Compressed Intumescent Layer for Fire-Resistant Engine Components
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Solution Overview
Problem
The use of intumescent materials in engine components is not common, and there is a lack of effective methods to produce layered composites with intumescent materials in a compact and efficient manner for fire-resistant applications in the engine sector.
Innovation Solution
A production method involving stacking intumescent, porous material layers with other material layers and impregnating them with a hardening resin, applying pressure to compress the intumescent material, and sealing it with the resin to create a fire-resistant composite with reduced resin usage and enhanced rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If intumescent porous material is used to create fire-resistant layers, then fire resistance is improved, but layer thickness and resin usage increase
Solution Approach 1:
The intumescent material is compressed before the resin hardens, preparing it in advance to expand when exposed to fire. This preliminary compression allows the material to be thin during manufacturing while still providing sufficient fire protection when needed.
Solution Approach 2:
The physical state of the intumescent material is changed from expanded to compressed form through application of pressure. This parameter change allows the material to occupy less space during manufacturing while maintaining its fire-resistant functionality when triggered by heat.
2Volume of moving object
If intumescent material is compressed to reduce thickness, then layer thickness is reduced, but structural integrity may be compromised
Solution Approach 1:
The intumescent material is combined with resin to form a composite structure. The resin provides structural integrity and mechanical strength to the compressed intumescent material, while the intumescent material provides fire resistance. This composite approach allows both thinness and strength to be achieved simultaneously.
Solution Approach 2:
The intumescent material and resin are merged into a single integrated layer. The resin impregnates the compressed intumescent material, creating a unified structure where the resin matrix provides mechanical strength while the intumescent particles provide fire protection functionality.
3Strength
If more resin is used to bind intumescent material, then structural integrity is improved, but resin usage and weight increase
Solution Approach 1:
The resin is applied locally to the compressed intumescent material rather than uniformly throughout the entire structure. The resin concentration is optimized in the regions where it is most needed to bind the intumescent particles, reducing overall resin usage while maintaining structural integrity.
4Reliability
If intumescent material is used in traditional configurations, then fire resistance is achieved, but manufacturing complexity increases
Solution Approach 1:
The compressed intumescent resin composite serves multiple functions simultaneously: it provides fire resistance, structural integrity, and thin profile. This multi-functionality eliminates the need for separate fire protection layers and structural layers, simplifying the manufacturing process.
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 method produces a layered composite with a thin, fire-resistant intumescent layer that swells to form a heat shield upon temperature increase, effectively preventing flame propagation while maintaining structural integrity and reducing resin usage.
Implementation Method 1
The use of an intumescent, porous material ensures that the introduced resin or the introduced resin mass can be absorbed by the porous or porous intumescent material and thus the intumescent material is saturated with the resin
Implementation Method 2
The supplied resin is used on the one hand to increase the rigidity and resistance of the layer with the intumescent, porous material in the layer composite and to bond the layer with the intumescent material to the at least one other layer
Implementation Method 3
In the event of a fire or when the temperature rises above a critical threshold value, the resin outgass or vaporizes from the intumescent material and thus releases the intumescent material so that it can swell or foam
Implementation Method 4
it is also known to use intumescent, porous building materials which swell or foam up under the influence of heat and thus increase their volume considerably in the event of a fire
Implementation Method 5
the resin outgass or vaporizes from the intumescent material and thus releases the intumescent material so that it can swell or foam
Data Source
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Figure 3A
AI summary
The invention relates in particular to a method for producing a layered composite (2, 2a, 2b) from which an engine component (FC, N, VK1, VK2) can be at least partially produced, wherein the layered composite (2, 2a, 2b) is multilayered and comprises at least one layer (21) with an intumescent, porous material and at least one further layer (20, 20a, 20b, 23), wherein, for the production of the layered composite (2, 2a, 2b), at least one material layer (21') of the intumescent and porous material is stacked together with at least one material layer (20', 20a', 20b', 23') for the at least one further layer (20, 20a, 20b, 23) in a tool (1), and after stacking the material layers (20', 20a', 20b'), 23', 21') at least the intumescent, porous material is impregnated by a hardening resin.According to the invention, it is provided that - before impregnation, a pressure (p1) is applied to the stacked material layers (20', 20a', 20b', 23', 21') in order to compress at least the material layer (21') of the intumescent, porous material, and - the curing resin holds the material layer (21') of the intumescent, porous material in its compressed form in the layered composite (2, 2a, 2b) and seals it against the penetration of a liquid.