GB2196010A

GB2196010A - Production of intumescent fireproofing material mouldings

Info

Publication number: GB2196010A
Application number: GB08719097A
Authority: GB
Inventors: Mathias Eschbach
Original assignee: W Doellken and Co GmbH
Current assignee: W Doellken and Co GmbH
Priority date: 1986-08-16
Filing date: 1987-08-12
Publication date: 1988-04-20
Anticipated expiration: 2007-08-12
Also published as: GB2196010B; FR2602782A1; GB8719097D0; EP0256967B1; DE3784408D1; GB2196010C; GR3007217T3; ES2041701T3; ATE86272T1; EP0256967A2; FR2602782B1; EP0256967A3

Abstract

A mixture which can be moulded at a temperature below 140 DEG C for the production of heat-foamable mouldings, in particular for preventative flame proofing, which contains, in addition to, in particular, plasticised polyvinyl chloride, a preferably predominant amount of a polyalcohol, such as pentaerythritol, a polyamide compound, such as dicyandiamide, and a phosphate.

Description

SPECIFICATION Production of fireproofing material mouldings This invention relates to a process for the production of fireproofing mouldings, in which a free-flowing basic mix of fireproofing materials containing at least one resin and substances capable of inflating into a foam at a certain inflation temperature (together with additives) is worked up into a plastically mouldable mass, and the plastically mouldable mass is moulded with the aid of moulding tools.

In the context of the invention, a resin is any synthetic material suitable for use a fireproofing material, more particularly including synthetic resins in the strict sense (cf.

Rompps ChemieLexikon, 1973, p.1893) but also including equivalent materials. Particularly suitable materials include polyamide compounds such as dicyandiamide, urea, melamine or their condensation products with formaldehyde for example. "Free-flowing" signifies powdery, finely granulated or granulated (granular). The mouldings are used for fireproofing purposes, for example in joints and gaps or as wall components where they will inflate in the case of fire and display their fireproofing -action. Under normal environmental conditions, including direct exposure to solar radiation, the mouldings are intended to remain unaffected, but they must remain active in case of fire after the longest possible time interval.

In a known process of this type (EP 00 03 772), the basic mix consists of a thermally active phenolic resin, an ammonium salt, a carbohydrate or polyvalent alcohol, a thermally degradable nitrogen compound and a binder selected from the group of polymers dispersible in water, aqueous solutions and/or solvents. Working up into a plastically mouldable mass is carried out by adding water and/or an organic solvent and mixing until the mass can be poured or used like a putty. The moulding of this plastically mouldable mass requires the use of a spatula. Alternatively, the mass can be poured into a mould and allowed to harden in the mould or on a slab. The known process requires a very specialised basic mix. In many practical applications there is a demand for mouldings of special shapes, which cannot be produced, except with difficulty, by following the known process.The active life of the known mouldings is undesirably short.

The object of the invention is to treat the basic mix so that mouldings of outstandingly long active life can be produced without difficulty, in any required shape, by applying modern manufacturing techniques.

According to the present invention, the basic mix is blended with a free-flowing synthetic thermoplastic having a plasticising temperature below the inflation temperature, the basic/synthetic blend is worked up into a plastically mouldable mass by thermally plasticising the thermoplastic at a working temperature below the inflation temperature, and the mass is moulded in the course of its thermoplastic working, for example by extrusion or injection moulding.

In general, the basic/synthetic blend is worked up in an extruder, a mixer or a kneading machine, to form the plastically mouldable mass.

The invention is based on the inventive discovery that fireproofing masses can be prepared from the specified basic mix blended in synthetic thermoplastic. The resulting plastically mouldable mass can be moulded in the same way as synthetic thermoplastics. The surprising result is that mouldings produced in this way have a substantially prolonged active life. They do not lose their activity under normal environmental conditions, even after long periods. It is self-evident that the highest possible proportion of basic mix as defined in the invention is blended in the synthetic thermoplastic. The specific blending ratios can easily be found by trial and error.

It is within the scope of the invention to use a wide variety of sythetic thermoplastics, as defined more particularly in Rompps Chemie-Lexikon, 1973, pp.1896 to 1902. The list also includes synthetic rubbers. One proven embodiment of the invention is characterised in that the basic mix is blended with polyvinyl chloride. A preferred embodiment of the invention is characterised in that the basic-mix is first blended with powdered synthetic thermoplastic, a softener is then added and the whole is blended. The proportion of softener is adapted to the proportion of basic mix, and is adjusted so that the basic/synthetic blend can be worked up in the manner described at below the inflation temperature. By providing a relatively high proportion of softener, the synthetic thermoplastic can accept a relatively high proportion of basic mix.

