US20040030004A1 - Intumescent electrical installation systems and processes for their production - Google Patents

Intumescent electrical installation systems and processes for their production Download PDF

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Publication number
US20040030004A1
US20040030004A1 US10/389,777 US38977703A US2004030004A1 US 20040030004 A1 US20040030004 A1 US 20040030004A1 US 38977703 A US38977703 A US 38977703A US 2004030004 A1 US2004030004 A1 US 2004030004A1
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US
United States
Prior art keywords
intumescent
electrical installation
installation system
injection molding
ethylene
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.)
Abandoned
Application number
US10/389,777
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English (en)
Inventor
Heinrich Horacek
Walter Pickhard
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
IMTUMEX GmbH
Original Assignee
IMTUMEX GmbH
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by IMTUMEX GmbH filed Critical IMTUMEX GmbH
Assigned to IMTUMEX GMBH reassignment IMTUMEX GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: PICKHARD, WALTER, HORACEK, HEINRICH
Publication of US20040030004A1 publication Critical patent/US20040030004A1/en
Priority to US11/312,372 priority Critical patent/US7521495B2/en
Abandoned legal-status Critical Current

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    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02GINSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G3/00Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
    • H02G3/02Details
    • H02G3/04Protective tubing or conduits, e.g. cable ladders or cable troughs
    • H02G3/0406Details thereof
    • H02G3/0412Heat or fire protective means

