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WO2025227168A1 - A fire resistance composition, a fire resistance board prepared from the composition, a process for preparing the board, and a construction structure made with the board. - Google Patents

A fire resistance composition, a fire resistance board prepared from the composition, a process for preparing the board, and a construction structure made with the board.

Info

Publication number
WO2025227168A1
WO2025227168A1 PCT/VN2024/000003 VN2024000003W WO2025227168A1 WO 2025227168 A1 WO2025227168 A1 WO 2025227168A1 VN 2024000003 W VN2024000003 W VN 2024000003W WO 2025227168 A1 WO2025227168 A1 WO 2025227168A1
Authority
WO
WIPO (PCT)
Prior art keywords
fire resistance
resistance composition
board
cementitious material
composition according
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/VN2024/000003
Other languages
French (fr)
Inventor
Sang LE HUU
Thi Thuy Trang HUYNH
Tran Minh Thai VO
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Saint Gobain Placo SAS
Hiep Phu Corp
Original Assignee
Saint Gobain Placo SAS
Hiep Phu Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Saint Gobain Placo SAS, Hiep Phu Corp filed Critical Saint Gobain Placo SAS
Priority to PCT/VN2024/000003 priority Critical patent/WO2025227168A1/en
Publication of WO2025227168A1 publication Critical patent/WO2025227168A1/en
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/10—Lime cements or magnesium oxide cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
    • C04B28/26—Silicates of the alkali metals
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures

