WO2013004306A1

WO2013004306A1 - Fire-resistant laminate

Info

Publication number: WO2013004306A1
Application number: PCT/EP2011/061412
Authority: WO
Inventors: Gerrit Janus Vos
Original assignee: Brabants Gelderse Vastgoed Groep B.V.
Priority date: 2011-07-06
Filing date: 2011-07-06
Publication date: 2013-01-10

Abstract

The invention pertains to a fire resistant laminate comprising a non-woven glass fibre web with an areal weight of 10-50 g/m2 which is provided on one side with a first layer of a coating comprising an intumescent component and on the other side with a second layer of a coating comprising an intumescent component, wherein both layers have a layer thickness of at least 100 microns. Preferably at least one coating layer comprises, in addition to an intumescent component, also an endothermic component. The fire resistant laminate according to the invention combines a high fire resistance with a low area! weight, a smooth surface, a certain pliability and a low susceptibility to the occurrence of cracks and tears. The invention also pertains to the use of the laminate in buildings, and to methods for the manufacture of the laminate.

Description

Fire resistant laminate

The invention pertains to a fire resistant laminate and to a method for the manufacture thereof.

Fire resistance is an important property of building

materials. For example, requirements are put to materials that are used on steel constructions in a building. For example, in building regulations, conditions may be put on the minimal time to fire penetration or fire spread of for example 30 or 60 minutes.

In the art plasterboard is often used to provide the required fire resistance. However, plasterboard has a number of disadvantages. It is relatively heavy, and not bendable by nature. Further, the fastening and finishing after mounting is relatively labor intensive,

Other fire resistant systems have specific applications such as for example fire resistant doors built up from different materials .

There is therefore need in the art for a fire resistant system which combines good fire resistant properties with a low area! weight. The invention provides a solution for this problem. Further advantages of the invention and problems solved by the invention will become apparent from, the further specifi cation .

The invention pertains to a fire resistant laminate

comprising a non-woven glass fibre web with an areal weight of 10-50 g/m2 which is provided on one side with a first layer of a coating comprising an intumescent component and on the other side with a second layer of a coating comprising an intumescent component , wherein both layers have a layer thickness of at least 100 microns .

The fire resistant laminate according the invention is relatively light and still has excellent fire resistant properties. Further, it is easy to process,, it has a smooth surface, it shows little tendency to show cracks or tears, and it does not show shrinkage or elongation. Additionally it is relatively pliable, as will be discussed below, and in case of fire it shows little or no smoke development. This combination of properties makes it suitable for use in numerous applications, e.g. , in construction or building, but also in the shipbuilding industry, in aviation, and in the manufacture of fire resistant systems .

The invention will be elucidated with reference to the following figures. The figures serve to illustrate the invention; the invention is not limited, thereto or thereby.

Figure 1 shows a first embodiment of the invention comprising a non-woven glass fibre web (1) with an areal weight of 10-50 g/∑rt2 which is provided on one side with a first layer (2) of a coating with an intumescent component and on the other side with a second layer (3) of a coating with an intumescent component, wherein both layers have a layer thickness of at least 100 microns .

Figure 2 shows a second embodiment of the invention

comprising a non-woven glass fibre web (1) wir.h an area! weight of 10-50 g/m2 which is provided on one side with a first layer (2) of a coating with an intumescent component and on the other side with a second layer (3) of a coating with an intumescent component _> wherein both layers have a layer thickness of at. least 100 microns, and wherein onto the first, layer (2) of a coating comprising an intumescent component a second layer (4) is provided of a non-woven glass fibre web with an area! weight of 10-50 g/m2 , onto which a further layer (5) is provided of a coating comprising an intumescent component; wherein the further layer has a layer thickness of at least 100 microns.

The fire resistant laminate comprises two coating layers comprising intumescent components. The presence of

intumescent components ensures that the coating layer expands upon exposure to heat, resulting in the formation of a thicker layer. It has been found that the presence of two layers with an intermediate glass fibre web results in an improved fire resistance as compared to a single layer with the same total thickness as the two layers (compare Example 1 with Comparative Example C) . It is assumed, that the mechanism behind this effect is as follows: If the fire resistant laminate according to the invention is exposed to heat, in the first instance the first layer will expand, forming a heat resistant layer. When the exposure to heat continues, the second layer will subsequently expand.

