Surface Sealed Building Element Using Radiation Curable Resin
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Solution Overview
Problem
Building materials like fibre cement struggle with low bending strength and moisture sensitivity, requiring costly reinforcement methods that are labor-intensive and time-consuming, especially in wet applications where durability and strength are compromised.
Innovation Solution
A method involving a radiation curable resin is used to adhere a reinforcing material to a rigid substrate, enhancing the mechanical properties of building elements by improving their strength and toughness, and simultaneously providing a surface seal, which can be automated for efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a reinforcing element is introduced into the main body of the building material during manufacture, then the bending strength is improved, but the manufacturing process complexity increases and flexibility is reduced
Solution Approach 1:
The reinforcement process is segmented into separate reinforcing elements (such as glass fibre mats or meshes) that are applied to the surface rather than being mixed into the bulk material. This allows the reinforcement function to be added as a separate layer, maintaining manufacturing flexibility while improving strength.
Solution Approach 2:
The reinforcing elements are applied to the building material surface before final manufacturing steps are completed. This preliminary application allows the reinforcement to be incorporated without requiring major modifications to the existing manufacturing process, as the reinforcement is added in advance of final product completion.
2Strength
If reinforcing elements are externally attached using fasteners or adhesive, then the bending strength is improved, but the manufacturing time and labor requirements increase
Solution Approach 1:
The reinforcement application process is merged with the existing manufacturing line operations. The reinforcing elements are applied using integrated equipment that works in conjunction with the primary manufacturing process, eliminating the need for separate offline reinforcement steps and reducing overall manufacturing time.
Solution Approach 2:
The building material itself serves as the substrate for the reinforcing elements, with the material's surface properties providing the necessary adhesion. This self-service approach eliminates the need for additional adhesives or fasteners, simplifying the process and improving productivity.
3Strength
If conventional reinforcement methods are used, then the bending strength is improved, but the cost of the product increases substantially
Solution Approach 1:
The reinforcement method utilizes changes in the physical and chemical parameters of the building material surface (such as surface energy, porosity, and texture) to enhance adhesion of reinforcing elements. This eliminates the need for expensive additional adhesives or fasteners, reducing manufacturing costs while maintaining reinforcement effectiveness.
Solution Approach 2:
The solution employs composite construction by combining the building material with reinforcing elements (such as glass fibre mats or meshes) in a layered composite structure. This composite approach provides the necessary strength improvement at lower cost than conventional reinforcement methods, as the reinforcing elements can be applied efficiently during or after the manufacturing process.
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 method significantly improves the bending strength and toughness of building elements, making them more durable and resistant to moisture, while simplifying the manufacturing process and reducing costs, particularly suitable for wet area applications like flooring and decking.
Implementation Method 1
a layer of reinforcing material is adhered to a first face of the rigid substrate using a radiation curable resin
Data Source
AI summary
A building element (1) that is suitable for use as a structural element in wet areas or external docking. The building element (1) comprises a rigid substrate (2) having an upper face (3). Over the first face (3) lies a radiation curable resin (4) into which a layer of reinforcing material (5) is at least partially embedded. The reinforcing material (5) and resin (3) can be applied separately or together onto the first face (3) of the rigid substrate (2) or in some cases can be applied to both faces. An apparatus and method for producing the building sheet are also disclosed.