Building Reinforcement with Zylon Fibre Cement Mortar
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Solution Overview
Problem
Existing building reinforcement methods face challenges such as installation difficulties, corrosion, limited temperature resistance, high costs, and impaired thermohygrometric transfer due to the use of electrically welded meshes and epoxy resin-based carbon fibre systems, and issues with cement mortar flow and degradation in vertical applications.
Innovation Solution
A reinforcement system utilizing a cement mortar with embedded poly[benz(1,2-D:5,4-D')bisoxazole-2,6-diyl-1,4-phenylen] fibres, marketed as 'zylon', which provides superior mechanical properties, fire resistance, and maintains thermohygrometric transfer, replacing traditional carbon fibre and epoxy resin systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If electrically welded mesh is used to reinforce building structures, then ductility is improved, but installation difficulty increases due to weight and poor manageability
Solution Approach 1:
The patent changes the material parameters from traditional steel mesh to synthetic fibres (polypropylene, polyester, polyethylene, aramid, glass, or polybenzoxazole) embedded in cement mortar. This material substitution reduces weight and improves manageability while maintaining or enhancing reinforcement effectiveness, directly resolving the installation difficulty contradiction.
2Strength
If electrically welded mesh is used to reinforce building structures, then ductility is improved, but corrosion risk increases in aggressive environments
Solution Approach 1:
The patent employs composite materials consisting of cement mortar embedded with synthetic fibres. This composite system replaces traditional steel mesh with corrosion-resistant synthetic fibres (polypropylene, polyester, polyethylene, aramid, glass, or polybenzoxazole), eliminating the corrosion risk while maintaining ductility and reinforcement properties.
3Reliability
If epoxy resin and carbon fibre bands are used for reinforcement, then adhesion to building structure is improved, but temperature resistance deteriorates above 80°C
Solution Approach 1:
The patent extracts and eliminates the epoxy resin component from the reinforcement system. By using only cement mortar as the binding medium and embedding synthetic fibres directly, the system removes the temperature limitation imposed by epoxy resin degradation, achieving fire resistance equivalent to the building structure itself while maintaining adhesion through the cement matrix.
4Reliability
If epoxy resin is used to apply carbon fibre bands, then adhesion is improved, but cost increases significantly
Solution Approach 1:
The patent substitutes expensive epoxy resin and carbon fibre bands with more economical materials: cement mortar combined with synthetic fibres (polypropylene, polyester, polyethylene, aramid, glass, or polybenzoxazole). This material substitution dramatically reduces cost while maintaining adhesion through the cement matrix and achieving comparable or superior mechanical reinforcement properties.
5Reliability
If epoxy resin is used for reinforcement, then adhesion is improved, but thermohygrometric transfer is blocked
Solution Approach 1:
The patent employs cement mortar as the binding medium, which inherently possesses porous characteristics that allow thermohygrometric transfer. The cement matrix with embedded synthetic fibres maintains adhesion to the building structure while its porous nature permits natural moisture migration, eliminating the barrier effect created by epoxy resin systems.
6Ease of manufacture
If cement mortar with styrene/acrylate dispersion is used for reinforcement, then fluidity is improved, but degradation with fissure formation occurs
Solution Approach 1:
The patent extracts and eliminates the styrene/acrylate dispersion component from the cement mortar formulation. By using conventional cement mortar without this additive, the system removes the source of degradation and fissure formation, achieving stable, durable reinforcement that maintains structural integrity over time while sufficient fluidity is maintained for proper application.
Data Source
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AI summary
The building component comprises a central structure covered by a layer of cement mortar in which a reinforcement structure formed of poly [benz (1, 2-D:5,4-D') bisoxazole-2, 6-diyl-l, 4-phenylen] fibre is embedded. The method consists of forming a layer of cement mortar on the structure to be reinforced and embedding in the cement mortar layer a reinforcement structure formed of poly [benz (1, 2-D: 5, 4-D') bisoxazole-2, 6-diyl-l, 4-phenylen] fibre. The mortar further comprises unsaturated copolymer resins, fluidifying and thixotropic additives.