Moisture-Resistant Foam Building Board with Reinforced Layers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing building boards coated with cement mortar or nonwoven fabric tend to distort or warp when exposed to moisture, making plane-parallel installation on walls impossible.
Innovation Solution
A building board design featuring a moisture-resistant foam-material core layer with a glued-on water-resistant paper sheet or non-stretchable plastic film on both sides, reinforced with a lattice material web and a nonwoven fabric web to prevent length changes and warping, while maintaining bending resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If building boards are coated with cement mortar or nonwoven fabric to provide reinforcement, then the board gains sufficient bending resistance, but the board distorts or warps when exposed to moisture
Solution Approach 1:
The patent applies composite materials by combining a foam core layer with two different types of reinforcement layers: a water-resistant paper web layer that prevents moisture-induced distortion, and a nonwoven fabric layer that provides bending resistance. This multi-layer composite structure resolves the contradiction by assigning different functional properties to different layers - the paper web layer handles moisture stability while the nonwoven fabric layer handles mechanical strength.
Solution Approach 2:
The patent applies local quality by giving different regions of the building board different properties: the water-resistant paper web is applied to the side exposed to moisture to prevent distortion, while the nonwoven fabric is applied to the opposite side to provide bending resistance. Each layer is strategically positioned to address specific local requirements, resolving the contradiction between moisture stability and structural strength.
2Productivity
If the board is made thinner to reduce material usage, then productivity and cost improve, but the board becomes more susceptible to distortion and lacks sufficient bending resistance
Solution Approach 1:
The patent uses composite materials to achieve high reliability in thin boards by combining a foam core with two specialized reinforcement layers. The water-resistant paper web and nonwoven fabric layers work together to provide both distortion prevention and bending resistance, enabling thin board construction without sacrificing reliability.
Solution Approach 2:
The patent applies parameter changes by modifying the structural parameters of the board - using a thin foam core layer (reducing material usage) compensated by the addition of reinforcement layers with optimized properties. The paper web and nonwoven fabric layers provide the necessary mechanical properties that would otherwise require much thicker material, thus improving productivity while maintaining reliability.
3Stability of the object's composition
If water-resistant paper web or non-stretchable plastic film is glued onto both sides of the foam core layer, then the board becomes unchanged in length under moisture impact, but the device complexity increases
Solution Approach 1:
The patent applies flexible shells and thin films by using water-resistant paper webs and non-stretchable plastic films as thin reinforcement layers. These thin film layers provide effective moisture protection and length stability without adding significant complexity, as they are applied directly to the foam core using standard gluing processes.
Solution Approach 2:
The patent resolves the complexity issue by creating a systematic composite structure where each layer serves a specific function. The water-resistant paper web layer addresses length stability, while the nonwoven fabric layer addresses bending resistance. This functional division within the composite structure makes the multi-layer design manageable and justifies the increased layer count through clear functional benefits.
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 solution ensures the building board remains unchanged in length and prevents distortion, providing a stable moisture-resistant substrate for surface claddings and sufficient bending resistance for installation on stud frames.
Implementation Method 1
a water-resistant paper sheet (2) or a non-stretchable plastic film is glued onto both sides of this foam-material core layer (1)
Implementation Method 2
the building board covered in such a manner becomes unchangeable in length even in case of unintentional moisture impact, since the glued-on water-resistant paper web or the non-stretchable plastic web cannot change in length
Implementation Method 3
By means of directly gluing paper webs or thin, non-stretchable plastic webs onto both sides of the foam-material core layer
Implementation Method 4
this web then forms the suitable carrier, as an adhesion base for the adhesive of a surface cladding or ceramic tiles
Data Source
AI summary
Building board for use as a carrier for a surface cladding of ceramic tiles, a stucco, or a thin-layer trowel mortar, on or in buildings, in which on a moisture-resistant and moisture-sealed foam-material core layer, there is glued on both sides a water-resistant paper web or thin plastic web, onto which webs in each case a web of nonwoven fabric or of a knitted or loom-knitted woven fabric is glued.