Floor Coatings with Diamond Particles for Scratch Resistance

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Solution Overview

Problem

Conventional abrasion-resistant coatings for flooring surfaces provide inadequate protection against scratches and tarnish, often requiring high amounts of abrasive particles and resulting in coatings that are either not flexible or prone to cracking.

Innovation Solution

A curable coating comprising a mixture of nano-sized and micron-sized diamond particles, a polyester urethane acrylate resin, and a cure system, which includes photo-initiators or thermal initiators, to create a scratch-resistant and wear-resistant layer with improved cleanability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional abrasion resistant particles (aluminum oxide, silicon carbide, silica) are incorporated into coatings, then scratch resistance is improved, but the coating requires large amounts of particles and still provides inadequate protection

Engineering Contradiction:

Improvescratch resistanceVSAvoidamount of abrasion resistant particles

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The patent changes the key parameter of abrasion resistance by substituting conventional particles (aluminum oxide, silicon carbide, silica) with diamond particles, which have superior hardness and abrasion resistance properties. This parameter change allows achieving better scratch protection with lower particle loading

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite coating system combining diamond particles with a polyurethane acrylate resin matrix. This composite approach leverages the exceptional hardness of diamond particles while utilizing the flexibility and adhesion properties of the polymer matrix, achieving superior scratch resistance without requiring high particle concentrations

Inventive Principle:

Principle #40Composite materials

2Strength

If harder resin with increased crosslinking is incorporated to improve scratch resistance, then glass transition temperature and crosslinking increase, but the coating becomes less flexible and prone to cracking

Engineering Contradiction:

Improvescratch resistanceVSAvoidflexibility

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent employs a composite formulation where diamond particles provide the hardness and scratch resistance, while the polyurethane acrylate resin matrix maintains flexibility and prevents cracking. The diamond particles are dispersed throughout the flexible polymer matrix, creating a composite that exhibits both high scratch resistance and good flexibility

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by concentrating the hardness function in the diamond particles while the resin matrix provides flexibility. This functional differentiation allows different regions of the coating to perform different functions: diamond particles resist scratching while the polymer matrix accommodates movement and prevents cracking

Inventive Principle:

Principle #3Local quality

3Reliability

If large amounts of abrasion resistant particles are used, then scratch protection is enhanced, but the coating still provides inadequate protection and requires more material

Engineering Contradiction:

Improveprotection from scratch and tarnishVSAvoidamount of particles required

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent changes the quality parameter of the abrasion resistant particles by using diamond particles with superior hardness and chemical inertness compared to conventional particles. This parameter change increases the effectiveness per particle, reducing the total quantity needed to achieve reliable protection

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent extracts only the essential function of abrasion resistance from conventional particles and fulfills it more efficiently using diamond particles. The superior properties of diamond allow achieving the same or better protection with lower particle loading, effectively taking out the excess material requirement

Inventive Principle:

Principle #2Taking out (Extraction)

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 offers enhanced scratch resistance, improved wearability, and reduced maintenance costs by maintaining a longer-lasting aesthetic appearance, while using lower amounts of abrasive particles compared to conventional coatings.

Implementation Method 1

The cure system contains a photo-initiator, a thermal initiator, or a combination of both

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentEP3523386B1Floor coatings comprising a resin, a cure system and diamond particles and methods of making the same

Publication Date: 2024.06.12 AHF LLC D B A AHF PROD

AI summary

A curable coating for a substrate is disclosed that includes a curable resin containing at least one polyester urethane acrylate and monomers, a cure system and diamond particles. Methods of making the curable coatings and methods of making a coated flooring material are also included.