Definitions

  • Electrical installation systems such as, for example, conduit boxes, junction boxes, switch boxes, armored boxes, conduits, etc.
  • materials are produced from a very wide range of materials, depending on the intended use.
  • Materials used to date are steel sheet, aluminum, cast iron, (polyvinyl chloride (PVC), polyphenylene ether/polyphenylene oxide (PPE/PPO), polycarbonate (PC), polystyrene (PS), polypropylene (PP), polyethylene (PE), ABS or polyamide (PA).
  • PVC polyvinyl chloride
  • PPE/PPO polyphenylene ether/polyphenylene oxide
  • PC polycarbonate
  • PS polystyrene
  • PP polypropylene
  • PE polyethylene
  • ABS or polyamide PA
  • flame retardance for electrical installation systems according to VDE 0471/DIN IEC 695 Part 2-1 are applicable: flame retardance for electrical installation systems for flush mounting and in concrete construction must be 650°, that for covers and lids must be 750° C., that for installation systems for mounting cavity walls must be 850° C. and that for terminals and semiflush-mounted conduit boxes for riser cables having 1.5 and 2.5 mm 2 copper conductors must be 960° C.
  • the installation systems protected in this manner may not exceed the temperature of 181° C. in a fire test according to ASTM E-119.
  • this object can be achieved by intumescent, electrical installation systems which are produced by the injection molding process from polyolefins or polyimides in combination with intumescent additives.
  • the invention accordingly relates to intumescent, electrical installation systems which comprise an injection molding material of polyolefins or polyimides in combination with intumescent additives, the melting points of the polyolefins and of the polyimides being lower than the intumescence temperature of the intumescent additives.
  • Electrical installation systems are to be understood as meaning, surface-mounted sockets and boxes, such as, for example, conduit boxes and armored boxes, flush-mounted sockets and boxes, such as, for example, equipment boxes or switch boxes and conduit boxes, and junction boxes, cavity wall sockets and boxes and installation systems for concrete construction.
  • the abovementioned installation systems may be in the form of conduits, angle boxes, branch-Ts, cross boxes, a combination conduit box/switch box, a double conduit box/switch box, a semiflush-mounted conduit box, a ceiling light connection box, a wall light connection box, a dome box, a double equipment or switch box, a triple equipment box, an equipment conduit box, a junction box/switch box, a transition box, a universal box, etc.
  • the intumescent, electrical installation systems according to the invention comprise an injection molding material of polyolefins or polyimides in combination with intumescent additives.
  • Polyolefins used may be thermoplastic polyolefins, such as polyethylene (PE) having a low density (LDPE) to high density (HDPE), preferably HDPE, ethylene-vinyl acetate (EVA) copolymers, ethylene-butyl acrylate copolymers, polypropylene, poly-1-butene poly(methyl-pentene), copolymers of ethylene and octene, ethylene/propylene-diene terpolymers (EPDM) or blends thereof.
  • PE polyethylene
  • LDPE low density
  • HDPE high density
  • EVA ethylene-vinyl acetate copolymers
  • EVA ethylene-butyl acrylate copolymers
  • polypropylene poly-1-butene poly(methyl-pentene)
  • EPDM ethylene/propylene-diene terpolymers
  • HDPE, EVA copolymers or copolymers of ethylene and octene or blends of HDPE and EVA copolymer are preferably used.
  • Suitable polyimides are those which are present as a low-melting precursor and form highly crosslinked products, such as, for example, bismaleimides by addition reaction under the action of heat.
  • Bismaleimides which consist of diphenylmethane 4 , 4 ′-bismaleimide and methylenedianiline or other aromatic diamines are preferably used.
  • the bismaleimides used should have a melting point below about 200° C.
  • Suitable intumescent additives are ammonium or amino compounds, such as, for example, ammonium polyphosphate, ammonium dihydrogen phosphate, ethylenediamine phosphate, ammonium pentaborate, melamine, dicyandiamide, full phosphoric esters with polyols, dipentaerythritol, pentaerythritol, sugar, dextran, starch, vermicular graphite, waterglass, expanded mica, vermiculite, perlite and mixtures thereof.
  • Preferred intumescent additives are ammonium polyphosphate, ethylenediamine phosphate, melamine, dipentaerythritol, pentaerythritol, sodium silicate or vermicular graphite or mixtures thereof.
  • Vermicular graphite is particularly preferably used as an intumescent additive in the case of polyimides, and ethylenediamine phosphate and/or ammonium polyphosphate and/or melamine and/or dipentaerythritol and/or vermicular graphite in the case of polyolefins.
  • the melting points of the polyolefins and of the polyimides are lower than the intumescence temperature of the intumescent additives.
  • the injection molding material according to the invention contains from 20 to 50% by weight, preferably from 30 to 40% by weight, of polyolefin or polyimide and from 50 to 80% by weight, preferably from 60 to 70% by weight, of intumescent additives.
  • the injection molding material according to the invention can optionally also contain inorganic fillers, such as, for example, kaolin, clays, mica, wollastonite, calcium silicates, titanium dioxide, zinc borate, quartz, zinc oxide, apatite, talc, aluminum phosphates, ATH, Mg(OH) 2 , chalk, glass fibers, mineral fibers, etc.
  • inorganic fillers such as, for example, kaolin, clays, mica, wollastonite, calcium silicates, titanium dioxide, zinc borate, quartz, zinc oxide, apatite, talc, aluminum phosphates, ATH, Mg(OH) 2 , chalk, glass fibers, mineral fibers, etc.
  • Preferred inorganic fillers are clays, mica and glass fibers.
  • clays or mica are used as inorganic fillers, it is preferable for them to be present as nanoparticles in the mixture of polymer, intumescent additive and filler.
