Composite material for making furniture components
A honeycomb cardboard composite material with intumescent paint and optional reinforcement addresses the high weight and fire resistance issues of aircraft furniture, offering lightweight, fire-resistant, and easily shapable solutions for aircraft components.
Patent Information
- Authority / Receiving Office
- FR · FR
- Patent Type
- Applications
- Current Assignee / Owner
- PROTECFLAM IND
- Filing Date
- 2024-12-04
- Publication Date
- 2026-06-05
AI Technical Summary
Aircraft furniture components made of metallic or composite materials face challenges of high weight and complex structure, which increase fuel consumption and do not adequately meet fire resistance requirements.
A composite material with a honeycomb cardboard structure, featuring a vinyl intumescent paint-coated outer face and edges, and optionally a reinforcement layer, providing fire resistance and mechanical strength while maintaining low weight.
The material achieves good fire resistance and mechanical properties, meeting aeronautical standards with reduced weight and ease of shaping, and complies with CS/FAR 25.853 Appendix F tests.
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Abstract
Description
Title of the invention: Composite material for the manufacture of furniture elements Technical field of the invention
[0001] The present invention relates to the technical field of materials used for the production of furniture elements.
[0002] It relates more particularly to a composite material designed for the production of furniture elements such as storage boxes or trolleys, in particular for equipping an aircraft cabin. State of the art
[0003] The materials used to manufacture aircraft furniture components must meet relatively strict and binding specifications to satisfy applicable standards, particularly in terms of fire resistance.
[0004] For this reason, furniture elements such as storage boxes or trolleys, in the aeronautical field, are often made of metallic or composite materials that are highly resistant to fire, but whose structure is relatively complex and whose weight penalizes fuel consumption. Presentation of the invention
[0005] In order to remedy the aforementioned drawback of the prior art, the present invention proposes a composite material designed for the manufacture of furniture elements such as storage boxes or trolleys, in particular for an aircraft cabin, which material is in the form of a plate delimited by two parallel plate faces and a plate edge,
[0006] one of said plate faces, referred to as the exposed face, being intended to be oriented outwards, i.e. towards said aircraft cabin and subjected primarily to the risk of fire,
[0007] which composite material (1) is in the form of a plate of the type with a honeycomb cardboard structure comprising:
[0008] - a central honeycomb paper core, delimited by two parallel core faces and a song of the soul,
[0009] - an outer paper coating layer, one face of which, called the inner face, is joined to one of the said soul faces, and the other face, called the outer face, is intended to be oriented towards the side of the said exposed face,
[0010] - an inner paper coating layer, one face of which, referred to as the inner face, is joined to the other of the said soul faces, and the other face, called the outer face, is intended to be oriented in the opposite direction to the said exposed face,
[0011] this composite material being characterized by the fact that at least said outer face of the outer paper coating layer is coated, directly or indirectly, with a layer of vinyl intumescent paint.
[0012] Such a plate structure has a relatively low weight and exhibits good mechanical characteristics.
[0013] It exhibits good fire resistance, enabling it to meet the requirements of fire protection in the aeronautical field.
[0014] Such a material meets the mechanical resistance requirements in the field of aeronautics and it is easily cut to shape the desired furniture element.
[0015] Other non-limiting and advantageous characteristics of the composite material according to the invention, taken individually or in all technically possible combinations, are as follows:
[0016] - the weight of the intumescent vinyl paint layer that covers said outer face of the outer paper coating layer is greater than 225 g / m2;
[0017] - the outer face of the inner paper coating layer is coated with a vinyl intumescent paint layer;
[0018] - the weight of the intumescent vinyl paint layer that covers said the outer face of the inner paper coating layer is greater than 100 g / m2
[0019] - the plate edges in contact with the outside are coated with a layer of vinyl intumescent paint;
[0020] - the weight of the intumescent vinyl paint layer that covers the edge weight of plate in contact with the outside is greater than 100 g / m2;
[0021] - the aqueous-phase vinyl intumescent paint is of the type comprising a mixture: of at least one vinyl resin, at least one inorganic acid source, at least one carbon source, at least one blowing agent and a water-based diluent.
