Slurry Floor Coating Uniform Particle Distribution
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Solution Overview
Problem
Conventional floor coating methods using multicomponent resin systems result in non-uniform particle distribution, inefficiencies in application, and suboptimal properties such as slip resistance, compressive strength, and adhesion, particularly due to particle settling and resin-heavy top regions.
Innovation Solution
A method involving mixing epoxy resin and hardener to form an activated multicomponent resin system with specific viscosity, incorporating particles to create a slurry coat that cures with uniform particle distribution throughout, and optionally applying a top coat for enhanced adhesion and friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If particles are broadcast onto the coating layer after application, then particle distribution can be achieved, but the distribution is non-uniform and the process is time-consuming
Solution Approach 1:
The patent combines the particle incorporation step with the coating application step by mixing particles directly into the resin system before application. This merging of operations eliminates the separate broadcasting step, achieving both uniform particle distribution and reduced application time.
Solution Approach 2:
The patent performs preliminary mixing of particles with the resin system before application to the substrate. This preliminary action ensures particles are uniformly distributed throughout the coating material before it is applied, eliminating the need for post-application broadcasting and ensuring uniform distribution.
2Manufacturing precision
If particles are mixed into the resin system to form a slurry, then particle distribution is initially uniform, but particles settle over time causing non-uniform distribution in the cured coating
Solution Approach 1:
The patent modifies the viscosity parameter of the resin system to a specific range (50-200 centipoises) that prevents particle settling while maintaining workability. This parameter change stabilizes the slurry composition, keeping particles uniformly distributed throughout the coating even after extended periods before curing.
Solution Approach 2:
The patent creates a composite resin system with specific rheological properties that balance particle suspension stability with application performance. The composite formulation includes resin, hardener, and particles in specific proportions that prevent settling while maintaining pourability and spreadability.
3Ease of operation
If the resin system viscosity is too low, then the slurry is easy to apply, but particles settle faster causing non-uniform distribution
Solution Approach 1:
The patent optimizes the viscosity parameter to a specific range (50-200 centipoises) that simultaneously provides ease of application and prevents particle settling. This parameter optimization resolves the contradiction by finding the viscosity window where both applicability and particle suspension stability are achieved.
4Area of stationary object
If the slurry coating is applied thickly to ensure full coverage, then coverage is improved, but particle distribution becomes non-uniform with resin-heavy top regions
Solution Approach 1:
The patent modifies the resin system viscosity to a range that maintains particle suspension stability even in thick applications. This parameter change prevents particle settling throughout the entire thickness of the coating, ensuring uniform distribution from bottom to top regardless of application thickness.
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 method achieves a uniformly distributed particle coating with improved compressive strength, slip resistance, and adhesion, maintaining particle uniformity from top to bottom, and allows for efficient repair of slurry coats with self-leveling properties.
Implementation Method 1
mixing together a Part A comprising an epoxy resin and a Part B comprising a hardener to form an activated multicomponent resin system
Implementation Method 2
allowing the slurry coat to cure. Before and after the slurry coat has cured, it has particles of the Part C distributed substantially uniformly throughout
Data Source
AI summary
The invention provides a method of treating a floor, such as with a curable epoxy resin-based system or another resin system. The method involves mixing together a Part A comprising a resin and a Part B comprising a hardener to form an activated multicomponent resin system. In certain embodiments, the activated multicomponent resin system has a viscosity in a range of 900-1,200 centipoise. The method further comprises mixing a Part C comprising particles into the activated multicomponent resin system to form a slurry, spreading the slurry over a floor to form a slurry coat, and allowing the slurry coat to cure. Before and after the slurry coat has cured, it has particles of the Part C distributed substantially uniformly throughout. The invention also provides slurry floor coats and floors bearing such coats, as well as methods for repairing such floor coats and floors.