A composite fire-resistant insulation board

Abstract

This application provides a composite fire-resistant insulation board, comprising a first layer composed of a fire-resistant fiber foam layer, a second layer composed of a flexible glass fiber layer, and a third layer composed of a fabric layer. The first, second, and third layers of the composite fire-resistant insulation board are sequentially connected by a fire-resistant adhesive, and the first layer is used to fix it to an external support surface. The composite fire-resistant insulation board disclosed in this application combines a fiber foam layer with a glass fiber layer, effectively ensuring that the fire-resistant board has sufficient fire resistance to achieve flame retardancy, while also possessing a relatively light weight and good mechanical rigidity and strength.

Description

Technical Field

[0001] This application relates to the field of refractory materials, and more specifically, to a composite refractory insulation board suitable for widespread use in shipbuilding and industrial construction. Background Technology

[0002] In shipbuilding and construction, inorganic materials such as rock wool, mineral wool, and calcium carbonate boards are commonly used as primary fireproofing and insulation materials. These inorganic insulation materials must provide sufficient rigidity and good mechanical structure while meeting fire resistance requirements. However, the fire resistance of traditional inorganic refractory materials is somewhat affected when meeting the requirements of high density and specific rigidity and strength for certain panels. This is mainly because existing inorganic refractory materials are manufactured by adding resins or adhesives to inorganic fibers to impart a certain mechanical consistency, achieving high density and high rigidity in the refractory board. However, excessive binder content can easily lead to a decrease in the final fire resistance of the refractory board, thus failing to pass fire resistance tests that meet international standards. Furthermore, inorganic refractory materials are generally heavy, failing to meet the lightweight requirements of ships. In practical applications, refractory boards used in certain ship structures, such as internal wall panels and ceiling slats, need to ensure both fire resistance and sufficient mechanical rigidity. Therefore, it is necessary to develop a new type of composite refractory material that possesses the necessary refractory properties, sufficient mechanical strength, and relatively light weight.

[0003] Furthermore, inorganic refractory materials, such as rock wool products, may have certain environmental impacts during production and use. For example, the production of inorganic refractory materials requires a large amount of electricity and coal resources, resulting in air pollution. Therefore, it is necessary to provide a new type of composite refractory material that is more environmentally friendly and sustainable.

[0004] Furthermore, conventional inorganic refractory materials, such as rock wool products, are hygroscopic. Without special treatment or if the original water-repellent coating is damaged, moisture can easily seep into the interior through capillary action, leading to a decline in insulation performance and structural strength, potentially causing safety hazards. Therefore, when inorganic refractory materials like rock wool products are exposed to humid environments for extended periods, such as in the use of refractory boards made from rock wool in ships, their performance and lifespan may be affected due to excessive moisture absorption. Therefore, it is necessary to provide a new type of composite material more suitable for use in highly humid environments. Utility Model Content

[0005] To address the problem that conventionally used inorganic refractory materials in the existing technology cannot simultaneously meet the fire resistance and mechanical properties required for use in the marine industry, and are also relatively heavy, this utility model provides a composite fire-resistant and heat-insulating board that simultaneously possesses sufficient fire resistance, good mechanical properties, and sound insulation and heat insulation properties, and its weight is significantly reduced compared to commonly used inorganic refractory materials on the market.

[0006] The composite fire-resistant insulation board of this utility model is configured to be fixed to an external support surface. The composite fire-resistant insulation board includes: a first layer composed of a fire-resistant fiber foam layer and configured to have two flat surfaces along the extension direction of the composite fire-resistant insulation board; and a second layer composed of a flexible glass fiber layer, wherein the first side flat surface of the first layer is configured to be connected to the external support surface, and the second side flat surface of the first layer is configured to be bonded to the first side surface of the second layer via a fire-resistant adhesive.

[0007] According to one aspect of this application, the composite fire-resistant insulation board further includes a third layer consisting of a fabric layer and configured to be attached to a second side surface of the second layer via a fire-resistant adhesive. Further, the third layer is configured to prevent direct contact between external dust and the second layer.

