CN101060975A - Laminated polyisocyanurate foam structure with improved ASTME-84 flame spread index and smoke developed index - Google Patents

Abstract

Improve ASTM E-84 flame spread index and smoke developed index ratings of polyisocyanurate or urethane-modified isocyanurate foams by coating one or both major planar surfaces of a foam body or board with an intumescent coating material that contains expandable graphite and a silicate. If desired, provide reinforcement for the intumescent coating when it intumesces using a material such as a carbon veil mat or a fiberglass mat. Add a moisture vapor barrier layer to minimize water-induced degradation or water absorption of the foam.

Description

Laminated polyisocyanurate foam structure with improved ASTME-84 flame spread index and cigarette diffusion index

The present invention relates generally to building products, particularly is used for the building panel and the heat-insulating material of pipeline or process equipment, relates more specifically to be known as the construction material of " sandwich type " structure.This class formation comprises a counter plate usually, clips the sandwich layer of expansion porous polymeric resin material between them, is commonly referred to as " foam ", " resin foam " or " plastic foam " sandwich layer.The present invention relates more specifically to have this class building products of layer structure---and this layer structure is by making product obtain a plurality of selected thin slice of the gratifying American Society of some purposes for Testingand Materials (ASTM) Test E-84 flame spread index (FSI) and cigarette diffusion index (SDI) is constituted.For the back pressure ventilating system that has adiabatic heat water pipe and adiabatic cold water pipe in the commercial building (for example school, office building and hospital), gratifying ASTM E-84 FSI and SDI number are respectively 25 and 50.Building panel has identical FSI, but qualified SDI is increased to 450.

The combustibility test rules are different and different with country with standard, and a country may have combustibility test rules or recognised standard qualified more than one.Regardless of testing regulations or standard, product of the present invention should be compared with the product of the one or more thin slices, layer or the strata that do not contain layer structure of the present invention improved performance is provided.

Plastic foam manufacturer and still has been in the halogenation blowing agent has been changed under the regulations and legislative pressures of blowing agent of more environmental protection." environmental protection " be meant with respect to the halogenation blowing agent, chlorofluorocarbon especially, and blowing agent has the ozone depletion trend of reduction and produces the what is called " greenhouse gases " of low amount.Hydrocarbon blowing agent, for example butane or pentane may belong to environment-friendly foaming agent classification, but its inflammability cause other challenge.For example, use the inflammable blowing agent of pentane and so on will obtain gratifying ASTM E-84 and the relative nonflammable blowing agent of use, for example 1,1-two chloro-1-fluoroethanes (HCFC-141b) or 1,1,1,2-HFC-134a (HFC-134a) is compared much more difficult.

Contain unprotect plastic foam, especially poly-isocyanurate (PIR) foam and the easy disintegration when bearing open fire flame of urethane-modified poly-isocyanurate (PU-PIR) foam of residual inflammable blowing agent.In the foam disintegration of burning or burning, when foams are disintegrated or peel off, new foam surface is exposed under the flame.This makes and itself shows higher relatively FSI and/or high SDI, and each all may make foam not test by ASTM E-84.

Some plastic foam manufacturers the most particularly make those of PIR foam and PU-PIR foam, use facing protection foam surface to avoid direct flame.The finishing material of supply has one or more shortcomings at present.For example, finishing material may aggravate life cigarette problem because the PIR that burns or PU-PIR foam are smouldered below the unburned facing.Some facings, aluminium foil for example, may its peel off or disintegration so that foam surface provides the flameproof protection with finite duration before being exposed under the flame.Some facings can not provide sufficient isolation to water vapor permeation again.Also have some facings to sustain damage because of the physical hazard of puncture or wearing and tearing and so on easily.

United States Patent (USP) (USP) 4,361,613 on the 2nd hurdle, 10-46 is capable to be pointed out, uses polystyrene foam, hard urethanes or hard isocyanuric acid ester group foam core and the compound or lamination sandwich type sheet material of the combination of the outside facing plate of two almost parallels staggered relatively being made by the galss fiber reinforced resin material that the excellent combination of excellent abrasive and intensity and light weight (for being easy to operation) is provided.The patentee proposes, and these sheet materials do not meet some standardization combustion test of Underwriter's Laboratories Incorporated and the execution of other test mechanism.

US 2002/0119717 provides and can avoid the compound thermal protection system that flame is damaged at the bottom of the protecting group.This system comprises active fire proofing material lower floor and ablative fire proofing material upper strata.This system can comprise reinforcing material, for example graphite (for example, graphite cloth), the combination of slurry weaving carbon fibre fabric, glass fibre, wire netting, polyimides, polybenzimidazoles, polyamide, pottery, siloxanes or these materials is arranged.The metal silicate that can use alumina silicate and so on is as fire resistant infilling.

USP 5,401, and 793 disclose many expanding fire-proof paint compositions and comprised lamination on it substrate of combination of expanding fire-proof paint and inorganic chopped fiber bundle or the fire proofing material of substrate.This patentee has also instructed, can substrate upper strata compression swelling type fireproof paint and at least the noncombustible textile made by glass fibre, carbon fiber etc. of one deck to improve the fire resistance of substrate.The patentee has further instructed, and when using woven glass fabric or weaving rove fabric, often intumescent coating is produced anchor effect and strengthens intumescent coating with physics.Suitable substrate comprises metal material, wood-base materials and inorganic salts mechanograph, for example plasterboard and calcium silicate board.

