Plate-type component with an outer membrane
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Solution Overview
Problem
Existing methods for producing plate-shaped components often result in blistering and air bubble formation due to air components in mineral mortars, leading to imperfections in the adhesive bond and compromised impermeability.
Innovation Solution
A method involving a cover layer with defined air permeability, typically between 6.0 and 21 l/dm²/min, is used to ensure gases can escape during curing, utilizing a prefabricated composite of mineral or polymer adhesive with a textile section, preventing bubble formation and achieving a full-surface adhesive connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a closed sealing film is applied to a carrier using mineral mortar adhesive, then adhesive bond strength is improved, but air bubbles are trapped causing blistering and reducing adhesive bond area
Solution Approach 1:
The patent applies a porous top layer with defined air permeability (6.0-21 l/dm²/min) that allows air bubbles to escape during the adhesive bonding process. This porous structure resolves the contradiction by enabling gas permeability while maintaining the adhesive bond, preventing blistering and ensuring full-surface contact between the film and carrier.
2Ease of manufacture
If mineral mortar adhesive is used to bond the film, then adhesive connection is achieved, but air components in the mortar form bubbles that cannot escape through impermeable film or rigid foam
Solution Approach 1:
The patent converts the harmful air bubbles generated by mineral mortar adhesive into a beneficial process by designing the top layer with controlled porosity. The air permeability of the top layer transforms the harmful trapped air into a controlled escape path, allowing bubbles to rise and exit during curing, thereby eliminating blistering while maintaining the ease of using mineral mortar adhesive.
3Reliability
If the top layer is made impermeable to ensure watertight bonding, then water resistance is improved, but gases released during curing cannot diffuse through the layer
Solution Approach 1:
The patent changes the permeability parameter of the top layer from completely impermeable to selectively permeable with defined air permeability (6.0-21 l/dm²/min). This parameter modification allows the layer to maintain water tightness while permitting gas diffusion during the curing process, resolving the contradiction between watertight bonding and gas release capability.
4Ease of operation
If adhesive layer contains air components for workability, then adhesive performance is improved, but bubbles are enclosed in place by hardening adhesive reducing bond area
Solution Approach 1:
The patent implements preliminary action by designing the top layer with predefined air permeability before the adhesive bonding process. This pre-configured porosity creates escape paths for air bubbles during the adhesive's working time, preventing bubble entrapment before it can reduce the effective bond area, thereby maintaining both adhesive workability and maximum bond strength.
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 a watertight and airtight bond without bubbles, enhancing the structural integrity and impermeability of the plate-shaped component.
Implementation Method 1
the top layer has an air permeability of between 6.0 and 21 l/dm2/min
Implementation Method 2
gases released on the one hand during the curing process diffuse through the nonwoven
Implementation Method 3
a full-surface adhesive connection of the top layer to the underlying layer
Implementation Method 4
during the curing process of the adhesive layer
Implementation Method 5
the composite of top layer and adhesive layer forming a waterproof composite
Implementation Method 6
the top layer in the hardened/bonded state and the overall structure of the plate-shaped component is impermeable to water and gas
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to a plate-type component (100, 100') with a sandwich structure, comprising the following: a support body (1) which is delimited by two flat faces (5, 5'); and at least one cover layer (3, 3') which is connected to the support body (1) on the flat face (5, 5') thereof by means of a mineral adhesive layer (2, 2'). According to the invention, the cover layer (3, 3') has an air permeability between 6.0 and 21 l/dm2/min in the non-assembled state, wherein the adhesive layer (2, 2') connected to the cover layer (3, 3') forms a watertight composite (6, 6'). The composite (6, 6') forms a barrier for adhesive particles which have not yet been cured and ensures that air can escape through the structure of the cover layer (3, 3') both during the placement of the cover layer as well as during the early stages of the curing process of the adhesive layer (2, 2'). The composite can be prefabricated. Furthermore, additional layers, such as a protective layer (11), can be applied onto the cover layer (3, 3'). The invention also relates to a method for producing a plate-type component (100, 100') and to the use of the cover layer (3, 3') for incorporation into a plate-type component (100, 100').