Fire Resistant Composite With Thermally Conductive Layers
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Solution Overview
Problem
Self-reinforced thermoplastic composite materials face challenges in achieving flame resistance without compromising stiffness, surface properties, and durability, as flame retardant materials often interfere with adhesion and strength, and protective layers can lead to flaming drips during vertical burn tests.
Innovation Solution
A fire-resistant composite structure featuring an inner core with interwoven fabric layers, a first and second flame stable thermally conductive layer on the upper and lower surfaces respectively, and an optional fire-resistant polymer layer, all adhered together with binding tie layers, providing high flame stability and thermal conductivity while maintaining material integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flame retardant material is introduced through the matrix material, then flame resistance is improved, but adhesion and strength properties deteriorate
Solution Approach 1:
The composite is divided into distinct functional layers: an inner core layer made of self-reinforced thermoplastic composite material (without flame retardant additives) and an outer protective layer with flame resistant properties. This segmentation allows each layer to perform its specific function without compromising the overall structure - the inner core maintains strength and adhesion while the outer layer provides flame resistance.
2Reliability
If protective outer layers with flame resistant properties are used, then flame resistance is improved, but surface properties and durability deteriorate
Solution Approach 1:
Flame resistant properties are applied locally to the outer protective layer rather than throughout the entire composite structure. This allows the inner core to maintain its original surface properties and durability characteristics, while only the exposed outer surface receives the flame resistant treatment. The binding tie layer ensures this local modification does not compromise overall structural integrity.
3Strength
If self-reinforced thermoplastic composite materials are used, then stiffness and lightweight properties are improved, but flame resistance deteriorates due to melting and flaming drips
Solution Approach 1:
The outer protective layer acts as an intermediary barrier between the flame source and the self-reinforced thermoplastic inner core. This protective layer prevents direct flame contact with the inner core, stopping the melting and flaming drip process before it can occur. The binding tie layer serves as a secondary intermediary, ensuring the protective layer remains firmly attached to the inner core during thermal stress.
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 composite achieves effective flame resistance without compromising stiffness or surface properties, as the thermally conductive layers draw heat away from the flame, and the flame stable layers prevent oxygen permeation, leading to self-extinguishment and preventing flaming drips during burn tests.
Implementation Method 1
the thermally conductive layers draw heat away from the flame
Implementation Method 2
the flame stable layers prevent oxygen permeation
Data Source
AI summary
A fire resistant composite containing an inner core having an upper surface and a lower surface and a plurality of fabric layers. Each fabric layer contains a plurality of interwoven tape elements with a base layer of a strain oriented thermoplastic polymer disposed between covering layers of a heat fusible polymer. The fire resistant composite contains a first flame stable thermally conductive layer on the upper surface of the inner core having a high flame stability and a thermal conductivity of at least about 10 W/m-K at 25° C. and a second flame stable thermally conductive layer on the lower surface of the inner core having a high flame stability and a thermal conductivity of at least about 10 W/m-K at 25° C. The fire resistant composite further contains a first fire resistant polymer layer on the first flame stable thermally conductive layer on the side opposite to the inner core.