Inorganic Composite Boards for Construction Surfaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current construction materials for solid surfaces, such as wood, steel, stone agglomerates, glass agglomerates, and ceramic materials, face limitations including bacterial growth, fire risk, low scratch resistance, UV degradation, acid resistance, water absorption, and limited aesthetic possibilities, making them unsuitable for high-hygiene environments and outdoor use.
Innovation Solution
A method for producing large, compacted inorganic boards with enhanced properties: chemical resistance, high scratch resistance, incombustibility, recyclability, UV resistance, thermal stability, and aesthetic versatility, achieved through controlled metering and processing of inorganic materials, wet milling, color addition, drying, compaction, and firing, allowing for large size, mechanical strength, and thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wood is used as a construction surface, then it provides natural aesthetics and workability, but it promotes bacterial growth, easily catches fire, and requires periodic maintenance
Solution Approach 1:
The patent creates a composite material combining natural stone aggregates (providing aesthetics and durability) with a chemically resistant binder system (epoxy or polyester resin with specific additives) to achieve both workability and high reliability. The composite structure allows integration of multiple functionalities: mechanical strength from stone, chemical resistance from the binder, and fire resistance through specific formulation.
Solution Approach 2:
The patent modifies the chemical and physical parameters of the binder system by adjusting resin-to-hardener ratios, adding specific additives (fire retardants, antimicrobial agents), and controlling curing conditions to transform the material properties. This allows the surface to maintain natural stone aesthetics while achieving superior hygiene and fire resistance properties.
2Strength
If steel is used as a construction surface, then it provides high mechanical strength, but it has low scratch resistance and limited aesthetic possibilities
Solution Approach 1:
The patent combines metal aggregates or coatings with resinous binders to create a composite surface that maintains the high mechanical strength of metal while incorporating natural stone elements for aesthetic versatility. The composite structure allows for varied colorations, patterns, and surface treatments that steel alone cannot provide.
3Strength
If stone agglomerates using polyester resin are used, then they provide high scratch resistance and mechanical properties, but they degrade in appearance due to UV radiation
Solution Approach 1:
The patent modifies the chemical composition of the polyester resin system by adding UV stabilizers, antioxidants, and specific pigments with high UV resistance. It also adjusts the curing parameters and incorporates inorganic fillers to create a surface that maintains its mechanical properties while achieving UV stability for outdoor applications.
4Duration of action of stationary object
If cement-based stone agglomerates are used, then they provide outdoor durability, but they have low acid resistance and high water absorption
Solution Approach 1:
The patent fundamentally changes the binder chemistry from cement-based (alkaline, porous) to resin-based (chemically inert, less porous). This parameter change in the binding matrix eliminates the high water absorption and acid sensitivity of cement while maintaining outdoor durability through the resin's inherent weathering resistance and the protective surface finish.
5Adaptability or versatility
If glass agglomerates are used, then they provide aesthetic transparency, but they exhibit brittleness and low scratch resistance
Solution Approach 1:
The patent creates a composite where glass aggregates (providing transparency and aesthetics) are embedded in a resinous matrix (providing mechanical strength and scratch resistance). The resin binder acts as a protective medium that prevents the brittleness of glass while maintaining its optical properties, creating a material that is both aesthetically pleasing and mechanically robust.
6Adaptability or versatility
If natural stone is used, then it provides natural aesthetics, but it has high porosity, lower mechanical strength, and cannot produce large homogeneous products
Solution Approach 1:
The patent creates an artificial stone composite that mimics natural stone aesthetics using carefully selected and arranged natural stone aggregates, but binds them with high-strength resin systems. This composite approach allows production of large, homogeneous slabs with consistent appearance and superior mechanical properties compared to natural stone, while maintaining the desired natural aesthetic through aggregate selection and distribution control.
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 method results in boards that are chemically resistant, highly scratch-resistant, recyclable, and resistant to UV radiation and sudden temperature changes, with high mechanical strength and thermal insulation capacity, offering a wide range of aesthetic options and reduced joint requirements for easier installation, suitable for both indoor and outdoor environments.
Implementation Method 1
The mixture is compacted under vibration
Implementation Method 2
The compacted board is dried
Implementation Method 3
The compacted board is fired
Implementation Method 4
The compacted board is fired at a temperature not greater than 1600°C
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a method for the production of solid surfaces for construction, in particular large boards made from completely inorganic components, for use as kitchen worktops, bathroom surfaces, building cladding materials, flooring and for other uses related to the field of construction. The invention is suitable for both indoor and outdoor environments.