CA2102214A1 - A flame-resistant flat pressed board and a process for its production - Google Patents
A flame-resistant flat pressed board and a process for its productionInfo
- Publication number
- CA2102214A1 CA2102214A1 CA002102214A CA2102214A CA2102214A1 CA 2102214 A1 CA2102214 A1 CA 2102214A1 CA 002102214 A CA002102214 A CA 002102214A CA 2102214 A CA2102214 A CA 2102214A CA 2102214 A1 CA2102214 A1 CA 2102214A1
- Authority
- CA
- Canada
- Prior art keywords
- weight
- board
- flameproofing agent
- substance
- flat pressed
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/02—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board the layer being formed of fibres, chips, or particles, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N9/00—Arrangements for fireproofing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/16—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer formed of particles, e.g. chips, powder or granules
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K21/00—Fireproofing materials
- C09K21/02—Inorganic materials
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/92—Protection against other undesired influences or dangers
- E04B1/94—Protection against other undesired influences or dangers against fire
- E04B1/941—Building elements specially adapted therefor
- E04B1/942—Building elements specially adapted therefor slab-shaped
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/306—Resistant to heat
- B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/716—Degradable
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/726—Permeability to liquids, absorption
- B32B2307/7265—Non-permeable
Abstract
A fire-retardant flat-pressed panel of per se combustible panel material, binder, flame protection agent and possibly auxiliary substances contains as the flame protection agent a combination of a substance capable of releasing an acid, especially an inorganic acid, at high temperatures, a carbon-containing substance with esterifiable hydroxyl groups and a substance which can release a non-combustible gas at high temperatures. The response temperatures of the first and last-mentioned substances are above the temperatures needed for making the flat-pressed panel. The flame protection agent has low water solubility and is mixed into the panel material in finely divided form. The flat-pressed panel is preferably a panel made using wood-containing substances, especially wood shavings.
Description
WO ~2/19696 ~ ~ / PCT/EP32/00873 ~rg~ ~ a a ~ 2 ~ ~
A flam~-r~sistant ~lat pres~ed board - and a proce~ ~or its prohuatio~
This inYention relates to a flame-resistant flat pressed board of basically flammable board material, binder, flameproofing ag~nt and optionally auxiliaries.
In the context of the invention, the expression "flat pressed board" encompasses a number of board-like : materials which are used in particular in building construction for load-bearing, stiffenlng, decorative and other purposes. To make these flat pressed boards5 ~~ a suitable base material is pressed with one or ~ore binders. Depending o~ the application envisaged, the : boards ~re of~en required to show certain beha~ior in : ; the event of fi~e. To this end, the flat pressed boards ; ~ may contain~additives which ensure that the boards are difficult to ignite in the event of fireO In building ~construction, for ex Q le, the building matexials used must ha~e a:Bl:or B2 classification according to DIN
: 4102, Part 1 (Building Materials~.
: ~ Comm~nly;used flat pressed boards are the so-called chipboards which are produced by pressing chips ~o of wood and/or other wood-like fibrous materials with bindersO If the chips used are solely wood chips, the board ultimately obtained is known as a wood chipboard.
: There are e~sentially two standard types of chipboard which contain binders of dif~erent kinds in different quantities. V 20 boards are intended for use in rooms with generally low air humidity leve~s. The binders used for these boards are mainly aminoplastics. So-called V 1~0 boards are intended for use in rooms having high air humidity levels and are normally bonded with alkali-curing phenolics, phenol/resorcinol resins or, f~ i u .~
- WO 92/196~6 2 ~?CT/EP92/00873 recently, with polyureas.
A common method for achisving a fireproofing effect ic ~o provide the boards with suitable coatings.
Known f ireproof coatings are the so-called insulating S layer formers which produce a foam on the particul ar substrate in the event of fire. This foam is intended to prevent the f ire f rom spreading on the substrate 1:o be protected. These coatings have the disadvantage that, in l:he production of the flat pressed board, an 10 additional step is required to apply the coating or, alternati~ely, the coating has to be subsequently applied to a board already in use. In addition, coat-ings on the outside of the boards are highly exposed to weathering and other outside inf luPnces . As already 15 mentioned, flat pressed boards containing flameproofing agents are al50 known . ConYentional flameproof ing agent~, suc~ as for example boric acid, monoammonium phosphate or diammonium phosphate, are used in their case. ~ood chipboards have also been produced by mixing 20 wood, cement, water and other additives and subsequently drying the pressed board. All these processes are a~tended by the disadvantage that relatively lar~.
quantities of ~dditiYes hav~ to be ussd to obtain a flame-resistant ~oard which, in particular, satîs~ie~
25~ th~: requiremen~s of DIN 4î02, Part 1., The largs quan-tities of additives seriously reduc:e the perc:entage of the base material, such as for examplP wood, so that it ~ay amount to only 20 to 40% by weight/ ~ased on the total weight of the board. Accordingly, flat pressed boards of this type are unable to satisfy the other requirements they are expected to meet, f~r example in regard to s rength, resistance to atmospheric moisture or the like.
Accordîngly, the proble~ addressed by the present in~ention was to provide flat pressed boards which, even ` ~ ~2 i' : -WO 92~19696 3 PCT/EP92/00873 with relatively small quantities of additives, would be flame-resis~ant, more particularly as required under DIN
4102, Part 1. At the same time, the other properties of the board would not be adversely affected by the addi-tives.
This problem has been solved by a flat pressedboard of the type mentioned above in which the flame~
proofing agent is a combination of a) a substance capable of releasing an acid, mor~
~ particularly an inorganic acid, at elevated ; temperature,~
~ b) a carbon-Gontaining substance bearing esterifi-:~ ~, able hydroxyl groups and c) a substance capable of releasing a non-inf~am-mable gas a~ elevated temperature~ .
~: Thé response temperatures of the substances a) and:: c) are above~ the temperature required for th~
production:of:the~flat pressed board. In addition, the 1ameproofing:~agent is sparingly soluble in water and i5 ; 20~ finely dispe~sed:throughout the board material.
: The flame r`esistance of the flat pressed board a`c ording to the invention in the event of fire is attri~utable ~o~:thè fact that the acid released at elevated temperature~and the substance mentioned under 25~ b)~;react with one another to form an ester and then carbonize under~he conditions prevaiIing in the event of fire. :~By rel;easing a gas, the substance described under c~ promotes the formation of a carbon-containing ~oam so that the three substances produce the flame-proofing effect by cooperating with one another in the : e*ent of fire. In the event of fire, khe ~lameproofingagent present in-the flat pressed board forms a fine cell, highly~insulating foam which e~fectively pre~ents the fire from spreading. The incorporation of the flameproofing agent in finely dispersed form provides :
~ ' ~
~ J '~
for a homogeneous fireproofing effect and for uniform foaming. The fact that the flameproofing agent is sparingly soluble in water contri~utes to the fireproof-ing effect being reliably developed, even when the board S is situated in an environment of high atmospheric humidity.
By virtue of the invention, the percentage of base material in the flat pressed board can be kept high so that the other requirements which the boaxd is expected to meet can readily be satisfied. The surface o~ the flat pressed board is not a~fected, as is the ~ase for example with coatings.
