Thermoplastic Pavement Marking Flake Manufacturing
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Solution Overview
Problem
Existing thermoplastic pavement markings are dusty, absorb moisture, labor-intensive, and costly due to their manufacturing processes, which affect their melting speed and adherence to specifications.
Innovation Solution
The method involves creating thermoplastic pavement marking material in flake form by applying non-adhesive ingredients to a flaker belt or drum before or after the remaining adhesive ingredients, allowing for a single process production of multi-layered free-flowing flakes with a larger surface area to mass ratio, reducing dust and moisture absorption, and eliminating the need for costly equipment and subsequent coating steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If dry blend method is used to manufacture thermoplastic pavement markings, then manufacturing cost is reduced, but the product becomes dusty and absorbs moisture
Solution Approach 1:
The patent applies preliminary action by pre-coating the flaker belt or drum with non-adhesive ingredients (waxes, glass spheres) before applying the adhesive ingredient mixture. This preliminary coating prevents dust formation and moisture absorption by creating a protective surface layer on the flakes before they are formed, thus resolving the harmful effects while maintaining cost-effectiveness of the dry blend approach
2Ease of manufacture
If dry blend method is used, then manufacturing cost is reduced, but melt speed decreases due to required agitation
Solution Approach 1:
By pre-applying non-adhesive ingredients to the flaker surface before the adhesive mixture, the patent creates a layered structure that facilitates faster melting. The non-adhesive coating reduces the energy required to break down the flake structure during melting, eliminating the need for significant agitation while maintaining low manufacturing costs
3Object-affected harmful factors
If block form is used to reduce dust and moisture absorption, then these harmful factors are reduced, but labor intensity increases due to breaking into pieces
Solution Approach 1:
The patent segments the thermoplastic material into flake form directly during the manufacturing process by flaking it off the cooled flaker belt or drum. This segmentation eliminates the need for subsequent breaking into pieces, reducing labor intensity while maintaining the low dust and moisture absorption characteristics of pre-formed structures
4Object-affected harmful factors
If pelletized form is used to reduce dust and labor, then these factors are improved, but manufacturing cost and equipment complexity increase
Solution Approach 1:
The patent uses segmentation by flaking the thermoplastic material off a cooled surface to create discrete flakes instead of pellets. This approach achieves the dust reduction and labor savings of pelletized form without requiring costly extrusion and pelletizing equipment, thereby maintaining manufacturing cost-effectiveness
5Object-affected harmful factors
If pelletized form is used, then dust and labor are reduced, but glass beads are damaged causing premature wear
Solution Approach 1:
The patent applies preliminary action by coating glass spheres with non-adhesive ingredients (waxes) before the extrusion and flaking process. This preliminary protective coating prevents glass bead damage during processing, eliminating premature wear while maintaining the dust and labor advantages of processed forms
6Device complexity
If flakes are created without non-adhesive coating, then production is simpler, but flakes deform and re-mass after packaging
Solution Approach 1:
The patent applies preliminary action by coating non-adhesive ingredients on the flake surfaces immediately during the flaking process, before packaging. This preliminary surface treatment prevents deformation and re-massing during storage and transport while adding minimal complexity to the production process, as the coating is applied in-line during flake formation
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 flake form ensures fast melting, minimizes re-massing, and maintains free-flowing properties, reducing production costs and labor while meeting specifications for road markings.
Implementation Method 1
heating and mixing the remaining ingredient portion
Implementation Method 2
applying the remaining ingredient portion in the molten state to the flaking device
Implementation Method 3
subsequently cooling the applied materials into a solid
Data Source
AI summary
A method of making a thermoplastic road marking material includes using a flaking device to form thermoplastic flakes from a cooled mixture. A method of marking a pavement includes melting the thermoplastic flakes and applying the melted composition to a roadway by screeding, extruding or spraying.