Waterproof Coating Method Using Two-Part Spray System
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Solution Overview
Problem
Water-based exterior coatings are vulnerable to water damage during application, requiring multiple applications and increased labor costs, and are difficult to deliver to elevated surfaces due to high viscosity and particle size, leading to inefficiencies and potential membrane failures in roof structures.
Innovation Solution
A two-part coating system comprising a resin solution of neoprene latex and liquid asphalt emulsion, combined with an accelerator solution of zinc sulfate in water, applied using a spray gun with distinct nozzles and pumps to achieve immediate curing upon application, allowing for a single-pass application and reduced labor costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If water-based exterior coatings are applied to protect exterior surfaces, then reduced toxic solvent emission and ease of application are achieved, but the coating is vulnerable to water damage during and immediately after application
Solution Approach 1:
The patent changes the chemical parameters of the coating system by introducing a two-component formulation where Component A (polymer latex with amine groups) reacts with Component B (crosslinking agent with carboxylic acid groups). This chemical transformation creates a crosslinked network structure that fundamentally alters the coating's water resistance properties, allowing it to withstand water exposure immediately after application.
Solution Approach 2:
The patent creates a composite coating system by combining two distinct chemical components: a polymer latex base with amine functional groups and a crosslinking agent with carboxylic acid groups. This composite approach allows the coating to maintain the ease of application and low toxicity of water-based systems while gaining the water resistance typically associated with more complex formulations.
2Productivity
If thick coating films (20-40 mils) are applied in a single application, then labor costs are reduced, but the coating loses water by evaporation slowly and is vulnerable to being washed off by precipitation
Solution Approach 1:
The patent applies preliminary action by formulating the coating to undergo immediate chemical curing upon application. The rapid crosslinking reaction that begins as soon as Components A and B mix creates a water-resistant film quickly, preventing washout even when thick applications are made in a single coat.
Solution Approach 2:
The patent fundamentally changes the curing mechanism from physical drying (water evaporation) to chemical curing (crosslinking reaction). This parameter change allows thick coatings to develop water resistance rapidly through chemical bond formation rather than relying on slow water evaporation, enabling single-application thick coats without washout risk.
3Reliability
If coating components with high viscosity and large particle sizes are used, then coating performance is improved, but it becomes very difficult to pump such liquids and particles to the rooftop from a lower level
Solution Approach 1:
The patent applies segmentation by dividing the coating into two separate components (Component A and Component B) that are stored and transported independently. Each component has optimized rheological properties for easy pumping, and the high-performance crosslinked structure is created only at the point of application through mixing, allowing rooftop application without pumping difficulties.
Solution Approach 2:
The patent uses water as an intermediary carrier in an emulsion system. The polymer latex and crosslinking agent are dispersed in water, creating a low-viscosity emulsion that is easy to pump. The water acts as a temporary carrier that facilitates delivery to the rooftop, and the crosslinking reaction occurs after application, creating the final high-performance coating structure.
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 system enables immediate curing of 80% of the coating in three seconds, reducing washout risks and labor costs, facilitating application on rooftops and other surfaces with improved adhesion and waterproofing, and allowing for longer tubing lengths for easier material delivery.
Implementation Method 1
an accelerator solution including an aqueous solution of zinc sulfate powder and water
Data Source
AI summary
A coating comprises a resin solution including a solution of neoprene latex and liquid asphalt emulsion and an accelerator solution including an aqueous solution of zinc sulfate powder and water. A spray system for applying the coating includes a spray gun having first and second nozzles, a first pump fluidly connected between the first nozzle and a resin solution reservoir for delivering the resin solution to the first nozzle at a first fluid pressure, and a second pump fluidly connected between the second nozzle and an accelerator solution reservoir for delivering the accelerator solution to the second nozzle at a second fluid pressure different from the first pressure. The accelerator solution may be aerated by a source of compressed air prior to discharge from the second nozzle.