Fire-Resistant Building Boards With Composite Mineral Formulation
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Solution Overview
Problem
There is a need for improved, eco-friendly fire-resistant compositions and articles that can effectively protect building infrastructure and occupants during fires, as existing materials may not provide adequate protection at high temperatures for extended periods.
Innovation Solution
The development of fire-resistant compositions comprising a binder, an additive, a filler, and a fire-resistant material, specifically using Portland cement, perlite, wollastonite, basalt fiber, sodium alpha olefin sulfonate, and zinc borate, which are combined in specific weight percentages to create a dry mixture that can be used to form fire-resistant articles such as boards and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional building materials are used, then the materials are easy to manufacture and cost-effective, but they do not provide adequate fire resistance and structural integrity at high temperatures
Solution Approach 1:
The patent applies composite materials by combining multiple components (cement, perlite, meta-kaolin, wollastonite, basalt fiber, zinc borate, and surfactant) to create a fire-resistant composition that achieves superior fire resistance while maintaining ease of manufacture through a simple mixing process. The composite nature allows each ingredient to contribute specific properties: cement provides structural base, perlite and meta-kaolin provide heat resistance and expansion, wollastonite enhances high-temperature strength, basalt fiber provides tensile strength, zinc borate offers fire retardancy, and surfactant ensures uniform distribution.
2Reliability
If fire resistant materials are designed to maintain integrity at higher temperatures, then reliability improves, but the complexity of the composition and preparation method increases
Solution Approach 1:
The patent applies parameter changes by optimizing the weight percentages of each ingredient to achieve the desired fire resistance and structural integrity. Specific parameter ranges are defined: cement (20-40%), perlite (30-50%), meta-kaolin (5-15%), wollastonite (5-20%), basalt fiber (0.1-1%), zinc borate (1-10%), and surfactant (0.1-1%). These parameter optimizations ensure the composition maintains structural integrity at high temperatures while keeping the formulation practical and not overly complex.
3Object-affected harmful factors
If eco-friendly materials are used, then environmental impact is reduced, but fire resistance performance may be compromised
Solution Approach 1:
The patent applies the blessing in disguise principle by using naturally occurring, eco-friendly materials (perlite, meta-kaolin, wollastonite, basalt fiber) that are abundant in nature and environmentally benign, yet combining them in specific proportions to achieve superior fire resistance performance. The surfactant component ensures uniform distribution of these natural materials, maximizing their fire-resistant properties. This approach converts potentially weak individual natural materials into a high-performance fire-resistant composite that outperforms many conventional fire-resistant materials while maintaining eco-friendliness.
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
These compositions and articles provide enhanced fire resistance, maintaining integrity at high temperatures and reducing damage to buildings and infrastructure, while being environmentally friendly and suitable for use in various applications including buildings, airplanes, and spacecraft.
Implementation Method 1
the additive comprising at least one of perlite or meta kaolin
Implementation Method 2
the fire resistant material comprising zinc borate
Implementation Method 3
the filler comprising at least one of wollastonite, basalt fiber or sodium alpha olefin sulfonate
Implementation Method 4
a binder comprising at least one of Portland cement or lime
Data Source
AI summary
Disclosed herein are fire resistant compositions and articles, for example, in the form of boards, insulation, sheeting, blocks, panels and similar materials of construction. Also disclosed are methods of preparing fire resistant compositions and articles and methods of use thereof.