| PATENT NUMBER | This data is not available for free |
| PATENT GRANT DATE | 21.11.00 |
| PATENT TITLE |
Fireproof panel and method for its manufacture |
| PATENT ABSTRACT |
Fireproof panels, and methods for their construction are provided. The fireproof panels comprise at least one sheet including a layer of glass fibres impregnated with at least one fireproof resin free from solvent. The method for the construction includes the successive steps of distributing a fireproof resin in the form of a powder free from solvents on a layer of glass fibres, subjecting the latter to a first compression and heating step to soften the resin and, to a second compression and heating step to cross-link the resin and form the said panel. The panels find particular use in the production of partitions and furnishings. |
| PATENT INVENTORS | This data is not available for free |
| PATENT ASSIGNEE | This data is not available for free |
| PATENT FILE DATE | December 9, 1996 |
| PATENT FOREIGN APPLICATION PRIORITY DATA | This data is not available for free |
| PATENT REFERENCES CITED |
Use of Plastics in Building Structures and Parts of Buildings," A.M. Ivanov, ed., English translations of pp. 85-86, 66-67, 174, 268, 271 and 505. "Sovetskaya Encyclopaedia" Publishing House, Moscow, 1977, English translations of pp. 498-502 (fragments). WPI/Derwnet Abstracts Database Accession No. 90-278513, abstract of JP 21-94942 [Kubota Co.]. Patent Abstracts of Japan, abstract of JP 21-94942. Copy of European Search Report for EP 94 20 2814 dated Dec. 1, 1995. |
| PATENT PARENT CASE TEXT | This data is not available for free |
| PATENT CLAIMS |
I claim: 1. A method for the production of fireproof panels according to RINA standards, said panels including at least one fireproof sheet which consists of glass fibers and a fireproof phenol-formaldehyde resin, the method comprising the successive steps of: forming a layer of the glass fibers: distributing the fireproof phenol-formaldehyde resin uniformly, in the form of a powder free from solvents, on the layer of glass fibers, in quantities of at least 5 g but no higher than 6 g of the resin per 100 g of the glass fibers; simultaneously compressing and heating the layer and the distributed resin to a temperature at which the resin softens for sufficient time to cause the softening of the resin, thereby impregnating the layer of glass fibers with the resin to form an impregnated layer; and compressing the impregnated layer at the cross-linking temperature of the resin to obtain said fireproof sheet. 2. A method according to claim 1, wherein the step of compression and heating to the softening temperature of the resin is carried out at a temperature of 80-100.degree. C. at a pressure of 1.5-2 atmospheres and for 5-7 minutes. 3. A method according to claim 1, wherein the step of compression at the cross-linking temperature of the resin is carried out at a temperature of 180-220.degree. C., at a pressure of 1.5-2 atmospheres and for 5-7 minutes. 4. A method according to claim 1, wherein the step of compression and heating to cause softening is carried out by placing the layer between heated surfaces of a first press and the step of compression at the cross-linking temperature is carried out by placing the layer between heated surfaces of a second press. 5. A method according to claim 4, wherein, in the step of compression and heating to cause softening of the resin, said heated surfaces of the first press are heated to 90.degree. C. 6. A method according to claim 4, wherein, in the step of compression at the cross-linking temperature of the resin, said heated surfaces of the second press are heated to 200.degree. C. 7. The method of claim 1, wherein the step of compression and heating to the softening temperature of the resin and the step of compression at the cross-linking temperature of the resin are carried out at the same pressure. 8. The method of claim 1, wherein the step of compression and heating to the softening temperature of the resin is carried out at a pressure of 1.5-2 atmospheres. 9. The method of claim 1, wherein the step of compression at the cross-linking temperature of the resin is carried out at a pressure of 1.5-2 atmospheres. 10. The method of claim 1, further comprising laminating two of said fiber sheets on either side of a core to comprise said fireproof panel. 11. The method of claim 10, wherein the core comprises an aluminum honeycomb, and the two fiber sheets are fixed to the core using a fireproof adhesive. -------------------------------------------------------------------------------- |
| PATENT DESCRIPTION |
FIELD OF THE INVENTION In its more general aspect, the present invention relates to panels or like structures which are fireproof and are usable as constituent elements of partitions or furniture. Moreover the present invention relates to a method for the production of fireproof panels suitable for the production of partitions and furniture for ships or aircraft, as well as panels obtained by this method. BACKGROUND OF THE INVENTION In the field of furnishing equipment for aircraft and ships, particularly for merchant ships, there is a great need for structural elements such as bulkheads and elements of furniture made from fireproof materials which do not transmit flames and form a barrier to the propagation of heat, without giving off fumes or toxic vapours. The materials usable for this purpose must answer very precise and often very strict requirements set out in the laws in force in various countries. In Italy, for example, these requirements are established by the regulations of the Italian Register of Shipping (RINA), prepared in accordance with international shipping-safety standards established by the SOLAS Convention 74(83). In addition to satisfying this primary requirement, research has for some time been directed at finding materials which