Construction panel and method for their preparation and their use
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Solution Overview
Problem
Existing building boards have unfavorable energy balance, limited recycling possibilities, and are costly due to energy-intensive production and disposal, while also failing to meet the specific insulation and moisture-resistant requirements of damp rooms.
Innovation Solution
A composite building board with a rigid foam core made of polyethylene terephthalate, optionally reinforced with protective layers and a sealing element, which is recyclable and compatible with CO2-reduced mortars, offering excellent mechanical properties and insulation performance, and can be produced with a low environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional building boards made of extruded polystyrene or expanded polystyrene are used, then thermal insulation and moisture resistance are achieved, but energy balance becomes unfavorable and recycling possibilities are limited
Solution Approach 1:
The patent changes the material parameter from traditional polystyrene foam to polyethylene terephthalate (PET) foam, which maintains the required thermal insulation and moisture resistance properties while improving energy balance and recyclability. The PET foam core provides comparable insulating properties to polystyrene but with better environmental characteristics throughout the product lifecycle.
Solution Approach 2:
The patent employs a composite structure combining PET foam core with protective layers and sealing elements. This composite approach allows optimization of individual material properties - the PET foam provides insulation and structural stability, while additional layers enhance moisture protection and recyclability, achieving both performance and sustainability goals.
2Reliability
If traditional building boards are used, then insulation properties are achieved, but disposal and recycling costs increase
Solution Approach 1:
The patent implements a design focused on material recovery and recycling. The PET foam core and protective layers are selected specifically for their recyclability, enabling recovery of valuable materials at end-of-life. This reduces disposal costs and creates economic value from what would otherwise be waste, addressing both environmental and economic aspects of material loss.
3Reliability
If rigid foam boards with closed-cell structure are used, then water and moisture resistance are achieved, but production energy intensity increases
Solution Approach 1:
The patent changes the foam material parameter from energy-intensive polystyrene to PET foam, which achieves comparable closed-cell structure and moisture resistance with lower production energy intensity. This parameter change in the base material maintains the required water and moisture resistance while improving the overall energy balance of the building board.
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 board provides long-term stability, moisture resistance, and improved energy efficiency, making it suitable for damp rooms with enhanced sealing capabilities and recyclability, while maintaining structural integrity and insulation performance.
Implementation Method 1
the building boards must have corresponding insulating properties... expanded polystyrene is used as a single-layer board for thermal and impact sound insulation... a rigid foam board made of polyethylene terephthalate is used as the core
Implementation Method 2
Both of these rigid foam materials have a low density and a closed-cell structure. They are resistant to water and moisture.
Data Source
Figure 1
AI summary
A three-dimensional building panel 1 is described for constructing a wall, for cladding an existing wall or ceiling, or for constructing a floor on an existing floor slab or floor slab in buildings. The building panel 1 comprises a composite panel 2 with a rigid foam board 3 as its core and at least one protective layer 4', 4" applied to a surface of the rigid foam board 3. The rigid foam board 3 is made of polyethylene terephthalate, and the building panel 1 includes a sealing element 5 for creating a waterproof layer. A method for manufacturing such a building panel 1 and various uses of the building panel 1 are also described.