Flameproof Laminated Composite via Segmented Inorganic Layer

Solution Overview

Problem

Conventional flameproof composite materials with high inorganic filler ratios face challenges in operability and application limitations due to increased viscosity and poor filler distribution, leading to suboptimal product quality and restricted usage.

Innovation Solution

A manufacturing method for a highly flameproof laminated composite material involving a shaping step to create an inorganic layer with a controlled weight ratio of inorganic powder to polymer material (0.01-0.1) and thickness (0.1 mm-8.0 mm), using specific powders and resins, and a combining step to attach the layer to a substrate via vacuum-assisted resin transfer molding or compression molding, enhancing fluidity and distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the weight ratio of inorganic filler to resin is increased to achieve sufficient flameproof properties, then flameproof performance is improved, but the slurry becomes too viscous and fluidity decreases

Engineering Contradiction:

Improveflameproof performanceVSAvoidoperability of manufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The inorganic layer is divided into multiple sub-layers with different inorganic filler contents. The first sub-layer has a higher inorganic filler content for flameproof performance, while the second sub-layer has a lower inorganic filler content for better fluidity and operability. This segmentation allows each layer to optimize its properties independently, resolving the contradiction between flameproof performance and manufacturability.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the weight ratio of inorganic filler to resin is increased to achieve sufficient flameproof properties, then flameproof performance is improved, but the inorganic filler is prone to poor distribution

Engineering Contradiction:

Improveflameproof performanceVSAvoiddistribution uniformity of inorganic filler

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The inorganic layer is divided into multiple sub-layers with different inorganic filler contents. The first sub-layer has a higher inorganic filler content for flameproof performance, while the second sub-layer has a lower inorganic filler content for better fluidity and operability. This segmentation allows each layer to optimize its properties independently, resolving the contradiction between flameproof performance and manufacturability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the inorganic layer have different inorganic filler contents to fulfill different functions. The first sub-layer (closer to the substrate) has higher inorganic filler content for flameproof performance, while the second sub-layer has lower inorganic filler content for better processability. This local quality variation allows the structure to optimize both flameproof performance and filler distribution uniformity simultaneously.

Inventive Principle:

Principle #3Local quality

3Reliability

If the weight ratio of inorganic filler to resin is increased to achieve sufficient flameproof properties, then flameproof performance is improved, but the weight and volume of the composite material significantly increase

Engineering Contradiction:

Improveflameproof performanceVSAvoidweight of composite material

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The inorganic layer is divided into multiple sub-layers with different inorganic filler contents. The first sub-layer has a higher inorganic filler content for flameproof performance, while the second sub-layer has a lower inorganic filler content for better fluidity and operability. This segmentation allows each layer to optimize its properties independently, resolving the contradiction between flameproof performance and manufacturability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The inorganic filler content is varied across different sub-layers rather than maintaining a uniformly high ratio throughout. This parameter change allows the first sub-layer to provide flameproof performance while the second sub-layer reduces overall weight and volume, resolving the contradiction between flameproof performance and material weight.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP4197759A1Highly flameproof laminated composite material and manufacturing method thereof

Publication Date: 2023.06.21 SWANCOR ADVANCED MATERIALS CO LTD

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Figure 2A~2B
Figure 3A~3B

AI summary

A manufacturing method of a highly flameproof laminated composite material is provided in the present disclosure. The manufacturing method of the highly flameproof laminated composite material includes the steps as follows. A raw material is provided, a shaping step is performed and a combining step is performed. The raw material includes an inorganic powder and a polymer material. In the shaping step, the raw material is made into at least one inorganic layer, an inorganic sheet, a ply of film, or a layer of coating. In the combining step, the inorganic layer is made to be connected to a surface of a substrate, so as to obtain the highly flameproof laminated composite material. A weight ratio of the inorganic powder and the polymer material is 0.01 - 0.1, and a thickness of the inorganic layer is 0.1 mm - 8.0 mm.