The degree of expansion of the laminate preferably is at least 1.05; calculated as the thickness of the expanded laminate divides by the thickness of the original laminate, more preferably at least 1,1, still more preferably at least 1,5. The degree of expansion may also be higher, for example at least 2, or even at least 3. Preferably, one or more of the coating layers in the laminate according to the invention also comprise an endothermic component , that is, a component which upon heating follows a chemical reaction in which heat is absorbed; which results in a cooling effect occurring. It is preferred that ail. coating layers comprise an endothermic component in addition to an inturoescent component. It will be evident that the layers can comprise one or more intuinescent components, and optionally one or more endothermic components.

The fire resistant laminate according to the invention comprises a non-woven glass fibre web with an areal weight of 10-50 g/m2. If the glass fibre web has an areal weight of more than 50 g/m.2_f the double-expanding effect of the

invention will not be obtained. If the glass fibre web has an areal weight below 10 g/m2, the strength of the laminate will become too low. As preferred range an areal weight of 30-50 g/m2 may be mentioned.

It has been found that when instead of such a non-woven glass fibre web a woven glass fibre fabric is used, the fire resistant properties of the material decrease. Further, when using a glass fibre fabric, the material is more sensitive to crack formation,, and more difficult to bend.

The coating layers both have a layer thickness of at least 100 microns. The effect of the invention will be improved when the de layer thickness is at least 200 microns, more specifically at least 350 microns. Preferably, the layer thickness will be not higher than 3000 microns. More

specifically it may be preferred if the layer thickness is not higher than 2000 microns. In some embodiments it may be preferred if the total layer thickness is not more than 1000 microns, or even not more than 750 microns . The layer thickness discussed above is the average layer thickness.

In pri.ncipe the thickness of both layers may be selected independently. It is preferred for both layers to have the same thickness, because in that case a symmetric laminate is obtained, where the person applying the laminate does not have to check which side of the laminate is the "front" and which side is the "back" . With "the same thickness" is meant that the difference in thickness between the two layers is such that in use there is no difference between the effect of laminates provided with one side to the front and laminates provided, with the other side to the front, A difference in thickness of, for example, 10% or less of the total thickness of the layers may be acceptable.

The laminate has a total thickness of at least 0.2 mm (200 microns). At a thickness of below 0.20 mm the effect of the invention will be insufficiently obtained. It is preferred for the laminate to have a thickness of at least 0.75 mm. The thickness of the laminate according to the invention is in general at most 6 mm (6000 microns) .

In one embodiment the laminate according to the invention has an area! weight of at least 200 g/m2 , more specifically at least 600 g/m2. If the areal weight of the laminate is too low, the fire retardancy of the system decreases. In one embodiment the areal weight is at most 1500 g/m2, more specifically at most 1200 g/m.2. It may be preferred for the areal weight of the laminate to be between 600 en 1000 g/re2. It is preferred for the laminate to have a certain pliability. This improves the processabili ty and impact resistance of the material. It is preferred for the laminate to have a pliability which is such that it can be bended without cracking to an angle of 90° around a cylindrical pipe with a diameter of 30 cm. Depending on the application a higher pliability may be desirable, such as around a pipe with a diameter of 15 cm, more preferably 10 cm, still more preferably 5 cm, even more preferably with a diameter of 2.5 cm, still more preferably a diameter of 1.5 cm.

The pliability of the material is provided on the one hand by the use of a non-woven glass fibre web instead of a woven glass fibre fabric. On the other hand the flexibility of the material may be improved by selecting a coating with visco- elastic properties. This will be elucidated below.

In one embodiment of the invention a fire resistant laminate is provided which comprises two layers of a glass fibre web, sandwiched between three coating layers. In other words, in this embodiment, illustrated in Figure 2, the invention pertains to a fire resistant laminate comprising a non-woven glass fibre web with an area! weight of 10-50 g/m2 which is provided on one side with a first layer of a coating

comprising intumescent and optionally endothermic components and on the other side with a second layer of a coating comprising intumescent and optionally endothermic components, wherein both layers have a layer thickness of at least 100 microns, wherein onto the first layer of a coating comprising intumescent and optionally endothermic components a second layer is provided of a non-woven glass fibre web with an area! weight, of 10-50 g/m.2, onto which a further layer is provided of a coating comprising intumescent and optionally endothermic components; wherein the further layer has a layer thickness of at least 100 microns. For the properties of both glass fibre webs and coating layers reference is made to what has been discussed above. This five-layer laminate generally has a total thickness between 0,6 mm and 9 mm, more

specifically between 1 mm and 6 ram.

The invention, also pertains to systems comprising still further layers of glass fibre web and coating, for example a system wherein onto the further layer of a coating with intumescent components a further layer is provided of a glass fibre web as described, above, onto which a still further layer of a coating is applied. The provision of even, further layers is also possible, in one embodiment the system with two coating layers as described on both sides of one layer of a glass fibre web is preferred. In another embodiment a system comprising two layers of glass fibre web and three coating layers as described is preferred.

