WO2002047900A1 - Method of making a fire resistant building panel - Google Patents

Method of making a fire resistant building panel Download PDF

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Publication number
WO2002047900A1
WO2002047900A1 PCT/IB2000/001879 IB0001879W WO0247900A1 WO 2002047900 A1 WO2002047900 A1 WO 2002047900A1 IB 0001879 W IB0001879 W IB 0001879W WO 0247900 A1 WO0247900 A1 WO 0247900A1
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WO
WIPO (PCT)
Prior art keywords
composition
layer
thermosetting resin
hydraulic binder
particles
Prior art date
Application number
PCT/IB2000/001879
Other languages
French (fr)
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 PCT/IB2000/001879 priority Critical patent/WO2002047900A1/en
Priority to AU2001226975A priority patent/AU2001226975A1/en
Publication of WO2002047900A1 publication Critical patent/WO2002047900A1/en

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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
    • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • C04B40/06—Inhibiting the setting, e.g. mortars of the deferred action type containing water in breakable containers ; Inhibiting the action of active ingredients
    • C04B40/0608—Dry ready-made mixtures, e.g. mortars at which only water or a water solution has to be added before use
    • C04B40/0616—Dry ready-made mixtures, e.g. mortars at which only water or a water solution has to be added before use preformed, e.g. bandages
    • 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
    • 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 wall panel, and to building panels so formed.
  • a method of making a fire resistant building panel comprising two outer layers and an inner core sandwiched between the two outer layers, from two compositions A and B, the composition A comprising: (a) a suitable amount of a thermosetting resin in finely divided dry powder form; (b) a suitable amount of a hydraulic binder selected from one of three groups of hydraulic binders consisting of: (b) (i) calcium sulphate alpha- or beta-hemihydrate, magnesium oxychloride, magnesium oxysulphate, and an alkali silicate; (b) (ii) a calcium aluminate cement; and
  • composition B comprising:
  • thermosetting resin optionally with a catalyst and optionally dissolved in a suitable solvent
  • 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
  • a dispersion of a dry powder thermosetting resin in a finely divided inorganic material so that the dry powder thermosetting resin is intimately mixed with the particles of vermiculite or perlite; whereafter any solvent present is removed; the method including the steps of:
  • the core layer being formed from either: a composition A when either the first layer is formed from a composition B or the first layer is formed from a composition A and the hydraulic binder in the composition A for the first layer is selected from a different group to the hydraulic binder in the composition A for the core layer, or: a composition B when the first layer is formed from a composition A;
  • step (3) subjecting the product of step (3) to suitable conditions of temperature and pressure to cause the thermosetting resin in the first and second layers and the core layer to set, to form a cohesive product;
  • a fire resistant building panel comprising two outer layers and an inner core sandwiched between the two outer layers, the layers and core being formed from two compositions A and B, the composition A comprising:
  • thermosetting resin in finely divided dry powder form
  • composition B comprising: (d) particles of an exfoliated vermiculite or an expanded perlite or a mixture thereof, which particles are resinated by either:
  • the panel consists of: either a first layer formed from a composition A, a core layer formed from a composition B, and a second layer formed from a composition A; or a first layer formed from a composition B, a core layer formed from a composition A, and a second layer formed from a composition B; or a first layer formed from a composition A containing a hydraulic binder selected from one of the groups (i),
  • Figures 1 are graphs showing the results of fire tests conducted on to 3 panels of the invention.
  • the crux of the invention is a method of making a fire resistant building panel, e.g a wall or roof panel, comprised of two outer layers and an inner core sandwiched between the outer layers.
  • a fire resistant building panel e.g a wall or roof panel
  • Each layer of the panel is formed from a composition which is chosen to provide that layer of the panel with a specific property, for example to give the layer a refractory quality, or to give the layer a coolant quality, or to give the layer weatherproof ness.
  • Composition A comprises a thermosetting resin, a hydraulic binder and an extender which is a mineral in dry finely divided particulate form, and which is preferably either finely divided exfoliated vermiculite particles or finely divided expanded perlite particles, or a mixture of the two.
  • the extender i.e the mineral in dry finely divided particulate form, must have a particle size of from 2 micron to 1000 micron inclusive, preferably from 20 micron to 250 micron inclusive.
  • Vermiculite belongs to the group of hydrated lamina industrial minerals, which are all aluminium-iron magnesium silicates, high in silica, and which propagate bonding in a cement matrix. They resemble a muscavite (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.
  • a typical particle size suitable for this composition is the grade FNX by Micronised Products of South Africa, with a screen analysis - 20 to 40% retained on a 2000 micron screen, 90 to 95% retained on a 710 micron screen, or alternatively the grade SFX where 50 to 75% is retained on a 1000 micron screen, 20 to 35% retained on a 710 micron screen and 0 to 10% retained on a 355 micron screen.
  • Perlite is a natural glass. It is an amorphous mineral consisting of fused sodium potassium aluminium silicate. It occurs naturally as a silicacious volcanic rock. The distinguishing feature that sets perlite apart from other volcanic glasses is that when heated rapidly to above 870°C, it expands to from four to twenty times its original volume as the chemically combined water vaporises. This creates countless tiny bubbles in the heat softened glassy particles.
  • Typical chemical analysis of perlite indicates that silicon oxide percentage exceeds 70%, aluminium oxide exceeds 11% and metallic oxides make up virtually the rest of the composition. Specific gravity is 2,3, softening point 870°C to 1093°C and fusion point 1260°C to 1345°C.
  • the preferred particle size is from 200 to 2000 micron.
  • the extender may also be a blend, in any proportion, of the two materials described above.
  • the extender may also be any other suitable mineral, e.g: siliceous diatoms; the lighter components of flyash or granulated blast furnace slag with a bulk density of 300g/litre or less; hollow glass (siliceous) balloons, principally derived from flyash, such as Fillite by Runcorn, England or Cenolite by Ash Resources, South Africa, with a bulk density of 150g/litre or less; and expanded minerals such as clay, aluminas, foamed gypsum and foamed cement aggregates.
  • suitable mineral e.g: siliceous diatoms; the lighter components of flyash or granulated blast furnace slag with a bulk density of 300g/litre or less; hollow glass (siliceous) balloons, principally derived from flyash, such as Fillite by Runcorn, England or Cenolite by Ash Resources, South Africa, with a bulk density of 150g/litre or less; and expanded minerals such as clay, aluminas, foamed gypsum and foame
  • thermosetting resin is preferably a novolac phenol formaldehyde resin, which is used with a suitable catalyst.
  • a novolac phenol formaldehyde resin is a resin in which the molar ratio of phenol to formaldehyde exceeds parity.
  • An example of a suitable catalyst for use with such a resin is hexamethylene tetramine.