~ The board material may be ~ntroduced into the board according to the invention in any form. For example, fibrous and/or particulate materials may be used. Besides wood and other wood~like fibrous materi~
- als, textile ma~erials, cellulose or plastics may be : used as the board material, textile waste, cellulose waste or plastic waste being particularly suitable.
Viscose may also be used as the base material. A board :~ which has been produced using ~ood-like mater.ials, particularly wood chips, is preferred. According to the inYention, a wood chipboard of the V100 type which meets ~he requirements of class Bl of DIN 4102, Part 1 (Build-25~ ing Materials), is particularly preferred, The wood :chips are preferably bonded by addi~ion of polyisocya-nates (formation of crosslinked polyureas). The flame-resistant wood chipboard obtained in this way is addi;
tionally free from formaldehyde and, hence, ecologically safe to a large extent. Since the temperatures at which wood chipboards are pressed are normally in the range from 200 to 220~C, the substances mentioned under a) and c) are best selected so that the corresponding response temperatures are above 200~C and, more particularly, above 220~C.
~o 92~19696 5 PCTJEP92/00873 In another embodiment of the invention, the flameproofing agent is preferably present in the flat pressed board in a quantity of 1 t~ 50% by weight, based on th~ to~al weigh~ of the board. ~uantities of 3 to 30% by weight, based on the total weight of the board, are preferred, quantities of 5 to 15~ by weight being particularly preferred. This means that the percentag~
of board material~ particularly wood, is always at l~ast 50% by weight or preferably even higher, so that the properties of the board attributable to the base materi-a~ remain largely unaffected by the flameproofing agent.
The flat pressed board may consist of one or more layers. Boards comprising an odd number of layers are preferred because boards having an even number of layers can warp more easily in use.
Other pre~err2d boards according to the inventiQn are ~lat pressed boards which consist of two surface ~: ~ lay~rs and at~ least one middle layerO The surface layers may~consist of fine board material, more particu~
:20:~ :larly fine wood chips, while coarser material, for : example 1 cm in diameter, is present in the middle layer. The two layers may differ not only in the size ~ of the material present, but also in their quantitati~e :: ~ composi~ion. ~In a preferred embodiment, the two surface ~25~ layers each ma~e up 20% of the overall thickness vf the board while the middle layers make up around 60~ of the : total thickness. According to the inventiont ~arious quantities of flameproofing agent may be provided in various layers of the board. This also means that, in the case of a single-layer board, the concentration of ~flameproofing agent can be varied over the lengthr width and thickness of the board.
In another embodiment of the invention, ~he flameproo~ng agent is present in the surface layers in a quantity of 5 to 50% by weight and preferably in a ~ ~ U)J~J~1 quanti~y o~ 15 to 35% by weight, based on the surface layer material. In the middle layer, the flameproofing agent is present in quantities of 0 to 50% by weight and, more par~icularly, in quantities of 0 to 20% by weight, based on the material of the middle layer. In another preferred embodiment, the flameproofing agent is present in a higher concentration in the surface layers than in the middle layers. In this way, the flameproof ing agent affords adequate protection against fire in the surface layexs alone and flame propagation is effectively prevented at the actual surfac~ of the boardO In one preferred embodiment of the invention, e*fective flameproofing is obtained even when the flameproofing agent is present solely in the two surface layersO This surprising result leads not only to a saving of material and costs, it also provides for easisr produrtion of the flat pressed board~ according to the invention. For example, a ~1100 wood chipboard with a B1 classification accsrding t~ DIN 4102, Part 1, can be easily and inexpensively produced.
The binders used in accordance with the invention ara preferably the binders typically used fvr binding :board materials~ The binders in ~uestion may be thermo plastic or thermoset binders. Thermoset binders are :~ 25 particularly suitable. Thermoplastic binders can have the disadvantage that they can cause the presses to s ck at the temp~ratures required for pressing.
Phenolics and phenol-resorcinol resin are men~ioned as advantageous binders. An isocyanate binder is preferab-ly used as the binder because the boards produced with an isocyanate binder, particularly wood chipboards, are formaldehyde-free. In particular, the bindPr may be added to the board material in a quantity of 2 to 15% by weight and preferably in a quantity of 3 to 1~% by weight, based on the weight of the board~
i d Wo 92/19696 7 PcT/Eps2/oos73 The flat pressed boards according to the inven-tion preferably develop their flameproofing effect at temperatures above 200C and, more particularly, at temperatures above 220C. It can be of advantage if this effect is only developed at even hi~her tempera-tures, for example 250C. This may depend on the temperature at which the board material, the binder, the flameproofing agent and any auxiliaries used are pressed to form the flat pressed board. The reaction by which the flameproofing effect is produced should not take place at the pressing temperature.
The auxiliaries according to the invention are : ` hydrophobicizing agents for~improving the resistance of ~~ the boards to :water or moisture (such as paraffin e~ulsions for example); conductivity additives for preventing or reducing:the static charging of the boards or~preservatives and dyes.
he p~esent invention also relates to a flam~-proofing agent-as:claimed in claim 13 for the production 20~ ~of flame-resistan~ flat pressed boards. In the event of ire, ~his flameproofing agent forms a carbon-contain-ing,~ highly insulating fine-cell foam.
I~ one particular:embodiment, the flameproofing agent is present in finely dispersed form and is prefer-:25~ ::ably a powder wi~h~a particle size of less th~n BO ~m.
A powder with a particle size of less than 40 ~m is even more preferred. Flameproofing agents ha~ing the fine distributions~:mentioned are particularly suitable ~or the production o~ ~lame-resistant flat pressed boards.
30: i The flameproofing agent pr2sent in the flat pressed board is composed of the substance a3 in quanti~
: ties of 10 to 60~ by weight and preferably 30 to 45% by weight, the substance ~ in quantities o~ 10 to 60% by weiyht and preferably 15 to 50% by weight and the substance c) in quantities of 5 to 55~ by weight and ` r~l~J,-, rJ ~ ~
prefera~ly 20 to 40~ by weight.
The substance a) is preferably a substance which is capable of releasing phosphoric acid and/or oligo-phosphoric acid andJor polyphosphoric acid. Substances such as these are, in particular, ammonium phosphates, such as monoammonium phosphate and ammonium polyphos-phates or mixtures of these compounds. These substances may preferably be present in condensed form~ Sub~tan-ces capable of releasing sulfuric acid may also be used in accordan~e with the invention. Substances which are aapable o~ releasing an organic acid, such as sulfonic acid for example, are also suitable.
~ The càrbon-containing substances b) bearing esterifiable hydroxyl groups are, i~ particular, polyhy-}5 dric alcohols or mix~ures thereof, among which tetrahy-dric alcoholst such as pen~aerythritol for example, are preferably used. Another suitable substance is dipenta-~rythritol. Water-soluble substances containing esteri-fiable hydroxyl groups, such as for example carbohy-drates, starch, sugar and cellulose, may also be used inaccordance with the invention providing the resulting solubility of the flameproofing agent in water does not ~ave any adverse effects on the flat pressed ~oard.
~mong the last substances mentione~, the carbohydrates ~re preferred.
According to the invention, preferred substances ~: c) which are capable of releasing a non-inflammable gas at elevated temperature are substances Which release water, carbon dioxide, nitrogen or preferably ammonia.
In these cases, substance c) may be a hydroxidet car-bonate, hydrs:)gen carbonate or an ammonium compound.
