Composite Cargo Sheet Flame Resistance
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Solution Overview
Problem
Existing cargo containers, particularly those used in aircraft, lack sufficient fire-resistant capabilities to contain the spread of flames originating from flammable materials like lithium-ion batteries, posing a safety risk and requiring enhanced durability and maintenance minimization.
Innovation Solution
A non-rigid composite sheet comprising multiple layers: a first fabric with high tenacity yarns and a polymeric layer for chemical resistance, a second component with aramid fiber paper for flame resistance, and a third fabric with a polymeric layer for abrasion resistance, designed to withstand high temperatures and maintain structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing container materials are used, then weight is reduced, but fire resistance capability is insufficient
Solution Approach 1:
The patent employs a multi-layer composite structure combining aramid fiber paper (providing flame resistance), polymeric fabrics (providing mechanical strength), and polymeric coatings (providing chemical resistance). This composite approach achieves fire resistance capability while maintaining lightweight properties, as each layer contributes specific functions without requiring excessive material mass.
Solution Approach 2:
The container wall is divided into distinct functional layers: an outer polymeric layer for chemical resistance, an intermediate aramid fiber paper layer for flame resistance, and inner polymeric layers for additional protection. This segmentation allows each layer to be optimized for its specific function while collectively achieving both fire resistance and lightweight requirements.
2Reliability
If fire resistant materials are used, then flame containment capability is improved, but durability under extreme conditions deteriorates
Solution Approach 1:
The aramid fiber paper is combined with chemically resistant polymeric fabrics and coatings to create a composite structure where the aramid provides flame containment while the polymeric components maintain structural integrity and resist chemical degradation from cargo materials, achieving both fire resistance and durability under extreme conditions.
Solution Approach 2:
Different layers of the composite structure provide different local properties: the aramid fiber paper layer specifically addresses flame resistance, while the polymeric fabric and coating layers provide chemical resistance and structural stability. This local specialization allows each material to excel at its intended function without compromising overall durability.
3Weight of stationary object
If lightweight materials are used, then container weight is reduced, but maintenance requirements increase
Solution Approach 1:
The composite structure combines lightweight aramid fiber paper with durable polymeric fabrics and chemically resistant coatings. This combination maintains lightweight properties while the chemically resistant polymeric layers protect the underlying structure from degradation by cargo materials, reducing maintenance requirements despite the use of lightweight materials.
Solution Approach 2:
The chemically resistant polymeric coating layers are applied beforehand to protect the lightweight aramid fiber paper and fabric layers from chemical degradation by cargo materials. This prior protection prevents damage before it occurs, reducing the need for maintenance and repair of the lightweight container structure.
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 composite sheet effectively prevents flame penetration, maintains structural integrity at extreme temperatures, and meets stringent durability standards while minimizing maintenance, thus enhancing safety and compliance with regulatory requirements.
Implementation Method 1
a second component having an areal weight of from 120 to 430 gsm comprising a paper positioned adjacent to the first fabric of the first component and the second fabric of the third component, the paper further comprising aramid fibers, a polymeric binder and mica
Implementation Method 2
a first component having an areal weight of from 88 to 678 gsm comprising a first fabric of filamentary yarns having a tenacity of at least 11 g/dtex and a first polymeric layer
Implementation Method 3
a first fabric of filamentary yarns having a tenacity of at least 11 g/dtex
Data Source
AI summary
This invention is directed to a non-rigid composite sheet comprising in order (i) a first component having an areal weight of from 88 to 678 gsm comprising a first fabric of filamentary yarns having a tenacity of at least 11 g/dtex and a UV and weather impervious first polymeric layer. (ii) a second component having an areal weight of from 120 to 430 gsm comprising a flame resistant paper and (iii) a third component having an areal weight of from 88 to 678 gsm comprising a second fabric of filamentary yarns having a tenacity of at least 11 g/dtex and an impact and scratch resistant second polymeric layer, the second fabric of the third component being adjacent to the paper of the second component.