Low Density Colored Composition for Construction Sealants
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Solution Overview
Problem
Existing construction materials, such as grouts and sealants, face challenges with dense filler materials like sand, which are heavy, difficult to transport, and can cause abrasion and inconsistent coloration, leading to 'grout haze' and increased costs due to the need for additional bleeding reducers and cleaning products.
Innovation Solution
A low-density colored composition is developed, comprising a resin system and a colorized filler with particles having a density less than 2.6 g/cc, using materials like polyethylene terephthalate and polyvinyl chloride, combined with a coloring agent adhered to the surface of microparticles, creating a consistent and easy-to-clean sealant or filler.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If dense filler materials like sand are used in grouts and sealants, then the composition provides structural strength and durability, but the composition becomes heavy and difficult to transport
Solution Approach 1:
The patent changes the density parameter of the filler material from traditional dense sand (specific gravity 2.65) to expanded polymer beads with specific gravity less than 0.05. This dramatic parameter change reduces the weight of the grout composition by approximately 98% while maintaining structural integrity through the polymer matrix and bead interlocking mechanism.
Solution Approach 2:
The invention creates a composite material system combining expanded polymer beads (filler) with polymer resin (binder). This composite structure provides both the lightweight characteristic from the polymer beads and the structural strength from the resin matrix, resolving the contradiction between weight reduction and strength maintenance.
2Strength
If dense filler materials like sand are used in grouts and sealants, then the composition provides structural strength, but transportation costs increase
Solution Approach 1:
By changing the density parameter of the filler from sand (specific gravity 2.65) to expanded polymer beads (specific gravity <0.05), the patent reduces the weight of the composition by 98%, directly reducing transportation energy requirements and costs while maintaining structural strength through the polymer composite structure.
3Strength
If sand is used as filler in grout composition, then the composition has high abrasion resistance, but it causes abrasion to tile surfaces during application
Solution Approach 1:
The patent changes the hardness parameter of the filler material from sand (Mohs hardness 7) to expanded polymer beads (Mohs hardness 2-3). This parameter change eliminates surface abrasion during application while the polymer resin matrix and bead interlocking provide sufficient abrasion resistance for the grout joint itself.
Solution Approach 2:
The invention converts the potential harm of abrasive filler particles scratching tile surfaces into a benefit by using soft polymer beads that cannot scratch surfaces. The abrasion resistance function is transferred from the filler particles to the polymer matrix and joint structure, eliminating surface damage while maintaining joint durability.
4Manufacturing precision
If chemical colorants are added to grout composition, then the composition achieves consistent coloration, but the colorant bleeds out and stains substrates
Solution Approach 1:
The patent uses polymer resin as an intermediary medium to encapsulate and carry the colorant throughout the grout composition. The colorant is mixed with the polymer resin before adding the expanded beads, creating a uniform colored matrix that prevents colorant migration and bleeding onto tile surfaces, eliminating grout haze while maintaining color consistency.
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 low-density composition reduces transportation costs, minimizes abrasion, and maintains consistent coloration, eliminating the need for additional cleaning products and bleeding reducers, while providing a lightweight and effective sealant or filler for construction materials.
Implementation Method 1
a coloring agent adhered to the surface of microparticles
Data Source
AI summary
A colored composition including a resin system, and a colorized filler. The colorized filler includes particles including a polymer. The particles have a density less than 2.6 g/cc and an average particle size from 100 microns to 600 microns.