GB2292337A

GB2292337A - Making fire-resisting slabs

Info

Publication number: GB2292337A
Application number: GB9416727A
Authority: GB
Inventors: Te-Fang Yu
Original assignee: YU TE FANG
Current assignee: YU TE FANG
Priority date: 1994-08-18
Filing date: 1994-08-18
Publication date: 1996-02-21
Anticipated expiration: 2014-08-18
Also published as: GB9416727D0; GB2292337B

Abstract

Fire resisting slabs, for use in construction or upholstery, are made by dipping two pieces of fabric in a coating material, which is prepared by firstly mixing powdered clay with urea, water and a stabilizing agent and secondly mixing the resultant mixture with an emulsion, sodium chloride and a pigment, bonding the coated fabrics together into a green slab by an intermediate bonding material, which is prepared by firstly mixing powdered clay with urea and water and secondly mixing the resultant mixture with a stabilizing agent and sodium chloride, squeezing and then drying the bonded fabrics thereby permitting the intermediate bonding material to form into a foamed structure and finally surface treating and trimming the product into a finished fire-resisting slab. <IMAGE>

Description

METHOD OF MAKING FIRE-RESISTING SLABS The present invention relates to a method of making fire-resisting slabs by mixing clay with urea, stabilizer, water, sodium chloride, etc.

Wooden boards and plywoods are intensively used in construction and upholstery.

Because these construction materials are inflammable, they must be coated with a layer of fire-resisting coating when installed. However, simply coating a wooden board or plywood with a layer of fire resisting coating cannot effectively isolate the fire. In some countries. wooden and plywood are prohibited from being used for making building partitions or ceilings.

The present invention has been accomplished under the circumstances in view. The method of the present invention is provided for making fire-resisting slabs suitable for use in construction and upholstery. The method comprises a step of dipping two pieces of fabrics in a coating material, which is prepared by mixing clay with urea, water, a stabilizing, an emulsion.

sodium chloride and a pigment, a step of bonding the coated fabrics with an intermediate bonding material, which is prepared by mixing mixing powdered clay with urea, water, sodium chloride and a stabilizing agent. The green slabs thus obtained are further dried and surface treated into finished products.

The present invention will now be described by way of example with reference to the annexed drawings, in which: Fig. 1 is a flow chart showing the process of preparing a coating material according to the present invention; Fig. 2 is a flow chart showing the process of preparing an intermediate bonding material according to the present invent ion; Fig. 3 is a flow chart showing the production of fire-resisting slabs according to the present invention: Fig. 4 is a plain view of a production line for making fire-resisting slabs according to the present invention; and Fig. 5 is a cross section of a fireresisting slab according td the present invention.

Referring to the various drawings attached herewith, a detailed description of the structural features of " METHOD OF MAKING FIRE RESISTING SLABS " of the present invention is as follows: A fire-resisting slab made according to the present invention is generally comprised of two opposite outer layers and an intermediate layer bonded between the outer layers (see Figure 5).

The outer layers are made by dipping fabrics in a coating material. The intermediate layer is made of an intermediate bonding material.

Figure 1 illustrates the process of preparing the coating material for coating the fabrics. The process includes the steps of: i) grinding well-dried clay into powder and then screening solid particles from the powdered clay thus obtained; ii) mixing the powdered clay (10-60t) with urea (20-40), water (5-10' o) and a stabilizing agent (1-) then mixing the mixture well, and then mixing the mixture thus obtained with an emulsion.

sodium chloride (10-15) and a pigment (5-10t) and mixing them well; iii) delivering the mixture thus obtained from step ii) to a storage trough and adding a bubble eliminating agent to the mixture while mixing; and iv) delivering the well-mixed material, namely the coating material to the material troughs 11 and 12 (see Figure 4).