  • the amount of added filler may be from 0 to 20% by weight, based on the total injection molding material.
  • the injection molding materials according to the invention may also contain conventional dispersants, such as, for example, zinc stearate or calcium stearate, glyceryl stearate, pentaerythrityl tetrastearate, cetyl palmitate, ethylenedistearoyldiamide C 14 -C 18 fatty alcohols, dicarboxylic esters, fatty amines, paraffins, etc., in an amount of from 0 to 5% by weight.
  • conventional dispersants such as, for example, zinc stearate or calcium stearate, glyceryl stearate, pentaerythrityl tetrastearate, cetyl palmitate, ethylenedistearoyldiamide C 14 -C 18 fatty alcohols, dicarboxylic esters, fatty amines, paraffins, etc.
  • a powder mixture or granules of the desired components is or are prepared by simple mixing together or by extrusion.
  • the intumescent electrical installation system according to the invention is shaped in only one operation in the injection molding process and optionally postcured.
  • the parameters such as, for example, temperature, injection pressure and locking force, depend on the respective starting mixture.
  • the material thickness is such that it corresponds to the box volume divided by the product of twice the lateral surface area and the maximum expansion factor, so that the installation system is completely filled with foam by intumescence.
  • This condition can be represented as a formula as follows:
  • V . . . Volume of the installation system (socket, distributor box, etc.)
  • Kf . . . Compression factor ratio of max. expansion factor to actual expansion factor
  • a compression factor of 2 should preferably be present.
  • the intumescent electrical installation systems according to the invention have several advantages over installation systems available to date.
  • the injection molding material contains no halogens, so that no corrosive gases can form in the event of a fire.
  • the installation systems according to the invention provide a fume-tight seal owing to the intumescent additives, so that additional fire protection measures, such as intumescent inlays or cements, are no longer required.
  • connection box 100 having the dimensions 107 ⁇ 107 ⁇ 57 mm and comprising high-impact polystyrene was mounted in a corresponding recess in a 100 mm Ytong wall so that the cover of the connection box is flush with the Ytong surface.
  • a thermocouple was fastened centrally on the back.
  • the box had melted after 30 minutes and a temperature of 700° C. was measured at the thermocouple after 2 hours.
  • [0046] having the dimensions of 4 mm diameter and 4 mm length were produced on a K 30 twin-screw extruder from Werner & Pfleiderer.
  • the extrusion temperature was 150° C. and the throughput was 10 kg/h.
  • connection box 100 having the dimensions 107 ⁇ 107 ⁇ 57 mm was injection molded on an FM 60 injection molding machine from Klöckner Ferromatik.
  • the temperature in the heating zone was 150-160° C. and that in the mold was 40-60° C.
  • the injection pressure was 10 bar.
  • connection box having a mean material thickness of 2.5 mm was closed by means of a steel sheet cover. This arrangement was mounted in a corresponding Ytong wall recess. The side with the steel sheet cover was installed facing the fire in the furnace.
  • thermocouple for temperature measurement was mounted on the back of the connection box. In the course of the fire test, the connection box became completely filled with foam. The temperature on the back panel after 2 hours was 300° C.
  • Test specimens were produced from another connection box and the mechanical properties in the tensile strength test according to DIN 53 455 and the expansion factor at 300° C. and in the course of 30 minutes were determined. The values are shown in table 1.
  • a round connection socket having the dimensions 70 mm diameter and 36 mm height were injection molded from the same granules and likewise mounted in a 100 mm thick Ytong wall in a corresponding circular recess, closed with a steel sheet cover and tested in the furnace. After 2 hours, the back panel reached a temperature of 320° C.
  • a powder mixture comprising
  • connection box was injection molded on a conventional injection molding machine for heat-curable plastics, having an L/D ratio of 15 and a compressionless screw with a pitch of 0.8, at a screw speed of 40 rpm.
  • the temperatures were 50-60° C. in the feed zone, 50-60° C. in the compression zone, 100-110° C. in the discharge zone and 230° C. in the mold.
  • the injection pressure was 600 bar.
  • a US distributor box having the dimensions 100 ⁇ 100 ⁇ 50 mm was likewise injection molded in order to be able to subject it to the UL test according to the setup of FIGS. 1 and 2. 180° C. was not exceeded in the course of 2 hours. To ensure that the material intumesces only in an inward direction, a glass fabric tape is placed around the box.
  • a powder mixture comprising
  • a powder mixture comprising
  • the wall thickness was once again 2.5 mm. In the fire test of tab. 2, once again complete foam-filling of the box was observed. The back panel temperature after 2 hours was 280° C.
  • Granules were produced from a mixture of
  • Granules having the following composition were produced by means of extrusion:
  • the extrusion temperature was 200° C.
  • round connection sockets having a diameter of 70 mm and a height of 35 mm were injection molded at 90° C.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Organic Insulating Materials (AREA)
US10/389,777 2002-03-19 2003-03-18 Intumescent electrical installation systems and processes for their production Abandoned US20040030004A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US11/312,372 US7521495B2 (en) 2002-03-19 2005-12-21 Intumescent electrical installation systems and processes for their production

