Self-Leveling Decorative Coating With Shelf-Stable Filler Suspension
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Solution Overview
Problem
Current decorative surface coating processes are labor-intensive, messy, and inefficient due to the need for on-site mixing of filler materials with resin, which tend to settle out over time, requiring additional steps like broadcasting and topcoating, and generate dust and waste.
Innovation Solution
A shelf-stable resin-filler mixture is developed with dispersing agents to maintain uniform suspension of decorative elements, eliminating the need for on-site mixing and broadcasting, and allowing for a one-coat application process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If filler material is pre-mixed into resin in the container, then on-site mixing time and labor are eliminated, but filler material settles out of suspension over time
Solution Approach 1:
The filler material is pre-mixed with the resin in the manufacturing container before shipment to the job site. This preliminary action eliminates the need for on-site mixing while maintaining product stability through proper formulation and sealing during storage and transport.
Solution Approach 2:
A dispersing agent is introduced as an intermediary substance that prevents filler material from settling out of the resin suspension. The dispersing agent maintains uniform distribution of filler particles throughout the resin matrix, enabling shelf-stable pre-mixed products without on-site mixing.
2Stability of the object's composition
If traditional separate application of filler and resin is used, then material stability is maintained, but application process becomes labor intensive and time consuming
Solution Approach 1:
The filler material and resin are merged into a single pre-mixed product in the manufacturing container. This combining of materials eliminates the need for separate application steps and on-site mixing, significantly improving application efficiency while maintaining material stability through proper formulation.
Solution Approach 2:
The mixing of filler and resin is performed as a preliminary action during manufacturing rather than during application. This allows the product to be shipped ready-to-use, improving productivity by eliminating labor-intensive on-site mixing operations.
3Stability of the object's composition
If on-site mixing of filler and resin is performed, then uniform suspension is achieved, but dust generation and cleanup requirements increase
Solution Approach 1:
The dispersing agent acts as an intermediary that maintains uniform suspension of filler particles in the resin without requiring on-site mixing operations. This eliminates dust generation associated with mixing while preserving the uniform suspension needed for proper application.
Solution Approach 2:
The uniform suspension is achieved as a preliminary action during manufacturing in a controlled environment, eliminating dust generation that would occur during on-site mixing operations. The pre-mixed product maintains uniform suspension until application time.
4Duration of action of stationary object
If resin is stored for extended periods, then shelf life is extended, but resin gains viscosity or hardens rendering it useless
Solution Approach 1:
The dispersing agent serves as a protective intermediary that prevents filler particle aggregation and resin hardening during extended storage. This maintains viscosity stability and prevents the resin from becoming useless, thereby extending shelf life while preserving compositional stability.
Solution Approach 2:
The formulation includes specific parameter changes in the dispersing agent concentration and resin composition to prevent viscosity increase and hardening during storage. These parameter adjustments enable extended shelf life while maintaining the resin's applicability.
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 provides a more efficient, waste-reducing, and cost-effective application process with improved durability and aesthetics, eliminating the need for on-site mixing and topcoating, and extending shelf life up to two years.
Implementation Method 1
addition of at least two dispersing agents to keep filler material containing decorative elements in suspension in a selected resin
Implementation Method 2
incorporation of decorative filler materials directly into a pre-mixed product composition in a way that keeps them uniformly dispersed in resin
Data Source
AI summary
The present invention comprises a shelf-stable, self-leveling, decorative surface coating product that is durable and easy to apply. The product allows for direct application to floor surfaces without the need for applying the decorative elements onsite. In certain embodiments, the product comprises of a selected resin, at least two dispersing agents, and a decorative filler material. Resins may include epoxy resin, polyurethane resin, polyaspartic resin, polyurea resin, polyester resin, or methyl methacrylate resin. Dispersing agents may include modified polyurethane and solutions of modified urea. Filler materials may include aluminum trihydrate, colorants, polyethylene terephthalate and cured polyester resin. Production of the decorative surface coatings involves adding a first dispersing agent to a resin, high-speed mixing, addition of a second dispersing agent, high-speed mixing, addition of a filler material, and high-speed mixing, all at ambient temperature. The decorative surface coating product may be shelf-stable for more than two years.