CA2562128A1 - Thermal insulation composite with improved thermal stability and improved fire resistance - Google Patents
Thermal insulation composite with improved thermal stability and improved fire resistance Download PDFInfo
- Publication number
- CA2562128A1 CA2562128A1 CA 2562128 CA2562128A CA2562128A1 CA 2562128 A1 CA2562128 A1 CA 2562128A1 CA 2562128 CA2562128 CA 2562128 CA 2562128 A CA2562128 A CA 2562128A CA 2562128 A1 CA2562128 A1 CA 2562128A1
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- Prior art keywords
- core material
- thermal insulation
- insulation composite
- thermally insulating
- insulating core
- Prior art date
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- Abandoned
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- 239000002131 composite material Substances 0.000 title claims abstract description 19
- 238000009413 insulation Methods 0.000 title claims abstract description 19
- 239000011162 core material Substances 0.000 claims abstract description 33
- 229910052751 metal Inorganic materials 0.000 claims abstract description 24
- 239000002184 metal Substances 0.000 claims abstract description 24
- 238000004519 manufacturing process Methods 0.000 claims abstract description 7
- 238000003860 storage Methods 0.000 claims abstract description 4
- 239000000203 mixture Substances 0.000 claims description 19
- 239000006260 foam Substances 0.000 claims description 15
- 229920006327 polystyrene foam Polymers 0.000 claims description 12
- 239000000853 adhesive Substances 0.000 claims description 11
- 230000001070 adhesive effect Effects 0.000 claims description 11
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 11
- 238000000034 method Methods 0.000 claims description 9
- 229910000831 Steel Inorganic materials 0.000 claims description 5
- 239000010959 steel Substances 0.000 claims description 5
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 4
- 239000004115 Sodium Silicate Substances 0.000 claims description 4
- 229910052910 alkali metal silicate Inorganic materials 0.000 claims description 4
- 239000010439 graphite Substances 0.000 claims description 4
- 229910002804 graphite Inorganic materials 0.000 claims description 4
- 229910052782 aluminium Inorganic materials 0.000 claims description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 3
- 239000010445 mica Substances 0.000 claims description 3
- 229910052618 mica group Inorganic materials 0.000 claims description 3
- 229910052911 sodium silicate Inorganic materials 0.000 claims description 3
- 239000004793 Polystyrene Substances 0.000 claims description 2
- 229920000136 polysorbate Polymers 0.000 claims 1
- 239000010410 layer Substances 0.000 description 10
- 239000000463 material Substances 0.000 description 8
- 235000019353 potassium silicate Nutrition 0.000 description 8
- 229920006248 expandable polystyrene Polymers 0.000 description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 3
- 239000011324 bead Substances 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- 239000006185 dispersion Substances 0.000 description 3
- 239000003063 flame retardant Substances 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 2
- 229920005830 Polyurethane Foam Polymers 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 238000004026 adhesive bonding Methods 0.000 description 2
- 238000005253 cladding Methods 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 239000004795 extruded polystyrene foam Substances 0.000 description 2
- 238000005187 foaming Methods 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 229910000000 metal hydroxide Inorganic materials 0.000 description 2
- 150000004692 metal hydroxides Chemical class 0.000 description 2
- 239000011490 mineral wool Substances 0.000 description 2
- 229920001568 phenolic resin Polymers 0.000 description 2
- 239000005011 phenolic resin Substances 0.000 description 2
- 239000004814 polyurethane Substances 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 238000003892 spreading Methods 0.000 description 2
- 229920005789 ACRONAL® acrylic binder Polymers 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 1
- 229920005832 Basotect® Polymers 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- 239000004640 Melamine resin Substances 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- 239000002313 adhesive film Substances 0.000 description 1
- 150000001805 chlorine compounds Chemical class 0.000 description 1
- 239000008199 coating composition Substances 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 239000011256 inorganic filler Substances 0.000 description 1
- 229910003475 inorganic filler Inorganic materials 0.000 description 1
- 230000005923 long-lasting effect Effects 0.000 description 1
- 150000007974 melamines Chemical class 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000012766 organic filler Substances 0.000 description 1