USP 5,433, and 991 have instructed to make to stick with glue flameproof protection coating (especially be known as " intumescent " those) and use and embed net and strengthen intumescent coating and be subjected to the foam-like coke that flame produces when hot.The patentee has quoted USP 5,580,648, and it has instructed use free floating carbon net with the gluing expanding fire-proof paint of set, and wherein coating is applied on the outer surface of structural detail of hydrocarbon processing devices.

USP 5; 622; 774 concentrate on and use graphite fibre or cardo-polymer cloth to strengthen (for example to be used for protection below substrate; static structure; for example petroleum storage tank, chemical production equipment, cable tray and structural steel; or transporting equipment, for example oil truck and cabin) in order to avoid the intumescent coating composition of propagation of flame.In background parts, about hot protective material, for example silicate solutions or ammonium phosphate paint vehicle or composition, the patentee has quoted USP 2,680, and 077 and USP3,284,216.

USP 4,292,358 relate to enough pliable and tough to be wrapped in existing structure (for example liquefied petroleum gas container) hot guard shield on every side.This shielding is made of one or more layers intumescent coating online in expanding metal independently (preferred water base but not solvent base).

USP 3,284, and 216 have also instructed and are fit to be applied to expansion type flame-retarding coating or paint composition in the substrate (for example steel I-beam surface) by traditional approach (for example brushing, roller coat and spraying).

USP 5,001, and 005 has instructed thermosetting plastic foam structure sheaf casting die, its comprise at least one plane facing plate and when foam forms integral body be attached to the lip-deep rigid foam of facing plate.Plane facing plate comprise 60 weight % (wt%) to 90wt% glass fibre, 10wt% to 40wt% non-glass filler and 1wt% to 30wt% non-asphaltene adhesive material (for example, SBR styrene butadiene rubbers or polyvinylidene chloride), adhesive material is bonded together fiber and filler is adhered on the fiber.

USP 5,147, and 710 disclose the low density structures goods that comprise thermoplasticity (for example, polyphenylene oxide, polyamide or polyolefin) resin foam substrate and adhere to the material of the generation anti-flammability on the substrate surface.A kind of material in back can be a paper tinsel, preferable alloy paper tinsel, or glass mat.The preferable alloy paper tinsel is the aluminium foil of brown paper backing.Glass mat can be weaving or nonwoven, and preferably contains the filler of exfoliated vermiculite and so on.

A first aspect of the present invention is the layered composite structure body, and it comprises:

A. heat insulation foam layer, this froth bed have primary principal plane and separate with primary principal plane and the secondary principal plane of almost parallel; With

B. cover and be adhered to the part surface at least of at least one principal plane of heat insulation foam layer, preferably almost whole lip-deep intumescent composition coating, layer or thin slice.Term " coating ", " layer " and " thin slice " can exchange use.The intumescent coating composition is the component by composition itself but not to pass through independent adhesive layer or thin slice and principal plane bonding preferably.

In related fields, in intumescent composition coating, layer or thin slice or between two-layer intumescent composition coating, layer or thin slice, placing porous carbon film (veil) or felt.Carbon film or felt have sufficient porosity, so only need to use the individual layer intumescent composition, because said composition is permeated carbon film or felt under liquid or semi-liquid stage, thereby effectively seal this carbon film or felt.In another related fields, replace carbon film or felt and place between two-layer intumescent composition coating, layer or the thin slice with glass mat.In related fields again, can under situation, on intumescent composition coating, layer or thin slice, spread the layer or the thin slice of water vapour isolated material with or without carbon film or glass mat.

When mentioning scope among the application, unless point out separately, scope comprises two end points of this scope.

Layered composite structure body of the present invention comprises heat insulation foam layer and covering and is adhered to intumescent composition coating, layer or thin slice on this heat insulation foam layer.The optional amplified medium that comprises of complex structure body, preferred carbon face felt or glass mat.If amplified medium is a glass mat, complex structure body comprises adhesive layer, be preferably second expanding layer, it is clipped in glass mat between two intumescent coatings or between intumescent coating and the adhesive layer when combining with the expanding layer that covers the heat insulation foam layer effectively.As the variant of the aforementioned structure that comprises adhesive layer and intumescent coating, can put upside down the order of layer without departing from the present invention so that adhesive layer covers froth bed and intumescent coating cover glass fibrofelt.The enough porous of carbon face felt are so that intumescent coating infiltration felt, thereby do not need second intumescent coating or the adhesive layer.Complex structure body is further chosen wantonly and is comprised the following separation layer of water vapour in greater detail.

Heat insulation foam comprises poly-isocyanurate (PIR) foam or urethane-modified polyisocyanurate foam (PU-PIR).This class A foam A and preparation thereof are as known in the art.Generally speaking, foam preparation comprises isocyanates (for example methylene diisocyanate) and the reaction of isocyanate-reactive materials (for example PEPA) in the presence of catalyst for trimerization and blowing agent.When preparation PU-PIR foam, make water as blowing promotor.The exemplary patent of discussing every kind of reactant, catalyst and blowing agent and PIR foam and/or PU-PIR foam preparation comprises USP 3,909,465, USP 3,931,065, USP 4,411, and 949, USP 4,247,656, USP4,623,673, USP 4,795, and 763, USP 4,898,893, USP 5,096,933 and USP5,286,789.The relevant teachings of these lists of references is incorporated herein by this reference.

