Fire-resistant panel and method of manufacture

• US 20060070321A1
• Filed: 09/29/2004
• Published: 04/06/2006
• Est. Priority Date: 09/29/2004
• Status: Abandoned Application

• Current Assignee: Republic Technologies
• Original Assignee: Republic Technologies
• Inventors: Au, B. L.
• Application Number:
  US10/954,249
• Publication Number:
  US 20060070321A1
• Time in Patent Office: Days
• US Class Current: 52/232
• CPC Class Codes: C04B 14/106 Kaolin
• CPC Class Codes: C04B 14/18 Perlite
• CPC Class Codes: C04B 14/303 Alumina
• CPC Class Codes: C04B 14/304 Magnesia
• CPC Class Codes: C04B 18/24 Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper , cork
• CPC Class Codes: C04B 18/26 Wood, e.g. sawdust, wood shavings
• CPC Class Codes: C04B 18/30 Mixed waste; Waste of undefined composition, C04B18/10 takes precedence
• CPC Class Codes: C04B 2103/65 Water proofers or repellants
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/27 Water resistance, i.e. waterproof or water-repellent materials
• CPC Class Codes: C04B 2111/28 Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• CPC Class Codes: C04B 22/0013 Boron compounds
• CPC Class Codes: C04B 22/124 Chlorides of ammonium or of the alkali or alkaline earth metals, e.g. calcium chloride
• CPC Class Codes: C04B 24/085 Higher fatty acids
• CPC Class Codes: C04B 24/32 Polyethers, e.g. alkylphenol polyglycolether
• CPC Class Codes: C04B 28/26 Silicates of the alkali metals
• CPC Class Codes: C04B 40/02 Selection of the hardening environment
• CPC Class Codes: C04B 40/0263 Hardening promoted by a rise in temperature C04B40/024 takes precedence
• CPC Class Codes: E04B 1/942 slab-shaped
• CPC Class Codes: E04B 2/7411 Details for fire protection
• CPC Class Codes: E04B 9/001 : characterised by provisions for heat or sound insulation
• CPC Class Codes: E04B 9/0421 : comprising ducts
• CPC Class Codes: E04B 9/045 : being laminated
• CPC Class Codes: H02G 3/0412 : Heat or fire protective means for fire in electric circuits A62C3/16
• CPC Class Codes: H02G 3/0487 : with a non-circular cross-section H02G3/0468, H02G3/0475 take precedence
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

A highly fire-resistant and environmentally-friendly panel of 2 mm to 28 mm may be manufactured by a blending of magnesium compounds, sodium silicate, kaolin, fillers, and additives to form the core materials, reinforced by 4 layers of fire-resistant glass fiber meshes and fabrics. Using a proprietary ITC process that accelerates the chemical reactions of the ingredients to generate sufficient heat without external supply of energy, the panels may be completely cured within 24 hours instead of 10 days. The use of waste materials, energy-saving curing system and no gas emission manufacturing process combined to make this panel an eco-friendly product which offers the world'"'"'s highest-rated fire resistance of 5 hours, high flexural strength, low density, durability and effective water-resistance.

Claims

1. A method of manufacturing a fire-resistant panel, comprising:

(a) preparing a panel composition having an exothermic curing process;

(b) forming the panel composition into a panel;

(c) arranging a plurality of panels so that the heat released by the panels during the exothermic curing process is sufficient to cure the plurality of panels with no additional heating.

2. The method of claim 1, wherein the panels are cured within about 24 hours with no additional heating.

3. The method of claim 1, wherein forming the panel composition into a panel includes incorporating one or more layers selected from fire-resistant glass fiber and fire-resistant fabric within the panel.

4. The method of claim 1, wherein the panel composition includes magnesium oxide, magnesium chloride, and sodium silicate.

5. The method of claim 4, wherein the panel composition further includes kaolin, one or more fillers, one or more hydrophobic agents, and one or more additives.

