Fire Resistant Composite Mat for Lightweight Sandwich Constructions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for lightweight, strong, and VOC-free sandwich constructions with high flame resistance to replace existing prefabricated walls and panels, which are often heavy, prone to water damage, and emit formaldehyde.
Innovation Solution
A composite mat comprising woven or non-woven fibers, a polymeric binder, and a fire-resistant additive, such as organophosphorus compounds or borate salts, applied as a laminate or dispersed throughout the fibers, which can be used in sandwich constructions without formaldehyde or styrene, and with a thermoplastic polymer film and clear coat for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional fiberglass reinforced plastics and plywood are used for sandwich constructions, then structural strength and rigidity are achieved, but the construction becomes heavy and prone to water damage
Solution Approach 1:
The patent uses a composite mat made of cellulosic fibers (such as wood fibers, bast fibers, or agricultural residues) bound with a polymeric binder and fire-resistant additives. This composite material provides structural strength comparable to traditional fiberglass and plywood while being significantly lighter and more resistant to water damage.
Solution Approach 2:
The patent changes the material composition parameters by using cellulosic fibers instead of fiberglass, and employs specific polymeric binders (such as polyvinyl acetate, polyurethane, or epoxy resins) with controlled fiber-to-binder ratios to achieve the desired strength-to-weight ratio while maintaining light weight properties.
2Reliability
If traditional prefabricated walls and panels are used, then structural integrity is maintained, but formaldehyde emissions and VOC release occur
Solution Approach 1:
The patent employs fire-resistant additives (such as borates, phosphates, or metal hydroxides) within the composite mat that create a chemically inert environment resistant to combustion and decomposition, preventing the release of harmful formaldehyde and VOC emissions while maintaining structural integrity under various conditions.
Solution Approach 2:
The patent uses naturally derived cellulosic fibers (such as wood fibers, agricultural residues, or paper products) as renewable, biodegradable materials that replace synthetic fiberglass and plywood, providing structural integrity without the harmful chemical emissions associated with traditional materials.
3Reliability
If fire-resistant additives are added to the composite mat, then flame resistance is improved, but the complexity of material composition increases
Solution Approach 1:
The patent combines fire-resistant additives (such as borates, phosphates, or metal hydroxides) directly into the polymeric binder matrix during the manufacturing process, creating a homogeneous composite material where fire protection and structural functions are merged into a single integrated material system, simplifying application despite the enhanced functionality.
Solution Approach 2:
The patent uses polymeric binders that serve multiple functions: providing structural binding between fibers, offering fire resistance through inherent flame-retardant properties or additive incorporation, and ensuring water resistance. This multi-functionality reduces the need for separate treatment layers or additional materials.
4Weight of moving object
If cellulosic materials are used in sandwich constructions, then lightweight and environmental friendliness are achieved, but flame resistance is insufficient
Solution Approach 1:
The patent converts the naturally occurring cellulosic structure, which is inherently combustible, into a fire-resistant material by incorporating fire-resistant additives (such as borates, phosphates, or metal hydroxides) that chemically modify the fiber-binder matrix, transforming the material's response to fire from combustible to flame-retardant while preserving the lightweight cellulosic base.
Solution Approach 2:
The patent creates a composite mat where cellulosic fibers (providing lightweight structure) are combined with polymeric binders and fire-resistant additives, forming a multi-phase composite material that simultaneously achieves light weight, structural integrity, and flame resistance through the synergistic interaction of its 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 composite mat provides excellent flame resistance, preventing combustion of core materials and allowing the use of cellulosic materials, while eliminating formaldehyde and styrene emissions, resulting in a lightweight, strong, and environmentally friendly construction solution.
Implementation Method 1
the fire resistant additive can be an organophosphorus compound, a borate salt, a melamine compound, an aluminum compound, and antimony compound
Implementation Method 2
preventing combustion of core materials
Data Source
Figure 1~2
AI summary
Disclosed herein are flame resistant composite mats. The composite mat contains a fiber, fire resistant additive, and a binder. The mats are useful in the production of flame resistant sandwich constructions.