Seamless Waterproof Construction Boards with Integrated Membrane
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Solution Overview
Problem
Conventional water-resistant systems in structures like shower stalls fail due to water penetration at fastening points and seams, leading to issues like mold, mildew, and structural damage, and existing materials can be harmful to humans and the environment.
Innovation Solution
A water-impermeable structure system using construction boards with a curable substrate and a seamless resilient membrane that extends beyond the board edges to create a seam-free, adhesive bond, preventing water ingress and supporting various loads, while being non-toxic and free from harmful materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional gypsum wallboard or silicate-based products are used for shower walls, then the structure can be easily fabricated, but water penetration occurs at fastening points and seams causing mold, mildew, and structural damage
Solution Approach 1:
The system divides the wall assembly into distinct functional layers: backer board for structural support, waterproof membrane for water barrier, and finish material for aesthetics. Each layer performs its specific function independently, preventing water penetration while maintaining ease of installation through modular components
Solution Approach 2:
The invention uses composite construction combining cementitious backer board with integrated waterproof membrane and adhesive layers. This multi-material composite system provides both the structural properties needed for easy installation and the waterproofing properties needed to prevent water damage
2Ease of operation
If moisture resistant drywall and caulk are used for shower waterproofing, then the structure can be installed conventionally, but water easily penetrates through porous materials and fastening points
Solution Approach 1:
The system uses a flexible waterproof membrane that conforms to the wall surface and integrates with the backer board. This thin film barrier prevents water penetration through the wall assembly while maintaining ease of installation through its flexibility and ability to conform to various surfaces
Solution Approach 2:
The waterproof membrane acts as an intermediary layer between the backer board and the finish materials. It mediates the conflicting requirements of ease of installation (providing a smooth surface for finishing) and water protection (creating a impermeable barrier)
3Reliability
If seam tape and bonded backer board are used to create water-proof vapor barrier, then water protection is improved, but failures occur at board to board joints, fasteners, and board to shower pan joints
Solution Approach 1:
The invention merges the backer board, waterproof membrane, and adhesive layers into an integrated system where these components work together as a unified assembly. This eliminates the separate application steps and potential failure points at interfaces between separately installed components
Solution Approach 2:
The waterproof membrane is pre-integrated with the backer board during manufacturing, creating a pre-assembled unit that reduces on-site assembly complexity and minimizes potential failure points at joints and fasteners
4Adaptability or versatility
If conventional construction materials are used, then the structure can be fabricated with standard materials, but harmful effects occur to construction workers from silicate-based products
Solution Approach 1:
The invention changes the chemical composition parameters of the backer board material, replacing silicate-based products with cementitious alternatives that have similar structural properties but do not produce harmful crystalline silica dust during installation
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 system effectively prevents water, vapor, and chemical penetration, ensuring the structure remains durable, resistant to mold and mildew, and safe for construction workers and users, with enhanced sealing properties and compatibility with various finishes like tiles and stone.
Implementation Method 1
Each construction board has a curable substrate and a water impermeable seamless resilient membrane adhered to the curable substrate
Implementation Method 2
Each construction board has a curable substrate which can be molded from a curable paste
Data Source
AI summary
A water impermeable structure comprising a plurality of construction boards fastened to a structure or a building. Each construction board comprises a curable substrate and a water impermeable seamless resilient membrane adhered to the curable substrate. The water impermeable seamless resilient membrane comprises one or more flaps that extend beyond the curable substrate. The flaps affix to the adjoining construction board creating a water impermeable structure and a water impermeable structure with at least one water impermeable area.