GB2535664A

GB2535664A - Fireproof container

Info

Publication number: GB2535664A
Application number: GB1607299.3A
Authority: GB
Inventors: Atkins Clive
Original assignee: FIRE PROT COATINGS Ltd
Current assignee: FIRE PROT COATINGS Ltd
Priority date: 2014-01-20
Filing date: 2014-01-20
Publication date: 2016-08-24
Anticipated expiration: 2034-01-20
Also published as: GB2523303B; GB201400913D0; GB2523303A; GB2535664B

Abstract

This invention relates to a fire proof or fire resistant container typically used for the protection of control boxes, actuators and other electrical or mechanical systems in the event of a fire. The container 10 consists of a base portion 9 and side walls 2a-d. A lid portion (30, figure 2) is also provided. The walls of the container comprise a plurality of layers, including an outer insulating layer 1 formed from a first synthetic fibre material layer, an intermediate layer 5 of fire resistant material and an inner layer 8 consisting of regions of a second synthetic fibre material and regions of an intumescent material. The synthetic fibre may be manufactured from a polymer such as a polyamide or a polysilic acid, and the fire resistant material may be a plastic such as glass reinforced plastic. The container may further comprise ports 17 or openings through which cables may be received. Each port may comprise a seal and may extend through one or more walls of the container, preferably through at least one of the portions of intumescent material 7a-b.

Description

Fireproof Container

Field

[0001] The invention relates to a fireproof container. In particular, the invention relates to a multi-walled fireproof container.

Background

[0002] During a fire, particularly in large buildings such as airports or shopping malls, there are typically a number of safety devices in place to localise and minimise the damage caused by fire. Many of these devices are managed by central control units which coordinate sprinkler systems, fire dampers, louvres and other fire safety devices when a fire is detected. However, electrical or mechanical components within control boxes, actuators or similar devices arc themselves vulnerable to fire. As such, it is critical that such systems are protected from fire long enough to bring a fire under control or necessitate the escape of individuals trapped within the building.

[0003] Various devices have been used to protect such systems from fire. Typically, these systems involve fire retardant casings containing intumescent materials, such as foams, which are used as a protective blanket to shield various systems from the heat and flames of a fire.

[0004] In addition to their fire-retardant properties, any device used to shield control systems from fires must also be lightweight and easy to enclose to a range of different sized control boxes as many of these systems are wall mounted.

[0005] A variety of technologies are known in the art which have been used to deal with this problem. These include the so-called "thermal boxes", for example those sold by Fire Protection Coatings Limited. Such devices rely heavily on the use of intumescent paints and intumescent materials which expand on heating and give off water in order to maintain the internal temperature of the box close to the boiling point of water. However, there are no devices that can provide effective protection to control systems and the like for a period of up to two hours. For instance, by maintaining an internal temperature of less than 100°C when exposed to a fire of 300°C for two hours and also maintaining an internal temperature of less than 100°C when exposed to a fire 400°C for thirty minutes.

[0006] The invention is intended to overcome or ameliorate some or all of the above problems.

Summary

[0007] There is provided in a first aspect of the invention, a fireproof container comprising one or more walls, wherein the walls comprise a plurality of layers including: a first outer layer of a first synthetic fiber insulating material; a second inner layer adjacent the first layer, the second layer comprising one or more regions of a second synthetic fibre insulating material and one or more regions of intumescent material; and a third layer, positioned between the first and second layers, comprising a fire resistant material.

[0008] It has surprisingly been found by the inventors that incorporating a synthetic fiber insulating material into the wall of a container as an outer layer leads to a significant improvement in heat resistant properties compared to existing systems.

Containers making use of this construction have been found by the inventors to maintain an internal temperature of 100°C or less when the container is exposed to a fire of 300°C for at least two hours. Many existing fireproof boxes, fail to provide this duration of thermal protection, and where it has been achieved, this is only using complex and expensive designs. Further, where fireproof containers use synthetic fiber insulating materials, this is present as an internal insulating material, and not as a "front line" fire protection material. Therefore, the container differs from established systems as the synthetic fiber insulating material is on the outside of the container, fulfilling both a fire barrier and heat insulation function.

