Isocyanate-Free Gel Binder for Masonry Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional masonry construction methods using mortar or polyurethane foam face challenges such as long preparation and drying times, sensitivity to weather conditions, and the use of toxic isocyanates, which limit their effectiveness and safety.
Innovation Solution
A method employing a binder in the form of a gel or putty free from isocyanates, encapsulated in a protective film that maintains its integrity and releases upon contact, allowing for quick and safe assembly under various conditions without the need for immediate placement, providing enhanced adhesion and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If polyurethane foam binder is used, then application is easier and drying time is reduced, but retraction is rapid reducing bonding power and elements must be placed immediately
Solution Approach 1:
The patent changes the physical and chemical parameters of the binder by using a gel-based composition with specific viscosity ranges (50-5000 Pa.s) and controlled retraction rates (0.1-5 mm/min), replacing the rapid-setting polyurethane foam. This allows extended working time while maintaining bonding effectiveness.
Solution Approach 2:
The invention uses a composite gel binder system combining water, thickening agents, adhesion promoters, and optional polymeric materials to create a binder with balanced properties - sufficient retraction for bonding but controlled enough to maintain adhesive strength during assembly.
2Ease of operation
If polyurethane foam binder is used, then application is easier, but in windy weather the foam does not remain in place and gluing becomes impossible
Solution Approach 1:
The gel binder's viscosity parameters (50-5000 Pa.s) and controlled retraction rate (0.1-5 mm/min) provide resistance to wind and environmental factors while maintaining ease of application, unlike volatile polyurethane foam that cannot remain in place under windy conditions.
Solution Approach 2:
The gel binder's inherent viscosity and adhesion properties provide a cushioning effect that prevents the binder from being blown away or degraded by weather conditions before the elements are assembled, ensuring reliable bonding regardless of external conditions.
3Productivity
If polyurethane foam is used, then binding speed is improved, but isocyanates are released which are toxic and reactive
Solution Approach 1:
The invention extracts and removes the harmful isocyanate component from the binder system entirely, using a water-based gel composition with thickening agents and adhesion promoters that provides equivalent bonding performance without toxic byproducts or vapor release.
Solution Approach 2:
The patent converts the potential harm of rapid setting (which causes isocyanate release issues) into a benefit by using a gel system that sets at a controlled rate, maintaining productivity while eliminating the toxic release problem through fundamentally different chemistry.
4Strength
If traditional mortar is used, then structural strength is achieved, but preparation time is long (about 1 hour) and drying time is extended (7 to 28 days)
Solution Approach 1:
The gel binder achieves structural strength comparable to traditional mortar but with dramatically reduced preparation time (no mixing required) and drying time (controlled retraction within minutes rather than weeks), due to its pre-mixed gel formulation and controlled evaporation rate.
Solution Approach 2:
The invention replaces the mechanical mixing and prolonged curing process of traditional mortar with a pre-formulated gel system that requires only application and controlled retraction, eliminating the need for extensive preparation and waiting time while maintaining structural integrity.
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
Enables non-toxic, efficient, and durable masonry assembly with reduced shrinkage and creep, allowing for flexible installation times and improved performance over traditional binders, while avoiding the hazards associated with isocyanates.
Implementation Method 1
when it is applied to the first construction element and in contact with air, a protective film encapsulating the composition of said binder can form
Implementation Method 2
at least a first construction element and at least a second construction element bonded to each other by a binder
Data Source
Figure 1A~6B
Figure 7~12
Figure 13~21
AI summary
The invention relates to a method for assembling a building assembly (100) comprising at least one first building element (1) and at least one second building element (2) bonded to each other by a binder (3), said assembly method comprising the following steps: - supply of the first building element, - supply of the binder, - application of the binder to at least a portion of a surface of the first building element intended to be in contact with the second building element of the building assembly, the binder being in the form of a gel or a sealant, said binder having a composition free of isocyanates or free of reactive isocyanates, - supply of the second building element,- bringing the bonded surface of the first building element into contact with at least a portion of a surface of the second building element so that the bonding agent is at least partially arranged between the first and second building elements, - joining the two building elements by applying pressure.