FRP Board With Non-Flammable Coating for Fire Resistance
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Solution Overview
Problem
Conventional fiberglass reinforced plastic (FRP) materials are lightweight, robust, and durable but are vulnerable to fire, limiting their application in environments exposed to fire and corrosion, necessitating the use of heavy and expensive metal materials.
Innovation Solution
An FRP material with a non-flammable coating layer composed of specific ingredients like 1,3,5-triazine-2,4,6-triamine, ammonium polyphosphate, dimethyl polysiloxane, xylene, and phosphonic acid, and optionally a phosphorus-based polymer, applied to a flame retardant FRP matrix, and a flame retardant coating layer with a vinyl ester resin containing halogen elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional FRP materials are used, then lightweight and robust properties are achieved, but non-flammability deteriorates
Solution Approach 1:
The patent applies composite materials by combining FRP with a non-flammable coating layer containing specific flame retardant chemicals (ammonium polyphosphate, melamine, antimony trioxide, etc.). This creates a multi-layer composite structure where the FRP provides lightweight and robust properties while the coating layer provides non-flammability, resolving the contradiction between weight and fire resistance.
Solution Approach 2:
The patent changes the chemical composition parameters of the surface layer by applying a coating containing specific ratios of flame retardant chemicals (ammonium polyphosphate 20-40 wt%, melamine 10-30 wt%, antimony trioxide 10-30 wt%). This parameter change transforms the flammable FRP surface into a non-flammable surface while maintaining the underlying FRP's lightweight properties.
2Reliability
If metal materials are used to improve non-flammability, then fire resistance is achieved, but weight increases
Solution Approach 1:
Instead of using solid metal materials that provide fire resistance but add weight, the patent creates a composite structure where a thin non-flammable coating layer (microscopic to sub-millimeter thickness) is applied on top of lightweight FRP. This composite approach achieves fire resistance equivalent to metal while maintaining the lightweight advantage of FRP.
Solution Approach 2:
The patent uses a thin film coating layer containing flame retardant chemicals as a protective shell on the FRP surface. This thin film provides fire resistance without the weight penalty of solid metal materials, allowing the structure to remain lightweight while achieving the required non-flammability for use in coal-fired power plants and other fire-prone environments.
3Strength
If epoxy-based FRP resin is used for reinforcement, then adhesiveness is improved, but temperature resistance deteriorates
Solution Approach 1:
The patent changes the temperature resistance parameter by applying a non-flammable coating layer that can withstand temperatures up to 1000°C or higher. This coating layer protects the epoxy-based FRP resin from thermal degradation above its glass transition temperature (around 102°C), allowing the reinforced structure to maintain both adhesiveness and temperature resistance in high-temperature environments like coal-fired power plants.
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 FRP material achieves enhanced non-flammability, corrosion resistance, and waterproofness, allowing it to replace metal materials in applications exposed to fire and corrosion, while maintaining lightweight and robust properties.
Implementation Method 1
a non-flammable coating layer which is formed by coating a surface of a flame retardant FRP matrix with a non-flammable agent
Implementation Method 2
a composition of the non-flammable coating layer includes 10 to 20 wt % of 1,3,5-triazine-2,4,6-triamine, 30 to 50 wt % of ammonium polyphosphate, 1 to 10 wt % of dimethyl polysiloxane, 10 to 20 wt % of xylene, and 10 to 30 wt % of phosphonic acid
Data Source
AI summary
There is provided an FRP material with reinforced non-flammability that can be utilized as an alternative to a metal material in a variety of applications. The FRP material with reinforced non-flammability includes a non-flammable coating layer formed by coating, with a non-flammable agent, a surface of a flame retardant FRP matrix containing a flame retardant resin, wherein a composition of the non-flammable coating layer includes 10 to 20 wt % of 1,3,5-triazine-2,4,6-triamine, 30 to 50 wt % of ammonium polyphosphate, 1 to 10 wt % of dimethyl polysiloxane, 10 to 20 wt % of xylene, and 10 to 30 wt % of phosphonic acid, p-methyl-, (5-ethyl-2-methyl-2-oxido-1,3,2-dioxaphosphorinan-5-yl)methyl methyl ester.