Composite building element
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Solution Overview
Problem
Existing construction elements for building surfaces, such as countertops, often face challenges with mechanical strength, thermal resistance, and handling due to their core materials, and either lack durability or are heavy and expensive.
Innovation Solution
A lightweight composite construction element featuring a sandwich-type panel with an expanded polyurethane core covered on all sides by a PVC, fiberglass-reinforced polyester resin, or high-pressure laminate (HPL) layer, topped with a 3 mm thick ceramic coating for enhanced mechanical, thermal, and acoustic resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If solid ceramic or stone materials are used for countertops, then thermal resistance and hardness are sufficient, but weight increases and handling becomes difficult
Solution Approach 1:
The patent applies composite materials by combining expanded polyurethane core (providing light weight) with PVC, fiberglass-reinforced polyester resin, or HPL facing layers (providing mechanical strength and thermal resistance), and optionally ceramic coating layers (providing enhanced thermal and chemical resistance). This composite structure achieves the thermal resistance of solid ceramic materials while maintaining the light weight and ease of handling of foam-based materials.
2Strength
If wood conglomerate core with plastic surface is used, then mechanical strength against scratches is achieved, but thermal resistance is insufficient
Solution Approach 1:
The patent uses a multi-layer composite structure where the wood conglomerate or foam core provides mechanical strength and structural integrity, the PVC or fiberglass-reinforced polyester resin facing layers provide thermal resistance and chemical resistance, and optional ceramic coating layers provide enhanced thermal and chemical resistance. This composite approach allows each layer to contribute its superior properties, achieving both mechanical strength and thermal resistance simultaneously.
3Weight of moving object
If expanded polyurethane core is used, then light weight and ease of handling are achieved, but mechanical strength and thermal resistance are insufficient
Solution Approach 1:
The patent combines expanded polyurethane core (providing light weight and ease of handling) with reinforced facing layers such as PVC, fiberglass-reinforced polyester resin, or HPL (providing mechanical strength and thermal resistance). The fiberglass reinforcement in the polyester resin layer specifically enhances mechanical strength while the multi-layer composite structure provides thermal resistance, thus maintaining the advantages of foam cores while compensating for their weaknesses.
4Reliability
If thicker facing layers are used to improve mechanical strength, then durability increases, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies different thicknesses and material compositions to different layers based on their specific functions. The facing layers are designed with optimal thickness (typically 0.5-2 mm) to provide sufficient mechanical strength and durability, while the core layers can be thicker to provide structural support and insulation. This localized optimization ensures each layer contributes efficiently to overall durability without unnecessary material usage or manufacturing complexity.
Data Source
AI summary
The invention relates to a lightweight composite building element which is easy to handle, has high thermal, mechanical and acoustic resistance, and is highly resistant to chemical products such as oils and detergents, or to microorganisms. Said element consists of a sandwich-type panel that includes an inner core consisting of rigid or expanded polyurethane coated on all of the faces thereof with a polyvinyl chloride (PVC) plastic resin, a glass-fibre-reinforced polyester resin, or a high-pressure-laminated (HPL) plate, and a layer of coating over the upper surface of the panel in the form of a finishing layer produced from a ceramic material.