- FWFGVMYFCODZRD-UHFFFAOYSA-N oxidanium;hydrogen sulfate Chemical class O.OS(O)(=O)=O FWFGVMYFCODZRD-UHFFFAOYSA-N 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000011496 polyurethane foam Substances 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- -1 salt hydrates Chemical class 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- IHQKEDIOMGYHEB-UHFFFAOYSA-M sodium dimethylarsinate Chemical class [Na+].C[As](C)([O-])=O IHQKEDIOMGYHEB-UHFFFAOYSA-M 0.000 description 1
- 235000019351 sodium silicates Nutrition 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- BIKXLKXABVUSMH-UHFFFAOYSA-N trizinc;diborate Chemical class [Zn+2].[Zn+2].[Zn+2].[O-]B([O-])[O-].[O-]B([O-])[O-] BIKXLKXABVUSMH-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- 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
-
- 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
-
- 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
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/292—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and sheet metal
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24496—Foamed or cellular component
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249955—Void-containing component partially impregnated with adjacent component
- Y10T428/249958—Void-containing component is synthetic resin or natural rubbers
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Electromagnetism (AREA)
- Acoustics & Sound (AREA)
- Building Environments (AREA)
- Laminated Bodies (AREA)
- Filling Or Discharging Of Gas Storage Vessels (AREA)
- Refrigerator Housings (AREA)
- Thermal Insulation (AREA)
Abstract
The invention relates to a thermal insulation composite, comprising two metal sheets with a thermally-insulating core material, whereby, between the thermally-insulating core material and at least one of the metal sheets, a fire protection layer with an intumescent mass is arranged. The invention further relates to a method for production thereof and use thereof for the manufacture of storage or refrigerated warehouses.
Description
THERMAL INSULATION COMPOSITE WITH IMPROVED THERMAL STABILITY AND
IMPROVED FIRE RESISTANCE
Description The invention relates to a thermal insulation composite, comprising two metal sheets with a thermally insulating core material, wherein a fire-protection layer has been intro-duced between the thermally insulating core material and at least one of the metal sheets, to a process for its production, and to its use for the production of storage build-ings or of cold-store buildings.
Sandwich panels composed of a thermally insulating core material and of bilaterally adhesive-bonded sheets of steel or of aluminum are used as structural elements or cladding in construction applications. Their heat resistance in the event of a fire is often inadequate. For example, in the event of a fire thermoplastic foams can melt merely as a result of exposure to heat, and impair the mechanical stability of the sandwich pan-els.
IMPROVED FIRE RESISTANCE
Description The invention relates to a thermal insulation composite, comprising two metal sheets with a thermally insulating core material, wherein a fire-protection layer has been intro-duced between the thermally insulating core material and at least one of the metal sheets, to a process for its production, and to its use for the production of storage build-ings or of cold-store buildings.
Sandwich panels composed of a thermally insulating core material and of bilaterally adhesive-bonded sheets of steel or of aluminum are used as structural elements or cladding in construction applications. Their heat resistance in the event of a fire is often inadequate. For example, in the event of a fire thermoplastic foams can melt merely as a result of exposure to heat, and impair the mechanical stability of the sandwich pan-els.
2 therefore proposes the use, as core material, of a polymer foam with a continuous phase composed of a phenolic resin and of dispersed polystyrene foam beads.
GB-A 2362586 discloses a process for improving the flame retardancy of polystyrene foam slabs, in which the prefoamed polystyrene foam beads are coated with a liquid phenolic resin which comprises a flame retardant based on phosphorus or chlorine compounds, and are then fused to give slabs. However, these flame-retardant polysty-rene foam slabs can be lost via melting on exposure to relatively high temperatures for a prolonged period.
DE-A 196 39 842 discloses fire-protected composite systems composed of polystyrene foam slabs whose surface has been provided with profiles or with grids or nets, this having been saturated with an intumescent composition. The profiles, grids, or nets are preferably introduced into the joints between the foam sheets.
