Expandable Fire-Resistant Sheet for Low-Temperature Long Roll Molding
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Solution Overview
Problem
Thermally expandable graphite used in fire-resistant sheets often forms a roughened surface and bubbles during molding, making it difficult to produce long sheets with a good appearance.
Innovation Solution
A thermally expandable fire-resistant sheet comprising a matrix component and thermally expandable graphite with an expansion onset temperature of 160°C or less, having a length of 1 m or more, and a thickness variation of 10% or less, incorporating a thermally expandable inorganic material and inorganic filler, with specific component ratios and adhesives to reduce kneading load and prevent degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermally expandable graphite with low expansion onset temperature is used, then fire resistance is improved, but surface quality deteriorates (roughened surface and bubbles form)
Solution Approach 1:
The patent changes the particle size parameter of thermally expandable graphite to 3 μm or less, and adjusts the expansion onset temperature to 160°C or less by selecting specific graphite types. These parameter changes allow the graphite to expand at lower temperatures without causing surface defects, resolving the contradiction between fire resistance and surface quality
Solution Approach 2:
The patent creates a composite material system combining thermally expandable graphite with specific resins (polyvinyl chloride, polyacrylic acid, and their copolymers) and inorganic fillers. This composite formulation enables controlled expansion at low temperatures while maintaining surface quality during molding, addressing both fire resistance and manufacturing precision requirements
2Reliability
If thermally expandable graphite is used in fire-resistant sheets, then fire-resistant insulating properties are improved, but production difficulty increases (bubbles form, making long sheets difficult to produce)
Solution Approach 1:
The patent changes the particle size parameter of thermally expandable graphite to 3 μm or less, which prevents bubble formation during molding while maintaining fire-resistant properties. This parameter adjustment makes it possible to produce long sheets (1 m or more) with good appearance, resolving the manufacturing difficulty
Solution Approach 2:
The patent applies local quality by using fine particle size graphite (3 μm or less) uniformly distributed in the resin matrix, ensuring that the expansion behavior is controlled locally without causing bubbles. This allows production of long sheets with consistent quality throughout
3Speed
If thermally expandable graphite expands at low temperatures, then response time in fire is improved, but sheet length is limited (cannot produce long sheets with good appearance)
Solution Approach 1:
The patent changes the particle size parameter to 3 μm or less and controls expansion onset temperature to 160°C or less, which enables rapid response while preventing surface defects. This allows production of long sheets (1 m or more) that maintain good appearance throughout their length
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 solution provides a thermally expandable fire-resistant sheet with a low expansion onset temperature, good appearance, and long length, enhancing fire resistance and productivity while maintaining dimensional accuracy and reducing gas generation.
Implementation Method 1
the fire-resistant sheets expand when heated, to form fire-resistant insulating layers of combustion residues, thereby exhibiting fire-resistant insulating properties
Data Source
AI summary
A thermally expandable fire-resistant sheet of the present invention is a thermally expandable fire-resistant sheet including a matrix component and thermally expandable graphite, and having an expansion onset temperature of 160°C or less, the thermally expandable fire-resistant sheet having an average thickness of 0.5 mm or more and a thickness variation that is 10% or less of the average thickness, and being a wound body with a length of 1 m or more. According to the present invention, a long thermally expandable fire-resistant sheet including thermally expandable graphite with a low expansion onset temperature can be provided.