Composite Structural Board with Foam Core and Cement Coating

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Solution Overview

Problem

Traditional structural block systems, roof membrane systems, and floor systems face issues such as mortar deterioration, lack of fire and wind resistance, low thermal insulation, and susceptibility to rot and mold growth, while existing deck systems are prone to cracking and require frequent maintenance.

Innovation Solution

A structural system comprising staggered foam core blocks with external coating plates and cement columns, a waterproof membrane system with alternating insulative and membrane layers, and a composite structural board with a wood core and resilient cement coating, which provides enhanced fire resistance, insulation, and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional mortar and wood materials are used in structural block systems, then ease of manufacture and initial cost are improved, but fire resistance, wind resistance, and durability deteriorate

Engineering Contradiction:
Improveease of manufactureVSAvoidfire resistance
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The patent employs composite materials by combining foam core blocks (providing insulation) with cementitious coating plates (providing fire and wind resistance). This composite structure resolves the contradiction by integrating materials with complementary properties: the foam provides thermal insulation while the cement coating provides fire resistance and durability, achieving both ease of manufacture and high reliability.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by using different materials for different functional requirements within the same structural block. The foam core provides insulation in the interior, while the cement coating plates provide fire and wind resistance on the exterior surfaces. This localized material assignment resolves the contradiction by optimizing each region for its specific function.

Inventive Principle:
Principle #3Local quality

2Ease of manufacture

If traditional wood deck systems are used, then ease of manufacture and initial cost are improved, but durability and resistance to rot and mold deteriorate

Engineering Contradiction:
Improveease of manufactureVSAvoiddurability
Core Design Contradiction:
Ease of manufactureVSDuration of action of stationary object

Solution Approach 1:

The patent uses composite materials in deck blocks by combining foam core (for insulation and light weight) with cementitious coating plates (for durability and rot/mold resistance). This composite construction resolves the contradiction by replacing traditional wood with a material combination that provides both ease of manufacture and enhanced durability against environmental degradation.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent replaces traditional wood deck materials with synthetic foam core blocks that have extended service life and resistance to rot and mold. This substitution resolves the contradiction by using materials that, while requiring specialized manufacturing, provide significantly longer duration of action and reduced maintenance needs compared to traditional wood.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

3Strength

If cement is poured through aligned cavities in traditional block systems, then structural binding is improved, but thermal insulation deteriorates

Engineering Contradiction:
Improvestructural bindingVSAvoidthermal insulation
Core Design Contradiction:
StrengthVSTemperature

Solution Approach 1:

The patent applies segmentation by dividing the block structure into distinct functional zones: foam core sections for thermal insulation and cementitious coating plates for structural binding. The aligned columnar apertures create discrete cement columns that provide structural binding without completely filling the block interior, thereby preserving thermal insulation properties while achieving structural integrity.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent uses local quality by concentrating cementitious material only in specific regions (coating plates and columnar apertures) where structural binding is needed, while leaving the majority of the block interior as foam core for thermal insulation. This localized material distribution resolves the contradiction by optimizing material placement for dual functionality.

Inventive Principle:
Principle #3Local quality

4Duration of action of stationary object

If plastic wood boards are used as deck material, then durability is improved, but cost and susceptibility to structural damage over time worsen

Engineering Contradiction:
ImprovedurabilityVSAvoidstructural damage
Core Design Contradiction:
Duration of action of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The patent uses composite materials with foam core and cementitious coating that provide both durability and resistance to structural damage. The foam core provides impact absorption and flexibility, while the cement coating provides surface durability and resistance to environmental factors, resolving the contradiction by combining materials with complementary protective properties.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent incorporates foam core material that provides beforehand cushioning by absorbing impacts and thermal stresses before they can cause structural damage to the deck system. This preventive cushioning mechanism resolves the contradiction by protecting the structure from harmful factors while maintaining durability.

Inventive Principle:
Principle #11Beforehand cushioning (Prior cushioning)

5Duration of action of stationary object

If stone panels and concrete layers are used in flooring systems, then durability is improved, but susceptibility to cracking and fissures worsens

Engineering Contradiction:
ImprovedurabilityVSAvoidcracking resistance
Core Design Contradiction:
Duration of action of stationary objectVSStability of the object's composition

Solution Approach 1:

The patent applies local quality by using foam core material in the interior of deck blocks where flexibility and crack resistance are needed, while using cementitious coating plates only on exterior surfaces where durability and surface strength are required. This localized material assignment resolves the contradiction by providing crack resistance where needed without sacrificing overall durability.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent changes the physical parameters of the deck material by using foam core with high compressibility and flexibility, allowing the structure to accommodate thermal expansion and contraction without cracking. This parameter change resolves the contradiction by providing durability through materials that can dynamically adjust to environmental changes.

Inventive Principle:
Principle #35Parameter changes

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 proposed systems offer improved fire resistance, increased durability, and reduced maintenance needs, with the structural system providing high flexural strength and insulation, and the membrane system ensuring water tightness and longevity, while the composite board addresses the challenges of traditional deck systems with enhanced durability and aesthetic appeal.

Implementation Method 1

Each foam core comprises insulative expanded polymeric foam

Methodology Applied
Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

A plurality of cement columns extended through adjacent rows of the plurality of blocks via aligned columnar apertures

Methodology Applied
Scientific EffectCement bonding: Chemical Bonding

Implementation Method 3

a plurality of membrane layers, each being flexible and waterproof

Methodology Applied
Scientific EffectWaterproofing: Hydrophobe

Data Source

PatentUS20240218659A1Structural block systems, roof membrane systems, composite structural boards, floor and deck systems, and related methods
Publication Date: 2024.07.04 YIGIT MEHMET
  • US20240218659A1 patent drawing
  • US20240218659A1 patent drawing
  • US20240218659A1 patent drawing

AI summary

A composite structural board has a wood board core; an internal mesh layer encasing the wood board core; and an external resilient cement coating. A driveway system has a cement base layer embedded with a plasticizing layer that comprises polymeric material; a stone panel layer, comprising a plurality of stone panels laid side-by-side; and an external overlayer.