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China, Chinese Ceramifiable Silicone Rubber Composites with Enhanced Self-Supporting1 Industrial Products Supplier Manufacturer Details, price list catalog:
China Products Details Supplier Manufacturer price list catalog
Silicone Silicone ProductsSilicone RubberCeramifiable Rubber
Hangzhou Dachuang Kehua New Material Co., Ltd.
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Product Description Product DescriptionDachuang ceramifiable silicone rubber represents a cutting-edge class of fire-resistant materials engineered to provide exceptional passive fire protection. Based on the advanced research published in Polymers (2022), this material is designed to maintain structural integrity and form a robust, self-supporting ceramic shield when exposed to the extreme temperatures of a fire.Core Technology and Mechanism:The composite is primarily composed of a silicone rubber (SR) matrix infused with two key functional fillers:Silicate Glass Frits (SGFs): These act as a flux, melting at high temperatures to form a glassy phase that binds the residue together.Sodium Tripolyphosphate (STPP): This is the innovative component that significantly enhances the material's performance. Unlike other phosphorus compounds (e.g., Ammonium Polyphosphate), STPP avoids releasing toxic or irritating gases during decomposition.At room temperature, the material behaves like a typical, flexible silicone rubber. However, when exposed to temperatures above 700°C, a remarkable transformation occurs:The organic silicone rubber matrix decomposes.The SGFs melt into a viscous glass.The STPP interacts with the molten glass, promoting the precipitation of cristobalite (a crystalline form of SiO) and forming new, strong sodium phosphate crystals.This chemical reaction creates a rigid, ceramic-like residue that is rich in crystalline structures, providing high mechanical strength. Key Performance Advantages:Excellent Self-Supporting Property: A critical feature for fire protection in cables and seals. The ceramic residue formed can support its own weight without dripping or collapsing, even at temperatures up to 1000°C. Tests showed a dramatic reduction in bending angle (from 90° to ~51°) with the addition of STPP, proving its efficacy in preventing structural failure.High Mechanical Strength of Ceramic Residue: The formed ceramic shield exhibits remarkable flexural strength, exceeding 5 MPa after firing at 850°C and reaching nearly 7 MPa at 1000°C. This strength ensures the ceramic barrier remains intact, effectively insulating and protecting the underlying substrate from the fire.Superior Shape Stability: The composite retains its original shape after ceramification, without significant deformation, cracks, or holes. This ensures a continuous protective layer.Eco-Friendly and Non-Toxic Formulation: The use of STPP eliminates the concerns associated with ammonia release from other common phosphorus-based flame retardants, making it a safer and more environmentally conscious choice.Main Parameters of the Ceramifiable Silicone Rubber CompositeThis breakdown separates the parameters into Formulation (Input) and Performance (Output). 1. Formulation & Processing ParametersThese are the "recipe" and how the material is made.ParameterValue / DescriptionSignificancePolymer MatrixSilicone Rubber (Grade: 771-u)Provides the base flexible material that decomposes to form a SiO-rich ash during firing.Curing Agent2,4-Dichlorobenzoyl Peroxide (DCBP)Initiates the cross-linking (vulcanization) of the silicone rubber at elevated temperature.Primary FillerSilicate Glass Frits (SGFs)Function: Fluxing agent. Melts at high temperature to form a glassy phase that binds the ceramic residue together. Composition: Primarily SiO and NaO.Key Functional FillerSodium Tripolyphosphate (STPP)Critical Innovation. Promotes crystallization (cristobalite & sodium phosphate), drastically improving self-supporting strength and shape stability without toxic gas release.Sample FormulationsSS: SR + 100phr SGFsSSP-1: SR + 100phr SGFs + 9phr STPPSSP-2: SR + 100phr SGFs + 18phr STPP"phr" = parts per hundred parts of rubber. Optimal performance was achieved with the highest loading (18phr) of STPP.Mixing ProcessTwo-roll millEnsures homogeneous dispersion of fillers within the rubber matrix.Curing ProcessHot-PressingTemperature: 120°CPressure: 10 MPaTime: 5 minCures the material into its final shape. 