Spherical Aggregate Polymeric Composition for On-Site Repair
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Solution Overview
Problem
Conventional methods for producing polymeric composite materials onsite are cumbersome, time-consuming, and require bulky equipment, making it difficult to transport and apply them efficiently for surface repairs, especially in remote locations, and often result in user exposure to chemicals.
Innovation Solution
A multi-component, chemically-curing, non-cellular polymeric composition comprising a resin component, a reactive component, and an aggregate component with similar densities, allowing for continuous dispensing and mixing using standard equipment, enabling efficient and labor-saving on-site repairs by forming a homogenous mixture that can be easily pumped and applied.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional mixing equipment is used to produce polymeric composite materials onsite, then the polymeric composition can be produced on-site, but the equipment is cumbersome and time-consuming to use
Solution Approach 1:
The aggregate component is segmented into spherical particles with specific size ranges (0.1-10 mm), which enables the material to flow and mix more easily through standard equipment without requiring complex mixing apparatus. The spherical shape reduces inter-particle friction and improves flow characteristics.
Solution Approach 2:
The density of the aggregate component is specifically adjusted to be within 2 lbs/gallon of the resin or reactive component density. This parameter change ensures uniform mixing and prevents segregation during transport and application, eliminating the need for complex mixing equipment while maintaining homogeneous composition.
2Manufacturing precision
If batch mixing equipment is used to mix components, then uniform coating of aggregate is achieved, but the equipment is bulky and expensive to transport to remote locations
Solution Approach 1:
By matching the density of aggregate to resin/reactive component within 2 lbs/gallon, the system achieves equipotential conditions where gravitational separation is minimized. This allows standard transport equipment to deliver the mixture uniformly without requiring specialized batch mixing equipment at the application site.
Solution Approach 2:
The aggregate is formulated as spherical particles rather than irregular shapes. This spheroidality improves flow characteristics and mixing uniformity, allowing the material to be transported and applied using simple gravity-fed or pump-based systems rather than requiring complex batch mixers.
3Productivity
If polymeric composite material is prepared in advance, then it can be transported to remote locations, but it may cure before reaching the site of repair
Solution Approach 1:
The polymeric composite is segmented into separate components (resin, reactive component, and aggregate) that can be transported independently in a stable state. Mixing occurs only at the point of application, maximizing the transport time window while ensuring the material remains workable until needed.
Solution Approach 2:
The aggregate is pre-prepared with optimal spherical shape and density characteristics before transport. This preliminary preparation ensures that when the components are mixed at the application site, they will maintain uniform distribution and proper flow characteristics throughout the extended transport period.
4Ease of manufacture
If aggregate with different density is used, then the aggregate can be easily separated from resin, but the mixture is not homogenous and settles during transport
Solution Approach 1:
The density of the aggregate is specifically modified to be within 2 lbs/gallon of the resin or reactive component density. This parameter change creates a stable mixture that resists gravitational separation during transport while still allowing for relatively easy separation if needed, achieving a balance between stability and manufacturability.
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 allows for efficient, labor-saving, and time-effective application of polymeric compositions to damaged surfaces, reducing the need for bulky equipment and minimizing chemical exposure, while ensuring the composition remains workable and flowable for extended periods, facilitating remote repairs.
Implementation Method 1
The aggregate component has a spherical shape, a diameter of about 0.1 mm to about 10 mm, and an aggregate density. The density of the aggregate component is within 2 lbs/gallon of the density of at least one of the resin component or the reactive component.
Implementation Method 2
The aggregate component has a spherical shape, a diameter of about 0.1 mm to about 10 mm
Data Source
AI summary
A multi-component, chemically-curing, non-cellular, polymeric composition includes a resin component having a resin density, a reactive component having a reactive component density, and an aggregate component having a spherical shape, a diameter of about 0.1 mm to about 10 mm and an aggregate density. The density of the aggregate component is within 2 lbs/gallon of the density of at least one of the resin component or the reactive component.