Lightweight Cement Panel with Fiber Reinforcement and Resin Layer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional concrete formwork panels face issues such as low durability, water absorption leading to increased weight and strength degradation, and limited repetitive use, along with environmental concerns due to lumber resource consumption and hazardous gas emissions during disposal.
Innovation Solution
A lightweight cement panel with a surface reinforcing sheet made of woven or unwoven cloth covering a porous compact of lightweight cement, reinforced with Vinylon fibers and a foaming agent, providing a specific gravity between 0.5 and 1.0, and a surface resin layer for enhanced strength and water resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If plywood is used as concrete formwork panel, then it provides good processing capabilities and light weight, but it has low durability, absorbs water causing weight increase and strength degradation, and limited repetitive use
Solution Approach 1:
The invention uses a composite structure consisting of a cement-based panel proper reinforced with polyvinyl alcohol fibers (Vinylon) and covered with a surface resin layer. This composite material combines the advantages of cement (durability, water resistance) with fiber reinforcement (strength, toughness) to create a panel that maintains processing capabilities while achieving high durability and resistance to water absorption, enabling repetitive use of 50 times or more
Solution Approach 2:
The invention changes the material parameters by using polyvinyl alcohol fibers with specific characteristics (fiber length 3-20mm, compounding ratio 0.1-5 parts by weight per 100 parts cement) and applying surface resin layers with controlled thickness (0.1-5mm). These parameter optimizations ensure the panel maintains good processing capabilities for nailing and cutting while achieving the required durability and water resistance for repetitive use
2Reliability
If synthetic resin-made panels are used for concrete formwork, then they provide high durability and resistance to water absorption, but they exhibit large variation in flexural rigidity due to temperature changes and have limited nailable range
Solution Approach 1:
The invention uses a composite structure consisting of a cement-based panel proper reinforced with polyvinyl alcohol fibers (Vinylon) and covered with a surface resin layer. This composite material combines the advantages of cement (durability, water resistance) with fiber reinforcement (strength, toughness) to create a panel that maintains processing capabilities while achieving high durability and resistance to water absorption, enabling repetitive use of 50 times or more
Solution Approach 2:
The invention changes the material parameters by using polyvinyl alcohol fibers with specific characteristics (fiber length 3-20mm, compounding ratio 0.1-5 parts by weight per 100 parts cement) and applying surface resin layers with controlled thickness (0.1-5mm). These parameter optimizations ensure the panel maintains good processing capabilities for nailing and cutting while achieving the required durability and water resistance for repetitive use
3Strength
If conventional cement-based panels with glass fiber reinforcement are used, then they provide high strength, but they are permanent forms that blend with cast concrete and cannot be repeatedly used
Solution Approach 1:
The invention extracts the reinforcing function from permanent glass fiber mesh embedded in concrete and replaces it with removable polyvinyl alcohol fiber-reinforced cement panels. The panels maintain high strength through fiber reinforcement but can be easily removed and reused, converting a permanent form system into a reusable formwork system with 50+ repetitive uses
Solution Approach 2:
The invention uses polyvinyl alcohol fibers (Vinylon) as reinforcing material that provides high strength at reasonable cost. The panels are designed as economical reusable forms that can be discarded or replaced after extensive use, replacing expensive permanent glass fiber reinforcement systems while maintaining structural integrity during the formwork service life
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 panel offers high strength, durability, and improved handling, allowing for multiple uses without weight increase or strength loss, reducing environmental impact and construction waste, while being suitable for various construction applications.
Implementation Method 1
a panel proper (2) formed by a porous compact (8) produced by filling, curing and solidifying a mixture prepared by kneading cement, water, reinforcing fibers and foam obtained by prefoaming a foaming agent
Implementation Method 2
a surface resin layer (9) including synthetic resin that integrally covers the surface of the panel proper (2), and a surface reinforcing sheet (4) including woven cloth or unwoven cloth that is disposed to be embedded in the surface resin layer (9)
Data Source
AI summary
The invention provides a lightweight cement panel which achieves light weight, high strength, and durability, is free of degraded strength or deformation due to water absorption or fluctuation of ambient temperature, etc., provides satisfactory processing capabilities including nailing, etc. and can be used as a concrete formwork panel, floor material, wall material, ceiling material, and others of architectural structures.A panel proper 2 is formed by a porous compact 8 produced by filling, curing, and solidifying a mixture prepared by kneading cement, water, reinforcing fibers, and foam obtained by prefoaming a foaming agent in a hermetically sealed cement form block block, contains the reinforcing fibers 7 and foam in a dispersion state in the compact 8, and provides the specific gravity within the range between 0.5 and 1.0. The surface of this panel proper 2 is integrally covered with a surface reinforcing sheet 4 comprising woven cloth or unwoven cloth, and the surface is further integrally covered by a surface protection layer 5.