Definitions

  • a fire resistance composition a fire resistance board prepared from the composition, a process for preparing the board, and a construction structure made with the board
  • the present disclosure relates to the field of material and in particular relates to a fire resistance composition, a fire resistance board prepared from the composition, a process for preparing the board and a construction structure made with the board.
  • Fire resistance material is widely used in various fields. According to the use filed and scenario, there are various types of fire resistance material comprising various types of fire resistance ingredients.
  • calcium silicate board is an environmentally friendly material that is widely used as, for example, suspended ceiling and partition wall in a building, wall panels for indoor engineering such as tunnels, furniture lining board, and the like.
  • the environment temperature at a fire site is usually extremely high, and thus there, is a relatively high requirement for fire resistance capability for fire resistance material which is used in different scenarios, and the requirement for exploring novel fire resistance material still exists.
  • a fire resistance composition comprising an inorganic cementitious materia’ of about 22 wt.% to about 60 wt.%; an organic fiber material of about 2 wt.% to about 15 wt.%; a silicate material of about 12 wt.% to about 60 wt.%; and a vitreous rock of about 1 wt.% to about 22 wt.%, based on the total weight of the fire resistance composition.
  • the inorganic cementitious material comprises a hydraulic inorganic cementitious material, an air hardening inorganic cementitious material or a combination thereof.
  • the silicate material comprises silica sand, talc, kaolinite, montmorillonite, mica, zeolite, wollastonite, or a combination thereof.
  • the cementitious material comprises cement of about 20 wt.% to about 55 wt.% and hydrated lime of about 2 wt.% to about 15 wt.%;
  • the organic fiber material is cellulosic fiber of about 2 wt.% to about 15 wt.%;
  • the silicate material comprises silica sand of about 10 wt.% to about 60 wt.%, wollastonite of about 1% to about 22 wt.%, and mica of about 1 wt.% to about 20 wt.%;
  • the vitreous rock is expanded perlite of about 1 wt.% to about 22 wt.%.
  • the fire resistance composition according to present disclosure further comprises a diatomite, a glass fiber or a combination thereof.
  • the diatomite has a content no more than about 23 wt.%; and/or the glass fiber has a content no more than about 2.5 wt.%, based on the total weight of the fire resistance composition.
  • a fire resistance board prepared from the fire resistance composition according to present disclosure.
  • a process for preparing the fire resistance board according to present disclosure comprising providing and mixing the ingredients to form a fire resistance composition; processing the composition into the fire resistance board according to present disclosure; wherein processing comprises curing, de-stacking and drying.
  • Figure 1 illustrates a workflow for preparing the fire resistance according to present disclosure.
  • the range “from about 2 wt.% to about 25 wt.%” includes about 2 wt.%, about 3 wt.%, about 4 wt.%, about 5 wt.%, about 6 wt.%, about 8 wt.%, about 10 wt.%, about 12 wt.%, about 15 wt.%, about 18 wt.%, about 20 wt.%, about 25 wt.% and any sub ranges formed by any two of the ratios thereof. For example, from about 2 wt.% to about 10 wt.%, from about 5 wt.% to about 15 wt.% and the like.
  • the range “1-20” includes 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20 and any sub ranges formed by any two of the ratios thereof.
  • the term “approximate” or “about” usually refers to the value of the variable and all the values of the variable within the experimental error (for example, within an average 95% confidence interval) or within ⁇ 10% of the specified value, or a wider range.
  • a combination thereof and “a mixture thereof’ refer to a multi-component mixture of the elements, such as two, three, four and up to the maximum possible multi-component mixture.
  • ingredients comprised in the present composition may be appropriately selected such that the total amount is 100%.
  • a fire resistance composition comprising an inorganic cementitious material, an organic fiber material, silicate material, and a vitreous rock.
  • cementitious material refers to a series of materials which can be transformed from a slurry into a sturdy stone-shape substance under physical and chemical reactions and can bond with other materials to form a composite solid with a certain mechanical strength. According to the components therein, a cementitious material can be categorized as inorganic cementitious material and organic cementitious material.
  • the fire resistance composition according to present disclosure comprises an inorganic cementitious material.
  • inorganic cementitious can be further categorized as hydraulic inorganic cementitious material and air hardening inorganic cementitious material.
  • the fire resistance composition according to present disclosure comprises an inorganic cementitious material, wherein the inorganic cementitious material comprises a hydraulic inorganic cementitious material, an air hardening inorganic cementitious material or a combination thereof.
  • the fire resistance composition according to present disclosure comprises an inorganic cementitious material, wherein the inorganic cementitious material is a hydraulic inorganic cementitious material or an air hardening inorganic cementitious material or a combination thereof.
  • the fire resistance composition according to present disclosure comprises an inorganic cementitious material, wherein the inorganic cementitious material is a combination of hydraulic inorganic cementitious material and air hardening inorganic cementitious material.
  • the inorganic cementitious material in the fire resistance composition has a content of about 22 wt.% to about 60 wt.%, or about 30 wt.% to about 60 wt.%, or about 35 wt.% to about 50 wt.%; for example, about 22 wt.%, about 25 wt.%, about 28 wt.%, about 30 wt.%, about 35 wt.%, about 40 wt.%, about 45 wt.%, about 50 wt.%, about 55 wt.%, about 60 wt.%.
  • the inorganic cementitious material has a content of about 22 wt.% or more, or about 25 wt.% or more, or about 30 wt.% or more. In another specific embodiment, based on the total weight of the fire resistance composition, the inorganic cementitious material has a content of about 60 wt.% or less, or about 50 wt.% or less.
  • An appropriate amount of cementitious material may contribute to an improved fire resistance property and mechanical properties for the obtained composition and the related products.
  • Hydraulic inorganic cementitious material refers to a material that can combine particulate material (e.g., sand and stone) and bulk material (e.g., brick) into a cemented integrity. Hydraulic inorganic cementitious material can be hardened not only in air but also better in water, maintaining and continuing to enhance its strength.
  • the hydraulic inorganic cementitious material in the fire resistance composition according to present disclosure comprises cement, concrete, mortar and a combination thereof.
  • the hydraulic inorganic cementitious material in the fire resistance composition according to present disclosure is selected from the group consisting of cement, concrete, mortar and a combination thereof.
  • the hydraulic inorganic cementitious material in the fire resistance composition according to present disclosure is cement.
  • An appropriate type of hydraulic inorganic cementitious material may contribute to an improved fire resistance property and mechanical properties for the obtained composition and the related products.
  • the cement has a content of about 20 wt.% to about 55 wt.%, or of about 20 wt.% to about 45 wt.%, or about 20 wt.% to about 35 wt.%; for example, about 20 wt.%, about 22 wt.% about 25 wt.%, about 28 wt.%, about 30 wt.%, about 35 wt.%, about 40 wt.%, about 42 wt.%, about 45 wt.%, about 50 wt.%, about 55 wt.%.. :
  • the cement has a content of about 20 wt.% or more, or about 25 wt.% or more, or about 30 wt.% or more. In another embodiment, based on the total weight of the fire resistance composition, the cement has a content of about 55 wt.% or less, or about 50 wt.% or less, or about 40 wt.% or less.
  • An appropriate amount of hydraulic inorganic cementitious material may render the obtained composition and the related products an improved fire resistance property and mechanical properties.
  • Air hardening inorganic cementitious material refers to those cementitious materials that can only be hardened in air, which as well can only maintain and enhance its strength in air.
  • the air hardening inorganic cementitious material in the fire resistance composition according to present disclosure comprises quick lime, hydrated lime, magnesite, water glass and a combination thereof.
  • the air hardening inorganic cementitious material in the fire resistance composition according to present disclosure is selected from the group consisting of quick lime, hydrated lime, magnesite, water glass and a combination thereof.
  • the air hardening inorganic cementitious material in the fire resistance composition according to present disclosure is hydrated lime.
  • An appropriate type of air hardening inorganic cementitious material may contribute to an improved fire resistance property and mechanical properties for the obtained composition and the related products.
  • the hydrated lime has a content of about 2 wt.% to about 15 wt.%; for example, about 2 wt.%, about 4 wt.%, about 5 wt.%, about 6 wt.%, about 9 wt.%, about 10 wt.%, about 12 wt.%, about 15 wt.%.
  • the hydrated lime has a content of about 2 wt.% or more. In another embodiment, based on the total weight of the fire resistance composition, the hydrated lime has a content of about 15 wt.%, or less.
