Flame-Resistant Silicone Resin Coating for Base Materials
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Solution Overview
Problem
Conventional flame-resistant materials for plastics, such as halogen-based and inorganic compounds, face issues like environmental concerns, decreased physical properties, and poor flexibility, leading to inadequate performance in preventing fire spread and carbonization, especially in applications like railway rolling stock illumination covers.
Innovation Solution
A flame-resistant composite member is created by forming a film of a silicone resin composition containing inorganic oxide particle-containing condensation-reactive silicone resin on a base material, which provides high flame resistance without igniting or carbonizing, even with thin flammable materials, using a combination of crosslinked polysiloxane resin and inorganic particles like glass frits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogen-based flame resistants are used, then flame resistance is improved, but environmental harm increases due to dioxins and flons generation
Solution Approach 1:
The patent changes the chemical composition parameters of the flame-resistant coating by using inorganic flame retardants (aluminum hydroxide, magnesium hydroxide) instead of halogen-based compounds, and by controlling the organic binder content to less than 5 mass% to eliminate harmful emissions while maintaining flame resistance
Solution Approach 2:
The patent creates a composite coating material combining inorganic flame retardant particles (aluminum hydroxide, magnesium hydroxide) with minimal organic binder and inorganic coating materials, forming a multi-component system that achieves flame resistance without environmental harm
2Reliability
If inorganic flame resistants like aluminum hydroxide are used, then flame resistance is improved, but water resistance and other physical properties decrease
Solution Approach 1:
The patent optimizes the ratio of inorganic flame retardant to inorganic coating material and controls the organic binder content to less than 5 mass%, creating a balanced composition that maintains both flame resistance and water resistance
Solution Approach 2:
The patent forms a composite structure where inorganic flame retardant particles are dispersed in an inorganic-based coating matrix with minimal organic binder, creating a synergistic effect that preserves the water resistance of the base material while providing flame protection
3Reliability
If inorganic coating materials are applied thickly for flame resistance, then flame resistance is improved, but flexibility decreases and cracking increases
Solution Approach 1:
The patent controls the thickness parameter of the inorganic coating layer and optimizes the particle size distribution of inorganic flame retardants to achieve flame resistance with minimal thickness, preserving the flexibility of the base material
Solution Approach 2:
The patent creates a porous or microstructured inorganic coating layer that provides flame resistance through its structure rather than just thickness, allowing the coating to be thin while maintaining both flame protection and flexibility
4Ease of operation
If organic binder is used in coating materials, then flexibility is improved, but carbonization occurs in flame contact
Solution Approach 1:
The patent changes the chemical composition by using inorganic binders (such as silicate-based binders) instead of organic binders, and controls the organic binder content to less than 5 mass%, eliminating carbonization while maintaining coating integrity and flexibility
Solution Approach 2:
The patent uses minimal amounts of organic binder only where absolutely necessary, treating it as a temporary component that does not compromise the overall non-carbonizing nature of the coating system
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 effectively prevents fire spread and carbonization, achieving remarkable flame resistance and flexibility, suitable for use in transport machinery, building materials, and electronic components, with improved mechanical strength and heat resistance.
Implementation Method 1
a condensation-reactive silicone resin (A) comprising a crosslinked structural body wherein an inorganic oxide particle dispersed in a polysiloxane resin having a condensation-reactive group and the polysiloxane resin are crosslinked through a chemical bond
Implementation Method 2
an inorganic oxide particle-containing condensation-reactive silicone resin on a base material
Data Source
Figure 1~3
AI summary
There is provided a flame-resistant composite member exhibiting remarkably high flame resistance even if having a flammable base material. The flame-resistant composite member according to the present invention has a film formed of a silicone resin composition (C) containing at least an inorganic oxide particle-containing condensation-reactive silicone resin on at least one surface of a base material. The inorganic oxide particle-containing condensation-reactive silicone resin may be a condensation-reactive silicone resin (A) including a crosslinked structural body wherein an inorganic oxide particle dispersed in a polysiloxane resin having a condensation-reactive group and the polysiloxane resin are crosslinked through a chemical bond. The silicone resin composition (C) may contain the condensation-reactive silicone resin (A) and an inorganic particle (B).