[0008] According to one aspect of this application, the thickness of the first layer is set between 5 mm and 100 mm, and the density of the first layer is set at 100 kg / m³. 3 Up to 450kg / m 3 between.

[0009] According to one aspect of this application, the thickness of the second layer is set between 4 mm and 100 mm, and the density of the second layer is set at 50 kg / m³. 3 Up to 300kg / m 3 between.

[0010] According to one aspect of this application, the first side flat surface of the first layer is connected to the external support surface via a refractory adhesive.

[0011] According to one aspect of this application, the first side flat surface of the first layer is connected to the external support surface via a physical connection structure.

[0012] According to one aspect of this application, the second flexible glass fiber layer is made by needle punching.

[0013] According to one aspect of this application, the thickness of the third layer is set to be less than the thickness of the first layer and the thickness of the second layer.

[0014] According to one aspect of this application, the refractory adhesive is selected from one or more of high-temperature resistant epoxy resin, silicone sealant, and polyimide adhesive.

[0015] Compared with the prior art, the present invention has the following advantages:

[0016] (1) The composite fire-resistant insulation board disclosed in this utility model uses a "sandwich" multi-layer structure, utilizing a combination of a first layer of fiber foam and a second layer of glass fiber to further improve the fire resistance rating of the composite material. The fire-resistant board provided by this utility model not only meets the fire resistance rating of B15-class ships, but also has excellent structural strength and rigidity, as well as superior sound absorption performance.

[0017] (2) The composite fire-resistant insulation board disclosed in this utility model has a significantly reduced weight compared to existing inorganic fire-resistant boards, and it has a weight and density widely recognized in the field of naval vessels. Therefore, its quality performance far exceeds that of inorganic fire-resistant boards such as high-density rock wool boards currently in use, which significantly improves the carrying capacity and combat capability of ships, and is therefore more suitable for the field of shipbuilding, especially for use on naval vessels.

[0018] (3) The composite fire-resistant insulation board disclosed in this utility model is more environmentally friendly than traditional inorganic fire-resistant boards during manufacturing and use, and reduces greenhouse gas emissions.

[0019] (4) The composite fire-resistant insulation board disclosed in this utility model is more suitable for use in high humidity and high corrosion environments (such as marine environments) than traditional inorganic fire-resistant boards, which makes the fire-resistant board provided in this application more suitable for the shipbuilding industry. Attached Figure Description

[0020] The following is a brief introduction to the accompanying drawings used in the description of the embodiments of this application:

[0021] Figure 1 This is an exploded structural diagram of the composite fire-resistant insulation board provided in the embodiments of this application;

[0022] Figure 2 This is a cross-sectional schematic diagram of the composite fire-resistant insulation board provided in the embodiments of this application;

[0023] Figure 3 This is a curve comparing the average internal temperature of the combustion chamber of the first to fourth samples with the standard temperature value during the fire resistance test.

[0024] Figure 4 The diagram shows the temperature measurement of the non-fire-exposed surface of the sample at five points selected during the fire resistance test.

[0025] Figure 5 The temperature changes at five locations on the non-fire-exposed surface of the first sample over 30 minutes are shown.

[0026] Figure 6The temperature changes at five locations on the non-fire-exposed surface of the second sample over 30 minutes are shown.

[0027] Figure 7 The temperature changes at five locations on the non-fire-exposed surface of the third sample over 30 minutes are shown.

[0028] Figure 8 The temperature changes at five locations on the non-fire-exposed surface of the fourth sample over 30 minutes are shown.

[0029] Figure 9 The graph shows the average surface temperature changes over 30 minutes at five measurement locations on the non-fire-exposed surfaces of samples one through four; and

[0030] Figure 10 The graph shows the average temperature change over 30 minutes at five measurement locations on the non-fire-exposed surfaces of the first to fourth samples. Detailed Implementation

[0031] To more clearly illustrate the technical solutions of the embodiments of this application, the specific implementation methods of this application will be described below with reference to the accompanying drawings. The accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings and other implementation methods can be obtained based on these drawings without creative effort. Adjustments and improvements made without departing from the concept of this application are all within the protection scope of this application.

