Fireproof Decorative Panel Using Calcium Sulphate and Glass Fibre
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Solution Overview
Problem
Current decorative panels lack fireproof and non-toxic properties, posing safety risks in public spaces where accidents can occur, and existing solutions may emit toxic volatile substances, deterring customers and risking legal issues.
Innovation Solution
A fireproof and non-toxic decorative panel composed of a layer of iron oxides and mortars, a water-based acrylic polymer mixture with calcium sulphate hemihydrate, a triaxial glass fibre sheet, and additional layers, providing fire protection and mechanical impact resistance without toxic emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polyurethane is used as the forming element in decorative panels, then the panel achieves good decorative appearance and structural properties, but the panel emits toxic volatile substances and is not fireproof
Solution Approach 1:
The patent uses a composite material system consisting of calcium sulphate hemihydrate as the base material, water-based acrylic polymer as binder, and iron oxide pigments for coloring. This composite replaces polyurethane entirely, achieving both decorative appearance through iron oxide pigmentation and non-toxic, fireproof properties through the inherent characteristics of calcium sulphate and water-based materials.
Solution Approach 2:
The patent changes the chemical composition parameters by using calcium sulphate hemihydrate instead of polyurethane, and water-based acrylic polymer instead of oil-based binders. This parameter change transforms the material from toxic and flammable to non-toxic and fireproof while maintaining decorative capabilities through controlled pigmentation.
2Adaptability or versatility
If polyurethane panels are used for interior and exterior decoration, then the panels provide good aesthetic value, but they degrade faster in exterior conditions and pose fire safety risks
Solution Approach 1:
The triaxial glass fibre reinforced calcium sulphate composite provides superior structural integrity and fire resistance compared to polyurethane. The glass fibres enhance mechanical strength while the calcium sulphate base material is inherently fireproof, creating a reliable decorative panel for both interior and exterior applications.
Solution Approach 2:
The patent employs iron oxide pigments and water-based acrylic coatings that provide durable coloration and protection. These materials resist degradation from weathering, UV exposure, and temperature variations, ensuring long-term aesthetic value and reliability in exterior conditions without the fire safety compromises of polyurethane.
3Ease of operation
If traditional decorative panels are used in public spaces, then installation is straightforward, but they pose fire hazards and health risks to occupants
Solution Approach 1:
The water-based acrylic polymer mixed with calcium sulphate hemihydrate creates a non-toxic, fireproof composite material that maintains ease of installation. The material can be applied in layers and cured to form durable decorative panels suitable for public spaces, eliminating fire hazards and health risks associated with traditional polyurethane panels.
Solution Approach 2:
The patent converts the potential harm of flammable polyurethane materials into benefit by using water-based acrylic polymer and calcium sulphate hemihydrate, which are inherently fireproof and non-toxic. This material substitution maintains installation simplicity while eliminating fire hazards and health risks in public spaces.
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 panel effectively prevents toxic substance release and offers enhanced safety and versatility for use in both interior and exterior settings, addressing the need for fireproof and non-toxic materials in public spaces.
Implementation Method 1
the fireproof and non-toxic decorative panel for interior and/or exterior use, object of the present invention, comprising a first layer formed by a layer of iron oxides and mortars applied manually in a horizontal and transverse manner, wherein the exposed face thereof incorporates the shape and/or motif of the decorative element and wherein there are added to said layer a second layer formed by a water-based acrylic polymer mixture mixed with calcium sulphate hemihydrate (CaSO4 0.5H2O)
Implementation Method 2
As a result of the water-based materials forming it, the panel herein described will be completely fireproof and/or non-toxic, i.e., it will serve as fire protection means, and will not give off toxic volatile substances
Implementation Method 3
the use of triaxial glass fibre provides the panel with mechanical impact resistance features which no other panel known in the state of the art presents
Implementation Method 4
a first layer formed by a layer of iron oxides and mortars applied manually in a horizontal and transverse manner, forming a compact block
Data Source
Figure 1~2
AI summary
The invention relates to a fireproof and non-toxic decorative panel for interior and/or exterior use, comprising a first layer (1) formed by a layer of iron oxides and mortars applied manually in a horizontal and transverse manner, forming a compact block, wherein the exposed face thereof incorporates the shape and/or motif of a decorative element and wherein there are added to said layer (1) a second layer (2) formed by a water-based acrylic polymer mixture mixed with calcium sulphate hemihydrate (CaSO4O4 0.5H20), a third layer (3) formed by a triaxial glass fibre sheet, and finally a fourth layer (4) formed by the water-based acrylic polymer mixture mixed with calcium sulphate hemihydrate (CaSO4O4 0.5H20).