Multilayer Foam Insulation for Fire Resistance and Low Smoke
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Solution Overview
Problem
Conventional flexible elastomeric foam (FEF) insulation products face challenges in achieving high flame resistance, low smoke production, and improved mechanical strength while maintaining thermal conductivity, water vapor transmission, and flexibility, especially when applied to both sheet and tube forms.
Innovation Solution
A multilayer insulation product comprising at least three layers: an outer layer of flexible elastomeric foam with specific fire resistance properties, a middle layer of inorganic fibrous material for mechanical reinforcement, and an inner layer of insulation material with optimized thermal conductivity and water vapor transmission, connected by suitable adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional FEFs use high levels of fillers and additives to improve flame resistance, then fire performance is improved, but smoke production increases significantly
Solution Approach 1:
The patent changes the chemical composition parameters of the foam by using chlorinated polymers (PVC, CPE, CM) as the base material instead of conventional NBR/PVC blends, and controls the filler content to be 20-80 parts per 100 parts polymer. This parameter optimization achieves both flame resistance (B or C classification) and low smoke production (s1 or s2 classification) simultaneously
Solution Approach 2:
The patent creates a composite foam material by combining chlorinated polymers (PVC, CPE, or CM) with specific fillers (such as calcium carbonate, talc, or glass fibers) and crosslinking agents. This composite structure provides inherent flame retardancy from the chlorinated polymers while the controlled filler content prevents excessive smoke generation, achieving both fire safety and low smoke requirements
2Reliability
If polyethylene foams use high loadings of fillers to improve insulation properties, then thermal insulation is improved, but foam structure collapses due to overnucleation
Solution Approach 1:
The patent optimizes the filler content parameter to be within 20-80 parts per 100 parts polymer, which prevents overnucleation and collapse of the foam structure while still providing sufficient thermal insulation. This parameter control ensures the foam maintains its cellular structure and insulation properties
3Ease of operation
If conventional FEFs are made more flexible by adding plasticizers and additives, then flexibility is improved, but fire resistance deteriorates
Solution Approach 1:
The patent uses chlorinated polymers (PVC, CPE, CM) as the base material which inherently provide both flexibility and flame resistance without requiring additional plasticizers. The crosslinking density is controlled at 5-50 parts per 100 parts polymer to maintain flexibility while achieving fire resistance classification of B or C
Solution Approach 2:
The patent creates a composite system where chlorinated polymers serve as both the flexible matrix and the flame-retardant component. The combination of PVC, CPE, and/or CM with specific crosslinking agents creates a material that is inherently both flexible and fire-resistant, eliminating the need to choose between these properties
4Reliability
If multilayer systems add multiple protective layers to improve fire resistance, then flame protection is improved, but mechanical strength and flexibility deteriorate
Solution Approach 1:
The patent extracts the fire protection function from separate protective layers and integrates it into the foam material itself by using chlorinated polymers with inherent flame retardancy. This eliminates the need for additional protective layers that would compromise mechanical strength and flexibility
Solution Approach 2:
The chlorinated polymer foam serves multiple functions simultaneously: thermal insulation, fire protection, flexibility, and mechanical strength. The single material system provides all these properties without requiring multiple specialized layers, maintaining both fire resistance and mechanical performance
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 multilayer product achieves high flame resistance, low smoke production, improved mechanical strength, and comparable thermal conductivity and water vapor transmission to conventional NBR/PVC-based FEFs, with enhanced flexibility and applicability to both sheet and tube forms, reducing installation time and costs.
Implementation Method 1
Layer A has a thermal conductivity of ≤0.0500 W/(m·K) at 0 °C
Implementation Method 2
The second layer B, which is arranged between layer A and layer C, comprises at least one layer of fibrous woven or nonwoven material
Implementation Method 3
connected by suitable adhesives
Implementation Method 4
Layer C has a thickness equal to or greater than the thickness of layer A and has a thermal conductivity of ≤ 0.0400 W/(m·K) at 0 °C
Data Source
Figure 1~2
AI summary
The present invention relates to, among others, a multilayer insulation product (MIP) comprising at least three layers A, B and C, wherein layer A is an outer layer comprising at least one flexible elastomeric foam (FEF), layer B is arranged between layer A and layer C, and layer C is an inner layer comprising at least one insulation material.