2. Performance & Ceramification ParametersThese are the key results achieved after exposure to high temperatures.ParameterTest Method/ConditionValue Achieved (Optimal SSP-2 Sample)Significance / StandardSelf-Supporting PropertyBending Angle Test @ 1000°C for 30 min~51° (vs. 90° for sample without STPP)Quantifies anti-drip/anti-collapse. A lower angle is better. This shows excellent shape retention.Flexural Strength of Ceramic Residue3-point bending test on residue@ 850°C: >5 MPa@ 1000°C: 6.86 ± 0.15 MPaMeasures mechanical strength of the ceramic shield. Exceeds typical industrial requirements for fire-resistant cables (>3 MPa).Phase Composition (XRD)Residue fired @ 850°C for 30 minCrystalline Content: 54.67% (25% increase vs. non-STPP sample)Phases: Cristobalite (SiO) + Sodium Phosphate (NPO)Explains the high strength. The crystalline phases form a reinforcing skeleton within the glassy matrix.Thermal Stability / LOILimited Oxygen Index (LOI)~25.5% (with 18phr STPP)Indicates a self-extinguishing material. The slight decrease vs. the base compound is due to STPP influencing combustion.Bulk Density of ResidueArchimedes' Principle @ 1000°C~1.95 g/cm3Indicates the densification of the ceramic residue at higher temperatures, contributing to strength.Water Absorption of ResidueArchimedes' Principle @ 1000°C~25%A lower value would indicate a more sintered, impervious ceramic. This parameter is a trade-off with strength in this formulation.Key Operating TemperaturesMuffle Furnace Hold (30 min)Ceramification Onset: ~700°COptimal Ceramificatio Our main products ---Innovative Material Solutions for Industrial ExcellenceDachuang Kehua specializes in advanced material technologies designed to meet the demands of modern industries such as automotive, electronics, energy storage, and construction. Our product portfolio focuses on thermal management, sealing, insulation, and vibration control, ensuring reliability, safety, and efficiency in high-performance applications. Below are our core product lines: 1. Silicone Foam SolutionsSealing ComponentsBattery pack sealing rings (IP67/IP68)Liquid cooling plate support padsCushioning & FillingEV inter-cell filling foam (thermal runaway prevention)Vibration-damping cushions for industrial equipment2. High-Temperature Specialty MaterialsTeflon & Ceramized Silicone ProductsFireproof barriers (ceramicizing at 500°C+)Chemically resistant liners/gasketsMica-Based SolutionsCell spacers for batteriesHeat-insulating sheets (1000°C+ resistance)3. Polymer Foams & InsulationPolyurethane Foam (PU)CR/EPDM variants for weather-resistant sealsMelamine foam for acoustic insulationLightweight Insulation SheetsPP/PC insulating layersPEF (Polyethylene foam) & aerogel composites4. Advanced Thermal ManagementMPP InsulationElectromagnetic shielding applicationsAerogel-Enhanced MaterialsUltra-thin, high-performance insulation for aerospace/EVs Key DifferentiatorsMulti-Material Expertise: Combines silicone, PU, and ceramic technologies.EV-Centric Solutions: 60% of products support battery/charging systems.Extreme Environment Focus: Materials rated for -60°C to 1000°C.Typical Clients: EV manufacturers (battery/PACK), 5G infrastructure suppliers, aerospace OEMs. Our productionThe production of Dachuang ceramifiable silicone rubber is a precisely engineered process that transforms a standard silicone polymer into an advanced, life-saving material capable of forming a protective ceramic shield under extreme heat. This production is characterized by its scalability, reliance on conventional rubber processing equipment, and a meticulous formulation that ensures a homogeneous dispersion of functional fillers-the key to its exceptional fire-resistant properties.The core production philosophy revolves around integrating specific inorganic fillers (Silicate Glass Frits and Sodium Tripolyphosphate) into a silicone rubber matrix. At room temperature, this combination yields a flexible and processable elastomer. However, when exposed to fire, these components interact synergistically through a controlled ceramification reaction, melting and recrystallizing to form a rigid, coherent, and mechanically strong ceramic residue that prevents fire spread and maintains critical