The purposes that intumescent composition and being used to is coated with various substrates (for example steel I-beam) is known.As USP 3,915,777 on the 1st hurdle, and described in 16-20 was capable, intumescent composition comprised filmogen, carbonaceous material, blowing agent and volatile liquid or carrier usually.Volatile liquid can be water or organic liquid, for example hydrocarbon, alcohol, ketone, ether or chlorinated hydrocabon.Make water eliminate the intrinsic smell of organic liquid as volatile liquid.Blowing agent includes, but not limited to USP 3,915,777, the 2 hurdles, listed those during 42-52 is capable.Exemplary blowing agent comprises dicyandiamide, melamine pyrophosphate, mono phosphoric acid ester or two ammoniums, poly-phosphamide, ammonium bromide, sodium tungstate, boric acid, Boratex and water-insoluble methyl phosphate, for example sodium salt, sylvite, calcium salt or zinc salt.Expansible graphite for example can be available from the GRAFGuard of UCAR Carbon Company Inc. ^TMExpansible graphite sheet rank 160 and 22 is served as suitable carbonaceous material.Filmogen desirably is an organic polymer, can be to produce continuous coated substantially any material after evaporation of volatile liquid.Exemplary filmogen comprises the polymer and the copolymer of styrene-propene acid copolymer, chlorinated rubber, vinyl chloride or vinylidene chloride, for example polyvinyl chloride, polyvinylidene chloride, vinylidene chloride/vinyl chloride copolymer.

The carbonaceous material that the intumescent coating composition must comprise coke formation amount is to improve combustibility and to account for the inorganic silicate of at least 40 weight % (wt%) of coating composition gross weight.If when commercially available intumescent coating does not contain the carbonaceous material of this tittle and/or inorganic silicate, can under agitation add the material that does not meet or exceed this tittle as yet of capacity simply.Similarly, carbonaceous material that can be by adding a certain amount of formation coke is measured and is changed the silicate adhesive composition, preferred water base silicate adhesive composition to equal or exceed above-mentioned coke formation.If carbonaceous material has 50 microns particle mean size or particle diameter, coke formation amount is the 10wt% at least of coating composition gross weight in each case, preferred 15wt% at least, and more preferably 25wt% at least, and be no more than 75wt%, preferably be no more than 60wt%.Be lower than 10wt% if form the carbonaceous material of coke, comprise the intumescent coating composition and often have as being higher than 25 the FSI desirably not low anti-flammability shown in increasing as the layered composite structure body of one deck, and as surpassing the desirably not high cigarette amount shown in 50 the SDI.Although can use above 60wt%, even up to the amount of 75wt%, they have increased the cost of layered composite structure body, can obviously not reduce FSI again.In addition, when the amount of carbonaceous material surpassed 75wt%, intumescent coating often became too sticking and is difficult for spreading, and coating lacks adherence enough useful when making gratifying layered composite structure body.The technical staff recognizes that carbonaceous material also can be with average diameter or the granularity supply beyond 50 microns.They also will appreciate that, if particle mean size bigger (for example 80 microns), just with above-mentioned scope to adjusted.Similarly, if particle mean size littler (for example, 35 microns) is just regulated above-mentioned scope downwards.The amount of inorganic silicate is the 25wt% to 75wt% of composition total weight, preferred 25wt% to 50wt%.If the amount of inorganic silicate, then comprises the layered composite structure body of intumescent coating composition layer less than 25wt% and can not reach by required FSI and the SDI value of ASTM E-84 test.The same with carbonaceous material, inorganic silicate can use with the amount that surpasses 75wt%, only can increase cost and can significantly not improve ASTM E-84 SDI and FSI value but do like this.

The commercially available intumescent coating that plays one's part to the full in layered composite structure body of the present invention and contain the carbonaceous material that drops in the above-mentioned scope and inorganic silicate amount comprises can be available from Hy-TechThermal Solutions, the HY-TECH of LLC ^TMHD-1, a kind of water base, adiabatic expansion type coating composition that volatile organic content is low.Also available from Hy-Tech Thermal Solutions, the HT1-GP of LLC and HT1-ED intumescent coating composition also provide gratifying result.

Use traditional program, for example roller coat or spraying are applied to coating on the principal plane of PIR foam or PU-PIR to produce the coating of desired thickness.Coating layer thickness desirably is that 1 mil (0.001 inch (in.) or 0.0254 millimeter (mm)) is to 100 mils (0.10 inch or 2.54 millimeters), preferred 5 mils (0.005 inch or 0.13 millimeter) are to 70 mils (0.070 inch or 1.78 millimeters), more preferably 8 mils (0.008 inch or 0.20 millimeter) are to 50 mils (0.050 inch or 1.27 millimeters), and most preferably 10 mils (0.010 inch or 0.25 millimeter) are to 30 mils (0.030 inch or 0.76 millimeter).Above-mentioned coating layer thickness is to spread the wet coating layer thickness that use can get available from the wet mil thickness instrumentation of Sherwin Williams in back 5 minutes.Provide less than the coating layer thickness of 1 mil (0.001 inch or 0.0254 millimeter) and to compare considerably lessly with uncoated foam, if any, FSI or SDI improve.The coating layer thickness that surpasses 100 mils (0.100 inch or 2.54 millimeters) has improved the weight of laminar composite and cost and has been reactive, because it may peel off in combustion process easily.

