Thin Cement-Based Stone Panels With Mesh Anchors for Seismic Cladding
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Solution Overview
Problem
Existing stone and ceramic plates for building decoration face issues with seismic resistance, high installation costs, environmental impact, and energy consumption due to their rigid connections and heavy weights, which pose safety risks and increase construction costs.
Innovation Solution
Cement-based ultra-high-performance artificial stone plates with embedded stainless steel mesh and fixing members, manufactured through high-frequency vibration, strong pressure, and vacuum forming, allowing for thin, durable, and flexible installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If natural stone plates or ceramic imitation stone plates are used for building decoration, then decorative effect is achieved, but the weight of the plates is large causing high installation costs and structural load increases
Solution Approach 1:
The patent changes the material composition parameters by using cement-based ultra-high-performance concrete with specific water-cement ratios (0.18-0.22) and adding steel fibers (6-12 kg/m³) to achieve high strength while reducing plate thickness to 6-12mm, thereby significantly reducing weight while maintaining decorative appearance
Solution Approach 2:
The patent employs thin plate structure (6-12mm thickness) with embedded stainless steel mesh reinforcement to create a lightweight yet strong decorative panel that maintains structural integrity despite reduced thickness, achieving weight reduction while preserving form and function
2Ease of operation
If wet paste installation method is used for stone plates, then installation simplicity is achieved, but seismic resistance is extremely poor and boards easily fall off
Solution Approach 1:
The patent creates a composite structure by embedding stainless steel mesh within the cement-based ultra-high-performance concrete matrix, forming a reinforced panel that combines the ease of panel installation with the strength of internal reinforcement, enabling both simple installation and high seismic resistance
Solution Approach 2:
The patent incorporates steel fibers and stainless steel mesh reinforcement beforehand during manufacturing to provide pre-cushioning against seismic forces, so that when installation occurs, the panel already possesses enhanced earthquake resistance without requiring complex installation procedures
3Reliability
If dry hanging installation method is used for stone plates, then seismic resistance is improved, but the thickness of plates must be not less than 25 mm and installation costs increase
Solution Approach 1:
The patent fundamentally changes the material strength parameters by using ultra-high-performance concrete with compressive strength ≥150 MPa and tensile strength ≥15 MPa, achieved through optimized water-cement ratio (0.18-0.22) and steel fiber addition, enabling plate thickness reduction to 6-12mm while maintaining sufficient strength for dry hanging installation
Solution Approach 2:
The patent creates a composite material system combining cement-based ultra-high-performance concrete with embedded stainless steel mesh to achieve both thin profile (6-12mm) and high structural strength, eliminating the need for thick plates (≥25mm) required by conventional materials for dry hanging installation
4Adaptability or versatility
If dry hanging installation method is used for thin stone plates, then installation flexibility is improved, but edge falling off and hole breaking occur easily reducing safety
Solution Approach 1:
The patent creates a composite structure with stainless steel mesh embedded in ultra-high-performance concrete, where the mesh provides tensile reinforcement that prevents edge cracking and hole breaking, enabling thin plate (6-12mm) dry hanging installation with high safety margins
Solution Approach 2:
The patent incorporates steel fibers (6-12 kg/m³) and stainless steel mesh reinforcement during manufacturing to provide pre-cushioning against edge and hole stress concentrations, so that during installation and service, these critical areas are protected against breaking and falling off
5Stability of the object's composition
If heavy stone plates are used for building decoration, then structural stability is achieved, but construction costs increase due to increased structural support requirements
Solution Approach 1:
The patent fundamentally changes the material density and strength parameters by using cement-based ultra-high-performance concrete with optimized composition (water-cement ratio 0.18-0.22, steel fiber addition), achieving high strength-to-weight ratio that provides structural stability with significantly reduced weight, thereby eliminating the need for costly structural reinforcement
6Manufacturing precision
If natural stone mining and ceramic high-temperature firing are used for plate production, then material quality is achieved, but environmental damage and energy consumption increase
Solution Approach 1:
The patent changes the manufacturing process by using cement-based ultra-high-performance concrete that cures at ambient or low temperatures through chemical hydration reactions, eliminating the need for high-temperature firing (savings of 1000-1200°C), thereby significantly reducing energy consumption and environmental impact while maintaining high material quality through controlled composition and curing parameters
Solution Approach 2:
The patent uses industrial by-products such as steel slag powder and fly ash as partial replacements for traditional cementitious materials, transforming waste materials into valuable construction resources, thereby reducing environmental damage from mining and production while maintaining material performance
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 provides enhanced seismic resistance, reduced installation costs, and environmental sustainability by minimizing material usage and energy consumption, while ensuring safety and durability of the decorative panels.
Implementation Method 1
manufactured through high-frequency vibration, strong pressure, and vacuum forming
Implementation Method 2
manufactured through high-frequency vibration, strong pressure, and vacuum forming
Implementation Method 3
a plurality of fixing members 2 are welded and fixed on the stainless steel mesh 1
Implementation Method 4
manufactured through high-frequency vibration, strong pressure, and vacuum forming
Data Source
AI summary
A cement-based artificial stone plate includes a cement-based plate body; and a metal mesh being embedded in the cement-based plate body; wherein the metal mesh is arranged with at least one fixing member, the fixing member defines a screw hole along its axis, and the screw hole of the fixing member is exposed on back of the cement-based plate body, and back of the plate body is provided with regular or irregular protrusions, between any two protrusions forms a groove, and bottom of each groove is close to the metal mesh.