Substances containing free amino groups are particularly suitable ~or releasing ammonia. Substances such as these ~re, for example, me-lamine and dicyanodiamide.
3S The melamine may be used in commercially available pure .
-WO 92/196g6 9 f~ J i~ pcT/EP92/0o873 form. Substances which give off carbon dioxide at elevated temperature and which are preferably sparingly soluble in water may also be used with advantage in accordance with the invention. One example of such a substan~e is lime.
The flameproofing agent according to the i~ven-~ion itself is preferably free from binders. The flame-proofing agent forms the described foam in the absence o~ other additives. This reduces cost~ and simplifies the production a~d use of the flameproofing agent.
In one adva~tageous embodiment of the invention, the ~lamepxoofing agent additionally contains anticaking and~or free~flow additives. This prevent~ the flame-proofing agent from caking and from losing its free-flow properties. In his way, the flameproofing agent may be us~d in homogeneously dispersed form, ~or example in the productio~ of flame-resistant flat pressed boards. In addition, the stability of th~ flameproofing agent during storage and transportation is improved~ Such additives can be of advantage particularly when the flameproofing agent is extremely fine~ The additives are pxeferably present in quantities of 0.1 to 10% by weight and, more particularly, in quantities of 0.5 to 2% by weight, based on the flameproofing agentO The 25: additives may be metal soaps or amorphous sili~a~ or mixtures of such substances.
~In another embodiment, the flameproofing agent : de~elops a ~lame-resistant effect at a temperature above 200GC, preferably at a temperature above 220C and, more particularly, at a temperature above 250C. This ensures that the flameproofing effect is only developed above a su~ficiently high temperature. This is of advantage particularly when the flameproofing agent is processed in the production of a flame-resistant flat pressed board and relatively high temperatures are Wo 92/19696 j ~ ~c~ pcT~EPs2/oo873 applied in the production process. This is particularly the case in the production of wood chip boards. In this case, the boards are~pressed at elevated temperature, the elevated temperature being required for curing the thermosets used as the binder.
The flameproofing agent according to the inven-tion is preferably sparingly soluble in water and, more particularly, is resistant to water. This is of advan-tage when the flameproofing agent is used for the produc~ion of flat pressed boards which are required to ~show high stability to atmospheric moisture. If the flàmeproofing~agent were to be soluble in wa~er in this case,` it would be dissolved out fr~m the board oYer a ~~ ~perio~of time~and would no longer be able sufficiently to develop its flameproofing effect in the e~ent of In another preferred embodiment~of th~ invention, ;the~flameproofing agent has a subs~antially neutr~l pH
value~and~does not release any acidic or alkaline 2~0~ substances, particularly on heating to~the temperature at~which the~ flat pressed board is produced. This is -use~ul~; if the~ curing process of the~;binder during the production~of~a flat pressed board were-~to-~be impeded by acidic~or alkaline substances. This~is~the case for 25~ exampl`e~with~polyi~socyanate binders~used for the produc-tion; of~ formaldehyde-free boards.~ ~In ~Gases; such as these,~ therefore, the flameproo~ing a~ent can~be pH-neutral~and;~does~ not release any acidic- or ~alkaline substances, such~as yases for example, eveD at elevated temperatures, particularly below the pressing tempera-ture of t~e board. `In this way, the flat pressed board is able readily~to meet the other requirements~ which it is expected;~to;satisfy, for example in~regard to its mechanical properties.
FinaIly, the Invention relates to a process for `:
`
WO 92/19696 11 ~ rfJ-~'~ PCT/EP92/OOB73 the production of a flame-resistant flat pressed board of basically flammable board material, binder, flame-proofing agent and, optionally, auxiliaries. According to the invention, the board material, binder, the auxiliaries, if any, and - as flameproofing agent - a combination of a) a substance which is capable of releasing an acid, particularly an inorganic acid, at e~e~ated temperature, b) a carbon-containing substance bearing esterifiable hydroxyl groups and c~ a substance which is capable of releasing a non-inflammable gas at elevated temperature are pressed together~ The pressing operation is preferably carried out at elevated tempera~
ture, more preferably at temperatures aboYe 200C and, most preferably, at temperatures above 220~C. By using lS the c~mbination of three components as the flameproofing : : agent, the ~process can be carried out particularly : ~ e~sily and inexpensively.
~ In ano~her: embodiment o~ the invention, the : flameproofing agent and the board material are mixed 2~ : together in a mixing unit before pressing and the binder îs subsequently applied, more particularly by sprayin~, to:~the resulting~ mixture in the form of a suspension ~ dispersion in water. Wood chips in particular may be ; used as th~ board material. In this case, a mixture of 25~ the flameproofing agent, particularly a dry mixture, and : the~ wood chips are mixed and the binder, preferably an isocyanate binder, is applied to the resulting mixture in water~
In another preferred embodiment of the process 30 according to the invention, the flameproofing agent is : : suspended in water and the suspension obtained is applied, more particularly by spraying, to the base material, more particularly the wood chips. It is advisable to suspend the binder, more particularly the isocyanate binder, in water together with the flame-r'~ 'J ? ~ ~
No 92/19696 12 PCTtEP92/00873 proofing agent.
In another advantageous embodiment, the processmay be carried out by applying the binder suspended/
dispersion in water to the board material, more particu-larly by spraying, and incorporating the flameproofingagent before pressing~
In the process, it is preferred to use the flameproofing agent in finely dispersed form, for example in the form of a powder, ~he powder particles being smaller than 80 ~m and preferably smaller than 40 ~m in size~ ~he powder-form flameproofing agent is advantageously used as a dry mixture in the process according to the in~ention.
~inally, the invention relate~ to the use of the descri~ed flameproofing agent claimed in claims 13 to 2~. The flameproofing agent is used to mak flat pressed boards flame-resiskant during their production.
In this way, effective protection against fire is achieved without any need for an additlonal step in the 20 production process and without any change in the surface of the board, for example by coating.
Further features of the invention will become apparent from the following description of preferred embodiments in conjunction with the subsidiary claims.
The individual features may be embodied either indi~idu-ally or in any combination with one another.
: ~xample 1 `30 To produce a three-ply flat pressed board, 65% by weight wood chips ~or the surface layer are intensively mixed with approx. 20% by weight of a flameproofing mixture in a high-speed mixing unit~ 75~ by w~ight wood chips for the middle layer are intensively ~ixed with 25% by weight of an identical flameproofing mixture in .,;, . a;~
W0 92/~696 13 PCTJEP92/00873 a second similar mixing unit. The flameproofing mixture consis~5 of 7.~% by weight mcnoammonium phosphate, 21%
by weigh~ ammonium polyphosphate, 2.5% by weight mel-amine phosphate, 25% by weight pentaerythritol, 12% by weight guanidinel 31% by weight melamine and 1~ by weight calcium stearate. The chips mixed with flame-proofing agent are then separately sprayPd with 15% by weight (b~sed on ~he total weight of the board) of an emulsion of 50~ by weight water, 40% by weight dimethyl methane diisocyanate and 10% by weight o~ a 50% by weight paraf~in emulsion.