  • An appropriate amount of air hardening inorganic cementitious material may render the obtained composition and the related products an improved fire resistance property and mechanical properties.
  • the fire resistance composition according to present disclosure comprises a combination of cement and hydrated lime as cementitious material.
  • Organic fiber material refers to those materials comprising fibers that are extracted from organic material.
  • the organic fiber material in the fire resistance composition according to present disclosure comprises plant fiber, polymer fiber, for example, PP fiber, PET fiber, bast fiber, bamboo fiber, cellulosic fiber and a combination thereof.
  • the organic liber material in the fire resistance composition according to present disclosure is selected from the group consisting of bast fiber, bamboo fiber, cellulosic fiber and a combination thereof.
  • the organic fiber material in the fire resistance composition according to present disclosure is cellulosic fiber (also can be referred as pulp).
  • An appropriate type of organic fiber material may contribute to an improved fire resistance property and mechanical properties for the obtained composition and the related products.
  • the organic fiber material in the fire resistance composition according to present disclosure has a content of about 2 wt.% to about 15 wt.%, or about 4 wt.% to about 12 wt.%; for example, about 2 wt.%, about 4 wt.%, about 5 wt.%, about 6 wt.%, about 7 wt.%, about 8 wt.%, about 10 wt.%, about 12 wt.%, about 15 wt.%.
  • cellulosic fiber based on the total weight of the fire resistance composition, cellulosic fiber has a content of about 2 wt.% or more, or about 4 wt.% or more. In another specific embodiment, based on the total weight of the fire resistance composition, cellulosic fiber has a content of about 15 wt.% or less, or about 12 wt:% or less.
  • An appropriate amount of organic fiber material may render the obtained composition and the related products an improved fire resistance property and mechanical properties.
  • Silicate material refers to those materials comprising silicate compounds. Due to various functions of silicate material (e.g., insulation, high temperature resistance and the like), silicate materials are widely used in various fields.
  • the silicate material in the fire resistance composition according to present disclosure comprises silica sand, talc, kaolinite, montmorillonite, mica, zeolite, wollastonite, and a combination thereof.
  • the silicate material in the fire resistance composition according to present disclosure is selected from the group consisting of silica sand, talc, kaolinite, montmorillonite, mica, zeolite, wollastonite, and a combination thereof.
  • the silicate material in the fire resistance composition according to present disclosure is selected from the group consisting of silica sand, mica, wollastonite, and the combination thereof.
  • the fire resistance composition according to present disclosure comprises a combination of silica sand, wollastonite, and mica as silicate material.
  • the silicate material in the fire resistance composition according to present disclosure is a combination of silica sand, wollastonite, and mica.
  • the silicate material in the fire resistance composition according to present disclosure has a content of about 12 wt.% to about 60 wt.%, or about 32 wt.% to about 55 wt.%; for example, about 32 wt.%, about 34 wt.%, about 36 wt.%, about 40 wt.%, about 42 wt.%, about 33 wt.%, about 45 wt.%, about 50 wt.%, about 55 wt.%, about 60 wt.%.
  • the silicate material has a content of about 12 wt.% or more, or about 32 wt.% or more. In another specific embodiment, based on the total weight of the fire resistance composition, the silicate material has a content of about 60 wt.% or less, or about 55 wt. % or less.
  • the silica sand has a content of about 10 wt.% to about 45 wt.%, or about 30 wt.% to about 40 wt.%; for example, about 30 wt.%, about 32 wt.%, about 34 wt.%, about 35 wt.%, about 36 wt.%, about 38 wt.%, about 40 wt.%, about 45 wt.%.
  • the silica sand based on the total weight of the fire resistance composition, has a content of about 10 wt.% or more, or about 30 wt.% or more, or about 35 wt.% or more. In another embodiment, based on the total weight of the fire resistance composition, silica sand has a content of about 45 wt.% or less, or about 40 wt.% or less.
  • the mica has a content of about 1 wt.% to about 20 wt.%, or about 2 wt.% to about 18 wt.%; for example, about 1 wt.%, about 2 wt.%, about 3 wt.%, about 5 wt.%, about 10 wt.%, about 12 wt.%, about 15 wt.%, about 18 wt.%, about 19 wt.%, about 20 wt.%.
  • the mica based on the total weight of the fire resistance composition, the mica has a content of about 1 wt.% or more, or about 2 wt.% or more. In another embodiment, based on the total weight of the fire resistance composition, the mica has a content of about 20 wt.% or less, or about 18 wt.% or less.
  • the wollastonite has a content of about 1 wt.% to about 22 wt.%, or about 1 wt.% to about 20 wt.%; for example, about 1 wt.%, about 2 wt.%, about 4 wt.%, about 6 wt.%, about 7 wt.%, about 8 wt.%, about 10 wt.%, (about 12 wt.%, about 15 wt.%, about 18 wt.%, about 20 wt.%, about 22 wt.%.
  • the wollastonite based on the total weight of the fire resistance composition, has a content of about 1 wt.% or more, or 2 wt.% or more. In another specific embodiment, based on the total weight of the fire resistance composition, the wollastonite has a content of about 22 wt.% or less, or about 20 wt.% or less.
  • An appropriate amount of silicate material may render the obtained composition and the related products an improved fire resistance property and mechanical properties.
  • “Vitreous rock” as used herein refers to a rock material that usually formed during volcano eruption.
  • the vitreous rock in the fire resistance composition according to present disclosure comprises perlite, obsidian, pitchstone, pumice, vermiculite, and a combination thereof.
  • the vitreous rock in the fire resistance composition according to present disclosure is selected from the group consisting of perlite, obsidian, pitchstone, pumice and a combination thereof.
  • the vitreous rock in the fire resistance composition according to present disclosure is perlite.
  • the vitreous rock in the fire resistance composition according to present disclosure is expanded perlite.
  • An appropriate type of vitreous rock may contribute to an improved fire resistance property and mechanical properties for the obtained composition and the related products.
  • the vitreous rock in the fire resistance composition has a content of about 1 wt.% to about 22 wt.%, or about 5 wt.% to about 20 wt.%; for example, about 2 wt.%, about 4 wt.%, about 5 wt.%, about 6 wt.%, about 8 wt.%, about 10 wt.%, about 11 wt.%, about 12 wt.%, about 15 wt.%, about 16 wt.%, about 18 wt.%, about 20 wt.%, about 21 wt.%, about 2 wt.%.
  • the vitreous rock has a content of about 2 wt.% or more, or about 5 wt.% or more. In another specific embodiment, based on the total weight of the fire resistance composition, the vitreous rock has a content of about 22 wt.% or less, or about 20 wt.% or less.
  • An appropriate amount of vitreous rock may render the obtained composition and the related products an improved fire resistance property and mechanical properties.
  • the fire resistance composition according to present disclosure further comprises a diatomite.
  • the diatomite in the fire resistance composition according to present disclosure has a content of no more than about 23 wt.%; for example, about 1 wt.%, about 2 wt.%, about 3 wt.%, about 4 wt.%, about 5 wt.%, about 6 wt.%, about 8 wt.%, about 10 wt.%, about 12 wt.%, about 15 wt.%, about 18 wt.%, about 19 wt.%, about 20 wt.%, about 22 wt.%, about 23 wt.%.
  • the diatomite based on the total weight of the fire resistance composition, the diatomite has a content of about 1 wt.% or more. In another specific embodiment, based on the total weight of the fire resistance composition, the diatomite has a content of about 23 wt.% or less.
  • An appropriate amount of diatomite may contribute to an improved fire resistance property and mechanical properties for the obtained composition and the related products.
  • the glass fiber in the fire resistance composition according to present disclosure has a content of no more than about 2.5 wt.%, or about 0.5 wt.% to about 2 wt.%; for example, about 0.5 wt.%, about 0.6 wt.%, about 0.8 wt.%, about 1 wt.%, about 1.2 wt.%, about 1.4 wt.%, about 1.6 wt.%, about 1.8 wt.%, about 2 wt.%.
  • the glass fiber has a content of about 2.5 wt.% or less, or about 2 wt.% or less.
  • An appropriate amount of composite fiber may render the obtained composition and the related products an improved fire resistance property and mechanical properties.
  • a fire resistance composition comprising a cement of about 20 wt.% to about 55 wt.%, a hydrated lime of about 2 wt.% to about 15 wt.% , a cellulose fiber of about 2 wt.% to about 15 wt.% , a silica sand of about 10 wt.% to about 60 wt.%, a perlite of about 1 wt.% to about 22 wt.%, a mica of about 1 wt.% to about 20 wt.% and a wollastonite of about 1 wt.% to about 22 wt.%, based on the total weight of the fire resistance composition.
  • a fire resistance composition comprising a cement of about 20 wt.% to about 55 wt.% , a hydrated lime of about 2 wt.% to about 15 wt.% , a cellulose fiber of about 4 wt.% to about 12 wt.% , a silica sand of about 30 wt.% to about 40 wt.%, a perlite of about 5 wt.% to about 20 wt.%, a mica of about 2 wt.% to about 18 wt.%, a wollastonite of about 2 wt.% to about 20 wt.%, a diatomite of no more than about 23 wt.% and a composite fiber of no more than about 2 wt.%, based on the total weight of the fire resistance composition.
  • a fire resistance board comprising the fire resistance composition according to present disclosure.
