GB2541074A - Fire resistant building material - Google Patents
Fire resistant building material Download PDFInfo
- Publication number
- GB2541074A GB2541074A GB1609389.0A GB201609389A GB2541074A GB 2541074 A GB2541074 A GB 2541074A GB 201609389 A GB201609389 A GB 201609389A GB 2541074 A GB2541074 A GB 2541074A
- Authority
- GB
- United Kingdom
- Prior art keywords
- fire resistant
- building material
- resistant building
- core
- graphite flakes
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/92—Protection against other undesired influences or dangers
- E04B1/94—Protection against other undesired influences or dangers against fire
- E04B1/941—Building elements specially adapted therefor
- E04B1/942—Building elements specially adapted therefor slab-shaped
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/92—Protection against other undesired influences or dangers
- E04B1/94—Protection against other undesired influences or dangers against fire
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/02—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board the layer being formed of fibres, chips, or particles, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/16—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer formed of particles, e.g. chips, powder or granules
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
- E04C2/16—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of fibres, chips, vegetable stems, or the like
-
- E—FIXED CONSTRUCTIONS
- E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
- E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
- E06B5/00—Doors, windows, or like closures for special purposes; Border constructions therefor
- E06B5/10—Doors, windows, or like closures for special purposes; Border constructions therefor for protection against air-raid or other war-like action; for other protective purposes
- E06B5/16—Fireproof doors or similar closures; Adaptations of fixed constructions therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
- B32B2260/025—Particulate layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/04—Impregnation, embedding, or binder material
- B32B2260/046—Synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
- B32B2264/06—Vegetal particles
- B32B2264/062—Cellulose particles, e.g. cotton
- B32B2264/067—Wood particles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
- B32B2264/10—Inorganic particles
- B32B2264/107—Ceramic
- B32B2264/108—Carbon, e.g. graphite particles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
- B32B2264/12—Mixture of at least two particles made of different materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/306—Resistant to heat
- B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2419/00—Buildings or parts thereof
-
- E—FIXED CONSTRUCTIONS
- E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
- E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
- E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
- E06B3/70—Door leaves
- E06B3/7015—Door leaves characterised by the filling between two external panels
- E06B2003/7042—Door leaves characterised by the filling between two external panels with a fire retardant layer
Abstract
The material 100 comprises a core 102 of expandable graphite flakes, and one or more covering layers 104, 106 on the core. The core may comprise furnish such as fibre, sawdust, shavings, flakes, or particles. The covering layers may have no expandable graphite flakes. The core and covering layer may be a wood such as fibreboard, MDF, particle board, chip board, strand board, or OSB. The core may comprise resin. Also claimed is a fire resistant door comprising the material and a fire resistant wall comprising the material. Also claimed is a method of manufacturing a fire resistant building material core comprising mixing expandable graphite flakes, furnish, and resin, and forming a board from the mix. Also claimed is a method of manufacturing a fire resistant building material comprising forming a core using the above method and applying one or more covering layers to the core.
Description
FIRE RESISTANT BUILDING MATERIAL
FIELD
This invention relates to a fire resistant building material.
BACKGROUND
Fire resistant doors or walls are generally designed to provide a specified period of time at withstanding a particular temperature of fire on one side. The materials used in such doors or walls can include chemically treated board, processed products such as oriented strand board (OSB) or medium-density fibreboard (MDF), or composite products such as fibreglass.
To increase the fire rating for a given material, the typical solution is to simply increase the material thickness. However this leads to doors that are thicker than standard door or wall fittings are designed for and may significantly increase the weight and/or cost of manufacturing. As a result there may be significant benefits to be made if the thickness of the fire resistance material can be decreased for a given fire rating.
Accordingly, the present invention may provide an improved fire resistant building material or provide the public with a useful choice.
SUMMARY
In general terms in a first aspect the invention provides a fire resistant building material comprising: a core of material incorporating a predetermined proportion of expandable graphite flake; and one or more covering layers on the core.