The prepared surface layer chips, then the middle layer chips and final~y the other surface layer chips are scattered in a conventional chîp board press in such a way that the surfa~e layer makes up approximately 15%
::: of the thickness of the board as a whole. The board as a whoIe is then pressed at 200C for ~5 seconds per mm board thick~ess. A three-ply chipboard with a density of 750 kg~m3 is obtained and satisfies the requixements of DI~ 4102 for flame-resistant building materials.
:
Example 2 To produce a three-ply flat pressed board, 68~ by :25 weight surface layer chips are mixed with 32% by weight of a flameproofin~ mixture consisting of 28% by weight : ammonium polyphosphate, 12% by weight melamine phos-phate, 20% by weig~t pentaerythritol and 40% by weight melamine. 12% by weight of an emulsion consisting of a phenol/resorcinol resin diluted with water in a ratio of 1:1 are then sprayed on with ~ontinued mixing. In a second mixing unit of the same type, 88~ by weight middle layer chips are simultaneously sprayed with 12%
by weight of an emulsion consisting of a phenol/resor-cinol resin similarly diluted with water in a ratio of W0 92/19696 14 pcT/Eps2/oo873 1:1.
First the prepared surface layer chips, then the middle layer chips and finally the other surface layer chips a~e scattered in a conventional chipboar~ press in such a way that the surface layer makes up approxîmately 20% of the thickness of the board as a whole. The board as a whole is then pressed at 200~C for 15 seconds per mm board thickness. A three-ply chipboard having a density of 750 kg/m3 is obtained and sa~isfies the requirements of DIN 4102 for flame-resistant buildi~g materials and the requirements of DIN 68763 for V100 boards.
~xample 3 To produce a one-pIy flat pressed board, 80% by weight wood fibers are sprayed wi~h 20% by weight of a binder mixture o~ 45~ by weight water and 55% by weight diphenyl methane diisocyanate in a high-speed mixing ~unit. 25% by wei~ht (based on the board as a whole) o~
~: ~a~ flameproofing mixture consisting of 21% by weight ammonium polyphosphate, 5% by weight monoammonium ~phosphate~ 5~:by `~weight melamine phosphate, 28% by weight dipentaerythritol, 5% by weight aluminium hydrox-:~;ide, 35~ by weigh~ melamine and 1~ by weight calciu~
~stearate are t~en~added with continued~intensi~e mixing.The mixture obtained is pressed in a conventional ~chipboard press at~210C and for 15 seconds per mm board thickness. A one-ply chipboard with a density o~ 1000 kg/m3 is obtained and satisf ies the requirements of DIN
4102 for flamP-resistant building materials.
A flam~-r~sistant ~lat pres~ed board - and a proce~ ~or its prohuatio~
This inYention relates to a flame-resistant flat pressed board of basically flammable board material, binder, flameproofing ag~nt and optionally auxiliaries.
In the context of the invention, the expression "flat pressed board" encompasses a number of board-like : materials which are used in particular in building construction for load-bearing, stiffenlng, decorative and other purposes. To make these flat pressed boards5 ~~ a suitable base material is pressed with one or ~ore binders. Depending o~ the application envisaged, the : boards ~re of~en required to show certain beha~ior in : ; the event of fi~e. To this end, the flat pressed boards ; ~ may contain~additives which ensure that the boards are difficult to ignite in the event of fireO In building ~construction, for ex Q le, the building matexials used must ha~e a:Bl:or B2 classification according to DIN
: 4102, Part 1 (Building Materials~.
: ~ Comm~nly;used flat pressed boards are the so-called chipboards which are produced by pressing chips ~o of wood and/or other wood-like fibrous materials with bindersO If the chips used are solely wood chips, the board ultimately obtained is known as a wood chipboard.
: There are e~sentially two standard types of chipboard which contain binders of dif~erent kinds in different quantities. V 20 boards are intended for use in rooms with generally low air humidity leve~s. The binders used for these boards are mainly aminoplastics. So-called V 1~0 boards are intended for use in rooms having high air humidity levels and are normally bonded with alkali-curing phenolics, phenol/resorcinol resins or, f~ i u .~
- WO 92/196~6 2 ~?CT/EP92/00873 recently, with polyureas.
A common method for achisving a fireproofing effect ic ~o provide the boards with suitable coatings.
Known f ireproof coatings are the so-called insulating S layer formers which produce a foam on the particul ar substrate in the event of fire. This foam is intended to prevent the f ire f rom spreading on the substrate 1:o be protected. These coatings have the disadvantage that, in l:he production of the flat pressed board, an 10 additional step is required to apply the coating or, alternati~ely, the coating has to be subsequently applied to a board already in use. In addition, coat-ings on the outside of the boards are highly exposed to weathering and other outside inf luPnces . As already 15 mentioned, flat pressed boards containing flameproofing agents are al50 known . ConYentional flameproof ing agent~, suc~ as for example boric acid, monoammonium phosphate or diammonium phosphate, are used in their case. ~ood chipboards have also been produced by mixing 20 wood, cement, water and other additives and subsequently drying the pressed board. All these processes are a~tended by the disadvantage that relatively lar~.
quantities of ~dditiYes hav~ to be ussd to obtain a flame-resistant ~oard which, in particular, satîs~ie~
25~ th~: requiremen~s of DIN 4î02, Part 1., The largs quan-tities of additives seriously reduc:e the perc:entage of the base material, such as for examplP wood, so that it ~ay amount to only 20 to 40% by weight/ ~ased on the total weight of the board. Accordingly, flat pressed boards of this type are unable to satisfy the other requirements they are expected to meet, f~r example in regard to s rength, resistance to atmospheric moisture or the like.
Accordîngly, the proble~ addressed by the present in~ention was to provide flat pressed boards which, even ` ~ ~2 i' : -WO 92~19696 3 PCT/EP92/00873 with relatively small quantities of additives, would be flame-resis~ant, more particularly as required under DIN
4102, Part 1. At the same time, the other properties of the board would not be adversely affected by the addi-tives.
This problem has been solved by a flat pressedboard of the type mentioned above in which the flame~
proofing agent is a combination of a) a substance capable of releasing an acid, mor~
~ particularly an inorganic acid, at elevated ; temperature,~
~ b) a carbon-Gontaining substance bearing esterifi-:~ ~, able hydroxyl groups and c) a substance capable of releasing a non-inf~am-mable gas a~ elevated temperature~ .
~: Thé response temperatures of the substances a) and:: c) are above~ the temperature required for th~
production:of:the~flat pressed board. In addition, the 1ameproofing:~agent is sparingly soluble in water and i5 ; 20~ finely dispe~sed:throughout the board material.
: The flame r`esistance of the flat pressed board a`c ording to the invention in the event of fire is attri~utable ~o~:thè fact that the acid released at elevated temperature~and the substance mentioned under 25~ b)~;react with one another to form an ester and then carbonize under~he conditions prevaiIing in the event of fire. :~By rel;easing a gas, the substance described under c~ promotes the formation of a carbon-containing ~oam so that the three substances produce the flame-proofing effect by cooperating with one another in the : e*ent of fire. In the event of fire, khe ~lameproofingagent present in-the flat pressed board forms a fine cell, highly~insulating foam which e~fectively pre~ents the fire from spreading. The incorporation of the flameproofing agent in finely dispersed form provides :
~ ' ~
~ J '~
for a homogeneous fireproofing effect and for uniform foaming. The fact that the flameproofing agent is sparingly soluble in water contri~utes to the fireproof-ing effect being reliably developed, even when the board S is situated in an environment of high atmospheric humidity.
