Basalt Casting Powder Extruded Boards for Dimensional Stability
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Solution Overview
Problem
Existing wall and floor covering systems are time-consuming, expensive, and messy to install, and they face issues with water damage, mold growth, and incompatibility with thin cut stone veneer layers due to unsuitable core layer compositions and materials.
Innovation Solution
The use of basalt casting powder-based extruded boards for wall coverings and stone dust-based shock absorbing core layers in floor coverings, which are manufactured using an extrusion process, providing improved physical properties such as sound dampening, abrasion resistance, and resistance to mold, and are compatible with thin cut stone veneer layers through specific gravity matching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gypsum drywall is used for wall coverings, then fire rating and sound absorption are improved, but moisture absorption leads to mold growth and dimensional instability
Solution Approach 1:
The patent changes the material composition parameters by replacing gypsum with basalt casting powder, which has different physical and chemical properties. Basalt casting powder provides the desired fire rating and sound absorption while being hydrophobic, thus preventing moisture absorption and mold growth.
Solution Approach 2:
The patent creates a composite material system combining basalt casting powder with specific binders and additives to achieve both the mechanical properties needed for fire rating and sound absorption, and the chemical properties needed for moisture resistance. This composite approach allows simultaneous optimization of conflicting requirements.
2Strength
If traditional wall board installation methods are used, then structural support is provided, but installation becomes time-consuming and messy
Solution Approach 1:
The patent replaces traditional mechanical fastening systems (screws, nails, mud, tape) with a magnetic attachment system. Magnets embedded in the wall board and corresponding magnetic elements in the frame provide structural support and attachment without requiring mechanical fasteners, significantly reducing installation time and mess.
Solution Approach 2:
The patent changes the attachment mechanism from mechanical to magnetic, fundamentally altering how wall boards are installed. This parameter change eliminates the need for time-consuming mudding, taping, and screwing operations while maintaining structural integrity.
3Ease of manufacture
If stone veneer layers are applied to wall coverings, then aesthetic appeal is improved, but compatibility issues arise with existing core layer materials
Solution Approach 1:
The patent adjusts the specific gravity parameter of the core layer material to match that of the stone veneer layer. By optimizing the density and composition of the basalt casting powder mixture, the core layer becomes compatible with thin cut stone veneers, preventing delamination and ensuring long-term durability.
Solution Approach 2:
The patent applies different material properties to different layers: the core layer uses basalt casting powder with specific gravity matched to the stone veneer, while the surface layer uses polished stone veneer for aesthetic purposes. This local differentiation ensures both compatibility and visual appeal.
4Object-affected harmful factors
If mineral wool is used for wall boards, then moisture resistance is improved, but production complexity and cost increase
Solution Approach 1:
The patent changes the primary material from mineral wool to basalt casting powder, which inherently provides moisture resistance due to its hydrophobic properties. This material substitution simplifies the production process compared to mineral wool while maintaining or improving moisture resistance.
Solution Approach 2:
The patent uses basalt casting powder, which is a readily available and cost-effective material, replacing more expensive and complex mineral wool. This substitution reduces production complexity and cost while achieving the desired moisture resistance.
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 results in dimensionally stable, cost-effective, and durable wall and floor coverings that are resistant to cracking and water damage, with reduced material usage and installation complexity, while maintaining sound absorption and aesthetic appeal.
Implementation Method 1
improved physical properties such as sound dampening
Implementation Method 2
shock absorbing core layer
Data Source
AI summary
The present invention provides a system, method, and apparatus for producing a dimensionally stable extruded board product for use in surface coverings. The board product may be a basalt casting powder-based product for use as a substrate for wall or other surface coverings or may be used as a core layer in a modular floor covering unit. The modular floor covering unit comprises multiple layers. The layers are a thin cut stone veneer layer, a core layer with a density similar to that of the thin cut stone veneer layer, and an optional magnetically receptive underlayment layer. Other layers or combinations of layers may also be used.