[0032] To keep the drawings simple, only the parts related to the corresponding embodiments are schematically shown in each figure, and they do not represent the actual structure of the product. Furthermore, for ease of understanding, some figures only schematically show parts of components with the same structure or function; in reality, there may be more or fewer components with the same structure or function. Unless otherwise specified, the raw materials or apparatus used in the embodiments below are available from conventional commercial sources or can be obtained by existing known methods.

[0033] In this application, unless otherwise expressly specified and limited, ordinal numbers, such as "first," "second," etc., are used only to distinguish and describe related objects, and should not be construed as indicating or implying the relative importance or order between related objects; furthermore, they do not represent the quantity of related objects. "Multiple" includes two or more, and other quantifiers are similar. " / " is used to describe the relationship between related objects, indicating an "or" relationship between them. "And / or" is used to describe the relationship between related objects, including any combination relationship between them, such as "a and / or b" including: "a alone," "b alone," or "a and b." "One or more" or "at least one" of multiple objects refers to any object or any combination of multiple objects, such as "one or more of a1, a2, a3" or "at least one of a1, a2, a3" including: "a1 alone," "a2 alone," "a3 alone," "a1 and a2," "a1 and a3," "a2 and a3," or "a1, a2 and a3."

[0034] For reference Figure 1 and Figure 2 This application illustrates an embodiment of the composite fire-resistant insulation board disclosed herein. The fire-resistant board has a "sandwich" multi-layer composite structure, comprising a first layer 1 (i.e., a fiber foam layer) and a second layer 2 (i.e., a glass fiber layer). The first layer 1 of the fire-resistant board can be made of a fiber foam layer, and the thickness and density of the first layer 1 can be determined based on actual needs. More specifically, the thickness of the first layer 1 is preferably set between 5 mm and 100 mm, and the density of the first layer 1 is preferably set at 100 kg / m³. 3 Up to 450kg / m 3 Within a certain range, to ensure its connection strength with other contact layers. The first layer 1 is configured to have two parallel, relatively flat side surfaces, wherein one side surface of the first layer 1 (also referred to as the "outer surface") is used to firmly connect to an external support surface, which can be a hull panel, ceiling, etc., and its shape is usually a relatively flat plane. Specifically, the outer surface of the first layer 1 can be connected to the external support surface using an adhesive such as glue or by using a physical connection structure, such as a pressure plate or fastening rivets. Since both the fiber foam layer and the external support surface have sufficient rigidity and flatness, a very small amount of adhesive can be used to achieve a firm fixation between them. In addition, the other side surface of the fiber foam layer is configured to be firmly connected to the second layer 2 of the fire-resistant board by a fire-resistant adhesive.

[0035] The composite fire-resistant insulation board disclosed in this application further includes a second layer 2, which can be made of a glass fiber layer, wherein the thickness and density of the second layer 2 can be determined based on actual needs. More specifically, the thickness of the second layer 2 is preferably set between 4 mm and 100 mm, and the density of the second layer 2 is preferably set at 50 kg / m³. 3 Up to 300kg / m 3 Within a certain range to ensure its connection strength with other contact layers. According to one embodiment of this application, the second layer 2 is preferably made by processing glass fibers using mechanical compression rather than using adhesives such as glue or resin. More specifically, the second layer 2 can be a flexible glass fiber layer processed by needle punching short glass fibers. It is made by needle punching short glass fiber mats after combing with needles, and mechanically entangled fibers between the glass fibers in the mat layer and between the glass fibers in the mat layer and the reinforcing glass fiber base fabric.

