Compositions – Fire retarding – Material physically quantified
Patent
1991-03-15
1992-06-30
Lovering, Richard D.
Compositions
Fire retarding
Material physically quantified
252607, 252609, 106 1811, 264 454, 264 458, 52517, 52DIG9, 428921, 428243, 4285375, C08J 1106, E04B 194
Patent
active
051260760
DESCRIPTION:
BRIEF SUMMARY
The invention relates to low-flammability structural elements, particularly boards, and to a process for constructing them.
In industrialized countries large quantities of waste products, such as plastics parts, plastics films, fabric pieces, synthetic fibres and non-woven fabrics, are created during many different industrial manufacturing processes. To a large extent these unwanted waste products have in the past been dumped in landfills, occasionally causing major problems because of their lightweight, space requirement, wind scatter, or also posing ecological difficulties because they are either not microbially degradable or because chemical substances which can damage air, soil and waterways are released during their degradation. Thus, attempts have constantly been made to use these waste materials as raw material for new articles. For example, German Patent 34 16 473 describes a process for constructing mouldings from fibrous waste products and adhesive. The parts thus constructed are, in terms of mechanical and insulating properties, comparable with lightweight construction and insulating boards made from foamed plastics and have the advantage of relieving environmental pollution. However, in terms of fire protection, they are clearly inferior. Using the fire-shaft test procedure in accordance with DIN 4102, Part 1, there is such a violent fire phenomenon, associated with a quick spread of fire, that boards obtained according to German Patent 34 16 473 can only be classified as structural elements of normal flammability (building material class B 2) or even as readily flammable building materials (building material class B 3). Building regulations, however, increasingly require low-flammability building materials (building material class B 1 in accordance with DIN 4102, part 1).
Tests by the Applicant have shown that the addition of conventional flame-proofing agents, such as combinations of antimony trioxide and halogen-containing substances or aluminum hydroxide, when boards are constructed from waste polyester fibre material, even at relatively high concentrations (up to 20 wt-%), does not lead to the desired degree of fire-proofing. Even higher concentrations of these flame-retardants are not possible, because then only mouldings having quite unsatisfactory mechanical properties are obtained. Surprisingly, the effect of the flame-retardants described is so small that, in terms of fire-proofing, the mouldings obtained are no better than when the quantity of conventional fire-proofing agent is merely replaced by inorganic inert material such as calcium carbonate powder. Surface coating and/or lamination with flame-proofing agents would suggest themselves as a further known process. This can be achieved, for example, by laminating with inorganic fabrics, which, if need be, are additionally treated with flame-proofing coatings. However, even this method does not lead to the desired result.
The object of the invention is to provide structural elements which have the desired mechanical properties and moreover, still have low-flammability, by employing waste materials.
It has been found that structural elements which, apart from the waste material and the adhesive, contain in addition a combination of non-combustible inorganic additives and a flame-proofing agent mixture, possess the desired low-flammability but nevertheless still have good mechanical properties.
According to one aspect of this invention, there are provided low-flammable structural elements, particularly boards, made from a compressed mixture of 5 to 50 wt-% of inherently-combustible organic waste material, 75 to 20 wt-% of non-combustible inorganic additives, 4 to 40 wt-% of a flame-proofing agent mixture, and 3 to 25 wt-% at least one hardened adhesive serving to bind the components together. Boards or other mouldings, including tube casings, which consist of such a mixture, meet with a significant safety margin the criteria applied to "low-flammable building materials". Moreover, compared with numerous commercially available boards,
REFERENCES:
patent: 3837989 (1970-03-01), McCoy
patent: 3957501 (1976-05-01), Matsuda et al.
patent: 4189619 (1980-02-01), Pedlow
patent: 4994113 (1991-02-01), Helmstetter
Annemaier Dieter
Graf Robert
Bhat N.
Chemische Fabrik Gruenau
Grandmaison Real J.
Jaeschke Wayne C.
Lovering Richard D.
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