FR2780999A1 - Fire-resistant and flame retardant panel made from sheets of mineral material with resin-impregnated and fiber-reinforced material between. - Google Patents

Abstract

The panel is made from sheets (1) of agglomerated mineral particles or a molded mineral material, interleaved and covered with woven or non-woven layers of fiber-reinforced material (2,3) of high thermal resistance and mechanical strength impregnated with a thermosetting reticulated organic resin. The assembly is fastened together mechanically by incombustible inserts (4) passing through the whole thickness of the panel. The reinforcing fibers can be glass, ceramic, carbon or polymers.

Description

-1 MINERALO-ORGANIC FIRE-RESISTANT AND FLAME-RESISTANT PANEL

  The present invention relates to a fire and flame retardant panel, for example intended for door leaves, partitions, ventilation ducts, flaps, protective boxes, etc. In general, for all insulation or pipe elements which must as far as possible resist mechanically or electrically under the action of fire so as to best prevent the propagation of heat or flames in order to ensure maximum preservation of organs they contain

  or that they are intended to protect.

  To date, there are many types of fire-resistant panels, but many of them have a number of disadvantages which limit them.

sometimes use.

  As such, mention should be made of the deformations caused by the panels containing metallic structures which under the action of heat become veiled and

so let the fire pass.

  Likewise, the often excessive weight and the corrosion over time of such structures are also well known, in particular often by accumulation.

indoor humidity.

  This phenomenon is further aggravated when it comes to the marine environment.

  Finally, any local modification or repair is often unacceptable.

  preservation of the original qualities of the panel in question.

  Indeed, their structure frequently includes many components which

  usually require specialist work.

  There are also composite panels, either molded in one piece, or made of plates of different materials which are subsequently

intimately assembled.

  For example, some panels are made of plywood or agglomerated wood particles, bonded together by a resin

  mineral or organic as described in patent FR 91 12760.

  Although the advantages of such a formula are numerous, experience shows, however, that the distillation of wood from a certain temperature nevertheless poses some difficulties in terms of the fumes which are generally

  flammable and / or more or less inconvenient.

  Likewise, their volume may in certain cases present an opacity capable of

  hinder relief or other or simply the movement of people.

  Other products have replaced wood-based panels with panels of agglomerated mineral particles, panels intimately assembled together by a mineral polymer also cross-linked cold or hot, this

  together not having the above drawbacks.

  This is for example the case of patent FR 93 07348. As indicated, in this technology, the intimate connection between these plates of mineral type being produced by a resin also mineral so as to maintain a total inertia to fire, it follows overall fragility,

  particularly impact and moisture.

  Such panels thus formed also have a certain natural porosity which makes them sensitive to water and in general to chemicals. Ultimately and under certain conditions, these plates can thus present

significant damage.

  The mechanical properties are also limited since the mineral resins have a very high modulus of elasticity (Young) and consequently an elongation in traction almost zero which induces properties both in traction

than in weak flexion.

  Finally, the use of glass fibers and mineral resins for the adhesion of the panels to each other and / or the reinforcement of the surfaces is not always without risk since it is well known that certain polymers of this type eventually corrode

  fiberglass, in particular mineral polymers of the alkaline type.

  It is then advantageous to replace glass fibers with ceramic fibers, but the gain is also apparent here since some are already of use prohibited by European legislation and doubts as to their physiological harmlessness

  in humans, remain for other similar products.

  The objective of the present invention is to overcome these drawbacks in particular presented by the two above inventions, either on the one hand the use of wood-based panels and on the other hand, the use of mineral-based panels with also mineral polymers used for bonding

so-called signs.

  For this, the panel is made up of plates of a non-combustible material such as, for example, agglomerated mineral particle plates or

  molded, whose fire classification according to NF P 92-507 is MO.

  These plates are intimately linked together by an organic resin of epoxy, unsaturated polyester, phenolic, polyurethane or other type, thereafter.

crosslinked cold or hot.

  In order to considerably increase the overall mechanical properties, it is advisable to have, between the plates and over their entire surface, one or more plies of a woven or non-woven reinforcement, constituted by threads of a material with high mechanical resistance. and thermal like fiberglass, even some ceramic fibers. Linked by the crosslinked organic resin, these layers constitute a composite material with high general performance which moreover maintains intimately

  assembled the plates together.

  It is just as judicious during the manufacturing or even if necessary afterwards, to treat

  exterior surfaces by the same process, including edges.

  Thus they will be shock resistant, liquid and gas tight and

good surface appearance.

  The risk of chemical reaction between the glass fibers, if these are used to constitute the reinforcing plies, and the plates with a mineral base is eliminated since the crosslinked organic resin which intimately binds this set belonging to a composition of sandwiche type , is chemically inert for each

  constituting that it isolates one from the other.

  Nevertheless, it is naturally well known that organic resins essentially of the epoxy or unsaturated polyester type for example, are in the state

  natural fuels, that is to say classified M4 according to NF P 92-507.

  A charge inert to fire, of hydrated alumina or aluminum oxide type for example, intimately mixed with the thermosetting organic resin, will reduce the combustible part and will provide, when the temperature rises, a shine conducive to the re ection of calories and to the good mechanical strength

  reinforcing plies woven or not.

  Finally, always during the rise in temperature, the thermal conduction will of course and to a certain extent, the propagation of the

  heat within the panel thus formed.

  However, organic resins of the epoxy, unsaturated polyester or other type having a limited glass transition temperature (80 to 250 C on average depending on the product) softening or even pyrolysis from a certain temperature will cause possible detachment of the first or even

  the second connection between plates exposed on the fire side.

  In order to overcome this drawback, non-combustible inserts under

  form of screws or others, will ensure mechanical continuity between plates.

