Biosoluble Insulation Layer for Fireproof Composite Panels
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Solution Overview
Problem
Current fireproof composite panels are costly, time-consuming to produce, and pose health and environmental risks due to the use of refractory ceramic fibers, which are not easily degradable and can be harmful if inhaled.
Innovation Solution
A fireproof composite panel design featuring a metal layer, an aluminum foil layer, and a biosoluble insulation layer, such as a soluble fiber layer or alkaline earth silicate cotton layer, which reduces production time, cost, and weight while ensuring effective fire resistance and heat insulation, and is safer for human health and the environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick rubber layer with neoprene and sodium silicate is used as the intumescent insulation layer, then fireproof performance is improved, but the curing time increases to up to 6 days and the price becomes high
Solution Approach 1:
The patent changes the chemical composition parameters of the insulation layer by replacing the conventional neoprene-rubber-sodium silicate system with a biosoluble material system comprising starch, gelatin, or casein as binders combined with intumescent agents. This parameter change enables the insulation layer to achieve required fireproof performance while eliminating the need for long curing periods, as these natural polymers set much faster than conventional rubber systems.
Solution Approach 2:
The patent employs biosoluble, biodegradable materials that are cheaper and do not require long-term curing. The insulation layer uses readily available natural polymers (starch, gelatin, casein) that provide sufficient fire protection for the required duration and then degrade naturally, eliminating disposal costs and long curing times associated with permanent rubber-based systems.
2Reliability
If conventional refractory ceramic fibers are used as the insulation layer, then fire resistance is provided, but dust and fine fibers are easily inhaled and are harmful to human health and the environment
Solution Approach 1:
The patent converts the harmful property of permanent, non-degradable ceramic fibers into a beneficial property by using biosoluble materials that degrade into harmless substances. The insulation layer materials (starch, gelatin, casein) naturally break down into carbon dioxide, water, and organic matter through biodegradation, transforming the potential harm of persistent fiber inhalation into a beneficial environmental cleanup mechanism.
Solution Approach 2:
The patent replaces permanent ceramic fibers with biodegradable organic materials that serve their fire protection function temporarily and then naturally decompose. This approach eliminates the health hazards of long-term fiber exposure while maintaining fire resistance during the required service period, as the organic materials are safely metabolized by microorganisms in the environment.
3Reliability
If a thick insulation layer is used to achieve high fireproof performance, then protective performance is improved, but the weight of the panel increases
Solution Approach 1:
The patent creates a composite insulation layer combining intumescent agents (ammonium polyphosphate, pentaerythritol, melamine) with natural polymer binders (starch, gelatin, casein) and reinforcing fillers (cellulose, calcium carbonate). This composite structure achieves high fireproof performance through the synergistic intumescent expansion mechanism while maintaining lower density and weight compared to solid ceramic fiber or thick rubber layers, as the intumescent foam provides insulation with much lower material density.
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 fireproof composite panel effectively provides cost-effective, safe, and environmentally friendly fire protection by simplifying the fabrication process, reducing weight, and ensuring required protective performance with a biosoluble insulation layer that is easily degradable and non-hazardous.
Implementation Method 1
once the expansion temperature of the intumescent insulation layer is reached, the intumescent insulation layer begins to expand, the expanded volume of which can reach 8 to 10 times the initial volume
Implementation Method 2
the fine fibers are not easily degraded nor easily dissolved in the human body... uses a biosoluble insulation layer... which is easily degradable and non-hazardous
Data Source
AI summary
A fireproof composite panel and a fireproof structure. The fireproof composite panel (10) comprises a metal layer (11), an aluminum foil layer (15), and a biosoluble insulation layer (13). The biosoluble insulation layer (13) is located between the metal layer (11) and the aluminum foil layer (15). The fireproof structure comprises the fireproof composite panel (10), and is used to seal through openings in a building.