  • the construction structure could be a door system, a wall system, a ceiling system, a ventilation system, a ducting system, or a facade system.
  • a process for preparing the fire resistance board according to present disclosure comprising: providing and mixing the ingredients to form a fire resistance composition; processing the fire resistance composition into the fire resistance board according to present disclosure; wherein the processing comprises curing, de-stacking and drying.
  • materials of ingredients for preparation of fire resistance composition are weighted for use in the present process.
  • the inorganic cementitious material comprises cement and hydrated lime.
  • Inorganic cementitious materials may be provided according to methods that are commonly used in the art. For example, cement may be stored in a silo and Will be weighed on a required scale when provided for preparation of the fire resistance composition according to present disclosure. As another example, hydrated lime may also be stored in a silo and will be weighed on a required sale when provided for preparation of the fire resistance composition according to present disclosure.
  • the organic fiber material may be provided according to technologies that are commonly used in the art.
  • the silicate material used in fire resistance composition according to present disclosure comprises silica sand and mica.
  • the silicate material may be provided according to methods that are commonly used in the art.
  • the silica sand may be grinded into a sand mortar comprising silica sand and water or other solution.
  • the obtained sand mortar may be pumped into a storage tank for weighing on a required scale to provide the silica sand.
  • the mica may be stored in a bag with a mass of 25 kg/bag.
  • the mica may be provided and calculated according to the number of bags that storing the mica.
  • the vitreous rock may be provided according to technologies that are commonly used in the art.
  • the vitreous rock may be stored in a bag with a mass of 7.5 kg/bag.
  • the vitreous rock may be provided and calculated according to the number of bags that storing the vitreous rock.
  • ingredients are mixed to obtain the fire resistance composition according to present disclosure.
  • the ingredients may be added into a reaction vessel arbitrarily without a specific order.
  • the ingredients may be added into a reaction vessel with the following order: water, silica sand (in a sand mortar form), plant fiber material (in a pulp mortar form), cement, hydrated lime, mica, metamorphic mineral (e.g., wollastonite), vitreous rock (e.g., expanded perlite).
  • a reaction vessel with the following order: water, silica sand (in a sand mortar form), plant fiber material (in a pulp mortar form), cement, hydrated lime, mica, metamorphic mineral (e.g., wollastonite), vitreous rock (e.g., expanded perlite).
  • the ingredients may be mixed for from about 10 minutes to about 20 minutes.
  • the obtained mixture may be then collected into a storage tank for preparation of a fire resistance board.
  • the obtained fire resistance composition is further processed to obtain an intermediate fire resistance board.
  • the obtained fire resistance composition mixture has a water content of from about 80% to about 90%.
  • the fire resistance composition mixture may be further processed through a flow on technology, which can render the plant fiber distribute properly in the system and then forms an interwoven matrix to bond with other ingredients including silica sand, hydrated lime, cement, mica, metamorphic mineral (e.g., wollastonite), vitreous rock (e.g., expanded perlite).
  • a flow on technology which can render the plant fiber distribute properly in the system and then forms an interwoven matrix to bond with other ingredients including silica sand, hydrated lime, cement, mica, metamorphic mineral (e.g., wollastonite), vitreous rock (e.g., expanded perlite).
  • the processed composition may form layers which have from about 0.7 mm to about 1.5 mm of thickness for each layer.
  • the composition layers may be wrapped layer by layer on a rolling roller to form an intermediate fire resistance board according to present disclosure.
  • the obtained intermediate board is further processed to obtain a product board.
  • the obtained intermediate board may be cut to reach a standard size.
  • the intermediate board may be cut by any methods that are commonly used in this art.
  • the obtained) intermediate board may be cut with a high pressure water jet cutting system.
  • the cut intermediate board may be stacked with a steel plate. Moreover, the stacked intermediate board and plate may be transmitted to a curing chamber.
  • the processed fire resistance intermediate board according to present disclosure has a low density of from about 0.95 g/cm 3 to about 1.05 g/cm 3 ;
  • the processed fire resistance intermediate board according to present disclosure has an excellent fire resistance and insulation
  • the processed fire resistance intermediate board according to present disclosure does not need to be compressed to form the product board.
  • the intermediate board may be transmitted through warm air into a curing chamber.
  • the transmission process may be sustained for from about 2 hours to about 6 hours.
  • the cured board may be transmitted into a de-stacker system to de-stack the cured board and steel plate.
  • the cured board may be transmitted into a high- pressure autoclave.
  • the board may form a stable, hard mineral (e.g., Tobermorite, Xonotlite and the like).
  • a stable, hard mineral e.g., Tobermorite, Xonotlite and the like.
  • the autoclaved board may be dried to obtain the product fire resistance board according to present disclosure.
  • the cement used in present preparation method may act as an adhesive and will react during autoclaving process. Additionally, due to the bonding between the plant fiber material (e.g., cellulosic fiber) and other materials which forms a bonding matrix, the flexibility of the obtained board may be increased.
  • silica sand and hydrated lime in present fire resistance composition may be a reactant during autoclaving process.
  • the silica sand and hydrated lime may bring a white color to the present fire resistance composition and fire resistance board.
  • Perlite has a light weight, low thermal conductivity, high chemical stability, low moisture absorption and thus may bring enhanced fire resistance and insulation to the product board.
  • Mica has a volumetric stability at a high temperature, increased fire resistance, high insulation, and thus may bring enhanced fire resistance and insulation to the product board. Wollastonite may bring enhanced board strength and increased fire resistance to the product board.
  • the fire resistance composition and fire resistance board according to present disclosure has an excellent fire resistance and insulation. Under a working temperature of about 1200- 1400 °C, the present board can still be stable and hard without disintegration.
  • the fire resistance composition and fire resistance board according to present disclosure has an excellent toughness.
  • the present fire resistance board complies with requirement of ASTM Cl 185 Grade 1 standard, showing high toughness.
  • the fire resistance composition and fire resistance board according to present disclosure are light-weight which extend their application field.
  • the present fire resistance board for example has a board density of about 1000 kg/m 3 .
  • the fire resistance composition and fire resistance board according to present disclosure has a light weight, it can be cut into desired shape and be transmitted easily, and thus can be widely applied in various fields.
  • the fire resistance board according to present disclosure can be easily cut into a desirable shape and applied into related scenario accordingly.
  • the obtained fire resistance board according to present disclosure has no warping with low shrinkage, e ven at a high working temperature.
  • the fire resistance board according to present disclosure shows an increased flexibility.
  • the diatomite added during process for preparing the present fire resistance composition may be a reactant in autoclaving process, which may contribute to the low thermal conductivity, increased fire resistance of the obtained board.
  • the obtained fire resistance board according to present disclosure has an excellent moisture resistance.
  • the obtained fire resistance composition and fire resistance board have an excellent safety and are friendly to health and environment due to environmentally friendly ingredients as used therein.
  • the fire resistance board can as well achieve an excellent high temperature stability.
  • the example fire resistance boards are prepared by the method with following procedures.
  • the ingredients were added by the following order: water, silica sand (in a sand mortar form), plant fiber material (in a pulp sand mortar form), cement, hydrated lime, mica, wollastonite, expanded perlite; the ingredients were mixed for 10-20 minutes;
  • the obtained mixture has a water content of 80-90%; the mixture were submitted to a flow on technology which can render the pulp distribute properly and then forms an interwoven matrix to bond with other ingredients including silica sand, hydrated lime, cement, mica, metamorphic mineral (e.g., wollastonite), vitreous rock (e.g., expanded perlite);
  • other ingredients including silica sand, hydrated lime, cement, mica, metamorphic mineral (e.g., wollastonite), vitreous rock (e.g., expanded perlite);
  • composition was then submitted into a high-pressure autoclave having a temperature of 170-180 °C for autoclaving.
  • Fire resistance of fire resistance board of examples 1-10 were prepared according to the above-mentioned process with the compositions in table 1.
  • Density of 'fire resistance board was determined according to ASTM Cl 185-08 standard.