[0022] - the plate edges in contact with the outside include an extension of the outer paper coating layer, folded down at 90° and bonded to the soul swath by gluing;
[0023] - the composite material may include an interposed reinforcement layer, of a part, between the outer paper coating layer and / or the inner paper coating layer, and on the other hand, the intumescent vinyl paint layer;
[0024] - the reinforcement layer can be made of woven or non-woven material, of a certain weight between 100 and 800 g / m2;
[0025] - the intumescent vinyl paint layer can be coated with a layer of protective finish;
[0026] - the protective topcoat preferably has a weight of less than 60 g / m2;
[0027] - the thickness of the material plate can be between 6 and 50 mm,
[0028] the basis weight of the paper constituting the outer coating layer and the inner coating layer can be between 70 and 500 g / m2 (advantageously between 250 and 430 g / m2),
[0029] and the weight of the paper constituting the central alveolar core can be between 75 and 350 g / m2 (advantageously between 100 and 150 g / m2).
[0030] The present invention also relates to a furniture element of the type storage box or trolley, in particular for an aircraft cabin, which is made at least in part with a composite material as defined above.
[0031] Of course, the various features, variants, and embodiments of the invention can be combined with one another in various ways, provided they are not incompatible or mutually exclusive. Detailed description of the invention
[0032] In addition, various other features of the invention become apparent from the attached description made with reference to the drawings which illustrate non-limiting embodiments of the invention and where:
[0033] [Fig-1] is a partial schematic cross-sectional view of a plate of material conforming to the invention;
[0034] [Fig.2] is a schematic cross-sectional view of the material plate of [Fig.1], illustrating an intermediate stage in its manufacture;
[0035] [Fig.3] is a partial schematic and cross-sectional view of a possible embodiment variant of the plate faces of a composite material according to the invention;
[0036] [Fig.4] is a schematic, cross-sectional view of an aircraft cabin incorporating storage boxes and a storage trolley made at least partly with the composite material according to the invention.
[0037] The composite material 1 illustrated in cross-section on [Fig.1] is in the form of a plate delimited by two parallel plate faces 2, 3, and a plate edge 4.
[0038] The thickness of the material plate 1 can be between 6 and 50 mm.
[0039] One of the plate faces is intended to be oriented outwards, with regard to the furniture element to be produced.
[0040] This plate face, which may be plate face 2 here, is conventionally referred to as the "exposed face".
[0041] This exposed face 2 is the one intended to be oriented towards the aircraft cabin and is therefore likely to be subjected first to the risk of fire.
[0042] The other face of plate 3 is intended to be oriented towards the interior of the furniture element to be produced.
[0043] The composite material 1 is in the form of a plate 5 of the type with a honeycomb cardboard structure comprising:
[0044] - a central cellular paper core 51, delimited by two core faces 511,512 parallels and a soul song 513,
[0045] - an outer coating layer 52 made of paper, of which one face 521, referred to as face the inner face, is joined to one of the said soul faces (in this case the soul face 511), and whose other face 522, called the outer face, is intended to be oriented towards the side of the said exposed face 2,
[0046] - an inner lining layer 53 made of paper, of which one face 531, referred to as face the inner face, is joined with the other of the said soul faces (in this case the soul face 512), and whose other face 532, called the outer face, is intended to be oriented in the opposite direction to the said exposed face 2.
[0047] Preferably, at least part of the edges of plate 4 is closed by a layer of paper 6. This is in particular the so-called "visible" edges of plate 4 of the material 1, that is to say those which, in the furniture element produced, are intended to be in contact with the outside.
[0048] The central core 51, the outer coating layer 52 and the inner coating layer 53, are made of paper.