Water vapour layer (being also referred to as " water vapor barrier ") can comprise any material that makes heat insulation foam layer minimum degree in below touch water, reduces the side effect of this class contact thus.When the one side of PIR or PU-PIR cystosepiment is subjected to temperature apparently higher than another side, PIR foam and PU-PIR foam have in time through (for example absorbing a small amount of water vapor, when testing according to ASTM C272, through 2 days, absorb the water account for foam wt 0.5wt%) and in time through making a small amount of water vapor see through foam (for example 4perm-inch) (6.25 nanograms/handkerchief. second. the trend of meter (ng/Pa.S.m) (under high humility (for example 97 to 99% humidity) through 4 to 5 days).This class condition is present in the air conditioning chamber that is incubated with PIR or PU-PIR cystosepiment, and wherein relative humidity surpasses 95%, and outdoor temperature surpasses 90 degrees Fahrenheits (32 ℃) and indoor temperature is 70  (21 ℃) or lower.Compare with the foam before absorbing water vapour, the water vapour of absorption has reduced the heat-proof quality of foam.In addition, the component of PIR foam and PU-PIR foam is reacted with water easily and is made the foam structure deterioration.

Carbon film or felt are Graphite cloth suitably, and for example USP 5,622,774, USP 5,580,648, USP 5,433,991 and USP 5,401, and the sort of described in 793.Graphite cloth can be the carbon or the precursor material of substantially pure as known in the art.Suitable carbon film or felt comprise can be with trade name AFN  available from Hollingsworth ﹠amp; The polyacrylonitrile nonwoven carbon felt of Vose Company, wherein rank 8000014 and 8000015 is suitable especially.Carbon film or felt desirably have 0.2 ounce per square yard (oz/yd ²) (6.8 gram/square metre (g/m ²) to 20oz/yd ²(680 gram/square metre (g/m ²), preferred 0.2oz/yd ²(6.8 gram/square metre (g/m ²) to 2oz/yd ²(68 gram/square metre (g/m ²) basic weight.

Glass mat is as USP 5,622 suitably, the glass fabric described in 774.The exemplary glass fibrofelt comprises can be available from the ARMORWELD  glass fabric of EMTECH.Plain weave white glass fiber cloth can be with various weight available from ARMORWELD  series WF, and the glass fabric that heat is cleaned can be with various weight available from ARMORWELD  series HCF.

The preparation of laminar composite of the present invention is preferably at least 0.5 inch of thickness (1.27 centimetres (cm)), the PIR or the PU-PIR foam substrate of more preferably 0.5 inch (1.27 centimetres) to 1.5 inches (2.81 centimetres) from the heat insulation foam layer.Up to 2 inches (5.1 centimetres) or even bigger thicker PIR or PU-PIR foam substrate provide satisfactory performance from FSI and SDI angle, but the thickness that improves may produce some challenges, wherein spatial constraints is crucial restriction.Substrate can be to have two substantially flats but the plain film or the flat type of the principal plane that separates.Substrate also can be to be adapted at around pipeline or the conduit or around part of appliance, for example the curvilinear structures form of using around cooler in chilled water system or the condenser.Curvilinear structures is fit to exist with the semi-cylindrical shells pieces of two hollows, forms hollow circular cylinder or conduit when they lump together.If desired, can use the housing fragment of greater number, as long as these fragments form the hollow circular cylinder of conduit when lumping together.Each housing fragment has case surface and inner casing surface.

Spread intumescent coating or adhesive coating on case surface or principal plane, whichever is suitable for selected heat insulation foam layer.If desired, can change adhesive coating, the selective hydrolysis silicate adhesive is to comprise a certain amount of expansible graphite.

If desired, intumescent coating or adhesive coating can be covered by finishing material.Suitable finishing material comprises polyvinylidene chloride film, paper tinsel-scrim-brown paper three-decker, all service sheath (ASJ) or another conventional finishing material.When finishing material is the vinylidene chloride film, obtain specially suitable result.

When using intumescent coating and/or adhesive coating, no matter whether adhesive coating is modified, and adds the enhancing felt and has improved FSI and/or SDI usually.If strengthening felt is carbon face felt, under the situation that coating still wets, place it in simply on intumescent coating or the adhesive coatings (no matter whether as mentioned above modification).The enough porous of carbon face felt are so that coating infiltration felt and effectively carbon face felt being encapsulated in the coating as the free floating felt.If strengthening felt is glass mat, for example hot glass fabric that cleans, no matter coating is intumescent or fusible, the degree of infiltration felt or cloth is more much smaller than the degree of infiltration carbon face felt.When using glass mat, usually must glass mat not with bonding or a side that intumescent coating contact on use second adhesive coating or second intumescent coating.When using glass mat as the enhancing felt, compare with other feasible layered composite structure, suitable structure especially comprises following: foam substrate/intumescent coating/glass mat/adhesive coatings/facing; Foam substrate/adhesive coatings/glass mat/intumescent coating/facing; Foam substrate/modification adhesive coatings/glass mat/adhesive coatings/facing; Foam substrate/adhesive coatings/glass mat/modification adhesive coatings/facing; Foam substrate/modification adhesive coatings/glass mat/modification adhesive coatings/facing; Foam substrate/intumescent coating/glass mat/modification adhesive coatings/facing; And foam substrate/modification adhesive coatings/glass mat/intumescent coating/facing.The technical staff understands easily, can further change these exemplary configurations without departing from the present invention.

