Multilayer Insulation Panel with Expansive Graphite Fire Barrier
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Solution Overview
Problem
Existing multilayer insulation panels for construction rely on metallic backing layers for fire-resistant properties, which are costly and not universally applicable, and there is a need for an alternative that maintains similar fire-resistance performance.
Innovation Solution
A multilayer insulation panel with a polyurethane foam core sandwiched between backing layers, one of which includes a reinforcement layer of fibrous material and a fire-resistant layer made from expansive graphite, which expands to create a barrier against flames, combined with a cladding layer containing flame retardants and refractory agents, and a binding layer using sodium silicates to secure the graphite.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallic backing layers are used to achieve fire-resistant properties, then fire resistance performance is improved, but manufacturing cost increases
Solution Approach 1:
The invention changes the material parameters from metallic to non-metallic (graphite and sodium silicate) while maintaining fire-resistant properties. The graphite content is controlled at 30-70 wt% and sodium silicate at 10-40 wt% to achieve optimal fire resistance without using expensive metals.
Solution Approach 2:
The invention replaces expensive metallic backing layers with cheaper non-metallic materials (graphite and sodium silicate) that can provide equivalent fire-resistant performance. This substitution significantly reduces manufacturing costs while maintaining the required reliability for construction insulation panels.
2Ease of manufacture
If non-metallic backing layers are used to reduce cost, then manufacturing cost decreases, but fire-resistant performance deteriorates
Solution Approach 1:
The invention creates a composite backing layer combining graphite (30-70 wt%) and sodium silicate (10-40 wt%) with the polyurethane foam core. This composite structure leverages the fire-resistant properties of both materials to achieve class B fire resistance, matching or exceeding metallic alternatives while reducing cost.
Solution Approach 2:
The invention optimizes the compositional parameters of the backing layer by controlling the specific ratios of graphite and sodium silicate. This parameter optimization ensures that the non-metallic composite achieves fire-resistant performance equivalent to metallic layers, resolving the contradiction between cost and performance.
3Reliability
If expansive graphite is added to the backing layer, then fire-resistant barrier properties are improved, but device complexity increases
Solution Approach 1:
The invention merges the fire-resistant functions of multiple materials (graphite, sodium silicate, and polyurethane foam) into a single integrated backing layer. This unified structure eliminates the need for separate metallic layers while maintaining equivalent fire protection, thereby reducing overall device complexity.
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 panel achieves high fire-resistant performance, classified in class B according to EN 13501-11925/2 standards, with the expansive graphite and sodium silicate layers providing effective barriers against flames, and the cladding layer enhancing thermal insulation and mechanical stability.
Implementation Method 1
a fire-resistant layer made from expansive graphite, which expands to create a barrier against flames
Implementation Method 2
a binding layer using sodium silicates to secure the graphite
Implementation Method 3
a cladding layer containing flame retardants and refractory agents, and a binding layer using sodium silicates to secure the graphite
Implementation Method 4
The panel achieves high fire-resistant performance, classified in class B according to EN 13501-11925/2 standards
Data Source
AI summary
A multilayer thermal insulation panel for construction and manufacturing method thereof are described. A manufacturing method of a backing layer of a multilayer thermal insulation panel for construction, the method comprising the steps of: providing a reinforcement layer in fibrous material, spreading a first fluid mineral mixture on the reinforcement layer to form a cladding layer of the reinforcement layer; forming a fire-resistant layer comprising expansive graphite on the cladding layer; and drying the backing layer.