Preferably the predetermined proportion of expandable graphite flakes is less than 10% by weight.
Preferably the core further includes furnish.
Preferably the furnish is selected from one or more of the group comprising fibre, sawdust, shavings, flakes, particles.
Preferably the covering layers are substantially free of expandable graphite flakes.
Preferably the core and/or the covering layers are a wood based material.
Preferably the wood based material is selected from the group consisting of fibreboard, medium density fibreboard, particle board, chip board, strand board and oriented strand board.
Preferably the covering layers include a substantially smooth outer finish configured for painting, laminating and/or encapsulating.
Preferably the core material further includes resin.
In general terms in a further aspect the invention provides a fire resistant combustible door comprising a fire resistant building material previously described.
In general terms in a further aspect the invention provides a fire resistant wall comprising a fire resistant building material previously described.
In general terms in a further aspect the invention provides a method of manufacturing a fire resistant building material core comprising the steps of: mixing expandable graphite flakes, furnish and resin; and forming a board from the mix.
Preferably the graphite flakes and resin are mixed first before mixing with the furnish.
In general terms in a further aspect the invention provides a method of manufacturing a fire resistant building material comprising the steps of: forming a fire resistant building material core using the method described above; and applying one or more covering layers to the fire resistant building material core.
It is acknowledged that the terms “comprise”, “comprises” and “comprising” may, under varying jurisdictions, be attributed with either an exclusive or an inclusive meaning. For the purpose of this specification, and unless otherwise noted, these terms are intended to have an inclusive meaning - i.e. they will be taken to mean an inclusion of the listed components which the use directly references, and possibly also of other non-specified components or elements.
Reference to any documents in this specification does not constitute an admission that those documents are prior art or form part of the common general knowledge.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings which are incorporated in and constitute part of the specification, illustrate embodiments of the invention and, together with the general description of the invention given above, and the detailed description of embodiments given below, serve to explain the principles of the invention, in which:
Figure 1 is a cross section of a building material according to an example embodiment; and
Figure 2 is a flow diagram of manufacturing a fire resistant building material core according to an example embodiment.
DETAILED DESCRIPTION
An example embodiment is shown generally in Figure 1. The inventors have discovered that a fire resistant building material 100 can be most effectively provided by using a composite of a highly fire resistant core material 102 laminated with facing layers 104,106 on either side.
The fire resistant core 102 may be strand board with a fire resistant additive. The additive may be chosen according to the application. For example in a hinged or sliding fire door, expandable graphite flakes may be mixed with the resin and/or the core material before forming the strand board. The inventors have found it to be practical to introduce the expandable graphite flake with the resin.
The facing layers 104,106 may be relatively thin, and may be integral to the core or laminated to the core subsequent to its manufacture. If integral the facing layers 104,106 may be medium density fibre or other furnish with smaller particle size than the core. Furnish refers to fibre, sawdust, shavings, flakes and particles. The facing layers 104,106 will generally provide a “paint quality” smooth finish suitable for directly painting or providing a base for further decorative or durable laminate.
When one side of the material is subjected to a fire, the facing layer will -burn away, exposing the core 102. The expandable graphite flakes in the core will substantially expand on heating. As a result any fissures or burning of the strand board will tend to self-heal. The exposed surface will tend to form an insulating char layer which resists or delays further penetration of and erosion by the flame and slows an increase in core temperature. This is as opposed to the typical use of expandable graphite particles which is to suppress flame spreading.
The core material 102, or the entire panel if facing layers 104, 106 are integral, will referring to Figure 2 be generally manufactured with expandable graphite flakes added to the core furnish 201 either directly 202 or mixed with the resin 203 prior to the furnish mat being laid 203. If the facing layers 104, 106 are applied post-production to a core containing graphite flakes they will be applied using standard panel laminating and pressing processes.
