Multi-layered Fire Resistant Panel with Rigid Core
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Solution Overview
Problem
Existing fire-resistant panel solutions fail to meet stringent ASTM E84 Class I fire and smoke ratings and aesthetic requirements for laboratory and clean room applications, lacking sufficient rigidity and thinness while maintaining structural integrity.
Innovation Solution
A multi-layered fire-resistant panel member is produced using a method involving pigmented polyester resin, organic peroxides, flame retardants, and fiber materials, with a substantially rigid core, applied in sequential layers to achieve ASTM E84 Class I ratings and aesthetic compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing fire-resistant panel solutions are used, then fire resistance is provided, but they fail to meet ASTM E84 Class I fire and smoke ratings and aesthetic requirements
Solution Approach 1:
The patent applies composite materials by combining multiple resin layers (pigmented polyester resin with organic peroxide, and polyester resin with flame retardant) and fiber materials to create a panel that achieves ASTM E84 Class I fire and smoke ratings. The composite structure integrates flame retardant properties with aesthetic pigmented surfaces, resolving the contradiction between fire resistance and meeting stringent fire safety ratings.
Solution Approach 2:
The patent applies local quality by incorporating flame retardant materials specifically in the core layers (third and fourth layers) while maintaining pigmented aesthetic surfaces in the outer layers (first and second layers). This localized placement of fire-resistant materials achieves the required flame spread index ≤25 and smoke development index ≤450 while preserving aesthetic appearance on visible surfaces.
2Reliability
If fire-resistant panel solutions are used, then fire resistance is provided, but they lack sufficient rigidity for structural components
Solution Approach 1:
The patent applies composite materials by integrating a substantially rigid core member within the multi-layered panel structure. This rigid core provides the necessary structural strength and rigidity for building construction applications while the surrounding fire-resistant resin layers and flame retardant materials maintain the required fire resistance properties.
Solution Approach 2:
The patent applies the nesting principle by placing a substantially rigid core member inside the multi-layered fire-resistant panel structure. The core is nested within the third and fourth layers, allowing the panel to achieve both fire resistance (ASTM E84 Class I) and sufficient rigidity for structural applications simultaneously.
3Reliability
If fire-resistant panel solutions are used, then fire resistance is provided, but they are not thin enough for aesthetic applications
Solution Approach 1:
The patent applies composite materials by using a multi-layered structure with thin pigmented polyester resin layers (first and second layers) providing aesthetic surfaces and thin polyester resin layers with flame retardant (third and fourth layers) providing fire resistance. This composite approach achieves ASTM E84 Class I ratings while maintaining a thin overall profile suitable for aesthetic applications.
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 provides a fire-resistant panel with a maximum flame spread index of ≤25 and smoke development index of ≤450, meeting ASTM standards, while offering substantial rigidity and a thin, aesthetically pleasing design suitable for laboratory and clean room applications.
Implementation Method 1
The first layer includes a first pigmented polyester resin and a first organic peroxide... applying a second layer to at least a portion of a surface of the first layer, the second layer including a second pigmented polyester resin and a second organic peroxide
Implementation Method 2
The third layer including a first polyester resin, a first flame retardant... the panel member is configured to have an ASTM E84 Class I fire and smoke rating
Data Source
AI summary
A fire resistant panel member and a related method for producing a fire resistant panel member where the panel member includes a first layer, a second layer covering at least a portion of a surface of the first layer, the first and second layers each comprising a pigmented polyester resin and a first organic peroxide, a third layer covering at least a portion of a surface of the second layer, a substantially rigid core member covering at least a portion of a surface of the third layer, and a fourth layer covering at least a portion of a surface of the core member, the third and fourth layers each comprising a polyester resin, a flame retardant, a second organic peroxide, and a fiber material, wherein the panel member is configured to have an ASTM E84 Class I fire and smoke rating.