Cement Panel Composite Laminate Eliminates Release Paper

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Solution Overview

Problem

The use of release paper in cement board manufacturing is unsustainable and generates significant waste, as it is single-use and contributes to the environmental footprint of the product.

Innovation Solution

A composite fabric laminate is used instead of release paper, which becomes a part of the cement board and does not need to be removed after the cement slurry has set, eliminating the need for release paper in the manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If release paper is used in cement board manufacturing, then the manufacturing process is simplified and material buildup is prevented, but significant waste is generated and sustainability attributes deteriorate

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidwaste generation

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The invention extracts and eliminates the release paper component from the manufacturing process by using a multi-ply facing material that does not require release paper, thereby preventing waste generation while maintaining manufacturing simplicity

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention eliminates the need to discard release paper by using a facing material structure where the first ply serves as both the forming surface and the final product component, recovering what would otherwise be waste material into a functional product element

Inventive Principle:

Principle #34Discarding and recovering

2Reliability

If release paper is used in cement board manufacturing, then material buildup on equipment is prevented, but environmental footprint increases

Engineering Contradiction:

Improveequipment performanceVSAvoidenvironmental footprint

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The invention removes the release paper element that causes environmental harm while retaining the equipment protection function through the multi-ply facing material design where the first ply prevents material buildup without requiring disposal

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention converts the potential harm of waste generation into a benefit by making the facing material itself the release surface, so that the material that would have been waste now serves as a functional component with protective properties

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of operation

If release paper is removed after cement board sets, then the board can be finished, but production time is lost and efficiency decreases

Engineering Contradiction:

Improveproduct completionVSAvoidproduction time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The invention performs preliminary action by designing the multi-ply facing material structure in advance so that the first ply serves dual purposes as both forming surface and final product component, eliminating the need for post-setting removal operations

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The first ply of the facing material serves multiple functions: it acts as the release surface during forming, provides structural reinforcement, and remains as part of the finished product, eliminating the need for separate release paper and removal operations

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This solution reduces waste, enhances product manufacturability, improves production efficiencies, and provides enhanced sustainability attributes for both the product and the manufacturing process.

Implementation Method 1

a slurry-permeable first lamina embedded in the longitudinal edge face, an entire width of the first major face from the first longitudinal edge face to the second longitudinal edge face, and at least opposed first and second end portions of the second major face

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

a slurry-impermeable second lamina bonded to the first lamina with opposed surfaces, each of the opposed surfaces of the slurry-impermeable second lamina directly bonded to a respective lamina of the plurality of laminas

Methodology Applied

Scientific EffectPermeability resistance: Semipermeable Membrane

Data Source

PatentUS20250162283A1Cement panel and method to eliminate release paper from cement panel manufacture

Publication Date: 2025.05.22 UNITED STATES GYPSUM CO

AI summary

A building composite panel including a core of a continuous phase comprising hydraulic binder. The core has first and second opposed longitudinal edge faces, and opposed first and second major faces, each major face adjoining the first and second opposed longitudinal edge faces. A slurry-permeable reinforcing material is attached to the first major face. A non-woven polymer fabric laminate facing material, that is different from the reinforcing material, covering and attached to and traversing the first major face and covering and attached to the opposed longitudinal edges of the core. The facing material includes a plurality of bonded laminas, wherein the plurality includes a first and second water-permeable laminas on opposed outer sides of the facing material, and a water-impermeable lamina between the first and second water-permeable laminas. The first water-permeable lamina attached to the core. A method for making the panel is also provided.