Elastomeric Coating System for Outdoor Wood Protection
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Solution Overview
Problem
Existing protective coatings for outdoor wooden structures are ineffective in providing long-term protection against UV light, pedestrian traffic, and structural failure, particularly at joints and screw areas, and the use of composite deck boards poses environmental concerns and requires removal of existing structures, leading to waste and maintenance issues.
Innovation Solution
A two-layer protective system comprising a first elastomeric composition layer applied to the top surface of the wooden structure and a second elastomeric granular composition layer with granular material, which includes ceramic tiles and a containment field to inhibit tile movement, providing water permeability and UV protection while accommodating structural movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional protective coatings (urethanes and paints) are applied to wooden structures, then the wood surface is protected from damage and discoloration, but the coatings wear off due to pedestrian traffic and degrade due to UV light, requiring frequent maintenance
Solution Approach 1:
The protective system is divided into two distinct layers: a first elastomeric coating layer applied directly to the wood surface, and a second elastomeric granular composition layer applied over the first layer. This segmentation allows each layer to perform its specific function - the first layer provides adhesion and flexibility, while the second layer provides UV resistance and wear protection, together achieving long-term durability
Solution Approach 2:
The second layer uses an elastomeric granular composition that combines elastomeric material with granular components, creating a composite structure that offers both the flexibility and adhesion of elastomeric materials and the UV resistance and durability of granular surfaces, solving the limitation of single-material coatings
2Duration of action of stationary object
If plastic composite deck boards are used to replace wooden structures, then the lifespan of the visible surface is prolonged and aesthetics are improved, but the old wooden boards must be removed creating toxic landfill waste, and the plastic boards do little to protect the underlying wooden structure
Solution Approach 1:
The protective system is applied as a preliminary protective measure over the existing wooden structure, eliminating the need to remove the old wood. The elastomeric coating system provides protection before any potential structural issues arise, allowing the original wood to remain in place and be protected rather than discarded
Solution Approach 2:
Instead of removing and discarding the old wooden structure (which creates landfill waste), the invention converts the existing wood into a protected substrate by applying the elastomeric coating system. The old wood becomes part of the protective assembly rather than waste, transforming a harmful disposal process into a beneficial protection process
3Reliability
If a solid impermeable coating is applied to protect wood from water, then water absorption is prevented, but water pooling occurs and structural movement accommodation is reduced
Solution Approach 1:
The elastomeric coating material forms a flexible protective film that can stretch and move with the wooden structure. This flexible membrane provides water protection while accommodating structural movement, preventing cracking and delamination that would occur with rigid impermeable coatings
Solution Approach 2:
The coating system changes the permeability parameters of the wood surface - the elastomeric material creates a water-resistant barrier that is not completely impermeable, allowing controlled water vapor transmission while blocking liquid water penetration, thus balancing protection with structural health
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 system effectively extends the lifespan of outdoor wooden structures by preventing water absorption, UV damage, and structural failure, while being environmentally friendly and reducing maintenance needs, as it allows water to pass through and accommodates ground shifting and pedestrian traffic without pooling or degradation.
Implementation Method 1
preventing water absorption
Implementation Method 2
UV protection
Implementation Method 3
allows water to pass through
Data Source
AI summary
Protective systems for outdoor wooden structures and methods of forming protective systems on outdoor wooden structures are described herein. The protective systems include a first layer covering at least a portion of a top surface of the outdoor wooden structure. The first layer includes a first elastomeric composition. The protective system also include a second layer that includes an elastomeric granular composition. The elastomeric granular composition includes a second elastomeric composition and a granular material.