Floor Cladding Process Using Gel Coat and Mineral Filler
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Solution Overview
Problem
Existing methods for producing cladding elements, such as plinths and bumpers, face challenges including insufficient strength, wear resistance, hygiene compliance, and aesthetic issues, particularly in hygienically sensitive areas like the food industry, due to material brittleness and complex manufacturing processes.
Innovation Solution
A process involving a gel coat layer and a filling composition with a reduced amount of curing polymer resin and a single initiator, which reduces curing time and deformation risks, while improving adhesion and surface finish, and incorporating mineral fillers for enhanced mechanical properties and fire performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If concrete is used for shock plinths to improve firmness and protection, then mechanical strength is improved, but brittleness increases and hygiene performance deteriorates
Solution Approach 1:
The invention uses a composite material consisting of mineral aggregate (such as quartz sand, gravel, or crushed stone) combined with a polymer binder (such as polyester resin, epoxy resin, or polyurethane). This composite structure provides both the mechanical strength of concrete and the hygiene benefits of non-porous, water-repellent materials. The mineral aggregate gives compressive strength while the polymer matrix creates a seamless, non-absorbent surface that meets hygiene requirements.
2Reliability
If a metal coating is applied to concrete plinths to improve hygiene and aesthetics, then hygiene performance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention extracts the metal coating layer from the composite structure and replaces it entirely with a polymer binder matrix. The polymer binder (such as polyester or epoxy resin) directly binds the mineral aggregate together to form a homogeneous, non-porous material that inherently provides hygiene performance without requiring an additional metal coating layer, thereby eliminating manufacturing complexity.
3Ease of manufacture
If traditional plastic plinths are used to improve ease of manufacture, then manufacturing simplicity is improved, but mechanical strength and wear resistance deteriorate
Solution Approach 1:
The invention creates a composite material where mineral aggregate (providing strength and wear resistance) is embedded in a polymer binder matrix (providing ease of manufacture and flexibility). The mineral component (such as quartz sand or gravel) gives the plinth concrete-like durability, while the polymer binder allows for simple casting and forming processes, combining the advantages of both materials.
4Manufacturing precision
If high amounts of additives are used to achieve smooth surface and good colouring, then surface finish is improved, but material cost and environmental impact increase
Solution Approach 1:
The invention applies local quality by using a gel coat layer applied to the mold cavity before inserting the filling composition. This gel coat forms a smooth, aesthetically pleasing surface layer on the plinth without requiring high amounts of additives in the bulk material. The surface quality is achieved locally at the interface with the mold, while the interior can use minimal additives.
5Manufacturing precision
If core and surface properties are made independent to achieve smooth surface, then surface finish is improved, but manufacturing complexity increases
Solution Approach 1:
The invention uses a gel coat layer that is applied to the mold cavity before the filling composition is inserted. This preliminary action creates a pre-formed smooth surface layer that will become the exterior surface of the plinth. The gel coat is applied in advance, allowing the subsequent filling material to simply fill the remaining space without requiring complex multi-step surface treatment processes.
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 process results in cladding elements with improved adhesion, reduced deformation, and enhanced mechanical and fire performance, suitable for hygienically sensitive areas, with a smoother surface finish and reduced styrene release, meeting stringent industrial hygiene standards.
Implementation Method 1
The binding agents are preferably polymeric resins which cure by cross-linking, so that they form a solid three-dimensional molecular structure
Data Source
AI summary
A process for the production of an article for the cladding of floors or walls, comprising the steps of, in a mold: a) optionally applying a gel coat layer, based on a first curing polymer resin, on the inside of the mold in order to obtain a coated mold, and b) introducing into the core of the mold or into the core of the coated mold from step a) a filling composition which is based on a second curing polymer resin supplemented with at least one mineral filler, wherein core contains at least 5% wt and at most 20% wt of curing polymer resin, relative to the dry amount of filling composition, and the filling composition contains only one single initiator in a concentration of 0.5% wt to 5.0% wt relative to the amount of curing polymer resin in the filling composition.