Composite Material Molten Polymer Barrier Flame Retardant
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current composite materials fail to effectively combine high heat resistance, molten polymer barrier effect, and sound absorption capacity, particularly in automotive applications where complex geometries and fire resistance are crucial, leading to inadequate performance in engine compartments and other high-temperature areas.
Innovation Solution
A composite material comprising a first layer of non-woven fabric with at least 40% oxidized polyacrylonitrile fibers and a barrier layer of hydro-entangled synthetic fibers, which are overlapped and optionally solidarized with a discontinuous interconnection to enhance thermobonding and adaptability, providing improved barrier and sound absorption properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If non-woven fabrics with oxidized polyacrylonitrile fibers are used to provide heat resistance and flame retardancy, then fire resistance and heat resistance are improved, but sound absorption capacity deteriorates
Solution Approach 1:
The patent combines oxidized polyacrylonitrile fibers (providing fire resistance) with hydroentangled synthetic fibers (providing sound absorption) into a single non-woven fabric structure. This merging allows the material to simultaneously achieve both fire safety requirements and acoustic insulation performance, resolving the contradiction between these two properties.
Solution Approach 2:
The invention creates a composite non-woven fabric integrating two distinct fiber types with complementary properties: oxidized PAN fibers for thermal stability and flame retardancy, and hydroentangled synthetic fibers for sound absorption. This composite structure enables the material to satisfy both fire resistance and acoustic insulation requirements that single-material solutions cannot achieve.
2Reliability
If thermoplastic polymer layers are deposited on oxidized PAN fiber-based non-woven fabrics to act as barrier layers, then molten material barrier effect is improved, but distribution homogeneity deteriorates
Solution Approach 1:
Instead of applying a continuous thermoplastic coating that creates distribution issues, the patent incorporates barrier functionality directly into the fiber structure itself through the hydroentangled synthetic fibers. This local integration of barrier properties throughout the fabric matrix ensures uniform performance without the defects of surface coating methods.
Solution Approach 2:
The invention replaces the mechanical coating/deposition process (which causes distribution irregularities) with an integrated fiber structure approach. The barrier effect is achieved through the inherent properties and arrangement of the hydroentangled synthetic fibers themselves, eliminating the need for separate thermoplastic layer application and its associated homogeneity problems.
3Ease of operation
If non-woven fabrics are used individually in molding processes for engine compartment areas, then simplicity of application is improved, but fire resistance and heat resistance deteriorate
Solution Approach 1:
The patent creates a multi-functional non-woven fabric that simultaneously provides fire resistance, heat resistance, and moldability in a single material solution. This universal material eliminates the need for multiple separate layers or components, maintaining application simplicity while achieving the fire safety performance required for engine compartment areas.
Solution Approach 2:
By integrating oxidized PAN fibers (fire resistance) with hydroentangled synthetic fibers (moldability and barrier effect) into a single composite non-woven fabric, the invention enables the material to be used alone in high-temperature applications without sacrificing fire resistance, unlike conventional single-material non-wovens.
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 material exhibits superior molten polymer barrier and flame-retardant properties while achieving high sound absorption capacity, adapting to complex geometries, and maintaining dimensional stability, thus addressing the limitations of existing materials in automotive applications.
Implementation Method 1
oxidized polyacrylonitrile (PAN) fibers, which are thermally stabilized due to their unique chemical structure, are known not to burn, melt, soften or drip
Implementation Method 2
the molded parts may be brought into contact with components that reach high temperatures because they are thermally insulated by the special fibers used (oxidized polyacrylonitrile)
Implementation Method 3
a barrier layer of hydro-entangled synthetic fibers, which are overlapped and optionally solidarized... suitable to counteract the passage of molten polymers through said composite material
Implementation Method 4
the composite material according to the present invention combines properties of heat resistance and a molten polymer barrier effect with a surprisingly high sound absorption capacity
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to a composite material (1) with a molten polymer barrier effect and with flame-retardant properties, comprising: - a first layer (10) of non-woven fabric comprising a percentage by weight of oxidized polyacrylonitrile fibers equal to or greater than 40% to confer flame-retardant properties to the composite material (1), the remaining percentage by weight consisting of other synthetic fibers, said first layer (10) having a basis weight between 200 g/m2 and 600 g/m2 and a thickness between 1.6 mm and 5 mm; - a barrier layer (20), overlapping said first layer (10) and suitable to counteract the passage of molten polymers through said composite material (1). The oxidized polyacrylonitrile fibers of said first layer (10) have a count between 1.5 - 5 dtex and the other synthetic fibers of said first layer (10) have a count between 0.8 dtex and 5 dtex. The barrier layer (20) consists of a second layer of non-woven fabric of hydro-entangled synthetic and/or artificial fibers. The barrier layer (20) has: - a basis weight of between 70 g/m2 and 150 g/m2; - a thickness of between 0.4 mm and 1.5 mm; and - a permeability to air of between 200 L/m2s and 2000 L/m2s under a pressure drop of 2 mbar, measured in accordance with ISO 9237. The composite material (1) has a thickness between 2 mm and 6.5 mm, and a basis weight between 270 g/m2 and 750 g/m2.