Fire-resistant and insulating multi-layer composite material

Abstract

The invention relates to a composite material (100) developed particularly for use in ventilation systems in the automotive industry, addressing the problems of mechanical durability and flammability encountered with conventional materials. The composite material (100) is characterized in that it comprises at least one textile layer (3) positioned between the first and third layers to provide high thermal insulation and flame resistance. The first layer is made of aluminum (1), and the second layer is made of polyethylene terephthalate (2). This multi-layer configuration ensures improved mechanical strength, flexibility, and fire safety, making it suitable for demanding automotive applications.

Description

[0001] Fire-Resistant and Insulating Multi-Layer Composite Material

[0002] Technical Field The invention relates to a multi-layer composite material structure designed for thermal insulation and fire safety and is intended for use in high-temperature applications. The basic three-layer structure comprises a fire-resistant textile material positioned between aluminum and polyethylene terephthalate (PET) layers. In the five-layer configuration, the fire-resistant textile material is replaced with a nonwoven textile material suitable for use in ventilation systems. This modification enables the material to be utilized in ventilation units, presenting potential for replacing traditional materials in the automotive industry. With its multi-layered architecture, the innovation provides both excellent thermal insulation and fire protection, while offering flexible solutions for different application requirements through varying layer compositions. The invention represents a technical advancement in the field of composite material engineering, as well as in the automotive and construction materials industries.

[0003] Background of the Invention

[0004] Composite materials are generally formed by combining multiple layers of different, yet compatible materials, thereby benefiting from the specific properties of each individual layer to achieve a level of performance and durability that cannot be attained when used separately. Such materials are particularly important in applications that require thermal insulation and fire safety. In current technology, materials such as aluminum and polyethylene terephthalate (PET) are commonly used to address these requirements.

[0005] Aluminum is known for its excellent thermal reflection properties and is therefore widely used in thermal insulation applications. However, a significant drawback of using aluminum alone is its limited mechanical strength. In applications that require high flexibility, aluminum layers can be easily torn or damaged. This leads to potential failures, especially in flexible structures or systems that are frequently subjected to physical impacts. Polyethylene terephthalate (PET) is another material known for its chemical and thermal resistance. Although PET films provide high resistance to tearing and punctures, it may not offer adequate flexibility compared to aluminum and thus may not be the optimal solution for certain applications. For example, structures combining PET with aluminum may remain limited in terms of flexibility and mechanical durability.

[0006] Conventional ventilation ducts are among the critical components used in the automotive industry. These ducts primarily serve to regulate airflow within the vehicle and assist in cooling critical systems such as the engine. The material and structure of the ducts are crucial in terms of both mechanical strength and thermal management. Ventilation ducts used in the current state of the art are typically made of metal or rigid plastic, each of which has its own advantages and disadvantages.

[0007] Metal ducts are resistant to high temperatures, but due to their weight and limited flexibility, their installation and maintenance can be challenging. Additionally, metal ducts are prone to rust, corrosion, and wear as a result of continuous exposure to vibration. Under conditions of high temperature and humidity, these ducts may lose effectiveness over time.

[0008] On the other hand, plastic ducts are lighter and more flexible, but they generally fail to provide sufficient protection against high temperatures and fire risks. The use of flammable materials poses serious safety risks, particularly in areas close to the engine compartment. Furthermore, prolonged exposure to UV radiation and ozone can lead to material fatigue and cracking in plastic ducts over time. These disadvantages impose significant limitations on the safety and performance of vehicles.

[0009] Currently available ventilation ducts also fall short in meeting the need for flexible installation and compatibility with narrow spaces. When traditional materials are used to design ducts suitable for tight and confined spaces, compromises often have to be made in terms of mechanical integrity and functionality. This presents a major challenge in modern automotive designs, which involve tight design tolerances and complex geometries. In addition, the assembly and integration processes of conventional duct systems can be time-consuming and costly. The installation of duct systems with complex shapes and connections slows down the manufacturing process and introduces additional costs. Furthermore, growing environmental standards and the demand for lightweight vehicles in the automotive industry necessitate the exploration of more environmentally friendly and lightweight alternatives in material selection.

