Polyurethane Cementitious Flooring Gloss via Three-Component Formulation
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Solution Overview
Problem
Polyurethane cementitious hybrid systems suffer from dull or matt surfaces, which are aesthetically unfavorable and difficult to clean, while epoxy resin-based compositions exhibit unwanted blushing and temperature-dependent gloss loss, and contain hazardous chemicals.
Innovation Solution
A three-component composition comprising a polyol component, a polyisocyanate component with a high average NCO functionality, and a powder component, including cement and calcined paper sludge, is used to create polyurethane cementitious hybrid flooring systems with improved gloss, mechanical resistance, and reduced blister formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyurethane cementitious hybrid systems are used to avoid hazardous chemicals and blushing effects, then chemical safety and stability are improved, but surface gloss deteriorates to dull or matt surfaces
Solution Approach 1:
The patent modifies the chemical composition parameters of the polyol component by incorporating specific polyester polyols with controlled molecular weights (500-5000 g/mol) and functionality (2-4), along with precise water content (5-20 wt%). These parameter changes enable the system to achieve both chemical stability and improved surface gloss, resolving the contradiction between reliability and illumination intensity.
Solution Approach 2:
The patent creates a composite polyol component combining polyester polyols, polyether polyols, and water in specific ratios. This composite approach allows the system to maintain chemical stability from the polyurethane matrix while the polyester polyol contribution enhances surface gloss, simultaneously satisfying both requirements.
2Illumination intensity
If epoxy resin based flooring compositions are used to achieve glossy surfaces, then surface gloss is improved, but hazardous chemicals and blushing effects are introduced
Solution Approach 1:
The patent extracts and eliminates the hazardous epoxy resin and amine hardener chemistry from the system, replacing it with a polyol-polyisocyanate-water system that is REACH compliant. This substitution removes the harmful factors while maintaining the desired surface gloss through careful formulation of the polyol component.
Solution Approach 2:
The patent uses water as a partial replacement for organic solvents and reactive components, creating a more environmentally friendly system. The water content (5-20 wt%) is carefully controlled to achieve gloss without introducing hazardous chemicals, aligning with green chemistry principles.
3Reliability
If polyol and water are used in PU cementitious hybrid systems, then chemical resistance is improved, but unwanted side reactions occur leading to blister formation
Solution Approach 1:
The patent takes preliminary anti-action by carefully controlling the water content (5-20 wt%) and selecting polyester polyols with specific properties that minimize the tendency for CO2 generation. The formulation is designed in advance to prevent the harmful side reaction between water and isocyanate that leads to blistering, while still maintaining chemical resistance.
Solution Approach 2:
The patent optimizes the molecular weight and functionality parameters of the polyester polyol to control the reaction kinetics and minimize CO2 evolution. By adjusting these parameters within specific ranges, the system achieves chemical resistance without excessive blister formation from water-isocyanate side reactions.
4Ease of operation
If water content is increased to improve workability and open time, then ease of operation is improved, but blister formation from side reactions increases
Solution Approach 1:
The patent optimizes the water content parameter within a specific range (5-20 wt%) to balance workability and blister formation. This parameter change allows sufficient water for good workability and open time while limiting the amount available to cause excessive CO2 generation and blistering during curing.
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 solution achieves glossy/semiglossy surfaces with excellent mechanical and chemical resistance, fast curing, and ease of cleaning, while avoiding blister formation and complying with REACH regulations, using renewable and recycled materials.
Implementation Method 1
the reaction of a polyol and a polyisocyanate to form the polyurethane
Implementation Method 2
the reaction of cement and water, generally called hydration. Upon hydration the cement is hardened to a solid material
Implementation Method 3
the reactive isocyanate compounds can react with water resulting in the generation of amine compounds and CO2 gas
Data Source
AI summary
The present invention relates to a three component composition consisting of a polyol component (A) comprising at least two polyols, one with high and one with low molecular weight, and water, a polyisocyanate component (B) comprising a methylene diphenyl diisocyanate (MDI) product with an average NCO functionality of at least 2.5, or a methylene diphenyl diisocyanate (MDI) product with an average NCO functionality of at least 2 and at least one further polyol with an amount of between 1 % and 30% based on the weight of said polyisocyanate component (B), wherein said MDI product and said polyol have reacted at least partially, and a powder component (C) comprising at least one hydraulic binder, preferably cement and/or calcined paper sludge, preferably a calcium compound selected from calcium hydroxide and/or calcium oxide, and optionally one or more aggregates. Polyurethane cementitious hybrid flooring or coating systems having glossy/semiglossy surfaces, good workability and outstanding mechanical properties can be achieved. Blister formation can be avoided.