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Abstract

Disclosed is a fire resistance composition, comprising an inorganic cementitious material, an organic fiber material, a silicate material, and a vitreous rock. Further disclosed is a fire resistance board prepared from the composition, a method for preparing the board, and a construction structure made with the board.

Description

A fire resistance composition, a fire resistance board prepared from the composition, a process for preparing the board, and a construction structure made with the board
Technical Field i
The present disclosure relates to the field of material and in particular relates to a fire resistance composition, a fire resistance board prepared from the composition, a process for preparing the board and a construction structure made with the board.
Background
Fire resistance material is widely used in various fields. According to the use filed and scenario, there are various types of fire resistance material comprising various types of fire resistance ingredients.
Among the commercially used fire resistance materials in the industry, calcium silicate board is an environmentally friendly material that is widely used as, for example, suspended ceiling and partition wall in a building, wall panels for indoor engineering such as tunnels, furniture lining board, and the like.
The environment temperature at a fire site is usually extremely high, and thus there, is a relatively high requirement for fire resistance capability for fire resistance material which is used in different scenarios, and the requirement for exploring novel fire resistance material still exists.
Summary
In an aspect, provided is a fire resistance composition comprising an inorganic cementitious materia’ of about 22 wt.% to about 60 wt.%; an organic fiber material of about 2 wt.% to about 15 wt.%; a silicate material of about 12 wt.% to about 60 wt.%; and a vitreous rock of about 1 wt.% to about 22 wt.%, based on the total weight of the fire resistance composition.
In an embodiment, the inorganic cementitious material comprises a hydraulic inorganic cementitious material, an air hardening inorganic cementitious material or a combination thereof.
In an embodiment, the silicate material comprises silica sand, talc, kaolinite, montmorillonite, mica, zeolite, wollastonite, or a combination thereof.
In an embodiment, based on the total weight of the fire resistance composition, the cementitious material comprises cement of about 20 wt.% to about 55 wt.% and hydrated lime of about 2 wt.% to about 15 wt.%; the organic fiber material is cellulosic fiber of about 2 wt.% to about 15 wt.%; the silicate material comprises silica sand of about 10 wt.% to about 60 wt.%, wollastonite of about 1% to about 22 wt.%, and mica of about 1 wt.% to about 20 wt.%; the vitreous rock is expanded perlite of about 1 wt.% to about 22 wt.%.
In an embodiment, the fire resistance composition according to present disclosure further comprises a diatomite, a glass fiber or a combination thereof. In a preferable embodiment, the diatomite has a content no more than about 23 wt.%; and/or the glass fiber has a content no more than about 2.5 wt.%, based on the total weight of the fire resistance composition.
In another aspect, provided is a fire resistance board prepared from the fire resistance composition according to present disclosure.
In another aspect, provided is a process for preparing the fire resistance board according to present disclosure, comprising providing and mixing the ingredients to form a fire resistance composition; processing the composition into the fire resistance board according to present disclosure; wherein processing comprises curing, de-stacking and drying.
In another aspect, provided with a construction structure made with the fire resistance board.
Brief Description of the Drawings
Figure 1 illustrates a workflow for preparing the fire resistance according to present disclosure.
Detailed Description
The present disclosure will be described in detail below, and the description is provided for the purpose of illustration rather than limitation. Those skilled in the art can easily understand the other advantages and efficacies of present disclosure according to the contents disclosed in present description. The present disclosure can also be implemented or applied through other specific embodiments. Those skilled in the art can perform various modifications and changes without deviation from the spirit of present disclosure.
General Definition and Terms
Unless otherwise stated, all publication, patent applications, patents and other reference referred to herein are incorporated by reference in entirety.
Unless otherwise stated, the technical and scientific terms used herein have the same meaning as commonly understood by a person skilled in the art. If there is a contradiction, the definition provided in this application shall prevail.
When expressing a certain amount, ratio, concentration or other value or parameter in the form of a range, a preferable range, or a preferable range upper limit and a preferable range lower limit, it should be understood that it corresponds to specifically revealing any range by combining any pair of upper limit of the range or preferable range value with the lower limit of any range or preferable range value, regardless of whether the range is specifically disclosed. Unless otherwise stated, the numerical ranges listed herein are intended to include the endpoints of the range and all integers and fractions (decimals) within the range. For example, the range “from about 2 wt.% to about 25 wt.%” includes about 2 wt.%, about 3 wt.%, about 4 wt.%, about 5 wt.%, about 6 wt.%, about 8 wt.%, about 10 wt.%, about 12 wt.%, about 15 wt.%, about 18 wt.%, about 20 wt.%, about 25 wt.% and any sub ranges formed by any two of the ratios thereof. For example, from about 2 wt.% to about 10 wt.%, from about 5 wt.% to about 15 wt.% and the like. As another example, the range “1-20” includes 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20 and any sub ranges formed by any two of the ratios thereof. For example, 2-6, 3-5, 2- 10, 3-15, 4-20, 5-19 and the like. When used with a numerical variable, the term “approximate” or “about” usually refers to the value of the variable and all the values of the variable within the experimental error (for example, within an average 95% confidence interval) or within ± 10% of the specified value, or a wider range.
Unless otherwise stated, the percentages, parts or the like herein are on a weight basis.
The expression “comprise” or its synonyms “contain”, “include”, “have” or the like are meant to be inclusive,, which does not exclude other unlisted elements, steps or ingredients. The expression “consist of’ excludes any unlisted elements, steps or ingredients. The expression “substantially consist of’ refers to specified elements, steps or ingredients within a given range, together with optional elements, steps or components which do not substantively affect the basic and novel feature of the claimed subject matter. It should be understood that the expression “comprise” encompasses the expressions “substantially consist of’ and “consist of’.
The articles “a”, “an”, and “the” preceding an element or component are intended to be nonrestrictive regarding the number of instances (i.e. occurrences) of the element or component. There “a”, “an”, and “the” should be read to include one or at least one, and the singular word form of the element or component also includes the plural unless the number is obviously meant to be singular.
The term “at least one” or “one or more” as used herein means one, two, three, four, five, six, seven, eight, nine or more.
Unless otherwise stated, the terms “a combination thereof’ and “a mixture thereof’ refer to a multi-component mixture of the elements, such as two, three, four and up to the maximum possible multi-component mixture.
The term “selected from” as used herein refers to one or more elements of the group listed thereafter, selected independently, and may encompass the combination of two or more elements.
When numericai values or range endpoints are described herein, it should be understood that the disclosure includes the particular value or endpoint recited.
Unless otherwise stated, the ratios, the percentages, parts or the like herein are on a weight basis.
A person skilled in the art will appreciate that the ingredients comprised in the present composition may be appropriately selected such that the total amount is 100%.
Fire resistance composition according to present disclosure
In one aspect, provided is a fire resistance composition comprising an inorganic cementitious material, an organic fiber material, silicate material, and a vitreous rock.
Inorganic cementitious material
“Cementitious material” as used herein refers to a series of materials which can be transformed from a slurry into a sturdy stone-shape substance under physical and chemical reactions and can bond with other materials to form a composite solid with a certain mechanical strength. According to the components therein, a cementitious material can be categorized as inorganic cementitious material and organic cementitious material.
In an embodiment, the fire resistance composition according to present disclosure comprises an inorganic cementitious material.
According to hardening condition during preparation of an inorganic cementitious material, inorganic cementitious can be further categorized as hydraulic inorganic cementitious material and air hardening inorganic cementitious material.
In an embodiment, the fire resistance composition according to present disclosure comprises an inorganic cementitious material, wherein the inorganic cementitious material comprises a hydraulic inorganic cementitious material, an air hardening inorganic cementitious material or a combination thereof. In an embodiment, the fire resistance composition according to present disclosure comprises an inorganic cementitious material, wherein the inorganic cementitious material is a hydraulic inorganic cementitious material or an air hardening inorganic cementitious material or a combination thereof. In a preferable embodiment, the fire resistance composition according to present disclosure comprises an inorganic cementitious material, wherein the inorganic cementitious material is a combination of hydraulic inorganic cementitious material and air hardening inorganic cementitious material.
In an embodiment, based on the total weight of the fire resistance composition, the inorganic cementitious material in the fire resistance composition according to present disclosure has a content of about 22 wt.% to about 60 wt.%, or about 30 wt.% to about 60 wt.%, or about 35 wt.% to about 50 wt.%; for example, about 22 wt.%, about 25 wt.%, about 28 wt.%, about 30 wt.%, about 35 wt.%, about 40 wt.%, about 45 wt.%, about 50 wt.%, about 55 wt.%, about 60 wt.%.
In a specific embodiment, based on the total weight of the fire resistance composition, the inorganic cementitious material has a content of about 22 wt.% or more, or about 25 wt.% or more, or about 30 wt.% or more. In another specific embodiment, based on the total weight of the fire resistance composition, the inorganic cementitious material has a content of about 60 wt.% or less, or about 50 wt.% or less.
An appropriate amount of cementitious material (e.g., cement and/or hydrated) may contribute to an improved fire resistance property and mechanical properties for the obtained composition and the related products.
Hydraulic inorganic cementitious material
“Hydraulic inorganic cementitious material” as used herein refers to a material that can combine particulate material (e.g., sand and stone) and bulk material (e.g., brick) into a cemented integrity. Hydraulic inorganic cementitious material can be hardened not only in air but also better in water, maintaining and continuing to enhance its strength.
In an embodiment, the hydraulic inorganic cementitious material in the fire resistance composition according to present disclosure comprises cement, concrete, mortar and a combination thereof. In an embodiment, the hydraulic inorganic cementitious material in the fire resistance composition according to present disclosure is selected from the group consisting of cement, concrete, mortar and a combination thereof. In a preferable embodiment, the hydraulic inorganic cementitious material in the fire resistance composition according to present disclosure is cement.
An appropriate type of hydraulic inorganic cementitious material may contribute to an improved fire resistance property and mechanical properties for the obtained composition and the related products.
In a specific embodiment, based on the total weight of the fire resistance composition, the cement has a content of about 20 wt.% to about 55 wt.%, or of about 20 wt.% to about 45 wt.%, or about 20 wt.% to about 35 wt.%; for example, about 20 wt.%, about 22 wt.% about 25 wt.%, about 28 wt.%, about 30 wt.%, about 35 wt.%, about 40 wt.%, about 42 wt.%, about 45 wt.%, about 50 wt.%, about 55 wt.%.. :
In an embodiment based on the total weight of the fire resistance composition, the cement has a content of about 20 wt.% or more, or about 25 wt.% or more, or about 30 wt.% or more. In another embodiment, based on the total weight of the fire resistance composition, the cement has a content of about 55 wt.% or less, or about 50 wt.% or less, or about 40 wt.% or less.