[0009] The walls of the fireproof box may contain more than three layers and additional layers may be interspersed between the first, seconds and third layers to improve the insulating properties of the device. However, it is typically the case that the first layer and third layer of the fire proof container are directly adjacent one another. It is also often the case that the second layer and third layer are directly adjacent one another.

[0010] As used herein the term "directly adjacent" is intended to mean that the first and second (or other) layers are positioned next to one another, without an intentional gap, space or interleaving layer between. The layers may be joined to one another using methods such as by gluing, mechanical retention (such as tacking, stapling, etc.), lamination, combinations thereof, or other means, but this is not essential in order for the two layers to be "directly adjacent" as defined herein. Where the layers are joined to one another this can help to reduce movement of the layers relative to one another which is desirable as this could reduce the effectiveness of the container.

However, in many constructions of the container such joining will not be required.

[0011] The term 'walls' as used herein is intended to refer to each of the sides of the container when assembled not just those sides being substantially vertical. For instance, in a container of "box" (cuboid) construction, the bottom, four vertical sides and top of the "box" are each intended to be interpreted as 'walls' of the container, the walls are therefore any external face of the container, regardless of the overall shape of the container.

[0012] The fireproof container is intended for use with a range of control boxes and other devices requiring protection from fire. As many of these devices are wall mounted, it is desirable to minimise the weight of the fireproof container in order to assist with fixing of the container to a wall mounted device.

[0013] Usually, the second layer comprises two regions of synthetic fibre insulating material and two regions of intumescent material. Each of the regions of synthetic fibre insulating material may he positioned on opposite sides of the container to one another. Further, each of the regions of intumescent material may also be positioned on opposite sides of the container to one another. Typically, each of the regions of synthetic fiber insulating material are positioned on opposite sides of the container to one another.

[0014] The synthetic fiber insulating material typically comprise one or more polymers and the polymers typically include one or more polyamines.

[0015] Often the polyamide is an aromatic polyamide and may be selected from: polypara-phenylene terephlthalamide, poly-meta-phenylene isophthalamide or combinations thereof. Typically, the polymer is poly-meta-phenylene isophthalamide.

[0016] The synthetic fiber insulating material typically comprises a polysilicic acid which may comprise 85-99 wt% SiO2 and 1-10 wt% A1203.

[0017] In one example, the synthetic fiber insulating material comprises a polyamide and a polysilicic acid as described herein. The inventors have found that by combining these materials together, it is possible to make a material which is both lightweight and demonstrates excellent insulating properties. Usually the ratio of polyamide to polysilicic acid is in the range of 5:1 and 1:5. However, it may be the case that the ratio of polyamide to polysilicic acid is in the range of 1:1 and 1:4 and it may be the case that the ratio is 2:5 and 2:7.

[0018] Further, it is typically the case that the synthetic fiber insulating material consists essentially of 25% poly-meta-phenylene isophthalamide and 75% polysilicic acid comprises 85-99 wt% SiO2 and 1-10 wt% A1203. The synthetic fiber insulating material used in the first layer of the container may be FabBloc 45A Insulating Fabric. The synthetic fiber insulating material used in the second layer of the container may be FabBloc Plain Insulating Fabric. The difference between FabBloc 45A and FabBloc plain is that FabBloc 45A includes a fire resistant coating of chemical coating Fabshield LP1205 (RTM).

[0019] By combining these two insulating materials together (poly-meta-phenylene isophthalamide and polysilicic acid), this provides an extremely light weight and efficient insulation layer. This technology is conventionally used in the insulation of aircraft fuselages to retain heat. When applied to the fire proof containers, this allows for containers to be made that are not only light weight but that can also provide enhanced fire protection.

[0020] Alternatively, the synthetic fiber insulating material may comprise 90% 100%o poly-meta-phenylene isophthalamide. Further, the synthetic fiber insulating material may be a needlefelt, and typically a non-woven, material. The synthetic fiber insulating material may he a weaved (or scrimped) material as well as a felt type material. The synthetic fiber insulating material usually also comprises a finish which can be tailored to specific applications as would be well appreciated by a skilled artisan.