By virtue of the invention, the percentage of base material in the flat pressed board can be kept high so that the other requirements which the boaxd is expected to meet can readily be satisfied. The surface o~ the flat pressed board is not a~fected, as is the ~ase for example with coatings.
~ The board material may be ~ntroduced into the board according to the invention in any form. For example, fibrous and/or particulate materials may be used. Besides wood and other wood~like fibrous materi~
- als, textile ma~erials, cellulose or plastics may be : used as the board material, textile waste, cellulose waste or plastic waste being particularly suitable.
Viscose may also be used as the base material. A board :~ which has been produced using ~ood-like mater.ials, particularly wood chips, is preferred. According to the inYention, a wood chipboard of the V100 type which meets ~he requirements of class Bl of DIN 4102, Part 1 (Build-25~ ing Materials), is particularly preferred, The wood :chips are preferably bonded by addi~ion of polyisocya-nates (formation of crosslinked polyureas). The flame-resistant wood chipboard obtained in this way is addi;
tionally free from formaldehyde and, hence, ecologically safe to a large extent. Since the temperatures at which wood chipboards are pressed are normally in the range from 200 to 220~C, the substances mentioned under a) and c) are best selected so that the corresponding response temperatures are above 200~C and, more particularly, above 220~C.
~o 92~19696 5 PCTJEP92/00873 In another embodiment of the invention, the flameproofing agent is preferably present in the flat pressed board in a quantity of 1 t~ 50% by weight, based on th~ to~al weigh~ of the board. ~uantities of 3 to 30% by weight, based on the total weight of the board, are preferred, quantities of 5 to 15~ by weight being particularly preferred. This means that the percentag~
of board material~ particularly wood, is always at l~ast 50% by weight or preferably even higher, so that the properties of the board attributable to the base materi-a~ remain largely unaffected by the flameproofing agent.
The flat pressed board may consist of one or more layers. Boards comprising an odd number of layers are preferred because boards having an even number of layers can warp more easily in use.
Other pre~err2d boards according to the inventiQn are ~lat pressed boards which consist of two surface ~: ~ lay~rs and at~ least one middle layerO The surface layers may~consist of fine board material, more particu~
:20:~ :larly fine wood chips, while coarser material, for : example 1 cm in diameter, is present in the middle layer. The two layers may differ not only in the size ~ of the material present, but also in their quantitati~e :: ~ composi~ion. ~In a preferred embodiment, the two surface ~25~ layers each ma~e up 20% of the overall thickness vf the board while the middle layers make up around 60~ of the : total thickness. According to the inventiont ~arious quantities of flameproofing agent may be provided in various layers of the board. This also means that, in the case of a single-layer board, the concentration of ~flameproofing agent can be varied over the lengthr width and thickness of the board.
In another embodiment of the invention, ~he flameproo~ng agent is present in the surface layers in a quantity of 5 to 50% by weight and preferably in a ~ ~ U)J~J~1 quanti~y o~ 15 to 35% by weight, based on the surface layer material. In the middle layer, the flameproofing agent is present in quantities of 0 to 50% by weight and, more par~icularly, in quantities of 0 to 20% by weight, based on the material of the middle layer. In another preferred embodiment, the flameproofing agent is present in a higher concentration in the surface layers than in the middle layers. In this way, the flameproof ing agent affords adequate protection against fire in the surface layexs alone and flame propagation is effectively prevented at the actual surfac~ of the boardO In one preferred embodiment of the invention, e*fective flameproofing is obtained even when the flameproofing agent is present solely in the two surface layersO This surprising result leads not only to a saving of material and costs, it also provides for easisr produrtion of the flat pressed board~ according to the invention. For example, a ~1100 wood chipboard with a B1 classification accsrding t~ DIN 4102, Part 1, can be easily and inexpensively produced.
The binders used in accordance with the invention ara preferably the binders typically used fvr binding :board materials~ The binders in ~uestion may be thermo plastic or thermoset binders. Thermoset binders are :~ 25 particularly suitable. Thermoplastic binders can have the disadvantage that they can cause the presses to s ck at the temp~ratures required for pressing.
Phenolics and phenol-resorcinol resin are men~ioned as advantageous binders. An isocyanate binder is preferab-ly used as the binder because the boards produced with an isocyanate binder, particularly wood chipboards, are formaldehyde-free. In particular, the bindPr may be added to the board material in a quantity of 2 to 15% by weight and preferably in a quantity of 3 to 1~% by weight, based on the weight of the board~
i d Wo 92/19696 7 PcT/Eps2/oos73 The flat pressed boards according to the inven-tion preferably develop their flameproofing effect at temperatures above 200C and, more particularly, at temperatures above 220C. It can be of advantage if this effect is only developed at even hi~her tempera-tures, for example 250C. This may depend on the temperature at which the board material, the binder, the flameproofing agent and any auxiliaries used are pressed to form the flat pressed board. The reaction by which the flameproofing effect is produced should not take place at the pressing temperature.
The auxiliaries according to the invention are : ` hydrophobicizing agents for~improving the resistance of ~~ the boards to :water or moisture (such as paraffin e~ulsions for example); conductivity additives for preventing or reducing:the static charging of the boards or~preservatives and dyes.
he p~esent invention also relates to a flam~-proofing agent-as:claimed in claim 13 for the production 20~ ~of flame-resistan~ flat pressed boards. In the event of ire, ~his flameproofing agent forms a carbon-contain-ing,~ highly insulating fine-cell foam.
I~ one particular:embodiment, the flameproofing agent is present in finely dispersed form and is prefer-:25~ ::ably a powder wi~h~a particle size of less th~n BO ~m.
A powder with a particle size of less than 40 ~m is even more preferred. Flameproofing agents ha~ing the fine distributions~:mentioned are particularly suitable ~or the production o~ ~lame-resistant flat pressed boards.
30: i The flameproofing agent pr2sent in the flat pressed board is composed of the substance a3 in quanti~
: ties of 10 to 60~ by weight and preferably 30 to 45% by weight, the substance ~ in quantities o~ 10 to 60% by weiyht and preferably 15 to 50% by weight and the substance c) in quantities of 5 to 55~ by weight and ` r~l~J,-, rJ ~ ~
prefera~ly 20 to 40~ by weight.
The substance a) is preferably a substance which is capable of releasing phosphoric acid and/or oligo-phosphoric acid andJor polyphosphoric acid. Substances such as these are, in particular, ammonium phosphates, such as monoammonium phosphate and ammonium polyphos-phates or mixtures of these compounds. These substances may preferably be present in condensed form~ Sub~tan-ces capable of releasing sulfuric acid may also be used in accordan~e with the invention. Substances which are aapable o~ releasing an organic acid, such as sulfonic acid for example, are also suitable.
~ The càrbon-containing substances b) bearing esterifiable hydroxyl groups are, i~ particular, polyhy-}5 dric alcohols or mix~ures thereof, among which tetrahy-dric alcoholst such as pen~aerythritol for example, are preferably used. Another suitable substance is dipenta-~rythritol. Water-soluble substances containing esteri-fiable hydroxyl groups, such as for example carbohy-drates, starch, sugar and cellulose, may also be used inaccordance with the invention providing the resulting solubility of the flameproofing agent in water does not ~ave any adverse effects on the flat pressed ~oard.
