Flexible Cement Sheet Coatings for Uniform Fire Protection
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Solution Overview
Problem
Conventional processes for producing cementitious panels are complex, costly, and environmentally unfriendly, with issues such as premature or delayed setting, uneven deposition, and the need for extensive equipment, while intumescent and thermal coatings applied in situ face challenges like imperfections and health hazards from liquid substrates.
Innovation Solution
A flexible cement sheet roll and intumescent/thermo-insulating sheets are manufactured using a simplified process involving a cement mortar mixture applied to a conveyor, set in an oven, and rolled onto a polymeric foil, providing a readymade, flexible sheet that can be easily applied to construction elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional processes are used to produce cementitious panels, then the panels can be manufactured with cement coating, but the process becomes complex and requires extensive equipment and working space
Solution Approach 1:
The invention separates the cement coating production from the panel manufacturing process. Pre-made cement sheets are produced independently and then applied to panels, dividing the complex integrated process into simpler, independent stages that can be performed with less equipment
Solution Approach 2:
Cement sheets are manufactured and prepared in advance as ready-to-apply materials. This preliminary preparation eliminates the need for complex on-site coating equipment and processes, simplifying the overall manufacturing system while maintaining coating quality
2Reliability
If conventional processes are used to produce cementitious panels, then the panels can be manufactured with cement coating, but the manufacturing cost increases
Solution Approach 1:
By separating cement sheet production from panel assembly, each component can be optimized independently using simpler, more cost-effective processes. The pre-made sheets eliminate the need for expensive specialized coating equipment
Solution Approach 2:
The invention uses simple, readily available materials and processes for producing cement sheets that can be applied directly to panels. This approach uses less expensive materials and methods compared to traditional integrated manufacturing processes
3Reliability
If liquid intumescent coatings are applied in situ, then fire protection can be provided, but health hazards and environmental contamination occur
Solution Approach 1:
The harmful liquid substrate is extracted and replaced with solid cement sheets that provide the same fire protection function. The intumescent properties are incorporated into the solid sheet material, eliminating health hazards associated with liquid coatings
Solution Approach 2:
The invention changes the physical state of the fire protective material from liquid to solid form. This parameter change eliminates the health hazards and environmental contamination associated with liquid substrates while maintaining the fire protection functionality
4Reliability
If liquid intumescent coatings are applied in situ, then fire protection can be provided, but the coating layer shows imperfections and non-uniform thickness
Solution Approach 1:
Cement sheets with uniform thickness and consistent properties are manufactured in advance under controlled conditions. This preliminary preparation ensures uniform fire protection without the variability introduced by on-site liquid application processes
Solution Approach 2:
The manual or mechanical liquid application process is replaced with the application of pre-manufactured solid sheets. This substitution eliminates the imperfections and non-uniformity inherent in liquid coating application while maintaining fire protection effectiveness
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 process reduces production space and equipment complexity, offers cost-effective, uniform, and environmentally friendly coatings for construction elements, enhancing fire resistance and thermal insulation without the drawbacks of traditional methods.
Implementation Method 1
set in an oven
Implementation Method 2
the thin intumescent substance layer swells when exposed to heat and forms a thick inflammable layer of low density
Implementation Method 3
becoming an obstacle to heat transfer, as the rate of heat transfer decreases with the material density and as it is indirectly proportional to the thickness of the obstacle
Data Source
AI summary
A continuous flexible cement sheet roll for coating construction slabs, is disclosed. The sheet comprising a flexible cement layer, which has a thickness of between 0.3 to 6 mm, such as between 0.5 and 5 mm, and which comprises a) essentially inorganic mortar and b) up to 15% polymeric binder. When the amount of a component in a mixture is expressed in % units, the weight % of the component relative to the weight of the whole mixture is intended. The flexible cement sheet roll of the invention comprises, a reinforcing layer of a thickness lower than the thickness of said cement layer, selected from films of a nonwoven fabrics, layers of organic or inorganic fibers, polymer webs, chop strand mat, and fiberglass mats, among others.