It is also within the scope of the invention to use a wide variety of basic mix materials (cf. the citations in and appertaining to EP 00 03 772). In one proven procedure, use is made of a basic mix having as resin components one or more amino-plastics and/or a polyamide compound. However, in another proven procedure use is made of a basic mix having as resin components at least one phenol-formaldehyde resin. Another proposal of the invention is characterised in that the two last procedures are as it were combined, i.e., that use is made of a basic mix having as resin components a mixture of at least one aminoplastic and at least one phenol-formaldehyde resin.Very goods results in respect of active life and fireproofing performance are attained with a basic mix having the composition: 15 to 40 wt.% of a thermally active phenolic resin, optionally in the presence of an aldehyde source, 25 to 40 wt.% of an ammonium salt, 10 to 20 wt.% of a carbohydrate and/or a polyvalent alcohol, 15 to 40 wt.% of a thermally degradable organic nitrogen compound, the components together adding up to 100 wt.%. The basic mix may include a binder selected from the group of vinyl polymers dispersible in water, aqueous solutions and/or solvents and may also include an aminoplastic.

The basic mix can comprise up to 90 wt.% of the basic/synthetic blend. Mouldings of extremely long active life are produced by a procedure characterised in that the mouldings are enveloped during co-extrusion or injection moulding in a jacket consisting entirely of synthetic thermoplastic, opertionally with the usual filter. One outstandingly successful basic mix has the composition: a) 10 to 70 wt.% softened polyvinyl chloride with the usual softener content, and b) 30 to 90 wt.% of a mixture of ba) 25 to 60 wt.% polyvalent alcohol, bb) 1 to 45 wt.% polyamide compound, and bc) 5 to 30 wt.% ammonium phosphate, a) plus b) and ba) plus bb) plus bc) making up 100 wt.% in each case.

The invention also covers this basic mix.

Claims

1. A process for the production of fireproofing material mouldings, in which a freeflowing basic mix of fireproofing materials containing at least one resin and substances capable of inflating into a foam at a certain inflation temperature is worked up into a plastically mouldable mass with the aid of moulding tools, and wherein the basic mix is blended with a free-flowing synthetic thermoplastic having a plasticising temperature below the inflation temperature, the basic/synthetic blend is worked up into aplastically mouldable mass by thermally plasticising the thermoplastic at a working temperature below the inflation temperature, and the mass is moulded in the course of its thermoplastic working.

2. A process as in Claim 1, wherein the mass is by extrusion or injection moulding.

3. A process as in either of Claims 1 and 2, wherein the basic mix is blended with polyvinyl chloride.

4. A process as in any one of Claims 1 and 3, wherein the basic mix is first blended with free-flowing synthetic thermoplastic, a softener is added, and the blend is worked up into a plastically mouldable mass.

5. A process as in any one of Claims 1 to 4, wherein the basic mix has as resin components one or more aminopiastics and/or a polyamide compound.

6. A process as in Claim4, wherein the basic mix has as resin components at least one phenolformaldehyde resin.

7. A process as in any one of Claims 1 to 4, wherein the basic mix has as resin components a mixture of at least one aminoplastic and at least one phenol-formaldehyde resin.

8. A process as in Claim 6, wherein the basic mix has the composition: 15 to 40 wt.% of a thermally active phenolic resin, optionally in the presence of an aldehyde source, 25 to 40 wt.% of an ammonium salt, 10 to 20 wt.% of a carbohydrate and/or a polyvalent alcohol, 15 to 40 wt.% of a thermally degradable organic nitrogen compound, the components together adding up to 100 wt.%.

9. A process as in Claim 8, wherein the basic mix includes a binder selected from the group of vinyl polymers dispersible in water, aqueous solutions and/or solvents.

10. A process as in either of Claims 8 and 9, wherein the basic mix also includes an aminoplastic.

11. A process as in any one of Claims 1 to 10, wherein the mouldings are enveloped during co-extrusion or injection moulding in a jacket of synthetic thermoplastic.

12. A process as in any one of Claims 1 to 11 and substantially as hereinbefore described.

13. A basic mix for use in the process of any one of Claims 1 to 11 and substantaally as hereinbefore described.