Static structures (e.g. – buildings) – With synthetic resinous component – Foam
Patent
1994-08-24
1997-10-21
Safavi, Michael
Static structures (e.g., buildings)
With synthetic resinous component
Foam
523097, 52478, 524891, 525921, 52714, 52781, 527921, 527941, E04B 258, E04C 2292
Patent
active
056783698
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
The present invention relates to refractory/heat insulating panels which are used as interior wall panels, exterior wall panels, roofing materials, ceiling materials, floor panels, partitions, fire doors, etc. of buildings and structures, which are required to be fire resistant, and more particularly to refractory/heat insulating panels which are light in weight, which have excellent fire resistance, thermal insulation and smoking resistance, and which have enhanced mechanical strength.
BACKGROUND ART
There are a number of known refractory panels for fire resistant structures which include, for example, Japanese Unexamined Patent Publication (kokai) No. 237756/1992, Japanese Unexamined Utility Model Publication (kokai) No. 185535/1982, Japanese Unexamined Utility Model Publication (Kokai) No. 1538/1983, Japanese Utility Model Publication (kokoku) No. 15444/1988, and Japanese Patent Publication (kokoku) No. 18230/1990. These prior art refractory panels have drawbacks as described below and improvement has so far been demanded.
First, the fire resistance of the joint parts of panels has turned out to be a weak point which affects the refractory performance of the structure of panels. In other words, deformation of a surfacing material and a backing material of a panel caused by the difference of thermal conduction under a high temperature makes crevices at the joint parts of panels, through which heat and flames spread to the opposite side. Thus, the 1-hour refractory construction test of JIS-A-1304 (Japanese Industrial Standards A-1304) cannot be passed.
Secondly, when a core material is formed by mixing a stock solution of resol-type phenol and a curing agent, and delivering the mixture for a foaming reaction, scores of percent, based on the total weight of the mixture, of condensed water generated during the reaction are held in the phenolic foams. The captured water is vaporized during the curing period of the product or after panels are assembled due to the change of the ambient temperature, etc., and the residual vapor is confined between the surfacing material and the core material of the refractory material because of no means of escape for the vapor. Thus, the surface of the panel swells, warps, etc. and the panel is adversely affected with passage of time.
Thirdly, the adhesion between the surfacing material and the core material or between the backing material and the core material is so weak that the surfacing material or the backing material easily separate from the core material by a slight impact at the adhesive portion of these materials.
On the other hand, there are disclosed techniques for improving the adhesion of refractory panels in Japanese Unexamined Patent Publication (kokai) Nos. 10359/1987 and 185613/1988. Techniques for improving the fire protecting performance by incorporating reinforcing fibers or short fibers to foams are also known. However, since such conventional techniques are constituted such that mat-like fibers are used as an aggregate, or short fibers are incorporated as an aggregate, viscosity is increased at the time of foaming, and it becomes difficult to uniformly impregnate a stock solution of unfoamed phenol into an aggregate for achieving a uniform foaming because of the uneven impregnation. Moreover, when short fibers are used, a large amount of fibers are needed, and yet foams of a high density must be achieved. This leads to low productivity and poor thermal insulation performance, increase of weight, and high costs, disadvantageously.
At present, refractory panels of this kind are attached to a wall substrate from the exterior side, i.e., from outside of a room. However, under such conditions that the space between buildings is too narrow to set up scaffolding for the assembly of panels from the exterior side, as seen in densely built-up areas of big cities, this construction method is hardly employed.
Accordingly, it is an object of the present invention to solve the aforementioned problems and to provide a refractory/heat insulating panel
REFERENCES:
patent: 3501883 (1970-03-01), Birum, Jr.
patent: 3560285 (1971-02-01), Schroter et al.
patent: 3815657 (1974-06-01), Malek et al.
patent: 4104840 (1978-08-01), Heintz et al.
patent: 4109436 (1978-08-01), Berloty
patent: 4843779 (1989-07-01), Whitney, Jr.
patent: 4981003 (1991-01-01), McCarthy
"Announcement from The Ministry of Construction", Japan.
Ishikawa Takashi
Kanno Yoshihiko
Kokubun Toshihide
Konta Hiroaki
Niizeki Takanobu
IG-Technical Research Inc.
Safavi Michael
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