The expandable graphite flakes will typically have a mean particle size of 250 microns to 350 microns and an expansion volume of 200 cubic centimetres per gram at 600 degrees Celsius. A larger particle size is preferred to compensate for any mechanical reduction of particle size during board processing.
Due to the effect of the graphite flakes, the resin loading may be increased to compensate to maintain the internal bond.
The fire resistant core 102 may be bound with any single one of, or a combination of resins: urea formaldehyde (UF); melamine formaldehyde (MF); melamine-urea formaldehyde (MUF); methyl diisocyanates esp. polymeric diphenyl methane diisocyanate (pMDI). The facing layers 104, 106 may be bound with any of the same resins as the core, but the resins used need not be the same as the core. The present invention has been successfully proven in UF resin bound strand board core faced with UF resin bound MDF, and in a pMDI resin bound strand board core, faced with UF resin bound MDF.
One or more embodiments may be expected to result in a board 10% thinner and/or a 15% lower density for the same fire resistance rating.
While the present invention has been illustrated by the description of the embodiments thereof, and while the embodiments have been described in detail, it is not the intention of the Applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, representative apparatus and method, and illustrative examples shown and described. Accordingly, departures may be made from such details without departure from the spirit or scope of the Applicant’s general inventive concept.
Claims (19)
1. A fire resistant building material comprising: a core of material incorporating a predetermined proportion of expandable graphite flakes; and one or more covering layers on the core.
2. The fire resistant building material in claim 1 wherein the predetermined proportion of expandable graphite flakes is less than 10% by weight.
3. The fire resistant building material in claim 1 or claim 2 wherein the core further includes furnish.
4. The fire resistant building material in claim 3 wherein the furnish is selected from one or more of the group comprising fibre, sawdust, shavings, flakes, particles.
5. The fire resistant building material in any preceding claim wherein the covering layers are substantially free of expandable graphite flakes.
6. The fire resistant building material in any preceding claim wherein the core and/or the covering layers are a wood based material.
7. The fire resistant building material in claim 6 wherein the wood based material is selected from the group consisting of fibreboard, medium density fibreboard, particle board, chip board, strand board and oriented strand board.
8. The fire resistant building material in any preceding claim wherein the covering layers include a substantially smooth outer finish configured for painting, laminating and/or encapsulating.
9. The fire resistant building material in any preceding claim wherein the core material further includes resin.
10. A fire resistant combustible door comprising a fire resistant building material according to any preceding claim.
11. A fire resistant wall comprising a fire resistant building material according to any one of claims 1 to 9.
12. A method of manufacturing a fire resistant building material core comprising the steps of: mixing expandable graphite flakes, furnish and resin; and forming a board from the mix.
13. The method of manufacturing a fire resistant building material as claimed in claim 12 wherein the graphite flakes and resin are mixed first before mixing with the furnish.
14. A method of manufacturing a fire resistant building material comprising the steps of: forming a fire resistant building material core using the method of claim 12 or claim 13; and applying one or more covering layers to the fire resistant building material core.
15. A fire resistant building material as hereinbefore described with reference to the drawings.
16. A combustible door comprising a fire resistant building material as hereinbefore described with reference to the drawings.
17. A fire resistant wall comprising a fire resistant building material as hereinbefore described with reference to the drawings.
18. A method of manufacturing a fire resistant building material core as hereinbefore described with reference to the drawings.
