WO2002007964A1 - Procédé de fabrication de panneaux de construction coupe-feu - Google Patents

Procédé de fabrication de panneaux de construction coupe-feu Download PDF

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Publication number
WO2002007964A1
WO2002007964A1 PCT/IB2001/001257 IB0101257W WO0207964A1 WO 2002007964 A1 WO2002007964 A1 WO 2002007964A1 IB 0101257 W IB0101257 W IB 0101257W WO 0207964 A1 WO0207964 A1 WO 0207964A1
Authority
WO
WIPO (PCT)
Prior art keywords
particles
inclusive
vermiculite
outer panel
dry powder
Prior art date
Application number
PCT/IB2001/001257
Other languages
English (en)
Inventor
Michael Windsor Symons
Original Assignee
Balmoral Technologies (Pty) Limited
Windsor Technologies Limited
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 Balmoral Technologies (Pty) Limited, Windsor Technologies Limited filed Critical Balmoral Technologies (Pty) Limited
Priority to AU2001279987A priority Critical patent/AU2001279987A1/en
Publication of WO2002007964A1 publication Critical patent/WO2002007964A1/fr

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • 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
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • 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
    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • B32B19/04—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C04B14/04—Silica-rich materials; Silicates
    • C04B14/20—Mica; Vermiculite
    • C04B14/204—Mica; Vermiculite expanded
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures

