Flexible Epoxy Floor System for Industrial Wood
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Solution Overview
Problem
Existing methods for replacing or refurbishing creosote-treated wood floors in industrial settings are laborious, hazardous, and require significant downtime, as they involve removing machinery and generating hazardous waste, with adhesion issues and inflexibility in epoxy bonding, and concrete replacement having long curing times and cracking problems.
Innovation Solution
A method involving sweeping sand to fill voids, laying metal lath, and applying self-leveling epoxy over the lath to create a flexible, non-bonded epoxy floor system that does not require machinery removal and minimizes hazardous waste, using a two-layer epoxy system with optional plastic separation and color coding for walkways.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If epoxy resin is bonded directly to treated wood, then adhesion is achieved, but the floor becomes stiff and non-flexible causing cracks under heavy loads
Solution Approach 1:
The patent introduces a plastic sheet as an intermediary layer between the treated wood floor and the epoxy resin. This plastic sheet prevents direct bonding between epoxy and wood, allowing the epoxy to remain flexible while still providing adequate adhesion through the intermediary medium. The plastic sheet acts as a buffer that maintains the flexibility needed to prevent cracking under heavy loads while enabling epoxy to be applied to the wood surface.
2Productivity
If concrete is used to replace wood floors, then replacement is achieved, but curing time is long (28 days) and cracking occurs under heavy loads
Solution Approach 1:
The patent changes the material parameter from concrete to epoxy resin, which cures rapidly compared to concrete's 28-day curing period. The epoxy resin system provides a much faster replacement time while maintaining reliability through its flexible nature that prevents cracking under heavy loads. The plastic sheet intermediary further enhances this by ensuring the epoxy remains flexible rather than becoming brittle like concrete would be.
3Productivity
If creosote-treated wood is removed and replaced, then floor replacement is achieved, but hazardous waste is generated and machinery must be removed
Solution Approach 1:
The patent converts the harmful creosote-treated wood surface into a beneficial foundation by applying a plastic sheet over it. This eliminates the need to remove the treated wood entirely, avoiding hazardous waste generation. The plastic sheet creates a barrier that prevents the creosote from posing hazards while allowing the floor to be quickly covered with epoxy resin. This approach maintains the existing floor structure while neutralizing the harmful aspects.
4Manufacturing precision
If sand is mixed with epoxy, then filling voids is achieved, but the floor becomes brittle and non-flexible
Solution Approach 1:
The patent uses a plastic sheet as an intermediary layer that prevents sand from mixing with the epoxy resin. The sand is applied to the plastic sheet rather than being mixed into the epoxy, allowing voids to be filled while maintaining the flexibility of the epoxy-sand-separator system. The plastic sheet acts as a barrier that ensures sand remains separate from the epoxy, preventing the epoxy from becoming brittle while still achieving proper void filling.
Data Source
AI summary
A method and system for covering industrial wood plank or wood block floors that can be installed quickly without creating a hazardous environment or hazardous wastes and without the necessity of removing installed equipment. Sand is swept over the wood to fill voids and cracks. Next metal lath is stapled to the wood. A first layer of epoxy is poured onto the metal lath. After this is cured, a second coat of finish epoxy can be installed on the first epoxy layer. When this dries, the job is done and operations can be restarted, or an optional topcoat can be applied. The epoxy material used can be self-leveling for ease of application and the final floor is approximately level. The finished floor is flexible to not crack under heavy loads and to absorb shock.