enable the manufacture of lightweight structural elements, including self-supporting elements, with little bulk and which are readily workable by a machine so as to be very versatile with regard to their use or applications. It is known that until now this research has given results which are not fully acceptable since, in general, the materials proposed do not answer the primary requirements listed above. The problem at the basis of the present invention is that of providing a fireproof panel suitable for the manufacture of partitions and furnishings for ships and aircraft which has all the properties specified above. SUMMARY OF THE INVENTION This problem has been resolved by a fireproof panel characterised in that it includes at least one sheet comprising a layer of glass fibres impregnated with at least one fireproof resin free from solvents. A phenol-formaldehyde, particularly a novolac, resin is preferably used as the fireproof resin. The use of the novolac resin LERIPHEN SM 1112 is particularly advantageous. In a preferred embodiment of the invention, the fireproof panel includes at least one element which has two such sheets between which is interposed an aluminium honeycomb structure. The present invention also relates to a method for the production of fireproof panels suitable for the production of partitions and furnishings, including at least one sheet of glass fibres, characterised in that it includes the successive steps of: distributing a fireproof resin uniformly, in the form of a powder free from solvents, on a layer of glass fibres in quantities of at least 5 g per 100 g of the glass fibres, compressing the layer and heating it to a temperature at which the resin softens for sufficient time to cause the softening thereof, compressing the layer further at the cross-linking temperature of the resin to obtain the said sheet. To advantage the fire-proof resin is a phenol-formaldehyde resin. The quantity of fireproof resin distributed on the layer of glass fibres is preferably between 5 and 6 g per 100 g of glass fibres. Preferably the step of compression and softening of the resin is carried out at a temperature of 80-100.degree. C., at a pressure of 1.5-2 atmospheres and for 5-7 minutes and the step of compression and cross-linking of the resin is carried out at a temperature of 180-220.degree. C., at a pressure of 1.5-2 atmospheres and for 5-7 minutes. Although a single press can be used, in a preferred embodiment of the present invention, the compression steps are carried out by placing the said layer between the heated surfaces of respective presses, one for compression at the softening temperature of the resin and the other for compression at the cross-linking temperature of the resin. During the compression and softening of the resin, the surfaces of the respective press are preferably heated to 90.degree. C. During the compression and cross-linking of the resin, the surfaces of the respective press are preferably heated to 200.degree. C. A phenol-formaldehyde resin which is particularly useful for the method described above is the novolac resin LERIPHEN SM 1112 made by the firm Industrie Chimiche Leri. BRIEF DESCRIPTION OF THE DRAWINGS The foregoing object and many of the attendant advantages will become more readily apparent from the following description and the accompanying drawing wherein FIG. 1 is a schematic section of part of a fireproof panel manufactured with the use of the sheets produced by the method of the invention. DETAILED DESCRIPTION OF THE INVENTION The fire-resisting properties of phenol-formaldehyde resins have been known for some time but fireproof panels and sheets made with the use of these resins, and able to satisfy the requirements set out above, are not known. The reason for this must be attributed to the fact that these panels or sheets, if prepared by the usual methods of impregnation based on contact with solutions of the resin in organic solvents, have good fireproof and heat-shielding properties but when exposed to high temperatures, inevitably give off vapours and toxic gases. With the method of the present invention, instead, it is found, surprisingly, that perfect impregnation of the layers of glass fibres with the selected fireproof resin is obtained, particularly with a phenol-formaldehyde resin, without the use of any solvent, simply by softening the resin applied in the dry, powdered state, without organic solvents, by mild compression (1.5 to 2 atmospheres) for example between the plates of a press heated to 80-100.degree. C. for 5-7 minutes. In these conditions the resin acquires a treacle-like consistency and impregnates the fibres uniformly. A second compression step, at the same pressure but at a higher temperature (180 to 220.degree. C.), between the heated plates of a press for 5 to 7 minutes, causes cross-linking of the resin, enabling sheets to be obtained which not only have very good fire-resisting and heat-shielding properties but are also easy to handle in that they are self-supporting. If an aluminium honeycomb structure is interposed between two sheets prepared by the method of the invention with the use of fixing means such as a fire-proof glue which does not give off toxic gas or vapour at high temperatures, such as, for example, the adhesive polyurethane XC 189 E made by the firm EXCEL or the adhesive DUNAPOL SP 1500 made by the firm DUNA-CORRADINI, panels are obtained which may be used in the manufacture of partitions, bulkheads and furnishing elements such as furniture, particularly for ships. Further advantages and characteristics of the invention will become more apparent from the embodiment of the method described above and from the results of tests carried out on fireproof panels and sheets made by this method, given below by way of non-limitative example. |
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