortar Items Conventional resin mortar according to the present invention Packaging Separate packaging of resin and filler. Mixed packaging. Impossible to store after being mixed The fluidity of the filler allows Storage because of precipitation and storage. coagulation. Agitator - Mixing hardener. Mixer-Mixing resin and filler. Machine and Laying machine-Evenly laying the Agitator-Mixing hardener. mixture on the surface. Rake-Plastering the mixed equipment Finisher-Plastering the mixture laid mortar. evenly. Plastering knife, thinner and liquid resin Assistant workers-Mixing the resin, and mixing and carrying the resin and filler. Assistant workers-Mixing Laying workers-Laying the mixture on and carrying the resin the surface. Workers Painter - Laying and Plastering workers - Mechanical plastering the mixed resin plasterers operating finisher and skilled mortar. finishing plasterers Painters - Coating the plastered surface with resin. Surface cleaning and levelling - priming coating - resin coating - Surface cleaning and levelling mixing resin and silica - laying on the - priming coating - resin Process upper surface - plastering by finisher mortar coating - hardening - plastering and finishing by workers - - complete hardening - 1st resin coating - 2nd primecoating - complete Hardening after prime coating - laying Hardening after prime coating and hardening after plastering - 1st Working period - laying and hardening the resin coating and hardening - 2nd mixed resin mortar resin coating and hardening The process is simple, so Working Working capacity is so limited because massive work is possible. (The capacity per day the processes are complex. working capacity increases by ten times or more.) Minimum Five days One day working period