structural integrity. Material Preparation: The process begins with the precise weighing of raw materials according to a tightly controlled formula. The key components include:Silicone Rubber (771-u): The polymer base that decomposes to a silica ash.Silicate Glass Frits (SGFs): The low-melting-point flux that forms the glassy matrix of the final ceramic.Sodium Tripolyphosphate (STPP): The critical ceramification promoter that drives crystallization for strength.Dichlorobenzoyl Peroxide (DCBP): The cross-linking agent (curing agent).Mixing and Compounding: This is the most critical stage for achieving product consistency and performance. The ingredients are compounded using a two-roll mill or an internal mixer. This process ensures the complete and homogeneous dispersion of the SGF and STPP fillers within the rubber matrix. Any agglomeration or poor dispersion would create weak points, compromising the integrity of the final ceramic shield.Shaping and Forming: The compounded rubber mix is then shaped into its final form-this could be through extrusion for cables, calendering for sheets, or molding for gaskets and seals.Vulcanization (Curing): The shaped product is then cured using a hot-pressing or continuous vulcanization (e.g., autoclave or salt bath) process. The standard curing parameters are:Temperature: 120°CPressure: 10 MPaTime: 5 minutesThis step cross-links the silicone polymer chains, transforming the soft compound into a durable, elastic elastomer with its final physical properties.Quality Control: Finished products undergo rigorous testing, including verifying dimensions, hardness, and most importantly, ceramification performance. This involves firing samples at temperatures such as 850°C and 1000°C to confirm the formation of a strong, self-supporting ceramic residue with flexural strength exceeding industry standards.Quality control Critical KPIs for QC:Flexural Strength of Ceramic Residue (@1000°C): The ultimate measure of performance. Must be >5 MPa.Bending Angle (@1000°C): The key indicator of anti-collapse performance. Must be low.Visual Integrity of Residue: No cracking, dripping, or loss of shape.Raw Material Consistency: Especially the composition and particle size of SGF and STPP.1. Incoming Raw Material QCThis is the first and most critical step. Poor quality inputs cannot be corrected later.MaterialKey Control ParametersTest Method / StandardSilicone Rubber (771-u)? Viscosity (Mooney)? Purity & Composition? Volatile ContentASTM D1646, COA (Certificate of Analysis) from supplier.Silicate Glass Frits (SGFs)? Chemical Composition (SiO2, Na2O % must be consistent)? Particle Size Distribution? Softening Point / Melting Behavior (DSC)? Morphology (SEM to check for agglomerates)XRF, Laser Particle Size Analyzer, Differential Scanning Calorimetry (DSC), SEM.Sodium Tripolyphosphate (STPP)? Purity / Assay? Particle Size Distribution? Free Moisture ContentTitration, Laser Particle Size Analyzer, Loss on Drying.Curing Agent (DCBP)? Active Oxygen Content? PurityCOA from supplier. 2. In-Process Production QCMonitoring the process ensures consistency and correct formulation.Process StageKey Control ParametersFrequency / MethodWeighing & Pre-Mixing? Accuracy of all components (especially critical fillers SGF & STPP)? Weighing traceabilityBatch record check. Automated weighing systems are ideal.Mixing (Two-Roll Mill)? Mixing time & temperature? Visual inspection for homogeneity (no streaks or agglomerates)? Mooney Viscosity of the compoundPer batch. Use a standardized mixing procedure.Shaping (e.g., Extrusion)? Dimensions & tolerances? Surface finish (should be smooth, no defects)? Line speed and temperaturesContinuous monitoring with laser gauges, regular manual checks.Vulcanization (Curing)? Temperature, Pressure, Time? Cross-link Density (via Curemeter, e.g., MDR)Continuous monitoring of press parameters. Rheometry (MDR) on samples from each batch. 