[0049] The basis weight of the paper constituting the outer coating layer 52 and the inner coating layer 53 is preferably between 70 and 500 g / m2. And even more preferably this basis weight is between 250 and 430 g / m2.
[0050] For its part, the weight of the paper constituting the central core 51 alveolar is between 75 and 350 g / m2 (preferably between 100 and 150 g / m2).
[0051] The plate 5 of the honeycomb cardboard structure type may include a central core of the honeycomb type (with hexagonal-shaped core cells), or a central core of corrugated or sinusoidal honeycomb cardboard.
[0052] According to the invention, at least the exposed face 2 of the material plate comprises a layer 7 of intumescent vinyl paint. This layer 7 of intumescent vinyl paint is applied directly to the outer face 522 of the outer paper coating layer 52.
[0053] The weight of this layer 7 of intumescent vinyl paint which covers the exposed face of the material is greater than 225 g / m2, and preferably this weight is greater than 300 g / m2.
[0054] Preferably, the face 3 opposite the exposed face 2 of the material 1 also comprises a layer 8 of intumescent vinyl paint. This layer 8 of intumescent vinyl paint is applied directly to the outer face 532 of the inner paper coating layer 53.
[0055] The weight of this layer 8 of intumescent vinyl paint which covers the face 3 of the material opposite the exposed face 2 is greater than 100 g / m2.
[0056] Also preferably, the visible edges of the plate 4 of the material 1, in contact with the outside, are coated with a layer 9 of intumescent vinyl paint. This layer 9 of intumescent vinyl paint is applied to the outer face of the paper layer 6.
[0057] The weight of this layer 9 of intumescent vinyl paint which covers the visible edges of plate 4 is greater than 100 g / m2.
[0058] The vinyl intumescent paint used is a paint or varnish which, under the action of heat, transforms into an expanded carbon structure which will act as a thermal shield for the material to be protected.
[0059] Oxygen diffusion is also reduced, which slows down the degradation of this material to be protected.
[0060] The intumescent formulation may consist in particular of:
[0061] - of at least one vinyl resin, for example of the polyvinyl acetate type,
[0062] - of a water-based diluent,
[0063] - of at least one source of inorganic acid, based on phosphoric acid or of a source of phosphoric acid, such as ammonium polyphosphates ((NH4PO3)n - APP with an n chain preferably greater than 100 to limit its hygroscopicity, which has a favorable ecotoxicological profile), which acts as a dehydrating agent with a quantity of phosphorus between 17 and 60% and a pH between 5 and 9 and a particle size between 10 and 30 µm and whose thermal decomposition is between 220 and 280°C, or such as phosphonates or phosphinates or a mixture of them (in proportions preferably between 30 and 60 molar%),
[0064] - from at least one carbon source, in the form of polyhydric compounds rich in carbon, such as carbohydrates, ethylene glycol, mannitol, sorbitol, xylitol, arabitol, dextrose, pentaerythrol, pentaerythritol or a mixture thereof (preferably in proportions between 40 and 70% molar),
[0065] - of at least one carbon coating expanding agent (or blowing agent) such as nitrogenous derivatives of the amine, amide, urea type or a mixture thereof, which generate gases that facilitate expansion.
[0066] The formulation does not use halogenated products, nor antimony or its derivatives, the ecotoxicological properties of which may pose health problems.
[0067] For example, one can use a paint marketed under the name Vemiflam AA2023 (registered trademark), by the company Protecflam Industries 44600 SAINT-NAZAIRE France.
[0068] As specified above, the visible edges of plate 4, i.e. those intended to be in contact with the outside in the furniture element to be produced, are closed by a layer of paper 6.
[0069] To obtain a quality finish, as illustrated in [Fig.2] this paper layer 6 of the edges 4 is advantageously made by an extension 523 of the outer coating layer 52 of paper, folded down at 90° and bonded by gluing with the core edge 513.
