Breakage-Resistant Composite Wall Panel with Metal Sheet
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Solution Overview
Problem
Existing penetration-resistant composites for stud walls, roofs, and ceilings are still vulnerable to intentional breakthroughs, as they are relatively easy to breach despite multiple layers connected via various means.
Innovation Solution
A composite structure comprising a cardboard-covered gypsum board, a metal sheet, and a gypsum fiber board, where the gypsum fiber board acts as a first hurdle, and the metal sheet represents a second hurdle, with a strong bond between them, including adhesive bonding or alternative fastening methods, creating a stable and difficult-to-penetrate assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple layers are connected by shear connectors (screws, nails, rivets), then the composite structure achieves structural integrity, but the structure remains vulnerable to deliberate breakthroughs
Solution Approach 1:
The patent employs a composite structure consisting of a gypsum fiberboard layer bonded to a metal sheet layer. This composite material approach creates a synergistic effect where the gypsum fiberboard provides mass and structural continuity while the metal sheet provides tensile strength and puncture resistance, together achieving penetration resistance that neither material could achieve alone.
Solution Approach 2:
The patent specifies particular parameter ranges for the gypsum fiberboard including density of 800-3000 kg/m³, thickness of 20-50 mm, and compressive strength of 15-50 MPa. By optimizing these parameters, the gypsum fiberboard achieves sufficient density and strength to resist penetration while maintaining structural integrity when bonded to the metal sheet.
2Reliability
If the composite structure uses heavier protective layers (gypsum fiberboard), then penetration resistance improves, but the overall weight of the assembly increases
Solution Approach 1:
The patent combines gypsum fiberboard with a metal sheet to create a composite structure that achieves high penetration resistance without requiring excessive weight from the gypsum layer alone. The metal sheet provides additional strength-to-weight ratio, allowing the gypsum fiberboard to be optimized for penetration resistance while the overall assembly weight remains manageable.
Solution Approach 2:
The patent applies gypsum fiberboard with specific local properties (density 800-3000 kg/m³, thickness 20-50 mm) only where penetration resistance is required, rather than uniformly increasing the weight of the entire assembly. The metal sheet is bonded to provide localized reinforcement at critical points.
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 composite structure significantly enhances burglary and escape security by creating a multi-layered, stable, and lightweight assembly that is challenging to break through, achieving classification in burglar-resistant standards such as class B according to VdS 2534 and bullet resistance class FB4 NS.
Implementation Method 1
at least one second gypsum board designed as a gypsum fiberboard arranged on the metal sheet... The bonding can be applied over the entire surface... to bond the first gypsum board to the metal sheet
Data Source
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AI summary
The present invention relates to a breakage-resistant composite material (10, 11) composed of multiple superposed layers, more particularly as panelling for a stud wall, roof or ceiling structure, the composite material comprising at least one first gypsum board panel (17) in the form of a paperbound gypsum board panel, at least one metal sheet (18) placed on the first gypsum board panel, and at least one second gypsum board panel (19), in the form of a gypsum fibreboard panel, placed on the metal sheet.