[0021] The inventors have found that if the synthetic fiber insulation material is used as a second layer to lag the portions of the container having high thermal conductivity, this reduces heat transfer to the chamber and provides a substantial increase in effectiveness. Typically, this enables the internal temperature of the container to remain at 100°C or less whilst exposed to an external temperature of 300°C for a duration of two hours. Alternatively, the synthetic fiber material may be used to lag at least a portion of the contents positioned within the chamber of the container.

[0022] The intumescent material used in the invention is typically an intumescent foam and it is often the case that the intumescent material comprises intumescent graphite. Such materials are useful in the fire proof container as they expand when exposed to heat. Typically, these materials are positioned about regions of the containers were gaps or ports are present to seal any air gaps in the event of a fire.

[0023] The third layer of the container is typically made from a rigid material. The inventors have found that existing containers can be outfitted with layers of material as described herein to repurpose existing containers for use as fire proof containers. The third layer may therefore serve as a scaffolding about which the various layers described herein can be positioned. As such, it is advantageous to use rigid materials.

[0024] Often, the third layer will be manufactured from a fire resistant plastics material and the third layer may be made from glass reinforced plastic (GRP).

[0025] Typically, the walls of the fireproof container have a thickness in the range of 10mm to 50mm and may be in the range of 20mm to 40mm. It is often the case that the walls have a thickness in the range of 10mm to 50mm.

[0026] It is sometimes the case that the fireproof container further comprises a fourth outermost layer. The term "outermost" is intended to mean that the fourth layer is the layer on the outside of the container which is exposed to the elements or fire (in the event of a fire). It is typically the case that the fourth layer is directly adjacent the first layer, however it is possible that there may be one or more layers between the first and fourth layers. For example layers of adhesives or additional insulating or intumescent material may be sandwiched between these layers in order to alter the thermal properties of the container.

[0027] This fourth layer can be used to provide structure to the container and/or can including indications and markings. Examples of such indications or markings may include instructions for operation of the control box and/or the container, warnings notices or fire safety information.

[0028] The fourth layer may be a fire resistant coating which is applied to the first layer of the container. This may include fire retardant chemicals and/or agents which modify the physical and thermal properties of the insulating foam material. It is typically the case that the fourth layer is a coating material selected from Fabshield LP1205 (RTM). This is advantageous as the containers undergo wear and tear throughout the course of their lifetime. Multiple openings, closings and remountings can damage the outer skin of the container. It is therefore important that outer first layer of synthetic fiber insulating material does not become significantly damaged in normal use as otherwise it will not perform correctly in the event of a fire.

[0029] Alternatively, the fourth layer may a casing. The casing may be fabricated from a variety of materials that show good fire resistant. However, typically, the casing is made from fire resistant plastic which may be glass reinforced plastic.

[0030] The skilled person would understand that the container could also include both types of fourth layer described above. As such, the container may include a coating layer may be applied to the insulating material and this in tern may be located within a casing as described herein.

[0031] Control boxes and other electric devices typically include cables which communicate with a range of devices within a building. Therefore, the container may be equipped with one or more ports for receiving cables. Often, these ports will comprise a seal in order to prevent flames, hot air or smoke from entering the container via the ports. If a port seal is breached, the ability of the container to keep the contents at less than 100°C is reduced. The seal may be made from an elastic material, typically a rubberised or neoprene material which closes around the perimeter of cables and forms a tight seal together with the container. Alternatively or in addition to this, the ports may extend through the wall of the container and through the at least one region of intumescent material. Accordingly, when the intumescent material becomes hot, it will expand and seal any gaps permitting air, flames or smoke into the container.

[0032] The fireproof container may comprise a base portion and one or more walls extending upwards relative to the base. The container is, in one example, intended to be fitted with wall mounted control units and other wall mounted electronic or mechanical devices. Therefore, a base portion is often provided to which control units and the like can be secured to. These ensures that when positioned on a wall, an air gap is maintained between the inner surface of the container and the control unit or the like. The base portion may also be used as a platform for fastening the container, with or with a contents, to wall or other surface. The base may be fabricated from a different material to the walls. This face is typically adapted to abut against the wall on which the control unit sits. Accordingly, the external face of the base is not exposed to fire when positioned on a wall. It may he that the base is manufactured from wood which may be treated with one or more fire resistant chemicals.