  • An example of a suitable novolac phenol formaldehyde resin and catalyst combination is a two stage resin with a hexamethylene tetramine content of between 6 and 14%, with a hot plate gel time at 150°C of between 40 and 120 seconds, with a flow in mm at 125°C of between 30 and 75mm, and with a particle size sieve analysis percentage retained on a 200 mesh screen of a maximum of 2%.
  • An example of a suitable resin is resin provided by Schenectady Corporation of South Africa, code 602.
  • thermosetting resin is preferably used in an amount of from 2% to 20% inclusive of the thermosetting resin of the total mass of the composition A, i.e the composition A comprises from 2% to 20% inclusive of the thermosetting resin, and from 98% to 80% inclusive of the combination of the hydraulic binder, the extender and any optional components.
  • the third component of the composition is a hydraulic binder, i.e a substance which hydrates and sets in combination with water.
  • the hydraulic binders are divided into three groups, viz:
  • a calcium aluminate cement i.e a high alumina cement containing 20% to 70% of Al 2 0 3 (alumina) which is capable of withstanding temperatures of from 800°C to 1800°C. This is a refractory hydraulic binder.
  • the hydraulic binder used in any particular layer of the building panel of the invention may be a combination of two or more hydraulic binders, provided that both or all the hydraulic binders in the combination are selected from the same group.
  • the hydraulic binder is preferably used in an amount of from 15% to 2000% inclusive of the hydraulic binder by mass of the extender, i.e a mass ratio of the hydraulic binder to the extender of from 1 :6.7 to 20:1 , preferably in a mass ratio of 1:3 to 3:1.
  • composition A may also be added into the composition A.
  • An example of another component is a suitable amount of a further filler material selected from inorganic or mineral fibres, inorganic particles, synthetic fibres, and mixture of two or more thereof.
  • Particularly preferred additional components include inorganic or mineral fibres such as rock wool, mineral wool, glass fibres and ceramic fibres.
  • the inorganic or mineral fibres may be included in the composition A in an amount of from 2% to 15% inclusive by mass of the total mass of the composition A.
  • composition A for formation of the layers, in a finely divided particulate form is important to prevent particle separation in the formation of the layers and subsequently the cohesive product.
  • a key feature of the cohesive product is that it may be formed from dry components that do not separate from one another during formation of the cohesive product.
  • Composition B comprises particles of an exfoliated vermiculite or an expanded perlite or a mixture thereof, which have been resinated in one of three ways.
  • exfoliated vermiculite particles there is meant exfoliated vermiculite in micron (0,5mm and smaller), superfine (1 mm and smaller), fine (2mm and smaller), medium (4mm and smaller) and large (9mm and smaller) particle size. This is the size range for component (d).
  • expanded perlite particles there is meant expanded perlite or volcanic glass in particle sizes of from 5 micron to 4000 micron diameter inclusive. This is the size range for component (d).
  • the particles may be resinated with a liquid thermosetting resin optionally with a catalyst and optionally dissolved in a suitable solvent.
  • the exfoliated vermiculite particles may be resinated with an isocyanate thermosetting resin optionally dissolved in a suitable solvent.
  • R(NCO) x wherein x is variable and denotes the number of NCO groups and R denotes a suitable group.
  • organic isocyanates examples include aromatic isocyanates such as m- and p-phenylenediisocyanate, toluene-2,4- and 2,6-diisocyanates, diphenylmethane-4,4Ddiisocyanate, diphenyltmethane-2,4-diisocyanate, and similar isocyanates.
  • MDIs in the industry.
  • a further description used is a di-isocyanato-diphenyl methane, examples being Suprasec DNR-5005, which is a polymeric MDl, or Suprasec 2020 which is a monomeric MDl with available NCO percentages of 30,7% and 29%.
  • 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 from 1 % to 50% by weight, or liquid carbon dioxide or a blend of the two, suitable for spray application.
  • the solvent may optionally be recovered for reuse.
  • the isocyanate thermosetting resin is left on and in the particles in a latent condition ready for subsequent polymerisation when subjected to the appropriate conditions of heat and pressure.
  • the particles may be resinated by immersion, or by spraying, following which the solvent may be recovered for reuse.
  • the particles may be resinated with a phenol formaldehyde resole resin, which is preferably uncatalysed, i.e in the B- stage, and which is subsequently condensed by heat (in step (4)).
  • a phenol formaldehyde resole resin which is preferably uncatalysed, i.e in the B- stage, and which is subsequently condensed by heat (in step (4)).
  • the resin is preferably applied by spraying.
  • An example of a suitable resin is J 2018 L by Borden Chemical Industries, United Kingdom.
  • the particles are preferably resinated with the resin in an amount of from 2% 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 2:98 to 20:80, more preferably in an amount of from 3% 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 adhesion promoter may be applied before, together with or after application of the dry powder resin to the particles.
  • the resin may be mixed with the dry particles before application of the adhesion promoter. Then, when the adhesion promoter is applied, the resin adheres to the surfaces of the particles.
  • the resin may be applied to the particles after application of the adhesion promoter.
  • 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 minus 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 1% to 10% of polyvinyl alcohol in water, e.g Mowiol 4/88 by Clariant, at a concentration of from 1% to 7,5% of polyvinyl alcohol to water, preferably also containing from 5% to 20% of hexamethylene tetramine on the dry mass of the polyvinyl alcohol.
  • the polyvinyl alcohol solution also serves as an auxiliary binder and formaldehyde scavenger.
  • the adhesion promoter is applied to the particles in an amount of from 1% to 10% inclusive of the adhesion promoter by weight of the particles.
  • the particles are preferably resinated with the resin in an amount of from 2% 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 2:98 to 20:80, more preferably in an amount of from 3% to 12% inclusive of the combined mass of the resin and particles.
  • thermosetting resin is preferably a novolac phenol formaldehyde resin for reasons of cost and performance in fire.
  • a novolac phenol formaldehyde resin is a resin based upon phenol and formaldehyde and any of the variations and modified forms of such a resin, where the molar ratio of phenol to formaldehyde exceeds parity.
  • the novolac resin may contain a catalyst, which on decomposition with heat gives rise to a source of formaldehyde, inducing the condensation of the polymer to form a three dimensional stable network with minimal shrinkage and which is hard, strong and insoluble.
  • the resin is used in finely divided powder form and has the property of commencing to flow at approximately 100 to 130°C, generally around 110°C, followed by the decomposition of the catalyst, for example, hexamethylene tetramine.
  • novolac resins are Schenectady Corporation of South Africa codes 602, 6240 or 3174, or Plyophen 24 - 700 and Plyophen 602N or Varcum 3337 of PRP Resins Division of Sentrachem Ltd of South Africa.
  • the adhesion promoter may be recovered for reuse or otherwise removed. This leaves the particles with a resinated surface which is dry and in a latent condition, ready for processing to form a finished product.