The following example illustrates, but does not limit the present invention in any way.Arabic numerals are represented embodiments of the invention (Ex), and Comparative Examples (Comp Ex) represented in letter.Unless indicate separately, all umbers and percentage are all by weight.In addition, unless indicate separately, all amounts shown in the table are all based on polymer weight contained in each composition.

Embodiment 1

Be that to sprawl basic weight on the principal plane of PIR foam substrate (TRYMERTM 2000i, The Dow Chemical Company) of 1.5 inches (in.) (3.8 centimetres (cm)) be 0.20 ounce per square yard (oz/yd at thickness ²) (6.8 gram/square meter (g/m ²)) carbon face felt (AFN  Grade 80014, Hollingsworth ﹠amp; Vose Company Advanced FiberNonwovens).Adopt 1 gallon of/square feet (gal/ft ²) (0.41 liter/square meter (L/m ²)) application base intumescent coating composition (HT-1 GP, Hy-Tech ThermalSolutions) is applied on the carbon face felt to obtain the wet coating layer thickness of 0.3 inch (0.76 millimeter (mm)).Use can be available from the wet surely coating layer thickness of the wet thickness instrumentation of Sherwin Williams paint store.This coating composition infiltration carbon face felt also contacts PIR foam principal plane, thereby the free floating carbon face that is placed in coating composition felt is provided effectively.With thickness is 4 mils (0.004in.) polyvinylidene chloride film (SARAN (0.10mm) ^TM540, The DowChemical Company) be applied on this coating composition.Be adhered to effectively after the coating composition drying on PIR foam principal plane and the polyvinylidene chloride film, form the layered composite structure body thus.

The comparative example A

Repeat embodiment 1, but omission of carbon face felt.

Embodiment 2

Repeat the comparative example A, but comprise the seam that obtains by the two-layer polyvinylidene chloride film of overlapping, and seal this seam as the double-sided pressure-sensitive adhesive tape of pressure sensitive adhesive tape substrate (3693FLE FR, Venture Tapes) with use polyamide or nylon film." FLE " is meant " fingerlift edge (referring to take off the edge) ".This partly overlapping sealing simulation insulating tube coats installs (wrapinstallation).

Embodiment 3

Repeat embodiment 2, but replace double-sided pressure-sensitive adhesive tape to seal this seam with the intumescent coating composition.

Comparative Examples B

Repeat embodiment 1, but comprise as the coating seam among the embodiment 2.

Embodiment 4

Repeat embodiment 1, but comprise as the coating seam among the embodiment 3.

Comparative Examples C

Repeat embodiment 1, but comprise, and replace polyvinylidene chloride film with paper substrate allservice sheath (ASJ) as the coating seam among the embodiment 3.ASJ (from FB 400 ASJ of CompacCorporation) is adhered to brown paper (45 pounds of (1b)/3000ft with 0.3 mil (0.00035in./9 micron) aluminium foil ²) (75 gram/square meter (g/m ²)) go up and between the two, accompany fiberglass scrim and the trilaminate material made.Adhesive is a fire retardant adhesive.

Embodiment 5

With intumescent coating (STAHRCOAT ^TM, Barrier Dynamics) and with 1 gallon/50ft ²(0.815L/m ²) the ratio coating thickness be the PIR foam substrate (TRYMER of 1.5 inches (in.) (3.8 centimetres (cm)) ^TM2000i, The Dow Chemical Company) principal plane.

Embodiment 1 to embodiment 5 and comparative example A are carried out ASTM E-84 test to Comparative Examples C, and the result is summarised in down in the Table I.

Table I

Embodiment/Comparative Examples title	ASTM E-84 FSI	ASTM E-84 SDI
			1	20	40
A	30	45
			2	25	45
3	25	30
			B	30	30
4	20	15
			C	35	130
5	25	250

Data in the Table I show that the layered structure of embodiment 1, embodiment 2, embodiment 3 and embodiment 4 has ASTM E-84FSI and the SDI that uses in the back pressure ventilating system that has adiabatic heat water pipe and adiabatic cold water pipe that is suitable in commercial building (for example school, office building and hospital).Data show that by replace the ASJ of Comparative Examples C with the polyvinylidene chloride film, the layered structure of Comparative Examples C can reach and not be higher than 25 low FSI grade.Even this SDI number does not change with this replacement, the gained layered structure also can have ASTM E-84 FSI and the SDI number that is applicable to building panel.In addition, the FSI measured value of comparative example A and Comparative Examples B enough passes through/fails number so that just can produce qualified FSI and SDI number in the structure of comparative example A and Comparative Examples B and/or the less change of forming near the ASTM E-84 FSI and the SDI of back pressure ventilating system.Use representative other layered structure of the present invention also to expect similar results, but in difference aspect above-mentioned instruction one or more.With the polyester-based pressure sensitive adhesive tape but not the nylon based pressure sensitive adhesive tape of embodiment 2 repeats embodiment is considered to produce much higher FSI and/or SDI number, this causes reaching the ASTM E-84 standard of back pressure ventilating system.

