Segmented Surface Coating for Slip Resistance and Crack Bridging
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Solution Overview
Problem
Existing surface coverings for traffic areas and garages face challenges in balancing moisture sealing and slip resistance, as synthetic resin coatings provide inadequate slip resistance and are prone to cracking, leading to reduced service life.
Innovation Solution
A dual-layer surface covering system where a crack-resistant sealing layer with no aggregates is paired with a top layer containing granular aggregates, structured to maintain high slip resistance through varying grain positions, ensuring extended service life and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If synthetic resin coatings are applied to seal surfaces against moisture and chemicals, then sealing performance is improved, but slip resistance deteriorates
Solution Approach 1:
The surface covering is divided into two distinct layers: a sealing layer without aggregate that provides moisture and chemical sealing, and a top layer with granular aggregate that provides slip resistance. This segmentation allows each layer to optimize its specific function without compromising the other.
2Object-generated harmful factors
If granular aggregate is incorporated into resin coating to improve slip resistance, then slip resistance is improved, but crack resistance deteriorates
Solution Approach 1:
By separating the aggregate-containing top layer from the aggregate-free sealing layer, the invention eliminates the harmful effect of aggregate on crack resistance while preserving its beneficial effect on slip resistance. The sealing layer remains smooth and flexible to bridge cracks, while the top layer provides the necessary traction.
Solution Approach 2:
The aggregate is locally concentrated in the top layer where it is needed for slip resistance, while the sealing layer remains free of aggregate to maintain its crack-bridging capability. This local differentiation of material properties resolves the contradiction.
3Object-generated harmful factors
If aggregate granules are distributed uniformly in the coating to ensure consistent slip resistance, then slip resistance is maintained, but wear resistance deteriorates
Solution Approach 1:
The top layer is structured with varied thickness to create local differences in aggregate exposure. Thinner areas expose aggregate sooner for immediate slip resistance, while thicker areas provide a reservoir of aggregate that maintains slip resistance as the surface wears, thereby extending service life.
4Duration of action of stationary object
If layer thickness is increased to extend service life, then durability is improved, but slip resistance deteriorates due to aggregate embedding
Solution Approach 1:
The structured top layer creates local thickness variations that optimize both slip resistance and service life. Thinner regions ensure aggregate remains exposed for slip resistance, while thicker regions provide material reserve for wear, eliminating the need to increase overall layer thickness.
Data Source
Figure 1
AI summary
Surface coating (1) and method for producing or repairing a surface coating (1) comprising: a sealing layer (4) based on a first synthetic resin and a top layer (6) arranged above the sealing layer (4) based on a second synthetic resin, wherein the top layer (6) has a granular aggregate (9) to improve the slip resistance and/or wear resistance of the surface coating (1), and wherein at least one underside (7) of the top layer (6) is structured, wherein the height difference between the elevations and the valleys of the structure of the underside (7) is preferably less than or equal to the maximum grain size of the aggregate (9) of the top layer (6).