Thermosetting Resin Fireproof Board with Graphene Oxide
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Solution Overview
Problem
Existing decorative panels lack the necessary combination of high strength, flame retardancy, wear resistance, and sound absorption, making them inadequate for applications requiring these properties, especially in high-temperature and noise-sensitive environments.
Innovation Solution
A high strength fireproof board and wear-resistant decorative panel are developed using a thermosetting resin-based structure with layers of fiber, foam fiber, and a balance layer, incorporating graphene oxide and nano-aluminum oxide for enhanced strength and wear resistance, and a manufacturing process involving hot pressing and foaming to create a three-dimensional network for sound absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing decorative panels are used, then they provide basic decorative function, but they lack high strength, flame retardancy, wear resistance, and sound absorption properties
Solution Approach 1:
The patent combines multiple functional layers (fiber layer, foam fiber layer, wear-resistant layer, pattern layer, balance layer) into a single composite panel structure. This merging of different functional components resolves the contradiction by achieving both high reliability (fire retardancy, strength) and adaptability (wear resistance, sound absorption, decorative function) in one integrated product.
Solution Approach 2:
The patent uses composite materials throughout the structure, including thermosetting resin-impregnated fibers, foam fibers with air pockets, and layered combinations of different materials. These composite structures provide enhanced fire retardancy, strength, and multi-functionality simultaneously, resolving the technical contradiction between reliability and adaptability.
2Ease of manufacture
If melamine foam is used as raw material, then cost performance ratio improves, but processing complexity increases
Solution Approach 1:
The patent performs preliminary impregnation of fibers and foam with thermosetting resin before final hot pressing. This preliminary action prepares the materials in advance with desired properties, making the subsequent manufacturing process more efficient despite the complex multi-layer structure, thus improving cost performance while managing processing complexity.
Solution Approach 2:
The patent utilizes parameter changes during hot pressing (temperature, pressure, time) to transform the impregnated fiber and foam layers into a solid composite structure. By controlling these parameters, the complex processing is optimized to achieve the desired product properties efficiently, balancing manufacturing ease with processing requirements.
3Reliability
If thermosetting resin is used, then flame retardancy and wear resistance improve, but manufacturing complexity increases
Solution Approach 1:
The patent merges the impregnation and hot pressing operations into an integrated manufacturing process. The thermosetting resin is applied to multiple layers simultaneously, and the hot pressing step consolidates all layers while curing the resin, achieving flame retardancy and wear resistance without proportionally increasing manufacturing complexity.
Solution Approach 2:
The use of thermosetting resin creates a composite material system where the resin matrix binds the fiber and foam layers together. This composite structure inherently provides flame retardancy and wear resistance while the integrated manufacturing process manages the complexity of working with thermosetting materials.
Data Source
AI summary
The invention discloses a high strength fireproof board, which has two structures. The first structure is a three-layer hot pressed composite structure, which is composed of fiber layer, foaming fiber layer and fiber layer respectively from top to bottom, and the second structure is composed of hot-pressed fiber layer. The invention also discloses a wear resistant fireproof decorative panel consisting of a high strength fireproof board which is hot pressed at one time, or can be hot pressed twice, or composite molded after glue coated. The invention also discloses a manufacturing method for high strength fireproof board and wear resistant decorative panel based on high strength fireproof base board. The stated high strength fireproof board and wear resistant decorative panel are made of thermosetting resin and have the characteristics of flame retardant, wear resistant, high, and low temperature resistant, sound absorbing and antistatic.