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ATA410/2002 2002-03-19
AT0041002A AT411261B (de) 2002-03-19 2002-03-19 Intumeszierende elektrische installationssysteme enthaltend eine kombination aus polyimiden und vermikulargraphit und zu deren herstellung

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US11/312,372 Division US7521495B2 (en) 2002-03-19 2005-12-21 Intumescent electrical installation systems and processes for their production

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US20040030004A1 true US20040030004A1 (en) 2004-02-12

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US10/389,777 Abandoned US20040030004A1 (en) 2002-03-19 2003-03-18 Intumescent electrical installation systems and processes for their production
US11/312,372 Expired - Lifetime US7521495B2 (en) 2002-03-19 2005-12-21 Intumescent electrical installation systems and processes for their production

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US (2) US20040030004A1 (de)
EP (1) EP1347549B1 (de)
AT (1) AT411261B (de)
AU (1) AU2003201367B2 (de)
CA (1) CA2419759C (de)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060019102A1 (en) * 2004-07-26 2006-01-26 Kuppsuamy Kanakarajan Flame-retardant halogen-free polyimide films useful as thermal insulation in aircraft applications and methods relating thereto
US20100029826A1 (en) * 2008-07-30 2010-02-04 Krizan Timothy D Polyimide resins for high temperature wear applications
US20130068487A1 (en) * 2011-09-19 2013-03-21 Hilti Aktiengesellschaft Fire protection element
US10415725B2 (en) 2015-04-27 2019-09-17 Hilti Aktiengesellschaft Fire protection sleeve
GB2588670A (en) * 2019-11-01 2021-05-05 Fire And Sound Solutions Group Ltd Electrical back box
GB2584442B (en) * 2019-06-03 2022-03-02 Vexbox Ltd A fire-proof extension for an electrical back box

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AT500875A1 (de) * 2004-07-23 2006-04-15 Intumex Gmbh Intumeszierende klippprofile für brandschutzeinrichtungen
DE202010017200U1 (de) 2009-07-09 2011-04-21 Kaiser Gmbh & Co. Kommanditgesellschaft Anordnung zur rauchgasdichten Durchführung eines Langformteils durch eine Wand
DE102009032460A1 (de) 2009-07-09 2011-01-13 Kaiser Gmbh & Co. Kommanditgesellschaft Anordnung zur rauchgasdichten Durchführung eines Langformteils durch eine Brandschutzwand
US8648256B1 (en) * 2010-06-07 2014-02-11 Intumescent Technologies, Llc Intumescent swell devices
CN103154139B (zh) * 2010-09-29 2016-09-07 纳幕尔杜邦公司 用于高温应用的聚酰亚胺树脂
CN103124772A (zh) * 2010-09-29 2013-05-29 纳幕尔杜邦公司 高温应用的聚酰亚胺树脂
DE102011004575A1 (de) 2011-02-23 2012-08-23 Hilti Aktiengesellschaft Leitungselementdurchführung
DE102011007654B4 (de) * 2011-04-19 2012-12-06 Hilti Aktiengesellschaft Komprimierbares Weichschott, Verfahren zu seiner Herstellung und seine Verwendung
DE102011089531A1 (de) 2011-12-22 2013-06-27 Hilti Aktiengesellschaft Brandschutzmanschette
WO2014005880A1 (de) 2012-07-03 2014-01-09 Hilti Aktiengesellschaft Form und verfahren zur herstellung eines formteils sowie formteil
DE102012218540A1 (de) 2012-10-11 2014-06-12 Hilti Aktiengesellschaft Brandschutzmanschette
DE102013200546A1 (de) 2013-01-16 2014-07-17 Hilti Aktiengesellschaft Akkumulator für eine Handwerkzeugmaschine und Verfahren zum Herstellen eines Akkumulators für eine Handwerkzeugmaschine
EP2821207A1 (de) 2013-07-03 2015-01-07 HILTI Aktiengesellschaft Verfahren und Spritzgiessanlage zur Herstellung von intumeszierenden Reaktionskunststoffformteilen und Reaktionskunststoffformteil
EP2821108A1 (de) 2013-07-03 2015-01-07 HILTI Aktiengesellschaft Intumeszierende Brandschutzeinlage und Baugruppe mit intumeszierender Brandschutzeinlage
EP2827465A1 (de) 2013-07-17 2015-01-21 HILTI Aktiengesellschaft Leitungsdurchführung, Verfahren zur Herstellung einer Leitungsdurchführung und Verfahren zur Montage einer Leitungsdurchführung
EP2826612A1 (de) 2013-07-17 2015-01-21 HILTI Aktiengesellschaft Schäumwerkzeug zur Herstellung eines Profilstranges, Verfahren zur Herstellung eines Profilstranges sowie Profilstrang
EP2826611A1 (de) 2013-07-18 2015-01-21 HILTI Aktiengesellschaft Verfahren zur Herstellung von Schaumformteilen in einer Verpackungshülle und Verkaufseinheit
EP2827041A1 (de) 2013-07-18 2015-01-21 HILTI Aktiengesellschaft Isoliermaterial sowie Isolierung für ein Rohr im Bereich einer Wand- oder Deckendurchführung
DE102013214499A1 (de) * 2013-07-24 2014-07-17 E.G.O. Elektro-Gerätebau GmbH Gehäusevorrichtung, Anordnung einer Gehäusevorrichtung und Verfahren zur Montage einer Gehäusevorrichtung
US20150218403A1 (en) * 2014-02-03 2015-08-06 3M Innovative Properties Company Intumescent caulking compositions and methods
EP3088785A1 (de) 2015-04-27 2016-11-02 Hilti Aktiengesellschaft Brandschutzmanschette
EP3088784A1 (de) 2015-04-27 2016-11-02 Hilti Aktiengesellschaft Brandschutzmanschette
US20170030490A1 (en) 2015-07-28 2017-02-02 Hilti Aktiengesellschaft Air, acoustic and/or fire sealing sleeve insert and air, acoustic and/or fire sealing device
US10145494B2 (en) 2016-11-18 2018-12-04 Hilti Aktiengesellschaft Air, acoustic and/or fire sealing device
DE102020212619A1 (de) 2020-10-06 2022-04-07 Siemens Aktiengesellschaft Faser-Matrix-Halbzeug für die Herstellung von Gehäuseteilen von Leistungsschutzschaltern

