Composite Fire Seal Material for Lower-Cost Flame Resistance

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional fire seals for aircraft are costly due to the use of expensive ceramic-based fabrics and require skilled labor for production, while they need to maintain high performance in resisting flame penetration for extended periods.

Innovation Solution

A fire seal mixture comprising a silicone or fluorosilicone polymer base compound with additives such as vitreous materials, intumescent materials, and short fiber strands like carbon fibers, which reduces the need for ceramic fabrics and labor-intensive processes, enhancing fire resistance and mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional ceramic-based fabrics are used in fire seals, then flame penetration resistance is improved, but manufacturing cost increases

Engineering Contradiction:

Improveflame penetration resistanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the material composition parameters by replacing expensive ceramic fabrics with a formulated mixture of silicone rubber, fiberglass, and intumescent materials. This substitution maintains fire resistance through the intumescent mechanism while significantly reducing material costs and simplifying the manufacturing process.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite material system combining silicone rubber base polymer with fiberglass reinforcement and intumescent additives. This composite achieves the required fire protection performance through synergistic material interactions, eliminating the need for expensive ceramic fabrics while maintaining or improving flame penetration resistance.

Inventive Principle:

Principle #40Composite materials

2Reliability

If ceramic-based fabrics are used in fire seals, then fire resistance performance is improved, but skilled labor requirements increase

Engineering Contradiction:

Improvefire resistance performanceVSAvoidskilled labor requirements

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the material form from rigid ceramic fabric layers requiring skilled assembly to a processable rubber compound mixture that can be molded and cured. This transformation eliminates complex multi-step assembly procedures and reduces dependency on skilled manual labor while maintaining fire resistance performance.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical assembly process of layering ceramic fabrics with a chemical-curing process where the rubber compound mixture is molded and cured into the final seal form. This substitution of mechanical assembly with chemical processing dramatically reduces skilled labor requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If conventional fire seal materials are used, then flame penetration resistance is achieved, but production time increases

Engineering Contradiction:

Improveflame penetration resistanceVSAvoidproduction time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces time-consuming mechanical assembly of multiple ceramic fabric layers with a single-mold curing process. The rubber compound mixture is placed in a mold and cured in one operation, significantly reducing production time while achieving the required flame penetration resistance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent merges multiple material functions (base polymer, reinforcement, fire protection additives) into a single integrated compound mixture. This consolidation eliminates the need for separate assembly steps for each functional layer, reducing production time while maintaining comprehensive fire resistance performance.

Inventive Principle:

Principle #5Merging (Combining)

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 improved fire seals exhibit equal or better performance than conventional seals, reducing production costs and the risk of failure, while providing effective flame resistance and mechanical stability without the need for expensive ceramic fabrics.

Implementation Method 1

an intumescent material that is between 5% and 50% of the total mass of the fire seal mixture

Methodology Applied

Scientific EffectIntumescent expansion: Intumescent Materials

Implementation Method 2

an additive that is a vitreous material between 2.5% and 50% of the total mass of the fire seal mixture

Methodology Applied

Scientific EffectVitrification: Vitrification

Implementation Method 3

The fire seal mixture also includes short fiber strands that are between 1% and 25% of the total mass of the fire seal mixture

Methodology Applied

Scientific EffectFiber reinforcement:

Implementation Method 4

a base rubber compound comprising a silicone or fluorosilicone polymer

Methodology Applied

Scientific EffectElastomeric properties:

Implementation Method 5

Flexible, elastomeric fireproof seals providing resistance to flame penetration

Methodology Applied

Scientific EffectFire resistance:

Data Source

PatentUS12157805B2Fire seals and methods of making same

Publication Date: 2024.12.03 MEGGITT AEROSPACE

AI summary

Rubber compounds with increased resistance to fire are disclosed. The rubber compounds are incorporated into fire seals and in particular into fire seals for aerospace applications. The advance rubber compounds are created by adding a powdered vitreous or glass material in combination with a fiber such as carbon fiber, with or without intumescent material to a base rubber compound and then curing.