Two-Part Waterproof Coating for Rapid Thick-Cure Application
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Solution Overview
Problem
Water-based exterior coatings are vulnerable to water damage during application, requiring multiple thin coats and increased labor costs, and face challenges in delivering high-viscosity materials to elevated surfaces like rooftops, with potential membrane failures due to joint details and penetrations.
Innovation Solution
A two-part water-based 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, thick coat application and reduced equipment handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If water-based coatings are applied as thick coating films (20-40 mils), then the coating provides adequate protection and reduces number of applications, but the coating loses water by evaporation slowly and is vulnerable to being washed off by precipitation
Solution Approach 1:
The invention changes the chemical parameters of the coating system by introducing a two-component formulation with accelerator that triggers rapid curing reaction. This parameter change transforms the coating from water-based to a chemically curing system, enabling thick applications to cure before water can evaporate or washout the coating.
Solution Approach 2:
The coating is applied in thick fashion first, and then the curing reaction is initiated by the accelerator component. This preliminary action of applying the full thickness before curing allows the coating to be in place and protected immediately, eliminating the need for multiple thin applications and protecting against washout.
2Reliability
If multiple separate applications are used to avoid washout, then the coating resistance to washout is improved, but the labor cost increases
Solution Approach 1:
By changing to a two-component chemical curing system with accelerator, the coating can be applied as a single thick coat that cures rapidly upon contact with the accelerator. This parameter change eliminates the need for multiple applications, reducing labor costs while maintaining washout resistance.
3Reliability
If high viscosity coating components are used, then the coating provides better protective properties, but it becomes difficult to pump and deliver to elevated surfaces
Solution Approach 1:
The coating system is segmented into two separate components: the resin solution (neoprene latex and liquid asphalt emulsion) and the accelerator solution (zinc sulfate in water). This segmentation allows each component to have optimal properties independently - the resin can provide protective properties while remaining pumpable, and the accelerator is a low-viscosity aqueous solution that is easy to deliver.
Solution Approach 2:
The invention uses a spray system with separate nozzles and pumps to deliver the two components through hydraulic and pneumatic means. The low viscosity of both components allows them to be pumped and sprayed effectively to elevated surfaces like rooftops, overcoming the pumpability issues associated with high viscosity single-component coatings.
4Productivity
If a single thick coat is applied, then the productivity is improved by reducing number of applications, but the coating is vulnerable to water damage during application
Solution Approach 1:
The full thickness coating is applied first as a preliminary action, and then the accelerator is applied to initiate curing. This sequence allows the coating to be in place immediately providing protection, and the rapid curing that follows prevents water damage during application while maintaining high productivity.
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 labor costs and preventing washout from precipitation, with the ability to apply thick coats in a single pass and extend hose lengths for easier material delivery, forming a seamless, waterproof membrane.
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.