3. Final Product QC (Room Temperature Properties)These tests verify the product is a good-quality rubber before it ever sees heat.ParameterStandard Test MethodTarget / SpecificationPhysical Properties ? Hardness (Shore A)ASTM D2240To meet design spec (e.g., 70 ± 5 Shore A)? Tensile StrengthASTM D412> X MPa (Based on product requirement)? Elongation at BreakASTM D412> Y % (Based on product requirement)Flammability ? Limited Oxygen Index (LOI)ASTM D2863~25.5% (Confirming self-extinguishing behavior) 4. Critical Performance QC (Ceramification Properties)This is the most important QC section, unique to ceramifiable products. It must be performed on samples from every production batch.ParameterTest Method / ConditionAcceptance Criteria (for SSP-2 formulation)Self-Supporting PropertyBending Angle Test:Sample: 50mm x 5mm x 3mm1000°C for 30 minBending Angle ≤ 55° (Must significantly outperform control sample)Ceramic Residue Strength3-Point Flexural Strength:On residue fired at 850°C & 1000°C for 30 minFlexural Strength ≥ 5.0 MPa (Minimum)Flexural Strength ~6.5 - 7.0 MPa (Typical at 1000°C)Shape IntegrityVisual Inspection:On residue fired at 700°C, 850°C, 1000°C for 30 min? No dripping or melting collapse? Retains original shape? Surface free of large cracksMicrostructure (Periodic Audit)SEM/EDS Analysis:On cross-section of residue? Homogeneous element distribution (Si, O, P, Na)? Dense, sintered structure with minimal large poresPhase Composition (Periodic Audit)X-Ray Diffraction (XRD):On residue fired at 850°CPackaging & ShippingProduct applications This material is ideally suited for applications where fire integrity is paramount:Fire-Resistant Cables: To maintain circuit integrity and ensure operational safety for critical systems during a fire.Building Seals and Gaskets: To prevent the spread of fire and smoke through openings in high-rise buildings and public facilities.Aerospace and Transportation: For fire protection in vehicles, trains, and aircraft where weight and performance are critical. Company ProfileHangzhou Dachuang Kehua New Materials Co., Ltd.Innovating Silicone Solutions for a Sustainable FutureCompany OverviewHangzhou Dachuang Kehua is a national high-tech enterprise and a pioneer in advanced silicone material solutions. Founded in 2020 and headquartered in Hangzhou's Qingshanhu Science and Technology Corridor, we integrate R&D, production, and sales to serve global industries with cutting-edge material technologies.Key Stats:51-100 employees (30% R&D specialists)10+ patents in silicone foaming and composites5,000+ tons annual production capacity Core Strengths1. Technological InnovationDC800 Series Foamed Silicone:Self-foaming technology (no external agents)Wide density range (0.05-0.5g/cm3) for customizable cushioning/sealingDC400 Fireproof Series:Ceramicizes at 500°C, preventing thermal runaway in EV batteries2. Certifications & ComplianceQuality: ISO9001, IATF16949 (automotive)Safety: UL94 V-0 flame retardant, EU RoHS/REACHSustainability: SGS-certified low VOC emissions3. Industry-Specific SolutionsIndustryChallengeOur SolutionEV BatteriesCell expansion stressDC800 cushioning pads (20% compression set)Energy StorageFire risksDC400 ceramicized barriers5G Base StationsWeather degradationUV-resistant sealing strips Success StoriesCase Study 1: Thermal Runaway Protection for EV Battery PacksClient: Top 3 Global EV ManufacturerProblem: Battery fires due to thermal propagation.Solution:DC400 ceramicized silicone layers between cells.Result: 30-minute fire containment (exceeding GB38031-2020 standard).Case Study 2: Lightweighting Energy Storage CabinetsClient: Tier-1 Energy Storage SupplierProblem: Heavy thermal pads reduced portability.Solution:DC10 aerogel-infused thermal pads (0.8W/mK conductivity, 50% lighter).Result: 15% weight reduction without sacrificing heat dissipation. Sustainability Commitment1. Eco-Friendly ProductionZero-waste water: Closed-loop recycling system.Low-carbon materials: 30% bio-based silicone in development.2. Green Product LinesRecyclable foamed silicone (DC800-E series).Halogen-free flame retardants (meeting IEC 61249-2-21).3. Partnerships for ImpactCollaborating with Hangzhou Low-Carbon Lab to achieve carbon-neutral production by 2028. Client Testimonials"Dachuang Kehua's DC800 foam solved our battery sealing challenges with exceptional temperature resistance. Their team's responsiveness was outstanding."- Engineering Director, Leading EV Battery OEM*"The only supplier that met our UL94 V-0 and IP68 requirements simultaneously. Highly recommend for critical applications."