[0033] It is typically the case that the container further comprises a lid portion which is engageable with the one or more walls of the container to form a scaled chamber. Although structures without lids are envisaged, it is useful to have a lid portion which can be removed and attached to the walls of the container in order to create an enclosed space or chamber and which also allows easy access to said space. This enables the lid to he removed when maintenance or operation of the electrical and/or mechanical device housed within the container is required and replaced once work is complete. Often, the lid portion is an integral part of the container and typically, the lid portion is hinged. In addition, when in use, the lid forms may form one of the walls of container.

[0034] In one embodiment, the lid comprises a fabric hood attached to the underside of the lid which, when the lid is positioned on the container, abuts against the contents of the container. Where the contents of the container is a control box, the fabric hood may contact a surface of the control box in order to from an effective seal between the lid and the container. The fabric hood is typically made from a synthetic fiber insulating material as described herein.

[0035] There is no particular restriction on the shape of the container, but it is typically the case that the container is substantially cuboid or box-shaped. This shape co-operates with most control units and other electrical or mechanical systems and is also straight forward to manufacture and retrofit to existing containers.

[0036] The contents of the container may comprise a control box and it is usually the case that the control box is encased in a casing material having a melting point of greater than 95°C. The container is therefore generally adapted to maintain a temperature of 100°C or less. This is because, if the temperature is high enough to melt the casing of the control box to he protected, then molten material (usually a plastics material) can seep into the control box and disrupt the electronic and mechanical systems continued within. Further, many electronics are themselves sensitive to heat and can melt or become damaged even if a heat resistant plastic is employed that resists becoming molten at high temperatures. However, in view of the risks associated with using lower melting point casing materials, such as plastics materials, typically it is the case that the casing material is a metal or metal alloy. For example, the casing material may comprise aluminium.

[0037] As mentioned above. the container is often adapted to maintain an internal temperature of 100°C or less when the container is exposed to a fire of 300°C for at least two hours. Further, it is typically the case that the container is adapted to maintain an internal temperature of 100°C or less when the container is exposed to a fire of 400°C for at least thirty minutes.

[0038] In a second aspect of the invention, there is provided a use of a fireproof container according to the first aspect of the invention, for protecting a contents of the container from a fire. Typically, the contents is an electronic or mechanical device.

[0039] In another aspect of the invention, the fireproof container can be made by attaching fireproof "walls" to the faces of existing boxes. Panels or sheets of material having the layered structure outlined above can he attached to the external faces of a container in order to clad the existing container in a fireproof skin. This allows existing systems to be retrofitting to provide thermal protection. Unless otherwise stated each of the integers described may be used in combination with any other integer as would be understood by the person skilled in the art. Further, although all aspects of the invention preferably "comprise" the features described in relation to that aspect, it is specifically envisaged that they may "consist" or "consist essentially" of those features outlined in the claims. In addition, all terms, unless specifically defined herein, are intended to be given their commonly understood meaning in the art.

[0040] Further, in the discussion of the invention, unless stated to the contrary, the disclosure of alternative values for the upper or lower limit of the pe nutted range of a parameter, is to be construed as an implied statement that each intermediate value of said parameter, lying between the smaller and greater of the alternatives, is itself also disclosed as a possible value for the parameter.

[0041] In addition, unless otherwise stated, all numerical values appearing in this application are to he understood as being modified by the term about".

[0042] The invention also provides: 1. A fireproof container comprising one or more walls, wherein the walls comprise a plurality of layers including: a first outer layer of a first synthetic fibre insulating material; a second inner layer adjacent the firs( layer, the second layer comprising one or more regions of a second synthetic fibre insulating material and one or more regions of intumescent material; and a third layer, positioned between the first and second layers, comprising a fire resistant material.

2. A fireproof container according to item 1, wherein the first layer and third layer are directly adjacent one another.

3. A fireproof container according to item 1 or item 2, wherein the second layer and third layer are directly adjacent one another.

