Cellular Cement Board with Closed-Cell Bubbles for Fire Resistance
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Solution Overview
Problem
Conventional cement materials lack refractory properties, leading to house collapse during fires, which poses a significant threat to human safety as they burst or perforate under high heat, trapping residents inside.
Innovation Solution
A method for manufacturing lightweight, thermally insulating cellular cement-based materials through a mixture of binders, activators, and blowing agents, which form a cellular structure with closed-cell bubbles, providing enhanced fire resistance and thermal insulation by foaming and curing simultaneously at elevated temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cement materials are used for construction, then the material provides basic structural support and fire resistance, but the material bursts or perforates under high heat, leading to house collapse
Solution Approach 1:
The patent introduces a cellular structure with closed-cell bubbles throughout the cement-based material. This porous structure reduces thermal conductivity and prevents heat penetration that would cause bursting or perforation, thereby maintaining structural integrity under high heat conditions while providing fire resistance.
Solution Approach 2:
The patent creates a composite material by combining cement-based binder with blowing agents that form closed-cell bubbles. This composite structure integrates the fire resistance of cement with the thermal insulation properties of the cellular structure, preventing both fire spread and structural collapse under heat.
2Duration of action of stationary object
If thermal insulating materials are used to slow fire spread, then evacuation time is extended, but the material must maintain structural integrity under high heat to prevent house collapse
Solution Approach 1:
The cellular structure with closed-cell bubbles provides thermal insulation that slows fire spread, extending evacuation time. Simultaneously, the cement-based binder maintains structural integrity under high heat, preventing house collapse and ensuring reliability during the extended evacuation period.
Solution Approach 2:
The patent modifies the thermal properties of cement by introducing a cellular structure, changing the thermal conductivity parameter to provide insulation while maintaining the mechanical strength parameters of cement under high temperature conditions.
3Weight of moving object
If lightweight materials are used to reduce building weight, then construction cost and energy consumption are reduced, but the material must still provide adequate fire resistance and structural support
Solution Approach 1:
The cellular structure reduces material density and weight while the cement-based binder and closed-cell configuration maintain fire resistance properties, allowing lightweight construction without sacrificing safety.
Solution Approach 2:
The composite of cement binder and cellular structure creates a lightweight material that retains the fire resistance of cement while reducing overall density, achieving both weight reduction and maintained reliability.
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 resulting material exhibits low thermal conductivity, minimal shrinkage at high temperatures, and extended fire resistance, maintaining structural integrity for 4 hours, thus enabling safer evacuation and rescue efforts during fires.
Implementation Method 1
the cellular structure is constructed by the simultaneous decomposition of the blowing agent, forming a plurality of closed-cell bubbles
Implementation Method 2
the curing of the cement slurry solidifies the cellular structure
Implementation Method 3
lightweight thermal insulating cellular cement-based materials
Data Source
AI summary
A method of manufacturing a lightweight thermal insulating cellular cement-based material and a lightweight thermal insulating cellular cement-based board made thereof are disclosed. A binder, an activator, and a blowing agent are mixed to obtain a mixture. The mixture is homogenized to form a cement slurry, which is poured into a mold afterwards. With the help of the activator and an increased temperature of the mold, the cement slurry in the mold will be activated and start foaming and curing to form a cellular cement-based material. The cellular structure is constructed by decomposition of the blowing agent to form a plurality of closed-cell bubbles, which are fixed in the cement slurry during the curing. After the formation, the mold is removed to obtain the cellular cement-based material. The material exhibits high integrity fire resistance and extraordinary insulation fire resistance.