[0070] The layers 7, 8, 9 of intumescent paint are applied by spray gun, in one or more passes, and before or after the aforementioned operation of covering the edges 4 with the layer of paper 6.
[0071] Preferably, this application of layers 7, 8 and 9 of intumescent paint is carried out after the edge covering operation 4 to optimize the finish.
[0072] Fig. 3 schematically illustrates a possible embodiment variant of the plate faces 2, 3 of a composite material 1 according to the invention.
[0073] On this [Fig.3], the outer face of the paper coating layers 52 and 53 receives a reinforcement layer 10 adapted to improve the mechanical resistance of the composite material 1.
[0074] The reinforcement layer 10 can be made of a woven or non-woven material (preferably a mineral or bio-based material). For example, a basalt fabric is used.
[0075] The weight of this reinforcement layer 10 can be between 100 and 800 g / m2.
[0076] The reinforcement layer 10 can be bonded to the outer face 522 of the layer of exterior coating 52, and / or on the outer face 532 of the inner coating layer 53, by means of a suitable adhesive or resin.
[0077] For example, a Hydroflam GLU22 resin (registered trademark) marketed by the company Protecflam industries, 44600 Saint-Nazaire, France, is used.
[0078] If the reinforcement layer 10 is present, the intumescent vinyl paint layer 7, 8 indirectly coats the outer face 522 of the layer of outer coating 52 and / or the outer face 532 of the inner coating layer 53.
[0079] The reinforcement layer 10 can also be provided on the edges of the plate 4 and in particular on the extension 523 of the outer coating layer 52.
[0080] In yet another possible embodiment, only one of the plate faces 2, 3 of the composite material 1 is coated with a reinforcement layer 10.
[0081] Still on [Fig.3], it is noted that the layer 7, 8 of vinyl intumescent paint can be coated with a protective topcoat 11 suitable for improving the surface mechanical resistance of the composite material 1 and for improving the behavior of this material in a humid environment.
[0082] Preferably, this protective topcoat 11 has a weight of less than 60 g / m2.
[0083] Preferably, but not obligatorily, a UV-curing material is used for this protective topcoat 11.
[0084] For example, a Verniflam UV topcoat (registered trademark) can be used, marketed by the company Protecflam Industries 44600 SAINT-NAZAIRE France.
[0085] The protective topcoat 11 can be provided independently of the presence of the reinforcement layer 10, and it can be provided on only part, or on the whole surface, of the layer 7, 8 of vinyl intumescent paint.
[0086] The protective finishing layer 11 can also be provided on the edges of the plate 4 and in particular on the extension 523 of the outer coating layer 52. Results
[0087] Cardboard-structured honeycomb panels:
[0088] - having between 6 and 50 mm in thickness, the central core of which is of the honeycomb type or corrugated or sinusoidal honeycomb cardboard,
[0089] - the outer coating layer of which is made of paper with a basis weight of between 250 and 430 g / m2, and a basalt film with a weight of 225 g / m2 bonded with Hydroflam GLU22 resin, with an outer face receiving a Verniflam AA2023 intumescent vinyl paint, with a weight of 225 g / m2, and a Verniflam UV topcoat, with a weight of less than 60 g / m2,
[0090] - the inner coating layer of which is made of paper with a weight of between 250 and 430 g / m2, and a basalt film with a weight of 225 g / m2 bonded with Hydroflam GLU22 resin, with an outer face receiving a Verniflam AA2023 intumescent vinyl paint, with a weight of 225 g / m2, and a Verniflam UV topcoat, with a weight of less than 60 g / m2,
[0091] comply with the CS / FAR 25.853 Appendix F aeronautical test standard (60s vertical flame resistance test, heat release measurement test, smoke release and toxicity measurement test).
[0092] The composite material according to the invention is particularly suitable for the field of aeronautics due to its fire resistance qualities and its low weight.
[0093] Fig. 4 schematically illustrates an aircraft cabin 12 comprising overhead storage compartments 13 and a storage / transport trolley 14, at least part of which may be made of the composite material as shown above.