19. A method of manufacturing a fire resistant building material as hereinbefore described with reference to the drawings.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
NZ70863215 | 2015-05-29 |
Publications (3)
Publication Number | Publication Date |
---|---|
GB201609389D0 GB201609389D0 (en) | 2016-07-13 |
GB2541074A true GB2541074A (en) | 2017-02-08 |
GB2541074B GB2541074B (en) | 2021-03-31 |
Family
ID=56410669
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
GB1609389.0A Active GB2541074B (en) | 2015-05-29 | 2016-05-27 | Fire resistant building panel |
Country Status (3)
Country | Link |
---|---|
AU (1) | AU2016203508B2 (en) |
GB (1) | GB2541074B (en) |
SG (1) | SG10201606637WA (en) |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN107363959B (en) * | 2017-08-10 | 2019-08-30 | 马鞍山市谷庆门业有限公司 | A kind of reinforcing ecological door and preparation method thereof |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2299054A (en) * | 1995-03-21 | 1996-09-25 | Dixon Int Group Ltd | Laminate for improving fire resistance |
US6182407B1 (en) * | 1998-12-24 | 2001-02-06 | Johns Manville International, Inc. | Gypsum board/intumescent material fire barrier wall |
EP1215420A2 (en) * | 2000-12-12 | 2002-06-19 | Marvon S.r.l. | Reinforced intumescent gasket |
GB2371827A (en) * | 2001-02-01 | 2002-08-07 | Lorient Polyprod Ltd | Gas seal |
JP2014025310A (en) * | 2012-07-30 | 2014-02-06 | Regulus Co Ltd | Fire spread prevention material, joint filler, and fittings |
US20140205789A1 (en) * | 2013-01-23 | 2014-07-24 | Firestone Building Products Co., LLC | Coated fabrics including expandable graphite |
Family Cites Families (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH02253936A (en) * | 1989-03-28 | 1990-10-12 | Michio Nagamatsu | Fireproof board |
JP3460868B2 (en) * | 1994-09-12 | 2003-10-27 | 株式会社フジタ | Wooden fire door |
JP3465857B2 (en) * | 1994-09-12 | 2003-11-10 | 株式会社フジタ | Wooden fire door |
JP2000054528A (en) * | 1998-08-04 | 2000-02-22 | Sekisui Chem Co Ltd | Fire floor |
US20110091713A1 (en) * | 2005-12-21 | 2011-04-21 | Miller Douglas J | Fire Resistant Composite Panel |
ITMI20091776A1 (en) * | 2009-10-15 | 2011-04-16 | Dow Global Technologies Inc | POLYESOCYANURATE-BASED ADHESIVE WITH TWO COMPONENTS AND INSULATING PANELS PREPARED WITH ITS USE |
MX2016013069A (en) * | 2014-04-18 | 2017-02-14 | Dow Global Technologies Llc | Panel with fire barrier. |
-
2016
- 2016-05-27 GB GB1609389.0A patent/GB2541074B/en active Active
- 2016-05-27 AU AU2016203508A patent/AU2016203508B2/en active Active
- 2016-08-11 SG SG10201606637WA patent/SG10201606637WA/en unknown
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2299054A (en) * | 1995-03-21 | 1996-09-25 | Dixon Int Group Ltd | Laminate for improving fire resistance |
US6182407B1 (en) * | 1998-12-24 | 2001-02-06 | Johns Manville International, Inc. | Gypsum board/intumescent material fire barrier wall |
EP1215420A2 (en) * | 2000-12-12 | 2002-06-19 | Marvon S.r.l. | Reinforced intumescent gasket |
GB2371827A (en) * | 2001-02-01 | 2002-08-07 | Lorient Polyprod Ltd | Gas seal |
JP2014025310A (en) * | 2012-07-30 | 2014-02-06 | Regulus Co Ltd | Fire spread prevention material, joint filler, and fittings |
US20140205789A1 (en) * | 2013-01-23 | 2014-07-24 | Firestone Building Products Co., LLC | Coated fabrics including expandable graphite |
Also Published As
Publication number | Publication date |
---|---|
AU2016203508B2 (en) | 2020-09-10 |
SG10201606637WA (en) | 2016-12-29 |
GB201609389D0 (en) | 2016-07-13 |
AU2016203508A1 (en) | 2016-12-15 |
GB2541074B (en) | 2021-03-31 |
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