Embodiment 6

Account for the expansible graphite (GRAFGUARD of the 25wt% of coating weight by interpolation ^TM160-50, particle mean size is 50 microns, the expanding volume under 600 ℃ is 250 cubic centimetres/gram (cm ³/ g), and UCAR Carbon Co.), change water base silicate adhesive (CALBOND ^TMGold, Industrial Insulation Group, LLC).It is the PIR foam substrate (TRYMER of 1.5 inches (in.) (3.8 centimetres (cm)) that this modified Portland adhesive is spread at thickness ^TM2000i, The Dow Chemical Company) on the principal plane.Before this adhesive drying, on this modified adhesive, apply with embodiment 1 in the seam-ripping layer (unseamed layer) of identical polyvinylidene chloride film to form the layered composite structure body.The ASTM E-84 FSI and the SDI number of this layered composite structure body are respectively 25 and 60.Bright this layered composite structure body of this numerical table is suitable for use as building panel, rather than is used in the back pressure ventilating system as band adiabatic heat water pipe in the commercial building of school, office building and hospital and so on and adiabatic cold water pipe.The further modification of this layered composite structure body can make it be useful in this type of back pressure ventilating system.

Embodiment 7

Repeat embodiment 6, but have two places to change.The first, on the modified Portland adhesive coating, apply the glass fabric that the thick heat of 30 mils (0.76 millimeter) cleans (Armil/CFS, 18-HCF-40-50).The second, on the side that glass fabric does not have with the modified Portland adhesive contacts, spread unmodified silicate adhesive (CALBOND ^TMGold, IndustrialInsulation Group, coating LLC).The ASTM E-84 FSI and the SDI number of this layered composite structure body are respectively 15 and 5, and this is useful in back pressure ventilating system or the building panel it.

Embodiment 8

Repeat embodiment 7, but have a place to change.The first, use with embodiment 1 in identical intumescent coating composition replace the modified Portland adhesive of embodiment 6.The ASTM E-84 FSI and the SDI number of this layered composite structure body are respectively 25 and 65, and this is useful in the building panel it.This layered composite structure body is further changed and this SDI number should be able to be reduced to 50 or lower, this version of further changing is useful in the back pressure ventilating system.

Embodiment 9

Repeat embodiment 8, but put upside down intumescent coating and silicate adhesive order so that silicate adhesive between the glass fabric of foam first type surface and heat cleaning.The ASTM E-84 FSI and the SDI number of this layered composite structure body are respectively 15 and 70, and this makes it be applicable to the purposes identical with embodiment 8, and can carry out and the similar change that embodiment 8 is advised.

Embodiment 10

Repeat embodiment 7, but put upside down the order of unmodified silicate adhesive and modified Portland adhesive.The ASTM E-84FSI and the SDI number of this layered composite structure are respectively 20 and 10, and this is useful in back pressure ventilating system or the building panel it.

Comparative Examples D

Repeat embodiment 7, but have three places to change.At first, use with embodiment 1 in identical carbon face felt replace the glass fabric that heat is cleaned.Secondly, the modified Portland adhesive that replaces embodiment 6 with the unmodified silicate adhesive of embodiment 7.The 3rd, remove the silicate adhesive coating that spreads among the embodiment 7 on glass fabric, because the enough porous of carbon face felt are so that be applied to the silicate adhesive coating infiltration carbon face felt on the foam first type surface and effectively carbon face felt be encapsulated in the silicate adhesive coating.The ASTM E-84 FSI and the SDI number of this layered composite structure body are respectively 45 and 75.These numerical tables are bright need further be changed laminar composite so that it is useful in building panel or the back pressure ventilating system.

Comparative Examples E

Repeat Comparative Examples D, but change to remove carbon face felt.The ASTM E-84 FSI and the SDI number of this layered composite structure body are respectively 50 and 70.With the same among the Comparative Examples D, these numerical tables are bright need further be changed laminar composite so that it is useful in building panel or the back pressure ventilating system.

Embodiment 11-15

With PIR foam (TRYMER ^TM2000i, The Dow Chemical Company) being cut into length is 2 feet (ft) (0.61 meter (m)), and width is 3.5 inches (8.9cm), and thickness is the plate of 1.0 inches (2.5cm).Plate has the suitable size that (standard test method (2-ft Tunnel Method) of the small-scale evaluation and test of fire-retardant paint vehicle) tested according to ASTM D 3086-79.

Embodiment 11

Repeat embodiment 1, but have two places to change.At first, use 2 feet (0.61m), 1.0 inches (2.5cm) thick PIR cystosepiment but not 1.5 inches (3.8 centimetres) thick foam substrate.Secondly, omission of carbon face felt.

Embodiment 12

Repeat embodiment 11, but use ECOFLEX ^TM(Avtec) intumescent coating replaces the intumescent coating of embodiment 11.

Embodiment 13

Repeat embodiment 12, but have a place to change.This change comprises that use is coated with the carbon face felt of granting embodiment 1 same type as program listed among the embodiment 1.

Embodiment 14

Repeat embodiment 6, but use 2 feet (0.61 meters), 1.0 inches (2.5 centimetres) thick PIR cystosepiments but not 1.5 inches (3.8 centimetres) thick foam substrate.

Embodiment 15

Repeat embodiment 14 but the heap(ed) capacity of expansible graphite is increased to the 50wt% that accounts for coating weight.