Claims
Demands
1. Composite material (1) designed for the manufacture of furniture elements such as storage boxes or trolleys, in particular for an aircraft cabin, said composite material (1) is in the form of a plate delimited by two parallel plate faces (2, 3) and a plate edge (4), one of said plate faces (2), referred to as the exposed face, being intended to be oriented outwards, i.e. towards said aircraft cabin and primarily subject to the risk of fire, said composite material (1) is in the form of a plate (5) of the type with a honeycomb cardboard structure comprising: - a central honeycomb paper core (51), delimited by two parallel core faces (511, 512) and a core edge (513), - an outer paper facing layer (52), one face (521), referred to as the inner face, being bonded to one of said core faces (511), and whose other face (522), called the outer face,is intended to be oriented towards said exposed face (2), - an inner paper coating layer (53), one face (531), referred to as the inner face, being bonded to the other of said core faces (512), and the other face (532), referred to as the outer face, being intended to be oriented opposite said exposed face (2), characterized in that at least said outer face (522) of the outer paper coating layer (52) is coated, directly or indirectly, with a layer (7) of vinyl intumescent paint.
2. Composite material (1) according to claim 1, characterized in that the basis weight of the layer (7) of intumescent vinyl paint which covers said outer face (522) of the outer coating layer (52) of paper is greater than 225 g / m2.
3. Composite material (1) according to any one of claims 1 or 2, characterized in that the outer face (532) of the inner coating layer (53) of paper is coated with a layer (8) of vinyl intumescent paint.
4. Composite material (1) according to claim 3, characterized in that the basis weight of the layer (8) of intumescent vinyl paint which covers said outer face (532) of the inner coating layer (53) of paper is greater than 100 g / m2.
5. Composite material (1) according to any one of claims 1 to 4, characterized in that the plate edges (4) in contact with the outside are coated with a layer (9) of vinyl intumescent paint.
6. Composite material (1) according to claim 5, characterized in that the basis weight of the layer (9) of intumescent vinyl paint which covers the edges of plate (4) in contact with the outside is greater than 100 g / m2.
7. Composite material (1) according to any one of claims 1 to 6, characterized in that said vinyl intumescent paint is of the type comprising a mixture of: at least one vinyl resin, at least one inorganic acid source, at least one carbon source, at least one blowing agent and a water-based diluent.
8. Composite material (1) according to any one of claims 1 to 7, characterized in that the plate edges (4) in contact with the outside comprise an extension (523) of the outer coating layer (52) of paper, which extension (523) is folded down at 90° and bonded to the core edge (513).
9. Composite material (1) according to any one of claims 1 to 8, characterized in that it comprises a reinforcement layer (10) interposed, on the one hand, between the outer paper coating layer (52) and / or the inner paper coating layer (53), and on the other hand, the vinyl intumescent paint layer (7, 8).
10. Composite material (1) according to claim 9, characterized in that said reinforcement layer (10) is made of woven or non-woven material, with a basis weight between 100 and 800 g / m2.
11. Composite material (1) according to any one of claims 1 to 10, characterized in that said layer (7, 8) of vinyl intumescent paint is coated with a protective topcoat (11).
12. Composite material (1) according to claim 11, characterized in that said protective topcoat (11) has a basis weight of less than 60 g / m2.
13. Composite material (1) according to any one of claims 1 to 12, characterized in that its thickness is between 6 and 50 mm, in that the basis weight of the paper constituting the outer coating layer (52) and the coating layer
14. interior (53) is between 70 and 500 g / m2, advantageously between 250 and 430 g / m2, and in that the weight of the paper constituting the central core (51) alveolar is between 75 and 350 g / m2, advantageously between 100 and 150 g / m2. Furniture element of the type box (13) or storage trolley (14), in particular for an aircraft cabin (12), characterized in that it is made at least partly with a composite material (1) according to any one of claims 1 to 13.