Definitions

  • THIS invention relates to a method of making a fire resistant building panel, e.g a door or wall panel, and to building panels so formed.
  • a method of making a fire resistant building panel comprising two outer panel elements and an inner core sandwiched between the two outer panel elements, including the steps of: (1) providing a composition for manufacture of the two outer panel elements, the composition comprising:
  • step (1 ) (2) forming the composition of step (1 ) into a layer and pressing the layer at a temperature of from 120°C to 240°C inclusive and at a pressure of from 20 kg/cm 2 to 75 kg/cm 2 inclusive to a thickness of between 3 mm and 9 mm inclusive at a density of from 1150 to 1750 kg/m 3 inclusive, to form the two outer panel elements, each panel element comprising 70% to 97% inclusive by mass of the vermiculite particuies;
  • a fire resistant building panel comprising two outer panel elements and an inner core adherently sandwiched between the two outer panel elements, each outer panel element comprising 70% to 97% inclusive by mass of particles of an exfoliated vermiculite, bound together with a thermosetting resin, each outer panal element having a thickness of from 3 mm to 9 mm inclusive and a density of from 1150 to 1750 kg/m 3 inclusive.
  • the crux of the invention is a method of making a fire resistant building panel, e.g a door or wall or roof panel, comprised of two outer panel elements or layers and an inner core sandwiched between the outer panel elements.
  • a fire resistant building panel e.g a door or wall or roof panel
  • Each of the outer panel elements has a high density and a low thickness, which imparts good fire resistant characteristics to the building panel.
  • Each of the panel elements is formed from a composition comprising particles of an exfoliated vermiculite, which particles have been resinated with a thermosetting resin.
  • finely divided exfoliated vermiculite particles there is meant exfoliated vermiculite with a particle diameter of 0,5 mm or less.
  • the particles preferably have a particle size of from 2 micron to 500 micron inclusive.
  • Vermiculite belongs to the group of hydrated lamina industrial minerals, which are all aluminum-iron magnesium silicates, high in silica. The resemble a muscovite (mica) in appearance. When subjected to heat, vermiculite exfoliates due to the inter lamina generation of steam. The pH is typically in the region of 9, specific gravity 2,5, melting point 1315°C, sintering temperature 1260°C and bulk densities are between 50 and 120g/litre. The product, exfoliated vermiculite is non-corrosive, non-combustible and non- abrasive.
  • An example of a suitable grade is Zonolite No 5 or FPSV by WR Grace. Another example is RSU submicron by Phalaborwa Mining Company.
  • the second component of the composition is a thermosetting resin.
  • the particles may be resinated with a liquid thermosetting resin optionally with a catalyst and optionally dissolved in a suitable solvent or dispersed in an oil.
  • organic isocyanates include aromatic isocyanates, such as m- and p-phenylenediisocyanate, toluene-2,4- and 2,6-diisocyanates, diphenylmethane-4,4 diisocyanate and diphenylmethane-2,4-diisocyanate and similar. These and similar are among those referred to as MDIs in the industry.
  • An example of a water dispersible MDI is Suprasec 1042 by Industrial Urethanes of South Africa.
  • a MDI suitable for oil dispersion is Duthane 2447 by Industrial Urethanes of South Africa
  • isocyanate thermosetting resin is intended to include the resins per se, i.e polyurethane resins, as well as those components which may be regarded as precursors of the resins, such as MDIs and TDIs.
  • the optional solvent may be any suitable solvent and is preferably dichloromethane, the isocyanate thermosetting resin being dissolved in the dichloromethane at a concentration of 1 ,0% to 50% by mass, or liquid carbon dioxide or a blend of the two, suitable for spray application.
  • thermosetting resin is a phenol formaldehyde resole resin, an example being J2018L by Borden Chemical Company catalysed with the catalyst known as Phencat 10.
  • the particles may be resinated by immersion or preferably by spraying, following which the water or solvent is removed.
  • the particles are preferably resinated with the resin in an amount of from 3% to 20% inclusive of the combined mass of the resin and particles, i.e in a mass ratio of the resin to the particles of from 3:97 to 20:80, more preferably in an amount of from 5% to 12% inclusive of the combined mass of the resin and particles.
  • the particles may be resinated with a dry powder thermosetting resin and if necessary a catalyst therefor, together with an adhesion promoter, so that the dry powder thermosetting resin adheres to the surfaces of the particles of vermiculite or perlite.
  • the particles of the thermosetting resin must have a particle size such that 98% pass a 200 mesh (74 micron) screen or finer.
  • a suitable resin is a novolac phenol formaldehyde resin, which is used with suitable catalyst such as hexamethylene tetramine.
  • a novolac phenol formaldehyde resin is a resin in which the molar ratio of phenol to formaldehyde exceeds parity.
  • the adhesion promoter is preferably either water or a compound dissolved or dispersed in water, such as those selected from the group comprising water soluble, dispersible or miscible polymers, which are stable to electrolytes with film forming temperatures between -15°C and 40°C, polyvinyl alcohol, polyvinyl acetate, an acrylic such as styrenated acrylic, starch and casein.
  • the adhesion promoter is preferably a solution of from 2,5% to 10% inclusively of a polyvinyl alcohol in water, e.g Mowiol 4/88 by Clariant preferably also containing about 5% to 20% inclusive, more preferably about 10% of hexamethylene tetramine by weight of the polyvinyl alcohol.
  • the solution may be applied to the particles at a rate of between 20% and 80% inclusive by mass of the mass of the particles.
  • the adhesion promoter may be applied before, together with or after application of the dry powder resin to the particles.
  • the particles are preferably resinated with the resin in an amount of from 3% to 20% inclusive of the combined mass of the resin and particles, i.e in a mass ratio of the resin to the particles of from 3:97 and 20:80, more preferably in an amount of from 5% to 12% inclusive of the combined mass of the resin and particles.
  • the particles may be resinated with a dispersion of a dry powder thermosetting resin, and if necessary a catalyst therefor, preferably a novolac phenol formaldehyde resin as discussed above, in a finely divided dry powder inorganic material, which is preferably light weight, such as for example undensified silica fume, fine particle size expanded perlite, bentonite, expanded clay, fine particle size milled exfoliated vermiculite, or the like.
  • a catalyst therefor preferably a novolac phenol formaldehyde resin as discussed above
