Compressed Cork Structure for Fire-Resistant Thermal Insulation
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Solution Overview
Problem
There is a need for a thermally insulating material that is easy to manufacture and can withstand extreme fire conditions, particularly for applications involving electrical batteries or accumulators.
Innovation Solution
A method of producing a cork product with a density of at least 1,050 kg/m³ by compressing cork by at least 50% of its initial volume, combined with additional materials to form a sandwich panel or 3D sandwich material, which is tested for fire resistance using gas burner and pyrotechnics tests.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cork is compressed to increase density for improved mechanical strength, then mechanical strength and handling are improved, but thermal insulation performance deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the compression process to achieve a specific density range (1,050-1,700 kg/m³) and compression ratio (50-85%). This optimized parameter range creates a unique cellular structure that simultaneously provides mechanical strength and thermal insulation, resolving the contradiction between these two properties.
Solution Approach 2:
The patent creates a composite structure within the cork material itself by forming a specific cellular architecture through controlled compression. The compressed cork develops a composite-like internal structure with cell walls and voids that work together to provide both mechanical strength and thermal insulation properties.
2Strength
If cork is highly compressed to achieve density of at least 1,050 kg/m³, then mechanical strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent simplifies manufacturing by establishing clear parameter ranges for compression (50-85% compression ratio, final density of 1,050-1,700 kg/m³). These defined parameters make the manufacturing process controllable and reproducible, reducing complexity while achieving the desired mechanical strength.
Solution Approach 2:
The patent applies preliminary action by pre-compressing the cork material to the target density range before final product assembly. This pre-compression step ensures the material has the required mechanical strength beforehand, simplifying subsequent manufacturing steps and reducing overall process complexity.
3Temperature
If compression ratio is increased to improve thermal insulation, then thermal insulation performance is improved, but volume of the cork product decreases
Solution Approach 1:
The patent optimizes the compression ratio parameter to a specific range (50-85%) that achieves the best balance between thermal insulation performance and volume retention. This optimized parameter range creates a cellular structure that provides excellent thermal insulation while minimizing excessive volume reduction.
Solution Approach 2:
The patent applies local quality by creating different density regions within the cork product through controlled compression. The compression is optimized to create a cellular structure with specific local characteristics that provide thermal insulation while maintaining overall volume efficiency for the application.
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 compressed cork product demonstrates thermal insulation and fire resistance, passing stringent fire tests even at high densities, making it suitable for protecting electrical components from extreme heat and flames.
Implementation Method 1
a thermally insulating cork product
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a method for producing a cork product. To provide a thermally insulating and fire-resistant material, in particular one that is easy to produce, the cork product produced according to the invention by compressing the cork by at least 50% of its initial volume has a density of at least 1,050 kg/m³. The invention further relates to the cork product and its use.