EP-A 0 942 107 describes a foam impregnated to give flame retardancy and in es-sence consisting of PU foam, which is laminated to two self-adhesive films, between which an intumescent material has been enclosed, and its use as fire-protection stop-per.
It was therefore an object of the present invention to eliminate the disadvantages men-tioned and to invent a thermal insulation composite with improved heat resistance and improved fire performance, and a process for its production.
The thermal insulation composite described at the outset has accordingly been in-vented. The metal sheets of the thermal insulation composite are generally composed of steel or of aluminum with a thickness of from 1 to 10 mm The thermally insulating core material may be composed of molded polystyrene foam, of extruded polystyrene foam sheets (XPS), of polyurethane foams or of PIR
foams, or of mineral wool. Preference is given to a thermally insulating core material composed of molded polystyrene foam sheets, obtainable via sintering of prefoamed polystyrene foam beads composed of expandable polystyrene (EPS), because this core material has low density together with processability and longlasting insulation performance.
Preference is given to molded polystyrene foam sheets whose density is in the range from 10 to 50 g/I and whose thickness is in the range from 50 to 250 mm.
The fire-protection layer applied to the molding may take the form of laminate, sheet, film, dispersion, or solution. The thickness of the fire-protection layer depends on the material used and is generally in the range from 0.1 to 50 mm, preferably in the range from 1 to 10 mm. An example of a suitable material is a foam film composed of a heat-resistant melamine resin foam (e.g. Basotect~) or a fire-protection laminate composed of gelled alkali metal silicate solution (e.g. Palusol~). The thermally insulating core ma-terial is preferably coated with an intumescent composition. The coating may be ap-plied by spraying, immersion, roller-application, or spreading, to one or more surfaces of the thermally insulating core material. The coating material itself is flame-retardant.
The result is that the heat-sensitive core material situated thereunder is protected from high temperatures and from flashover, and retains its structural integrity.
Intumescent compositions are materials which foam on exposure to relatively high temperatures, generally abovel 80 -100°C, and during this process form an insulating and heat-resistant foam which protects the thermally insulating core material situated thereunder from exposure to fire and to heat.
The intumescent composition present in the thermal insulation composite is preferably an alkali metal silicate, in particular a hydrous sodium silicate, expandable graphite, or expandable mica.
The inventive thermal insulation composite may be produced via bonding of two metal sheets and of a thermally insulating core material, where a fire-protection layer is intro-duced between the thermally insulating core material and at least one metal sheet, preferably between the thermally insulating core material and both metal sheets.
Commercially available machines for producing thermal insulation composites may be used for this purpose.
GB-A 2362586 discloses a process for improving the flame retardancy of polystyrene foam slabs, in which the prefoamed polystyrene foam beads are coated with a liquid phenolic resin which comprises a flame retardant based on phosphorus or chlorine compounds, and are then fused to give slabs. However, these flame-retardant polysty-rene foam slabs can be lost via melting on exposure to relatively high temperatures for a prolonged period.
DE-A 196 39 842 discloses fire-protected composite systems composed of polystyrene foam slabs whose surface has been provided with profiles or with grids or nets, this having been saturated with an intumescent composition. The profiles, grids, or nets are preferably introduced into the joints between the foam sheets.
EP-A 0 942 107 describes a foam impregnated to give flame retardancy and in es-sence consisting of PU foam, which is laminated to two self-adhesive films, between which an intumescent material has been enclosed, and its use as fire-protection stop-per.
It was therefore an object of the present invention to eliminate the disadvantages men-tioned and to invent a thermal insulation composite with improved heat resistance and improved fire performance, and a process for its production.
The thermal insulation composite described at the outset has accordingly been in-vented. The metal sheets of the thermal insulation composite are generally composed of steel or of aluminum with a thickness of from 1 to 10 mm The thermally insulating core material may be composed of molded polystyrene foam, of extruded polystyrene foam sheets (XPS), of polyurethane foams or of PIR
foams, or of mineral wool. Preference is given to a thermally insulating core material composed of molded polystyrene foam sheets, obtainable via sintering of prefoamed polystyrene foam beads composed of expandable polystyrene (EPS), because this core material has low density together with processability and longlasting insulation performance.