4. A fireproof container according to any of items 1 to 3, wherein the second layer comprises two regions of the second synthetic fibre insulating material and two regions of insulating foam material.

5. A fireproof container according to item 4, wherein each of the regions of the second synthetic fibre insulating material are positioned on opposite sides of the container to one another.

6. A fireproof container according to item 4 or item 5, wherein each of the regions of intumescent material are positioned on opposite sides of the container to one another.

7. A fireproof container according to any preceding item, wherein the first and second synthetic fibre insulating material comprises one or more polymers.

8. A fireproof container according to any preceding item, wherein the first. and second synthetic fibre insulating material comprise one or more polyamincs. 20 9. A fireproof container according to item 8, wherein the polyamide is an aromatic polyamide.

10. A fireproof container according to item 9, wherein the polyamide is selected from: poly-para-phenylene terephlthalamide, poly-meta-phenylene isophthalamide or combinations thereof.

11. A fireproof container according to item 10, wherein the polyamide is poly-rnetct-phenylene isophthalamide.

12. A fireproof container according to item 7, wherein the synthetic fibre insulating material comprises a polysilicic acid.

13. A fireproof container according to item 12, wherein the polysilicic acid comprises 85-99 wt% SiO2 and 1-10 wt% A1203.

14. A fireproof container according to any of items 1 to 7, wherein the first and second synthetic fibre insulating material comprise a polyamide and a polysilicic acid 15. A fireproof container according to item 14, wherein the ratio of polyamide to polysilicic acid is in the range of 5:1 and 1:5.

16. A fireproof container according to item 15, wherein the ratio of polyamide to polysilicic acid is in the range of 1:1 and 1:4.

17. A fireproof container according to item 16, wherein the first and second synthetic fibre insulating material consist essentially of 25% poly-meta-phenylene isophthalamide and 75% polysilicic acid comprising 85-99 wt% SiO2 and 1-10 wt% A1203.

18. A fireproof container according to item 16, wherein the first synthetic fibre insulating material comprises FabBloc 45A.

19. A fireproof container according to item 16, wherein the second synthetic fibre insulating material comprises FabBloc Plain.

20. A fireproof container according to any preceding item, wherein the intumescent material is a foam intumescent.

21. A fireproof container according to item 20, wherein the foam intumescent comprises intumescent graphite.

22. A fireproof container according to any preceding item, wherein the third layer is a rigid material.

23. A fireproof container according to item 22, wherein the third layer is a fire resistant plastic.

24. A fireproof container according to item 23, wherein the fire resistant plastic is a glass reinforced plastic.

25. A fireproof container according to any preceding item, wherein the walls have a thickness in the range of 10mm to 50mm.

26. A fireproof container according to any preceding item, wherein the container further comprises a fourth outermost layer.

27. A fireproof container according to item 26, wherein the fourth layer is directly adjacent the first layer.

28. A fireproof container according to item 26 or item 27, wherein the fourth layer is a fire resistant coating.

29. A fireproof container according to any preceding item, wherein the container further comprises one or more ports for receiving cables.

30. A fireproof container according to item 29, wherein the ports comprise a seal.

31. A fireproof container according to item 29 or 30, wherein the ports extend through the walls of the container and through at least one of the portions of intumescent material.

32. A fireproof container according to any preceding item, wherein the container comprises a base portion and one or more upstanding walls extending upwards relative to the base.

33. A fireproof container according to any preceding item, wherein the container further comprises a lid portion engageable with the one or more walls of the container to form a sealed chamber.

34. A fireproof container according to item 33, wherein the lid portion is an integral part of the container.

35. A fireproof container according to item 33 or item 34, wherein the lid portion is hinged.

36. A fireproof container according to any preceding item, wherein the container is substantially cuhoid or box-shaped.

37. A fireproof container according to any of items 33 to 36, where in use, the lid forms one of the walls of container.

38. A fireproof container according to any preceding item, wherein the contents of the container comprises a control box.

39. A fireproof container according to item 38, wherein the control box is encased in a casing material having a melting point of greater than 95°C.

