WO2000069626A1 - Composite panel and method for its formation - Google Patents

Composite panel and method for its formation Download PDF

Info

Publication number
WO2000069626A1
WO2000069626A1 PCT/EP2000/004240 EP0004240W WO0069626A1 WO 2000069626 A1 WO2000069626 A1 WO 2000069626A1 EP 0004240 W EP0004240 W EP 0004240W WO 0069626 A1 WO0069626 A1 WO 0069626A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
panel
resin
flexible material
layers
Prior art date
Application number
PCT/EP2000/004240
Other languages
French (fr)
Inventor
Eros Doimo
Original Assignee
Frezza S.R.L.
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
Priority claimed from IT1999TV000055 external-priority patent/IT1311835B1/en
Priority claimed from ITTV990090 external-priority patent/IT1311855B1/en
Application filed by Frezza S.R.L. filed Critical Frezza S.R.L.
Priority to AU45649/00A priority Critical patent/AU4564900A/en
Priority to EP00927191A priority patent/EP1185416A1/en
Publication of WO2000069626A1 publication Critical patent/WO2000069626A1/en

Links

Classifications

    • 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
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/045—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of 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
    • B32B27/00—Layered products comprising a layer of 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K21/00—Fireproofing materials
    • C09K21/02—Inorganic 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • 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
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/712—Weather resistant
    • 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
    • B32B2307/70—Other properties
    • B32B2307/714—Inert, i.e. inert to chemical degradation, corrosion
    • B32B2307/7145—Rot proof, resistant to bacteria, mildew, mould, fungi
    • 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
    • B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
    • B32B2315/02—Ceramics
    • 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
    • B32B2375/00—Polyureas; Polyurethanes
    • 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
    • B32B2605/00—Vehicles
    • B32B2605/12—Ships

Definitions

  • This invention relates to a composite panel and a method for its formation.
  • An object of the invention is to provide a composite panel, in particular for use as a ship-fitting bulkhead offering considerable noise abatement, mechanical strength before and after the ageing cycle, fire-resistance, weather resistance, salt fog and mildew resistance, resistance to natural ship vibration and resistance to temperature change.
  • a further object of the invention is to provide a panel of low cost.
  • a further object of the invention is to provide a panel which can be easily machined, is robust and durable, and is of pleasant outer appearance.
  • a further object of the invention is to provide a simple, low-cost method for forming the panel.
  • Figure 1 is an exploded view of the components of a first embodiment of the panel
  • the composite of the invention comprises an intermediate first layer 2 of porous calcium silicate material (insulating material) produced in an autoclave from siliceous sand, slaked iime and a small percentage of cellulose reinforcement fibres enabling a compact layer to be obtained which is incombustible (class 0), fir-resistant (REI 180) and non-toxic, but extremely fragile.
  • porous calcium silicate material insulating material
  • This material preferably has a density of 250 kg/m 3 , a thickness of 22 mm and a weight of 5.5 kg/m 2 .
  • Said first layer 2 is covered with two films 4 of sodium silicate acting as a hardener, to counteract the surface friability of the calcium silicate.
  • An aluminium layer 10 preferably of 0.6 mm thickness is applied to the outside of the viscoelastic resin layer 6, and a layer 12 of self-extinguishing biaxial glass fibre matting with fibres crossing at 90° is applied to the outside of the resin layer 8.
  • a further layer of two-component poiyurethane resin is applied to the outside of said layer 12.
  • the panel of the invention attains the stated objects, in that: - it enables good noise abatement to be achieved because of the presence of the viscoelastic two-component poiyurethane resin layer 6, - it presents good fire-resistance by virtue of the perfect synergy of the different panel constituent materials and the good fire-resistance of the calcium layer 2,
  • the method for forming the panel of the invention comprises applying a layer 6 of viscoelastic two-component poiyurethane resin to an aluminium sheet 10 unwound from a reel 18, then applying to said layer a plurality of side-by-side plates 20 of calcium silicate covered on both their surfaces with a film of sodium silicate. To the free surface of said plates there is then applied a two-component poiyurethane layer 8 followed by a layer 12 of biaxial glass fibre matting unwound from a reel 22. A further component two-component poiyurethane layer 8 is then applied to the outside of said layer 12.
  • the entire assembly obtained in this manner is subjected to the action of a dynamic press 24, at the exit of which the panel is cut by a cutter 26 to the desired length.
  • the composition of the central layer remains unchanged, whereas in the outer part of the panel the two- component poiyurethane resin layers 8 are replaced by viscoelastic two- component poiyurethane resin layers 8.
  • the panel has the same composition as the panel shown in Figure 1 , but with the central layer of this latter now replaced by two smaller-thickness calcium silicate layers 2, between which one viscoelastic two-component poiyurethane resin layer 6 and two sodium silicate layers 4 are interposed.
  • the panel shown in Figure 4 has substantially the same components as the panel shown in Figure 2, but with the central layer similar to that shown in Figure 3.
  • the panel shown in Figure 5 has a central calcium silicate layer 2 interposed between two sodium silicate layers 4, external to which there are two layers 14 of two-component unsaturated polyester resin with a low flame propagation propensity, to these two latter layers there being applied a layer 12 of seif-extinguishing biaxial glass fibre matting.
  • a further layer 14 of two-component unsaturated polyester resin followed, on that latter layer which faces inwards, by a layer 16 of plastic laminate preferably of 0.6 mm.