Preference is given to molded polystyrene foam sheets whose density is in the range from 10 to 50 g/I and whose thickness is in the range from 50 to 250 mm.
The fire-protection layer applied to the molding may take the form of laminate, sheet, film, dispersion, or solution. The thickness of the fire-protection layer depends on the material used and is generally in the range from 0.1 to 50 mm, preferably in the range from 1 to 10 mm. An example of a suitable material is a foam film composed of a heat-resistant melamine resin foam (e.g. Basotect~) or a fire-protection laminate composed of gelled alkali metal silicate solution (e.g. Palusol~). The thermally insulating core ma-terial is preferably coated with an intumescent composition. The coating may be ap-plied by spraying, immersion, roller-application, or spreading, to one or more surfaces of the thermally insulating core material. The coating material itself is flame-retardant.
The result is that the heat-sensitive core material situated thereunder is protected from high temperatures and from flashover, and retains its structural integrity.
Intumescent compositions are materials which foam on exposure to relatively high temperatures, generally abovel 80 -100°C, and during this process form an insulating and heat-resistant foam which protects the thermally insulating core material situated thereunder from exposure to fire and to heat.
The intumescent composition present in the thermal insulation composite is preferably an alkali metal silicate, in particular a hydrous sodium silicate, expandable graphite, or expandable mica.
The inventive thermal insulation composite may be produced via bonding of two metal sheets and of a thermally insulating core material, where a fire-protection layer is intro-duced between the thermally insulating core material and at least one metal sheet, preferably between the thermally insulating core material and both metal sheets.
Commercially available machines for producing thermal insulation composites may be used for this purpose.
In one preferred process, an intumescent composition is used to coat at least one sur-face of the thermally insulating core material, and the material is then adhesive-bonded to the metal sheets. It is also possible to mix the intumescent composition with the ad-hesive and to apply the materials together to the thermally insulating core material or to the metal sheet, or to use an intumescent composition which has sufficient adhesion to the metal sheet.
The adhesives used may comprise single- or two-component adhesives based on po-lyurethane resins or on epoxy resins. However, it is also possible to use adhesives based on dispersions, e.g. acrylate dispersions (Acronal~).
In one embodiment, the adhesive forms all or part of the fire-protection layer. To this end, additives, such as expandable graphite, hydrous sodium silicates, zinc borates, melamine compounds, metal hydroxides, or metal salt hydrates, or a mixtures of these, are admixed with the adhesive. The proportion of the additives is generally in the range from 2 to 98% by weight, preferably from 40 to 90% by weight, based on the adhesive.
To improve processability, e.g. during the spreading or spraying process, or to acceler-ate drying, or to improve adhesion, other conventional fillers may be admixed with the adhesive.
In one preferred embodiment, the fire-protection layer is formed from an intumescent composition based on a sodium silicate. To this end, use is made of a commercially available waterglass solution with a water content of about 65% by weight, and this is mixed with waterglass powder with a water content of about 18% by weight. The gelling times for the mixture can be adjusted as desired by way of the amount of waterglass powder. If appropriate, amounts of from 0 to 50% by weight of inorganic fillers, such as metal hydroxides or metal sulfate hydrates, or else up to 10% by weight of organic fill-ers, may be added to the mixture. The liquid mixture may be directly applied or sprayed onto the sheets of the panel core material. The coating layer thicknesses here may be from 0.05 to 5 mm.
The gelling takes place at room temperature, but can be accelerated by exposure to higher temperatures up to 80°C. The sheets of the core material are thus coated on all sides, or only on the broad sides subsequently used for adhesion to a metal sheet.
It is also possible to coat the thermally insulating core material with the waterglass mix-ture and to press it with the metal sheets on both sides prior to complete gelling.
The exposed edges and corners of the core material not covered by the metal sheets may also likewise be provided with the coating composition, or critical points, such as ends or joints, may be protected from exposure to heat or from flashover via introduc-tion of insulating wedges composed of mineral wool into the panel structure.
