FR2460204A1 - DELAYED INFLAMMATION LAMINATE AND METHOD FOR THE PRODUCTION THEREOF - Google Patents

Abstract

DELAYED INFLAMMATION LAMINATE COMPRISING A FLAMMABLE SUPPORT 10, A METAL SHEET 11 ADHESIVE TO A SIDE OF THE SUPPORT AND A FIBROUS TABLECLOTH 12 SATURATED RESIN GLUEED TO THE SHEET, THE SHEET 11 BEING BETWEEN THE FIBROUS TABLECLOTH 12 AND THE NAP 10. 12 IS MAINLY FORMED OF FIRE RESISTANT FIBERS, SUCH AS GLASS, CERAMIC MATERIAL, PHENOLIC RESIN, CARBON AND ASBESTOS. THE TABLECLASS SATURING RESIN IS SELECTED AMONG VINYLIC COMPOUNDS, ACRYLIC RESINS, POLYESTERS, POLYAMIDES, POLYIMIDES, MELAMINE RESINS, PHENOLIC RESINS, UREE-FORMALDEHYDE RESINS, EPOXY RESINS, CELL RESINS, . SHEET 11 MAY BE FORMED FROM ANY SUITABLE METAL, SUCH AS ALUMINUM, OF A THICKNESS OF UP TO SEVERAL TENS OF MICRONS. THE SUPPORT MAY BE A CONSTRUCTION MATERIAL SUCH AS CONSTRUCTION WOOD, PLYWOOD, A PRESSED PANEL, A PARTICLE PANEL, A HARD PANEL OR AN INSULATING PLASTIC FOAM.

Description

I The present invention aims to give

  fire resistance properties to inflammable materials

  mables and it relates more particularly to the stra-

  tification of layers of material on insulated supports

  flammable to protect media from

  combustion when exposed to a flame.

  Protection against flammability in building materials is necessary

  so that the occupants of buildings, vehicles

  tomobiles, planes, etc., are not exposed to an unjustified danger resulting from the flammability of the materials which surround them. Significant progress has been made in recent years in the area of flammability protection,

  partly due to more stringent building regulations

  and improved criteria for testing. All-

  However, obtaining protection against inflam-

  often only possible by sacrificing

very advantageous properties.

  For example, incombustible structures

  of metal plates have the disadvantages

  come to be heavy, to lack resistance to

  corrosion and be difficult to manufacture. Compo-

  flame resistant fibrous sections do not have a

  great durability and are difficult to decorate. Likewise

  me, fibrous panels, cement and gypsum man-

  quent of durability and are very heavy when given a sufficient thickness so that they have a

  structural rigidity and mechanical strength

  por4antes. There are flame resistant paints to protect flammable media, but they often include toxic or unwanted components for another reason. Paints without these unwanted components tend to be lacking

of durability.

  The object of the present invention is to

  mediate these disadvantages by delaying

  ignition to in- building materials

  flammable, such as wood or plastic foam, without excessively increasing the

  support weight and providing support

  durable face. It also aims to provide such a delay in inflammation by using materials

readily available.

  A peculiarity of the present invention

  tion relates to the stratification on the support of a metal sheet and a fibrous web saturated with resin, the sheet being between the support and the fibrous web.

  Other purposes, particularities and advantages

  ges of the invention will also result from the descrip-

  tion below, in which reference is made to the drawing

  Annex. The drawing is a view, partially in pers-

  pective and partially in cross section, of a delayed ignition laminate according to the present invention. In the figure, the support 10 can be a building material of any type of which

  it may be advantageous to make it fire resistant.

  On one side of the support 10, a layer of

  metal sheet 11. On the face of the sheet 11 op-

  placed on the face glued to the support 10, there is a

  fibrous web 12 saturated with resin.

  The support can be such a material

  only lumber, plywood, pan-

  pressed water, particle board or panel

  hard, having rigidity and structural strength

  rale. The support could be an insulating material,

  like polystyrene foam, urea foam

  thane or other plastic foams.

