Multi-layer Coating for Expanded Polymers
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Solution Overview
Problem
Existing fire protection systems for expanded organic polymers are limited in achieving high flame retardancy and low smoke generation, often leading to incomplete combustion and high smoke density, and are costly, complex, and environmentally unfriendly, failing to meet stringent modern regulations.
Innovation Solution
A multi-layer coating system featuring a glass fibre layer as the outermost layer, a non-perforated metal foil layer underneath, and a substrate of expanded polymer, with an adhesion system and optional additional functional layers, designed to disperse flames and heat while preventing smoke formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flame retardant agents or non-combustible fillers are used to improve fire retardancy of the polymers, then flame retardancy is improved, but the expansion or foaming of the polymers is severely impacted and other final properties are adversely affected
Solution Approach 1:
The fire protection function is segmented from the polymer substrate by applying a separate multi-layer coating system consisting of metal foil and fibre layers, rather than incorporating flame retardant agents directly into the polymer matrix. This allows the polymer to maintain its expansion and foaming properties while the coating system provides fire protection.
Solution Approach 2:
The metal foil and fibre layers act as intermediary protective barriers between the fire source and the polymer substrate. These layers intercept and reflect thermal energy, preventing it from reaching the polymer, thereby protecting the polymer's expansion properties while providing fire retardancy.
2Reliability
If traditional fire protection systems with metal foil or fibres are used, then flame spread is reduced, but smoke creation and smoke density increase due to incomplete combustion
Solution Approach 1:
The invention uses a composite multi-layer system combining metal foil (aluminium) and fibre layers (glass fibre, basalt fibre, or aramid fibre). This composite structure provides both flame spread resistance and low smoke generation, as the fibres promote complete combustion while the metal foil reflects thermal energy.
Solution Approach 2:
The invention changes the combustion parameters by using fibre layers that promote complete combustion, thereby reducing smoke density. The specific fibre materials (glass, basalt, aramid) have high thermal stability and promote efficient burning, reducing incomplete combustion products.
3Reliability
If multiple layers with different materials are used to achieve high flame retardancy, then fire protection performance is improved, but the system becomes costly and complex
Solution Approach 1:
The metal foil and fibre layers serve multiple functions simultaneously: they act as thermal barriers, reflect radiant heat, provide mechanical protection, and promote complete combustion. This multi-functionality reduces the need for additional specialized layers, simplifying the overall system while maintaining high flame retardancy performance.
4Reliability
If halogenated fire retardants or additional substrate treatments are used to meet fire standards, then flame retardancy is improved, but environmental friendliness and economic viability deteriorate
Solution Approach 1:
The invention extracts the fire retardant function from the polymer substrate and implements it through a separate coating system. This eliminates the need for halogenated fire retardants and chemical treatments of the substrate, as the physical barrier and thermal reflection properties of the metal foil and fibre layers provide fire protection without harmful chemicals.
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 system effectively achieves high flame retardancy and low smoke generation, meeting stringent fire test standards without requiring additional substrate treatments or halogenated fire retardants, and is economically and environmentally friendly, with versatility in application and manufacturing processes.
Implementation Method 1
a non-perforated metal foil layer (B) underneath
Implementation Method 2
metal foil layer (B)...for heat dispersion
Implementation Method 3
glass fibre layer (A) being applied as outermost layer...to disperse flames and heat
Implementation Method 4
an adhesion system...to bond the compounds (A), (B) and (C) to each other
Data Source
Figure 1
AI summary
The present invention relates to versatile multi-layer (A)(B) coating systems for anti-flame purposes especially for protection of expanded organic polymers (C) leading to improved fire retardant properties together with low smoke generation, the process for manufacturing of such systems, the application of such systems on substrates and the use of such systems and resulting composites.