Figure 2 illustrates the process of preparing the intermediate bonding material for making the intermediate layer. The process includes the steps of: i) grinding well-dried clay into powder and then screening solid particles from the powdered clay thus obtained; ii) mixing the powdered clay (0-;0) with urea (20-35%) and water (D-10 /o) then mixing the mixture well, and then mixing the mixture thus obtained with sodium chloride (10-15%) and a stabilizing agent (1-5); iii) delivering the mixture thus obtained from step ii) namely, the intermediate bonding material to the dispensing trough 21.

Referring to Figures 3 and 4, the production process of the fire-resisting slabs includes the steps of: i) placing two fabrics 1 and 10 on the two opposite input ports of the machine table (the width of the fabrics is set according to the width of the fire-resisting slabs to be made plus edges for further trimming); ii) sending the fabrics l and 10 to the material troughs 11 and 12 for coating with the coating material prepared according to the aforesaid coating material preparation process; iii) sending the coated fabrics thus obtained through the gap between rollers 13 and 14 permitting the coated fabrics to be squeezed into a uniform thickness; iv) sending the coated fabrics thus obtained from the step iii) to a first drying tank 17 by chain conveyers 15 and 16 permitting the coated fabrics to be dried;; v) sending the coated fabrics through impression rollers 150 and 160 and then delivering them to a second drying tank 18 by chain conveyers 15 and 19. permitting the coated fabrics to be dried to 90-100tt dryness; vi) applying the intermediate bonding material to the top surface of the coated fabric 10 by a roller (not shown) being disposed at the bottom output port of a material trough 21 and applying the intermediate bonding material to the bottom surface of the coated fabric 1 by a spry gun 22, then sending the well coated fabric 10 to a third drying tank 24 by a chain conveyer 23 for drying the coating to 40-60t dryness. and sending the coated fabrics 1 and 10 through rollers 25 permitting them to be bonded together; ; vii) squeezing the bonded fabrics 1 and 10 into a green slab through pitch-fixed rollers 26, then sending the green slab thus obtained through drying machines 27, 28 and 29 to let the intermediate layer (the intermediate bonding material) of the green slab to be formed into a foamed structure; viii) surface treating the green slab through a glazing or painting process or covering the green slab with a veneer or plastic cover sheet; and ix) trimming the surface treated slab into the desired size.

A fire-resisting slab made according to the aforesaid procedure provides a satisfactory sound-proof effect. It can be used as a floor tile, partition board, ceiling board, etc.

Claims

Claims:

1. A fire-resisting slab making method comprising the steps of: I) preparing a coating material by: i) grinding well-dried clay into powder and then screening solid particles from the powdered clay thus obtained; ii) mixing the powdered clay with urea, water and a stabilizing then mixing the mixture well. and then mixing the mixture thus obtained with an emulsion, sodium chloride and a pigment and mixing them well; and iii) delivering the mixture thus obtained from step ii) to a storage trough and adding a bubble eliminating agent to the mixture while mixing.

II) preparing an intermediate bonding material by: i) grinding well-dried clay into powder and then screening solid particles from the powdered clay thus obtained; and ii) mixing the powdered clay with urea and water then mixing the mixture well, and then mixing the mixture thus obtained with sodium chloride and a stabilizing agent.

III) dipping two pieces of fabrics in the coating material obtained from step I); IV) squeezing the coated fabrics into a predetermined thickness: V) drying the coated fabrics to 50-80 < dryness: VI) bonding the dried. coated fabrics by the intermediate bonding material obtained from step II) permitting the intermediate bonding material and the coated fabrics to be bonded into a green slab: VII) squeezing the green slab thus obtained from step VI) into a uniform thickness and then drying it, permitting the intermediate bonding material to form into a foamed structure under a predetermined pressure; VIII) surface treating and trimming the green slab thus obtained from step VIII) into a finished fire-resisting slab.

2. A method of making fire-resisting slabs as hereinbefore described with reference to and as illustrated in Figures 1.2,3,4, and 5 of the accompanying drawings.