40. A fireproof container according to item 39, wherein the casing material is a metal or metal alloy.

41. A fireproof container according to item 40, wherein the casing material comprises aluminium.

42. A fireproof container according to any preceding item, wherein the container maintains an internal temperature of 100°C or less when the container is exposed to a fire of 300°C for at least two hours.

43. A fireproof container according to any preceding item, wherein the container maintains an internal temperature of 100°C or less when the container is exposed to a fire of 400°C for at least thirty minutes.

44. Use of a fireproof container according to any preceding item, for protecting a contents of the container from a fire.

45. Use of a fireproof container according to item 44, wherein the contents is an electronic or mechanical device.

Brief Description of the Drawings

[0043] The invention will now be described with reference to the following figures: [0044] Figure 1 shows a plan view of the container of the invention; [0045] Figure 2 shows a plan view of the container of figure I without the lid; and [0046] Figure 3 shows a cross sectional view through the container bisecting sides 2c 10 and 2a [0047] Figure 4 shows a cross sectional view through the container bisecting sides 2h and 2d.

Detailed Description

[0048] The container 10 is shown in figure 1, comprising a rounded rectangular base portion 9 and four walls 2a-d, the walls 2a-d located along the perimeter of the base portion 9 and extending upwards in a substantially perpendicular orientation relative to the base portion 9. The base portion 9 is made from wood and the upstanding walls 2a-d consist of three discrete layers encased within a casing 19. The walls 2a-d have three layers -an outer layer I, a middle layer 3 and an inner layer 8 consisting of four sections 5a, 5b, 7a, 7b which together define a chamber 11 suitable for receiving a contents. The outer layer 1 is made from a synthetic fiber insulating material consisting essentially of 25% poly-meta-phenylene isophthalamide and 75% polysilicic acid comprises 85-99 wt% SiO2 and 1-10 wt% A1203. This material is commonly known as FABBLOC Insulating Fabric (RTM). The middle layer 3 is a box made from glass reinforced plastics.

[0049] The inner layer 8 is made up of 4 sections -a north, a south, an east, and a west section 5a, 56, 7a, 7b. The north and south sections 5a, 5b are made from a mixture of 25% poly-nzeta-phenylene isophthalamidc and 75% polysilicic acid comprising 85-99 wt% SiO2 and 1-10 wt% A1201 and are positioned along the full length of the north wall 2c and the south wall 2a and extend partially along the length of east and west walls 2d, 2h. Reference to north, south, cast and west in the context of the description is intended to describe the relative positions of components of the container relative to one another. This is not intended to refer to the position of any features of the container when in use. mounted on a wall or otherwise.

[0050] The east and west sections 7a and 7b are made from an inintumescent graphite material and are positioned in the centre of the east and west walls 2d, 2b respectively and extend part way along the length of the east and west walls 2d, 2b respectively, abutting against the north and south sections 5a, 5b to form a continuous inner layer 8 around the internal perimeter of the walls 2a-d.

[0051] The container 10 also includes an outer casing 19 which is also made from glass reinforced plastic (GRP) which is attached directly to the outer layer 1 of walls 15 2a-d.

[0052] The east wall 2d includes a series of hinge barrels 13 mounted at the top of the east wall 2d, the hinge barrels 13 having a bore 15 adapted to communicate with a corresponding pin portion on the lid of the container 10 (not shown in figure 1).

[0053] The container 10 includes several ports 17 which are located in the east and west walls 2d, 2b. These ports 17 include an elastic, rubberised or neoprene seal (not shown) which forms a close fit about a cable inserted through one of the ports 17 and into the chamber 11 of the container 10. The seals are also adapted to remain dosed in the absence of a cable passing through one of the ports 17 and, if a cable is removed, the seals contract under their own elastic potential.

[0054] The outer layer 1 and middle layer 3 are shown as being a single piece of material wrapped around the internal perimeter of the container 10. However, each layer of the container 10 may be made from multiple sheets or pieces of material arranged around the internal perimeter of the container 10 or may be a single piece of one or more materials.

[0055] The walls 2a-d have a thickness of approximately 50mm at their narrowest point and 60mm at their widest point. The north and south sections 5a, 5b of the inner layer have a thickness of approximately 20mm and the east and west sections 7a, 7h of the inner layer have a thickness of approximately 30mm. The middle layer 3 has a thickness of approximately 20mm and the thickness of the outer layer 1 has a thickness of approximately 10mm The casing 19 has a thickness of approximately 1-2mm.