An appropriate amount of hydraulic inorganic cementitious material (e.g., cement) may render the obtained composition and the related products an improved fire resistance property and mechanical properties.
Air hardening inorganic cementitious material
“Air hardening inorganic cementitious material” as used herein refers to those cementitious materials that can only be hardened in air, which as well can only maintain and enhance its strength in air.
In an embodiment, the air hardening inorganic cementitious material in the fire resistance composition according to present disclosure comprises quick lime, hydrated lime, magnesite, water glass and a combination thereof. In an embodiment, the air hardening inorganic cementitious material in the fire resistance composition according to present disclosure is selected from the group consisting of quick lime, hydrated lime, magnesite, water glass and a combination thereof. In a preferable embodiment, the air hardening inorganic cementitious material in the fire resistance composition according to present disclosure is hydrated lime.
An appropriate type of air hardening inorganic cementitious material may contribute to an improved fire resistance property and mechanical properties for the obtained composition and the related products.
In a specific embodiment, based on the total weight of the fire resistance composition, the hydrated lime has a content of about 2 wt.% to about 15 wt.%; for example, about 2 wt.%, about 4 wt.%, about 5 wt.%, about 6 wt.%, about 9 wt.%, about 10 wt.%, about 12 wt.%, about 15 wt.%.
In an embodiment, based on the total weight of the fire resistance composition, the hydrated lime has a content of about 2 wt.% or more. In another embodiment, based on the total weight of the fire resistance composition, the hydrated lime has a content of about 15 wt.%, or less.
An appropriate amount of air hardening inorganic cementitious material (e.g., hydrated lime) may render the obtained composition and the related products an improved fire resistance property and mechanical properties.
In a preferabler?embodiment, the fire resistance composition according to present disclosure comprises a combination of cement and hydrated lime as cementitious material.
Organic fiber material
“Organic fiber material” as used herein refers to those materials comprising fibers that are extracted from organic material.
In an embodiment, the organic fiber material in the fire resistance composition according to present disclosure comprises plant fiber, polymer fiber, for example, PP fiber, PET fiber, bast fiber, bamboo fiber, cellulosic fiber and a combination thereof. In an embodiment, the organic liber material in the fire resistance composition according to present disclosure is selected from the group consisting of bast fiber, bamboo fiber, cellulosic fiber and a combination thereof. In a preferable embodiment, the organic fiber material in the fire resistance composition according to present disclosure is cellulosic fiber (also can be referred as pulp).
An appropriate type of organic fiber material may contribute to an improved fire resistance property and mechanical properties for the obtained composition and the related products.
In an embodiment, based on the total weight of the fire resistance composition, the organic fiber material in the fire resistance composition according to present disclosure has a content of about 2 wt.% to about 15 wt.%, or about 4 wt.% to about 12 wt.%; for example, about 2 wt.%, about 4 wt.%, about 5 wt.%, about 6 wt.%, about 7 wt.%, about 8 wt.%, about 10 wt.%, about 12 wt.%, about 15 wt.%.
In a specific embodiment, based on the total weight of the fire resistance composition, cellulosic fiber has a content of about 2 wt.% or more, or about 4 wt.% or more. In another specific embodiment, based on the total weight of the fire resistance composition, cellulosic fiber has a content of about 15 wt.% or less, or about 12 wt:% or less.
An appropriate amount of organic fiber material may render the obtained composition and the related products an improved fire resistance property and mechanical properties.
Silicate material
“Silicate material” as used herein refers to those materials comprising silicate compounds. Due to various functions of silicate material (e.g., insulation, high temperature resistance and the like), silicate materials are widely used in various fields.
In an embodiment, the silicate material in the fire resistance composition according to present disclosure comprises silica sand, talc, kaolinite, montmorillonite, mica, zeolite, wollastonite, and a combination thereof. In an embodiment, the silicate material in the fire resistance composition according to present disclosure is selected from the group consisting of silica sand, talc, kaolinite, montmorillonite, mica, zeolite, wollastonite, and a combination thereof. In a preferable, embodiment, the silicate material in the fire resistance composition according to present disclosure is selected from the group consisting of silica sand, mica, wollastonite, and the combination thereof. In another preferable embodiment, the fire resistance composition according to present disclosure comprises a combination of silica sand, wollastonite, and mica as silicate material. In a more preferable embodiment, the silicate material in the fire resistance composition according to present disclosure is a combination of silica sand, wollastonite, and mica.
An appropriate type of silicate material may contribute to an improved fire resistance property and mechanical properties for the obtained composition and the related products. In an embodiment, based on the total weight of the fire resistance composition, the silicate material in the fire resistance composition according to present disclosure has a content of about 12 wt.% to about 60 wt.%, or about 32 wt.% to about 55 wt.%; for example, about 32 wt.%, about 34 wt.%, about 36 wt.%, about 40 wt.%, about 42 wt.%, about 33 wt.%, about 45 wt.%, about 50 wt.%, about 55 wt.%, about 60 wt.%.
In a specific embodiment, based on the total weight of the fire resistance composition, the silicate material has a content of about 12 wt.% or more, or about 32 wt.% or more. In another specific embodiment, based on the total weight of the fire resistance composition, the silicate material has a content of about 60 wt.% or less, or about 55 wt. % or less.
In a specific embodiment, based on the total weight of the fire resistance composition, the silica sand has a content of about 10 wt.% to about 45 wt.%, or about 30 wt.% to about 40 wt.%; for example, about 30 wt.%, about 32 wt.%, about 34 wt.%, about 35 wt.%, about 36 wt.%, about 38 wt.%, about 40 wt.%, about 45 wt.%.
In an embodiment, based on the total weight of the fire resistance composition, the silica sand has a content of about 10 wt.% or more, or about 30 wt.% or more, or about 35 wt.% or more. In another embodiment, based on the total weight of the fire resistance composition, silica sand has a content of about 45 wt.% or less, or about 40 wt.% or less.
In a specific embodiment, based on the total weight of the fire resistance composition, the mica has a content of about 1 wt.% to about 20 wt.%, or about 2 wt.% to about 18 wt.%; for example, about 1 wt.%, about 2 wt.%, about 3 wt.%, about 5 wt.%, about 10 wt.%, about 12 wt.%, about 15 wt.%, about 18 wt.%, about 19 wt.%, about 20 wt.%.
In an embodiment, based on the total weight of the fire resistance composition, the mica has a content of about 1 wt.% or more, or about 2 wt.% or more. In another embodiment, based on the total weight of the fire resistance composition, the mica has a content of about 20 wt.% or less, or about 18 wt.% or less.
In an embodiment, based on the total weight of the fire resistance composition, the wollastonite has a content of about 1 wt.% to about 22 wt.%, or about 1 wt.% to about 20 wt.%; for example, about 1 wt.%, about 2 wt.%, about 4 wt.%, about 6 wt.%, about 7 wt.%, about 8 wt.%, about 10 wt.%, (about 12 wt.%, about 15 wt.%, about 18 wt.%, about 20 wt.%, about 22 wt.%.
In a specific embodiment, based on the total weight of the fire resistance composition, the wollastonite has a content of about 1 wt.% or more, or 2 wt.% or more. In another specific embodiment, based on the total weight of the fire resistance composition, the wollastonite has a content of about 22 wt.% or less, or about 20 wt.% or less.
An appropriate amount of silicate material may render the obtained composition and the related products an improved fire resistance property and mechanical properties.
Vitreous rock
“Vitreous rock” as used herein refers to a rock material that usually formed during volcano eruption.
Tn an embodiment, the vitreous rock in the fire resistance composition according to present disclosure comprises perlite, obsidian, pitchstone, pumice, vermiculite, and a combination thereof. In an embodiment, the vitreous rock in the fire resistance composition according to present disclosure is selected from the group consisting of perlite, obsidian, pitchstone, pumice and a combination thereof. In a preferable embodiment, the vitreous rock in the fire resistance composition according to present disclosure is perlite. In a more preferable embodiment, the vitreous rock in the fire resistance composition according to present disclosure is expanded perlite.
An appropriate type of vitreous rock may contribute to an improved fire resistance property and mechanical properties for the obtained composition and the related products.
In an embodiment, based bn the total weight of the fire resistance composition, the vitreous rock in the fire resistance composition according to present disclosure has a content of about 1 wt.% to about 22 wt.%, or about 5 wt.% to about 20 wt.%; for example, about 2 wt.%, about 4 wt.%, about 5 wt.%, about 6 wt.%, about 8 wt.%, about 10 wt.%, about 11 wt.%, about 12 wt.%, about 15 wt.%, about 16 wt.%, about 18 wt.%, about 20 wt.%, about 21 wt.%, about 2 wt.%.
In a specific embodiment, based on the total weight of the fire resistance composition, the vitreous rock has a content of about 2 wt.% or more, or about 5 wt.% or more. In another specific embodiment, based on the total weight of the fire resistance composition, the vitreous rock has a content of about 22 wt.% or less, or about 20 wt.% or less.
An appropriate amount of vitreous rock may render the obtained composition and the related products an improved fire resistance property and mechanical properties.
Diatomite ■
In an embodiment, the fire resistance composition according to present disclosure further comprises a diatomite.
In an embodiment, based on the total weight of the fire resistance composition, the diatomite in the fire resistance composition according to present disclosure has a content of no more than about 23 wt.%; for example, about 1 wt.%, about 2 wt.%, about 3 wt.%, about 4 wt.%, about 5 wt.%, about 6 wt.%, about 8 wt.%, about 10 wt.%, about 12 wt.%, about 15 wt.%, about 18 wt.%, about 19 wt.%, about 20 wt.%, about 22 wt.%, about 23 wt.%.
In a specific embodiment, based on the total weight of the fire resistance composition, the diatomite has a content of about 1 wt.% or more. In another specific embodiment, based on the total weight of the fire resistance composition, the diatomite has a content of about 23 wt.% or less.
An appropriate amount of diatomite may contribute to an improved fire resistance property and mechanical properties for the obtained composition and the related products.
Glass fiber
In an embodiment, based on the total weight of the fire resistance composition, the glass fiber in the fire resistance composition according to present disclosure has a content of no more than about 2.5 wt.%, or about 0.5 wt.% to about 2 wt.%; for example, about 0.5 wt.%, about 0.6 wt.%, about 0.8 wt.%, about 1 wt.%, about 1.2 wt.%, about 1.4 wt.%, about 1.6 wt.%, about 1.8 wt.%, about 2 wt.%.
In a specific embodiment, based on the total weight of the fire resistance composition, the glass fiber has a content of about 2.5 wt.% or less, or about 2 wt.% or less.
An appropriate amount of composite fiber may render the obtained composition and the related products an improved fire resistance property and mechanical properties.
In a particular embodiment, provided is a fire resistance composition comprising a cement of about 20 wt.% to about 55 wt.%, a hydrated lime of about 2 wt.% to about 15 wt.% , a cellulose fiber of about 2 wt.% to about 15 wt.% , a silica sand of about 10 wt.% to about 60 wt.%, a perlite of about 1 wt.% to about 22 wt.%, a mica of about 1 wt.% to about 20 wt.% and a wollastonite of about 1 wt.% to about 22 wt.%, based on the total weight of the fire resistance composition. In a more particular embodiment, provided is a fire resistance composition comprising a cement of about 20 wt.% to about 55 wt.% , a hydrated lime of about 2 wt.% to about 15 wt.% , a cellulose fiber of about 4 wt.% to about 12 wt.% , a silica sand of about 30 wt.% to about 40 wt.%, a perlite of about 5 wt.% to about 20 wt.%, a mica of about 2 wt.% to about 18 wt.%, a wollastonite of about 2 wt.% to about 20 wt.%, a diatomite of no more than about 23 wt.% and a composite fiber of no more than about 2 wt.%, based on the total weight of the fire resistance composition.
Fire resistance board