  The sheet 11 can be formed of a metal

  any tal having a fairly high melting point

  so that it remains intact when exposed to cha-

  them with an open flame. However, in practice, the sheet is not exposed directly to a flame, since it is protected against the flame by the

  support 10, on one side, and by the web 12 on the other.

  The sheet 11 has a thickness of between a few microns and a few tens of microns, and it is formed of a metal, such as aluminum, which is fairly malleable.

  to be put in the form of a sheet of such

  thickness. Any suitable adhesive capa-

  ble to stick the metal sheet to the support can

be used for this purpose.

  The fibrous web 12, which is saturated with a resin, has the dual role of isolating the sheet

  so as to protect it when the laminate is exposed

  dried over a flame, and to provide the laminate with an over-

  durable and decorative face. The tablecloth can be a

  woven or non-woven material, and is formed principally

  also fire-resistant fibers, such as glass, ceramic, phenolic resin, carbon

  and minerals, for example asbestos. My tablecloths

  woven fabrics can be formed by wet deposition of fibers, as in a manufacturing process

  paper, or by air deposition of the fibers in a process

  dry dice. Preferably, the sheet is formed of fibers

  of glass with diameters between 1 and 15 mi-

  crons. The resin used to saturate the web 12 can be any suitable material and is chosen so as to meet the requirements for

  special applications. For example, we can choose

  if a resin will provide resistance to ultra-

  purple when considering outdoor exposure, or which will provide abrasion resistance when needed. Resin can also

  be chosen for its decorative or decorative qualities

  wheat. Although the resin is not necessarily

  combustible, the flammability and the heat resistance can be taken into account when choosing the resin used. Resins usable for purposes

  of the present invention include compounds vi-

  nylics (e.g. vinyl chloride, vinyl acetate and vinyl fluoride), acrylic resins, polyesters, polyamides, polyimides,

  melamines, phenolic resins, urea resins-

  formaldehyde, epoxy resins and cell resins

modified losiques.

  The resin can be applied to the nap-

  eg fibrous without dilution in any vehicle,

  from a solution, a dispersion of the type la-

  tex, or materials such as plastisols or organosols. Any suitable adhesive can be

  used to bond the saturated fibrous web of re--

  Dry sine 12 to the sheet 11. Alternatively, the web, while it is wet, can be applied to the sheet so that the resin, after drying, serves to bond together the web and the sheet. Preferably, the saturated wet sheet, the sheet and the support are placed in face-to-face contact and heat and pressure are then applied to the laminate for one

  sufficient time to cure the resin.

  If desired, pigments can be added to the resin for decorative purposes. In addition, fillers delaying inflammation, such as antimony oxide and hydrated alumina, can be added to the resin to increase its delay in inflammation. Although the invention is believed to be

  clear from the description above, it will

  further illustrated by the following examples.

- EXAMPLE I -

  A support consisting of hardboard, sold commercially under the brand name "Masonite", is coated on one side with a mixture of epoxy resin

  epichlorohydrin-bisphenol based and polya- resin

  mide to a thickness of about 54 g / m, the epoxy resin

  xy and the polyamide being present in a weight ratio of 3: 1. An aluminum sheet having a thickness of about 0.02 mm is placed on the coated side of the support. The exposed side of the sheet is covered

  a layer of the epoxy / polyamide resin described above

  top at a thickness of about 215 g / m. A tablecloth

  composed of 90% glass fibers and 10% fiber

  wood, having been formed by a wet process and weighing 60 2 is placed on the resin layer. The resin is allowed to soak the fibrous web and saturate it completely and then the exposed face of the web is covered with a non-stick sheet coated with fluorocarbon. The laminate is placed in a heated press and subjected to a pressure of about 48,800 kg / m at 1600C for a period of seven minutes, the resin then being cured. Remove the laminate from the press and tear off the sheet

non-stick laminate.

- EXAMPLE II -

  We prepare a laminate in the same way

  3O writes in Example I, except that the water table

  machine has a weight per unit area of 30 g / m and that the thickness of the layer of epoxy / polyamide resin applied to the exposed face of the sheet corresponds

at around 108 g / m2.