To embodiment 11-15, and for 2 feet (0.61 meters) not containing intumescent coating or facing that are designated as Comparative Examples F that compare, 1.0 inches (2.5 centimetres) thick PIR cystosepiments, with according to ASTM D3086-79 (standard test method (2-ftTunnel Method) of the small-scale of fire-retardant paint vehicle evaluation and test) test to collect the sample data relevant with FSI and SDI." by 2 feet flues of fire-retardant paint vehicle calibration of usefulness method E-84-evaluation; the result who is obtained by this method should represent those results that obtain with bulk specimen in the E-84 flue " are tested among the embodiment 1-10 as mentioned like that described in second page of ASTM D 3086-79.Following Table II has been summarized the result of the test of propagation of flame (FS), serves as at interval with 1 inch (2.54 centimetres) fragment calibration with 15 seconds.In other words, it shows how far flame has spread downwards in flue.Table II also comprises two subjective gradings.A subjective grading is classified as 1 to 5 with cigarette diffusion (SD), and wherein 1 is best grading, shows relatively low cigarette diffusion, and the 5th, the poorest grading shows higher relatively cigarette diffusion levels.Another subjective grading is according to flame intensity or brightness evaluation and test burning quality.Difference means that flame is quite bright, means that preferably flame intensity is far below " poor ".Good and the better intermediate grade of representing.

Table II

Time	Comparative Examples F		Embodiment 11		Embodiment 12		Embodiment 13		Embodiment 14		Embodiment 15
														FS	SD	FS	SD	FS	SD	FS	SD	FS	SD	FS	SD
0:15	24	ND *	12	1	18	3	10	5	12	2	11	3
													0:30	1 5		12		18		15		12		11
0:45	13		11		18		16		12		11
													1:00	12		9		17		17		10		11
1:15	11		9		15		15		10		10
													1:30	10		9		12		13		10		10
1:45	10				12		13		9		10
													2:00	10				12		12		8		10
2:15	10				12		12		8		10
													Burning quality	Difference		Good		Good		Better		Best		Best

^*ND does not mean detection

The listed data of Table II show that the PIR foam that does not contain intumescent coating or facing as among the Comparative Examples F is very poor in the inflammability test according to ASTM D 3086-79.Under identical testing regulations, embodiment 11 compares with embodiment 13 with embodiment 12, shows when comprising carbon face felt in layer structure, and good result of the test obtains to improve, and sees it is such from the angle of burning quality at least.Embodiment 14, combine with embodiment 6, confirmed the supposition that the ASTMD3086-79 test can connect each other with ASTM E-84 test.Embodiment 15 shows, can significantly improve the amount of carbonaceous material (being expansible graphite among the embodiment) under situation the about performance of layer structure not being had a negative impact according to inflammability test.For representative other layered structure of the present invention, can expect similar result, but according to above-mentioned one or more aspects difference that is taught in.

Embodiment 16-18

With embodiment 2 triplicates, but the wet coating layer thickness of intumescent is reduced to 10 mils (0.010 inch or 0.25 millimeter) at every turn.Give birth to row ASTM E-84 FSI/ASTM E-84 SDI value as the ASTM E-84 testing producing of embodiment 5: embodiment 16=25/35; Embodiment 17=25/30; And embodiment 18=25/35.

Embodiment 19

Repeat embodiment 2, but as embodiment 16-18, the wet coating layer thickness of intumescent is increased to 10 mils (0.010 inch or 0.25 millimeter) and changes intumescent coating into HT1-ED (Hy-TechThermal Solutions).Give birth to row ASTME-84 FSI/ASTM E-84 SDI value as the ASTM E-84 testing producing of embodiment 5: 25/35.

Embodiment 20

Repeat embodiment 16, but interpolation accounts for the water of coating weight 5 weight % (wt%) with the dilution coating composition.Give birth to row ASTM E-84FSI/ASTM E-84 SDI value as the ASTM E-84 testing producing of embodiment 5: 25/20.

Embodiment 21

Repeat embodiment 20, but the water addition is increased to the 10wt% that accounts for coating weight.Give birth to row ASTM E-84 FSI/ASTM E-84SDI value as the ASTM E-84 testing producing of embodiment 5: 25/35.

Data shown in the embodiment 16-21 show, relatively thin (10 mils or 0.010 inch or 0.25 millimeter), and the intumescent coating produces and makes this laminar composite be applicable to the ASTM E-84 FSI and the SDI value of various final uses.Coating composition necessarily diluted and when using not water mixing coating composition, the result is favourable.Use other coating in the scope of the invention can expect similar result.

Comparative Examples F-H

For Comparative Examples F-H, use CALBOND ^TM(IIG make a kind of calcium silicates based adhesive) will be adhered on the cementatious plate with a principal plane of the PIR foam substrate of embodiment 1 same type as adhesive.Give birth to row ASTM E-84 FSI/ASTM E-84 SDI value: Comparative Examples F=25/40 as the ASTM E-84 testing producing of embodiment 5; Comparative Examples G=25/105; Comparative Examples H=25/55.

Comparative Examples I

Repeat embodiment 16, but with containing titanium dioxide as pigment (220 Latex FireRetardant Coating, Benjamin Moore ﹠amp; The coating of vinylacrylic acid latex-based fire retardant coating compositions Co.) replaces the intumescent coating of embodiment 16.Give birth to row ASTM E-84FSI/ASTM E-84SDI value as the ASTM E-84 testing producing of embodiment 5: 25/300.

