Polymer Foam Form Boards with Fibrous Facer for Waterproof Concrete Walls
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Solution Overview
Problem
Concrete walls used in underground structures face challenges with water seepage and thermal insulation due to their inherent non-waterproof and poor insulating properties, requiring additional measures for waterproofing and insulation post-construction.
Innovation Solution
A waterproofed concrete wall assembly is created using boards with a polymer foam layer and fibrous facer, where the concrete infuses into the fibrous layer during pouring, and shaped perimeter edges allow for overlapping and sealing with a sealant or tape, optionally including a waterproof membrane for enhanced protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If concrete walls are used for foundations and underground structures, then high strength and durability are achieved, but waterproofing and thermal insulation properties are insufficient
Solution Approach 1:
The patent combines the concrete wall structure with integrated waterproofing and insulation layers into a single composite wall assembly. The waterproofing membrane and insulation material are merged with the concrete formwork, creating a unified structure that provides both structural strength and protective functions simultaneously, eliminating the need for separate post-construction waterproofing layers.
Solution Approach 2:
The invention uses composite materials by combining concrete with waterproofing membranes and insulation materials in a multi-layer wall assembly. This composite structure integrates the high strength of concrete with the waterproofing and thermal insulation properties of additional materials, resolving the contradiction between structural strength and waterproofing reliability.
2Strength
If concrete walls are used for foundations and underground structures, then high strength and durability are achieved, but thermal insulation properties are insufficient
Solution Approach 1:
The patent merges thermal insulation material with the concrete formwork structure, integrating insulation into the wall assembly during construction. This combined structure provides both structural strength and thermal insulation properties, eliminating the need for separate post-construction insulation layers.
Solution Approach 2:
The invention employs composite materials by combining concrete with insulation materials to create a multi-layer wall assembly that simultaneously provides structural strength and thermal insulation, resolving the contradiction between these two properties.
3Reliability
If traditional waterproofing methods are applied post-construction, then waterproofing is achieved, but construction time and complexity increase
Solution Approach 1:
The patent applies waterproofing membrane and insulation material during the formwork stage, before concrete pouring. This preliminary action integrates waterproofing and insulation into the construction process itself, eliminating the need for separate post-construction waterproofing steps and reducing overall construction time.
Solution Approach 2:
By merging waterproofing and insulation functions into the formwork structure itself, the patent combines multiple construction steps into a single integrated process, reducing construction time and complexity while maintaining waterproofing reliability.
4Reliability
If separate waterproofing and insulation layers are added to concrete walls, then waterproofing and insulation are improved, but device complexity increases
Solution Approach 1:
The patent merges waterproofing membrane, insulation material, and concrete formwork into a single integrated wall assembly. This consolidation reduces the number of separate components and assembly steps, simplifying the overall structure while maintaining waterproofing and insulation performance.
Solution Approach 2:
The integrated wall assembly performs multiple functions simultaneously: structural support, waterproofing, and thermal insulation. This multi-functionality reduces the need for separate specialized layers, simplifying the overall device complexity while achieving all required performance goals.
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
This method provides a durable, thermally insulated, and waterproof concrete wall system that prevents water seepage and reduces the need for post-construction waterproofing, allowing for immediate exposure to elements and indefinite contact with backfill soil without the use of volatile organic compounds.
Implementation Method 1
the polymer foam of the polymer foam layer is a polyisocyanurate foam... the polyisocyanurate foam has a density between 2.5 lb/ft3 and 25 lb/ft3
Implementation Method 2
Some of the concrete is infused into the fibrous layer, the fibrous layer having been present during pouring of the concrete
Data Source
AI summary
Systems and methods for making a waterproofed concrete wall assembly, such as for a basement wall. A form is constructed. At least a first side of the form is made of one or more boards having a polymer foam and a fibrous facer. At least some of the boards have perimeter edges shaped such that some adjacent boards overlap at the shaped perimeter edges. Concrete is poured into the gap between the sides of the form, and is allowed to harden. The other side of the form may be removed, while leaving the boards of the first side of the form in place adjacent the hardened concrete. Some of the concrete is infused into the fibrous facers of at least some of the boards.