FR3009323A1 - FIRE RESISTANT MULTILAYER PANEL HAVING INSULATION AND BARRIER - Google Patents

Abstract

The present invention relates to a fire-resistant sandwich panel, which can be used in particular for the production of doors integrated in fire door blocks or facades of fire-fighting technical ducts or for the realization of fire inspection door gates, said panel consisting of of exactly two layers assembled by means of a binder, preferably by gluing, an insulator (1) made of an insulating material, said material also being structural so as to withstand the mechanical stresses to which the panel is subjected during its usual use, and a barrier (2) of non-combustible material, said material also being structural, so as to support the weight of the panel during a fire from the side of said insulator (1) for a predetermined time. The present invention also relates to a multilayer acoustic and / or thermal insulation panel, usable in particular for the production of doors integrated in fire door blocks or facades fireproof technical sheaths or for the realization of door inspection hatches cut light, said panel consisting of at least three layers assembled by means of a binder, preferably by bonding, an insulator (1) made of an insulating material, said insulating material being also structural so as to withstand the mechanical stresses experienced by the panel during its usual use, surrounded by two barriers (2) of a non-combustible material, said non-combustible material being also structural, so that the barrier (2) away from the fire supports the weight of the panel during a fire coming from the side of said insulation (1) for a predetermined period.

Description

The present invention relates to a multi-layer panel, fire resistant, usable for the realization of integrated doors including fireproof door blocks, facades of ducts cutting technical -fire or for the realization of gates fire inspection hatches. Fire resistant panels are constantly being upgraded to increase their fire resistance. However, this increase in the fire resistance time is generally accompanied by a significant increase in their thickness, their weight or their price. The fire resistant panels known in the state of the art are first of all the wood fiber board (MDF) and the combined fiberglass (MDF) sandwich panel on flax fiber or wood chipboard with wood sheets. The first is simple to implement, the second more complex and both allow the fixing of lock type door closing means and hinges. However, to resist fire for 30 minutes, they must have a current thickness of about 40 mm. This thickness is incompatible with an installation applied, invisible forging, on a frame, generally used configuration for fitted cupboards. FR 2 849 460 discloses a composite panel, consisting of a core made of plaster or fiber-reinforced gypsum material, and two wood fiber facings, forming a sandwich with a total thickness of 25 mm. This panel is actually thinner than the standard 40 mm and it successfully passes the fire test at 30 minutes. However, it has the disadvantage of having friable edges, characterizing insufficient hardness and cohesion of the plaster or gypsum core material, the corollary being poor durability of bonding over time between the core and the siding of the sandwich panel (fiber, plaster, fiber). It also has a weight per m2 greater than 25 Kg per m2, which is quite high. FR 2 897 883 discloses a composite panel of 34 mm total thickness with a 25 mm thick but very light core of expanded perlite.

Nevertheless, this material has weaknesses of mechanical strength, and requires the addition of awnings on which can be fixed in particular the hinges. This makes the door manufacturing process more complex, such as that of the classic flax fiber door, which has to be reinforced on the banks by wooden awnings. Also known is FR 2 943 698 which discloses a fire resistant sandwich panel consisting of at least one core disposed between two facings based on wood fibers. The core consists of a fiber-reinforced cement-based material.

Also known is FR 2 943 699 which discloses a fire resistant sandwich panel consisting of at least one core disposed between two facings based on wood fibers. The core consists of a fiber reinforced silicate material. The production of fireproof panels therefore requires the use of a combination of layers and particular materials to achieve the desired performance. These materials often have a significant cost in the manufacture of these panels. The object of the present invention is to develop an acoustic and / or thermal insulation panel, resistant to fire for at least 30 minutes according to the criteria of standard NF EN 1634-1 (E11 two directions of fire). Another object of the present invention is to propose a panel with a thickness equal to or less than 25 mm to be compatible with a surface application (according to the commonly accepted aesthetics and / or the usual characteristics of conventionally invisible hinge systems. used in applied), but lighter than previous inventions, while having a non-brittle hard edge and also good resistance to tearing mechanical fastening systems, during normal use of the product or during and after a fire . Another object of the present invention is to provide a panel 30 or less preferably 25 mm thick, but whose fire resistance is preferably more than 60 minutes or a panel of less than 35 mm thickness preferably The object of the present invention is to provide a panel with the aforementioned performance and whose cost of the constituent materials is substantially reduced. Most panels, like those mentioned in the introduction, have a number of disadvantages and do not achieve all the desired performance. In particular they all offer a symmetrical structure, usually a layer of a non-combustible material surrounded by two facings of wood or MDF. It is by a first inventive step that the applicant has realized, following a large number of symmetrically structured tests as indicated above, a few tests with exclusively two layers, a layer of MDF, and a layer made of an incombustible material. .

