Water-Based Floor Coating With Vapor-Permeable Composite Structure

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing coatings for public building floors suffer from poor vapor permeability, leading to moisture-related construction damages, microbial growth, and environmental health concerns due to high VOC content, while also compromising acoustic and walking comfort properties.

Innovation Solution

A one-component water-based coating composition comprising a polymeric matrix of polyurethane and acrylate with inorganic granular particles and biobased fibers, which forms a vapor permeable, flexible, and wear-resistant coating upon drying.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional two component resins or solvent based coatings are used, then vapor permeability and durability are improved, but environmental health concerns and VOC content increase

Engineering Contradiction:

ImprovedurabilityVSAvoidVOC content

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters by using water-based polymeric dispersions instead of solvent-based systems, and employs hydrolysis-resistant polymers with specific functional groups to maintain durability while eliminating VOCs. The coating achieves durability through chemical crosslinking via moisture-curing mechanism rather than solvent evaporation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite coating system combining hydrolysis-resistant polymers with reactive silane modifiers and inorganic fillers. This composite structure provides both vapor permeability and enhanced durability while being water-based, thus eliminating VOC content associated with traditional solvent-based coatings.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If water-based or one-component coatings are used, then environmental friendliness and ease of application are improved, but crack formation and poor self-levelling properties occur

Engineering Contradiction:

Improveease of applicationVSAvoidcrack formation

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent modifies the rheological parameters by incorporating specific thickening agents and viscosity modifiers that enable self-levelling behavior in one-component water-based systems. The chemical composition is adjusted to include flexible polymer chains that accommodate substrate movement without cracking.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent develops a composite formulation combining water-based polymeric dispersion with reactive diluents, crosslinking agents, and functional additives. This composite structure maintains the ease of application of water-based coatings while preventing crack formation through flexible molecular architecture and controlled crosslinking density.

Inventive Principle:

Principle #40Composite materials

3Ease of operation

If resilient floorings are used, then walking comfort is improved, but vapor permeability decreases leading to moisture damage

Engineering Contradiction:

Improvewalking comfortVSAvoidvapor permeability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent creates a porous coating structure that allows vapor transmission while maintaining the flexible, cushioning properties needed for walking comfort. The porous network is formed through the water-based dispersion mechanism and controlled drying process, creating channels for moisture vapor to escape.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent formulates a composite coating combining flexible polymers with inorganic fillers and porogen materials. This composite structure provides both the mechanical flexibility for walking comfort and the porous architecture for vapor permeability, eliminating the trade-off present in traditional resilient floorings.

Inventive Principle:

Principle #40Composite materials

4Reliability

If ceramic tiles or hard surfaced floorings are used, then vapor permeability is improved, but acoustic properties and walking comfort deteriorate

Engineering Contradiction:

Improvevapor permeabilityVSAvoidacoustic properties

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent creates a composite coating system that combines vapor-permeable inorganic components with sound-absorbing organic materials. The flexible polymer matrix and incorporated porogens provide acoustic damping and walking comfort while maintaining vapor transmission pathways, unlike hard ceramic tiles.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies different functional properties to different aspects of the coating: the polymer matrix provides acoustic damping and comfort, while the porous structure and inorganic fillers provide vapor permeability. This local differentiation of properties allows simultaneous achievement of both requirements.

Inventive Principle:

Principle #3Local quality

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 coating provides self-levelling properties, low toxicity, and excellent durability with thermal insulation, noise absorption, and improved walking comfort, while preventing microbial growth and reducing VOC emissions.

Implementation Method 1

The coating composition further comprises a stabilizer in the form of suspended biobased fibres... the stabilizer preventing crack formation in the coating upon drying

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 2

the inorganic granular particles have an average particle size of at least 20 μm and comprise at least two inorganic components, the first inorganic component having a lower density than the at least one further inorganic component... providing for good properties in use, such as walking comfort and wear resistance

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 3

provide for good properties in use, such as walking comfort and wear resistance... noise absorption

Methodology Applied

Scientific EffectAcoustic absorption: Acoustic Absorption

Implementation Method 4

the polymeric matrix is in the form of a water-based dispersion... forms a vapor permeable, flexible and wear resistant coating upon drying

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 5

forms a vapor permeable, flexible and wear resistant coating... allowing moisture transfer through the seams

Methodology Applied

Scientific EffectVapor permeability: Permeation

Data Source

PatentEP4640771A1Water-based coating composition

Publication Date: 2025.10.29 BUILD CARE

Figure 1~2

AI summary

The present invention concerns a one-component water-based coating composition comprising a polymeric matrix and inorganic granular particles, which are mixed with the polymeric matrix. The polymeric matrix is a water-based dispersion and comprises at least two polymeric components, and mixed therein inorganic granular particles that have an average particle size of at least 20 µm, as well as a stabilizer in the form of suspended biobased fibres. The present invention further concerns a surface coated with such a coating composition as well as a method for the preparation thereof.