[0036] According to the disclosure of this application, the combined use of a fiber foam layer and a flexible glass fiber layer significantly improves the fire resistance, mechanical strength, noise reduction, and overall weight reduction of the composite fire-resistant insulation board disclosed in this application compared to traditional fire-resistant insulation boards. This is particularly crucial in the shipbuilding industry. The fiber foam layer used as the first layer has good mechanical rigidity, which helps improve the overall rigidity of the fire-resistant board. Furthermore, the fiber foam layer also has good coplanarity and flatness, allowing it to be firmly bonded to other materials with only a very small amount of adhesive, which is essential for passing fire resistance tests. In addition, the fiber foam layer also possesses extremely strong fire resistance. Therefore, as the material for the first layer, the fiber foam layer ensures fire resistance and mechanical properties while achieving the lightest weight and simplest structure, making it the most suitable fire-resistant insulation material for the shipbuilding industry.

[0037] The second layer of needled glass fiber can significantly improve fire resistance. At the same time, due to the sound insulation and sound absorption properties of the needled glass fiber layer itself, it is also suitable for greatly reducing noise transmission, thus enabling the fire-resistant insulation board of this application to have a noise reduction function. Meanwhile, the needled glass fiber layer can also ensure the structural rigidity and strength of the fire-resistant board, and ensure that its fire resistance meets the international standard of B15.

[0038] Furthermore, compared to traditional inorganic refractory materials, glass fiber layers do not use any resins or glues as adhesives during manufacturing, so their production and use will not cause environmental pollution or health hazards to users.

[0039] Furthermore, compared with traditional inorganic refractory materials, fiber foam layers and glass fiber layers are less prone to absorbing moisture and are also more corrosion resistant. Therefore, the refractory insulation board disclosed in this application is more suitable for use in high humidity and high corrosion environments (such as marine environments), which makes the refractory board provided in this application more suitable for the marine industry.

[0040] According to the disclosure of this application, the fire-resistant insulation board of this application also includes a third layer 3 (i.e., a fabric layer), which is configured to isolate external dust from direct contact with the second layer 2. The third layer 3 can be composed of fiberglass fabric; however, it can also be composed of any other type of dustproof fabric, such as silicone-coated fiberglass cloth, polytetrafluoroethylene-coated fiberglass cloth, aramid fabric, aluminum silicate fiber cloth, or flame-retardant polyester dustproof cloth. According to one embodiment of this application, the third layer 3 is configured to completely cover and firmly bond to the fiberglass layer. According to embodiments of this application, the texture and weight of the third layer 3 (i.e., the fabric layer) can be configured according to actual needs. This third layer is designed to prevent dust from the environment from settling on the surface of the fire-resistant board, thereby contaminating the board and causing a reduction in its performance. At the same time, the fabric layer also makes the fire-resistant board more aesthetically pleasing and gives it a comfortable and consistent feel.

[0041] According to the disclosure of this application, the first, second, and third layers of the fire-resistant board are sequentially connected together using a fire-resistant adhesive. The fire-resistant adhesive can be high-temperature resistant epoxy resin, silicone sealant, polyimide adhesive, or other types of fire-resistant adhesives, and different types of fire-resistant adhesives can be used for the connection between different layers and for the connection between different areas within the same layer.

[0042] The following section details the fire resistance testing of the products, specifically comparing the fire resistance of some commonly used refractory materials with that of a refractory material according to an embodiment of this application. Examples of using fiber foam layers as heat-resistant insulation materials already exist in the prior art, and different thicknesses of fiber foam layers can be selected according to actual needs. Several commonly used thicknesses of fiber foam layers (i.e., the first sample, the second sample, and the third sample) and a fire-resistant board according to an embodiment of this application (i.e., the fourth sample) were selected, and fire resistance tests were conducted on the four samples, which will be described in detail below.

