Cork Powder Coating for Floor Sound Reduction

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Solution Overview

Problem

Existing floor solutions require a separate, expensive layer for footfall sound insulation, particularly when cork is bonded, which is inefficient and costly.

Innovation Solution

A coating varnish containing cork powder is applied to the floor element, providing sound reduction properties through a homogeneous distribution of the binder, allowing for easy machine processing and application, with a thickness and grain size optimized for effective sound modification.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a separate layer of cork is bonded for footfall sound insulation, then sound insulation performance is improved, but manufacturing cost and process complexity increase

Engineering Contradiction:

Improvefootfall sound insulationVSAvoidmanufacturing cost and process complexity

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent combines the sound insulation function with the coating layer by incorporating cork powder into the coating varnish. This merges the previously separate sound insulation layer with the protective coating, eliminating the need for additional materials and processing steps while maintaining sound reduction effectiveness.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The coating varnish is designed to serve multiple functions simultaneously: it provides protective coating properties (hardness, wear resistance) and sound insulation properties through the incorporated cork powder. This multi-functionality eliminates the need for separate specialized layers.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Object-affected harmful factors

If cork powder is incorporated into coating varnish, then sound reduction is achieved, but coating processability must be maintained

Engineering Contradiction:

Improvesound reductionVSAvoidcoating processability

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent specifies optimal parameters for cork powder incorporation, including particle size ranges (0.1-2.0 mm) and content proportions (5-50 wt%). These parameter optimizations ensure that the cork powder integrates well with the varnish binder, maintaining coating flow properties and applicability while achieving effective sound reduction.

Inventive Principle:

Principle #35Parameter changes

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 varnish effectively reduces footfall sound by modifying the sound properties of the floor elements, offering a cost-effective and environmentally friendly solution that integrates sound insulation directly into the manufacturing process.

Implementation Method 1

the coating varnish comprises a cork powder... the sound properties of floor elements are significantly and positively modified by the back coating proposed here... effectively reduces footfall sound

Methodology Applied

Scientific EffectSound absorption: Acoustic Absorption

Data Source

PatentUS20240191086A1Coating for a floor element and a floor element for sound reduction

Publication Date: 2024.06.13 KNEHO-LACKE GMBH

AI summary

What is disclosed is a coating for a floor element comprising a coating varnish for application to the floor element, the coating varnish comprising a cork powder.