  • a finely divided dry powder inorganic material which is preferably light weight, such as for example undensified silica fume, fine particle size expanded perlite, bentonite, expanded clay, fine particle size milled exfoliated vermiculite, or the like.
  • the finely divided dry powder inorganic material must have a particle size of a maximum of 150 micron.
  • the dry powder thermosetting resin is dispersed in the finely divided dry powder inorganic material, and then this dispersion is mixed with the particles of vermiculite so that there is little or no separation of the resin particles and the particles of vermiculite.
  • the particles of vermiculite are preferably resinated with the resin in an amount of from 3% to 20% inclusive of the combined mass of the resin and particles, i.e in a mass ratio of the resin to the particles of from 3:97 to 20:80, more preferably in an amount of from 5% to 12% inclusive of the combined mass of the resin and particles.
  • the dry powder thermosetting resin may be mixed with the finely divided dry powder inorganic material in a mass ratio of inorganic material to resin of from 1 :1 to 5:1.
  • each outer panel element comprises from 70% to 97% inclusive by mass, preferably 85% to 95% inclusive by mass of the vermiculite particles. These particles are bound together with a binder which is a thermosetting resin.
  • the outer panel elements contain no other binder such as a hydraulic binder which has been set.
  • the finely divided dry powder inorganic material may comprise a hydraulic binder but this is being used not as a binder but solely as a carrier or dispersant for the finely divided dry powder thermosetting resin. There is no water present in the method and thus any hydraulic binder present cannot set.
  • the second step of the method of the invention is to form the composition into a layer and to press the layer, generally between the platens of a press, at a temperature between 120°C and 240°C inclusive, preferably at a temperature of from 200°C to 220°C inclusive, and at a pressure of from 20 kg/cm 2 , to 75 kg/cm 2 , preferably at a pressure of from 60 kg/cm 2 to 75 kg/cm 2 to a thickness of from 3 mm to 9 mm inclusive, preferably from 3 mm to 6 mm inclusive, at a density of from 1 150 to 1750 kg/m 3 inclusive, preferably of from 1200 to 1550 kg/m 3 inclusive.
  • the third step of the method of the invention is to provide an inner core.
  • the inner core may be for example:
  • a panel formed from a foamed hydraulic binder e.g gypsum, Portland cement, a high alumina cement or a calcium aluminate cement
  • an engineered wood product such as particle board, medium density fibreboard, oriented strand board, plywood, softboard, hardboard, or a laminated veneer lumber;
  • a conventional building board such as gypsum board (sheetrock), cement bound particleboard, cement fibreboard, or gypsum fibreboard;
  • a polymeric foam having a density of from 7 kg/m 3 to 45 kg/m 3 inclusive such as an expanded polystyrene foam, a closed or open cell polyurethane foam, a phenol formaldehyde resole resin foam, a polyvinyl chloride foam, a polyethylene foam, or a polypropylene foam.
  • the fourth step of the method of the invention is to adhere the two outer panel elements on either side of the inner core to form the building panel.
  • the two outer panel elements may be adhesively attached to the inner core using, for example a dispersion in water of a polyvinyl acetate or an acrylic; or a phenol formaldehyde resole resin which is acid catalysed; or a polyurethane precursor, or any other suitable adhesive, with the first three mentioned being the preferred adhesive systems.
  • the adhesion of the outer panel elements to the inner core may be assisted by pressing the two outer panel elements to the inner core in a press.
  • a suitable polymeric foam may be injected between the two outer panel elements firstly to form the inner core and secondly to adhere the inner core to the two outer panel elements.
  • a suitable foam is a polyurethane foam.
  • the method of the invention may include the step of providing an edging for attachment to the edges of the building panel, particularly to protect the core of the panel and to provide structural strength.
  • the edging may be made from the same composition as is used for the outer panel elements, or may be made from wood, metal, or a compressed expanded mineral product.
  • the edging may be attached to the core or to the building panel in any suitable manner, for example using an adhesive as mentioned above.
  • the key to the performance of the building panel of the invention is the high density of the outer panel elements of the building panel, coupled with the thickness thereof.
  • the building panel of the invention a light weight, high impact strength, good flexural strength, good dimensional stability, good refractory characteristics which enable the building panel to withstand the temperatures associated with a fully developed fire without cracking for extended periods of time, and providing a suitable surface for decoration with veneers, foils, melamines and the like.
  • a wall panel measuring 2.7 m by 1.2 m and with a 58 mm overall thickness was formed from a 50 mm thick core of a gypsum foam panel with a density of 400 kg/m 3 and weighing 48 kilograms, to which was adhesively joined two outer panel elements of vermiculite bound by 6% by mass of novolac resin Code 602 by Schenectady, each outer panel element being 4 mm thick and having a density of 1450 kg/m 3 and weighing 18.8 kg.
  • the panel included an all round structural frame of vermiculite with a density of 1250 kg/m 3 and a cross-section of 50 mm by 25 mm and weighing 12 kg.
  • the total panel weight was thus 98 kg, i.e 30 kg/m 2 , which is to be compared with a conventional panel fire rated at 120 minutes, which has a weight of 75 kg/m 2 and a thickness of 80 mm.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Civil Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Building Environments (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention concerne un procédé de fabrication d'un panneau de construction coupe-feu constitué de deux éléments de panneaux extérieurs entre lesquels une partie centrale intérieure est prise en sandwich. Les deux éléments de panneaux extérieurs sont fabriqués avec une composition à base de particules de vermiculite exfoliée, lesquelles sont traitées avec une résine thermodurcissable. Cette composition est transformée en couche puis pressée à une température et une pression appropriées pour obtenir une épaisseur comprise entre 3 et 9 mm et une densité correcte. Les deux panneaux extérieurs sont ensuite collés de part et d'autre de la partie centrale intérieure pour former le panneau de construction. Ce panneau de construction présente de bonnes propriétés pare-feu.
PCT/IB2001/001257 2000-07-25 2001-07-16 Procédé de fabrication de panneaux de construction coupe-feu WO2002007964A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2001279987A AU2001279987A1 (en) 2000-07-25 2001-07-16 Method of making a fire resistant building panel