The foam-ing of the coating can also seal apertures produced and thus inhibit flashover into the core material.
The inventive thermal insulation composite is preferably suitable in the construction industry, for facade cladding, or as what are known as "structural insulation panels" for the production of storage buildings or of cold-store buildings.
Examples:
Inventive example 1:
A molded polystyrene foam sheet composed of EPS (600x1000x100 mm) with a foam density of 18 g/I was provided on both sides with a layer, thickness 2 mm, of a water-glass mixture, composed of waterglass solution (water content 65% by weight) mixed with waterglass powder (water content 18% by weight). After gelling and hardening of the layer, the resultant sheet was coated on both sides with a layer, thickness 50 Nm, of a PU adhesive, and steel sheets, thickness 1 mm, were applied by adhesive bond-ing. In order to assess heat resistance and flame retardancy, the resultant panel was secured horizontally after the adhesive had hardened, and exposed for 30 minutes to a gas flame (flame temperature >500°C) from below. Only a small proportion of the EPS
foam core material melted during the entire 30-minute period of the test, and the mate-rial did not ignite. The foaming protective layer composed of waterglass substantially inhibited damage to the core material, and the structural integrity of the panel was re-tained.
Comparative experiment A molded polystyrene foam sheet composed of EPS (600x1000x100 mm) with a foam density of 18 g/I was provided on both sides with a layer, thickness 50 Nm, of a PU ad-hesive, and steel sheets, thickness 1 mm, were applied by adhesive bonding. In order to assess heat resistance and flame retardancy, the resultant panel was secured hori-zontally after the adhesive had hardened, and exposed for 30 minutes to a gas flame (flame temperature >500°C) from below. After as little as 5 minutes, the EPS foam core material melted and ignited, and the structural integrity of the panel was lost.
The adhesives used may comprise single- or two-component adhesives based on po-lyurethane resins or on epoxy resins. However, it is also possible to use adhesives based on dispersions, e.g. acrylate dispersions (Acronal~).
In one embodiment, the adhesive forms all or part of the fire-protection layer. To this end, additives, such as expandable graphite, hydrous sodium silicates, zinc borates, melamine compounds, metal hydroxides, or metal salt hydrates, or a mixtures of these, are admixed with the adhesive. The proportion of the additives is generally in the range from 2 to 98% by weight, preferably from 40 to 90% by weight, based on the adhesive.
To improve processability, e.g. during the spreading or spraying process, or to acceler-ate drying, or to improve adhesion, other conventional fillers may be admixed with the adhesive.
In one preferred embodiment, the fire-protection layer is formed from an intumescent composition based on a sodium silicate. To this end, use is made of a commercially available waterglass solution with a water content of about 65% by weight, and this is mixed with waterglass powder with a water content of about 18% by weight. The gelling times for the mixture can be adjusted as desired by way of the amount of waterglass powder. If appropriate, amounts of from 0 to 50% by weight of inorganic fillers, such as metal hydroxides or metal sulfate hydrates, or else up to 10% by weight of organic fill-ers, may be added to the mixture. The liquid mixture may be directly applied or sprayed onto the sheets of the panel core material. The coating layer thicknesses here may be from 0.05 to 5 mm.
The gelling takes place at room temperature, but can be accelerated by exposure to higher temperatures up to 80°C. The sheets of the core material are thus coated on all sides, or only on the broad sides subsequently used for adhesion to a metal sheet.
It is also possible to coat the thermally insulating core material with the waterglass mix-ture and to press it with the metal sheets on both sides prior to complete gelling.
The exposed edges and corners of the core material not covered by the metal sheets may also likewise be provided with the coating composition, or critical points, such as ends or joints, may be protected from exposure to heat or from flashover via introduc-tion of insulating wedges composed of mineral wool into the panel structure.
The foam-ing of the coating can also seal apertures produced and thus inhibit flashover into the core material.
The inventive thermal insulation composite is preferably suitable in the construction industry, for facade cladding, or as what are known as "structural insulation panels" for the production of storage buildings or of cold-store buildings.
