Thermally Expandable Graphite Resin Composition for Fire Resistance
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Solution Overview
Problem
Thermally expandable resin compositions face challenges in achieving both high expansion and high residue hardness after combustion, as high expansion typically results in reduced residue hardness.
Innovation Solution
The resin composition is formulated with thermally expandable graphite having an expansion starting temperature lower than the decomposition starting temperature of the resin component, ensuring high expansion and high residue hardness by forming a hard heat-insulating layer that delays resin decomposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermally expandable graphite is used to achieve high expansion, then fire resistance is improved, but residue hardness is reduced
Solution Approach 1:
The invention changes the temperature parameter relationship between expansion agent and resin by selecting thermally expandable graphite with expansion starting temperature of 200°C or lower, which is lower than the decomposition starting temperature of the resin component. This parameter change ensures that graphite expands first to form a protective layer before resin decomposes, thereby maintaining both high expansion and high residue hardness
Solution Approach 2:
The invention applies preliminary action by having the thermally expandable graphite expand before the resin component decomposes. The graphite forms a hard heat-insulating layer in advance that protects the underlying resin, preventing premature decomposition and maintaining residue hardness while achieving high expansion
2Strength
If thermally expandable graphite expands before resin decomposition, then high residue hardness is achieved, but expansion rate may be limited
Solution Approach 1:
The invention optimizes the temperature parameter by selecting graphite with expansion starting temperature of 200°C or lower, creating an ideal temperature sequence where graphite expands first at lower temperature, then resin decomposes at higher temperature, achieving both high expansion rate and high residue hardness
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 achieves long-time stable extrusion molding of complex shapes with excellent fire resistance, maintaining high expansion rates and residue hardness, as demonstrated by the expansion rate exceeding 10 and residue hardness exceeding 24.5 kPa after heating.
Implementation Method 1
thermally expandable graphite having an expansion starting temperature lower than the decomposition starting temperature of the resin component
Implementation Method 2
forming a hard heat-insulating layer that delays resin decomposition
Implementation Method 3
decomposition starting temperature of the resin component
Data Source
Figure 1~2
AI summary
This invention relates to a resin composition comprising a resin component in an amount of 100 parts by weight, thermally expandable graphite in an amount of 3 to 300 parts by weight, and an inorganic filler in an amount of 2 to 200 parts by weight, wherein the expansion starting temperature of the thermally expandable graphite is lower than the decomposition starting temperature of the resin component.