The laminates according to the invention are suitable, for example, for use as lining in buildings, for example on building constructions , on facades, ceilings, and wall systerns . It may be used as intermediate layer which is provided with a further finish in the form of for example paint, wallpaper, or veneer. The materia.! may also be used in for example the ship building industry, aviation, or

installation industry, or in the manufacture of fire

resistant moving parts such as doors, hatches, and panels. Other suitable applications will be evident to the skilled person . The length and width of the laminate be set at any desired value, dependent on the intended use. The laminate can for example have a width of at least 30 cm, and a length of at least 1 metre . It can easily be converted into smaller pieces . Depending on. for example the thickness and the pliability, the laminate can be provided in the form of a roll with any desirable width .

The fire resistant laminate according to the invention may be manufactured by providing a layer of a coating composition on both sides of a glass fibre web, and allowing the layers to dry. The provision of the layers can be carried out in a conventional manner, e.g., by brushing, rolling, using a doctor blade, spraying, dipping, or combinations thereof, in one or more steps . In one embodiment the glass fibre web is first impregnated by applying a relatively diluted low- viscosity coating composition, followed by applying the coating layers using a less diluted more viscous composition. Drying of the coating layers can be performed in a

conventional manner, e.g. , to the air.

In general the material will oe dried completely in air. In some cases it may be attractive to provide the material in. partially dried form, because it will then have a higher pliability. It can then be dried further after installation.

The five-layer laminates as described above may be obtained by stacking of two three-layer laminates before the coating layers have been dried, pressing them together, for example using a roll, and allowing the combined material to dry. In general, the coating composition used to manufacture the coating layers comprises a carrier medium,, a binder, and intumescent and endothermic components. The coating

composition is liquid. The carrier medium generally comprises water. The binder is the material that forms the layer and keeps it together. The coating composition may also comprise other conventional components such as fillers, stabilizers, pigments, etc, Intumescent components include for example the combination of a carbon source which forms the foam and a propeliant which forms the gas that causes the foaming .

Examples of endothermic components are hydrated metal oxides ana borates, for example aluminium, trihydrate, magnesium hydroxide, and zinc borate.

Suitable coating compositions with intumescent and

endothermic components are known, and commercially available. They can also be obtained by mixing compositions. It is preferred if the coating composition results in a layer with viscoelastic properties. This can for example be attained by providing the coating composition in whole or in part from, coatings sold for use on cables.

Examples of suitable coating compositions are a combination of Hensotherm 4 KS or Hensotherm 4 KS viskos with. Hensomastik 5 KS, and a combination of 4 KS with Hensotherm 4 KS viskos.

To make the system not more complicated than necessary it is preferred for the coating layers to have the same

composition ,

The invention, will be elucidated by the following examples, without being limited thereto or thereby. Examples

General manufacturing method The coating was diluted until a sprayable composition was obtained. This was provided onto the glass fibre web using an Airlespomp with a pressure of about 60 bar until a thin layer was obtained. The thus-obtained impregnated web, with a thickness of 200 microns, was dried. Subsequent ly, the impregnated web was coated on one side (comparative example) or on both sides with a coating composition. This was done using an Mrlesporap with a pressure of about 200 bar.

Subsequently, the panel was dried in air. The following coating compositions were used:

- Kensotherm 4KS, a water-based intumescent coating

- Hensoraastik 5KS_f a water-based viscoelastic coating with endothermic properties !·.χ.^::η;ρ^'Ρ_; ..

10 kg Hensotherra 4KS was mixed with 2 kg Hensomastik 5KS. A non-woven glass fibre web (Relius Benelux) with an areai weight of 45 g/nc^' was coated as described above. The

thickness of the layers on both sides of the glass fibre web was 550 microns, The total thickness of the system was 1100 microns (determined with an elektra Physik minitest 600),

The system, was applied onto a MDF panel, with a thickness of 10 mm. Het panel consisted of two parts which were glued together in the middle. The panel was placed in a fixed test unit and exposed on the side of the laminate to a propane burner, wherein the distance between the burner and the material was 8 cm . The distance between the flame core and the material was 4 cm. The temperature was determined at the front of the panel and at the back of the panel using an infrared thermometer T . Q . C . TE 1006,

The results over time are presented in table 1.

Comparative example Ά

Example 1 was repeated, except that instead of a non-woven glass fibre web a woven glass fiber web was used with a mesh width of 5 mm and an area! weight of 100 g/lih , The results over trme are presented in table 1,

Example 1Ά

Example 1 was repeated, except that no Hensomastik 5 KS was added. The results over time are presented in table 1.

