Cementitious Board Reinforcing Layer with Non-Porous Membrane

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Solution Overview

Problem

Cementitious boards, which are used in the construction industry, face challenges with the brittleness of hydraulic gypsum and cement, requiring reinforcement to enhance tensile and flexural strength, and existing glass scrim reinforcements have limitations in mechanical properties and durability.

Innovation Solution

A reinforcing layer for cementitious boards is introduced, comprising an alkali-resistant fabric and a non-porous membrane, which provides improved mechanical properties and resistance to environmental degradation, with the non-porous membrane having a water vapor permeance of less than 0.5 perm and a breaking strength greater than 170 psi, enhancing the board's waterproofing and dimensional stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If glass fiber scrim with PVC plastisol coating is used as reinforcement, then tensile strength is improved, but mechanical properties and durability are limited

Engineering Contradiction:

Improvetensile strengthVSAvoiddurability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent uses a composite reinforcing layer combining alkali-resistant fabric with a non-porous membrane coating. This composite structure provides both the tensile strength needed from the fabric and the durability/water resistance from the membrane, resolving the contradiction between strength and reliability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The non-porous membrane acts as a thin film coating on the alkali-resistant fabric, providing a protective barrier that enhances durability and water resistance while maintaining the underlying fabric's tensile strength properties.

Inventive Principle:

Principle #30Flexible shells and thin films

2Strength

If glass fiber scrim is embedded in cement board, then mechanical properties are improved, but waterproofing is insufficient

Engineering Contradiction:

Improvemechanical propertiesVSAvoidwaterproofing

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The non-porous membrane functions as a waterproof thin film that prevents water penetration while allowing vapor transmission. When combined with the alkali-resistant fabric, it creates a reinforcing layer that provides both mechanical strength and waterproofing capabilities.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The composite structure of fabric combined with non-porous membrane creates a multi-functional reinforcing layer that simultaneously provides mechanical reinforcement and waterproofing, eliminating the need for separate waterproofing layers.

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If separate waterproofing steps are used, then waterproofing is achieved, but installation time increases

Engineering Contradiction:

ImprovewaterproofingVSAvoidinstallation time

Core Design Contradiction:

Object-affected harmful factorsVSLoss of time

Solution Approach 1:

The patent merges the reinforcing layer and waterproofing function into a single integrated component. The non-porous membrane in the reinforcing layer provides waterproofing while the fabric provides reinforcement, eliminating the need for separate waterproofing steps and reducing installation time.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The reinforcing layer is designed to perform multiple functions simultaneously: mechanical reinforcement from the fabric, waterproofing from the non-porous membrane, and alkali resistance from the fabric. This multi-functionality eliminates the need for separate waterproofing operations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Adaptability or versatility

If porous materials are used for reinforcement, then breathability is improved, but water resistance decreases

Engineering Contradiction:

ImprovebreathabilityVSAvoidwater resistance

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The non-porous membrane acts as a selective barrier that blocks liquid water while allowing water vapor to pass through. This thin film structure provides both water resistance and breathability, resolving the contradiction between these two properties.

Inventive Principle:

Principle #30Flexible shells and thin films

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 reinforcing layer significantly improves the mechanical performance of cementitious boards by providing enhanced tensile strength, waterproofing, and resistance to alkali environments, ensuring improved durability and performance in moisture-rich conditions without mold growth, and facilitating faster installation by eliminating the need for separate waterproofing steps.

Implementation Method 1

a non-porous membrane having a water vapor permeance of less than 0.5 perm

Methodology Applied

Scientific EffectPermeation: Permeation

Implementation Method 2

an alkali-resistant fabric

Methodology Applied

Scientific EffectChemical resistance:

Data Source

PatentUS11865820B2Reinforcing layer, a cementitious board, and method of forming the cementitious board

Publication Date: 2024.01.09 SAINT GOBAIN ADFORS CANADA LTD

AI summary

A reinforcing layer for a cementitious board includes an alkali-resistant fabric and a non-porous membrane. The cementitious board includes (a) a cementitious core; and (b) the reinforcing layer disposed on at least one face of the cementitious core, the reinforcing layer including the alkali-resistant fabric and the non-porous membrane.