  • the particles may be resinated with a dispersion of a finely divided 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 dry powder thermosetting resin is dispersed in the finely divided dry powder inorganic material, and then this dispersion is mixed with the particles so that there is little or no separation of the resin particles and the particles of vermiculite or perlite.
  • the particles are preferably resinated with the resin in an amount of from 2% 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 2:98 to 20:80, more preferably in an amount of from 3% 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.
  • the finely divided dry powder inorganic material preferably has a particle size of from 0,5 micron to 40 micron inclusive.
  • the dry powder thermosetting resin preferably has a particle size such that 98% passes a 200 mesh screen.
  • the first step of the method of the invention is to form a first layer from either a composition A or a composition B.
  • This may be achieved by any known means.
  • the first layer, together with all the other layers, may be formed using a mechanical forming head as is typically used for laying up pre-press mats in the board manufacturing industry.
  • the second step of the method of the invention is to lay a core layer on the first layer.
  • the core layer may be formed either from a composition A when the first layer is formed from a composition B or from a composition A when the first layer is also formed from a composition A and the hydraulic binder in the composition A for the first layer is selected from a different group to the hydraulic binder in the composition A for the core layer, or from a composition B when the first layer is formed from a composition A.
  • the third step of the method of the invention is to lay a second layer on the core layer, the second layer being formed from a composition A when the first layer is formed from a composition A and wherein when the core layer is formed from a composition A the hydraulic binder in the composition A for the second layer is selected from a different group to the hydraulic binder in the composition A for the core layer, or from a composition B when the first layer is formed from a composition B.
  • the first layer and the second layer do not need to be formed from substantially similar compositions, provided that both compositions fall within the definition given above.
  • each layer of the fire resistant building panel is formed from a composition which is selected to impart certain properties to the layer.
  • the building panel of the invention may be formed from the compositions A and B in a variety of manners as set out below.
  • the panel may consist of a first layer formed from a composition A, a core layer formed from a composition B and a second layer formed from a composition A.
  • the panel of the invention may consist of a first layer formed from a composition B, a core layer formed from a composition A, and a second layer formed from a composition B.
  • the panel of the invention may consist of a first layer formed from a composition A containing a hydraulic binder selected from one of the groups (i), (ii) and (iii), a core layer formed also from a composition A but wherein the hydraulic binder in this composition A is selected from another of the groups (i), (ii) and (iii), so that the hydraulic binders in the first layer and the core layer impart different properties to the respective layers, and a second layer formed from a composition A containing a hydraulic binder selected from a different group to the hydraulic binder in the composition A for the core layer.
  • the hydraulic binders in the compositions A from which the first and second layers are formed may be the same or different
  • An example of the third alternative is a panel consisting of a first layer formed from a composition A containing a refractory hydraulic binder, e.g a calcium aluminate cement, a core layer containing a coolant hydraulic binder, e.g calcium sulphate beta-hemihydrate, and a second layer containing a refractory hydraulic binder, e.g a calcium aluminate cement.
  • a refractory hydraulic binder e.g a calcium aluminate cement
  • a core layer containing a coolant hydraulic binder, e.g calcium sulphate beta-hemihydrate
  • a second layer containing a refractory hydraulic binder e.g a calcium aluminate cement.
  • the fourth step of the method of the invention is to subject the product of step (3) to suitable conditions of temperature and pressure to cause the thermosetting resin in the first and second layers to set, and to cause the thermosetting resin in the core layer to set, to form a cohesive product.
  • first layer, the core layer and the second layer may be compressed and heated in a suitable press at temperatures from 120°C to 250°C inclusive, preferably from 130°C to 220°C inclusive, and pressures of from 2 to 70 kg/cm 2 inclusive, preferably of from 10 to 50 kg/cm 2 inclusive.
  • any layers of the cohesive product containing a hydraulic binder water in an amount sufficient for the hydration of the hydraulic binder so that the hydraulic binder sets to form the fire resistant building panel.
  • water in the context of hydration of the hydraulic binder this is intended to mean liquid water, as well as water vapour or steam.
  • water may be applied to the cohesive product to allow the penetration of a suitable quantity thereof to provide for complete hydration of the hydraulic binder to form the finished product.
  • the method used should avoid water wetting of the core if possible, if this does not contain a hydraulic binder.
  • the cohesive product may be placed under pressure in a pressure cylinder, with the introduction of water vapour or steam to provide the water for hydration of the hydraulic binder so that the hydraulic binder sets to form the fire resistant building panel.
  • the fire resistant building panel produced according to steps (1) to (5) of the method of the invention may then be-further processed.
  • the wall panel of the invention may have an suitable thickness.
  • the wall panel may have a thickness of approximately 50 mm, with the two outer layers being from 6 to 9 mm inclusive and with the inner core being from 32 to 38 mm inclusive.
  • the wall panel of the invention preferably has a density of from 350 kg/m 3 to 750 kg/m 3 inclusive.
  • the building panel of the invention has the main advantage that it has a high degree of fire resistance. It is thus of particular use in areas where a fire rating is required.
  • the fire resistant qualities of the wall panels of the invention have been tested by the South African Bureau of Standards (SABS) in the standard ISO time/temperature to 120 minutes test.
  • SABS South African Bureau of Standards
  • the first panel comprised two outer layers each comprising: Gypsum 1267g
  • the second panel comprised two outer layers each comprising:
  • Total 2114g and a core comprising:
  • the third panel comprise two outer layers each comprising:
  • Total 2112g and a core comprising:
  • Figures 1 to 3 are graphs of temperature of the unexposed face of the panel in degrees C as against the time in minutes. From these graphs, it can be seen that the panels of the invention remain at a temperature below 90°C for at least 60 minutes, before the temperature of the unexposed face of the panel begins to rise. Particularly good results were achieved with the second panel, where the temperature of the unexposed face remained at just over 70°C until 70 minutes had passed.
  • a panel for refractory applications comprised two outer layers each comprising
  • Exfoliated vermiculite with 150 micron size size 25% and a core comprising
  • the panel was pressed to a density of 600 kg/m 3 .
  • the outer layers comprised 15% each of the total mass of the panel.
  • a lightweight building panel comprised two outer layers each comprising
  • Novolac resin (Code 602) 5% and a core comprising
  • Novolac resin (Code 602) 4% (All % by mass)
  • the panel was pressed to a density of 350 kg/m 3 .
  • the outer layers comprised 7,5% each of the total mass of the panel.
  • a fire resistant panel comprised two outer layers each comprising:
  • Polyvinyl alcohol solution 4/88 Mowiol 2% and a core comprising
  • the panel was pressed to a density of 750 kg/m 3 .