Examples:
Inventive example 1:
A molded polystyrene foam sheet composed of EPS (600x1000x100 mm) with a foam density of 18 g/I was provided on both sides with a layer, thickness 2 mm, of a water-glass mixture, composed of waterglass solution (water content 65% by weight) mixed with waterglass powder (water content 18% by weight). After gelling and hardening of the layer, the resultant sheet was coated on both sides with a layer, thickness 50 Nm, of a PU adhesive, and steel sheets, thickness 1 mm, were applied by adhesive bond-ing. In order to assess heat resistance and flame retardancy, the resultant panel was secured horizontally after the adhesive had hardened, and exposed for 30 minutes to a gas flame (flame temperature >500°C) from below. Only a small proportion of the EPS
foam core material melted during the entire 30-minute period of the test, and the mate-rial did not ignite. The foaming protective layer composed of waterglass substantially inhibited damage to the core material, and the structural integrity of the panel was re-tained.
Comparative experiment A molded polystyrene foam sheet composed of EPS (600x1000x100 mm) with a foam density of 18 g/I was provided on both sides with a layer, thickness 50 Nm, of a PU ad-hesive, and steel sheets, thickness 1 mm, were applied by adhesive bonding. In order to assess heat resistance and flame retardancy, the resultant panel was secured hori-zontally after the adhesive had hardened, and exposed for 30 minutes to a gas flame (flame temperature >500°C) from below. After as little as 5 minutes, the EPS foam core material melted and ignited, and the structural integrity of the panel was lost.
Claims (9)
1. A thermal insulation composite, comprising two metal sheets with a thermally insulating core material composed of molded polystyrene foam, wherein a fire-protection layer which comprises an intumescent composition based on an alkali metal silicate, expandable graphite, or expandable mica has been introduced be-tween the thermally insulating core material and at least one of the metal sheets.
2. The thermal insulation composite according to claim 1, wherein the molded poly-styrene foam has a density in the range from 10 to 50 g/1.
3. The thermal insulation composite according to claim 2, wherein the intumescent composition comprises a hydrous sodium silicate.
4. The thermal insulation composite according to any of claims 1 to 3, wherein the metal sheet is composed of steel or of aluminum.
5. The thermal insulation composite according to any of claims 1 to 4, wherein the metal sheets have a thickness of 1 to 10 mm, the thermally insulating core mate-rial has a thickness in the range from 50 to 250 mm and the fire-protection layer has a thickness in the range from 0.1 to 50 mm.
6. A process for producing a thermal composite via bonding of two metal sheets and of a thermally insulating core material composed of molded polystyrene foam, which comprises introducing a fire-protection layer which comprises an in-tumescent composition based on an alkali metal silicate, expandable graphite, or expandable mica between the thermally insulating core material and at least one metal sheet.
7. The process according to claim 6, wherein the core material is coated on at least one surface with an intumescent composition to form the fire-protection layer, and is then adhesive-bonded to the metal sheets.
8. The process according to claim 6, wherein the core material is adhesive-bonded to the metal sheets with an adhesive comprising the intumescent composition.
