Fire Insulation Composition for Thin Single-Layer Duct Protection
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Solution Overview
Problem
Current fire insulation materials for ductwork and other components often require multiple layers and thick insulation to meet fire resistance standards, and recent European standards mandate insulation for drop rods over 1.5 meters in length to prevent elongation due to temperature rise during fires, posing challenges in achieving effective fire protection while maintaining structural integrity.
Innovation Solution
A fire insulation precursor material comprising cement (10-30% w/w), aluminium or magnesium hydroxide (60-90% w/w), and a cracking resistant agent like mica or fibers (2-10% w/w), which can be mixed with an aqueous solution to create a mortar for use in panels, ducts, and drop rods, providing enhanced fire resistance and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple layers and thick insulation material are used to achieve fire resistance standards, then fire resistance is improved, but device complexity and material quantity increase
Solution Approach 1:
The invention uses a composite material formulation combining cement (10-30% w/w), aluminium or magnesium hydroxide (60-90% w/w), and cracking resistant agents (2-10% w/w) to achieve required fire resistance in a single layer, eliminating the need for multiple layers while maintaining or improving fire protection performance
Solution Approach 2:
The invention changes the chemical composition parameters of the insulation material by incorporating specific ratios of cement, metal hydroxides, and cracking resistant agents, which fundamentally alters the material's fire resistance properties and structural behavior under thermal stress
2Reliability
If thick insulation material is used to meet fire standards, then fire resistance is improved, but material quantity and weight increase
Solution Approach 1:
The composite formulation with optimised ratios of cement, metal hydroxides, and cracking resistant agents enables thinner insulation sections to achieve the same fire resistance performance, reducing the quantity of material required while meeting fire safety standards
Solution Approach 2:
By changing the chemical composition parameters to include high concentrations of metal hydroxides (60-90% w/w) which decompose endothermically during fire exposure, the material achieves superior fire resistance per unit thickness, reducing the required insulation thickness
3Reliability
If insulation material is applied to drop rods to prevent elongation during fire, then structural integrity is improved, but device complexity increases
Solution Approach 1:
The single-layer composite insulation material provides complete fire protection for drop rods in one application layer, eliminating the need for complex multi-layer systems while effectively preventing thermal elongation and maintaining structural integrity
Solution Approach 2:
The inclusion of cracking resistant agents (mica or fibres at 2-10% w/w) changes the physical parameters of the insulation material to prevent cracking under thermal stress, ensuring continuous protection and maintaining structural integrity without additional components
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 effectively meets or exceeds fire resistance standards, such as 1-2 hours of fire resistance, as demonstrated by compliance with BS EN1366 and other standards, while maintaining structural integrity and reducing material thickness, thus offering improved fire protection and efficiency.
Implementation Method 1
an aluminium or magnesium hydroxide, huntite or hydromagnesite, in an amount of between 60 - 90% w/w
Implementation Method 2
cement, in an amount of between 10-30% w/w
Implementation Method 3
a cracking resistant agent wherein the cracking resistant agent is mica or fibres in an amount of between 2-10% w/w
Data Source
Figure 1
Figure 2
AI summary
A fire insulation precursor material comprising: (i) cement, in an amount of between 10-30% w/w;and (ii) analuminium or magnesium hydroxide, huntite or hydromagnesite in an amount of between 60 -90% w/w