Insulation Panel Fire Barrier Using Expandable Graphite
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Solution Overview
Problem
There is a need for building insulation products that combine excellent thermal insulation with improved fire behavior, as highly insulated buildings pose challenges for passive fire protection, and existing solutions with metal facings may not be feasible or desirable in all applications.
Innovation Solution
The development of insulation panels with a non-steel based facing, such as a combustible material or low melting point thin metal foil, and a fire barrier layer containing a dispersion of expandable graphite in a polyisocyanate polymer matrix, which enhances fire behavior by protecting the insulating foam from flame impingement and preventing fast flame propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a non-steel based facing (combustible material or low melting point thin metal foil) is used, then the panel achieves good thermal insulation and adaptability, but the fire behavior deteriorates
Solution Approach 1:
A fire barrier layer is introduced as an intermediary component between the non-steel based facing and the insulating foam layer. This barrier layer, containing expandable graphite dispersed in a polymer matrix, prevents direct flame contact with the combustible facing and foam, thereby protecting the thermal insulation performance while improving fire behavior to meet Euroclass Bs1d0 classification.
Solution Approach 2:
The fire barrier layer is constructed as a composite material system combining expandable graphite particles dispersed in a polymer matrix (polyester, polyacrylonitrile, polyvinylidene fluoride, or polytetrafluoroethylene). This composite structure provides both fire protection functionality and maintains the flexibility of non-steel facings, enabling the panel to achieve both adaptability and improved fire behavior.
2Object-affected harmful factors
If a fire barrier layer with expandable graphite is added, then the fire behavior improves, but the device complexity increases
Solution Approach 1:
The fire barrier layer is applied locally only at the critical interface between the facing and the insulating foam, rather than throughout the entire panel. This localized application provides fire protection precisely where it is most needed (at the flame exposure surface) while minimizing the overall complexity and material usage of the panel structure.
Solution Approach 2:
The fire barrier layer utilizes parameter changes in the expandable graphite material - specifically, its ability to undergo rapid volume expansion when exposed to fire temperatures. This phase change behavior allows the barrier to automatically activate and provide fire protection only when needed, without requiring complex control systems or additional structural elements.
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 proposed solution meets Euroclass Bs1d0 classification standards by reducing fire growth rate, smoke production, and heat release, while maintaining excellent thermal insulation properties, making it suitable for various construction applications.
Implementation Method 1
The fire barrier layer includes a dispersion of expandable graphite in a polyisocyanate polymer matrix and the amount of expandable graphite per unit area is 200-1250g/m2
Implementation Method 2
Insulating products that include polymer foams provide good thermal insulation
Data Source
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AI summary
An insulation panel includes a first non-steel based facing that is a combustible material, a glass-fleece based material, or a low melting temperature thin metal foil; an insulating foam layer; and a fire barrier layer adjacent to the first non-steel based facing and between the first non-steel based facing and the insulating foam layer. The fire barrier layer includes a dispersion of expandable graphite in a polyisocyanate polymer matrix and the amount of expandable graphite per unit area is at least 50 g/m2.