The first tests were made, with the fireproof non-combustible material layer, which made it possible to obtain fire resistance comparable to panels with a symmetrical structure of the same thickness, and especially to note that the panel remained substantially flat for the duration of the test, which is very surprising for a non-symmetrical structure.

By a second inventive step, the applicant has made a few tests with the MDF layer on the fire side, and in a totally surprising manner the fire resistance is clearly superior in this sense. The invention therefore proposes a multilayer acoustic and / or thermal insulation panel, which can be used in particular for the production of doors integrated in fire door blocks or facades of fireproof ducts or for the realization of inspection hatches. fire, said panel being particular in that it consists of exactly two layers assembled by means of a binder, preferably by gluing, an insulator made of an insulating material, said material being also structural so as to withstand the mechanical stresses the panel is subjected to its usual use, and a barrier made of a non-combustible material, said non-combustible material being also structural, so as to support the weight of the panel during a fire from the side of said insulator for a predetermined period of time. Thanks to these provisions, we obtain a very resistant panel for a very moderate cost, thanks to the fact that there are only two layers to assemble. The insulation must be an insulating layer to protect the fire barrier for as long as possible, and it must be structural, to support almost alone the normal use constraints, thereby reducing as much as possible the thickness of the barrier, generally more expensive and support the hinges for attaching the doors to a frame; insulating materials such as glass wool, rockwool or expanded perlite are unsuitable. The barrier must be a noncombustible layer to play its role of maintaining the insulation during a fire, and also structural, to wear the insulation, and to wear itself, without burning to maintain also a smoke-tightness for the duration fire. However, this mechanical stress is much lower than for the insulator, since during a fire the door is in the closed position, supported by its frame. This allows the least thickness of the barrier relative to the insulation. By a third inventive step, the applicant imagined to complete the panel to make it fire resistant in both directions, which again gives a symmetrical panel, but comprising in both directions a series of insulating / barrier layers. WO2011124292 discloses a structural panel composed of a non-structural insulating layer of expanded perlite, surrounded by two barrier layers of plaster or cement. The examples given give thicknesses of 25 panels greater than 155 mm, the main function of which is thermal insulation. However expanded perlite insulation does not perform any mechanical function, and needs both barriers to maintain itself. The invention therefore also proposes a multilayer acoustic and / or thermal insulation panel, which can be used in particular for the production of doors 30 integrated in fire door blocks or facades of fire-resistant technical ducts or for the realization of hatch gates. visit firewall, said panel being particular in that it consists of at least three layers assembled by means of a binder, preferably by gluing, an insulator made of an insulating material, said insulating material being also structural so as to support the mechanical stresses experienced by the panel during its usual use, surrounded by two barriers made of an incombustible material, said incombustible material also being structural, so that the barrier remote from the fire supports the weight of the panel during a fire coming from the side of said insulator for a predetermined duration. Such a panel makes it possible to manufacture a door with excellent fire resistance in both directions of fire, the first layer, the barrier, fire acting as a retarder, the second layer, the insulation, then protecting the second barrier which in turn keeps the insulation in place during the fire. Non-combustible materials are classified in the category MO of the standard NF P.92.507 according to the French classification and in the items A1 and A2-sl-d0 of the European classification defined in the technical regulation 2005.

According to other characteristics: said insulation may have a thickness at least twice that of said barrier, preferably at least 12 mm, thus allowing significant protection of the barrier, said insulation may be made of a wood-based material or cellulose, preferably an MDF, material easy to implement for this type of application; another possible material is, for example, OSB, a material made by bonding wood particles. - said barrier may have a thickness of less than 6 mm, sufficient thickness to keep the insulation in place during its combustion, - the incombustible material may have a thermal conductivity less than 1 W / mK, thus contributing to the overall thermal resistance of the panel said insulating material may have a thermal conductivity of less than 0.5 W / mK and preferably less than 0.2 W / mK, thus making it possible to better protect the barrier, - said noncombustible material may be a material based on cement, magnesia cement, plaster, gypsum, silicate, all these materials being ordinary, or reinforced with fibers, constituting noncombustible and structural materials well suited to such an application, unlike other incombustible materials such as glass wool, - said panel may comprise exactly three layers, said barriers surrounding said insulation, thus constituting a simple and economical solution, - said panel may comprise two faces on both sides of the barriers, in particular siding made of a material based on wood fibers, thus making it possible to further improve the holding time fire. Such a panel also allows to obtain a hard edge, not friable in time, and excellent mechanical strength by screwing fasteners (hinges, cremones, strikers, brackets, ...) not only in normal cold use , but also during and after a fire (simulated by the reference to the protocol of standard NF EN 1634-1). According to an exemplary embodiment of the panel according to the invention, the material based on cement or plaster is reinforced by fibers, of the cellulose fiber type. The fibers are for example in powder form. The fibers can also be long in woven or non-woven form.