Comparative Example C

Example 1 was repeated, except that only one side of the glass fibre web was provided with a coating layer. The total thickness of the system was 1100 microns, The system was provided onto the MDF panel with the glass fibre web side facing the panel. The results over time are presented in table 1.

As can be seen from Table 1, the system according to the invention results in a lower temperature at the back of panel than the comparative systems. The addition of an endotherirtal component gives improved results.

In comparison, when an MDF panel that had not been provid with a fire resistant laminate was subjected to the above mentioned test conditions, the panel, burned through after minutes door, under the formation of smoke and hazardous fumes ,

Example _2

Two systems according to Example 1 were stacked onto each other before drying, and subsequently bonded together by pressing the stack together using a roller. The result was subsequently dried. In this manner a system was obtained which comprised, from top to bottom, a coating layer with a thickness of 550 microns, a layer of a glass fibre web, a coating layer with a thickness of 1100 microns, a layer of a glass fibre web, and a coating layer with a thickness of 550 microns. The system was tested, as described in example 1. The results are in table 2.

Table 2 shows that a multilayer system also provides good results .

Example 3 -^■ influence of the thickness of the non-woven web

Two systems were manufactured, one according to the invention, on the basis of a non-woven class fibre web with an areal weight of 45 g/m2 , and one comparative on the basis of a non- woven glass fibre web with an areal weight of 80 g/m2 , The systems were manufactured as follows.

10 kg Hensotherm 4KS was mixed with 2, 5 kg Hensotherm 4KS Viscos . The glass fibre web was coated as described in

Example 1» The thickness of the layers on both sides of the glass fibre web was about 750 microns. The total thickness of the systems was about 1500 microns (determined with an

elektra Physik minitest 600) .

The systems were each applied, onto an Okoume panel with a thickness of 10 mm, Het panel consisted of two parts which were glued together in the middle. The panel was placed in a fixed test unit and exposed on the side of the laminate to a propane burner, wherein the distance between the burner and the material was 8 cm. The distance between the flame core and the material was 4 cm. The temperature was determined at the front of the panel and at the back of the panel using an infrared thermometer T.Q.C, TE 1006,

The results over time are presented in table 3,

As can be seen from Table 3, the temperature at the back of the panel is significantly lower in the system according to the invention than in the eomparat ive system. Further_y the system according to the invention was very flexible, did not tear, and was easy to process. The comparative system was not flexible, but fractured at the slightest bending, and tore easily .

Claims

Fire resistant laminate comprising a non-woven glass fibre web with an area! weight of 10-50 g/m2 which is provided on one side with a first layer of a coating comprising an intumescent component and on the other side with a second layer of a coating comprising an intumescent component , wherein both layers have a layer thickness of at least 100 microns.

Fire resistant laminate according to claim 1

characterised in that onto the first layer of a coating comprising an intumescent component a second layer is provided of a non-woven glass fibre web with an area! weight of 10-50 g/m2, onto which a further layer is provided of a coating comprising an intumescent

component; wherein the further layer has a layer thickness of at least 100 microns.

Fire resistant laminate according to any one of the preceding claims characterised in that at least one coating layer comprises,, in addition to an intumescent component , also an endothermic component.

Fire resistant laminate according to any one of the preceding claims, characterised in that the coating layers have a layer thickness of at least 200 microns, more specifically at least 350 microns.

Fire resistant laminate according to any one of the preceding claims, characterised in that the coating layers have a layer thickness of not more than 3000 microns ,

Fire resistant laminate according to any one of the preceding claims, characterised in that the layer thickness of both coating layers differs not more than 10% from each other, calculated on the total thickness of the layers.

Fire resistant laminate according to any one of the preceding claims, characterised in that the total thickness of the laminate is between 0,2 mm and 6 mm.

Fire resistant laminate according to any one of the preceding claims, characterised in that it has an area! weight of at least 500 g/m.2, more specifically at least 600 g/m2, and of at. most 1500 g/m2, more specifically at most 1200 g/m.2.

Fire resistant laminate according to any one of the preceding claims, characterised in that the laminate has a pliability which is such that it can be bended without cracking to an angle of 90° around a cylindrical pipe with a diameter of 30 cm.

Use of the fire resistant laminate according^' to any one of the preceding claims as fire resistant material in buildings .

Method for the manufacture of a fire resistant laminate according to claim 1 in which both sides of a glass fibre web are provided with a layer of a coating composition, and the layers are dried.