Cementitious Panel Adhesion via Radiation Curing
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Solution Overview
Problem
The existing manufacturing processes for cementitious panels face issues with adhesive bleed-through and accumulation on equipment, leading to process downtime and defects in panel quality due to the use of porous facing materials.
Innovation Solution
The implementation of radiation-curable adhesives and the use of radiation-emitting devices to cure these adhesives during the manufacturing process, ensuring effective adhesion between facing materials without excessive bleed-through and equipment buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a porous facing material is used, then the facing material allows better moisture vapor transmission and breathability, but the adhesive bleeds through and accumulates on the surface of the facing material
Solution Approach 1:
The patent changes the chemical and physical parameters of the adhesive by using a two-part polyisocyanate system with specific molecular weight ranges and isocyanate content. This formulation allows the adhesive to achieve proper bonding while minimizing bleed-through through the porous facing material.
Solution Approach 2:
The patent uses a composite adhesive system consisting of two separate polyisocyanate components that are applied sequentially. This composite approach allows optimization of each component's properties to achieve both porosity compatibility and reduced bleed-through.
2Strength
If adhesive is applied to adhere sheets of facing material together, then the sheets are bonded effectively, but the adhesive accumulates on manufacturing equipment such as forming plates, rolls, and conveyor belts
Solution Approach 1:
The patent applies a first coat of adhesive, allows it to skin over or partially cure, and then applies a second coat. This preliminary action of the first coat creates a stable bonding layer that reduces subsequent adhesive migration and accumulation on equipment.
Solution Approach 2:
The patent uses a periodic application process where adhesive is applied in multiple stages with intermediate drying or skinning periods. This periodic action allows controlled bonding while minimizing continuous adhesive presence that would lead to equipment accumulation.
3Productivity
If a continuous manufacturing process is used, then production efficiency is high, but process downtime increases due to equipment cleanup and maintenance
Solution Approach 1:
The adhesive formulation and application method are designed to skin over quickly during the manufacturing process, creating a stable layer before the panel proceeds to the next stage. This preliminary stabilization reduces the frequency and duration of equipment cleanup operations.
Solution Approach 2:
The patent uses specific adhesive parameters including viscosity, solids content, and curing characteristics that allow the adhesive to set quickly enough to minimize equipment contamination while maintaining continuous production flow.
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 approach minimizes adhesive accumulation on manufacturing equipment and defects on panels, while providing a rapid curing process that enhances the bonding strength of cementitious panels.
Implementation Method 1
at least partly curing the radiation-curable adhesive with one or more beams of radiation emitting from one or more radiation-emitting devices
Data Source
AI summary
The present disclosure embraces cementitious panels, and systems and methods of manufacturing cementitious panels. An exemplary cementitious panel includes a cementitious core material, a plurality of sheets of facing material surrounding the cementitious core material, and a radiation-cured adhesive. An exemplary method of manufacturing a cementitious panel includes conveying a slurry of cementitious core material and a plurality of sheets of facing material, applying a radiation-curable adhesive to at least one of the sheets of facing material, forming a continuous length of cementitious panel material, at least partly curing the radiation-curable adhesive with one or more beams of radiation emitting from one or more radiation-emitting devices, and cutting the continuous length of cementitious panel material laterally to a desired length, providing a cementitious panel.