[0056] Figure 2 shows a lid 30 adapted to fit on top of and seal the container 10 (shown in figure 1). The lid 30 has a generally rounded rectangular shape defined by each of the four sides of the rectangle 32a-d. The lid 30 has a three layer structure similar to the walls 2a-d of the container shown in figure 1. The inner layer 33 is visible in figure 2 and it is to this layer that internal features of the lid 30 are affixed.

[0057] A middle layer (not visible) is made from a glass reinforced plastic. This is attached directly adjacent to the inner layer 30. Additionally, an outer layer (also not visible in figure 2) made from a synthetic fiber insulating material consisting essentially of 25% poly-tneta-phenylene isophthalamide and 75% polysilicic acid comprises 85-99 wt% Sift and 1-10 wt% A1203. This is attached directly adjacent to the middle layer to form a three layer structure forming a barrier similar to the walls 2a-d shown in figure 1.

[0058] The thickness of these three layers of the lid combined is approximately 50mm. The inner layer 33 has a thickness of approximately 20mm, the middle layer (not shown) has a thickness of approximately 20mm and the thickness of the outer layer (not shown) has a thickness of approximately 10mm. The casing 31 has a thickness of approximately 1-2mm.

[0059] The lid 30 also includes a casing or capping portion 31 made from glass reinforced plastic which provides some fire resistance and some structural support for the lid 30.

[0060] The underside of the lid 30 includes a number of features mounted to the inner layer 33. A rounded rectangular rim 35 is provided which is made from a rubberised or neoprene elastic material adapted to form an airtight seal when the lid 30 is closed on top of the container 10 shown in figure 1. This rim 35 extends around the perimeter of the underside of lid 30, slightly spaced from the edge. Within the perimeter defined by the rim 35, a plinth, fabric hood or mounting plate4l is provided, made from the FABBLOC Insulating Fabric (RTM) described above. This plinth, fabric hood or mounting plate 41 is mounted to the inner layer 33 of the lid 30 via one or more blocks of FABBLOC Insulating Fabric (RTM) 39a, 39h and or graphite intumescent material.

[0061] The lid is also provided with regions of intumescent material 43a, 43b mounted to the underside of the lid 30 on the inner layer 33 within the perimeter of the rim 35.

[0062] The lid 30 is connected to the container 10 by means of hinge portions 45 attached to the east side 32d of the lid 30. These hinge portions 45 have a bore or pin section 47 which communicates with the hinge barrels 13 on the container 10 to create a functioning hinge.

[0062] It should be appreciated that (he fireproof container of the invention is capable of being implemented in a variety of ways, only a few of which have been illustrated and described above.

