Ultra-Thin Composite Flame Barrier for 2,400°F Fire Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current lightweight flame barriers are susceptible to degradation from high temperature flames, aggressive flames, molten electrolyte expulsion, hydrofluoric acid exposure, and burning metal particles, and lack cost-effective solutions for higher temperature fire protection.
Innovation Solution
A flame barrier comprising multiple metallic and non-metallic layers, with a thickness ranging from 0.08 to 20 mils, designed to maintain a cold side temperature of 700°F or less in environments up to 2,400°F, using materials like alloy steels, aluminum, and ceramics, and an adhesive containing inorganic salts for enhanced protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If current lightweight flame barriers are used, then weight is reduced, but protection against high temperature flames and aggressive flames is insufficient
Solution Approach 1:
The patent employs a composite structure consisting of a reflective metallic layer (aluminum, stainless steel, or other metals) combined with an insulating layer (ceramic fiber, fiberglass, or other thermal insulators). This composite material approach allows the flame barrier to maintain lightweight properties while achieving superior protection against high temperature flames up to 2,400°F by combining the reflective properties of metals with the thermal insulation capabilities of ceramic materials.
Solution Approach 2:
The invention changes the thermal parameters of the flame barrier by introducing a reflective layer that actively reflects radiant heat, in addition to passive insulation. The metallic layer reflects a significant portion of thermal radiation, thereby reducing the heat load on the insulating layer and improving overall performance against high temperature flames without proportionally increasing weight.
2Reliability
If thicker flame barriers are used to improve protection, then fire resistance is enhanced, but weight and thickness increase
Solution Approach 1:
The reflective metallic layer combined with a thin insulating layer creates a high-performance composite that achieves superior fire resistance at reduced thickness and weight compared to traditional single-layer insulation. The reflective layer provides immediate heat rejection, allowing the insulating layer to be thinner while maintaining equivalent or superior protection.
Solution Approach 2:
The metallic reflective layer acts as a thin film that provides significant thermal protection through reflection rather than thickness. This thin-film approach allows the flame barrier to achieve high fire resistance ratings without the substantial weight and thickness increases associated with traditional thick insulation layers.
3Ease of manufacture
If traditional flame barrier materials are used, then cost is reduced, but protection against molten electrolyte expulsion and hydrofluoric acid exposure is insufficient
Solution Approach 1:
The combination of a metallic reflective layer with a chemically resistant insulating layer (such as ceramic fiber or fiberglass) creates a composite structure that provides both thermal protection and chemical resistance. The insulating layer serves as a barrier to molten electrolyte expulsion and hydrofluoric acid exposure, while the metallic layer provides thermal reflection, achieving multi-hazard protection at reasonable cost.
Solution Approach 2:
The insulating layer acts as an intermediary barrier between the external hazards (molten electrolyte, HF acid) and the protected substrate. This intermediate layer prevents direct contact between the harmful substances and the substrate, while the metallic reflective layer provides an additional layer of protection against thermal radiation.
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 flame barrier effectively protects against high temperature flames, prevents flame penetration, and maintains a low cold side temperature, even in extreme conditions, while being lightweight and cost-effective.
Implementation Method 1
a first metallic layer... a second metallic layer... configured to maintain a cold side temperature of 700° F. or less in an environment with temperatures up to 2,400° F.
Implementation Method 2
a non-metallic layer positioned between the first metallic layer and the second metallic layer
Data Source
AI summary
Embodiments relate to a flame barrier that may be adhered or mechanically fastened to a substrate to provide fire resistance and/or an outer protective surface. The flame barrier may alternatively be adhered or mechanically fastened to an existing flame barrier to provide increased fire resistance and/or increased protective ability. The flame barrier is configured to protect against high temperature flames, prevent flame penetration, and contain aggressive flames to reduce the severity of the flame's impact, heat, and velocity.