One-Component Water-Based Coating for Vapor-Permeable Floors

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Solution Overview

Problem

Existing coatings for public building floors face issues with poor vapor permeability, leading to moisture-related construction damages and microbial growth, while also compromising acoustic properties and walking comfort, and often contain harmful VOCs or require multiple components that are difficult to apply and prone to cracking.

Innovation Solution

A one-component water-based coating composition comprising a polymeric matrix of polyurethane and acrylate with inorganic granular particles and biobased fibers, which forms a flexible, vapor-permeable, and wear-resistant coating upon drying.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If resin-based coatings are used to provide durability and wear resistance, then wear resistance is improved, but VOC content increases and environmental/health concerns arise

Engineering Contradiction:

Improvewear resistanceVSAvoidVOC content

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent changes the fundamental parameter of the coating medium from solvent-based to water-based, eliminating VOCs while maintaining durability through specific polymer selections (polyurethane and acrylate) and particle size control (20-500 μm)

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite water-based coating system combining polyurethane and acrylate polymers with inorganic particles, achieving both environmental friendliness and mechanical durability through the synergistic effect of multiple materials

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If water-based coatings are used to reduce VOCs, then environmental friendliness is improved, but crack formation and applicability deteriorate

Engineering Contradiction:

ImproveVOC contentVSAvoidcrack resistance

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent changes the particle size parameter to 20-500 μm and uses specific polymer ratios to optimize the water-based coating's mechanical properties, preventing crack formation while maintaining low VOC content

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The composite structure of polyurethane-acrylate polymers with inorganic particles provides both flexibility and strength, enabling crack resistance in water-based coatings that would otherwise be prone to cracking

Inventive Principle:

Principle #40Composite materials

3Strength

If traditional two-component resins are used to achieve durability, then wear resistance is improved, but device complexity and ease of application deteriorate

Engineering Contradiction:

ImprovedurabilityVSAvoidnumber of components

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges the functions of multiple components into a single water-based coating formulation, combining polymer matrices, inorganic particles, and stabilizers in one application that delivers durability without requiring separate components

Inventive Principle:

Principle #5Merging (Combining)

4Ease of operation

If resilient floorings are used to provide walking comfort, then walking comfort is improved, but vapor permeability deteriorates leading to moisture damage

Engineering Contradiction:

Improvewalking comfortVSAvoidvapor permeability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent incorporates porous inorganic particles (20-500 μm) into the coating matrix, creating a porous structure that maintains vapor permeability while providing the cushioning and comfort properties of resilient floorings

Inventive Principle:

Principle #31Porous materials

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 coating provides self-levelling properties, low toxicity, and excellent durability, with improved acoustic and thermal insulation, while preventing microbial growth and cracking, and is easy to apply with minimal mixing.

Implementation Method 1

the inorganic granular particles have an average particle size of at least 20 μm and comprise at least two inorganic components, the first inorganic component having a lower density than the at least one further inorganic component

Methodology Applied

Scientific EffectDensity-based separation: Density Gradient

Implementation Method 2

forms a vapor permeable, flexible and wear resistant coating upon drying

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS20250333618A1Water-based coating composition

Publication Date: 2025.10.30 BUILD CARE

AI summary

The present invention concerns a one-component water-based coating composition comprising a polymeric matrix and inorganic granular particles, which are mixed with the polymeric matrix. The polymeric matrix is a water-based dispersion and comprises at least two polymeric components, and mixed therein inorganic granular particles that have an average particle size of at least 20 μm, as well as a stabilizer in the form of suspended biobased fibres. The present invention further concerns a surface coated with such a coating composition as well as a method for the preparation thereof.