9. The use of the thermal insulation composite according to any of claims 1 to 6 for the production of storage buildings or of cold-store buildings.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE200410016081 DE102004016081A1 (en) | 2004-03-30 | 2004-03-30 | Thermal insulation composite with improved thermal stability and improved fire behavior |
| DE102004016081.3 | 2004-03-30 | ||
| PCT/EP2005/003214 WO2005095728A1 (en) | 2004-03-30 | 2005-03-26 | Thermal insulation composite with improved thermal stability and improved fire resistance |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2562128A1 true CA2562128A1 (en) | 2005-10-13 |
Family
ID=34963319
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2562128 Abandoned CA2562128A1 (en) | 2004-03-30 | 2005-03-26 | Thermal insulation composite with improved thermal stability and improved fire resistance |
Country Status (12)
| Country | Link |
|---|---|
| US (1) | US20080038516A1 (en) |
| EP (1) | EP1733102A1 (en) |
| KR (1) | KR20070004916A (en) |
| CN (1) | CN1934322A (en) |
| AR (1) | AR050404A1 (en) |
| AU (1) | AU2005229118A1 (en) |
| BR (1) | BRPI0508977A (en) |
| CA (1) | CA2562128A1 (en) |
| DE (1) | DE102004016081A1 (en) |
| MX (1) | MXPA06010475A (en) |
| RU (1) | RU2006137945A (en) |
| WO (1) | WO2005095728A1 (en) |
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|---|---|---|---|---|
| KR20060011868A (en) * | 2003-05-15 | 2006-02-03 | 헌트스만 인터내셔날, 엘엘씨 | Polyisocyanate-based adhesive formulation for use in sandwich panels |
| WO2008145599A1 (en) * | 2007-05-30 | 2008-12-04 | Ineos Nova International Sa | Fire retardant polystyrene |
| DE102007034543B4 (en) * | 2007-07-20 | 2018-11-22 | Fritz Egger Gmbh & Co. Og | Method and device for producing a lightweight board and lightweight board |
| EP2207672A1 (en) | 2007-11-06 | 2010-07-21 | Basf Se | Flame protection and adhesive layer |
| BRPI0821290A2 (en) * | 2007-12-19 | 2015-06-16 | Basf Se | Molding processable by a process, process for producing a molding, panel, and use of a molding |
| KR20100106615A (en) * | 2008-02-08 | 2010-10-01 | 쓰리엠 이노베이티브 프로퍼티즈 캄파니 | Multi-layer intumescent fire protection barrier with adhesive surface |
| US20110189465A1 (en) * | 2008-07-24 | 2011-08-04 | Myron Maurer | Process for manufacturing a shaped foam composite article |
| ES2320403B1 (en) * | 2008-10-22 | 2009-11-23 | Leopoldo Vicedo Uliarte | WAREHOUSE IGNIFUGO FOR EXPLOSIVE PRODUCTS. |
| US20120121921A1 (en) * | 2009-07-22 | 2012-05-17 | Basf Se | Aqueous polymer dispersion as a binding agent for plasters and coating materials having improved fire behavior |
| KR101113577B1 (en) * | 2009-10-01 | 2012-02-22 | 기아자동차주식회사 | Fire safety apparatus of high-pressure gas fuel tank |
| DE202009017484U1 (en) * | 2009-12-22 | 2010-03-25 | Saint-Gobain Isover G+H Ag | Insulation element for fire protection |
| CN102917852A (en) | 2010-05-27 | 2013-02-06 | 陶氏环球技术有限责任公司 | Method of manufacturing a shaped foam article |
| WO2012058177A1 (en) | 2010-10-29 | 2012-05-03 | Dow Global Technologies Llc | Method of forming a shaped foam laminate article |
| PL2702119T3 (en) * | 2011-04-28 | 2016-12-30 | Fire retardant polystyrene | |
| DE102011053560A1 (en) | 2011-06-16 | 2012-12-20 | IKJ S.à.r.l. | Fire protection system as well as fire door, fire protection wall element and fire protection board therefor |
| WO2013115859A2 (en) * | 2011-10-25 | 2013-08-08 | B/E Aerospace, Inc. | Heat shielded composite panel |
| EP2809492B1 (en) | 2012-02-02 | 2016-04-06 | Covestro Deutschland AG | Method for continuous production of a sandwich compound element |
| EP2777926A1 (en) | 2013-03-14 | 2014-09-17 | Dow Global Technologies LLC | Panel with fire barrier |