Abstract

A composite panel characterised by comprising: a central layer (2) of calcium silicate; two sodium silicate films (4) coating said central layer; two resin layers (6, 8, 14) covering said calcium silicate layer coated by said films; two outer layers (10, 12, 16) of flexible material having high mechanical strength.

Description

COMPOSITE PANEL AND METHOD FOR ITS FORMATION
This invention relates to a composite panel and a method for its formation.
An object of the invention is to provide a composite panel, in particular for use as a ship-fitting bulkhead offering considerable noise abatement, mechanical strength before and after the ageing cycle, fire-resistance, weather resistance, salt fog and mildew resistance, resistance to natural ship vibration and resistance to temperature change.
A further object of the invention is to provide a panel of low cost. A further object of the invention is to provide a panel which can be easily machined, is robust and durable, and is of pleasant outer appearance.
A further object of the invention is to provide a simple, low-cost method for forming the panel.
These and further objects which will be apparent from the ensuing description are attained according to the invention by a panel as claimed in claim 1.
Some preferred embodiments of the invention are described in detail hereinafter with reference to the accompanying drawings, on which: Figure 1 is an exploded view of the components of a first embodiment of the panel,
Figure 2 shows a second embodiment thereof, Figure 3 shows a third embodiment thereof, Figure 4 shows a fourth embodiment thereof, Figure 5 shows a fifth embodiment thereof, and Figure 6 shows an apparatus for forming the panel of the invention. As can be seen form the figures, the composite of the invention comprises an intermediate first layer 2 of porous calcium silicate material (insulating material) produced in an autoclave from siliceous sand, slaked iime and a small percentage of cellulose reinforcement fibres enabling a compact layer to be obtained which is incombustible (class 0), fir-resistant (REI 180) and non-toxic, but extremely fragile.
This material preferably has a density of 250 kg/m3, a thickness of 22 mm and a weight of 5.5 kg/m2.
Said first layer 2 is covered with two films 4 of sodium silicate acting as a hardener, to counteract the surface friability of the calcium silicate.
To the outside of one of the sodium silicate films 4 there is applied a layer 6 of viscoelastic two-component poiyurethane resin having a low flame propagation propensity.
To the outside of the other sodium silicate film 4 there is applied a layer 8 of two-component poiyurethane resin having a low flame propagation propensity.
An aluminium layer 10 preferably of 0.6 mm thickness is applied to the outside of the viscoelastic resin layer 6, and a layer 12 of self-extinguishing biaxial glass fibre matting with fibres crossing at 90° is applied to the outside of the resin layer 8.
A further layer of two-component poiyurethane resin is applied to the outside of said layer 12.
From the aforegoing it is apparent that the panel of the invention attains the stated objects, in that: - it enables good noise abatement to be achieved because of the presence of the viscoelastic two-component poiyurethane resin layer 6, - it presents good fire-resistance by virtue of the perfect synergy of the different panel constituent materials and the good fire-resistance of the calcium layer 2,
- it presents good water resistance because of the presence of the aluminium layer 10 and the biaxial glass fibre matting layer 12 covering the extremely porous calcium silicate layer 2,
- it presents good resistance to salt fog, mildew, and natural ship vibration, with consequent good durability, by virtue of the perfect synergy of the main inert constituent materials of the panel, - it is of low weight because of the use of very light materials (aluminium and silicates),
- it provides good machinability (in particular the formation of very rigid continuous angles) because of its good mechanical strength,
- it is of pleasant outer appearance. The method for forming the panel of the invention comprises applying a layer 6 of viscoelastic two-component poiyurethane resin to an aluminium sheet 10 unwound from a reel 18, then applying to said layer a plurality of side-by-side plates 20 of calcium silicate covered on both their surfaces with a film of sodium silicate. To the free surface of said plates there is then applied a two-component poiyurethane layer 8 followed by a layer 12 of biaxial glass fibre matting unwound from a reel 22. A further component two-component poiyurethane layer 8 is then applied to the outside of said layer 12. The entire assembly obtained in this manner is subjected to the action of a dynamic press 24, at the exit of which the panel is cut by a cutter 26 to the desired length. In the embodiment shown in Figure 2, the composition of the central layer remains unchanged, whereas in the outer part of the panel the two- component poiyurethane resin layers 8 are replaced by viscoelastic two- component poiyurethane resin layers 8. In the embodiment shown in Figure 3, the panel has the same composition as the panel shown in Figure 1 , but with the central layer of this latter now replaced by two smaller-thickness calcium silicate layers 2, between which one viscoelastic two-component poiyurethane resin layer 6 and two sodium silicate layers 4 are interposed. The panel shown in Figure 4 has substantially the same components as the panel shown in Figure 2, but with the central layer similar to that shown in Figure 3.
The panel shown in Figure 5 has a central calcium silicate layer 2 interposed between two sodium silicate layers 4, external to which there are two layers 14 of two-component unsaturated polyester resin with a low flame propagation propensity, to these two latter layers there being applied a layer 12 of seif-extinguishing biaxial glass fibre matting.
To the outside of said biaxial glass fibre matting layers 12 there is applied a further layer 14 of two-component unsaturated polyester resin followed, on that latter layer which faces inwards, by a layer 16 of plastic laminate preferably of 0.6 mm.

