Phosphate Ceramic Fire-Resistant Component with Partially Detached Layer
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Solution Overview
Problem
Existing fire-resistant components for passenger ships, such as window frames and fire protection walls, face challenges in meeting Class B-15 or B-30 fire resistance requirements without being excessively expensive or heavy, and previous materials like glass fiber reinforced plastic lack the necessary fire resistance and thermal insulation.
Innovation Solution
A fire-resistant component composed of multiple layers of phosphate ceramics and fibers, where the phosphate ceramic is mixed from a solid and liquid component, providing refractory and pressure-resistant properties, and the fibers enhance tensile strength. The component features a partially detached layer near the heat source to create gas insulation passages, reducing thermal conductivity and maintaining a surface temperature below the permissible limit during fires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermally insulated steel structures are used to achieve fire resistance class B-15 or B-30, then fire resistance requirements are met, but the component becomes expensive and has relatively high weight
Solution Approach 1:
The patent uses a composite structure consisting of a steel profile core combined with phosphate ceramic layers and fiber reinforcement. This composite material approach allows achieving fire resistance class B-15 or B-30 with reduced weight compared to solid steel structures, as the phosphate ceramic provides thermal insulation while the steel profile maintains structural integrity.
Solution Approach 2:
The component is divided into multiple functional layers: a steel profile providing structural strength, phosphate ceramic layers providing thermal insulation, and fiber reinforcements providing tensile strength. This segmentation allows each layer to optimize its specific function, reducing overall weight while maintaining fire resistance.
2Reliability
If thermally insulated steel structures are used to achieve fire resistance, then fire resistance requirements are met, but production cost increases
Solution Approach 1:
The composite structure of steel profile with phosphate ceramic and fiber layers provides fire resistance at lower production cost by using cost-effective materials that can be applied through standardized manufacturing processes rather than requiring expensive solid steel sections with complex thermal insulation systems.
Solution Approach 2:
The invention changes the material parameters by substituting portions of steel with phosphate ceramic and fiber composites, maintaining fire resistance performance while reducing material costs and simplifying production processes.
3Ease of manufacture
If glass fiber reinforced plastic is used to manufacture components, then production is inexpensive and shape variety is unlimited, but the required fire resistance is not achieved
Solution Approach 1:
The patent combines glass fiber reinforcement with phosphate ceramic to create a composite material that maintains the ease of manufacturing and shape versatility of GRP while achieving the required fire resistance. The phosphate ceramic provides the necessary thermal insulation and fire resistance properties that pure organic resins lack.
Solution Approach 2:
The invention changes the chemical composition parameters by replacing organic resins with inorganic phosphate ceramic binders, transforming the material from flammable to fire-resistant while maintaining processability and shape-forming capabilities.
4Reliability
If phosphate ceramic with heat conduction of 1 W/mK is used, then the material is non-flammable and processable, but the maximum permissible temperature on the side facing away from fire cannot be met with normal thickness
Solution Approach 1:
The patent creates a composite structure where phosphate ceramic layers are combined with air gaps and fiber reinforcements. This composite approach effectively reduces the thermal conductivity of the overall component, allowing meeting temperature requirements on the fire-exposed side without increasing the thickness of the phosphate ceramic material itself.
Solution Approach 2:
The component is segmented into multiple thin phosphate ceramic layers separated by air gaps or fiber layers. This segmentation creates thermal barriers that reduce heat transfer, allowing the component to meet temperature requirements with reduced overall thickness compared to a solid phosphate ceramic block.
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 component achieves fire resistance meeting Class B-15 standards with low weight and high stability, maintaining a surface temperature below 140°C during fires, and can be easily manufactured and shaped for versatile applications like fire protection walls and window frames.
Implementation Method 1
When exposed to high temperatures of more than 700°C, this layer separates from the lower one, creating a passage that provides gas insulation
Implementation Method 2
The phosphate ceramic, which is mixed from a solid and a liquid component in accordance with EP 861 216 B1, is refractory, ie it is very flame-resistant and pressure-resistant
Implementation Method 3
creating a passage that provides gas insulation and through which the hot gases are returned to the fire compartment
Data Source
Figure 1
AI summary
The invention relates to a fire-resistant component (1) which satisfies the requirements of at least class B-15. Such components are known per se and are manufactured as insulated steel structures. In order that the component (1) can be manufactured more easily and with greater versatility in the manner of glass-fibre-reinforced plastic, it is proposed that it is manufactured with multiple layers of phosphate ceramic and also of fibres (7, 8, 9), and that a layer structure of the component (1) comprises at least one layer (4), on the surface thereof which faces towards a potential heat source, which is joined together only partially with a layer (5) arranged thereunder, i.e. remote from the heat source. The invention also relates to a process for producing such a component.