*- Procurement Manager, Global 5G Infrastructure Co.Why Choose Us?End-to-end customization (from R&D to mass production)Faster lead times: 15 days for samples, 30 days for bulk orders.24/7 technical support with on-site troubleshooting available. Vision & Future2025 Goal: Launch DC1000 Series-the world's first self-healing silicone foam for aerospace.Long-Term Mission: Drive the global transition to sustainable industrial materials.Let's Innovate Together!Certifications FAQQ1: What is ceramifiable silicone rubber, and how does it work?A: Our ceramifiable silicone rubber is a high-performance fire-resistant material. At room temperature, it behaves like a normal, flexible silicone elastomer. When exposed to extreme heat (above 700°C), it undergoes a unique "ceramification" process: the organic content burns away, and the specialized inorganic fillers within the compound melt and react to form a rigid, self-supporting ceramic shield. This ceramic layer provides excellent insulation and prevents the spread of fire.Q2: What makes your product superior to other fire-resistant materials?A: Our key advantage lies in our patented formulation using Sodium Tripolyphosphate (STPP). Unlike many competitors who use Ammonium Polyphosphate (APP), our compound:Eliminates Toxic Gas: It does not release ammonia during a fire, making it safer for human exposure.Enhances Strength: STPP actively promotes the formation of strong crystalline phases (cristobalite and sodium phosphate), resulting in a ceramic residue with superior mechanical strength (>6 MPa at 1000°C).Provides Excellent Shape Stability: It exhibits minimal deformation and no dripping, crucial for maintaining fire barriers.Q3: What is the typical operating temperature range?A: The material begins its ceramification process around 700°C and forms a fully coherent, high-strength ceramic residue at temperatures between 850°C and 1000°C. It is designed to withstand standard fire test conditions (e.g., IEC 60331, BS 6387 CWZ) and beyond.Q4: What are the key performance specifications?A:Flexural Strength of Ceramic Residue: >5 MPa at 850°C, ~7 MPa at 1000°C.Self-Supporting Property: Bending angle of approximately 51° at 1000°C (far superior to the 90° collapse of non-STPP formulas).Limited Oxygen Index (LOI): ~25.5%, classifying it as a self-extinguishing material.Ceramic Phase Content: Over 54% crystalline phase in the residue at 850°C.Q5: How is this material processed?A: It is designed for easy integration into standard rubber manufacturing processes. It can be compounded using a two-roll mill or an internal mixer and shaped via extrusion, calendering, or molding. The standard curing (vulcanization) parameters are 120°C and 10 MPa pressure for 5 minutes.Q6: What are the primary applications for this product?A: Its primary use is in any application where maintaining integrity during a fire is critical:Fire-Resistant Cables: For critical circuits in power plants, data centers, high-rise buildings, and public transportation.Building Seals & Penetration Seals: To prevent fire and smoke from spreading through gaps in walls and floors.Aerospace & Marine: For fire protection in vehicles and vessels where weight and safety are paramount.Q7: How do you ensure quality and consistency?A: We implement a rigorous multi-stage Quality Control protocol. This includes strict incoming material checks, in-process monitoring, and, most importantly, batch-level testing of ceramification performance. We routinely test the flexural strength and structural integrity of the ceramic residue formed from our production batches to guarantee every shipment meets our high standards.Q8: Is this product environmentally friendly?A: Yes. The formulation is halogen-free and, crucially, avoids the use of ammonium-based compounds that release toxic ammonia gas when heated. This makes it a more environmentally and human-friendly choice for advanced fire protection.Q9: Can the formulation be customized?A: Yes. While our standard formulation offers exceptional performance, we can work with you to customize properties like hardness, color, processing characteristics, or ceramification temperature to meet specific application requirements.Q10: Where can I get technical data sheets (TDS) and request samples?A: Please contact our technical sales team through [Website/Contact Information]. We will be happy to provide detailed TDS and discuss your sample requirements for testing and validation.
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