In an aspect, provided is a fire resistance board comprising the fire resistance composition according to present disclosure.
Construction structure
In an aspect, provided is a construction structure made with the fire resistance board. The construction structure could be a door system, a wall system, a ceiling system, a ventilation system, a ducting system, or a facade system.
Process for preparing the fire resistance board according to present disclosure
In another aspect, provided is a process for preparing the fire resistance board according to present disclosure, comprising: providing and mixing the ingredients to form a fire resistance composition; processing the fire resistance composition into the fire resistance board according to present disclosure; wherein the processing comprises curing, de-stacking and drying.
Providing ingredients for preparation of fire resistance composition
In an embodiment, in present process, materials of ingredients for preparation of fire resistance composition are weighted for use in the present process.
Specifically, the inorganic cementitious material comprises cement and hydrated lime.
Inorganic cementitious materials may be provided according to methods that are commonly used in the art. For example, cement may be stored in a silo and Will be weighed on a required scale when provided for preparation of the fire resistance composition according to present disclosure. As another example, hydrated lime may also be stored in a silo and will be weighed on a required sale when provided for preparation of the fire resistance composition according to present disclosure.
The organic fiber material may be provided according to technologies that are commonly used in the art.
In an embodiment, the silicate material used in fire resistance composition according to present disclosure comprises silica sand and mica.
The silicate material may be provided according to methods that are commonly used in the art. For example, the silica sand may be grinded into a sand mortar comprising silica sand and water or other solution. Additionally, the obtained sand mortar may be pumped into a storage tank for weighing on a required scale to provide the silica sand. As another example, the mica may be stored in a bag with a mass of 25 kg/bag. Moreover, the mica may be provided and calculated according to the number of bags that storing the mica.
The vitreous rock may be provided according to technologies that are commonly used in the art. For example, the vitreous rock may be stored in a bag with a mass of 7.5 kg/bag. In addition, the vitreous rock may be provided and calculated according to the number of bags that storing the vitreous rock.
Mixing the ingredients to obtain fire resistance composition In an embodiment, ingredients are mixed to obtain the fire resistance composition according to present disclosure.
Specifically, the ingredients may be added into a reaction vessel arbitrarily without a specific order.
For example, the ingredients may be added into a reaction vessel with the following order: water, silica sand (in a sand mortar form), plant fiber material (in a pulp mortar form), cement, hydrated lime, mica, metamorphic mineral (e.g., wollastonite), vitreous rock (e.g., expanded perlite).
Particularly, the ingredients may be mixed for from about 10 minutes to about 20 minutes.
In addition, the obtained mixture may be then collected into a storage tank for preparation of a fire resistance board.
Processing the fire resistance composition to obtain an intermediate fire resistance board
In an embodiment, the obtained fire resistance composition is further processed to obtain an intermediate fire resistance board.
Particularly, the obtained fire resistance composition mixture has a water content of from about 80% to about 90%.
Specifically, the fire resistance composition mixture may be further processed through a flow on technology, which can render the plant fiber distribute properly in the system and then forms an interwoven matrix to bond with other ingredients including silica sand, hydrated lime, cement, mica, metamorphic mineral (e.g., wollastonite), vitreous rock (e.g., expanded perlite).
Moreover, the processed composition may form layers which have from about 0.7 mm to about 1.5 mm of thickness for each layer. Specifically, the composition layers may be wrapped layer by layer on a rolling roller to form an intermediate fire resistance board according to present disclosure.
Further processing to obtain a product board
In an embodiment, the obtained intermediate board is further processed to obtain a product board.
According to actual requirements for the product board, the obtained intermediate board may be cut to reach a standard size.
The intermediate board may be cut by any methods that are commonly used in this art. For example, the obtained) intermediate board may be cut with a high pressure water jet cutting system.
For further processing of the intermediate board, the cut intermediate board may be stacked with a steel plate. Moreover, the stacked intermediate board and plate may be transmitted to a curing chamber.
The processed fire resistance intermediate board according to present disclosure has at least one of following advantages over a normal fiber cement board:
(i) the processed fire resistance intermediate board according to present disclosure has a low density of from about 0.95 g/cm3 to about 1.05 g/cm3;
(ii) the processed fire resistance intermediate board according to present disclosure has an excellent fire resistance and insulation;
(iii) with flow on technology, the processed fire resistance intermediate board according to present disclosure does not need to be compressed to form the product board.
In an embodiment, the intermediate board may be transmitted through warm air into a curing chamber. The transmission process may be sustained for from about 2 hours to about 6 hours.
In an embodiment, the cured board may be transmitted into a de-stacker system to de-stack the cured board and steel plate. For example, the cured board may be transmitted into a high- pressure autoclave.
During autoclaving process, the board may form a stable, hard mineral (e.g., Tobermorite, Xonotlite and the like).
When the autoclaving process is finished, the autoclaved board may be dried to obtain the product fire resistance board according to present disclosure.
In the present process, the cement used in present preparation method may act as an adhesive and will react during autoclaving process. Additionally, due to the bonding between the plant fiber material (e.g., cellulosic fiber) and other materials which forms a bonding matrix, the flexibility of the obtained board may be increased. In the present process, silica sand and hydrated lime in present fire resistance composition may be a reactant during autoclaving process. In addition, the silica sand and hydrated lime may bring a white color to the present fire resistance composition and fire resistance board. Perlite has a light weight, low thermal conductivity, high chemical stability, low moisture absorption and thus may bring enhanced fire resistance and insulation to the product board. Mica has a volumetric stability at a high temperature, increased fire resistance, high insulation, and thus may bring enhanced fire resistance and insulation to the product board. Wollastonite may bring enhanced board strength and increased fire resistance to the product board.
Beneficial effects
The fire resistance composition and fire resistance board according to present disclosure has an excellent fire resistance and insulation. Under a working temperature of about 1200- 1400 °C, the present board can still be stable and hard without disintegration.
The fire resistance composition and fire resistance board according to present disclosure has an excellent toughness. The present fire resistance board complies with requirement of ASTM Cl 185 Grade 1 standard, showing high toughness.
The fire resistance composition and fire resistance board according to present disclosure are light-weight which extend their application field. The present fire resistance board for example has a board density of about 1000 kg/m3.
As the fire resistance composition and fire resistance board according to present disclosure has a light weight, it can be cut into desired shape and be transmitted easily, and thus can be widely applied in various fields. For example, the fire resistance board according to present disclosure can be easily cut into a desirable shape and applied into related scenario accordingly.
As the materials are grinded during the preparation process, and volume stable materials are also used, the obtained fire resistance board according to present disclosure has no warping with low shrinkage, e ven at a high working temperature.
Due to formation of bonding matrix between the composite fiber and cellulose fiber and other materials, the fire resistance board according to present disclosure shows an increased flexibility.
The diatomite added during process for preparing the present fire resistance composition may be a reactant in autoclaving process, which may contribute to the low thermal conductivity, increased fire resistance of the obtained board.
As the materials of present fire resistance composition are finely grinded during preparation process, which may contribute to a close bonding of the ingredients, the obtained fire resistance board according to present disclosure has an excellent moisture resistance.
Moreover, the obtained fire resistance composition and fire resistance board have an excellent safety and are friendly to health and environment due to environmentally friendly ingredients as used therein.
The fire resistance board can as well achieve an excellent high temperature stability.
Examples
The technical solutions of the present disclosure will be further described below by reference to specific examples. It should be noted that the examples are exemplary only, rather than any limitation to the protection scope of present disclosure. The present disclosure can also have other embodiments or be practiced with various means. Unless otherwise stated, all percentages, parts, ratios or the like herein are provided on a weight basis. Unless otherwise stated, the apparatus, reagents, raw materials or the like herein are commercially available. Material
All the materials used in present Examples, including, cement, hydrated lime, pulp (cellulosic fiber), silica sand, expanded perlite, mica, wollastonite, are all commercially available.
Equipment ,
All of the equipment used in present Examples, high pressure autoclave and balance, are all commercially available.
Examples
The example fire resistance boards are prepared by the method with following procedures.
(i) materials of ingredients having corresponding contents in the table below were provided;
(ii) The pulp was diluted in water to reach a concentration of 3.0-4.0% and then refined for 5-10 minutes; then the refined pulp solution can be provided ;
(iii) Silica sand was grinded into silica sand mortar to reacn a concentration of 40% - 60% ;
(iv) The ingredients were added by the following order: water, silica sand (in a sand mortar form), plant fiber material (in a pulp sand mortar form), cement, hydrated lime, mica, wollastonite, expanded perlite; the ingredients were mixed for 10-20 minutes;
(v) The obtained mixture has a water content of 80-90%; the mixture were submitted to a flow on technology which can render the pulp distribute properly and then forms an interwoven matrix to bond with other ingredients including silica sand, hydrated lime, cement, mica, metamorphic mineral (e.g., wollastonite), vitreous rock (e.g., expanded perlite);
(vi) The obtained composition was transmitted through warm air at a temperature of about 40-50 °C into a curing chamber;
(vii) The board was cured in the curing chamber;
(viii) The composition was then submitted into a high-pressure autoclave having a temperature of 170-180 °C for autoclaving.
(ix) After autoclaving, the fire resistance board was submitted for drying;
(x) After drying, the product fire resistance board was obtained.
Table 1 Composition of example fire resistance board
Fire resistance of fire resistance board of examples 1-10 were prepared according to the above-mentioned process with the compositions in table 1.
Test Examples
Fire resistance boards of examples 1-10 were submitted to the following testing standard to evaluate the corresponding properties:
(1) Flexural strength of fire resistance board was determined according to ASTM C 1185- 08 test method standard.
(3) Water absorption of fire resistance board was determined according to ASTM C 1185- 08 standard.
(4) Moisture content of fire resistance board was determined according to ASTM Cl 185- 08 standard.
(8) Density of 'fire resistance board was determined according to ASTM Cl 185-08 standard.
The example fire resistance boards were subjected to the above-mentioned tests and the test results are as shown in table 2 below.
Table 2 Test results for fire resistance boards of examples
The preferable embodiments of the present disclosure are provided above and it should be understood that those skilled in the art, without departing from the principles of the present disclosure, can make changes and modifications, and such changes and modifications should also be encompassed with the scope of the present disclosure.