  These inserts will naturally be arranged throughout the thickness of the panel, whether they are through or not. 4- Thus, this particular composition of a fire-resistant panel, allows it to benefit from both the high mechanical properties of a composite material based on organic resins and reinforcements such as fiberglass or ceramic fiber and thermal properties specific to those of assembled mineral plates without having the disadvantages of

each of the constituents.

  It should be noted that in certain cases, it is also possible to replace the reinforcements of mineral type such as fiberglass or ceramic fiber, by high tenacity organic fibers such as para-aramid known under the trade name. Kelvar or other fibers such as polyamide,

  polypropylene, polyethylene or polyester.

  Whichever solution is chosen, the present invention therefore constitutes a mineral-organic type fire and flame retardant sandwich panel which combines the remarkable properties of each of the products.

entering into its composition.

  Indeed: - The exterior surfaces are shock resistant, inert to

  most chemicals, good looking and smooth.

  - These same surfaces can be pigmented and play a role

aesthetic.

  - The combustible part of the composite material is low since

  should remove the reinforcement and inert loads.

  - The general mechanical properties are very high, in

particularly in flexion.

  - The heat transfer coefficient of the panel is significantly lower than with the use of mineral resins for bonding between

plates and on the surface.

  - It is possible to add, as explained below, an intumescent agent such as carbon or intumescent graphite, which

  further decreases the coefficient of thermal conduction.

  - The weight gain is also substantial since the organic resins have a density of about 1.20 while the

  mineral resins display about 2.40 to 2.50.

  - Even in the case where the resin would lose all or part of its mechanical properties, the non-combustible inserts bonding the plates together throughout their thickness continue to provide

  minimal cohesion of the whole.

  By way of example and to facilitate understanding, the following description

allows a detailed approach.

  The panel represented by FIG. 1 is made up as follows: The epoxy resin retained has a glass transition temperature (Tg or Tv) of around 800C. The inert filler included in the resin consists of hydrate

  alumina of suitable particle size.

  Each 12 mm thick plate -1- is made up of particles

  minerals agglomerated by a binder also of a mineral nature.

  Between each plate, a fabric of plain weave glass (taffeta) and a surface mass of 300 g / rr2 -2- also bonded by the same epoxy resin

  thus prepared, is deposited over the entire surface.

  At least four inserts per m2 have been laid -4-. They link

  mechanically all the plates together along their entire thickness.

  Two glass weave fabrics with a surface mass of 300 g / m2 are then placed on the outer surfaces and then carefully impregnated with

  resin as above, as well as the plates -3-.

  The assembly is then pressed and heated to around 50 ° C. during the whole cycle of

  polymerization of the epoxy resin.

  At the end of this, the panel is then cut with a diamond saw and ready

to work.

  Its thickness is close to 51 mm for a weight per m2 of around 55 kg, i.e.

density of 1.10.

  Such a panel, tested with a propane gas burner for two hours at an average temperature of 980 C, has a temperature rise face not

  exposed to a fire of around 90 C, which is remarkable.

  No significant mechanical effect that could eventually lead to its destruction is noteworthy. Finally, two specific provisions allowed by this type of panel such as

  described above, are in some cases of significant interest.

  On the one hand, it is perfectly possible to mix intimately with the resin

  organic, an intumescent agent such as carbon or intumescent graphite.

  When the temperature rises, this agent expands strongly and produces a kind of foam, bulky and very light, incombustible and which protects the

  underlying structure, i.e. the panel.

  This phenomenon induces a very low coefficient of thermal conduction which leads by direct consequence, a lower elevation of

  temperature face not exposed to heat or fire.

  On the other hand, between the plates, it is also perfectly possible to insert wires, sheets or electrically conductive plates which, in the event of accidental or caused rupture, will break the electrical continuity and thus generate,

  for example, an alarm or other signal.

Claims (8)

  1) Fire-retardant and flame-retardant panel, characterized in that plates made up of agglomerated mineral particles or of a molded mineral product, between which plates are sandwiched in sandwich and intimately linked with layers of fiber reinforcement material with high thermal and mechanical resistance, this reinforcing material being impregnated with a crosslinked organic thermosetting resin and covering at least the external faces of the panel, the assembly also being mechanically linked by   non-combustible inserts arranged throughout the thickness of the panel.   2) Panel according to claim 1, characterized in that the outer plies of said reinforcing material, impregnated with a resin   organic thermosetting, also cover the edges of the panel.   3) Panel according to claims 1 or 2, characterized in that said   reinforcement material of the plies consists of woven or non-woven fibers.   4) Panel according to any one of the above claims, characterized   in that the fibers of said reinforcing material are glass fibers, ceramic or carbon.   ) Panel according to any one of the above claims, characterized   in that the fibers of said reinforcing material are organic fibers of   polyamide, para-aramid, polypropylene, polyethylene or polyester type.   6) Panel according to any one of the above claims, characterized   in that said resin impregnating the plies of the reinforcing material is an organic resin of the unsaturated polyester, epoxy, phenolic or polyurethane type.   7) Panel according to any one of the above claims, characterized   in that said resin impregnating the layers of the reinforcing material is an organic resin of the unsaturated polyester, epoxy, phenolic, polyurethane type, to which have been added and intimately mixed inert and non-combustible fillers such as aluminum oxides, alumina hydrate.   8) Panel according to any one of the above claims, characterized   in that said resin impregnating the plies of the reinforcing material is an organic resin of the unsaturated polyester, epoxy, phenolic or polyurethane type, to which an intumescent agent such as intumescent graphite.   9) Panel according to any one of the above claims, characterized   in that between the plates constituting the panel are inserted wires, or   electrically conductive sheets or plates.