[0010] The disadvantages of conventional ventilation ducts — such as their weight, limited flexibility, high cost, and complexity of installation — necessitate the development of new and improved material solutions for ventilation systems. Innovative composite material structures can overcome these drawbacks and offer safer, lighter, more flexible, and more cost-effective ventilation solutions. These solutions are of critical importance in meeting the mechanical, thermal, and safety requirements of the modern automotive industry.

[0011] In the automotive sector, materials used in applications such as ventilation units must be both lightweight and durable. Moreover, materials used in environments exposed to high temperatures and fire must exhibit flame-retardant properties. Many of the currently used materials fail to perform adequately under such demanding conditions. In particular, aluminum's poor resistance to mechanical impacts, tendency to tears, and low flame resistance constitute significant disadvantages for such applications.

[0012] Since materials used in components such as automotive ventilation ducts are expected to possess multiple properties — including high flexibility, tear and puncture resistance, and fire resistance — existing technical solutions have not always been satisfactory. Therefore, an ideal composite material structure should adopt a novel approach that simultaneously offers durability, flexibility, and fire safety to meet these challenging conditions. Such an approach should also overcome the limitations of existing materials and ensure safer and more efficient use.

[0013] In conclusion, the limitations of current composite materials used in sectors such as automotive — particularly in terms of thermal and mechanical performance as well as fire safety — highlight the need for the development of innovative solutions in these areas. Objectives of the Invention

[0014] The primary objective of the present invention is to develop an innovative composite material structure for the automotive industry that overcomes the problems encountered in the prior art, such as inadequate resistance to mechanical impacts, tendency to tear, low flame resistance, and limited durability under high temperatures. This new composite structure is intended to serve as a fire-resistant alternative by providing high thermal insulation, particularly in critical applications such as ventilation systems.

[0015] Another objective of the invention is to overcome the limitations of conventional materials such as aluminum and polyethylene terephthalate (PET), and to provide a material structure that demonstrates enhanced mechanical flexibility and durability by incorporating additional layers beyond these conventional components. The structure is particularly suitable for use in confined and flexible installation areas within the automotive industry and allows easy integration and assembly in applications requiring complex shapes.

[0016] A further objective of the invention is to provide a material solution that meets the increasing environmental standards and demands for lightweight vehicles in the automotive industry by offering both lightness and environmentally friendly characteristics. The proposed material structure is designed to eliminate the disadvantages of currently used materials in terms of weight, limited flexibility, and high cost.

[0017] An additional objective of the invention is to develop a high-performance composite material that combines flexibility, resistance to tearing and punctures, and fire resistance, thereby offering a superior alternative to existing material solutions. The developed material is expected to comply with the tight design tolerances and complex geometries of modern automotive designs while enhancing both safety and performance.

[0018] Description of Figures

[0019] Figure-1 is a schematic view of the three-layer composite material according to the present invention. Figure-2 is a schematic view of the five-layer structure of the material according to the present invention.

[0020] Description of Part References

[0021] 100. Composite material

[0022] 1. Aluminum

[0023] 2. Polyethylene terephthalate (PET)

[0024] 3. Textile A. Binder

[0025] Detailed Description of the Invention

[0026] The present invention relates to a multi-layered composite material (100) designed specifically for use in the automotive industry, which is fire-resistant and provides thermal insulation. The invention aims to offer innovative solutions to problems encountered in the current state of the art, where conventional materials fall short.