  • the outer layers comprised 15% each of the total mass of the panel.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
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  • Laminated Bodies (AREA)

Abstract

A method of making a fire resistant building panel which comprises two outer layers and an inner core sandwiched between the two outer layers, is disclosed. The two outer layers are formed from a composition A containing a thermosetting resin in finely divided dry powder form, a hydraulic binder in finely divided dry powder form and an extender. The core layer is formed from a composition B comprising exfoliated vermiculite particles or expanded perlite particles which are resinated with a suitable thermosetting resin. Alternatively the two outer layers may be formed from a composition B and the core layer may be formed from a composition A. The two outer layers and the core layer are subjected to conditions of temperature and pressure to cause the thermosetting resins to set, whereafter there is provided to the layers, water in an amount sufficient for the hydration of the hydraulic binder, so that the hydraulic binder sets to form the panel.

Description

METHOD OF MAKING A FIRE RESISTANT BUILDING PANEL
BACKGROUND OF THE INVENTION
This invention relates to a method of making a fire resistant building panel, e.g a wall panel, and to building panels so formed.
SUMMARY OF THE INVENTION
According to a first aspect of the invention there is provided a method of making a fire resistant building panel comprising two outer layers and an inner core sandwiched between the two outer layers, from two compositions A and B, the composition A comprising: (a) a suitable amount of a thermosetting resin in finely divided dry powder form; (b) a suitable amount of a hydraulic binder selected from one of three groups of hydraulic binders consisting of: (b) (i) calcium sulphate alpha- or beta-hemihydrate, magnesium oxychloride, magnesium oxysulphate, and an alkali silicate; (b) (ii) a calcium aluminate cement; and
(b) (iii) Portland cement, a calcium sulphoaluminate cement, and a pozzolan; in finely divided dry powder form; and
(c) an extender which is a mineral in dry finely divided particulate form; the composition B comprising:
(d) particles of an exfoliated vermiculite or an expanded perlite or a mixture thereof, which particles are resinated by either:
(e) (i) applying to the particles a liquid thermosetting resin optionally with a catalyst and optionally dissolved in a suitable solvent; or (ii) applying to the particles 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; or (iii) applying to the particles a dispersion of a dry powder thermosetting resin in a finely divided inorganic material so that the dry powder thermosetting resin is intimately mixed with the particles of vermiculite or perlite; whereafter any solvent present is removed; the method including the steps of:
(1) forming a first layer from either a composition A or a composition B;
(2) laying a core layer on the first layer, the core layer being formed from either: a composition A when either the first layer is formed from a composition B or the first layer is formed from a composition A and the hydraulic binder in the composition A for the first layer is selected from a different group to the hydraulic binder in the composition A for the core layer, or: a composition B when the first layer is formed from a composition A; (3) laying a second layer on the core layer, the second layer being formed from either: a composition A when the first layer is formed from a composition A and wherein when the core layer is formed from a composition A the hydraulic binder in the composition A for the second layer is selected from a different group to the hydraulic binder in the composition A for the core layer, or a composition B when the first layer is formed from a composition B;
(4) subjecting the product of step (3) to suitable conditions of temperature and pressure to cause the thermosetting resin in the first and second layers and the core layer to set, to form a cohesive product; and
(5) providing to any of the layers of the cohesive product which contain a hydraulic binder, water in an amount sufficient for the hydration of the hydraulic binder so that the hydraulic binder sets to form the panel, with the first and second layers forming the two outer layers.
According to a second aspect of the invention there is provided a fire resistant building panel comprising two outer layers and an inner core sandwiched between the two outer layers, the layers and core being formed from two compositions A and B, the composition A comprising:
(a) a suitable amount of a thermosetting resin in finely divided dry powder form;
(b) a suitable amount of a hydraulic binder selected from one of three groups of hydraulic binders consisting of:
(b) (i) calcium sulphate alpha- or beta-hemihydrate, magnesium oxychloride, magnesium oxysulphate, and an alkali silicate; (b) (ii) a calcium aluminate cement; and
(b) (iii) Portland cement, a calcium sulphoaluminate cement, and a pozzolan; in finely divided dry powder form; and
(c) an extender which is a mineral in dry finely divided particulate form; the composition B comprising: (d) particles of an exfoliated vermiculite or an expanded perlite or a mixture thereof, which particles are resinated by either:
(e) (i) applying to the particles a liquid thermosetting resin optionally with a catalyst and optionally dissolved in a suitable solvent; or (ii) applying to the particles 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; or (iii) applying to the particles a dispersion of a dry powder thermosetting resin in a finely divided inorganic material so that the dry powder thermosetting resin is intimately mixed with the particles of vermiculite or perlite; wherein the panel consists of: either a first layer formed from a composition A, a core layer formed from a composition B, and a second layer formed from a composition A; or a first layer formed from a composition B, a core layer formed from a composition A, and a second layer formed from a composition B; or a first layer formed from a composition A containing a hydraulic binder selected from one of the groups (i), (ii) and (iii), a core layer formed from a composition A containing a hydraulic binder selected from another of the groups (i), (ii) and (iii), (e.g if the composition A for the first layer contains a hydraulic binder from group (i) then the composition A for the core layer must contain a hydraulic binder from group (ii) or (iii)), and a second layer formed from a composition A containing a hydraulic binder selected from a different group to the hydraulic binder in the composition A for the core layer; the layers having been subjected to suitable conditions of temperature and pressure to cause the thermosetting resins to set, and any layers which contain a hydraulic binder having been provided with water in an amount sufficient for the hydration of the hydraulic binder so that the hydraulic binder has set to form the panel. BRIEF DESCRIPTION OF THE DRAWINGS
Figures 1 are graphs showing the results of fire tests conducted on to 3 panels of the invention.
DESCRIPTION OF EMBODIMENTS
The crux of the invention is a method of making a fire resistant building panel, e.g a wall or roof panel, comprised of two outer layers and an inner core sandwiched between the outer layers. Each layer of the panel is formed from a composition which is chosen to provide that layer of the panel with a specific property, for example to give the layer a refractory quality, or to give the layer a coolant quality, or to give the layer weatherproof ness.
Composition A comprises a thermosetting resin, a hydraulic binder and an extender which is a mineral in dry finely divided particulate form, and which is preferably either finely divided exfoliated vermiculite particles or finely divided expanded perlite particles, or a mixture of the two.
The extender, i.e the mineral in dry finely divided particulate form, must have a particle size of from 2 micron to 1000 micron inclusive, preferably from 20 micron to 250 micron inclusive.
Vermiculite belongs to the group of hydrated lamina industrial minerals, which are all aluminium-iron magnesium silicates, high in silica, and which propagate bonding in a cement matrix. They resemble a muscavite (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. A typical particle size suitable for this composition is the grade FNX by Micronised Products of South Africa, with a screen analysis - 20 to 40% retained on a 2000 micron screen, 90 to 95% retained on a 710 micron screen, or alternatively the grade SFX where 50 to 75% is retained on a 1000 micron screen, 20 to 35% retained on a 710 micron screen and 0 to 10% retained on a 355 micron screen.
