Composite Cleaning Pad Material for Uneven Non-Slip Floors
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Solution Overview
Problem
Conventional motorized floor cleaning machines with abrasive pads are unable to effectively clean hard surface floors with micro-porous systems, such as concrete and epoxy floors, due to their inability to conform to surface irregularities, leading to inadequate cleaning and potential slip hazards.
Innovation Solution
A composite material comprising mm-sized particles of porous open-cell melamine formaldehyde resin and non-rigid foamed resin, bonded with a reactive adhesive, is produced through a process involving mixing, bonding, and irreversible compression to create a durable pad that can clean non-slip floors without pre-wetting and maintain cleaning properties even on uneven surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional abrasive pads are used on motorized floor cleaning machines, then the cleaning process is simple and straightforward, but the pads are unable to conform to surface irregularities on micro-porous floors, resulting in inadequate cleaning
Solution Approach 1:
The pad is constructed from multiple discrete particles (melamine formaldehyde resin particles and flexible foam particles) rather than a continuous homogeneous material. This segmentation allows each particle to independently conform to surface irregularities while collectively providing effective cleaning across the entire pad surface.
Solution Approach 2:
The pad utilizes particles with different physical properties - rigid melamine formaldehyde resin particles for abrasive cleaning action and flexible foam particles for conforming to surface irregularities. This parameter differentiation enables the pad to simultaneously maintain structural integrity and adapt to varying floor topographies.
2Strength
If traditional melamine-formaldehyde resin pads are used, then the pads provide abrasive cleaning capability, but they have limited lifetime and wear out quickly
Solution Approach 1:
The cleaning pad is formulated as a composite material system combining melamine formaldehyde resin particles (providing abrasive strength) with flexible foam particles (providing durability and shock absorption). This composite structure allows the rigid abrasive particles to perform cleaning while the flexible particles protect against premature wear and deformation.
Solution Approach 2:
The flexible foam particles act as a cushioning matrix that absorbs mechanical stresses and impacts before they reach the more brittle melamine formaldehyde resin particles. This beforehand cushioning prevents fracture and premature failure of the abrasive particles, extending the overall pad lifetime.
3Shape
If dense rigid foam is used to provide structural support, then the pad maintains its shape well, but it cannot conform to uneven floor surfaces, reducing cleaning effectiveness
Solution Approach 1:
The pad employs a heterogeneous particle composition where rigid melamine formaldehyde resin particles provide local structural support and shape maintenance, while flexible foam particles provide local adaptability and conformability. Each particle type performs its specialized function at the micro-scale, achieving both shape stability and surface conformability simultaneously.
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 composite material significantly extends the lifetime of cleaning pads, enhances cleaning and polishing capabilities on concrete and epoxy floors, and maintains effectiveness despite wear, providing superior durability and performance compared to traditional melamine-formaldehyde resin pads.
Implementation Method 1
reacting said reactive adhesive with said particles in the presence of aerial moisture thereby bonding said particles together
Implementation Method 2
highly hydrophilic and oleophilic due to its open-cell structure
Implementation Method 3
good thermal insulation properties
Implementation Method 4
high sound insulation capacity
Data Source
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AI summary
A process for producing a composite material comprising the steps of: providing mm-sized particles comprising at least particles of a porous optionally at least partially compressed open-cell melamine formaldehyde resin and mm-sized particles of at least one non-rigid foamed resin; mixing said particles with at least one reactive adhesive in a concentration of 6 to 18 g of reactive adhesive per 100 g of mm-sized particles; reacting said reactive adhesive with said particles in the presence of aerial moisture thereby bonding said particles together during said mixing process; transporting said mixture into a mould; and irreversibly compressing said mixture to a block in a mould without additional heat to a density greater than 50 kg/m3 to form a block of said composite material; a composite material obtainable by this process; and the use of this composite material for polishing and/or cleaning applications with a liquid.