Cork Chip Floor Construction Using Silylated Polyurea Binder
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Solution Overview
Problem
Existing methods for manufacturing cork chips for floor construction face issues with inconsistent physical properties due to environmental factors, slow curing times, and adhesion problems, which affect the dimensional change rate and tensile strength of the final product.
Innovation Solution
A method involving the crushing and drying of cork chips, followed by the addition of silylated polyurea as a binder, which is heated and cooled to achieve rapid curing without adhesion, and optionally including antimicrobial agents for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If high-temperature water vapor is injected to prevent adhesion during curing, then adhesion is prevented, but dimensional change rate deteriorates by 0.5 to 1%
Solution Approach 1:
The patent changes the temperature parameter from high-temperature water vapor injection to low-temperature curing (10-30°C) using a temperature-controlled curing chamber, thereby preventing adhesion while maintaining dimensional stability without the harmful effects of high heat
Solution Approach 2:
The patent replaces the mechanical/thermal shock method (water vapor injection) with a chemical approach using a specific curing agent system that enables adhesion prevention through controlled chemical reaction at low temperatures, substituting physical thermal treatment with chemical curing control
2Productivity
If additional processes such as adding water-soluble curing accelerator and pressing with roller are used to increase curing rate, then curing rate increases, but tensile strength and dimensional change rate decrease
Solution Approach 1:
The patent introduces a specific curing agent as an intermediary substance that enables rapid curing without compromising strength. The curing agent acts as a mediator between the binder and environmental conditions, allowing the reaction to proceed quickly at low temperatures while maintaining structural integrity
Solution Approach 2:
The patent changes the curing mechanism by using a temperature-independent curing agent system that allows curing to proceed rapidly at low temperatures (10-30°C) without requiring external pressing or additional accelerators, thereby maintaining tensile strength while achieving high curing rates
3Strength
If polyurethane binder is used with mixed cork chips, then construction is achieved with good physical properties, but physical properties are not constant due to temperature and humidity influences
Solution Approach 1:
The patent replaces the polyurethane binder with a temperature-resistant binder system that maintains stable physical properties across a wide temperature range. The new binder chemistry is designed to be less sensitive to temperature and humidity variations, ensuring consistent tensile strength and other physical properties in varying environmental conditions
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
This method results in cork chips with improved dimensional change rate, tensile strength, and elongation, allowing for faster installation and long-term storage with enhanced antimicrobial properties, while preventing cohesion and agglomeration.
Implementation Method 1
heating the mixture to cure the same
Implementation Method 2
cooling the cured mixture
Data Source
AI summary
The present invention relates to a method for manufacturing processed cork chips, and a floor construction method using the same. The processed cork chips are manufactured by the method, including: crushing and drying cork chips; adding polyurea to the dried cork chips to prepare a mixture; heating the mixture to cure the same; and cooling the cured mixture. Further, the floor construction method includes: laying the processed cork chips on the surface of a floor formed of concrete, a water-permeable base layer or crushed stone with a solidified top surface; and flattening the processed cork chips and pressing the same by means of a roller at a fixed temperature.