Fire-Resistant Composite Material with Lightweight High-Strength Layers
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Solution Overview
Problem
Existing carbon fiber composite materials for aerospace and construction are costly, heavy, and lack an optimal combination of mechanical strength, heat resistance, and light weight, making them impractical for widespread use.
Innovation Solution
A process involving a binder matrix composed of acetone, natural inert material (kaolin), synthetic aramid fiber powder (kevlar), and phenolic resin is used to create a fire-resistant composite material, which is then impregnated into a glass fiber backing layer and heated to enhance mechanical and thermal properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If carbon fiber composite materials are used to achieve high mechanical strength and heat resistance, then the material performance is improved, but the cost and weight increase significantly
Solution Approach 1:
The patent uses a composite material system consisting of a glass fiber backing layer combined with a fire-resistant composition containing phenolic resin, natural inert material, and synthetic aramid fiber powder. This composite structure achieves mechanical strength and heat resistance comparable to carbon fiber composites while using cheaper, lighter materials. The glass fiber provides structural strength, while the phenolic resin matrix provides heat resistance, creating an effective composite that resolves the contradiction between performance and weight/cost.
2Strength
If carbon fiber composite materials are used to achieve high mechanical strength and heat resistance, then the material performance is improved, but the cost increases significantly
Solution Approach 1:
The patent replaces expensive carbon fiber with cheaper alternatives: glass fiber backing layer and a fire-resistant composition using phenolic resin, natural inert material (like alumina or silica), and synthetic aramid fiber powder. These materials provide comparable mechanical strength and heat resistance at significantly lower cost, making the composite material economically viable for widespread construction applications rather than just high-end aerospace uses.
3Reliability
If materials are designed to withstand high temperatures and mechanical stress, then fire resistance is improved, but the material becomes heavier
Solution Approach 1:
The patent applies fire resistance locally where needed through the fire-resistant composition coating on the glass fiber backing layer, rather than making the entire structure heavy and fire-resistant. The composition contains phenolic resin (providing fire resistance), natural inert material (providing thermal stability), and synthetic aramid fiber powder (providing structural reinforcement). This localized application achieves fire resistance without adding excessive weight throughout the entire structure.
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 process produces a fire-resistant composite material with high mechanical and thermal resistance at a lower cost, achieving properties similar to expensive materials while maintaining lightweight characteristics.
Implementation Method 1
a binder matrix, in which a backing layer is subsequently impregnated
Implementation Method 2
heated to enhance mechanical and thermal properties
Data Source
AI summary
The present invention relates to a process for making a fire-resistant composite material and related high strength fire-resistant composite material made.