~mong the last substances mentione~, the carbohydrates ~re preferred.
According to the invention, preferred substances ~: c) which are capable of releasing a non-inflammable gas at elevated temperature are substances Which release water, carbon dioxide, nitrogen or preferably ammonia.
In these cases, substance c) may be a hydroxidet car-bonate, hydrs:)gen carbonate or an ammonium compound.
Substances containing free amino groups are particularly suitable ~or releasing ammonia. Substances such as these ~re, for example, me-lamine and dicyanodiamide.
3S The melamine may be used in commercially available pure .
-WO 92/196g6 9 f~ J i~ pcT/EP92/0o873 form. Substances which give off carbon dioxide at elevated temperature and which are preferably sparingly soluble in water may also be used with advantage in accordance with the invention. One example of such a substan~e is lime.
The flameproofing agent according to the i~ven-~ion itself is preferably free from binders. The flame-proofing agent forms the described foam in the absence o~ other additives. This reduces cost~ and simplifies the production a~d use of the flameproofing agent.
In one adva~tageous embodiment of the invention, the ~lamepxoofing agent additionally contains anticaking and~or free~flow additives. This prevent~ the flame-proofing agent from caking and from losing its free-flow properties. In his way, the flameproofing agent may be us~d in homogeneously dispersed form, ~or example in the productio~ of flame-resistant flat pressed boards. In addition, the stability of th~ flameproofing agent during storage and transportation is improved~ Such additives can be of advantage particularly when the flameproofing agent is extremely fine~ The additives are pxeferably present in quantities of 0.1 to 10% by weight and, more particularly, in quantities of 0.5 to 2% by weight, based on the flameproofing agentO The 25: additives may be metal soaps or amorphous sili~a~ or mixtures of such substances.
~In another embodiment, the flameproofing agent : de~elops a ~lame-resistant effect at a temperature above 200GC, preferably at a temperature above 220C and, more particularly, at a temperature above 250C. This ensures that the flameproofing effect is only developed above a su~ficiently high temperature. This is of advantage particularly when the flameproofing agent is processed in the production of a flame-resistant flat pressed board and relatively high temperatures are Wo 92/19696 j ~ ~c~ pcT~EPs2/oo873 applied in the production process. This is particularly the case in the production of wood chip boards. In this case, the boards are~pressed at elevated temperature, the elevated temperature being required for curing the thermosets used as the binder.
The flameproofing agent according to the inven-tion is preferably sparingly soluble in water and, more particularly, is resistant to water. This is of advan-tage when the flameproofing agent is used for the produc~ion of flat pressed boards which are required to ~show high stability to atmospheric moisture. If the flàmeproofing~agent were to be soluble in wa~er in this case,` it would be dissolved out fr~m the board oYer a ~~ ~perio~of time~and would no longer be able sufficiently to develop its flameproofing effect in the e~ent of In another preferred embodiment~of th~ invention, ;the~flameproofing agent has a subs~antially neutr~l pH
value~and~does not release any acidic or alkaline 2~0~ substances, particularly on heating to~the temperature at~which the~ flat pressed board is produced. This is -use~ul~; if the~ curing process of the~;binder during the production~of~a flat pressed board were-~to-~be impeded by acidic~or alkaline substances. This~is~the case for 25~ exampl`e~with~polyi~socyanate binders~used for the produc-tion; of~ formaldehyde-free boards.~ ~In ~Gases; such as these,~ therefore, the flameproo~ing a~ent can~be pH-neutral~and;~does~ not release any acidic- or ~alkaline substances, such~as yases for example, eveD at elevated temperatures, particularly below the pressing tempera-ture of t~e board. `In this way, the flat pressed board is able readily~to meet the other requirements~ which it is expected;~to;satisfy, for example in~regard to its mechanical properties.
FinaIly, the Invention relates to a process for `:
`
WO 92/19696 11 ~ rfJ-~'~ PCT/EP92/OOB73 the production of a flame-resistant flat pressed board of basically flammable board material, binder, flame-proofing agent and, optionally, auxiliaries. According to the invention, the board material, binder, the auxiliaries, if any, and - as flameproofing agent - a combination of a) a substance which is capable of releasing an acid, particularly an inorganic acid, at e~e~ated temperature, b) a carbon-containing substance bearing esterifiable hydroxyl groups and c~ a substance which is capable of releasing a non-inflammable gas at elevated temperature are pressed together~ The pressing operation is preferably carried out at elevated tempera~
ture, more preferably at temperatures aboYe 200C and, most preferably, at temperatures above 220~C. By using lS the c~mbination of three components as the flameproofing : : agent, the ~process can be carried out particularly : ~ e~sily and inexpensively.
~ In ano~her: embodiment o~ the invention, the : flameproofing agent and the board material are mixed 2~ : together in a mixing unit before pressing and the binder îs subsequently applied, more particularly by sprayin~, to:~the resulting~ mixture in the form of a suspension ~ dispersion in water. Wood chips in particular may be ; used as th~ board material. In this case, a mixture of 25~ the flameproofing agent, particularly a dry mixture, and : the~ wood chips are mixed and the binder, preferably an isocyanate binder, is applied to the resulting mixture in water~
In another preferred embodiment of the process 30 according to the invention, the flameproofing agent is : : suspended in water and the suspension obtained is applied, more particularly by spraying, to the base material, more particularly the wood chips. It is advisable to suspend the binder, more particularly the isocyanate binder, in water together with the flame-r'~ 'J ? ~ ~
No 92/19696 12 PCTtEP92/00873 proofing agent.
In another advantageous embodiment, the processmay be carried out by applying the binder suspended/
dispersion in water to the board material, more particu-larly by spraying, and incorporating the flameproofingagent before pressing~
In the process, it is preferred to use the flameproofing agent in finely dispersed form, for example in the form of a powder, ~he powder particles being smaller than 80 ~m and preferably smaller than 40 ~m in size~ ~he powder-form flameproofing agent is advantageously used as a dry mixture in the process according to the in~ention.
~inally, the invention relate~ to the use of the descri~ed flameproofing agent claimed in claims 13 to 2~. The flameproofing agent is used to mak flat pressed boards flame-resiskant during their production.
In this way, effective protection against fire is achieved without any need for an additlonal step in the 20 production process and without any change in the surface of the board, for example by coating.
Further features of the invention will become apparent from the following description of preferred embodiments in conjunction with the subsidiary claims.
The individual features may be embodied either indi~idu-ally or in any combination with one another.
: ~xample 1 `30 To produce a three-ply flat pressed board, 65% by weight wood chips ~or the surface layer are intensively mixed with approx. 20% by weight of a flameproofing mixture in a high-speed mixing unit~ 75~ by w~ight wood chips for the middle layer are intensively ~ixed with 25% by weight of an identical flameproofing mixture in .,;, . a;~
W0 92/~696 13 PCTJEP92/00873 a second similar mixing unit. The flameproofing mixture consis~5 of 7.~% by weight mcnoammonium phosphate, 21%
by weigh~ ammonium polyphosphate, 2.5% by weight mel-amine phosphate, 25% by weight pentaerythritol, 12% by weight guanidinel 31% by weight melamine and 1~ by weight calcium stearate. The chips mixed with flame-proofing agent are then separately sprayPd with 15% by weight (b~sed on ~he total weight of the board) of an emulsion of 50~ by weight water, 40% by weight dimethyl methane diisocyanate and 10% by weight o~ a 50% by weight paraf~in emulsion.
