Composite Sheet Fire Barrier for Cargo Containers
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Solution Overview
Problem
Current cargo containers, particularly those used in aircraft, face challenges in containing fire spread due to the increasing risk of flammable materials like lithium-ion batteries, necessitating a lightweight, durable, and low-maintenance solution with enhanced fire-resistant capabilities that meet stringent regulatory standards.
Innovation Solution
A non-rigid composite sheet comprising a first fabric of continuous filament yarns, a second fabric of continuous glass yarns, and a polymeric layer, with specific weight ranges and materials chosen for optimal flame barrier coverage, tensile strength, and durability, including a polymeric coating to enhance flame resistance and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional cargo container materials are used, then weight is reduced, but fire resistance capability deteriorates
Solution Approach 1:
The patent applies composite materials by combining multiple fabric layers with different properties (aramid, glass fiber, carbon fiber) and polymeric coatings to create a lightweight yet fire-resistant composite sheet. The composite structure leverages the high strength-to-weight ratio of aramid fibers, the thermal stability of glass fiber, and the flame retardancy of carbon fiber, achieving both fire resistance and weight reduction simultaneously.
Solution Approach 2:
The patent utilizes parameter changes by selecting specific areal weight ranges (88-678 gsm for first component, 136-508 gsm for second component) and polymeric coating weights (20-50% of fabric weight) to optimize the balance between fire resistance and weight. By carefully controlling these parameters, the composite sheet achieves enhanced flame barrier coverage while maintaining minimal weight.
2Reliability
If fire resistant materials are used, then fire containment capability is improved, but weight increases
Solution Approach 1:
The patent applies local quality by positioning different fabric types in specific locations within the composite sheet structure. The first fabric layer (aramid) provides primary fire resistance, the second fabric layer (glass fiber) provides structural stability, and the polymeric coating enhances flame barrier properties. This localized assignment of functional properties optimizes fire containment while minimizing overall weight.
3Weight of moving object
If lightweight materials are used, then weight is reduced, but structural integrity deteriorates
Solution Approach 1:
The patent uses composite materials to achieve both lightweight and high structural integrity. The combination of aramid, glass fiber, and carbon fiber fabrics creates a multi-layer composite that leverages the complementary strengths of each material: aramid provides high tensile strength, glass fiber provides dimensional stability, and carbon fiber provides flame retardancy. The polymeric coating binds these layers together while maintaining lightweight properties.
4Object-affected harmful factors
If heavy fire resistant materials are used, then fire resistance is improved, but weight increases
Solution Approach 1:
The patent applies parameter changes by optimizing the areal weight ranges of individual fabric components and polymeric coating weights to achieve maximum flame barrier coverage with minimum weight. The first fabric is selected with areal weight of 88-678 gsm, the second fabric with 136-508 gsm, and polymeric coating at 20-50% of fabric weight. These parameter optimizations ensure effective fire resistance without excessive weight gain.
Data Source
AI summary
A non-rigid composite sheet comprising in order (i) a first component comprising at least one first fabric of continuous filament yarns having a tenacity of at least 11 g/dtex and a first polymeric layer, (ii) a second component comprising at least one second fabric of continuous filament glass yarns, the at least one second fabric being adjacent to the at least one first fabric of the first component, and (iii) a third component comprising a second polymeric layer.