[0043] In this fire resistance test, all samples were vertically fixed to a frame within the combustion chamber. The internal width, height, and depth of the combustion chamber were set to 700 mm, 1100 mm, and 600 mm, respectively. Three burners were located at the bottom of the combustion chamber, parallel to the samples under test. The burners were powered by a variable-flow-rate gas mixture (e.g., a mixture of air and propane), and the average temperature inside the combustion chamber could be controlled manually or automatically to conform to the standard time-temperature curve specified in Section 8.3.1.1 of Annex 1, Part III of the FTP Code to be followed in this test. The fire resistance test lasted for 30 minutes, calculated according to the standard time-temperature curve formula T = 345log 10 (8t+1)+20(1) (where T is the average temperature inside the combustion chamber in °C; t is the time in min), the estimated average temperature inside the combustion chamber will be as follows:

[0044] t = 5 min, T = 576℃;

[0045] t = 10 min, T = 679℃;

[0046] t = 15 min, T = 738℃;

[0047] t = 30 min, T = 841℃.

[0048] According to the requirements of the fire resistance test, the deviation between the actual temperature in the combustion chamber and the above-mentioned standard temperature should conform to the range specified in Part III of Annex 1 of the FTP Code.

[0049] First sample: 15mm thick fiber foam layer

[0050] For the first sample, the standard curve temperature and the actual average temperature inside the combustion chamber were recorded per minute during the fire resistance test. A comparison curve was also plotted between the average temperature inside the combustion chamber of the first sample and the standard temperature value during the fire resistance test. See the attached diagram for details. Figure 3 The average temperature change curve is represented by line A1, while line S is the standard curve.

[0051] In addition, in this fire resistance test, in accordance with the requirements of FTP Code 2010 resolution, the temperature of the non-fire-exposed surface of the first sample was also measured. As stipulated, five points were selected on the non-fire-exposed surface of this sample for temperature measurement; the locations of these five points are detailed in [link to relevant documentation]. Figure 4 .and Figure 5 The diagram shows the temperature change of the first sample at each of the five selected locations during this fire resistance test, relative to the initial temperature before the test. Furthermore, the average temperature change at these five points was calculated and the corresponding curve was plotted; see [link to relevant documentation] for details. Figure 9 and Figure 10 As shown.

[0052] Second sample: 25mm thick fiber foam layer

[0053] The second sample underwent a similar fire resistance test as the first sample. The curve showing the change in the actual average temperature inside the combustion chamber of the second sample versus the standard curve temperature per minute is shown below. Figure 3 As shown, the average temperature change curve is represented by line A2, while line S is the standard curve.

[0054] In addition, the temperature of the non-fire-exposed surface of the second sample was also measured at five points. Figure 6 The diagram shows the temperature change of the second sample at each of the five selected locations during this fire resistance test, relative to the initial temperature before the test. Furthermore, the average temperature change at these five points was calculated and the corresponding curve was plotted; see [link to relevant documentation] for details. Figure 9 and Figure 10 As shown.

[0055] Third sample: 35mm thick fiber foam layer

[0056] The third sample underwent a similar fire resistance test as the first and second samples. The curve showing the change in the actual average temperature inside the combustion chamber of the third sample versus the standard curve temperature per minute is shown below. Figure 3 As shown, the average temperature change curve is represented by line A3, while line S is the standard curve.

[0057] In addition, the temperature of the non-fire-exposed surface of the third sample was also measured at five points. Figure 7 The diagram shows the temperature change of the third sample at each of the five selected locations during this fire resistance test, relative to the initial temperature before the test. Furthermore, the average temperature change at these five points was calculated and the corresponding curve was plotted; see [link to relevant documentation] for details. Figure 9 and Figure 10 As shown.

[0058] Fourth sample: Composite fire-resistant insulation board disclosed in this application

[0059] According to one embodiment disclosed in this application, a composite fire-resistant insulation board is provided, wherein the first layer of the fire-resistant board is a fiber foam layer with a thickness of 15 mm, and the second layer of the fire-resistant board is needle-punched glass fiber with a thickness of 10 mm. The composite fire-resistant insulation board in this embodiment underwent fire resistance testing similar to that of the aforementioned first to third samples.

[0060] The curve showing the change in the actual average temperature inside the combustion chamber of the third sample versus the standard curve temperature per minute is shown below. Figure 3 As shown, the average temperature change curve is represented by line A4, while line S is the standard curve.