The prepared surface layer chips, then the middle layer chips and final~y the other surface layer chips are scattered in a conventional chîp board press in such a way that the surfa~e layer makes up approximately 15%
::: of the thickness of the board as a whole. The board as a whoIe is then pressed at 200C for ~5 seconds per mm board thick~ess. A three-ply chipboard with a density of 750 kg~m3 is obtained and satisfies the requixements of DI~ 4102 for flame-resistant building materials.
:
Example 2 To produce a three-ply flat pressed board, 68~ by :25 weight surface layer chips are mixed with 32% by weight of a flameproofin~ mixture consisting of 28% by weight : ammonium polyphosphate, 12% by weight melamine phos-phate, 20% by weig~t pentaerythritol and 40% by weight melamine. 12% by weight of an emulsion consisting of a phenol/resorcinol resin diluted with water in a ratio of 1:1 are then sprayed on with ~ontinued mixing. In a second mixing unit of the same type, 88~ by weight middle layer chips are simultaneously sprayed with 12%
by weight of an emulsion consisting of a phenol/resor-cinol resin similarly diluted with water in a ratio of W0 92/19696 14 pcT/Eps2/oo873 1:1.
First the prepared surface layer chips, then the middle layer chips and finally the other surface layer chips a~e scattered in a conventional chipboar~ press in such a way that the surface layer makes up approxîmately 20% of the thickness of the board as a whole. The board as a whole is then pressed at 200~C for 15 seconds per mm board thickness. A three-ply chipboard having a density of 750 kg/m3 is obtained and sa~isfies the requirements of DIN 4102 for flame-resistant buildi~g materials and the requirements of DIN 68763 for V100 boards.
~xample 3 To produce a one-pIy flat pressed board, 80% by weight wood fibers are sprayed wi~h 20% by weight of a binder mixture o~ 45~ by weight water and 55% by weight diphenyl methane diisocyanate in a high-speed mixing ~unit. 25% by wei~ht (based on the board as a whole) o~
~: ~a~ flameproofing mixture consisting of 21% by weight ammonium polyphosphate, 5% by weight monoammonium ~phosphate~ 5~:by `~weight melamine phosphate, 28% by weight dipentaerythritol, 5% by weight aluminium hydrox-:~;ide, 35~ by weigh~ melamine and 1~ by weight calciu~
~stearate are t~en~added with continued~intensi~e mixing.The mixture obtained is pressed in a conventional ~chipboard press at~210C and for 15 seconds per mm board thickness. A one-ply chipboard with a density o~ 1000 kg/m3 is obtained and satisf ies the requirements of DIN
4102 for flamP-resistant building materials.
Claims (32)
1. A flame-resistant flat pressed board of basically flammable board material, binder, flameproofing agent and optionally auxiliaries, characterized in that the flameproofing agent is a combination of a) a substance capable of releasing an acid, more particularly an inorganic acid, at elevated temperature, b) a carbon-containing substance bearing esterifi-able hydroxyl groups and c) a substance capable of releasing a non-inflam-mable gas at elevated temperature, the response temperatures of a) and c) being above the temperature required for the production of the flat pressed board, in that the flameproofing agent is finely dispersed throughout the board material and in that the flameproofing agent is sparingly soluble in water, with the proviso that the flameproofing agent i) is present in a quantity of 1 to 50% by weight, based on the weight of the board, and ii) component a) is present in a quantity of 10 to 60% by weight, component b) is present in a quantity of 10 to 60% by weight and component c) is present in a quantity of 5 to 55% by weight.
2. A flat pressed board as claimed in claim 1, characterized in that the board material consists of wood-like materials, particularly wood chips.
3. A flat pressed board as claimed in claim 1 or 2, characterized in that the flameproofing agent is present in a quantity of 3 to 30% by weight and, more particu-larly, in a quantity of 5 to 15% by weight, based on the weight of the board.
4. A flat pressed board as claimed in any of the preceding claims, characterized in that it consists in known manner of several layers, more particularly of at least two surface layers and at least one middle layer.
5. A flat pressed board as claimed in claim 4, characterized in that the flameproofing agent is present in a higher concentration in the surface layers than in the middle layers.
6. A flat pressed board as claimed in claim 4 or 5, characterized in that the flameproofing agent is present in the surface layers in a quantity of 5 to 50% by weight and preferably in a quantity of 15 to 35% by weight, based on the material of the surface layer.
7. A flat pressed board as claimed in any of claims 4 to 6, characterized in that the flameproofing agent is present in the middle layer in a quantity of 0 to 50% by weight and more particularly in a quantity of 0 to 20%
by weight, based on the material of the middle layer.
by weight, based on the material of the middle layer.
8. A flat pressed board as claimed in any of claims 4 to 7, characterized in that the flameproofing agent is present solely in the surface layers.
9. A flat pressed board as claimed in any of the preceding claims, characterized in that the binder is a binder suitable for binding the board material, more particularly a thermoset binder.
10. A flat pressed board as claimed in any of the preceding claims, characterized in that the binder is a phenolic, a phenol/resorcinol resin or preferably an isocyanate binder.
11. A flat pressed board as claimed in of any the preceding claims, characterized in that the binder is added to the board material in a quantity of 2 to 15% by weight and more particularly in a quantity of 3 to 10%
by weight, based on the weight of the board.
by weight, based on the weight of the board.
12. A flat pressed board as claimed in any of the preceding claims, characterized in that it develops a flameproofing effect at a temperature above 200°C and, more particularly, at a temperature above 220°C.
13. A flameproofing agent for the production of flame-resistant flat pressed boards in the form of a combination of a) a substance capable of releasing an acid, more particularly an inorganic acid, at elevated temperature, b) a carbon-containing substance bearing esterifi-able hydroxyl groups and c) a substance capable of releasing a non-inflam-mable gas at elevated temperature, with the proviso that the flameproofing agent contains component a) in a quantity of 10 to 60% by weight, component b) in a quantity of 10 to 60% by weight and component c) in a quantity of 5 to 55% by weight.
14. A fIameproofing agent as claimed in claim 13, characterized in that it is present in finely dispersed form, more particularly in the form of a powder, with a particle size of smaller than 80 µm and preferably smaller than 40 µm
15. A flameproofing agent as claimed in claim 13 or 14, more particularly in a flat pressed board, charac-terized in that it consists of 30 to 45% by weight of a substance a), 15 to 50% by weight of a substance b) and 20 to 40% by weight of a substance c).
16. A flameproofing agent as claimed in any of claims 13 to 15, characterized in that the substance a) is capable or releasing phosphoric acid and/or oligophos-phoric and/or polyphosphoric acid, the substance a) being in particular at least one ammonium phosphate or a mixture of ammonium phosphates, preferably in con-densed form.
17. A flameproofing agent as claimed in any of claims 13 to 16, characterized in that the substance b) is at least one polyhydric alcohol or a mixture of polyhydric alcohols.