- EXAMPLE III -

  A laminate is prepared in the manner described

  te in Example I, except that we use a

  brominated epoxy in place of epoxy / polya- resin

  mide and press the laminate for 20 minutes

at 180 0 to harden the resin.

- EXAMPLE IV -

  A laminate is prepared in the manner described

  te in Example I, except that we use a

  phenolic sine instead of epoxy / polyamide resin

of.

-EXAMPLEV-

  A laminate is prepared in the manner described

  te in Example 1, except that we use a friend

  intumescent noplast in place of epoxy resin / po-

lyamide.

  The laminates of Examples I to V are pre-

trimmed according to the present invention. For comparison purposes

reason, laminates are prepared as described in

the following four examples.

- EXAMPLE VI -

  A laminate is prepared in the manner described

  te in Example I, except that no sheet is used. Instead, the 215 g / m2 resin layer is applied directly to the Masonite backing and the fibrous web is placed over this layer. The laminate is heated and pressed as described

in Example I to harden the resin.

- EXAMPLE VII -

  We prepare a laminate in the same way

  described in Example I, except that no fibrous web saturated with resin is used. Instead, after coating Masonite backing with

  resin and placed the sheet layer on the coated side

  kills, the laminate is heated and pressed as described

  in Example I to harden the resin.

- EXAMPLE VIII -

  We prepare a laminate in the same way

  written in Example I, except that the positions of the sheet and the fibrous sheet are reversed. The

Masonite support is coated with epoxy resin / po-

  lyamide at a rate of 215 g / m2 and we place the sheet

  breuse on the resin layer. After the resin has soaked the sheet, the sheet layer is placed on

the tablecloth. The laminate is heated and pressed as de-

written in Example I to harden the resin.

- EXAMPLE IX -

  We prepare a laminate in the same way

  written in Example I, except that a tablecloth

lulosique, i.e. a sheet formed entirely of combustible cellulose fibers, having a weight per unit area of 34 g / m2, is used for the

place the glass / wood tablecloth.

  To determine the relative resistance to combustion of the laminates prepared as described in the preceding examples, use is made of a procedure as described by HL Vandersall in "Journal of Paint Technology" 1, Volume 39, N 511, page 494 (1967). According to this procedure, a tunnel having a length of 61 cm and a width of approximately cm is used. The tunnel is tilted at 280 from the horizontal and the laminate samples are

placed one at a time in the tunnel. As a source of information

  flammation, a Meeker burner is placed 28.6 mm from the bottom of each sample and the current is adjusted

gas at a constant value of 21.15 liters per cm.

  Each trial is conducted for a period of four

  minutes and note the maximum flame spread

me down the tunnel.

As reference materials, an index of 0 is assigned to an asbestos-cement panel and a

  index of 100 to parquet boards in red chême.

  The "flame spread" index for each sample is determined by the following relationship: Flame spread index = Lo - La x 100 O Ls = maximum distance traveled by the flame for the samples La = maximum distance traveled by the flame for the asbestos-cement panel Lo = maximum distance traveled by the flame for

red oak planks.

Flammability test results

Description of samples

Propagation index

flame

me I 60 g / m2 tablecloth, epoxy / polyamide, sheet II 30 g / m2 tablecloth, III 60 g / m2 tablecloth, IV 60 g / m2 tablecloth, V 60 g / m2 tablecloth, VI No epoxy / polyamide sheet, sheet brominated epoxy resin, sheet 79 phenolic resin, sheet 95 aminoplast, sheet 48 + VII No fibrous layer VIII Tablecloth on the outside of the sheet The panel

burns

the panel

burns

  fully IX Cellulose tablecloth, epoxy / polyamide, The panel

leaf burns

quite.

It will be understood from these results that only

Laminates having all the essential features of the present invention, like those of Examples I to V, exhibit superior fire resistance properties. These features include the simultaneous use of a fibrous web saturated with resin and a layer of metal foil, placing the sheet layer between the support and the fibrous web and the use of a fibrous web

  mainly made of fire resistant fibers.

  3o When a sheet is not used (Example VI) or when a fibrous sheet is not used (Example VII) or when

Example

N the fibrous web is between the sheet and the support (Example VIII) or when using a combustible fibrous sheet (Example IX), the resistance to

fire is severely reduced.