Other advantages of the invention will appear on reading the description of an embodiment illustrated by the drawing of FIGS. 1 and 2, in which: FIG. 1 represents a perspective view of an insulating / barrier panel according to the invention, - Figure 2 illustrates an embodiment of a barrier / insulator / barrier panel according to the invention. According to a first embodiment shown in Figure 1, the panel according to the invention has an insulator 1 in the form of a structural insulating layer, for example MDF, quite thick, and a barrier 2, thin layer of incombustible material for example plaster or cement.

According to the thicknesses retained, the panel according to the invention is fire resistant E11, fire direction, MDF fire side, more than 30 minutes, or even more than 45 minutes. With sufficient thickness, it can be fire resistant E12, 2 fire sense, more than 30 minutes.

According to a second embodiment shown in FIG. 2, the panel according to the invention has two barriers 2, surrounding an insulator 1 made of an insulating and structural material, for example made of thicker MDF. Depending on the thicknesses used, this panel is fire resistant E12, 2 directions of fire, more than 30 minutes, or even more than 45 minutes.

The mechanical characteristics of the two barriers 2 and the insulator 1 make it possible to avoid the installation of latches. The barriers 2 are made for example with a material based on cement, silicate, a mixture of oxide and magnesium chloride also called magnesia cement, gypsum or plaster.

Given the hardness of the barriers 2, a panel according to the invention can be painted or laminated on the edge 3, and one obtains a durable aesthetic over time. The following examples describe panels according to the invention with a thickness of about 25 mm, a weight per m2 less than 24 kg or an overall density of less than 950 kg / m3. By way of example, the panel according to the invention comprises an insulator 1 with a thickness of 22 mm made of MDF, and a barrier 2 with a thickness of 3 mm made of magnesia cement, a name used for a mixture of magnesium chloride and of magnesium oxide. Such a panel will withstand fire (at a standard flame) for more than 45 minutes in the fire MDF direction, and 30 minutes in the cement fire direction. Another example is to give a thickness of 4 mm to the barrier 2, and 21 mm to the insulator 1, or 6 mm to the barrier 2, and 19 mm to the insulator 1. The results are similar. The MDF material, also called "medium density fiber" is a material based on cellulose fibers, to offer structural panels with good flatness and good durability. This material is well suited for the insulator 1 according to the invention. The OSB material, consisting of glued wood particles, may also be suitable. For the present invention, it is important to have a fairly thick insulator 1 (for example MDF). Its role is first to resume the constraints of support, impact, holding of hinges, throughout the life of the door consists of this panel. In the context of the present invention, the term "structural" means the property of a material to be able to withstand such mechanical forces and to ensure the holding of a door, in a normal situation for the insulation, and in fire situation for the barrier. It is clear that highly insulating materials such as glass wool, wood wool or expanded perlite are not suitable in the context of the present invention, can not be considered as structural materials in this sense. The barrier 2 is much thinner, the mechanical forces to bear during a fire being much lower, essentially because the door remains in the closed position. During a fire, or fire test, fire MDF, the MDF burns little by little. If he is alone, he soon reaches a state where he no longer stands, and collapses. Barrier 2 holds it in place while it is burning, allowing it to perform its role of insulation and fire resistance for much longer. The barrier 2 also ensures the smoke-tightness that the insulation 1 in MDF no longer provides. MDF protects the fire barrier 2, the longer it stays in place and does not collapse. Surprisingly, the door attachment hinges, attached to the MDF, also take longer, probably because the MDF parts holding the hinges are also held by the barrier 2.

For comparison, a single 22mm MDF board does not fit a 15-minute standard fire test. It needs a minimum thickness of 25mm, and to hold 30 minutes, it takes 40mm. This illustrates the surprising contribution of the barrier 2, even of a thickness of only 3 mm, especially when the barrier 2 is protected from fire by the insulator 1.