18. A flameproofing agent as claimed in any of claims 13 to 17, characterized in that the substance b) is a carbohydrate.
19. A flameproofing agent as claimed in any of claims 13 to 18, characterized in that the substance c) is capable of releasing nitrogen and/or ammonia, the substance c) being in particular a substance containing free amino groups.
20. A flameproofing agent as claimed in any of claims 13 to 19, characterized in that it is free from binders.
21. A flameproofing agent as claimed in any of claims 13 to 20, characterized in that it additionally contains anticaking and/or free-flow additives.
22. A flameproofing agent as claimed in claim 21, characterized in that the additives are present in quantities of 0.1 to 10% by weight and particularly in quantities of 0.5 to 2% by weight, based on the flame-proofing agent.
23. A flameproofing agent as claimed in claim 21 or 22, characterized in that the additives are at least one metal soap and/or at least one amorphous silica.
24. A flameproofing agent as claimed in any of claims 13 to 23, characterized in that it develops a flame-retarding effect at temperatures above 200°C and more particularly at temperatures above 220°C.
25. A flameproofing agent as claimed in any of claims 13 to 24, characterized in that it is sparingly soluble in water and, more particularly, is water-resistant.
26. A flameproofing agent as claimed in any of claims 13 to 25, characterized in that it has a substantially neutral pH value and, in particular, releases hardly any acidic or alkaline substances on heating to the tempera-ture at which the flat pressed board is produced.
27. A process for the production of a flame-resistant flat pressed board of basically flammable board materi-al, binder, flameproofing agent and, optionally, auxili-aries, characterized in that the board material, binder, the auxiliaries, if any, and - as flameproofing agent -a combination of a) a substance which is capable of releasing an acid, particularly an inorganic acid, at elevated temperature, b) a carbon-containing substance bearing esterifi-able hydroxyl groups and c) a substance which is capable of releasing a non-inflammable gas at elevated temperature and optionally anticaking and/or free-flow additives are pressed together, the response temperatures of a) and c) being above the temperature required for the production of the flat pressed board, the flameproofing agent being finely dispersed throughout the board material and the flameproofing agent being sparingly soluble in water, with the proviso that the flameproofing agent i) is present in a quantity of 1 to 50% by weight, based on the weight of the board, and ii) component a) is present in a quantity of 10 to 60% by weight, component b) is present in a quantity of 10 to 60% by weight and component c) is present in a quantity of 5 to 55% by weight.
28. A process as claimed in claim 27, characterized in that pressing is carried out at elevated temperature, more particularly at around 200°C.
29. A process as claimed in claim 27 or 28, charac-terized in that the flameproofing agent and the board material are mixed together before pressing and the binder suspended/dispersed in water is subsequently applied to the mixture obtained, more particularly by spraying.
30. A process as claimed in claim 27 or 28, charac-terized in that the binder suspended/dispersed in water is applied to the board material, more particularly by spraying, and the flameproofing agent is added before pressing.
31. A process as claimed in claim 27 or 28, charac-terized in that the flameproofing agent is suspended/
dispersed in water, more particularly together with the binder, before pressing and the suspension/dispersion obtained is applied to the base material, more par-ticularly by spraying.
dispersed in water, more particularly together with the binder, before pressing and the suspension/dispersion obtained is applied to the base material, more par-ticularly by spraying.
32. The use of the flameproofing agent claimed in claims 13 to 26 for flameproofing flat pressed boards during their production.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE4114068A DE4114068A1 (en) | 1991-04-30 | 1991-04-30 | FLAME-RETARDABLE FLAT PRESSING PLATE AND METHOD FOR THEIR PRODUCTION |
| DEP4114068.0 | 1991-04-30 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2102214A1 true CA2102214A1 (en) | 1992-10-31 |
Family
ID=6430651
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002102214A Abandoned CA2102214A1 (en) | 1991-04-30 | 1992-04-21 | A flame-resistant flat pressed board and a process for its production |
Country Status (5)
| Country | Link |
|---|---|
| EP (1) | EP0582604B1 (en) |
| AT (1) | ATE126823T1 (en) |
| CA (1) | CA2102214A1 (en) |
| DE (2) | DE4114068A1 (en) |
| WO (1) | WO1992019696A1 (en) |
Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE4436981A1 (en) * | 1994-10-06 | 1996-04-11 | Hartmut Faerber | Lightweight moulded thermal insulation made from renewable resources |
| JPH08165468A (en) * | 1994-12-12 | 1996-06-25 | Erika Balle | Fireproofing substance,production of fire-proofing substanceand method of adhering fireproofing substance |
| EP2035632A4 (en) * | 2006-06-30 | 2014-05-14 | Buckeye Technologies Inc | Fire retardant nonwoven material and process for manufacture |
| DE102012204238B4 (en) | 2012-03-16 | 2017-06-08 | Technische Universität Dresden | Use of water-soluble nitrogen- and phosphorus-containing polysaccharide derivatives as flame retardants, wood composite material with improved flame retardance properties and process for its preparation |
| CN111119687B (en) * | 2019-12-05 | 2023-07-04 | 重庆双羽家俱有限公司 | Fire-resistant straw door plate and preparation method thereof |
| EP4183841A1 (en) | 2021-11-17 | 2023-05-24 | Wolman Wood and Fire Protection GmbH | Water-based intumescent adhesive |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4165409A (en) * | 1978-02-23 | 1979-08-21 | Jack Maine | Method of fabricating wood composite panels having enhanced fire retardancy |
| CA1096104A (en) * | 1978-12-18 | 1981-02-24 | Hans A. Corver | Flame retardant particleboard |
| DE3100626C2 (en) * | 1981-01-12 | 1985-05-15 | Schmittmann, Hans-Bernd, Dipl.-Chem. Dr.Rer.Nat., 5620 Velbert | Flame-retardant plastics, especially those which can be used as building materials or the like, processes for their production and their use as components |
| DE3416662A1 (en) * | 1983-11-05 | 1985-05-15 | Hoechst Ag, 6230 Frankfurt | FLAME-RETARDANT EXTRACT BODIES, ESPECIALLY EXTRESS PLATES, AND FLAME-RESISTANT VENEERED OR COATED EXTRACT PLATES, A METHOD FOR THEIR PRODUCTION AND THEIR USE |
-
1991
- 1991-04-30 DE DE4114068A patent/DE4114068A1/en not_active Withdrawn
-
1992
- 1992-04-21 EP EP92909118A patent/EP0582604B1/en not_active Revoked
- 1992-04-21 CA CA002102214A patent/CA2102214A1/en not_active Abandoned
- 1992-04-21 WO PCT/EP1992/000873 patent/WO1992019696A1/en not_active Application Discontinuation
- 1992-04-21 DE DE59203399T patent/DE59203399D1/en not_active Revoked
- 1992-04-21 AT AT92909118T patent/ATE126823T1/en not_active IP Right Cessation
Also Published As
| Publication number | Publication date |
|---|---|
| ATE126823T1 (en) | 1995-09-15 |
| WO1992019696A1 (en) | 1992-11-12 |
| DE4114068A1 (en) | 1992-11-05 |
| EP0582604B1 (en) | 1995-08-23 |
| EP0582604A1 (en) | 1994-02-16 |
| DE59203399D1 (en) | 1995-09-28 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Discontinued |