Perlite is a natural glass. It is an amorphous mineral consisting of fused sodium potassium aluminium silicate. It occurs naturally as a silicacious volcanic rock. The distinguishing feature that sets perlite apart from other volcanic glasses is that when heated rapidly to above 870°C, it expands to from four to twenty times its original volume as the chemically combined water vaporises. This creates countless tiny bubbles in the heat softened glassy particles. Typical chemical analysis of perlite indicates that silicon oxide percentage exceeds 70%, aluminium oxide exceeds 11% and metallic oxides make up virtually the rest of the composition. Specific gravity is 2,3, softening point 870°C to 1093°C and fusion point 1260°C to 1345°C. The preferred particle size is from 200 to 2000 micron. An example is Genulite Grade M 75 S by Chemserve Perlite (Pty) Ltd of South Africa.
The extender may also be a blend, in any proportion, of the two materials described above.
The extender may also be any other suitable mineral, e.g: siliceous diatoms; the lighter components of flyash or granulated blast furnace slag with a bulk density of 300g/litre or less; hollow glass (siliceous) balloons, principally derived from flyash, such as Fillite by Runcorn, England or Cenolite by Ash Resources, South Africa, with a bulk density of 150g/litre or less; and expanded minerals such as clay, aluminas, foamed gypsum and foamed cement aggregates.
The thermosetting resin is preferably a novolac phenol formaldehyde resin, which is used with a suitable catalyst.
A novolac phenol formaldehyde resin is a resin in which the molar ratio of phenol to formaldehyde exceeds parity. An example of a suitable catalyst for use with such a resin is hexamethylene tetramine. An example of a suitable novolac phenol formaldehyde resin and catalyst combination is a two stage resin with a hexamethylene tetramine content of between 6 and 14%, with a hot plate gel time at 150°C of between 40 and 120 seconds, with a flow in mm at 125°C of between 30 and 75mm, and with a particle size sieve analysis percentage retained on a 200 mesh screen of a maximum of 2%. An example of a suitable resin is resin provided by Schenectady Corporation of South Africa, code 602.
The thermosetting resin is preferably used in an amount of from 2% to 20% inclusive of the thermosetting resin of the total mass of the composition A, i.e the composition A comprises from 2% to 20% inclusive of the thermosetting resin, and from 98% to 80% inclusive of the combination of the hydraulic binder, the extender and any optional components.
The third component of the composition is a hydraulic binder, i.e a substance which hydrates and sets in combination with water.
The hydraulic binders are divided into three groups, viz:
(i) calcium sulphate alpha- or beta-hemihydrate, magnesium oxychlohde, magnesium oxysulphate and an alkali silicate such as sodium silicate. These hydraulic binders all have coolant properties, i.e all of these hydraulic binders include water of hydration which is released and acts as a coolant in a fire. The preferred hydraulic binder in this group is calcium sulphate beta-hemihydrate.
(ii) a calcium aluminate cement, i.e a high alumina cement containing 20% to 70% of Al203 (alumina) which is capable of withstanding temperatures of from 800°C to 1800°C. This is a refractory hydraulic binder.
(iii) Portland cement, calcium sulphoaluminate cement, and a pozzolan such as ground granulated blast furnace slag. These hydraulic binders impart weatherproofness to any layer formed therefrom. They are also low cost hydraulic binders. The hydraulic binder used in any particular layer of the building panel of the invention may be a combination of two or more hydraulic binders, provided that both or all the hydraulic binders in the combination are selected from the same group.
The hydraulic binder is preferably used in an amount of from 15% to 2000% inclusive of the hydraulic binder by mass of the extender, i.e a mass ratio of the hydraulic binder to the extender of from 1 :6.7 to 20:1 , preferably in a mass ratio of 1:3 to 3:1.
Other components may also be added into the composition A.
An example of another component is a suitable amount of a further filler material selected from inorganic or mineral fibres, inorganic particles, synthetic fibres, and mixture of two or more thereof.
Particularly preferred additional components include inorganic or mineral fibres such as rock wool, mineral wool, glass fibres and ceramic fibres. The inorganic or mineral fibres may be included in the composition A in an amount of from 2% to 15% inclusive by mass of the total mass of the composition A.
The provision of this composition A, for formation of the layers, in a finely divided particulate form is important to prevent particle separation in the formation of the layers and subsequently the cohesive product. A key feature of the cohesive product is that it may be formed from dry components that do not separate from one another during formation of the cohesive product.
Composition B comprises particles of an exfoliated vermiculite or an expanded perlite or a mixture thereof, which have been resinated in one of three ways.
By exfoliated vermiculite particles there is meant exfoliated vermiculite in micron (0,5mm and smaller), superfine (1 mm and smaller), fine (2mm and smaller), medium (4mm and smaller) and large (9mm and smaller) particle size. This is the size range for component (d).
By expanded perlite particles there is meant expanded perlite or volcanic glass in particle sizes of from 5 micron to 4000 micron diameter inclusive. This is the size range for component (d).
Firstly, the particles may be resinated with a liquid thermosetting resin optionally with a catalyst and optionally dissolved in a suitable solvent.
For example, the exfoliated vermiculite particles may be resinated with an isocyanate thermosetting resin optionally dissolved in a suitable solvent. Isocyanates are compounds containing the group - N=C=O and are characterised by the general formula:
R(NCO)x. wherein x is variable and denotes the number of NCO groups and R denotes a suitable group.
Examples of organic isocyanates include aromatic isocyanates such as m- and p-phenylenediisocyanate, toluene-2,4- and 2,6-diisocyanates, diphenylmethane-4,4Ddiisocyanate, diphenyltmethane-2,4-diisocyanate, and similar isocyanates.
These and similar are among those referred to as MDIs in the industry. A further description used is a di-isocyanato-diphenyl methane, examples being Suprasec DNR-5005, which is a polymeric MDl, or Suprasec 2020 which is a monomeric MDl with available NCO percentages of 30,7% and 29%.
It is to be noted that the term "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 from 1 % to 50% by weight, or liquid carbon dioxide or a blend of the two, suitable for spray application.
After the treatment of the particles with the isocyanate thermosetting resin in the solvent, the solvent may optionally be recovered for reuse. The isocyanate thermosetting resin is left on and in the particles in a latent condition ready for subsequent polymerisation when subjected to the appropriate conditions of heat and pressure.
The particles may be resinated by immersion, or by spraying, following which the solvent may be recovered for reuse.
As another example, the particles may be resinated with a phenol formaldehyde resole resin, which is preferably uncatalysed, i.e in the B- stage, and which is subsequently condensed by heat (in step (4)).
The resin is preferably applied by spraying. An example of a suitable resin is J 2018 L by Borden Chemical Industries, United Kingdom.
The particles are preferably resinated with the resin in an amount of from 2% 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 2:98 to 20:80, more preferably in an amount of from 3% to 12% inclusive of the combined mass of the resin and particles.
