Flame or fire protection agent and production and use thereof in particular for wood-, cellulose-, and polyolefin-based products
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current flame retardants for wood and cellulose-based materials fail to adequately prevent afterglow and decomposition during processing, leading to unsatisfactory fire protection, especially in foamed, felted, or pressed products, and often release toxic gases, posing environmental and safety concerns.
Innovation Solution
The use of expandable graphite in combination with a mixture of boric acid, borax, and sodium chloride as a flame retardant, which is applied to wood and cellulose fibers, either as a dry powder or in an aqueous solution, to reduce flammability and combustibility without releasing toxic gases, and is effective in preventing afterglow and maintaining material integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flame retardants are used on wood and cellulose materials, then flammability is reduced, but afterglow and decomposition occur during processing
Solution Approach 1:
The invention uses a composite flame retardant system combining expandable graphite with metal hydroxides (aluminum hydroxide and/or magnesium hydroxide). This composite approach provides synergistic effects where expandable graphite forms an intumescent char layer that protects the underlying material, while metal hydroxides decompose to release water and form protective scales, together preventing both flammability and afterglow while maintaining material integrity.
Solution Approach 2:
The invention exploits phase transitions of the flame retardant components during fire exposure. Expandable graphite undergoes a phase transition from a compact structure to an expanded intumescent foam when heated, providing immediate protective coverage. Metal hydroxides undergo decomposition phase transitions that release water vapor and form protective oxide scales. These controlled phase transitions provide fire protection without causing material decomposition.
2Reliability
If conventional flame retardants are applied to achieve fire protection, then flammability decreases, but toxic gases are released
Solution Approach 1:
The invention converts the harmful effect of heat into a beneficial protective mechanism. When exposed to fire, the expandable graphite undergoes endothermic expansion, absorbing heat energy and transforming it into the formation of a protective char layer. The metal hydroxides undergo endothermic decomposition, absorbing heat and releasing water vapor that dilutes toxic gases. This converts the harmful thermal energy into beneficial protective actions without releasing toxic substances.
3Reliability
If expandable graphite is used as flame retardant, then afterglow is prevented, but the manufacturing process becomes more complex
Solution Approach 1:
The invention merges the application of expandable graphite with metal hydroxides into a single integrated flame retardant treatment process. Rather than applying separate treatments for char formation and flame suppression, both components are combined in one formulation and applied simultaneously to the wood or cellulose material. This unified approach achieves afterglow prevention and flame suppression together without significantly increasing manufacturing complexity.
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
This solution effectively prevents afterglow and decomposition in wood and cellulose-based products, providing enhanced fire protection without compromising material properties or releasing harmful gases, making it suitable for various applications including insulation and flooring.
Implementation Method 1
expandable graphite... to reduce flammability and/or combustibility
Implementation Method 2
expandable graphite... preventing afterglow and decomposition
Implementation Method 3
boric acid, borax, and sodium chloride as a flame retardant
Implementation Method 4
expandable graphite... providing enhanced fire protection without compromising material properties
Data Source
AI summary
The invention relates to the use of expanded graphite for reducing flammability and/or combustibility, in particular the use thereof as a flame protection agent and/or a fire protection agent, for materials and/or products which consist of or comprise wood fibers, cellulose fibers, wood powder, cellulose powder, wood granulates, cellulose granulates, and/or polyolefin-based materials. The invention further relates to materials and/or products which consist of or comprise wood fibers, cellulose fibers, wood powder, cellulose powder, wood granulates, cellulose granulates and/or polyolefin-based materials. In order to reduce the flammability and/or combustibility, expanded graphite is embedded into the materials and/or products, in particular in the form of a flame protection agent and/or a fire protection agent. The invention also relates to such an agent, in particular a flame protection agent and/or a fire protection agent, wherein expanded graphite is used alone or in combination with a boric acid/borax/alkali salt mixture. A particularly preferred area of use is binders, glues, and/or materials, products, and/or preproducts containing polyolefin-based materials in particular, preferably for damping (walls, floors, ceilings) and/or for floor and wall fittings. The invention is characterized by surprising advantages in fire protection tests with vertical edge flaming.