Expandable Graphite Coating for Flame-Resistant Fabrics

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Solution Overview

Problem

Coated fabrics used in construction lack effective flame resistance and resistance to flame spread, which is a critical concern for safety and performance in building materials.

Innovation Solution

Incorporating expandable graphite into the coating of fabrics, combined with a polymeric binder and optional additional binders and fillers, to create a fire-resistant and flame-retardant material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional coating materials (mineral pigment, polymer latex adhesive, inorganic binder) are used, then the coating provides basic protective functions, but the flame resistance and resistance to flame spread are insufficient

Engineering Contradiction:

Improveflame resistanceVSAvoidflame spread

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies composite materials by combining expandable graphite with conventional coating materials (polymer latex adhesive and inorganic binder) to create a multi-functional coating. The expandable graphite particles are dispersed throughout the coating matrix, providing flame resistance and resistance to flame spread while maintaining the protective functions of the conventional coating materials.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent utilizes parameter changes by incorporating expandable graphite that undergoes thermal expansion when exposed to fire. The graphite particles expand volumetrically in response to heat, creating a physical barrier that insulates the underlying fabric and prevents flame spread, thereby transforming the coating's physical state in response to thermal conditions.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If expandable graphite is added to the coating, then flame resistance and resistance to flame spread are improved, but the coating composition complexity increases

Engineering Contradiction:

Improveflame resistivityVSAvoidcoating composition

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The expandable graphite serves multiple functions simultaneously: it acts as a flame retardant, provides thermal insulation through expansion, and maintains structural integrity of the coating. This multi-functionality reduces the need for additional specialized additives that would further complicate the coating composition.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 coated fabrics exhibit enhanced flame resistivity and resistance to flame spread, making them suitable for use in construction materials that require improved safety and performance.

Implementation Method 1

expandable graphite dispersed throughout the binder

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS10273693B2Coated fabrics including expandable graphite

Publication Date: 2019.04.30 AMRIZE TECHNOLOGY SWITZERLAND LLC

AI summary

A coated fabric comprising a fabric substrate and a coating on said substrate, the coating comprising a binder and expandable graphite dispersed throughout the binder.