Self-levelling Anhydrous Coating for Floor Noise and Moisture
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Solution Overview
Problem
Existing self-levelling coating materials for hard floors fail to adequately address footfall noise and moisture barrier issues, with insulating mats being problematic due to slippage and uneven surfaces, and direct insulating layers on hard floor panels being technically complex and costly.
Innovation Solution
A self-levelling, anhydrous coating material composed of silane-terminated polyoxyalkylenes, chalk powder, drying agents, curing catalysts, and adhesion promoters, applied directly to sub-floors to create a uniform, sound-insulating, and moisture-barrier layer with adjustable viscosity and thickness, allowing for easy application and economical production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If insulating mats are used under hard floors, then footfall noise is reduced, but the mats slip and create uneven surfaces
Solution Approach 1:
The patent changes the physical state of the insulation material from solid mats to a liquid coating that cures in place. The coating material has adjustable viscosity allowing it to flow and self-level, then cures to form a stable, flat surface that eliminates both noise and surface irregularities
Solution Approach 2:
The invention uses composite coating materials combining silane-terminated polyoxyalkylenes with chalk powder and other additives. This composite formulation provides both sound insulation properties and self-levelling characteristics, resolving the contradiction between noise reduction and surface flatness
2Object-affected harmful factors
If insulating layers are attached to hard floor panels, then sound insulation improves, but production complexity and costs increase
Solution Approach 1:
The patent merges the sound insulation function with the sub-floor coating into a single integrated solution. The coating material is applied directly to the sub-floor before laying hard floor panels, eliminating the need for separate insulating layers and reducing production complexity
Solution Approach 2:
The coating material serves multiple functions simultaneously: it provides sound insulation, creates a level surface, and acts as a bonding layer between sub-floor and hard floor panels. This multi-functionality eliminates the need for separate insulation components
3Manufacturing precision
If self-levelling coating material is applied to sub-floors, then surface flatness improves, but moisture barrier properties must be maintained
Solution Approach 1:
The patent uses composite coating materials incorporating silane-terminated polyoxyalkylenes with specific molecular structures that provide both self-levelling flow characteristics and moisture barrier properties. The chalk powder and additives further enhance these dual properties
Solution Approach 2:
The coating material's viscosity is carefully controlled to allow self-levelling flow, then cures to form a dense, moisture-impermeable layer. The chemical composition and curing process are optimized to maintain moisture barrier integrity while achieving surface flatness
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 material effectively reduces footfall noise by up to 15 dB(A) and prevents moisture rise, providing a level surface for hard floors with improved sound insulation and reduced production complexity and costs.
Implementation Method 1
The coating materials are applied directly to the sub-floors by means of a knife coater or toothed spatula. Owing to the adjustable viscosity, the coating material spreads in a self-levelling manner to the same height.
Implementation Method 2
The curing by atmospheric humidity in the case of 2 mm layer thickness then takes about 24 hours, depending on air temperature and atmospheric humidity.
Implementation Method 3
The footfall sound occurring during walking can then be absorbed by elastic deformation and hence damped.
Implementation Method 4
In addition, the laying surface of the sub-floor must be made completely flat in order to rule out elevations or unevenness of the hard floor, but also air-filled cavities under the hard floor.
Data Source
AI summary
The invention describes self-levelling, anhydrous coating materials on floor surfaces, consisting of silane-modified polyethers, preferably methoxyalkylsilane-terminated polyoxypropylenes, calcium carbonate powder, drying agent, curing catalyst, adhesion promoter and optionally further additives and/or fillers. The moisture-curing coating materials obtained, preferably used on cement- or calcium sulphate-bound floor surfaces, are distinguished by good adhesion, high sound insulation, a barrier effect against rising moisture and excellent surface planarity, as are desired for the laying of hard floors, in particular laminate or parquet boards.