Curable Fireproof Composition Shape Retention

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Solution Overview

Problem

The thermally expandable fireproof materials described in existing patents exhibit insufficient strength and shape retention when the expansion ratio exceeds 5, making it difficult to maintain the shape of the cured product after firing.

Innovation Solution

A curable composition is developed that includes a shape retention agent, such as novolac-type epoxy resin, phosphorus compounds, or benzoxazine compounds, combined with (meth)acrylic acid ester polymers containing crosslinkable silicon groups and thermally expandable graphite, which maintains fluidity for application and achieves excellent shape retainability even at high expansion ratios.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the expansion ratio of the thermally expandable fireproof material is increased to enhance fireproof performance, then the fireproofing capability is improved, but the strength and shape retention of the expanded residue becomes insufficient

Engineering Contradiction:

Improvefireproof performanceVSAvoidstrength of expanded residue

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent uses a composite material system consisting of a resin component, thermally expandable component, and shape retention agent. The shape retention agent forms a crosslinked structure with the resin component, creating a composite that maintains both high expansion ratio and shape retention. This composite approach allows the material to achieve both fireproof performance and structural integrity after expansion.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the chemical and physical parameters of the fireproof material by introducing a shape retention agent that forms crosslinked structures. This modification alters the material's properties to enable it to maintain shape and strength even at high expansion ratios, resolving the contradiction between expansion capability and structural integrity.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If the expansion ratio is set high to improve fire blocking capability, then the fire spread prevention is enhanced, but the shape retention after firing becomes poor

Engineering Contradiction:

Improvefire spread preventionVSAvoidshape retention after firing

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The shape retention agent acts as an intermediary substance that mediates between the thermally expandable component and the resin component. It forms crosslinked structures that maintain shape integrity while allowing the thermally expandable component to provide fire blocking capability through high expansion ratio.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The composite material system with the shape retention agent creates a synergistic effect where the resin component provides structural matrix, the thermally expandable component provides fire blocking through expansion, and the shape retention agent ensures shape maintenance. This composite structure enables both high expansion ratio for fire prevention and excellent shape retention.

Inventive Principle:

Principle #40Composite materials

3Ease of operation

If the curable composition is made to have high fluidity for easy application, then the ease of application is improved, but the shape retention capability after curing is reduced

Engineering Contradiction:

Improveease of applicationVSAvoidshape retention capability

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The shape retention agent is incorporated into the curable composition in advance, forming crosslinked structures during the curing process. This preliminary action ensures that once the material is applied and cured, it automatically gains shape retention capability without requiring additional processing steps, thus maintaining both ease of application and shape stability.

Inventive Principle:

Principle #10Preliminary action

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 composition forms a cured product with excellent fireproof performance and shape retention, maintaining at least 50% of its volume after firing, providing enhanced fireproofing and structural integrity even under high temperature exposure.

Implementation Method 1

a thermally expandable fireproof material that is used where the thermally expandable fireproof material is injected in a hollow portion of a resin framework

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

a curable composition for fireproofing... when a cured product after curing of the fireproof curable composition is fired

Methodology Applied

Scientific EffectCuring reaction: Chemical Bonding

Data Source

PatentUS11827773B2Curable composition for fireproofing

Publication Date: 2023.11.28 CEMEDINE CO LTD

AI summary

Provided is a curable composition which forms a cured product that has excellent fireproof performance, while having excellent shape retainability even in cases where the expansion ratio of the cured product after firing is set to a high value. This curable composition includes a shape retention agent, while having fluidity when applied; and if a cured product that is obtained by curing this curable composition is fired in 600° C. air atmosphere for 30 minutes, the cured product after firing has shape retainability.