| BE1021837B1 (en) * | 2014-04-30 | 2016-01-21 | Es-Projects, Besloten Vennootschap Met Beperkte Aansprakelijkheid | COMPOSITION OF AN INSULATION MATERIAL, METHOD FOR MANUFACTURING INSULATION MATERIAL AND USE OF SUCH INSULATION MATERIAL |
| WO2016089543A1 (en) * | 2014-12-03 | 2016-06-09 | Albemarle Corporation | Metal composite core composition panels and process for making same |
| RU2683110C2 (en) | 2015-01-16 | 2019-03-26 | Больё Интернешнл Груп Нв | Coating for floor, walls or ceilings and method of obtaining coating |
| RU2673055C1 (en) | 2015-01-16 | 2018-11-21 | Больё Интернешнл Груп Нв | Coating and method of obtaining coatings |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3466222A (en) * | 1967-07-26 | 1969-09-09 | Lexsuco Inc | Fire retardant insulative structure and roof deck construction comprising the same |
| US4015386A (en) * | 1975-02-07 | 1977-04-05 | Clark Door Company, Inc. | Fire-retardant low temperature insulating building panel |
| US4035315A (en) * | 1976-05-03 | 1977-07-12 | Arco Polymers, Inc. | Fire-resistant styrene polymer foams |
| US4168347A (en) * | 1978-01-03 | 1979-09-18 | Arco Polymers, Inc. | Fire and heat resistant structures |
| JPS56130341A (en) * | 1980-03-19 | 1981-10-13 | Takeda Chemical Industries Ltd | Manufacture of refractory heat insulating material |
| CA1288637C (en) * | 1986-04-04 | 1991-09-10 | John S. Luckanuck | Fire resistant steel door |
| DE4318743A1 (en) * | 1993-06-05 | 1994-12-08 | Hoechst Ag | Process for foaming flame-retardant polystyrene and molded polystyrene bodies |
| US5786095A (en) * | 1996-07-03 | 1998-07-28 | H.B. Fuller Licensing & Financing, Inc. | Inorganic based intumescent system |
| DE19639842C2 (en) | 1996-09-27 | 2002-04-18 | Wolman Gmbh Dr | Fire-protected composite system |
| DE19809973C1 (en) | 1998-03-09 | 1999-07-01 | Salamander Ind Produkte Gmbh | Fire-resistant foam product for constructional applications, e.g. joint filling |
| GB2362586B (en) | 2000-05-24 | 2003-11-12 | Prometheus Developments Ltd | Fire stable expanded polystyrene foam materials |
| AUPR309101A0 (en) | 2001-02-14 | 2001-03-08 | Styrophen International Pty Ltd | Polymeric composite foam |
| GB2405112B (en) * | 2002-06-03 | 2006-03-01 | Chong Hak Tay | A fire resistant insulation material |
-
2004
- 2004-03-30 DE DE200410016081 patent/DE102004016081A1/en not_active Withdrawn
-
2005
- 2005-03-26 MX MXPA06010475A patent/MXPA06010475A/en unknown
- 2005-03-26 US US10/593,656 patent/US20080038516A1/en not_active Abandoned
- 2005-03-26 AU AU2005229118A patent/AU2005229118A1/en not_active Abandoned
- 2005-03-26 WO PCT/EP2005/003214 patent/WO2005095728A1/en active Application Filing
- 2005-03-26 RU RU2006137945/03A patent/RU2006137945A/en not_active Application Discontinuation
- 2005-03-26 CN CNA2005800091387A patent/CN1934322A/en active Pending
- 2005-03-26 KR KR1020067022506A patent/KR20070004916A/en not_active Application Discontinuation
- 2005-03-26 CA CA 2562128 patent/CA2562128A1/en not_active Abandoned
- 2005-03-26 BR BRPI0508977-8A patent/BRPI0508977A/en not_active IP Right Cessation
- 2005-03-26 EP EP05728978A patent/EP1733102A1/en not_active Withdrawn
- 2005-03-30 AR ARP050101242 patent/AR050404A1/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| DE102004016081A1 (en) | 2005-10-20 |
| KR20070004916A (en) | 2007-01-09 |
| US20080038516A1 (en) | 2008-02-14 |
| WO2005095728A1 (en) | 2005-10-13 |
| AU2005229118A1 (en) | 2005-10-13 |
| RU2006137945A (en) | 2008-05-10 |
| CN1934322A (en) | 2007-03-21 |
| MXPA06010475A (en) | 2007-03-27 |
| AR050404A1 (en) | 2006-10-25 |
| EP1733102A1 (en) | 2006-12-20 |
| BRPI0508977A (en) | 2007-08-28 |
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| Date | Code | Title | Description |
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