Secondly, 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 adhesion promoter may be applied before, together with or after application of the dry powder resin to the particles. Thus the resin may be mixed with the dry particles before application of the adhesion promoter. Then, when the adhesion promoter is applied, the resin adheres to the surfaces of the particles.
Alternatively, the resin may be applied to the particles after application of the adhesion promoter.
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 minus 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 1% to 10% of polyvinyl alcohol in water, e.g Mowiol 4/88 by Clariant, at a concentration of from 1% to 7,5% of polyvinyl alcohol to water, preferably also containing from 5% to 20% of hexamethylene tetramine on the dry mass of the polyvinyl alcohol. The polyvinyl alcohol solution also serves as an auxiliary binder and formaldehyde scavenger.
The adhesion promoter is applied to the particles in an amount of from 1% to 10% inclusive of the adhesion promoter by weight of the particles.
The particles are preferably resinated with the resin in an amount of from 2% 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 2:98 to 20:80, more preferably in an amount of from 3% to 12% inclusive of the combined mass of the resin and particles.
The thermosetting resin is preferably a novolac phenol formaldehyde resin for reasons of cost and performance in fire.
A novolac phenol formaldehyde resin is a resin based upon phenol and formaldehyde and any of the variations and modified forms of such a resin, where the molar ratio of phenol to formaldehyde exceeds parity. The novolac resin may contain a catalyst, which on decomposition with heat gives rise to a source of formaldehyde, inducing the condensation of the polymer to form a three dimensional stable network with minimal shrinkage and which is hard, strong and insoluble. The resin is used in finely divided powder form and has the property of commencing to flow at approximately 100 to 130°C, generally around 110°C, followed by the decomposition of the catalyst, for example, hexamethylene tetramine. Examples of suitable novolac resins are Schenectady Corporation of South Africa codes 602, 6240 or 3174, or Plyophen 24 - 700 and Plyophen 602N or Varcum 3337 of PRP Resins Division of Sentrachem Ltd of South Africa.
After the dry powder novolac phenol formaldehyde thermosetting resin has adhered to the surface of the particles, the adhesion promoter may be recovered for reuse or otherwise removed. This leaves the particles with a resinated surface which is dry and in a latent condition, ready for processing to form a finished product.
Thirdly, the particles may be resinated with a dispersion of a finely divided 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.
Firstly, the dry powder thermosetting resin is dispersed in the finely divided dry powder inorganic material, and then this dispersion is mixed with the particles so that there is little or no separation of the resin particles and the particles of vermiculite or perlite.
The particles are preferably resinated with the resin in an amount of from 2% 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 2:98 to 20:80, more preferably in an amount of from 3% 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.
The finely divided dry powder inorganic material preferably has a particle size of from 0,5 micron to 40 micron inclusive.
The dry powder thermosetting resin preferably has a particle size such that 98% passes a 200 mesh screen.
The first step of the method of the invention is to form a first layer from either a composition A or a composition B. This may be achieved by any known means. For example, the first layer, together with all the other layers, may be formed using a mechanical forming head as is typically used for laying up pre-press mats in the board manufacturing industry.
The second step of the method of the invention is to lay a core layer on the first layer.
The core layer may be formed either from a composition A when the first layer is formed from a composition B or from a composition A when the first layer is also formed from a composition A and the hydraulic binder in the composition A for the first layer is selected from a different group to the hydraulic binder in the composition A for the core layer, or from a composition B when the first layer is formed from a composition A.
The third step of the method of the invention is to lay a second layer on the core layer, the second layer being formed from a composition A when the first layer is formed from a composition A and wherein when the core layer is formed from a composition A the hydraulic binder in the composition A for the second layer is selected from a different group to the hydraulic binder in the composition A for the core layer, or from a composition B when the first layer is formed from a composition B. It is to be noted that the first layer and the second layer do not need to be formed from substantially similar compositions, provided that both compositions fall within the definition given above.
As is indicated above, each layer of the fire resistant building panel is formed from a composition which is selected to impart certain properties to the layer. Thus, the building panel of the invention may be formed from the compositions A and B in a variety of manners as set out below.
Firstly, the panel may consist of a first layer formed from a composition A, a core layer formed from a composition B and a second layer formed from a composition A.
Secondly, the panel of the invention may consist of a first layer formed from a composition B, a core layer formed from a composition A, and a second layer formed from a composition B.
Thirdly, the panel of the invention may consist of a first layer formed from a composition A containing a hydraulic binder selected from one of the groups (i), (ii) and (iii), a core layer formed also from a composition A but wherein the hydraulic binder in this composition A is selected from another of the groups (i), (ii) and (iii), so that the hydraulic binders in the first layer and the core layer impart different properties to the respective layers, and a second layer formed from a composition A containing a hydraulic binder selected from a different group to the hydraulic binder in the composition A for the core layer. The hydraulic binders in the compositions A from which the first and second layers are formed may be the same or different
An example of the third alternative is a panel consisting of a first layer formed from a composition A containing a refractory hydraulic binder, e.g a calcium aluminate cement, a core layer containing a coolant hydraulic binder, e.g calcium sulphate beta-hemihydrate, and a second layer containing a refractory hydraulic binder, e.g a calcium aluminate cement. In this way there is formed a panel with two outer layers which have refractory properties, and a core layer which has coolant properties, i.e wherein the hydraulic binder releases its water of hydration in a fire.
The fourth step of the method of the invention is to subject the product of step (3) to suitable conditions of temperature and pressure to cause the thermosetting resin in the first and second layers to set, and to cause the thermosetting resin in the core layer to set, to form a cohesive product.
For example, the first layer, the core layer and the second layer may be compressed and heated in a suitable press at temperatures from 120°C to 250°C inclusive, preferably from 130°C to 220°C inclusive, and pressures of from 2 to 70 kg/cm2 inclusive, preferably of from 10 to 50 kg/cm2 inclusive.
The result is a cohesive product which may then be further treated as described below.
In the fifth step of the method of the invention, there is provided to any layers of the cohesive product containing a hydraulic binder, water in an amount sufficient for the hydration of the hydraulic binder so that the hydraulic binder sets to form the fire resistant building panel. Whenever reference is made to water in the context of hydration of the hydraulic binder, this is intended to mean liquid water, as well as water vapour or steam.
For example, after pressing, water may be applied to the cohesive product to allow the penetration of a suitable quantity thereof to provide for complete hydration of the hydraulic binder to form the finished product.
Generally the method used should avoid water wetting of the core if possible, if this does not contain a hydraulic binder.
In another example, the cohesive product may be placed under pressure in a pressure cylinder, with the introduction of water vapour or steam to provide the water for hydration of the hydraulic binder so that the hydraulic binder sets to form the fire resistant building panel.
