Epoxy Floor Coating With Bio-Based Granulate for Anti-Settling Thickness
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Solution Overview
Problem
Epoxy resin-based floor protection systems face challenges in achieving high hardness and durability due to insufficient thickening with quartz sand, necessitating additional synthetic fibers, and quartz sand's limited availability.
Innovation Solution
Using bio-based granules, particularly olive kernel flour with a specific particle size distribution, to enhance the yield point and prevent settling, eliminating the need for additional thickeners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If quartz sand is added to thicken the epoxy resin coating, then the viscosity and yield point increase, but the quartz sand settles during application, reducing the thickening effect
Solution Approach 1:
The patent combines quartz sand with synthetic fibers to create a composite thickening system. The fibers form a three-dimensional network that traps quartz sand particles, preventing settlement while maintaining high yield point and viscosity. This composite approach addresses both the thickening requirement and the settlement resistance issue.
Solution Approach 2:
Synthetic fibers act as an intermediary between the epoxy resin and quartz sand particles. The fibers create a matrix that holds the sand particles in suspension, mediating the interaction between the liquid resin and solid filler to prevent separation while maintaining desired rheological properties.
2Strength
If additional synthetic fibers are added as thickening agents, then the yield strength increases and quartz sand settlement is prevented, but the material complexity and cost increase
Solution Approach 1:
The synthetic fibers serve multiple functions simultaneously: they act as thickening agents to increase yield strength, prevent quartz sand settlement through network formation, and provide reinforcement to the coating. This multi-functionality reduces the need for separate additives and simplifies the overall material composition.
3Manufacturing precision
If quartz sand is used for filling, then the coating thickness is maintained, but quartz sand is a scarce raw material with limited availability
Solution Approach 1:
The patent modifies the particle size distribution parameters of the quartz sand, using a specific range (d10: 0.1-0.3mm, d50: 0.3-0.6mm, d90: 0.5-0.8mm) to optimize both coating thickness control and material efficiency. This parameter optimization allows effective use of quartz sand while reducing overall consumption.
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 method provides a high-quality, smooth surface with excellent mechanical resistance, adhesion, and durability, while being environmentally friendly and cost-effective.
Implementation Method 1
The additional filling results in a higher viscosity and yield point during application, ensuring that the applied coating remains at the desired layer thickness and does not flow away too much
Implementation Method 2
the bio-based granulate demonstrates G1It exhibits only a slight tendency to settle
Data Source
AI summary
The invention relates to a method for applying a floor protection system, comprising the steps (i) mixing the components of an epoxy resin coating, (ii) adding at least one bio-based granulate G1 to the epoxy resin coating during or after step (i), (iii) applying the liquid epoxy resin coating containing the bio-based granulate G1 to a floor surface, and (iv) curing the applied coating under ambient conditions, in particular at a temperature of 0 to 40 °C, preferably 5 to 35 °C, wherein the bio-based granulate G1 has a particle size distribution of 0.1 to 1 mm and a volume-based d50 value of 0.2 to 0.8 mm. The bio-based granulate G1 enables a very efficient increase in the yield strength with a small amount of material and has little tendency to settle. It allows for a smooth surface largely free of craters or pores.The resulting soil protection system retains its excellent resistance to mechanical stress, moisture and chemicals, and exhibits very good adhesion to the substrate and during overcoating.