Thermally expandable refractory material composition, thermally expandable refractory material, and method for producing thermally expandable refractory material
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Solution Overview
Problem
Thermally expandable fire-resistant materials require a long curing time due to their thickness, necessitating a shelf for curing, which leads to inefficient production.
Innovation Solution
A thermally expandable fire-resistant material composition comprising a polymer with a moisture-curable functional group, a thermally expandable compound, and a curing catalyst, which can be cured in 60 minutes or less at 50°C and 13% RH, and includes a combination of a first agent containing the polymer and curing catalyst, and a second agent with polymer and water.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a moisture-curing polymer composition is used for thermally expandable fire-resistant material, then the material can be applied in liquid state and cured in place, but the internal curing time becomes excessively long due to material thickness
Solution Approach 1:
The patent changes the chemical parameters of the curing system by introducing a curing catalyst and controlling water content, which accelerates the moisture-curing reaction rate and reduces the deep curing time from hours to 60 minutes or less while maintaining the liquid state application advantage
Solution Approach 2:
The patent introduces a curing catalyst as an intermediary substance that mediates the moisture-curing reaction, enabling the curing process to proceed rapidly at room temperature without requiring extended curing time for thick sections
2Reliability
If the thermally expandable fire-resistant material has sufficient thickness for fire resistance, then fire protection performance is improved, but the curing time increases significantly
Solution Approach 1:
The patent modifies the curing reaction parameters by adding a curing catalyst and optimizing water content, which enables the composition to cure rapidly even at sufficient thicknesses required for fire protection, eliminating the inverse relationship between thickness and curing time
Solution Approach 2:
The patent incorporates water within the composition itself as a preliminary source for the curing reaction, eliminating the need to wait for external moisture penetration and enabling rapid internal curing throughout the entire thickness of the fire-resistant material
3Reliability
If a long curing time is required, then complete internal curing is achieved, but production efficiency decreases and shelves are needed for curing
Solution Approach 1:
The curing catalyst acts as an intermediary that accelerates the moisture-curing reaction, enabling complete internal curing to be achieved in 60 minutes or less, which eliminates the need for curing shelves and significantly improves production efficiency while ensuring thorough curing
Solution Approach 2:
The composition is formulated with pre-incorporated water and curing catalyst, creating a self-sufficient curing system that completes the curing process rapidly without requiring external curing facilities or extended time, thereby maintaining both curing completeness and high productivity
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 composition allows for rapid curing of the material, improving productivity and enabling efficient production of thermally expandable fire-resistant materials.
Implementation Method 1
a polymer having a moisture-curable functional group
Implementation Method 2
Thermally expandable fire-resistant materials that expand when heated
Data Source
AI summary
Provided is a thermally expandable fire-resistant material composition comprising a polymer having a moisture-curable functional group, a thermally expandable compound, and a curing catalyst, wherein a coating film obtained by applying the thermally expandable fire-resistant material composition at a thickness of 2 mm has a deep curing time of 60 minutes or less under an environment at 50°C and 13% RH.