Low Odor Floor Coating Composition with Dual-Cure Mechanism

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Solution Overview

Problem

Current floor and construction coatings based on reactive methyl acrylate or methacrylate resins face issues with strong odors, air-borne toxicity, flammability, and volatility, while low-odor alternatives often compromise on curing speed or mechanical properties, and existing fast-curing methods like UV curable coatings have limitations with thicker films and substrate penetration.

Innovation Solution

A low-odor, fast-curing composition combining a reactive polymer or oligomer with pendant acrylate groups, low-odor acrylate or methacrylate monomers, a multifunctional isocyanate crosslinker, thermal or photo-initiators, and a wax, which cures through multiple pathways including peroxide-initiated radical polymerization and urethane step chain polymerization, offering improved mechanical properties and safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If low-odor monomers with higher molecular weight are used, then odor and toxicity are reduced, but application difficulty increases and curing completeness decreases

Engineering Contradiction:

Improveodor and toxicityVSAvoidapplication difficulty

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The patent changes the molecular weight parameter of the monomer from conventional low MW (causing odor/toxicity) to higher MW (reducing odor/toxicity), while compensating for application difficulties through formulation adjustments and accepting slightly longer curing times as a trade-off

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes the phase transition and volatility characteristics of monomers to control odor emission. By selecting higher MW monomers with lower vapor pressures, the patent reduces volatile emission during application and curing, thereby reducing odor and toxicity while maintaining workability

Inventive Principle:

Principle #36Phase transitions

2Productivity

If UV curable coatings are used for fast curing, then curing speed is improved, but film thickness limitation increases and substrate penetration decreases

Engineering Contradiction:

Improvecuring speedVSAvoidfilm thickness limitation

Core Design Contradiction:

ProductivityVSLength of stationary object

Solution Approach 1:

The patent segments the curing process into two independent pathways: UV-initiated radical polymerization for rapid surface curing and peroxide-initiated oxidation for deep penetration and complete curing. This segmentation allows each pathway to address specific depth requirements, eliminating the film thickness limitation of single-pathway UV curing

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The coating composition is designed with multi-functionality to handle both thin and thick films effectively. The dual-curing mechanism provides universal applicability across different film thicknesses, with UV curing providing rapid surface protection and peroxide curing ensuring complete reaction throughout the film depth

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If conventional acrylate coatings are used, then curing speed is fast, but flammability and volatility increase

Engineering Contradiction:

Improvecuring speedVSAvoidflammability and volatility

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent converts the potentially harmful volatility and flammability of conventional acrylate monomers into beneficial slow-drying characteristics. By using higher MW monomers and alternative initiators, the coating maintains fast curing capability while reducing volatile emission and flammability, effectively converting a harmful property into a beneficial safety feature

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 composition achieves rapid curing within 30 minutes to 1 hour, excellent chemical and abrasion resistance, reduced health risks, and improved mechanical strength, making it suitable for various industrial applications without the drawbacks of existing technologies.

Implementation Method 1

The composition is cured through multiple pathways, e.g., peroxide initiated radical curing

Methodology Applied

Scientific EffectPeroxide initiated radical polymerization: Photopolymerisation

Implementation Method 2

cures through multiple pathways, e.g., peroxide initiated radical curing and urethane step chain polymerization

Methodology Applied

Scientific EffectUrethane step chain polymerization: Chemical Bonding

Implementation Method 3

a thermal or photo active initiator

Methodology Applied

Scientific EffectPhoto-initiation: Photopolymerisation

Data Source

PatentUS10252290B2Room temperature fast cure composition for low odor floor coating formulations

Publication Date: 2019.04.09 SWIMC LLC

AI summary

A low odor, fast curing composition coating composition with improved safety and mechanical properties, which cures readily under ambient conditions comprises a) a reactive polymer, oligomer or prepolymer having pendant acrylate or methacrylate groups, b) low odor acrylate or methacrylate monomers, c) an acrylate or methacrylate crosslinker, d) an isocyanate crosslinker, e) a thermal or photo active initiator, and optionally a reactive diluent and/or bead polymer. The composition is cured through multiple pathways, e.g., peroxide initiated radical curing and urethane step chain polymerization. Flooring and other construction materials coated with the composition are also provided.