19. A fire-resistant panel, prepared according to the method of any of claims 1-18.

20. The fire-resistant panel of claim 19, having a composition that is

45%-60% by weight of magnesium compounds;

8%-15% by weight of sodium silicate;

10%-15% by weight of kaolin;

15%-20% by weight of fillers;

0.5%-1% of hydrophobic agents; and

2%-3% of additives.

21. The fire-resistant panel of claim 19, wherein the panel is capable of withstanding fire at a temperature of at least 1,000°

C., and is configured for use in fire-resistant construction.

22. The fire-resistant panel of claim 20, wherein the fillers include organic agricultural waste materials.

23. The fire-resistant panel of claim 19, wherein the panel has a thickness of about 2 mm to about 28 mm, and a width of about 1 foot to about 4 feet, and a length of about 1 foot to about 16 feet.

25. A suspended ceiling system comprising a fire-resistant panel of any of claims 19-24, characterized in that the suspended ceiling system is capable of achieving a fire rating of 5 hours integrity at a temperature of approximately 1,200°

C. in accordance with the British Standard 476;

Part 22;

1987.

26. A non-loadbearing partition system comprising a fire-resistant panel of any of claims 19-24, characterized in that the partition system is capable of achieving a fire-rating of 4 hours integrity and insulation at a temperature of approximately 1,200°

C. in accordance with the British Standard 476;

Part 22;

1987.

27. A steel stud hoarding system comprising a fire-resistant panel of any of claims 19-24, characterized in that the hoarding system is capable of achieving a fire-rating of 4 hours integrity at a temperature of approximately 1,200°

C. in accordance with the British Standard 476;

Part 22;

1987.

28. An electrical and mechanical services enclosure system comprising a fire-resistant panel of any of claims 19-24, characterized in that the enclosure system is capable of achieving a fire-rating of 2 hours integrity and insulation at a temperature of approximately 1,050°

C. in accordance with the British Standard 476;

Part 20;

1987.

6. A method of manufacturing a fire-resistant panel, comprising:

(a) blending an aqueous composition that includes magnesium compounds, sodium silicate, and kaolin;

(b) incorporating one or more layers selected from fire-resistant glass fiber and fire-resistant fabric within the composition and forming the composition into a panel;

(c) arranging a plurality of panels so that heat released by the panels collectively raises the temperature of the arranged panels sufficiently to cure the composition, with no external heating;

(d) shaping the sheets into fire-resistant panels.

7. The method of claim 6, wherein the composition further includes one or more of additional fillers, hydrophobic agents, and additives.

8. The method of claim 6, including incorporating one or more layers of glass fiber mesh and one or more layers of fire-resistant fabric within the composition on each side of the panel.

9. The method of claim 6, wherein the panels are arranged with substantially no intervening space between adjacent panels.

10. The method of claim 6, wherein the panels are held at a temperature sufficient to cure the panel composition, for a time sufficient to cure the composition.

11. The method of claim 10, wherein the time sufficient to cure the composition is about 24 hours.

12. The method of claim 6, wherein the temperature of the panels is raised to about 100°

C.

13. The method of claim 6, wherein the composition is prepared from an aqueous solution of magnesium chloride and magnesium oxide.

14. The method of claim 7, wherein the fillers include perlite.

15. The method of claim 7, wherein the fillers include organic agricultural waste.

16. The method of claim 15, wherein fillers include at least one of sawdust, wood fibers, rice hulls, and wheat straw.

17. The method of claim 7, wherein the hydrophobic agents are selected from oils, fatty acids and boric acid.

18. The method of claim 7, wherein the additives include at least one of aluminum oxide and polyoxyethylene alkyl ether.

24. An environmentally-friendly fire-resistant panel, comprising a core material that includes magnesium compounds, sodium silicate, kaolin, fillers, and additives, which is reinforced by 2 or more layers of fire-resistant glass fiber mesh and 2 or more layers of fire-resistant fabric;

where the panel is cured by an internal exothermic process in about 24 hours without the application of external heating; and

the panel exhibits high fire-resistance, low density, high flexural strength and effective water-resistance.