  If the results of the tests concerning the laminates of Examples I and II are compared, it will be noted

  that the laminate of Example II has an index of propa-

of the flame more advantageous than that of Example-

  ple I, although the laminate of Example I includes a thicker fibrous web. The reason seems to be that the laminate of Example I includes a larger amount of resin saturating the web, and it is the combustion of the resin which has an influence on the flame propagation indices. Consequently, we

prepare another sample as described in Example-

ple next.

- EXAMPLE X -

  A laminate is prepared as described in Example I, except that the fibrous web is saturated with a chlorinated polyester resin catalyzed by

  methyl ethyl ketone peroxide, a flame retardant resin-

te, instead of epoxy / polyamide resin. In addition, the laminate is pressed at a pressure of 48,800 kg / m2 for 5 minutes at a temperature of 130 C. When subjected to a flame test as described above, the laminate has an index of propagation of the flame

of 22.

It will therefore be seen that although the invention provides

  establishes a significant fire resistance whatever

  the resin used, the use of an inflam-

  delayed mation improves the fire resistance of the

tified.

  It is obvious that the invention is not limited to

  ted to the embodiments described and which can be adapted thereto.

  wear all variants coming within the scope of the invention

tion. he

Claims (12)

1) A delayed ignition laminate, characterized in that it comprises: a) - a flammable support, b) - a metal sheet bonded to one face of the support and c) - a fibrous sheet saturated with resin bonded to the face of the sheet opposite the face of the latter which is glued to the support, so that the sheet is between the sheet and the support, the web being mainly made up of fibers fire resistant. 2) A delayed ignition laminate as defined in claim 1, characterized in   that the metal sheet has a thickness comprised between-   be a few microns and a few tens of microns.   3) A delayed ignition laminate as defined in claim 1, characterized in that that the metal sheet is aluminum foil.   4) A delayed ignition laminate as defined in claim 1, characterized in that the web is the product of a manufacturing process wet paper. ) A delayed ignition laminate as defined in claim 1, characterized in that the tablecloth is formed mainly of selected fibers sies among glass fibers, ceramic material,   phenolic, carbon and asbestos resin. 6) A delayed ignition laminate as defined in claim 1, characterized in that the web is formed mainly of fibers of   glass having a diameter between 1 and 15 microns.   7) A delayed ignition laminate as defined in claim 1, characterized in that the resin saturating the sheet is chosen from vinyl compounds, acrylic resins, poly- esters, polyamides, polyimides, resins   melamine, phenolic resins, urea resins-   formaldehyde, epoxy resins and cell resins modified losiques. 8) A delayed ignition laminate as defined in claim 1, characterized in   what the resin saturating the tablecloth is a flame retardant   elusive. 9) A delayed ignition laminate as defined in claim 1, characterized in that it comprises dispersed flame retardant fillers   in the resin that saturates the tablecloth.   ) A delayed ignition laminate as defined in claim 1, characterized in   what it includes a resin adhesive sticking the film the support.   11) A delayed ignition laminate as defined in claim 1, characterized in that the resin which saturates the sheet also sticks to the sheet tablecloth.   12) A delayed ignition laminate as defined in claim 1, characterized in that the resin which saturates the sheet has been hardened by   application of heat and pressure. 13) A method for forming a delayed ignition laminate, characterized in that it comprises the steps consisting in a) applying a metallic foil to one face of the support and   b) apply to the face of the sheet op- placed on the one facing the support, a fibrous sheet   is saturated with resin, the tablecloth being made up mainly   mainly fire resistant fibers.   14) A process as defined in the re- vendication 13, characterized in that it comprises the state   eg consisting of adhesive bonding the sheet to the support and of bonding the fibrous web to the sheet to   resin that saturates the tablecloth.   15) A process as defined in the   vendication 13, characterized in that it comprises the step of including a resinous adhesive between the sheet and the support and subjecting the entire support, sheet and saturated tablecloth of resi-   do not heat and press in a direction perpendicular to the plane of the suit until the resin is hardened.