Mineral Wool Fire Protection Element with Inorganic Binder
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fire protection manufacturing processes for mineral wool slabs are inefficient and costly due to the need for multiple non-automatic steps and drying energy to form solid inorganic fire retarding layers between mineral wool slabs.
Innovation Solution
A process where mineral wool slabs are coated with an inorganic fire retardant, such as gypsum, on one side and pressed together to form a layer that acts as a binder upon drying, eliminating the need for separate drying steps and allowing for continuous, automated production of thinner fire protection elements with improved fire resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manufacturing processes are used to form solid inorganic fire retarding layers between mineral wool slabs, then fire protection properties are achieved, but the process requires multiple non-automatic steps and drying energy, increasing manufacturing complexity and cost
Solution Approach 1:
The patent combines the fire retarding layer formation with the mineral wool slab assembly process. The inorganic fire retarding material is applied directly to the mineral wool slabs during the pressing operation, merging two functions (fire protection and structural assembly) into a single process step, thereby eliminating separate drying steps and reducing manufacturing complexity
Solution Approach 2:
The inorganic fire retarding material serves multiple functions simultaneously: it provides fire protection, acts as a binder to assemble the slabs, and eliminates the need for separate drying operations. This multi-functionality reduces the number of process steps and energy requirements while maintaining fire safety
2Reliability
If traditional manufacturing processes are used to form solid inorganic fire retarding layers, then fire protection is achieved, but drying energy is required, increasing energy consumption
Solution Approach 1:
The inorganic fire retarding material is applied in a pre-coated state during the slab assembly process, allowing it to set and form a solid layer without requiring subsequent drying energy. The material is prepared and positioned in advance, eliminating the need for post-application drying operations
Solution Approach 2:
The inorganic fire retarding material itself serves as the binder and structural element, eliminating the need for external binding agents and separate drying processes. The material sets automatically during the pressing operation, providing self-sufficient fire protection without additional energy input
3Productivity
If thinner fire protection elements are manufactured, then material usage and cost are reduced, but fire protection duration may be compromised
Solution Approach 1:
The patent changes the physical and chemical parameters of the fire retarding material to enhance its effectiveness in thinner layers. By using inorganic materials with high thermal stability and water-liberating properties, the fire protection duration is maintained even when the layer thickness is reduced, allowing for more efficient manufacturing
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
This process simplifies and reduces the cost of manufacturing while achieving enhanced fire protection at lower temperatures, with gypsum providing effective water liberation at temperatures just above 100 °C, significantly prolonging fire protection duration.
Implementation Method 1
gypsum, which is applied in the form of an aqueous paste... providing effective water liberation at temperatures just above 100 °C
Implementation Method 2
the mineral wool slabs are pressed against each other, so that a layer of the inorganic fire retardant is formed between them, whereby the mineral wool slabs are glued together by the inorganic fire retardant upon its drying
Data Source
Figure 1a1b
Figure 2~3
Figure 4
AI summary
The invention relates to a fire protection element (1 or 1') having a layer structure, a process for manufacturing thereof as well as use of the fire protection element for buildings or equipment in buildings of all kind. The fire protection element (1 or 1') comprises at least two mineral wool layers in the form of slabs (2a, 2b), between which is arranged at least one inorganic material layer (3), which liberates water or carbon dioxide under the influence of heat. The manufacturing process comprises the following steps: a) at least one of two mineral wool slabs (2a, 2b) which are to be joined together is coated on one side with an inorganic fire retardant in a form of an aqueous suspension or paste, whereafter b) the mineral wool slabs (2a, 2b) are pressed against each other so that a layer (5) consisting of the inorganic fire retardant is formed between them whereby the mineral wool slabs are glued together by means of the inorganic fire retardant when it dries up.