Claims

C L A I M S
1. A composite panel characterised by comprising:
- a central layer (2) of calcium silicate,
- two sodium silicate films (4) coating said central layer, - two resin layers (6,8, 14) covering said calcium silicate layer coated by said films,
- two outer layers (10,12,16) of flexible material having high mechanical strength.
2. A panel as claimed in claim 1 , characterised in that at least one resin layer consists of a viscoelastic two-component poiyurethane resin (6) having a low flame propagation propensity.
3. A panel as claimed in claim, characterised in that at least one resin layer consists of a two-component poiyurethane resin (8) having a low flame propagation propensity.
4. A panel as claimed in claim 1 , characterised in that at least one resin layer consists of an unsaturated polyester resin (14) having a low flame propagation propensity.
5. A panel as claimed in claim 1 , characterised in that at least one outer layer of flexible material consists of a self-extinguishing layer (12) of biaxial glass fibre matting with fibres crossing at 90°.
6. A panel as claimed in claim 1 , characterised in that at least one outer layer of flexible material consists of aluminium (10).
7. A panel as claimed in claim 1 , characterised in that at least one outer layer of flexible material consists of plastic laminate (16).
8. A panel as claimed in claim 1 , characterised in that the central layer consists of two calcium silicate layers between which one viscoelastic two- component poiyurethane resin layer (6) and two sodium silicate layers (4) are interposed.
9. A panel as claimed in claim 1 , characterised in that at least one outer layer of flexible material consists of a layer of biaxial glass fibre matting with fibres crossing at 90°.
10. A method for the continuous formation of panels claimed in claims 1 to 9, characterised by comprising the following steps:
- applying a resin layer to a continuous layer of high-strength flexible material, - applying to said resin layer a plurality of side-by-side calcium silicate plates covered on both their surfaces with a sodium silicate film,
- applying a further resin layer to said plates,
- applying a further layer of high-strength flexible material,
- subjecting the assembly obtained in this manner to the action of a press, - cutting the panel to the required length.
PCT/EP2000/004240 1999-05-12 2000-05-10 Composite panel and method for its formation WO2000069626A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
AU45649/00A AU4564900A (en) 1999-05-12 2000-05-10 Composite panel and method for its formation
EP00927191A EP1185416A1 (en) 1999-05-12 2000-05-10 Composite panel and method for its formation

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
ITTV99A000055 1999-05-12
IT1999TV000055 IT1311835B1 (en) 1999-05-12 1999-05-12 Composite panel used in building, has several layers of various low fire propagation materials
ITTV99A000090 1999-08-02
ITTV990090 IT1311855B1 (en) 1999-08-02 1999-08-02 Composite panel used in building, has several layers of various low fire propagation materials

Publications (1)

Publication Number Publication Date
WO2000069626A1 true WO2000069626A1 (en) 2000-11-23

Family

ID=26332477

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2000/004240 WO2000069626A1 (en) 1999-05-12 2000-05-10 Composite panel and method for its formation

Country Status (3)

Country Link
EP (1) EP1185416A1 (en)
AU (1) AU4564900A (en)
WO (1) WO2000069626A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1637666A2 (en) * 2004-09-15 2006-03-22 Gamax S.r.l. Self-supporting calcium silicate panel and related prefabricated living module

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1388744A (en) * 1971-07-13 1975-03-26 Shimizu K Incombustible plate for architectural use
WO1999019140A1 (en) * 1997-10-15 1999-04-22 Alfredo Varini Fire-resistant structure

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1388744A (en) * 1971-07-13 1975-03-26 Shimizu K Incombustible plate for architectural use
WO1999019140A1 (en) * 1997-10-15 1999-04-22 Alfredo Varini Fire-resistant structure

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1637666A2 (en) * 2004-09-15 2006-03-22 Gamax S.r.l. Self-supporting calcium silicate panel and related prefabricated living module
EP1637666A3 (en) * 2004-09-15 2009-07-15 Gamax S.r.l. Self-supporting calcium silicate panel and related prefabricated living module

Also Published As

Publication number Publication date
EP1185416A1 (en) 2002-03-13
AU4564900A (en) 2000-12-05

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