Claims

Claims
1. A fire resistance composition comprising an inorganic cementitious material of about 22 wt.% to about 60 wt.%; an organic fiber material of about 2 wt.% to about 15 wt.%; a silicate material of about 12 wt.% to about 60 wt.%; and a vitreous rock of about 1 wt.% to about 22 wt.%; based on the total weight of the fire resistance composition.
2. The fire resistance composition according to claim 1, wherein the inorganic cementitious material comprises a hydraulic inorganic cementitious material, an air hardening inorganic cementitious material or a combination thereof, preferably a combination of a hydraulic inorganic cementitious material and an air hardening inorganic cementitious material.
3. The fire resistance composition according to claim 2, wherein the content of the hydraulic inorganic cementitious material ranges from about 20 wt.% to about 55 wt.%; the content of the air hardening inorganic cementitious material ranges from about 2 wt.% to about 15 wt.%, based on the total weight of the fire resistance composition.
4. The fire resistance composition according to any one of claims 1-3, wherein the hydraulic inorganic cementitious material comprises cement, concrete, mortar or a combination thereof, preferably cement; and/or the air hardening inorganic cementitious material comprises quick lime, hydrated lime, magnesite, water glass or a combination thereof, preferably hydrated lime.
5. The fire resistance composition according to any one of claims 1-4, wherein the organic fiber material comprises PP fiber, PET fiber, bast fiber, bamboo fiber, cellulosic fiber or a combination thereof, preferably cellulosic fiber.
6. The fire resistance composition according to any one of claims 1-5, wherein the silicate material comprises silica sand, talc, kaolinite, montmorillonite, mica, zeolite, wollastonite or a combination thereof; preferably a combination of silica sand, wollastonite and mica.
7. The fire resistance composition according to claim 6, wherein the content of silica sand ranges from about 10 wt.% to 45 wt.%, the content of mica ranges from about 1 wt.% to about 20 wt.%, the content of wollastonite ranges from about 1 wt.% to about 22 wt.%, based on the total weight of the fire resistance composition.
8. The fire resistance composition according to any one of claims 1-7, wherein the vitreous rock comprises perlite, obsidian, pitchstone, pumice or a combination thereof; preferably perlite; more preferably expanded perlite.
9. The fire resistance composition according to any one of claims 1 wherein the cementitious material comprises cement of about 20 wt.% to about 55 wt.% and hydrated lime of about 2 wt.% to about 15 wt.%; the organic fiber material is cellulosic fiber of about 2 wt.% to about 15 wt.%; the silicate material comprises silica sand of about 10 wt.% to about 6Q wt.%, wollastonite of about 1% to about 22 wt.%, and mica of about 1 wt.% to about 20 wt.%; the vitreous rock is expanded perlite of about 1 wt.% to about 22 wt.%; based on the total weight of the fire resistance composition.
10. The fire resistance composition according to any one of claims 1-9, wherein the fire resistance composition further comprises a diatomite, a glass fiber, or a combination thereof.
11. The fire resistance composition according to claim 10, wherein the diatomite has a content of no more than about 23 wt.%, or no more than 18 wt.%; and/or the glass fiber has a content of no more than about 2.5 wt.%, or no more than about 2 wt.%; based on the total weight of the fire resistance composition.
12. A fire resistance board prepared from the fire resistance composition according to any one of claims 1-11.
13. A process for preparing the fire resistance board according to claim 12, comprising providing and mixing the ingredients to form a fire resistance composition; processing the fire resistance composition into the fire resistance board, wherein the processing comprises curing, do-stacking and drying.
14. A construction structure, made with the fire resistance board according to claim 12.
PCT/VN2024/000003 2024-04-26 2024-04-26 A fire resistance composition, a fire resistance board prepared from the composition, a process for preparing the board, and a construction structure made with the board. Pending WO2025227168A1 (en)

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Citations (4)

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Publication number Priority date Publication date Assignee Title
US4132555A (en) * 1975-01-02 1979-01-02 Cape Boards & Panels Ltd. Building board
US4840672A (en) * 1986-03-14 1989-06-20 Redco N.V. Lightweight insulating boards and process for manufacturing same
US6139620A (en) * 1995-05-30 2000-10-31 Ask Corporation Calcium silicate board and method of manufacturing same
CN1350992A (en) * 2000-10-26 2002-05-29 苏州台荣建材有限公司 Light calcium silicate plate and its preparing process

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4132555A (en) * 1975-01-02 1979-01-02 Cape Boards & Panels Ltd. Building board
US4840672A (en) * 1986-03-14 1989-06-20 Redco N.V. Lightweight insulating boards and process for manufacturing same
US6139620A (en) * 1995-05-30 2000-10-31 Ask Corporation Calcium silicate board and method of manufacturing same
CN1350992A (en) * 2000-10-26 2002-05-29 苏州台荣建材有限公司 Light calcium silicate plate and its preparing process

Non-Patent Citations (1)

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Title
DATABASE WPI Week 200259, 29 May 2002 Derwent World Patents Index; AN 2002-549147, XP002812567 *

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