When fire tested with fire barrier 2, barrier 2 is not protected by firewood, and deteriorates fairly rapidly, leaving the MDF alone to resist as long as it can. Barrier 2 then acts as a retarder for MDF, which improves performance over MDF alone, but to a lesser extent. To obtain panels holding 60 minutes to the standardized test in a direction of fire, one can for example have an insulator 1 of 25mm, and a barrier 2 of 5 4mm, or an insulator 1 of 22mm, and a barrier 2 of 6mm. To obtain according to the invention good fire resistance in both directions of fire, it is proposed a structure of barrier type 2 / insulator 1 / barrier 2. In each direction of fire, the succession of a barrier 2 is thus obtained. first, which serves as a retarder, then a fairly thick insulator 1, for example MDF followed by a barrier 2 which holds it in place for the duration of a fire test or fire, while by being protected from fire by the insulator 1. By way of example, the panel according to the invention comprises an insulator 1 with a thickness of 19 mm made of MDF, and two barriers 2 with a thickness of 3 mm made of magnesia cement. . Such a panel is fire resistant (at a standard flame) for more than 45 minutes in both directions of fire. We can also pass the thickness of the barriers 2 to 4 or 6mm, and reduce the insulation 1 to 16 or 12mm, without significantly changing the results. Nevertheless, a large thickness must be left to the insulator 1, for example at least twice the thickness of each of the barriers 2, in order to take advantage of the combined effect of the protection formed by the insulator 1, even partially consumed for the barrier 2, and the maintenance by the barrier 2 of this insulator 1 partially consumed. Below such thicknesses, the barriers 2 are no longer protected, and offer only their own fire resistance. In addition, the mechanical stresses to which the door must withstand in normal use (held by the hinges in the open position and during opening and closing, impact by slamming the door, or an object or a person) are much more important than the mechanical stresses it must withstand during a fire, essentially because the door is necessarily in a closed position. For this reason also, the insulation must be much thicker than the barriers. To obtain panels holding at 60 minutes in the standardized test in both directions of fire, it is possible, for example, to have an insulator 1 made of MDF of 22 mm, and two barriers 2 of 4 mm, or else an insulator 1 made of MDF of 19 mm. and two barriers 2 of 6mm. One can also add two siding on either side of the barriers 2, to form a symmetrical sandwich with five layers, the insulator 1 is in the center. Although the invention has been described in connection with particular structures, it is in no way limited and many variations can be made.

The combinations of the different embodiments described above are not outside the scope of the invention. The reference signs inserted after the technical features mentioned in the claims are only intended to facilitate the understanding of the latter and in no way limit its scope.

Claims (9)

REVENDICATIONS1. Multilayer acoustic and / or thermal insulation panel, usable in particular for the production of doors integrated in fire door blocks or facades of fire-fighting technical ducts or for the realization of fire inspection hatches, said panel being characterized in that it consists of at least three layers assembled by means of a binder, preferably by bonding, an insulator (1) made of an insulating material, said insulating material being also structural so as to withstand the mechanical stresses undergone by the panel during its usual use, surrounded by two barriers (2) in a non-combustible material, said non-combustible material being also structural, so that the barrier (2) away from the fire supports the weight of the panel during a fire from the side said insulator (1) for a predetermined time. 2. Panel according to the preceding claim, wherein said insulator (1) has a thickness at least twice that of said barrier (2), preferably at least 12mm. 3. Panel according to one of the preceding claims, wherein said insulator (1) is a material based on wood or cellulose, preferably an MDF. 4. Panel according to one of the preceding claims, wherein said barrier (2) has a thickness of less than 6mm. 5. Panel according to one of the preceding claims, wherein said incombustible material has a thermal conductivity less than 1 W / m.K. 6. Panel according to one of the preceding claims, wherein said insulating material has a thermal conductivity less than 0.5 W / m.K. and preferably less than 0.2 W / m.K. 7. Panel according to one of the preceding claims, wherein said incombustible material is a material based on cement, magnesia cement, plaster, gypsum, or silicate, all these materials being ordinary, or reinforced with fibers. 8. Panel according to claim 2, comprising exactly three layers, said barriers (2) surrounding said insulator (1). 9. Panel according to claim 2, comprising two facing layers on either side of the barriers (2), in particular cladding made of a material based on wood fibers.