Layered Formed Sheet Composition for Strong, Stable Cement Boards
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Solution Overview
Problem
Existing cementitious boards produced by a paper-making method lack sufficient bending strength and dimensional stability, and there is a need for a more environmentally friendly alternative with improved properties.
Innovation Solution
A layered formed sheet composed of a curable composition containing an aluminosilicate source, alkaline metal hydroxide, cellulose-based fibers, and alkali-resistant fibers, with a specific surface area of blast furnace slag between 1000 cm²/g to 9000 cm²/g, and optimized proportions of these components to enhance bending strength and dimensional stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a paper-making method is used to produce cementitious boards, then the production process is simple and versatile, but the bending strength and dimensional stability are insufficient
Solution Approach 1:
The patent uses a composite material system consisting of aluminosilicate source, alkaline metal hydroxide, and dual fiber reinforcement (cellulose-based and alkali-resistant fibers). This composite approach resolves the contradiction by combining multiple materials with complementary properties to achieve both ease of manufacture and high bending strength.
Solution Approach 2:
The patent changes the chemical and physical parameters of the slurry composition, specifically using aluminosilicate source with controlled specific surface area (1000-9000 cm²/g) and optimized component ratios. This parameter optimization enables the paper-making process to produce boards with sufficient bending strength while maintaining manufacturing simplicity.
2Strength
If cementitious materials are used, then the board has sufficient strength, but huge energy is required and large amount of carbon dioxide is discharged
Solution Approach 1:
The patent converts the typically waste material (blast furnace slag) into a valuable aluminosilicate source for board production. This transforms an environmental burden into a beneficial resource, achieving both strength requirements and environmental friendliness by eliminating the need for high-energy cement production.
Solution Approach 2:
The patent uses readily available, low-cost materials such as blast furnace slag, fly ash, and natural fibers instead of expensive, energy-intensive cement. These materials provide sufficient strength for architectural applications without requiring the huge energy input needed for cement production.
3Object-generated harmful factors
If blast furnace slag is blended in small amounts, then the production is environment-friendly, but the bending strength is poor and dimensional stability is insufficient
Solution Approach 1:
The patent optimizes the specific surface area parameter of the blast furnace slag to be between 1000-9000 cm²/g, which significantly enhances the reactivity and strength contribution of the slag. This parameter control allows using 30-53% blast furnace slag (environmentally friendly) while achieving sufficient bending strength through improved surface area-to-volume ratio.
Solution Approach 2:
The patent creates a composite system where blast furnace slag works synergistically with fly ash, alkaline metal hydroxide, and dual fiber reinforcement. This composite approach ensures that even at moderate slag content levels, the combined effect of all components achieves both environmental friendliness and high bending strength with dimensional stability.
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 layered formed sheet achieves high bending strength, impact strength, and dimensional stability, utilizing waste materials like blast furnace slag effectively, and reducing environmental impact.
Implementation Method 1
a cured composite of a mat produced by dehydrating a slurry which contains a blast furnace slag... an alkaline material... and an inorganic admixture
Implementation Method 2
a mat produced by dehydrating a slurry which contains a blast furnace slag
Implementation Method 3
forming the dehydrated product... a cured composite
Data Source
AI summary
The present invention relates to a layered formed sheet comprising two or more formed sheets each formed from a curable composition comprising (A) an aluminosilicate source, (B) an alkaline metal hydroxide, (C) cellulose-based fibers and (D) alkali-resistant fibers other than cellulose-based fibers, in which the aluminosilicate source (A) comprises a blast furnace slag, and the content of a blast furnace slag having a specific surface area of 1000 cm2/g or more and 9000 cm2/g or less is more than 55% by mass and 90% by mass or less related to a total solid content in the curable composition.