Non-flammable sheet and production method therefor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional architectural film materials using polytetrafluoroethylene (PTFE) require a firing step and lack flexibility, necessitating improvements in weather resistance, heat-shielding, hydrophilicity, non-flammability, chemical resistance, flexibility, and handling properties while reducing manufacturing costs.
Innovation Solution
A non-flammable sheet is developed by forming a resin layer with a fluorocarbon resin containing vinylidene fluoride copolymer, acrylic copolymer, water, and titanium oxide on a woven fabric, eliminating the need for firing through a coating process that includes a drying step to reduce manufacturing costs and energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PTFE resin is used for architectural film material, then non-flammable property and chemical resistance are improved, but manufacturing complexity increases due to required firing step
Solution Approach 1:
The patent changes the chemical composition parameters of the fluorocarbon resin from pure PTFE to a copolymer containing vinylidene fluoride (50-90 mass%), vinyl fluoride (5-30 mass%), and trifluoroethylene (5-30 mass%). This compositional modification allows the resin to achieve the desired non-flammable properties while eliminating the need for high-temperature firing, thus simplifying the manufacturing process.
Solution Approach 2:
The patent creates a composite coating layer combining multiple fluorocarbon resin components with specific functional additives. The coating includes vinylidene fluoride copolymer for flexibility, titanium oxide for heat shielding, and surfactants for hydrophilicity. This composite approach achieves multiple performance requirements simultaneously without requiring complex multi-step manufacturing processes.
2Reliability
If PTFE resin is used for architectural film material, then non-flammable property is improved, but manufacturing cost increases due to firing step
Solution Approach 1:
The patent modifies the resin composition to use a fluorocarbon copolymer that can be processed at lower temperatures. The specific monomer ratios (vinylidene fluoride 50-90%, vinyl fluoride 5-30%, trifluoroethylene 5-30%) are optimized to achieve appropriate melting and curing characteristics that eliminate the need for expensive high-temperature firing equipment and energy consumption.
Solution Approach 2:
The patent replaces the expensive and energy-intensive PTFE firing process with a more economical coating and drying process. The modified fluorocarbon resin formulation allows for lower processing temperatures, reducing both equipment investment and operational energy costs, making the manufacturing process more economically viable.
3Reliability
If fluorocarbon resin coating is applied to woven fabric, then weather resistance and heat-shielding are improved, but flexibility deteriorates due to hard resin layer
Solution Approach 1:
The patent adjusts the molecular structure parameters of the fluorocarbon resin by incorporating vinylidene fluoride units (50-90 mass%) which provide chain flexibility. The copolymer structure with vinyl fluoride and trifluoroethylene components creates a resin matrix that is sufficiently crosslinked for weather resistance but maintains adequate chain mobility for flexibility, eliminating the need for thick rigid coatings.
Solution Approach 2:
The patent formulates a composite coating system where the fluorocarbon copolymer is combined with titanium oxide particles for heat shielding and surfactant molecules for hydrophilicity. This composite approach allows the resin matrix to remain flexible while the dispersed particles provide protective functions, avoiding the formation of a continuous hard layer that would reduce flexibility.
4Reliability
If conventional PTFE coating process is used, then non-flammable property is ensured, but energy consumption increases due to high-temperature firing
Solution Approach 1:
The patent changes the thermal processing parameters by using a fluorocarbon copolymer with lower decomposition and curing temperatures compared to PTFE. The specific copolymer composition (vinylidene fluoride 50-90%, vinyl fluoride 5-30%, trifluoroethylene 5-30%) enables effective coating formation and crosslinking at temperatures below 200°C, dramatically reducing energy consumption compared to PTFE firing which requires temperatures above 300°C.
Solution Approach 2:
The patent replaces the energy-intensive PTFE firing process with a lower-temperature coating and drying process. The modified resin formulation achieves equivalent non-flammable performance through chemical composition rather than high-temperature sintering, significantly reducing both energy consumption and equipment requirements.
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 solution enhances weather resistance, heat-shielding, hydrophilicity, non-flammability, chemical resistance, flexibility, and handling properties while simplifying the manufacturing process, reducing costs, and improving surface-printing characteristics.
Implementation Method 1
a heat-shielding property
Implementation Method 2
a drying step to such an extent that water is blown away
Implementation Method 3
the first fluorocarbon resin can contain titanium oxide
Data Source
Figure 1
Figure 2
Figure 3
AI summary
In order to reduce manufacturing cost and required energy largely and to improve weather resistance, a heat-shielding property, hydrophilicity, a nonflammable property, chemical resistance, flexibility, a handling property, and a surface printing excellent characteristic, in a nonflammable sheet, a resin layer including a first fluorocarbon resin containing a vinylidene fluoride copolymer, an acrylic copolymer, and titanium oxide, and a second fluorocarbon resin containing a vinylidene fluoride polymer, a siloxane polymer, and a crosslinked acrylic polymer is formed on a surface of a woven fabric formed of a nonflammable fiber.