Phosphate Ceramic Composite for Fire-Resistant Thermal Insulation
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Solution Overview
Problem
Existing fire protection materials are highly specialized for fire protection purposes but lack versatility in meeting other structural requirements, such as thermal insulation, and are often difficult to mount and adapt for various applications.
Innovation Solution
A lightweight insulating material is developed using a high-temperature-resistant phosphate ceramic as a support structure, combined with lightweight building materials like expanded polystyrene, which provides both thermal insulation and fire resistance, and can be easily shaped and attached using a curable mixture that forms a cohesive shell or lattice structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If special fire protection materials are used, then fire resistance is improved, but thermal insulation performance deteriorates and structural versatility is limited
Solution Approach 1:
The patent creates a composite material combining phosphate ceramic granules (fire protection component) with polyurethane foam (thermal insulation component). This composite structure allows both materials to contribute their respective properties: the phosphate ceramic provides fire resistance while the polyurethane foam provides thermal insulation, resolving the contradiction between fire protection specialization and thermal insulation performance
Solution Approach 2:
The resulting composite material serves multiple functions simultaneously: it provides fire protection, thermal insulation, and structural support capability. The material can be applied to various substrates including walls, ceilings, and structural components, making it versatile for different construction applications while maintaining both fire safety and thermal efficiency
2Loss of energy
If lightweight building materials are used for thermal insulation, then thermal insulation performance is improved, but fire resistance deteriorates
Solution Approach 1:
The patent combines lightweight polyurethane foam (excellent thermal insulator) with phosphate ceramic granules (fire-resistant material). The polyurethane foam matrix provides superior thermal insulation with low energy loss, while the distributed phosphate ceramic granules throughout the matrix provide fire resistance, simultaneously achieving both thermal efficiency and fire safety
3Strength
If phosphate ceramic is used as support structure, then fire resistance and structural strength are improved, but ease of shaping and mounting deteriorates
Solution Approach 1:
The patent utilizes the temperature-dependent properties of the phosphate ceramic-polyurethane composite. At room temperature, the material remains soft and pliable, allowing easy shaping and mounting. When exposed to fire or high temperatures, the polyurethane carbonizes and the phosphate ceramic strengthens, providing structural support. This parameter change with temperature resolves the contradiction between ease of manufacture and high-temperature strength
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 material achieves effective thermal insulation and fire resistance while being easy to process and attach, with the phosphate ceramic support structure preventing combustion of organic lightweight materials and maintaining thermal insulation integrity.
Implementation Method 1
The material described by publication in the English-speaking world as 'phosphate ceramic' is not in the sense of a clay ceramic or a material to be produced by a firing or sintering process, but rather by an exothermic reaction of the patent mentioned three components arises.
Implementation Method 2
Insulating materials are used on a large scale, especially in construction, in vehicles and in equipment technology for insulation against external influences such as noise, heat and fire.
Data Source
Figure 1
AI summary
The invention relates to an insulating material particularly for applications in construction and devices, comprising a proportion of an inorganic moulding compound in the form of phosphate ceramic which consists of metal phosphate containing an acidic aqueous solution of a phosphoric acid, as well as an oxy-boron compound and a wollastonite compound. In order for this to be suitable for thermal insulation or fire protection and for easy handling in construction, said material is designed to contain a predominant proportion by volume of an organic or inorganic lightweight construction material or lightweight construction material mixture which is embedded into a carrying support structure of said proportion of phosphate ceramic.