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ZA2000/3740 2000-07-25
ZA200003740 2000-07-25

Publications (1)

Publication Number Publication Date
WO2002007964A1 true WO2002007964A1 (fr) 2002-01-31

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2001/001257 WO2002007964A1 (fr) 2000-07-25 2001-07-16 Procédé de fabrication de panneaux de construction coupe-feu

Country Status (2)

Country Link
AU (1) AU2001279987A1 (fr)
WO (1) WO2002007964A1 (fr)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2394917A (en) * 2002-10-28 2004-05-12 British Mica Co Holdings Ltd Fire retardant panel
WO2011110536A3 (fr) * 2010-03-09 2012-01-12 Borealis Agrolinz Melamine Gmbh Utilisation de particules inorganiques modifiées en tant que désactiveur d'aldéhyde et d'agent de durcissement, en particulier dans des panneaux à base de bois
EP2500484A1 (fr) * 2011-03-18 2012-09-19 RService Panneau en sandwich resistant au feu
EP3461633A1 (fr) * 2017-10-02 2019-04-03 Orosz Sen, László Plaque de plâtre de protection contre l'incendie
WO2020023915A1 (fr) * 2018-07-27 2020-01-30 Superior Tire and Rubber Corp. Bande de protection de trémie
CN111662665A (zh) * 2020-06-17 2020-09-15 山东农业大学 一种多组分高强度耐水复合胶黏剂及其制备方法

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1998037032A1 (fr) * 1997-02-18 1998-08-27 Windsor Technologies Limited Procede de traitement d'une matiere lignocellulosique ou d'un mineral expanse pour former un produit fini

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1998037032A1 (fr) * 1997-02-18 1998-08-27 Windsor Technologies Limited Procede de traitement d'une matiere lignocellulosique ou d'un mineral expanse pour former un produit fini

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
"CHEMICAL ABSTRACTS + INDEXES,US,AMERICAN CHEMICAL SOCIETY. COLUMBUS", CHEMICAL ABSTRACTS + INDEXES,US,AMERICAN CHEMICAL SOCIETY. COLUMBUS, vol. 97, no. 24, 13 December 1982 (1982-12-13), XP000392665, ISSN: 0009-2258 *

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2394917A (en) * 2002-10-28 2004-05-12 British Mica Co Holdings Ltd Fire retardant panel
WO2011110536A3 (fr) * 2010-03-09 2012-01-12 Borealis Agrolinz Melamine Gmbh Utilisation de particules inorganiques modifiées en tant que désactiveur d'aldéhyde et d'agent de durcissement, en particulier dans des panneaux à base de bois
EP2371891A3 (fr) * 2010-03-09 2012-04-25 Borealis Agrolinz Melamine GmbH Utilisation de particules inorganiques modifiées en tant que désactivateur d'aldéhyde et agent durcissant, en particulier sur les panneaux à base de bois
EP2500484A1 (fr) * 2011-03-18 2012-09-19 RService Panneau en sandwich resistant au feu
EP3461633A1 (fr) * 2017-10-02 2019-04-03 Orosz Sen, László Plaque de plâtre de protection contre l'incendie
WO2019068447A1 (fr) * 2017-10-02 2019-04-11 Rozinka, Zsolt Illés Plaque de plâtre anti-feu
WO2020023915A1 (fr) * 2018-07-27 2020-01-30 Superior Tire and Rubber Corp. Bande de protection de trémie
CN111662665A (zh) * 2020-06-17 2020-09-15 山东农业大学 一种多组分高强度耐水复合胶黏剂及其制备方法
CN111662665B (zh) * 2020-06-17 2021-04-23 山东农业大学 一种多组分高强度耐水复合胶黏剂及其制备方法

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