[0027] Referring to Figure 1 , the invention is fundamentally based on a three-layer structure composed of aluminum (1), polyethylene terephthalate (2), and a specially selected textile (3) material. The outermost layer, aluminum (1), constitutes the core of the thermal performance of the composite material (100). Known for its heat-reflective properties, aluminum (1) is a widely preferred material in thermal insulation applications. Its high reflectivity allows the composite material (100) to effectively manage heat and thus provide efficient thermal insulation. However, the mechanical properties of aluminum (1) -such as flexibility and impact resistance- are limited for high-performance applications. This means that the sole use of aluminum (1) may not be sufficient for automotive applications that are frequently subjected to dynamic and physical stress.

[0028] To overcome this limitation and improve the overall durability of the composite material (100), a layer of polyethylene terephthalate (2) is positioned directly beneath the aluminum (1) layer. Polyethylene terephthalate (2) is known for its chemical resistance and high resistance to tearing and puncture. These properties complement the aluminum (1) layer by reinforcing the mechanical strength of the composite structure. Furthermore, polyethylene terephthalate (2) works in synergy with aluminum (1) to further enhance the thermal insulation capabilities of the composite material (100).

[0029] At the center of the composite material (100) lies a specialized textile (3) layer, which completes this multi-layer structure. The textile (3) layer is made from a flame-retardant material, significantly increasing the safety performance of the material by offering high resistance to fire. In addition, the flexibility of the textile (3) layer contributes to the overall flexibility and impact resistance of the composite material (100). These features are of critical importance in meeting the strict safety and durability requirements of the automotive industry.

[0030] This three-layer structure allows each material to contribute its unique properties, resulting in enhanced overall performance. The thermal reflectivity of aluminum (1), the mechanical strength of polyethylene terephthalate (2), and the fire resistance and flexibility of the textile (3) layer are the main reasons why this composite material (100) is well-suited for use in the automotive industry and other high-performance applications.

[0031] Referring now to Figure 2, a more advanced version of the invention — the five-layered composite material (100) — is described. This structure builds upon the features of the three-layer design and is specifically intended for use in targeted applications such as ventilation systems. It is formed by integrating two additional layers, significantly improving the material’s functionality and application flexibility.

[0032] The aluminum (1) layers forming the outermost surfaces of the five-layered structure provide the same high thermal reflectivity as in the three-layer version and continue to support the thermal insulation capabilities of the composite material (100). The presence of aluminum (1) on both sides enables the material to provide insulation from both surfaces, optimizing heat management performance.

[0033] The polyethylene terephthalate (2) layers are placed between the aluminum (1) layers and serve to improve the mechanical integrity and tear resistance of the composite material (100). The use of polyethylene terephthalate (2) on both sides creates a symmetrical structure, offering balanced durability and flexibility from all directions. One of the key innovations of the five-layered structure lies in the modification of the central textile (3) layer. In this version, the fire-resistant textile (3) material is replaced with a nonwoven textile (3) in order to better meet the specific requirements of ventilation systems. The nonwoven textile (3) provides high air permeability and flexibility, which improves the efficiency of ventilation systems while facilitating easier handling and assembly of the material.

[0034] The integration of the nonwoven textile (3) layer transforms the five-layered composite material (100) into a lightweight, flexible, and high-performance alternative capable of replacing conventional ventilation ducts. This structural enhancement broadens the range of applications for the composite material (100) across the automotive industry and beyond.

[0035] In conclusion, the five-layered composite material (100) combines the unique properties of each layer to offer advantages such as high thermal insulation, mechanical strength, flexibility, and suitability for use in ventilation systems. This multi-layered structure provides innovative solutions to the challenges of the modern automotive industry and increases the potential of the material (100) to replace conventional materials.

[0036] Equally important is the binder (A), which ensures the connection between the layers of the composite material (100) and enhances its mechanical integrity. The binder (A) is a special adhesive formulation containing co-reactive components that, when mixed in specific ratios, achieve the desired viscosity and density. These components not only optimize the durability and functionality of the composite material (100) but also improve its ability to accommodate flexible installation needs and adapt to complex geometries.