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Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060019102A1 (en) * 2004-07-26 2006-01-26 Kuppsuamy Kanakarajan Flame-retardant halogen-free polyimide films useful as thermal insulation in aircraft applications and methods relating thereto
US20100029826A1 (en) * 2008-07-30 2010-02-04 Krizan Timothy D Polyimide resins for high temperature wear applications
US7858687B2 (en) 2008-07-30 2010-12-28 E.I. Du Pont De Nemours And Company Polyimide resins for high temperature wear applications
US20130068487A1 (en) * 2011-09-19 2013-03-21 Hilti Aktiengesellschaft Fire protection element
US10415725B2 (en) 2015-04-27 2019-09-17 Hilti Aktiengesellschaft Fire protection sleeve
US10641417B2 (en) 2015-04-27 2020-05-05 Hilti Aktiengesellschaft Fire protection sleeve
US11137091B2 (en) 2015-04-27 2021-10-05 Hilti Aktiengesellschaft Fire protection sleeve
US11655919B2 (en) 2015-04-27 2023-05-23 Hilti Aktiengesellschaft Fire protection sleeve
GB2584442B (en) * 2019-06-03 2022-03-02 Vexbox Ltd A fire-proof extension for an electrical back box
GB2588670A (en) * 2019-11-01 2021-05-05 Fire And Sound Solutions Group Ltd Electrical back box
GB2588670B (en) * 2019-11-01 2024-05-15 Fire And Sound Solutions Group Ltd Electrical back box

Also Published As

Publication number Publication date
US7521495B2 (en) 2009-04-21
ATA4102002A (de) 2003-04-15
CA2419759A1 (en) 2003-09-19
EP1347549A1 (de) 2003-09-24
AU2003201367A1 (en) 2003-10-09
AT411261B (de) 2003-11-25
AU2003201367B2 (en) 2009-01-08
US20060160926A1 (en) 2006-07-20
CA2419759C (en) 2012-04-17
EP1347549B1 (de) 2017-03-29

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