Claims

Claims 1. A fireproof container comprising one or more walls, wherein the walls comprise a plurality of layers including: a first outer layer of a first synthetic fibre insulating material; a second inner layer adjacent the first layer, the second layer comprising one or more regions of a second synthetic fibre insulating material and one or more regions of intumescent material; and a third layer, positioned between the first and second layers, comprising a fire resistant material.
2. A fireproof container according to claim 1, wherein the first layer and third layer are directly adjacent one another.
3. A fireproof container according to claim 1 or claim 2, wherein the second layer and third layer are directly adjacent one another.
4. A fireproof container according to any of claims 1 to 3, wherein the second layer comprises two regions of the second synthetic fibre insulating material and two regions of insulating foam material.
5. A fireproof container according to claim 4, wherein each of the regions of the second synthetic fibre insulating material are positioned on opposite sides of the container to one another.
6. A fireproof container according to claim 4 or claim 5, wherein each of the regions of intumescent material are positioned on opposite sides of the container to one another.
7. A fireproof container according to any preceding claim, wherein the first and second synthetic fibre insulating material comprises one or more polymers.
8. A fireproof container according to any preceding claim, wherein the first and second synthetic fibre insulating material comprise one or more polyamines.
9. A fireproof container according to claim 8, wherein the polyamide is an aromatic polyamide.
10. A fireproof container according to claim 9, wherein the polyamide is selected from: poly-para-phenylene terephlthalamide, poly-meta-phenylene isophthalamide or combinations thereof
11. A fireproof container according to claim 10, wherein the polyamide is poly-meta-phenylene isophthalamide.
12. A fireproof container according to claim 7, wherein the synthetic fibre insulating material comprises a polysilicic acid.
13. A fireproof container according to claim 12, wherein the polysilicic acid comprises 85-99 wt% SiO2 and 1-10 wt% A1203.
14. A fireproof container according to any of claims 1 to 7, wherein the first and second synthetic fibre insulating material comprise a polyamide and a polysilicic acid
15. A fireproof container according to claim 14, wherein the ratio of polyamide to polysilicic acid is in the range of 5:1 and 1:5.
16. A fireproof container according to claim 15, wherein the ratio of polyamide to polysilicic acid is in the range of 1:1 and 1:4.
17. A fireproof container according to claim 16, wherein the first and second synthetic fibre insulating material consist essentially of 25% poly-meta-phenylene isophthalamide and 75% polysilicic acid comprising 85-99 wt% SiO2 and 1-10 wt% A1203.
18. A fireproof container according to claim 16, wherein the first synthetic fibre insulating material comprises FabBloc 45A.
19. A fireproof container according to claim 16, wherein the second synthetic fibre insulating material comprises FabBloc Plain.
20. A fireproof container according to any preceding claim, wherein the intumescent material is a foam intumescent.
21. A fireproof container according to claim 20, wherein the foam intumescent comprises intumescent graphite.
22. A fireproof container according to any preceding claim, wherein the third layer is a rigid material.
23. A fireproof container according to claim 22, wherein the third layer is a fire resistant plastic.
24. A fireproof container according to claim 23, wherein the fire resistant plastic is a glass reinforced plastic.
25. A fireproof container according to any preceding claim, wherein the walls have a thickness in the range of 10m tn to 50mm.
26. A fireproof container according to any preceding claim, wherein the container further comprises a fourth outermost layer.
27. A fireproof container according to claim 26, wherein the fourth layer is directly adjacent the first layer.
28. A fireproof container according to claim 26 or claim 27, wherein the fourth layer is a fire resistant coating.
29. A fireproof container according to any preceding claim, wherein the container further comprises one or more ports for receiving cables.
30. A fireproof container according to claim 29, wherein the ports comprise a seal.
31. A fireproof container according to claim 29 or 30, wherein the ports extend through the walls of the container and through at least one of the portions of intumescent material.
32. A fireproof container according to any preceding claim, wherein the container comprises a base portion and one or more upstanding walls extending upwards relative to the base.
33. A fireproof container according to any preceding claim, wherein the container further comprises a lid portion engageable with the one or more walls of the container to form a sealed chamber.
34. A fireproof container according to claim 33, wherein the lid portion is an integral part of the container.
35. A fireproof container according to claim 33 or claim 34, wherein the lid portion is hinged.
36. A fireproof container according to any preceding claim, wherein the container is substantially cuboid or box-shaped.
37. A fireproof container according to any of claims 33 to 36, where in use, the lid forms one of the walls of container.
38. A fireproof container according to any preceding claim, wherein the contents of the container comprises a control box.
39. A fireproof container according to claim 38, wherein the control box is encased in a casing material having a melting point of greater than 95°C
40. A fireproof container according to claim 39, wherein the casing material is a metal or metal alloy.
41. A fireproof container according to claim 40, wherein the casing material comprises aluminium.
42. A fireproof container according to any preceding claim, wherein the container maintains an internal temperature of 100°C or less when the container is exposed to a fire of 300°C for at least two hours.
43. A fireproof container according to any preceding claim, wherein the container maintains an internal temperature of 100°C or less when the container is exposed to a fire of 400°C for at least thirty minutes.
44. Use of a fireproof container according to any preceding claim for protecting a contents of the container from a fire.
45. Use of a fireproof container according to any of claims 44, wherein the contents is an electronic or mechanical device.
46. A fireproof container or use substantially as described herein with reference to theaccompanying description and drawings.