[0037] The manufacturing process of the composite material (100) begins with the placement of a heat-reflective aluminum (1) layer as the outermost surface. Directly beneath it, a polyethylene terephthalate (2) layer is added to improve mechanical strength and tear resistance. Subsequently, a textile (3) layer is positioned under the polyethylene terephthalate (2) to ensure air permeability. During a lamination process carried out under high temperature and pressure, a binder (A) is applied between the layers to establish strong interlayer adhesion. For the production of the five-layered composite material (100), a second polyethylene terephthalate (2) layer is added beneath the textile (3) to further enhance mechanical strength and tear resistance. Finally, a second aluminum (1) layer is positioned at the bottom to provide additional heat reflectivity. As with the three-layer version, the binder (A) is applied between all layers during lamination to secure the integrity of the structure under high temperature and pressure. This stepwise and detailed production method enables the fabrication of a high-performance composite material (100) tailored for critical applications such as automotive ventilation systems. In summary, the invention offers a high-performance composite material (100) suitable for various applications, particularly automotive ventilation systems. With its excellent thermal insulation, fire resistance, flexibility, and mechanical strength, the material addresses several limitations of the prior art and provides new and effective solutions. The developed multi-layered structure responds to the challenges of the modern automotive industry while ensuring safe and efficient use.

Claims

CLAIMS1. The invention is a composite material (100) developed particularly for use in ventilation systems in the automotive industry, intended to address the issues of mechanical durability and flammability encountered with conventional materials, characterized in that it comprises at least one textile (3) layer positioned between a first and a third layer in order to provide high thermal insulation and flame resistance, wherein the first layer is aluminum (1) and the second layer is polyethylene terephthalate (2).

2. The composite material (100) according to claim 1 , characterized in that the textile (3) layer is made of a flame-retardant material to improve the overall fire resistance properties of the composite material (100) in automotive applications.

3. The composite material (100) according to claim 1 , characterized in that it comprises at least one textile (3) layer positioned between a first and a fifth layer to meet flexible installation requirements and to provide increased flexibility in ventilation system applications in the automotive industry, wherein the first and fifth layers are aluminum (1), and the second and fourth layers are polyethylene terephthalate (2).

4. The composite material (100) according to claim 3, characterized in that the textile (3) layer positioned between the first and fifth layers is made of nonwoven material to enhance processability and ease of installation during assembly and stitching operations.

5. The composite material (100) according to any one of the preceding claims, characterized in that it comprises a binder (A) positioned between the layers to provide adhesion and to improve the mechanical integrity and structural durability of the composite material (100).

6. The composite material (100) according to claim 5, characterized in that the binder (A) comprises an adhesive and co-reactant component mixture placed between each layer, which, when mixed in specific ratios, achieves the desired viscosity and density, thereby enhancing interlayer bonding and mechanical strength.

7. The invention is a method for manufacturing a composite material (100) developed particularly for use in ventilation systems in the automotive industry and intended toaddress issues of mechanical durability and flammability associated with conventional materials, characterized by comprising the steps of:• preparing a first aluminum (1) layer having heat reflective properties and placing it as the outermost layer, • positioning a first polyethylene terephthalate (2) layer beneath the aluminum(1) layer to enhance mechanical strength and tear resistance,• positioning a textile (3) layer beneath the polyethylene terephthalate (2) layer to provide air permeability,• applying a lamination process under high temperature and pressure by introducing a binder (A) between the layers to reinforce interlayer bonding.

9. The method for manufacturing a composite material (100) according to claim 7, is characterized by comprising the additional steps, prior to the lamination process with the binder (A) under high temperature and pressure, to obtain a five-layered structure:• placing a second polyethylene terephthalate (2) layer beneath the textile (3) layer to further improve mechanical integrity and tear resistance,• placing a second aluminum (1) layer with heat reflective properties as the lowermost layer.

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