Bio-Based Fire-Resistant Foam Structure for Safer Substrate Protection
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Solution Overview
Problem
Existing passive fire-resistant structures for oil and gas extraction substrates, particularly those using phenolic resins, pose environmental and health concerns, necessitating a safer and more environmentally friendly alternative.
Innovation Solution
A passive fire-resistant structure comprising a tie coat bonded to a substrate, with a passive fire-resistant foam layer made from a bio-based resin and a hardener, optionally including additives like para toluene sulphonic acid, boric acid, amino functional silane coupling agents, glass strands, inorganic fiber matrix, hollow microspheres, and surfactants, providing enhanced fire protection without the hazards of phenolic resins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phenolic resins are used for passive fire-resistant structures, then fire protection performance is achieved, but environmental and health safety concerns arise
Solution Approach 1:
The patent changes the chemical composition parameters of the fire-resistant coating by replacing phenolic resins with bio-based resin systems. This substitution maintains the fire protection function while eliminating the harmful properties of phenolic resins, thereby resolving the contradiction between reliability and harmful factors.
Solution Approach 2:
The patent employs composite material systems combining bio-based resins with specific hardeners and functional additives. This composite approach achieves the required fire protection performance through synergistic material interactions while using environmentally benign base materials, thus resolving the contradiction between performance and safety.
2Object-affected harmful factors
If bio-based resin systems are used instead of phenolic resins, then environmental safety is improved, but fire protection performance must be maintained
Solution Approach 1:
The patent adjusts the chemical and physical parameters of the bio-based resin system, including resin-to-hardener ratios, molecular weight, and functional group composition, to achieve fire protection performance equivalent to phenolic resins while maintaining environmental safety benefits.
Solution Approach 2:
The patent introduces functional additives as intermediaries that enhance the fire protection capabilities of the bio-based resin system. These additives act as mediators to bridge the performance gap between bio-based and phenolic resins, ensuring equivalent fire protection while maintaining environmental safety.
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 bio-based resin system offers effective fire protection for on-shore and off-shore substrates, comparable to phenolic resin-based systems, while being safer and more environmentally friendly, withstanding extreme temperatures and mechanical stress, and providing protection against various fire regimes and blast pressures.
Implementation Method 1
the passive fire-resistant foam layer is the reaction product of a first material comprising a bio-based resin and a second material comprising a hardener
Implementation Method 2
passive fire-resistant structures for fabricating substrates to be resistant to fires and the intense heat emanating from combustion
Data Source
AI summary
A passive fire-resistant structure for a substrate. The structure comprises a tie coat bonded to the substrate and a passive fire-resistant foam layer bonded to the tie coat. The passive fire-resistant foam layer is the reaction product of a first material comprising a bio-based resin and a second material comprising a hardener.