Embodiment 22

Repeat embodiment 4, but as embodiment 16-18, the wet coating layer thickness of intumescent is reduced to 10 mils (0.010 inch or 0.25 millimeter).Give birth to row ASTM E-84 FSI/ASTM E-84 SDI value as the ASTM E-84 testing producing of embodiment 5: 25/35.

Embodiment 23 and embodiment 24

Embodiment 22 is repeated twice, but change the PIR foam substrate into TRYMER ^TM2000blue (The Dow Chemical Company).Give birth to row ASTM E-84FSI/ASTME-84SDI value as the ASTM E-84 testing producing of embodiment 5: embodiment 23=25/45; And embodiment 24=25/20.

Comparative Examples J and Comparative Examples K

Comparative Examples F is repeated twice, but with containing 6 parts of (is 100 parts with the PIR foam wt) FYROL ^TMPCF (a kind of Tris Chloro Phenyl Phosphate (TCPP) fire retardant) replaces used PIR foam substrate among the Comparative Examples F as the tentative PIR foam of flame-retardant additive.Give birth to row ASTM E-84 FSI/ASTME-84 SDI value as the ASTM E-84 testing producing of embodiment 5: Comparative Examples J=25/130, and Comparative Examples K=25/85.

Comparative Examples L-N

With Comparative Examples F triplicate, but the thickness of foam substrate is reduced to 1 inch (2.5 centimetres).Give birth to row ASTM E-84 FSI/ASTME-84 SDI value: Comparative Examples L=25/65 as the ASTM E-84 testing producing of embodiment 5; Comparative Examples M=25/50; Comparative Examples N=25/40.

In a plurality of tests (for example Comparative Examples F-H and embodiment 23-24) expansion of SDI value be considered to small part be since E-84 tests the variability in the flue and the PIR cystosepiment that downcuts from the PIR foam-plastic blocks between certain difference.The technical staff will appreciate that, in ASTM E-84 test, foam contacts with flame and can cause foam to be heated reaching autoignition temperature until it.In case foam takes fire, it begins cracking, the crackle expansion occurs along foam length and the direction of crossing foam length.Expand side by side with crackle, foam begins coking and produces cigarette.When crackle was expanded, new foam surface contacted with flame, and this causes further coking and gives birth to cigarette.Layered composite structure body of the present invention provides shown in embodiment 1-24 and is equal to or less than 25/50 the more consistent FSI/SDI value of the structure than Comparative Examples A-N.

Claims (17)

1. layered composite structure body, it comprises:

A. heat insulation foam layer, this froth bed have primary principal plane and separate with primary principal plane and the secondary principal plane of almost parallel; With

B. cover and be adhered to the intumescent composition of one deck at least coating, layer or thin slice at least one major planar surface of heat insulation foam layer.

2. layered composite structure body according to claim 1, wherein complex structure body further comprises carbon face felt, and this carbon face felt is embedded in single coating of intumescent coating composition.

3. layered composite structure body according to claim 1, wherein complex structure body further comprises the amplified medium that is selected from carbon face felt or glass mat, and this amplified medium is between two-layer intumescent coating composition coating, layer or thin slice and be adhered on it.

4. according to claim 1,2 or 3 described layered composite structure bodies, wherein this complex structure body further comprises water vapour and isolates thin slice, and the water vapour thin slice comprises and is selected from vinylidene chloride polymer film, metal forming, metal forming-scrim-brown paper lamination material or PETG film-metal forming-PETG film laminate.

5. layered composite structure body according to claim 4, wherein water vapour isolation thin slice is the vinylidene chloride polymer film.

6. according to claim 1,2 or 3 described layered composite structure bodies, wherein intumescent coating comprises the water-based mixture of expansible graphite, clay, acid imide, carbon black and silicate.

7. layered composite structure body according to claim 4, wherein intumescent coating comprises the water-based mixture of expansible graphite, clay, acid imide, carbon black and silicate.

8. according to claim 1,2 or 3 described layered composite structure bodies, wherein the heat insulation foam layer comprises polyisocyanurate foam or urethane-modified polyisocyanurate foam.

9. layered composite structure body according to claim 4, wherein the heat insulation foam layer comprises polyisocyanurate foam or urethane-modified polyisocyanurate foam.

10. layered composite structure body according to claim 6, wherein inorganic silicate is selected from sodium metasilicate, calcium silicates, alumina silicate.

11. layered composite structure body according to claim 7, wherein inorganic silicate is selected from sodium metasilicate, calcium silicates, alumina silicate.

12. according to the arbitrary described layered composite structure body of claim 1 to 11, wherein this composite has 25 or lower ASTM E-84 flame spread index and 50 or lower cigarette diffusion index.

13. according to the arbitrary described layered composite structure body of claim 1 to 11, wherein this complex structure body has 25 or lower ASTM E-84 flame spread index and 450 or lower cigarette diffusion index.

14. according to the arbitrary described layered composite structure body of claim 1 to 11, its floating coat has the spread thickness of 1 mil (0.0254 millimeter (mm)) to 100 mils (2.54 millimeters).

15. layered composite structure body according to claim 14, wherein thickness is that 5 mils (0.13 millimeter) are to 70 mils (1.78 millimeters).

16. layered composite structure body according to claim 14, wherein thickness is that 8 mils (0.20 millimeter) are to 50 mils (1.27 millimeters).

17. layered composite structure body according to claim 14, wherein thickness is that 10 mils (0.25 millimeter) are to 30 mils (0.76 millimeter).