Multi-Layer Abrasion-Resistant Coating for Concrete Dams

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Solution Overview

Problem

Existing abrasion-resistant coatings for dams, such as organic composite materials and polyurea, face issues with weather resistance, cost, and blister formation due to water reaction, leading to poor durability and detachment.

Innovation Solution

A multi-layer coating system comprising an epoxy mortar bottom layer, an epoxy resin adhesive middle layer, and a nanomaterial-modified polyaspartic surface layer, with specific viscosity and curing times, and composition ratios, providing enhanced adhesion, flexibility, and abrasion resistance while being economical and adaptable.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If organic composite materials (epoxy mortar) are used for abrasion resistance, then abrasion resistance is improved, but weather resistance deteriorates and the coating ages, cracks, warps, delaminates, and powders

Engineering Contradiction:

Improveabrasion resistanceVSAvoidweather resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The coating system is divided into three distinct layers: bottom layer (epoxy mortar, 1-3mm) for abrasion resistance, middle layer (epoxy resin adhesive, 0.1-0.5mm) for adhesion and flexibility, and surface layer (nanomaterial-modified polyaspartic, 0.3-0.5mm) for weather resistance. Each layer performs its specific function without compromising the others, resolving the contradiction between abrasion resistance and weather resistance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses composite materials in each layer: epoxy mortar (epoxy resin + cement + sand), nanomaterial-modified polyaspartic (polyaspartic ester + inorganic nanomaterials like SiO2 or TiO2). These composites combine the advantages of different materials to achieve both abrasion resistance and weather resistance simultaneously.

Inventive Principle:

Principle #40Composite materials

2Reliability

If polyurea is used for weather resistance and abrasion resistance, then weather resistance is improved, but cost increases and isocyanate reacts with water to produce blisters

Engineering Contradiction:

Improveweather resistanceVSAvoidblisters from water reaction

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent extracts and eliminates the problematic isocyanate component from polyurea, replacing it with polyaspartic ester in the surface layer. This substitution maintains weather resistance and abrasion resistance while removing the harmful water reaction that causes blisters.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces expensive polyurea with a more economical polyaspartic ester-based coating that achieves similar protective performance without the costly isocyanate component, making the solution both cheaper and safer.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Strength

If polyurea is used for abrasion resistance, then abrasion resistance is improved, but cost increases

Engineering Contradiction:

Improveabrasion resistanceVSAvoidcost

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The patent substitutes expensive polyurea with a more economical polyaspartic ester-based coating system that provides comparable abrasion resistance and weather resistance, significantly reducing material cost while maintaining performance.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Device complexity

If a single-layer coating is used, then device complexity is reduced, but adhesion and flexibility deteriorate

Engineering Contradiction:

Improvecoating structureVSAvoidadhesion

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The coating is segmented into three functional layers: bottom layer for abrasion resistance and adhesion to concrete, middle layer for enhanced adhesion and flexibility, and surface layer for weather resistance. This segmentation allows each layer to optimize its specific function, achieving superior overall adhesion and flexibility compared to single-layer coatings.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The coating system effectively protects concrete dams from abrasion and weathering, maintaining integrity and color over time, with strong bonding to concrete and resistance to sand-containing currents, extending the service life of dams.

Implementation Method 1

the middle layer is an epoxy resin adhesive having a thickness of between 0.1 and 0.5 mm

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

the surface layer is a nanomaterial-modified polyaspartic having a thickness of between 0.3 and 0.5 mm

Methodology Applied

Scientific EffectAbrasion resistance: Abrasion

Data Source

PatentUS10184066B2Abrasion-resistant coating material and method of using the same

Publication Date: 2019.01.22 CHANGJIANG RIVER SCI RES INST CHANGJIANG WATER RESOURCES COMMISSION

AI summary

A coating material, including a bottom layer, a middle layer and a surface layer. The bottom layer is an epoxy mortar having a thickness of between 1 and 3 mm, the middle layer is an epoxy resin adhesive having a thickness of between 0.1 and 0.5 mm, and the surface layer is a nanomaterial-modified polyaspartic having a thickness of between 0.3 and 0.5 mm. The epoxy resin adhesive has a viscosity of between 50 and 200 mPa·s.