No-Wax Rubber Flooring with Polyurethane Protective Coat
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Solution Overview
Problem
Traditional rubber flooring materials require frequent maintenance due to their susceptibility to abrasion, cracking, fading, and wear, and lack resistance to soiling and mechanical damage, necessitating regular waxing and protective coatings that also require maintenance.
Innovation Solution
Development of surface coverings comprising a base and a protective coat that are no-wax, resistant to abrasion, cracking, and wear, and can be easily cleaned with water and mild detergents, featuring a polyurethane or polyacrylic protective coat that adheres well to the base and provides a durable, flexible surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional rubber flooring is used, then it provides elasticity and resiliency, but it requires frequent maintenance due to susceptibility to abrasion, cracking, and wear
Solution Approach 1:
The patent applies composite materials by combining a rubber base layer with a protective coating layer consisting of polyurethane and/or polyacrylic materials. This composite structure integrates the elasticity and resiliency of rubber with the abrasion and crack resistance of the protective coating, eliminating the need for frequent maintenance while maintaining the inherent benefits of rubber flooring.
2Reliability
If a protective coating is applied to enhance abrasion resistance, then abrasion resistance is improved, but the coating itself requires maintenance such as waxing and buffing
Solution Approach 1:
The patent applies parameter changes by selecting specific polyurethane and/or polyacrylic materials with optimized chemical composition and physical properties. These material parameters are chosen to provide superior abrasion resistance and durability that eliminate the need for maintenance procedures like waxing and buffing, while still allowing the surface to be cleaned with water and mild detergents.
3Strength
If the protective coat is made more durable to resist cracking and wear, then durability is improved, but flexibility may be compromised
Solution Approach 1:
The patent resolves this contradiction through composite materials where the protective coating of polyurethane and/or polyacrylic is formulated to balance durability and flexibility. The specific composition and thickness of the coating layer are optimized to provide resistance to cracking and wear while maintaining the flexibility needed for the flooring to adapt to substrate movements and installation conditions.
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 surface coverings exhibit superior resistance to abrasion, cracking, and wear, maintaining their appearance and functionality without the need for regular maintenance, remaining cleanable and flexible even under heavy use and extreme conditions.
Implementation Method 1
a protective coat that adheres well to the base
Data Source
AI summary
The present disclosure provides, among other things, surface coverings with a protective coat applied thereto a rubber material. As provided herein, in some embodiments, a surface covering has or includes an exposed surface that is no-wax. The present disclosure further provides methods of making, and methods of using. Such surface coverings have surprising and beneficial attributes. They are particularly advantageous as resistant to soiling and abrasion. These surface covering are also resistant to crumbling under load. Such surface coverings would be useful as flooring products with desirable properties. In particular, such abrasion and soil resistant surfaces could be useful as a rubber flooring product.