Coating System High Surface Roughness Aggregate Bonding
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Solution Overview
Problem
Existing floor coating systems for industrial and carpark floors require additional steps such as strewing silica sand and subsequent removal, which are time-consuming and material-intensive, and necessitate a separate seal layer for long-term bonding, increasing costs and complexity.
Innovation Solution
A coating system that incorporates aggregates like sand directly into the formulation, eliminating the need for additional strewing and sand removal, and providing sufficient surface roughness and long-term bonding without the need for a separate seal layer, using a reactive resin system, thixotropic assistants, and inorganic aggregates with specific particle sizes and viscosities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If silica sand is strewn onto the coating before curing to ensure surface roughness, then surface roughness is improved, but material consumption increases and excess sand must be removed
Solution Approach 1:
The patent combines the aggregate (sand) directly into the coating formulation itself, merging the coating material and the roughness-providing aggregate into a single integrated product. This eliminates the need to strew separate sand onto the coating, as the aggregate is already incorporated in the applied layer, providing both coating protection and surface roughness simultaneously.
Solution Approach 2:
The aggregate is pre-incorporated into the coating formulation before application. This preliminary mixing ensures that the sand is evenly distributed and firmly embedded in the coating matrix from the start, eliminating the need for subsequent sand strewing and removal operations.
2Reliability
If a seal layer of sufficient thickness is applied to ensure reliable bonding of aggregates, then bonding reliability is improved, but material consumption and processing time increase
Solution Approach 1:
The seal layer function is merged into the coating formulation itself. The coating contains built-in bonding agents and ad promoters that provide both coating adhesion to the substrate and aggregate bonding simultaneously, eliminating the need for a separate thick seal layer application.
Solution Approach 2:
The coating formulation is designed to perform multiple functions: providing base coating protection, ensuring substrate adhesion, and bonding aggregates all in one layer. This multi-functional coating eliminates the need for separate seal layer operations.
3Manufacturing precision
If silica sand is strewn and then removed with a broom to eliminate excess sand, then surface cleanliness is improved, but processing time and labor increase
Solution Approach 1:
The aggregate is pre-incorporated into the coating at the correct concentration before application. This preliminary preparation ensures that the applied coating contains exactly the right amount of sand embedded in the matrix, eliminating the need for subsequent brooming to remove excess sand.
Solution Approach 2:
The coating formulation self-regulates the aggregate content and distribution. The viscosity and formulation characteristics ensure proper sand incorporation during application, and the coating itself prevents sand loss, eliminating the need for manual brooming operations.
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 achieves sufficient surface roughness and reliable aggregate bonding with reduced material consumption and processing time, eliminating the need for additional sand application and seal layers, thus enhancing efficiency and cost-effectiveness.
Implementation Method 1
at least one thixotropic assistant TH selected from the group consisting of urea preparations HZ and fibers FS
Implementation Method 2
at least one reactive resin system RH
Data Source
AI summary
A coating system including at least one reactive resin system RH, at least one thixotropic assistant TH selected from the group consisting of urea preparations HZ and fibers FS and at least one inorganic aggregate AZ having a particle size in the range from 0.2 to 3.0 mm. The coating system has a viscosity as measured with a shear rate of 1 s−1 of 9000-100,000 Pas and a viscosity as measured with a shear rate of 100 s−1 of 400-15,000 Pas. The coating system is notable for high surface roughness and for reliable and long-term bonding of the aggregates to the coating with no need for sealing. There is also no need for the coating to be subsequently strewn with aggregates such as sand, for example.