The fire resistant building panel produced according to steps (1) to (5) of the method of the invention, may then be-further processed.
The wall panel of the invention may have an suitable thickness. For example the wall panel may have a thickness of approximately 50 mm, with the two outer layers being from 6 to 9 mm inclusive and with the inner core being from 32 to 38 mm inclusive.
The wall panel of the invention preferably has a density of from 350 kg/m3 to 750 kg/m3 inclusive.
The building panel of the invention has the main advantage that it has a high degree of fire resistance. It is thus of particular use in areas where a fire rating is required.
Examples
Example 1
The fire resistant qualities of the wall panels of the invention have been tested by the South African Bureau of Standards (SABS) in the standard ISO time/temperature to 120 minutes test.
Three panels of the invention were subjected to this test.
The first panel comprised two outer layers each comprising: Gypsum 1267g
Vermiculite 423g
Reactive gamma-alumina 85g Novolac resin (Code 602) containing
6 to 8% hexamethylene tetramine as a catalyst) 152g
Total 1927g and a core comprsing:
Vermiculite 3329g
Gypsum 169g
Reactive gamma-alumina 338g
Novolac resin (Code 602) 338g
Total core weight 4174g
The second panel comprised two outer layers each comprising:
Gypsum 1521g
Vermiculite 423g
Novolac resin (Code 602) 170g
Total 2114g and a core comprising:
Vermiculite 3412g
Undensified silica fume 85g
Novolac resin (Code 602) 302g
Total core weight 3799g
The third panel comprise two outer layers each comprising:
Gypsum 1419g
Vermiculite 423g
Glass fibre 6mm 100g
Novolac resin (Code 602) 170g
Total 2112g and a core comprising:
Vermiculite 3412g
Undensified silica fume 85g
Novolac resin (Code 602) 302g
Total core weight 3799g
The results of the fire tests are illustrated in Figures 1 to 3 which are graphs of temperature of the unexposed face of the panel in degrees C as against the time in minutes. From these graphs, it can be seen that the panels of the invention remain at a temperature below 90°C for at least 60 minutes, before the temperature of the unexposed face of the panel begins to rise. Particularly good results were achieved with the second panel, where the temperature of the unexposed face remained at just over 70°C until 70 minutes had passed.
These results are achieved as a result of the presence of the hydraulic binder which releases water in a fire and thus keeps the panel cool.
Example 2
A panel for refractory applications comprised two outer layers each comprising
Cement Fondu Lafarge 60%
Portland cement 10%
Novolac resin (Code 602) 5%
Exfoliated vermiculite with 150 micron size size 25% and a core comprising
Dicalite expanded perlite of 100 mesh size 40%
Exfoliated vermiculite with 0,5 mm particle diameter 53%
Novolac resin (Code 602) 7%
(All % by mass)
The panel was pressed to a density of 600 kg/m3. The outer layers comprised 15% each of the total mass of the panel.
Example 3
A lightweight building panel comprised two outer layers each comprising
Portland cement 75%
Expanded perlite, 100 mesh 20%
Novolac resin (Code 602) 5% and a core comprising
Calcium sulphate beta-hemihydrate 21 %
Expanded perlite, bulk density 45 g/l 75%
Novolac resin (Code 602) 4% (All % by mass)
The panel was pressed to a density of 350 kg/m3. The outer layers comprised 7,5% each of the total mass of the panel.
Example 4
A fire resistant panel comprised two outer layers each comprising:
Exfoliated vermiculite, with 150 micron particle size 93%
Novolac resin (Code602) 5%
Polyvinyl alcohol solution, 4/88 Mowiol 2% and a core comprising
Cement Fondu Lafarge 35%
Portland cement 35%
Novolac resin (Code 602) 5%
Exfoliated vermiculite, 150 micron particle size 25%
(All % by mass)
The panel was pressed to a density of 750 kg/m3. The outer layers comprised 15% each of the total mass of the panel.

Claims

CLAIMS 1 A method of making a fire resistant building panel comprising two outer layers and an inner core sandwiched between the two outer layers, from two compositions A and B, the composition A comprising: (a) a suitable amount of a thermosetting resin in finely divided dry powder form; (b) a suitable amount of a hydraulic binder selected from one of three groups of hydraulic binders consisting of: (b) (i) calcium sulphate alpha- or beta-hemihydrate, magnesium oxychloride, magnesium oxysulphate, and an alkali silicate; (b) (ii) a calcium aluminate cement; and (b) (iii) Portland cement, a calcium sulphoaluminate cement, and a pozzolan; in finely divided dry powder form; and (c) an extender which is a mineral in dry finely divided particulate form; the composition B comprising: (d) particles of an exfoliated vermiculite or an expanded perlite or a mixture thereof, which particles are resinated by either: (e) (i) applying to the particles a liquid thermosetting resin optionally with a catalyst and optionally dissolved in a suitable solvent; or (e) (ii) applying to the particles 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; or (e) (iii) applying to the particles a dispersion of a dry powder thermosetting resin in a finely divided inorganic material so that the dry powder thermosetting resin is intimately mixed with the particles of vermiculite or perlite; whereafter any solvent present is removed; the method including the steps of:
(1) forming a first layer from either a composition A or a composition B;
(2) laying a core layer on the first layer, the core layer being formed from either: a composition A when either the first layer is formed from a composition B or the first layer is formed from a composition A and the hydraulic binder in the composition A for the first layer is selected from a different group to the hydraulic binder in the composition A for the core layer, or: a composition B when the first layer is formed from a composition A;
(3) laying a second layer on the core layer, the second layer being formed from either: a composition A when the first layer is formed from a composition A and wherein when the core layer is formed from a composition A the hydraulic binder in the composition A for the second layer is selected from the a different group to the hydraulic binder in the composition A for the core layer, or a composition B when the first layer is formed from a composition B;
(4) subjecting the product of step (3) to suitable conditions of temperature and pressure to cause the thermosetting resin in the first and second layers and the core layer to set, to form a cohesive product; and
(5) providing to any of the layers of the cohesive product which contain a hydraulic binder, water in an amount sufficient for the hydration of the hydraulic binder so that the hydraulic binder sets to form the panel, with the first and second layers forming the two outer layers.
2 A method according to claim 1 wherein in composition A the extender is selected from the group consisting of substantially dry finely divided exfoliated vermiculite particles, substantially dry finely divided expanded perlite particles, and a mixture of the two.
3 A method according to claim 1 or claim 2 wherein in composition A the thermosetting resin is a novolac phenol formaldehyde resin which is used with a catalyst. A method according to any one of claims 1 to 3 wherein in composition A the hydraulic binder is used in an amount of from 15% to 2000% inclusive of the hydraulic binder by mass of the extender.
A method according to any one of claims 1 to 4 wherein in composition A the thermosetting resin is used in an amount of from 2% to 20% inclusive of the thermosetting resin by mass of the composition A.
