Composite Sheet Flame Barrier for Cargo Containers

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

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, such as lithium-ion batteries, and lack the necessary durability and maintenance-free longevity while maintaining fire resistance.

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, providing a flame barrier cover of at least 90% and enhanced durability through chemical, thermal, or mechanical bonding, and resistance to temperature extremes and water immersion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If conventional cargo containers are used, then weight reduction is achieved, but fire containment capability deteriorates

Engineering Contradiction:

Improvecontainer weightVSAvoidfire containment capability

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent applies composite materials by combining multiple fabric layers with different properties (first fabric with continuous filament yarns, second fabric with continuous glass yarns) and polymeric layers to create a composite sheet that achieves both lightweight construction and fire containment capability. The composite structure allows each material to contribute its strengths while compensating for weaknesses.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent uses flexible shells and thin films through the polymeric layers (first polymeric layer and second polymeric layer) that provide fire resistance and structural integrity. These thin film layers act as barriers to fire spread while maintaining the lightweight and flexible characteristics needed for cargo container applications.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If fire resistant materials are added to cargo containers, then fire containment capability is improved, but weight increases

Engineering Contradiction:

Improvefire containment capabilityVSAvoidcontainer weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent applies local quality by strategically placing different material layers at specific positions within the composite sheet structure. The first fabric, second fabric, and polymeric layers are arranged in a specific sequence to provide fire containment where needed while maintaining overall lightweight construction. Each layer is positioned to contribute its specific function without unnecessary weight.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent utilizes parameter changes by specifying precise parameters for the fabric layers (yarn types, filament continuity, fabric density) and polymeric layers to optimize the balance between fire resistance and weight. By carefully controlling these parameters, the composite sheet achieves maximum fire containment capability with minimum weight.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If existing fire protection products are used, then fire resistance is provided, but durability and maintenance-free operation are insufficient

Engineering Contradiction:

Improvefire resistanceVSAvoidservice lifetime

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent uses composite materials to enhance durability by combining multiple fabric layers with different mechanical properties and polymeric layers. This composite structure provides both fire resistance and long-term durability, with each material contributing to structural integrity and resistance to degradation from environmental factors such as water immersion and temperature extremes.

Inventive Principle:

Principle #40Composite materials

4Reliability

If the composite sheet uses heavier fabrics to improve flame barrier cover, then fire containment is improved, but weight increases

Engineering Contradiction:

Improveflame barrier coverVSAvoidcomposite sheet weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent applies local quality by using different fabric types with specific properties in different layers. The first fabric with continuous filament yarns and the second fabric with continuous glass yarns are selected to provide optimal flame barrier cover while maintaining lightweight construction. Each layer is designed with specific characteristics that contribute to fire containment without unnecessary weight.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent utilizes parameter changes by specifying precise parameters for the fabric layers including yarn types, filament continuity, and fabric density to optimize the balance between flame barrier cover and weight. By carefully controlling these parameters, the composite sheet achieves the required fire containment capability with minimum weight.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS10029439B2Composite sheet and cargo container comprising same

Publication Date: 2018.07.24 DUPONT SAFETY & CONSTRUCTION INC

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.