Reinforced Polyurethane Substrate with Penetrating Cementitious Coating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need to enhance the production methods and properties of organic-inorganic composite materials for building applications, particularly in achieving improved mechanical and weathering stability, which existing methods have not adequately addressed.
Innovation Solution
The method involves creating a reinforced substrate by applying a fabric material to a substrate, followed by a hydrophobic polymeric woven mesh, and then a cementitious coating, which penetrates the mesh and fabric, forming a strong bond after curing, using a polyurethane or polyisocyanurate foam with inorganic fillers like fly ash, and optionally applying a facing material to the second surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fabric material is applied to the substrate to improve tensile properties and weathering resistance, then the mechanical strength and durability are enhanced, but the production process complexity increases
Solution Approach 1:
The fabric material is applied to the substrate surface before the coating is applied, preparing the surface in advance to receive the coating. This preliminary positioning allows the coating to subsequently penetrate and bond with the fabric, achieving enhanced tensile properties and weathering resistance without requiring complex post-processing steps.
Solution Approach 2:
The invention creates a composite structure by combining the fabric material with the coating material that penetrates it. The fabric provides tensile strength and weathering resistance, while the coating provides rigidity and toughness, forming an integrated composite material system that achieves multiple properties simultaneously.
2Strength
If an inorganic coating is applied to penetrate the fabric material to improve rigidity and toughness, then the mechanical properties are enhanced, but the manufacturing complexity increases
Solution Approach 1:
The fabric material acts as a porous structure that allows the coating material to penetrate through it. This porosity enables the coating to infuse into the fabric, creating a bonded composite structure that enhances rigidity and toughness while maintaining a relatively simple manufacturing process where the coating is simply applied and allowed to penetrate.
Solution Approach 2:
The fabric material is positioned on the substrate before the coating is applied, preparing the structure in advance. This preliminary arrangement allows the coating to penetrate and bond with the fabric during the normal coating application process, avoiding the need for complex subsequent bonding operations.
3Strength
If a hydrophobic polymeric woven mesh is applied to improve structural reinforcement, then the mechanical strength is enhanced, but the production process complexity increases
Solution Approach 1:
The hydrophobic polymeric woven mesh is merged with the fabric material and substrate in a single integrated structure. The mesh is applied over the fabric, and the coating penetrates both layers simultaneously, combining multiple reinforcement functions into one unified production step rather than requiring separate operations for each layer.
Solution Approach 2:
The woven mesh is positioned on the substrate before the coating is applied, preparing the reinforcement structure in advance. This allows the coating to penetrate and bond with the mesh during the normal coating process, achieving structural reinforcement without requiring complex post-application bonding steps.
4Reliability
If multiple layers of materials are applied to the substrate to improve mechanical properties and weathering stability, then the composite material performance is enhanced, but the production time increases
Solution Approach 1:
Multiple layers including fabric material and woven mesh are positioned on the substrate before the coating is applied. This preliminary arrangement of all layers allows the coating to penetrate and bond with all layers simultaneously in a single operation, achieving enhanced weathering stability without requiring multiple separate bonding steps that would increase production time.
Solution Approach 2:
The coating application process is merged with the penetration and bonding process for multiple layers. Instead of applying and bonding each layer separately, the coating is applied once and penetrates through all layers (fabric, mesh, and substrate) simultaneously, combining multiple functions into one production step and reducing overall production time.
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 approach results in building materials with increased flexural strength, hardness, stiffness, and flame resistance, suitable for various structural applications, such as tile backers, sheathing, and roofing products, while maintaining a lightweight density.
Implementation Method 1
applying a coating to the hydrophobic polymeric woven mesh thereby allowing the coating to penetrate the hydrophobic polymeric woven mesh and fabric material
Implementation Method 2
curing the coating thereby bonding the fabric material to the first surface of the substrate
Data Source
AI summary
Methods for producing building materials comprising a reinforced substrate are described herein. The method can include providing a substrate having a first surface and an opposed second surface, applying a fabric material to the first surface of the substrate, applying a hydrophobic polymeric woven mesh to the fabric material, applying a coating to the hydrophobic polymeric woven mesh thereby allowing the coating to penetrate the hydrophobic polymeric woven mesh and fabric material, removing the hydrophobic polymeric woven mesh, and curing the coating thereby bonding the fabric material to the first surface of the substrate. The substrate can include a polymeric material. In some embodiments, the substrate can include a polyurethane foam. The substrate can further include a filler. The hydrophobic polymeric woven mesh used in the building materials can be derived from alkylene monomers.