[0061] In addition, a similar five-point temperature measurement was performed on the non-fire-exposed surface of the fourth sample. Figure 8 The diagram shows the temperature change of the fourth sample at each of the five selected locations during this fire resistance test, relative to the initial temperature before the test. Furthermore, the average temperature change at these five points was calculated and the corresponding curve was plotted; see [link to relevant documentation] for details. Figure 9 and Figure 10 As shown.

[0062] Based on the above test data, the temperature rise inside the combustion chamber of all samples during the fire resistance test met the standard temperature rise value. Therefore, the deviation between the actual temperature inside the combustion chamber and the aforementioned standard temperature during the fire resistance test complies with the range specified in Part III of Annex 1 of the FTP Code. (Reference) Figures 5 to 10 It is evident that, 15 minutes after combustion, the temperature change trend of the non-fire-exposed surfaces of the first to third samples shows that the thicker the sample, the smaller the temperature rise, and thus the better the fire resistance. However, for the fourth sample, the fire-resistant board disclosed in this application, with an overall thickness of 25mm, its fire resistance is comprehensively superior to the first and second samples, and slightly lower than the third sample. In particular, compared to the second sample, which has the same thickness, the fire resistance of the fire-resistant board disclosed in this application far exceeds that of the second sample. Compared to the third sample, although its fire resistance is slightly inferior, the fire-resistant board disclosed in this application is lighter in terms of thickness and weight. In other words, the fire-resistant board used in this application, which is made by bonding a fiber foam layer and a glass fiber layer, achieves the best balance in terms of fire resistance, thickness, weight, and mechanical properties.

[0063] In the above embodiments, the descriptions of each embodiment have their own emphasis. Parts not described in detail or in a particular embodiment can be referred to in the relevant descriptions of other embodiments. Furthermore, the above embodiments can be freely combined as needed.

Claims

1. A composite fire-resistant insulation board, characterized in that, The composite fire-resistant insulation board is configured to be fixed to an external support surface, the composite fire-resistant insulation board comprising: The first layer, comprising a refractory fiber foam layer, is configured to have two flat surfaces along the extension direction of the composite refractory insulation board; and The second layer is composed of a flexible glass fiber layer. The first side flat surface of the first layer is configured to be connected to the external support surface, and the second side flat surface of the first layer is configured to be bonded to the first side surface of the second layer via a refractory adhesive.

2. The composite fire-resistant insulation board according to claim 1, characterized in that, The composite fire-resistant insulation board further includes a third layer, which is composed of a fabric layer and is configured to be connected to the second side surface of the second layer via the fire-resistant adhesive.

3. The composite fire-resistant insulation board according to claim 2, characterized in that, The third layer is configured to isolate external dust from direct contact with the second layer.

4. The composite fire-resistant insulation board according to claim 1, characterized in that, The thickness of the first layer is set between 5 mm and 100 mm, and the density of the first layer is set at 100 kg / m³. 3 Up to 450kg / m 3 between.

5. The composite fire-resistant insulation board according to claim 1, characterized in that, The thickness of the second layer is set between 4 mm and 100 mm, and the density of the second layer is set at 50 kg / m³. 3 Up to 300kg / m 3 between.

6. The composite fire-resistant insulation board according to claim 1, characterized in that, The first side flat surface of the first layer is adapted to be connected to the external support surface via a refractory adhesive.

7. The composite fire-resistant insulation board according to claim 1, characterized in that, The first side flat surface of the first layer is adapted to be connected to the external support surface via a physical connection structure.

8. The composite fire-resistant insulation board according to claim 1, characterized in that, The second layer of flexible glass fiber is made using a needle punching method.

9. The composite fire-resistant insulation board according to claim 2, characterized in that, The thickness of the third layer is set to be less than the thickness of the first layer and the thickness of the second layer.

10. The composite fire-resistant insulation board according to claim 1, characterized in that, The fire-resistant adhesive is selected from one or more of high-temperature resistant epoxy resin, silicone sealant, and polyimide adhesive.

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