3D Molded Fibrous Part with Flame-Resistant Granules
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Solution Overview
Problem
Existing three-dimensional molded fiber parts have poor insulating properties and are combustible, limiting their application in thermal insulation and safety-critical areas.
Innovation Solution
Incorporating non-flammable, water-repellent, or oil-repellent granules with fibers during the molding process, which are blown into a multi-part mold and bonded with heat or a binder, allowing for adjustment of thermal conductivity and combustibility, thereby enhancing the fiber part's insulating ability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fibers are used to form three-dimensional molded fiber parts, then the parts can be produced with lightweight and strong properties, but the parts are easily flammable and have poor insulating properties with relatively high thermal conductivity
Solution Approach 1:
The patent applies composite materials by combining traditional fibers with granules having specific properties (non-flammable, water-repellent, or oil-repellent characteristics). This creates a hybrid material structure where the granules provide flame resistance and improved insulation while the fibers maintain the lightweight and strong structural properties, thus resolving the contradiction between structural integrity and fire safety
Solution Approach 2:
The patent changes the material composition parameters by incorporating granules with controlled properties into the fiber matrix. This parameter modification allows tuning of thermal conductivity and flammability characteristics while preserving the essential mechanical properties of the original fiber-based structure
2Reliability
If traditional fibers are used to form three-dimensional molded fiber parts, then the parts can be produced with lightweight and strong properties, but the parts have poor insulating properties with relatively high thermal conductivity
Solution Approach 1:
The patent uses composite materials by integrating granules with specific thermal properties into the fiber structure. These granules act as thermal barriers, reducing heat transfer through the material while maintaining the lightweight characteristics of the original fiber-based composite
Solution Approach 2:
The incorporation of granules creates a porous or heterogeneous structure within the molded fiber part. This increased porosity traps air pockets and reduces thermal pathways, thereby improving insulating capacity while maintaining low density and lightweight properties
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 resulting molded fiber parts exhibit improved thermal insulation, reduced flammability, and increased safety, making them suitable for applications like building insulation and tunnel structures without the risks associated with combustible materials.
Implementation Method 1
the fibers are blown into a multi-part, perforated mold by an airflow. The fibers adhere to the inner wall of the mold
Implementation Method 2
The fibers adhere to the inner wall of the mold and are bonded to each other by the application of heat and/or a binding agent
Data Source
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AI summary
A three-dimensional fiber molded part (1) comprising fibers (2) which are blown into a mold (17) and bonded to one another by the application of heat and/or a binding agent. The fiber molded part (1) additionally comprises granules (3) mixed with the fibers (2). Method and apparatus (10) for producing a three-dimensional fiber molded part (1).