A method according to any one of claims 1 to 5 wherein in composition B (e)(i) the liquid thermosetting resin is selected from the group consisting of an isocyanate thermosetting resin and a phenol formaldehyde resole resin.
A method according to any one of claims 1 to 5 wherein in composition B (e)(ii) the thermosetting resin is a dry powder novolac thermosetting resin.
A method according to any one of claims 1 to 5 and 7 wherein in composition B (e)(ii) the adhesion promoter is water or a compound dissolved or dispersed in water.
A method according to claim 8 wherein the adhesion promoter is a solution of polyvinyl alcohol in water.
A method according to any one of claims 1 to 5 wherein in composition B (e)(iii) the thermosetting resin is a dry powder novolac thermosetting resin.
A method according to any one of claims 1 to 5 and 10 wherein in composition B (e)(iii) the finely divided inorganic material is selected from the group consisting of undensified silica fume, fine particle size expanded perlite, bentonite, expanded clay, and fine particle size milled exfoliated vermiculite. 12 A method according to any one of claims 1 to 11 wherein in step (4), the product of step (3) is subjected to a temperature of from 120°C to 250°C inclusive and a pressure of from 2 to 70 kg/cm2 inclusive.
13 A fire resistant building panel comprising two outer layers and an inner core sandwiched between the two outer layers, the layers and core being formed from two compositions A and B, the composition A comprising:
(a) a suitable amount of a thermosetting resin in finely divided dry powder form;
(b) a suitable amount of a hydraulic binder selected from one of three groups of hydraulic binders consisting of:
(b) (i) calcium sulphate alpha- or beta-hemihydrate, magnesium oxychloride, magnesium oxysulphate, and an alkali silicate; (b) (ii) a calcium aluminate cement; and
(b) (iii) Portland cement, a calcium sulphoaluminate cement, and a pozzolan; in finely divided dry powder form; and
(c) an extender which is a mineral in dry finely divided particulate form; the composition B comprising:
(d) particles of an exfoliated vermiculite or an expanded perlite or a mixture thereof, which particles are resinated by either:
(e) (i) applying to the particles a liquid thermosetting resin optionally with a catalyst and optionally dissolved in a suitable solvent; or (e) (ii) applying to the particles 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; or (e) (iii) applying to the particles a dispersion of a dry powder thermosetting resin in a finely divided inorganic material so that the dry powder thermosetting resin is intimately mixed with the particles of vermiculite or perlite; wherein the panel consists of: either a first layer formed from a composition A, a core layer formed from a composition B, and a second layer formed from a composition A; or a first layer formed from a composition B, a core layer formed from a composition A, and a second layer formed from a composition B; or a first layer formed from a composition A containing a hydraulic binder selected from one of the groups (i), (ii) and (iii), a core layer formed from a composition A containing a hydraulic binder selected from another of the groups (i), (ii) and (iii), and a second layer formed from a composition A containing a hydraulic binder selected from a different group to the hydraulic binder in the composition A for the core layer; the layers having been subjected to suitable conditions of temperature and pressure to cause the thermosetting resins to set, and any layers which contain a hydraulic binder having been provided with water in an amount sufficient for the hydration of the hydraulic binder so that the hydraulic binder has set to form the panel.
A fire resistant building panel according to claim 13 wherein in composition A the extender is selected from the group consisting of substantially dry finely divided exfoliated vermiculite particles, substantially dry finely divided expanded perlite particles, and a mixture of the two.
A fire resistant building panel according to claim 13 or claim 14 wherein in composition A the thermosetting resin is a novolac phenol formaldehyde resin which is used with a catalyst.
A fire resistant building panel according to any one of claims 13 to 15 wherein in composition B the liquid thermosetting resin is selected from the group consisting of an isocyanate thermosetting resin and a phenol formaldehyde resole resin. A fire resistant building panel according to any one of claims 13 to 15 wherein in composition B the dry powder thermosetting resin is a dry powder novolac thermosetting resin.
A fire resistant building panel according to any one of claims 13 to 15 and 17 wherein in composition B the adhesion promoter is water or a compound dissolved or dispersed in water.
A fire resistant building panel according to any one of claims 13 to 15 and 17 wherein in composition B the finely divided inorganic material is selected from the group consisting of undensified silica fume, fine particle size expanded perlite, bentonite, expanded clay, and fine particle size milled exfoliated vermiculite.
A fire resistant building panel according to any one of claims 13 to 19 wherein the first layer is formed from a composition A, the core layer is formed from a composition B, and the second layer is formed from a composition A.
A fire resistant building panel according to any one of claims 13 to 19 wherein the first layer is formed from a composition B, the core layer is formed from a composition A, and the second layer is formed from a composition B.
A fire resistant building panel according to any one of claims 13 to 19 wherein the first layer is formed from a composition A containing a hydraulic binder selected from one of the groups (i), (ii) and (iii), the core layers is formed from a composition A wherein the hydraulic binder in the composition A is selected from another of the groups (i), (ii) and (iii), and the second layer is formed from a composition A containing a hydraulic binder selected from a different group to the hydraulic binder in the composition A for the core layer.
PCT/IB2000/001879 2000-12-15 2000-12-15 Method of making a fire resistant building panel WO2002047900A1 (en)

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WO2002090293A2 (en) * 2001-05-09 2002-11-14 Balmoral Technologies (Proprietary) Limited Method of making a finished product from a feedstock, a portland cement, and a thermosetting resin
CN102992712A (en) * 2012-11-16 2013-03-27 鞍钢集团矿业公司 Method for preparing light thermal insulating panel by utilizing iron tailings
CN106193346A (en) * 2016-07-08 2016-12-07 中国冶金矿业长春矿产资源开发有限公司 Iron ore mine foam concrete composite insulation boards and manufacture method
EP3461633A1 (en) * 2017-10-02 2019-04-03 Orosz Sen, László Fire protective plasterboard

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2002090293A2 (en) * 2001-05-09 2002-11-14 Balmoral Technologies (Proprietary) Limited Method of making a finished product from a feedstock, a portland cement, and a thermosetting resin
WO2002090293A3 (en) * 2001-05-09 2007-11-08 Balmoral Technologies Propriet Method of making a finished product from a feedstock, a portland cement, and a thermosetting resin
CN102992712A (en) * 2012-11-16 2013-03-27 鞍钢集团矿业公司 Method for preparing light thermal insulating panel by utilizing iron tailings
CN106193346A (en) * 2016-07-08 2016-12-07 中国冶金矿业长春矿产资源开发有限公司 Iron ore mine foam concrete composite insulation boards and manufacture method
EP3461633A1 (en) * 2017-10-02 2019-04-03 Orosz Sen, László Fire protective plasterboard
WO2019068447A1 (en) * 2017-10-02 2019-04-11 Rozinka, Zsolt Illés Fire protective plasterboard

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