Bio-Based Fire-Retardant Coating With Fast Drying Nanocellulose
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Solution Overview
Problem
Current fire retardant chemicals pose environmental and health hazards, and existing bio-based solutions are inefficient and time-consuming due to low consistency nanocellulose suspensions requiring large water usage and slow processing.
Innovation Solution
A bio-based fire-retardant composition comprising high consistency nanofibrillated cellulose and mineral components that self-assemble into a protective layer, allowing direct application and fast drying on surfaces, leveraging the natural film-forming properties of cellulose nanofibrils and mineral particles for enhanced thermal insulation and gas barrier properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fire-retardant additives (aluminum hydroxide, magnesium hydroxide, ammonium polyphosphate) are used, then fire resistance is improved, but processing difficulties and resin incompatibility occur
Solution Approach 1:
The patent modifies the chemical structure of fire-retardant additives by introducing organomodified variants (e.g., organomodified aluminum hydroxide, organomodified magnesium hydroxide) and adjusting molecular parameters such as chain length and functional groups. This improves compatibility with polymer resins while maintaining fire-resistant properties, thereby reducing processing difficulties without sacrificing fire resistance.
Solution Approach 2:
The patent employs composite fire-retardant systems combining multiple additives (e.g., phosphorus-containing compounds combined with metal hydroxides, or silane-modified flame retardants combined with traditional additives). These composite formulations achieve synergistic effects that improve fire resistance while enhancing processability and reducing incompatibility issues associated with single-additive systems.
2Reliability
If halogen-containing fire-retardant additives are used, then fire resistance is improved, but toxic fume generation increases
Solution Approach 1:
The patent replaces halogen-containing fire-retardant additives with halogen-free alternatives such as phosphorus-containing compounds, nitrogen-containing compounds, or metal hydroxides. These alternatives maintain effective fire resistance through mechanisms like char formation and radical quenching while eliminating the generation of toxic halogenated fumes during combustion, thus converting a harmful chemical composition into a safer one.
Solution Approach 2:
The patent changes the chemical composition parameter from halogen-based to halogen-free fire-retardant mechanisms. By selecting additives based on phosphorus, nitrogen, or metal hydroxide chemistry instead of halogen chemistry, the system achieves comparable fire resistance performance while fundamentally altering the combustion byproducts to eliminate toxic fume generation.
3Reliability
If fire-retardant additives are added to polymer composition, then fire resistance is improved, but mechanical properties deteriorate
Solution Approach 1:
The patent optimizes the molecular structure and physical parameters of fire-retardant additives, including particle size distribution, surface area, and chemical functionality. By controlling these parameters, the additives achieve better dispersion and interfacial adhesion within the polymer matrix, maintaining mechanical integrity while providing effective fire protection. For example, using nano-sized particles or surface-modified additives reduces stress concentration points that would otherwise weaken the material.
Solution Approach 2:
The patent develops composite formulations where fire-retardant additives are chemically or physically integrated with the polymer matrix through coupling agents, grafting, or reactive extrusion. This composite approach ensures that the fire-retardant particles are well-bonded to the polymer chains, preventing premature failure and maintaining tensile strength, impact resistance, and other mechanical properties even at higher fire-retardant loading levels.
4Reliability
If fire-retardant additives are added to polymer composition, then fire resistance is improved, but viscosity increases causing processing difficulties
Solution Approach 1:
The patent adjusts physical parameters of fire-retardant additives such as particle size, surface area, and shape to optimize flow characteristics. Using smaller, more uniformly distributed particles or particles with optimized aspect ratios reduces agglomeration and improves dispersion, thereby minimizing the increase in melt viscosity. Additionally, surface modification of additives with compatibilizers or lubricants reduces interfacial friction during processing, maintaining lower viscosity despite higher additive loadings.
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 composition provides a sustainable, non-toxic, and efficient fire protection with fast application and drying, achieving superior flame retardancy and thermal insulation, suitable for various surfaces including cellulose, wood, and metal.
Implementation Method 1
the fire-retardant additives in the composition of claim 1 undergo decomposition at a relatively low degree of curing
Implementation Method 2
provides intumescent protection to a substrate when exposed to fire
Data Source
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AI summary
According to an example aspect of the present invention, there is provided a non-toxic bio-based fire-retardant composition and fire-protective coating comprising high consistency nanofibrillated cellulose together with mineral component(s).