Board-Shaped Component With Eccentric Fabric Reinforcement
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Solution Overview
Problem
Existing panel-shaped components for building walls and ceilings lack a simple, cost-effective solution that combines the functions of a carrier plate and decorative cladding while ensuring stability and visual appeal without requiring additional cladding.
Innovation Solution
A plate-shaped component with a lightweight mineral filler and binder, featuring external and internal fabric reinforcements, where the internal reinforcement is arranged eccentrically and separates layers of the same material, creating a reinforcement-free surface for aesthetic appeal and load-bearing functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a carrier plate with fabric reinforcement is used to ensure stability, then the structural strength is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the carrier plate and decorative cladding element into a single integrated component. The plate-shaped component includes a front side with decorative aggregate exposure and a rear side with fabric reinforcement, eliminating the need for separate carrier plates and cladding layers. This merging reduces manufacturing steps and overall complexity while maintaining both structural strength and aesthetic appearance.
Solution Approach 2:
The patent uses a composite material structure where aggregate particles (such as glass, stone, or ceramic) are embedded in a binder matrix, with fabric reinforcement integrated within the component. This composite construction provides both the decorative surface quality and the structural strength required, while the fabric reinforcement is encapsulated within the material itself rather than being a separate external layer.
2Shape
If additional cladding is added to achieve visual appeal, then the aesthetic quality is improved, but the device complexity and number of components increase
Solution Approach 1:
The patent integrates the decorative cladding function directly into the carrier plate structure. The front side of the plate-shaped component is formed with exposed aggregate particles that provide the desired aesthetic appearance, while the rear side contains the fabric reinforcement for structural support. This single integrated component replaces what would traditionally require separate carrier plate and cladding layers.
Solution Approach 2:
The plate-shaped component performs multiple functions simultaneously: it serves as the structural carrier plate, provides the decorative cladding surface, and incorporates reinforcement all within a single element. This multi-functionality eliminates the need for additional separate components while achieving both structural and aesthetic requirements.
3Stability of the object's composition
If fabric reinforcement is added to the carrier plate, then the stability is improved, but the manufacturing cost increases
Solution Approach 1:
The fabric reinforcement is incorporated during the initial casting or forming process of the plate-shaped component, rather than being added as a separate subsequent step. The fabric is placed within the mold cavity before the binder material is poured in, allowing the reinforcement to be encapsulated within the component as it cures. This preliminary integration simplifies the overall manufacturing process and reduces labor costs compared to post-assembly reinforcement methods.
Solution Approach 2:
The manufacturing process merges the reinforcement integration step with the base component formation step. By incorporating the fabric reinforcement during the same casting or forming operation that creates the plate-shaped component, the process eliminates separate reinforcement installation steps, reducing manufacturing complexity and cost while ensuring stable structural composition.
Data Source
AI summary
The plate-shaped element has a plate-shaped component that is provided with an external reinforcement in the form of a woven fabric, non-woven fabric or paper. An additional reinforcement is arranged on the inner side, so that the plate-shaped element has a reinforced and reinforce-free surface. The spacing of the additional reinforcement of the reinforced surface of the plate-shaped component is greater than the distance to the surface of the plate-shaped component reinforce-free surface. An independent claim is included for a method for producing a plate-shaped component.